Polaris PTV 6x6 SERIES 10 Owner'S Manual Download Page 104

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102

MAINTENANCE AND LUBRICATION

Lights

Headlight Housing Replacement

1. Remove the Phillips screws from the bottom of the headlight pod

at each front corner.

NOTE:

To aid in accessing these screws, it

may be helpful to turn handlebars to the left or right and use a very

short screwdriver. Removal of the front rack and cover may also

allow easier access.

2. Remove the three screws in the back of the headlight pod.
3. Lift the pod cover. Disconnect

the speedometer harnesses from

the speedometer. Unplug the

indicator light harness and

remove the pod cover.

4. Unplug the headlamp from the

wiring harness.

5. Remove the o-ring (1) from the

headlight pivot pins.

6. Pull the headlight housing up to

release from the locking tabs.

7. Lift the adjusting knob up to

remove from the locking tabs.

8. Carefully pull the assembly up

and out of pod.

9. Reverse the steps to install the

new housing and reassemble the

pod.

NOTE:

The distance from the headlamp parting line to the end of the

adjustment knob stop is 5 1/8

″

(13 cm). See illustration.

10. Adjust the headlight aim by turning the adjusting knob.

5 1/8

″

(13 cm)

Summary of Contents for PTV 6x6 SERIES 10

Page 1: ......

Page 2: ...WARNING The engine exhaust from this product contains chemicals known to cause cancer birth defects or other reproductive harm ...

Page 3: ...1 ...

Page 4: ...ting Polaris Industries Inc reserves the right to make product changes and improvements that may affect illustrations or explanations No part of this manual shall be reproduced or used without the written permission of Polaris Industries Inc Copyright 2002 Polaris Industries Inc All Rights ReservedPrinted in the U S A ...

Page 5: ...cle making it the finest vehicle we ve ever produced For safe and enjoyable operation of your vehicle be sure to follow the instructions and recommendations in this owner s manual Your manual contains instructions for minor maintenance but information about major repairs is outlined in the Polaris Service Manual and should be performed only by a Factory Certified Master Service Dealer MSD Technici...

Page 6: ... parts If your vehicle is stolen these numbers are essential to its recovery and identification NOTE Record your vehicle s ID numbers in the spaces provided Remove the spare key and store it in a safe place Your key can be duplicated only by mating a Polaris key blank with an existing key NOTE If both keys are lost see your dealer for ignition switch replacement 2 1 Frame VIN Engine Serial Number ...

Page 7: ... FEATURES 34 CONTROLS 37 OPERATION 46 NOISE EMISSION CONTROL SYSTEM 65 MAINTENANCE AND LUBRICATION 66 SPECIFICATIONS 106 POLARIS RECOMMENDED PRODUCTS 108 TROUBLESHOOTING 109 WARRANTY 113 INDEX 115 NOTE Illustrations used in this manual are for general representation only Your model may differ ...

Page 8: ...are thoroughly inspected at specific intervals Safety Training When you purchased your new PTV 6x6 your dealer offered a hands on safety training course that covers all aspects of vehicle safety You were also provided with printed materials that explain safe operating procedures You should review this information on a regular basis If you purchased a used Polaris PTV 6x6 from a party other than a ...

Page 9: ...on your vehicle or in this manual alerts you to the potential for personal injury The safety alert warning indicates a potential hazard that may result in serious injury or death The safety alert caution indicates a potential hazard that may result in minor personal injury or damage to the vehicle CAUTION NOTE A note will alert you to important information or instructions A caution indicates a sit...

Page 10: ...ing an approved helmet that fits properly Always wear eye protection goggles or face shield gloves boots a long sleeved shirt or jacket and long pants S Never consume alcohol or drugs before or while operating this ve hicle S Never operate at excessive speeds Travel at speeds appropriate for the terrain visibility and operating conditions and your experience S Never attempt wheelies jumps or other...

Page 11: ...s follow proper procedures for crossing the side of a hill Avoid hills with excessively slippery or loose surfaces Shift your weight to the uphill side of the vehicle Never attempt to turn the vehicle around on any hill until you ve mastered on level ground the turning technique outlined in this manual Avoid crossing the side of a steep hill when possible S Always use proper procedures if the vehi...

Page 12: ...ngles S Always use the size and type of tires specified for your vehicle and always maintain proper tire pressure S Never modify this vehicle through improper installation or use of accessories S Never exceed the stated load capacity for your vehicle Cargo must be properly distributed and securely attached Reduce speed and follow the instructions in this manual for hauling cargo or towing Allow a ...

Page 13: ...accessories including but not limited to mowers blades tires sprayers or large racks may change the handling characteristics of the vehicle Use only Polaris approved accessories and familiarize yourself with their function and effect on the vehicle WARNING Make sure your PTV 6x6 is in excellent operating condition at all times We strongly recommend that the operator check all safety components bef...

Page 14: ...e operating techniques described in the owner s manual For more information about the training course contact an authorized Polaris dealer or call Polaris at 1 800 342 3764 POTENTIAL HAZARD Failure to follow the age recommendations for this vehicle WHAT CAN HAPPEN Severe injury and or death could occur if a person under the age of 16 operates the PTV 6x6 Even though a child may be within the recom...

Page 15: ... to the operator and or passenger HOW TO AVOID THE HAZARD Never carry a passenger The purpose of the long seat is to allow the operator to shift position as needed during operation It is not intended for carrying passengers POTENTIAL HAZARD Operating a PTV 6x6 on paved surfaces including sidewalks paths parking lots and driveways WHAT CAN HAPPEN PTV 6x6 tires are designed for off road use Operatin...

Page 16: ...ng an approved helmet eye protection and protective clothing WHAT CAN HAPPEN Operating a PTV 6x6 without an approved helmet increases the risk of a severe head injury or death in the event of an accident Operating without eye protection could result in an accident and could increase the chance of a severe injury in the event of an accident HOW TO AVOID THE HAZARD Always wear an approved helmet tha...

Page 17: ...you begin rolling backwards Keep your body weight toward the front of the vehicle uphill Do not apply engine power Do not apply the rear brakes Gradually apply the service brake When fully stopped apply the auxiliary brake as well and then lock the parking brake Dismount on the uphill side or to either side if the vehicle is pointed straight uphill Turn the vehicle around and remount following the...

Page 18: ...D Always operate the vehicle at a speed that s proper for the terrain visibility and operating conditions and your experience POTENTIAL HAZARD Improperly operating in reverse WHAT CAN HAPPEN The PTV 6x6 could collide with an obstacle or person resulting in severe injury HOW TO AVOID THE HAZARD Before shifting into reverse gear always check for obstacles or people behind the vehicle When it s safe ...

Page 19: ...procedures and schedules described in the owner s manual POTENTIAL HAZARD Removing hands from the handlebars or feet from the footrests during operation WHAT CAN HAPPEN Removing even one hand or foot can reduce ability to control the vehicle or could cause loss of balance and ejection from the vehicle If the operator s foot is not firmly planted on the footrest it could come into contact with the ...

Page 20: ...AZARD Travel slowly and use extra caution when operating on unfamiliar terrain Always be alert to changing terrain conditions POTENTIAL HAZARD Skidding or sliding WHAT CAN HAPPEN Skidding or sliding can cause loss of control If the tires regain traction unexpectedly the vehicle could overturn HOW TO AVOID THE HAZARD On slippery surfaces such as ice travel slowly and use extra caution to reduce the...

Page 21: ... rough slippery or loose terrain could cause loss of traction or loss of control which could result in an accident or overturn HOW TO AVOID THE HAZARD Do not operate on excessively rough slippery or loose terrain until you ve learned and practiced the skills necessary to control the vehicle on such terrain Always use extra caution on rough slippery or loose terrain WARNING ...

Page 22: ...nual Practice turning at slow speeds before attempting to turn at faster speeds Never turn at excessive speed POTENTIAL HAZARD Operating on excessively steep hills WHAT CAN HAPPEN The vehicle may overturn and cause serious injury or death HOW TO AVOID THE HAZARD Never operate on hills too steep for the vehicle or for your abilities Never operate the PTV 6x6 on hills steeper than 15_ Practice on sm...

Page 23: ...cribed in the owner s manual beginning on page 57 Always check the terrain carefully before ascending any hill Never climb hills with excessively slippery or loose surfaces Shift your weight forward Never open the throttle suddenly while traveling uphill The vehicle could flip over backwards Never go over the top of any hill at high speed An obstacle a sharp drop or another vehicle or person could...

Page 24: ... HAZARD Always follow proper procedures for traveling down hills as described in the owner s manual Always check the terrain carefully before descending a hill Shift your weight backward Never travel down a hill at high speed Avoid traveling down a hill at an angle which would cause the vehicle to lean sharply to one side Travel straight down the hill when possible WARNING ...

Page 25: ...n the PTV 6x6 around on any hill until you ve mastered the turning technique on level ground as described in the owner s manual See page 59 Use extra caution when turning on any hill Avoid crossing the side of a steep hill If it s unavoidable always follow proper procedures as described in the owner s manual Avoid hills with excessively slippery or loose surfaces Shift your weight to the uphill si...

Page 26: ...ZARD Overloading the vehicle or carrying towing cargo improperly WHAT CAN HAPPEN Overloading and towing can cause changes in vehicle handling which could lead to loss of control or an accident HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this vehicle Cargo should be properly distributed and securely attached Reduce speed when hauling cargo or pulling a trailer Allow a greater ...

Page 27: ...el slowly balance your weight carefully avoid sudden movements and maintain a slow and steady forward motion Do not make sudden turns or stops and do not make sudden throttle changes Wet brakes may have reduced stopping ability Always test the brakes after leaving water If necessary apply them several times to let friction dry out the pads POTENTIAL HAZARD Attempting wheelies jumps and other stunt...

Page 28: ...er tire pressure POTENTIAL HAZARD Operating the vehicle with improper modifications WHAT CAN HAPPEN Improper installation of accessories or modification of the vehicle may cause changes in handling which could lead to an accident HOW TO AVOID THE HAZARD Never modify the PTV 6x6 through improper installation or use of accessories All parts and accessories added to the vehicle must be genuine Polari...

Page 29: ...operator as well as the force created by a moving vehicle Exercise extreme caution POTENTIAL HAZARD Operating the vehicle after consuming alcohol or drugs WHAT CAN HAPPEN Consumption of alcohol and or drugs could seriously affect operator judgment Reaction time may be slower and operator balance and perception could be affected Consuming alcohol and or drugs before or while operating the vehicle c...

Page 30: ...5 lbs 34 kg IMPROPER TIRE PRESSURE OR OVERLOADING can cause loss of control resulting in SEVERE INJURY OR DEATH TIRE PRESSURE PSI FRONT 5 CENTER 5 REAR 5 MAXIMUM WEIGHT CAPACITY Gross Vehicle Weight INCLUDING MACHINE DRIVER AND CARGO IS 1970 LBS Reduce speed and allow greater distance for braking when carrying cargo Overloading or carrying tall off center or unsecured loads will increase your risk...

Page 31: ...WAYS DUse an approved HELMET AND PROTECTIVE GEAR DAvoid paved surfaces Pavement may seriously affect handling and control DUse proper RIDING TECHNIQUES to avoid vehicle overturns on hills and rough terrain and in turns DUseOVERRIDE for reversespeed limiter with caution To preventloss of control never activate override button with open throttle DREVERSE operation can be dangerous even at low speeds...

Page 32: ...ever carry passengers ALL WHEEL DRIVE SWITCH Do not push switch to engage AWD if the rear wheels are spinning This may cause severe drive shaft and clutch damage See your owner s manual 7079780 7079604 AWD Models WARNING Pushing reverse override button may cause sudden in creases in pow er and traction if too much throttle is ap plied Loss of control or for ward flipover may result es pecially in ...

Page 33: ...OUND 850 LBS 368 KG UP TO 15 GRADE HITCH MAX VERTICAL WEIGHT 35 LBS 16 KG 7078261 ATTENTION S Operation of this vehicle without the filter element will severely damage the engine S Clean air filter often more frequent cleaning required in dusty condi tions S Operation of this vehicle without en gine breather filter s can cause en gine damage Consult owner s manual for details S Specific carburetor...

Page 34: ...nk Do not fill the tank neck S If gasoline spills on your skin or clothing immediately wash it off with soap and water and change clothing S Never start the engine or let it run in an enclosed area Gaso line powered engine exhaust fumes are poisonous and can cause loss of consciousness and death in a short time S Turn the fuel valve off whenever the vehicle is stored or parked The engine exhaust f...

Page 35: ...nt of Transportation DOT label the American National Standards Institute label ANSI z90 1 or the Snell Memorial Foundation label 2 Eye Protection Do not depend on sunglasses for proper eye protection A pair of goggles or a helmet face shield offer the best protection for your eyes They should be kept clean and be of shatterproof design bearing the markings z2 1 or VESC 8 3 Gloves Gloves with knuck...

Page 36: ...RES Component Locations 1 Service Brake Lever 2 Middle Axle Auxiliary Brake 3 Throttle Lever 4 Bed Dump Latch Release 5 Gearbox Shift Lever 6 Floorboards 7 Backrest 8 Cargo Bed 9 Front Rack 1 2 3 4 4 5 6 7 8 9 ...

Page 37: ... the front wheels will automatically disengage NOTE The override switch 2 allows activation of AWD in reverse if the AWD switch is on A red AWD light on the switch indicates when the vehicle is in AWD There is no limit to the length of time the vehicle may remain in AWD The AWD switch may be turned on or off while the vehicle is moving If the switch is turned off when the front hubs are driving th...

Page 38: ...ted Disengage the hubs by stopping shifting to reverse and backing for a short distance Then proceed in forward again NOTE If the hubs remain engaged after following this procedure return the vehicle to your dealer for service To continue using AWD while operating in reverse activate both the override switch and the Demand 6 Drive AWD switch See page 37 Operating with only one front hub engaged co...

Page 39: ...se if the AWD switch is on 2 Engine Stop Switch The engine will not start or run when the switch is in the OFF position Its purpose is to provide the operator with a quick means of engine shutdown in case of stuck throttle or other emergency NOTE Both the main switch and the emergency engine stop switch shut off all electrical power to the entire vehicle including lights To stop the engine slide t...

Page 40: ...low 4 Transmission Neutral Indicator green 5 All Wheel Drive Indicator red 6 Engine High Temp Warning Indicator red The high temp indicator will light only if the engine overheats 6 1 4 3 5 2 Operating the vehicle on streets or roads especially in darkness could result in an accident and serious injury or death Your PTV 6x6 is not equipped with highway approved lights It s designed for and must be...

Page 41: ...s the engine in the event of a throttle system malfunction and is provided for your safety Do not attempt to modify the ETC system or replace it with any after market throttle mechanisms WARNING Do not start or operate a vehicle with sticking or improperly operating throttle controls Doing so could cause an accident and lead to severe injury or death Always contact your dealer for service repairs ...

Page 42: ...er travel and reservoir fluid level before riding When squeezed the lever should feel firm Any sponginess would indicate a possible fluid leak or low master cylinder fluid level which must be corrected before operating Contact your dealer for proper diagnosis and repairs Auxiliary Brakes The auxiliary brake lever 2 is located on the right handlebar This lever controls the auxiliary brake for the r...

Page 43: ...be clear NOTE When checking the fluid level the vehicle should be on level ground with the handlebars turned so the top of the reservoir is level If the fluid level is low add DOT 3 brake fluid 2 1 After opening a bottle of brake fluid always discard any unused portion Never store or use a partial bottle Brake fluid is hygroscopic meaning it rapidly absorbs moisture from the air The moisture cause...

Page 44: ...f left on for a long period of time Al ways block the wheels to prevent rolling S Always block the wheels on the downhill side of the vehicle if leav ing it parked on a hill Another option is to park the vehicle in a sidehill position S Never depend on the parking brake alone for more than five minutes if the vehicle is parked on a hill Always block the wheels to pre vent rolling Operating the veh...

Page 45: ...R M 2 octane The fuel tank supply valve 2 is located on the left side of the vehicle and has three positions OFF For vehicle storage and when transporting ON For normal operation RES For reserve supply if main supply is exhausted NOTE There s a 7 to 10 mile 11 2 to 16 km range on reserve gas Always refill the gas tank as soon as possible after exhausting the main supply After refueling switch the ...

Page 46: ...cked whenever the vehicle is left unattended Maintaining shift linkage adjustment is important to assure proper transmission function See your dealer if you experience any shifting problems Belt Life To extend belt life refrain from continuous operation of the vehicle at the point of engagement the point at which the vehicle begins to move Continuous operation in this manner increases belt wear F ...

Page 47: ...al 3 Grasp the recoil starter tightly and pull slightly until the starter mechanism engages 4 Pull the rope abruptly to start the engine 1 Extending the starter rope too far will cause damage to the recoil assembly Do not extend the starter rope so far that it stops If the starter rope handle is not seated properly water may enter the recoil housing and damage components Make sure the handle is fu...

Page 48: ...low room to familiarize yourself with vehicle operation and handling 4 Vary the throttle positions 5 Perform regular checks on fluid levels controls and areas outlined on the daily pre ride inspection checklist See page 47 6 Pull only light loads during the break in period 7 During the break in period change the oil and oil filter at 20 hours or 200 miles CAUTION Excessive heat build up during the...

Page 49: ...uts and axle nuts check that axle nuts are secured by cotter pins 8 Drive chain check condition and slack refer to drive chain adjustment procedure 9 Air cleaner element check for dirt clean or replace 10 Steering check for free operation noting any unusual looseness in any area 11 Loose parts visually inspect vehicle for any damaged components or loose nuts bolts or fasteners 12 Riding gear wear ...

Page 50: ...Activate the starter for a maximum of five seconds releasing the switch when the vehicle starts If the engine does not start release the starter and wait five seconds Then activate the starter for another five seconds Repeat this procedure until the engine starts 7 If the engine slows or stops position the choke knob half way in to allow proper engine warm up 8 Vary the engine RPM slightly with th...

Page 51: ...n the fuel tank valve to ON 4 Sit on the vehicle 5 If the engine has cooled to a point where it does not readily start intermittent use of the choke button pulled half way out may be necessary 6 If the engine is over choked when warm depress the throttle lever fully while cranking to aid in starting 7 Release the throttle lever immediately after the engine starts If the engine does not start and a...

Page 52: ...ght is 35 lbs 16 kg Overloading the vehicle or carrying or towing cargo improperly can alter vehicle handling and may cause loss of control or brake instability S Never exceed the stated load capacity for this vehicle S Do not obstruct the headlight when loading the front rack S Cargo should be properly distributed and carried as low and for ward in the cargo bed as possible S Reduce speed and all...

Page 53: ...bed release lever forward 5 Lift the front of the cargo bed and dump the cargo If the weight distribution on the bed is located toward the rear of the bed when the release lever is pulled forward the bed may dump on its own which could cause serious injury Never operate the dump lever without checking the position of the load This will prevent unexpected dumping of the cargo bed Never carry passen...

Page 54: ...Unintentional bed tilting will result if weight is placed in the rear of the bed and the latch is not secured Maximum Front Rack 75 lbs 34 kg Maximum Cargo Bed PTV 6x6 800 lbs 363 kg WARNING Operating with the cargo bed in the raised position can cause serious injury and damage to the vehicle The cargo bed could close unexpectedly and injure the driver The rear tires will also catch the rear of th...

Page 55: ...warm up shift the transmission into gear 3 Check your surroundings and determine your path of travel 4 Release the parking brake 5 Slowly depress the throttle with your right thumb and begin driving Vehicle speed is controlled by the amount of throttle opening PVT shifting is automatic 6 Drive slowly Practice maneuvering and using the throttle and brakes on level surfaces ...

Page 56: ...e inside tire must slip traction slightly To turn steer in the direction of the turn leaning your upper body to the inside of the turn while supporting your weight on the outer footrest This technique alters the balance of traction between the rear wheels allowing the turn to be made smoothly The same learning technique should be used for turning in reverse WARNING Turning at sharp angles in rever...

Page 57: ...ll transferring your upper body weight toward the hill while keeping your feet on the footrests 3 Steer slightly into the hill to maintain vehicle direction NOTE If the vehicle begins to tip quickly turn the front wheel downhill if possible or dismount on the uphill side immediately Improperly crossing hills or turning on hills can result in loss of control or vehicle overturn resulting in severe ...

Page 58: ...rward Never brake during a skid 3 Drive with Demand 6 Drive All Wheel Drive engaged to assist in controlling the vehicle in slippery areas Severe damage to the drive train may occur if the AWD is engaged while the wheels are spinning Activate the AWD switch only when the rear wheels have traction CAUTION WARNING Failure to exercise care when operating on slippery surfaces can result in loss of tir...

Page 59: ...e 3 Slow down 4 Apply the brakes slightly to aid in slowing Hard use of the braking system while descending a hill could result in a front end overturn causing serious injury or death Always operate the brakes slightly when descending a hill Excessive speed can cause loss of control and lead to serious injury or death Always operate slowly when traveling downhill WARNING ...

Page 60: ...e opening 6 Remain alert and be prepared to take emergency action This may include quick dismounting of the vehicle 15_ Maximum WARNING Braking and handling are greatly affected when operating in hilly terrain Improper procedure could cause loss of control or overturn and result in serious injury or death Avoid climbing steep hills 15_ maximum Use extreme caution when operating on hills and follow...

Page 61: ...ease the parking brake lock and slowly allow the vehicle to roll around to your right until it s pointing across the hill or slightly downward 6 Lock the parking brake and remount the vehicle from the uphill side keeping body weight uphill 7 Restart the engine with the transmission still in forward 8 Release the parking brake and proceed slowly controlling speed with the service brake until the ve...

Page 62: ...t avoid water that exceeds the recommended maximum depth go slowly balance your weight carefully avoid sudden movements and maintain a slow and steady forward motion Do not make sudden turns or stops and do not make sudden throttle changes IMPORTANT After running the vehicle in water it s critical to have it serviced as outlined in the maintenance chart See pages 67 69 The following areas need spe...

Page 63: ... Incline Avoid parking on an incline if possible If it s unavoidable follow these precautions 1 Place the transmission in gear 2 Set the parking brake 3 Always block the rear wheels on the downhill side See illustration 4 Shut off fuel supply ...

Page 64: ... backing 6 Never activate the override button while the throttle is open Loss of control may result NOTE This vehicle is equipped with a reverse speed limiter The override button should be used with caution as rearward vehicle speed is greatly increased Do not operate at wide open throttle Open the throttle just enough to maintain a desired speed Opening the throttle more than required may cause f...

Page 65: ...ult in serious injury or death Before shifting into reverse gear always check for obstacles or people behind the vehicle When it s safe to proceed back slowly Do not use the override switch unless additional power is required for vehicle movement Avoid backing on inclines Avoid turning at sharp angles in reverse ...

Page 66: ...d the terrain you re traveling on Be constantly alert for hazards such as logs rocks and low hanging branches Severe injury or death can result if your vehicle comes in contact with a hidden obstacle Not all obstacles are immediately visible Travel with caution in unfamiliar terrain WARNING ...

Page 67: ...ESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW 1 Removal or alteration or the puncturing of the muffler or any engine component which conducts removal of engine exhaust gases 2 Removal or alteration or the puncturing of any part of the engine air induction system 3 Replacement of any vehicle parts with parts not in compliance with federal regulations 4 Lack of proper maintenance USFS App...

Page 68: ...S Spark plug wrench and handle S Torx wrench rack removal Accessories Polaris has a wide variety of accessories for your vehicle Contact your Polaris dealer for a complete list The addition of certain accessories including but not limited to mowers blades tires sprayers or large racks may change the handling characteristics of the vehicle Be sure any accessories added to the vehicle have been appr...

Page 69: ...r dusty areas should be inspected and serviced more frequently If you are not familiar with safe service and adjustment procedures have a qualified dealer perform these operations Inspect clean lubricate adjust and replace parts as necessary When inspection reveals the need for replacement parts use genuine Polaris parts available from your Polaris dealer NOTE Service and adjustments are critical ...

Page 70: ...y Daily Inspect drain deposits whenever visible Air filter pre cleaner Daily Daily Inspect and clean Coolant level Daily Daily Replace engine coolant every two years Air Filter main element Weekly Weekly Inspect replace if necessary J Brake pads 10 hrs 100 miles Monthly Inspect for wear periodically Breather filter 20 hrs Monthly Inspect replace annually and as needed Battery 20 hrs Monthly Inspec...

Page 71: ...n fasteners J Valve clearance 100 hrs 12 months Inspect adjust J Fuel system 100 hrs 12 months Check for leaks at tank cap lines fuel valve filter pump and carburetor replace lines ev ery two years J Fuel filter 100 hrs 12 months Replace annually Radiator 100 hrs 12 months Inspect clean external surface Cooling system hoses 100 hrs 12 months Inspect Engine mounts 100 hrs 12 months Inspect Spark ar...

Page 72: ...ee page 41 As required change every two years or 200 hours Drive Chains O Ring chain lube or SAE 80 90 Lubricate as often as re quired before each ride in wet conditions As required Gear Selector Oil 1 10 W Non detergent Oil Maintain oil level at the center of the shift rail Do not overfill Change every 2 years or 200 hours Transmission Oil 2 Polaris Premium Synthetic gearcase lube Fill to bottom ...

Page 73: ... zerk on back side of struts and grease with grease gun Every 3 months or at 50 hrs Front A Arm Pivot Shaft 3 LGrease Locate zerk on pivot shaft and grease with grease gun Every 3 months or at 50 hrs More often under severe use such as wet or dusty conditions L Use Polaris Premium All Season Grease or grease conforming to NLGI No 2 F Use Polaris Premium U Joint Lube every 500 miles before long per...

Page 74: ...xle Bearings 4 Grease Locate fitting on eccentric and grease with grease gun Every 3 months or 50 hrs Center Swing Arm Housing 5 Grease Locate fitting on swing arm hous ing and grease with grease gun Every 3 months or 50 hrs Rear Strut 6 Grease Locate fitting on rear strut and grease with grease gun Every 3 months or 50 hrs More often under severe use such as wet or dusty conditions L Use Polaris ...

Page 75: ...il should be kept at the bottom of the fill plug thread NOTE Use Polaris Premium Synthetic Gearcase Lubricant in the transmission See page 108 for a list of Polaris recommended products 3 Replace the fill plug Transmission Oil Change 1 Remove the propshaft shield from the right side of the vehicle 2 Remove the fill plug 3 Remove the transmission drain plug 2 located on the bottom left hand side an...

Page 76: ...d oil if needed Oil should be kept at the bottom of the fill plug thread Add Premium Front Gearcase Fluid if needed See page 108 for a list of Polaris recommended products 3 Replace the fill plug Gearcase Oil Changing Procedure 1 Remove the fill plug 2 Remove gearcase drain plug located on the bottom right hand side and drain the oil 3 Clean and reinstall the drain plug and tighten securely 14 ft ...

Page 77: ...d Follow the manufacturer s recommendations for ambient temperature operation See page 108 for the part numbers of Polaris recommended products Oil System The oil tank is located on the left side of the vehicle To check the oil 1 Position the vehicle on a level surface 2 Start the engine and let it idle for 20 30 seconds 3 Stop the engine Remove the dipstick and wipe it dry with a clean cloth 4 Sc...

Page 78: ...om of the oil tank and the bottom of the engine 2 Run the engine for two to three minutes then turn it off 3 Place a drain pan beneath the oil tank and remove the drain plug 1 Allow the oil to drain completely 4 Install a new sealing washer 2 on the oil drain plug NOTE The sealing surfaces on the drain plug and the oil tank should be clean and free of burrs nicks or scratches 5 Reinstall the drain...

Page 79: ...e drain plug and crankcase should be clean and free of burrs nicks or scratches 11 After draining reinstall the drain plug 12 Remove the dipstick 2 and add two quarts 1 9 l of Polaris Premium 4 synthetic oil Reinstall the dipstick NOTE If the sump is not drained add about 1 3 4 quarts initially 13 Place the gear selector in neutral and set the parking brake 14 Start the engine and let it idle for ...

Page 80: ...NCE AND LUBRICATION Periodic Maintenance Record Use the following chart to record periodic maintenance Maintenance Interval Performed Servicing Date Servicing Dealer or Person Remarks 10 hrs 20 hrs 50 hrs 100 hrs ...

Page 81: ...ressure cap will not allow the recovery system to function properly Contact your dealer for the correct replacement part NOTE To ensure that the coolant maintains its ability to protect the engine we recommend that the system be completely drained every two years and a fresh mixture of antifreeze and water added Polaris recommends the use of Polaris Premium 60 40 anti freeze coolant or a 50 50 mix...

Page 82: ...ays follow the manufacturer s mixing recommendations for the freeze protection required in your area Cooling System Operation The engine coolant level is controlled or maintained by the recovery system The recovery system components are the recovery bottle the radiator filler neck the radiator pressure cap and the connecting hose As coolant operating temperature increases the expanding heated exce...

Page 83: ...e clamp and remove the filter 4 Remove the fabric type pre filter 1 from the main filter 2 Wash the pre filter in soapy water rinse and allow to dry thoroughly 5 Reinstall the pre filter over the main filter Replace the main filter if necessary 6 Reinstall the filter into the air box and tighten the clamp Do not over tighten the clamp or filter damage may occur CAUTION Operating the vehicle withou...

Page 84: ...NOTE It s not necessary to remove the lower hose from the engine 2 Inspect the filter for debris Blow gently through the filter in the direction of the arrow to check for clogging Replace if necessary 3 Check the hoses for cracks deterioration abrasion or leaks Replace as needed 4 Reinstall the filter and clamps with the arrow pointing toward the engine NOTE The breather filter is intended to be u...

Page 85: ...rear tires See illustration 3 Tie an elastic string around the stands making sure the string just touches the side surface of the rear tires on each side of the vehicle and goes around the stands in front of the vehicle 2 4 Measure the distance from the string to the rim at the front and rear of the front rim 3 The rear measurement should be 1 16 1 8 2 to 3 cm more than the front measurement NOTE ...

Page 86: ...en gaps in the block 4 Torque the handlebar adjuster block bolts to 10 12 ft lbs Optional Suspension Springs Although the Polaris PTV 6x6 suspension has the capability of providing the best ride possible the following accessory springs are available to better suit individual riding preferences NOTE Optional springs may be a different color than standard springs Springs may be painted to a desired ...

Page 87: ...age 41 Under normal functioning the diaphragm extends into the reservoir as fluid level drops If the fluid level is low and the diaphragm is not extended a leak is likely and the diaphragm should be replaced Always fill the reservoir as needed whenever the cover is loosened or removed to ensure proper diaphragm operation Use Polaris DOT 3 brake fluid 2 Check the brake system for fluid leaks 3 Chec...

Page 88: ...cessive wear Throttle Cable Free Play Adjustment Throttle cable free play is adjusted at the handlebar 1 Slide the boots 1 off the inline cable adjuster sleeve 2 Loosen the adjuster locknut 3 2 Turn the adjuster until 1 16 to 1 8 freeplay is achieved at the thumb lever Flip the throttle lever several times to confirm adjustment 3 Tighten the locknut and slide the boots over the cable adjuster unti...

Page 89: ...h through the sprocket hub and into the eccentric axle housing 5 Roll the vehicle ahead or back to adjust chain slack to the proper dimension 6 Tighten the caliper mount bolts to 10 12 ft lbs 1 4 1 7 kg m 7 Tighten the eccentric locking bolts to 45 ft lbs 6 2 kg m 8 Confirm correct tension by rolling the vehicle forward checking chain tension in several places around the chain 9 Reinstall the chai...

Page 90: ...RPM is 1200 200 If the engine idle speed is unsatisfactory and all other conditions are favorable the carburetor can be adjusted as follows 1 Start the engine and allow it to warm up for approximately five minutes 2 Place the transmission in gear with the parking brake applied 3 Adjust the carburetor idle screw 1 in or out until the desired idle RPM is reached Turning the screw in clockwise will r...

Page 91: ...ase in elevation Although this power cannot be regained adjustments to the carburetor and drive system can be made to allow more efficient operation Optional jets available from your Polaris dealer are required for operation above 6 000 feet and temperatures below 40 degrees F 4 degrees C NOTE Continuous operation of the engine without proper jetting when required can cause poor performance overhe...

Page 92: ...on top of the side panel behind the fuel tank With a quick and firm motion push down on the side panel to disengage the top rear two tabs Then pull up on side panel to disengage front upper and lower tabs 4 To reinstall the side panel align the panel tabs with the slots on the front cab Push the panel upward and forward until the tabs lock Bend the rear of the side panel and insert the two tabs in...

Page 93: ...rrows on the tire point toward forward rotation 2 Attach the wheel nuts and finger tighten them Make sure the tapered side of the rear wheel nut fits into the taper on the wheel 1 3 Lower the vehicle to the ground 4 Securely tighten the wheel nuts to the following torque Torque center and rear wheel nuts to 50 ft lbs 6 9 kg m Torque front wheel nuts to 20 ft lbs 2 1 kg m Improper wheel installatio...

Page 94: ...uld lead to loss of control and serious injury or death Always replace tires when the tread depth measures 1 8 3 cm or less Use of non standard size or type of tires or improper tire inflation may adversely affect vehicle maneuverability and cause loss of control resulting in serious injury or death Maintain proper tire pressure as outlined in this owner s manual When replacing a tire always use o...

Page 95: ...0 lbs 363 kg Front Rack Load Capacity 75 lbs 34 kg Gross Vehicle Weight 1970 lbs 894 kg including vehicle driver and cargo Vehicle weighs 895 lbs 406 kg The following items should be checked for tightness occasionally or if they ve been loosened for service Axle and Wheel Nut Torque Specifications Item Specification Front Spindle Nut s 100 in lbs Front Wheel Nuts 20 ft lbs Center and Rear Axle Nut...

Page 96: ... caused by use of an improper spark plug or incorrect carburetion adjustments 2 Wet Fouled The wet fouled insulator tip is black A damp oil film covers the firing end There may be a carbon layer over the entire nose Generally the electrodes are not worn General causes of fouling are excessive oil use of non recommended oil improper use of the choke or incorrect carburetion adjustments Spark Plug R...

Page 97: ...e still suspected to be in the muffler drive the vehicle onto the incline so the front of the vehicle is one foot higher than the rear Set the parking brake and block the wheels Make sure the vehicle is in neutral and repeat steps 3 and 4 7 Repeat steps 3 through 6 until no more particles are expelled when the engine is revved 8 Stop the engine and allow the arrestor to cool Reinstall the arrestor...

Page 98: ...G Failure to comply with the instructions in this warning can result in severe injury or death Do not modify any component of the PVT system Doing so may reduce its strength so that a failure may occur at a high speed The PVT system has been precision balanced Any modification will cause the system to be out of balance creating vibration and additional loads on components The PVT system rotates at...

Page 99: ...n If cleaning is necessary remove the corrosion with a stiff wire brush Wash with a solution of one tablespoon baking soda and one cup water Rinse well with tap water and dry off with clean rags Coat the terminals with dielectric grease or petroleum jelly Be careful not to allow cleaning solution or tap water into the battery 2 1 Battery electrolyte is poisonous It contains sulfuric acid Serious b...

Page 100: ...e the battery vent tube from the battery 3 Disconnect the black negative battery cable first 4 Disconnect the red positive battery cable next 5 Lift the battery out of the vehicle Becareful not to tip it sideways and spill electrolyte 1 Improperly connecting or disconnecting battery cables can result in an explosion and cause serious injury or death When removing the battery always disconnect the ...

Page 101: ...he black negative cable 5 Reinstall the battery cover and attach the hold down strap 6 Verify that cables are properly routed NOTE When installing a new battery make sure it s fully charged prior to its initial use Using a new battery that has not been fully charged can damage the battery and result in a shorter life It can also hinder vehicle performance Battery Storage When the vehicle is placed...

Page 102: ...emove the boot and locking collar from the back of the lamp housing 7 Grasp the base of the lamp and lift it out 8 Reverse the previous steps to replace the lamp and reassemble the pod Make sure the tab on the lamp locates properly in the housing WARNING Poor lighting while driving can result in severe injury or death Headlight and taillight lenses become dirty during normal operation Wash the hea...

Page 103: ...m a wall 2 Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height 3 Start the engine and turn the headlight switch to high beam 4 Observe the headlight aim on the wall The most intense part of the headlight beam should be aimed two inches 5 1 cm below the mark placed on the wall NOTE Include rider weight on the seat when measuring 5 Adjust...

Page 104: ... the speedometer harnesses from the speedometer Unplug the indicator light harness and remove the pod cover 4 Unplug the headlamp from the wiring harness 5 Remove the o ring 1 from the headlight pivot pins 6 Pull the headlight housing up to release from the locking tabs 7 Lift the adjusting knob up to remove from the locking tabs 8 Carefully pull the assembly up and out of pod 9 Reverse the steps ...

Page 105: ...sembly 2 Remove the lamp 1 and replace it with the recommended lamp 3 Test the taillight brakelight to see that it s working 4 Reinstall the gasket and lens cover Indicator Lamp Replacement 1 Follow steps 1 3 of Headlight Housing Replacement on page 102 2 Unplug the light from the harness 3 Using a screwdriver turn the light 1 4 turn counterclockwise 1 4 Install new light and use a screwdriver to ...

Page 106: ...t and the lower parts last Rinse with water frequently and dry with a chamois to prevent water spots If a high pressure car wash system is used not recommended use extreme care to avoid water damage to the drive chain wheel bearings transmission seals body panels brakes and warning labels Grease all zerk fittings immediately after washing with a high pressure system Allow the vehicle to run long e...

Page 107: ...nsion pivot points the lower steering post and the rear axle fittings 6 Drain the recoil housing 7 Block the vehicle so all tires are suspended off the ground 8 Cover the vehicle with a canvas cover Do not use plastic or coated materials since they do not allow ventilation of the vehicle Transporting the Vehicle Follow these procedures before transporting the vehicle with another unit 1 Turn off t...

Page 108: ...ight 895 lbs 406 kgs Minimum Turning Radius 98 in 249 cm unloaded Front Suspension MacPherson Strut 6 7 17 cm travel Rear Suspension Swing arm w scissor stabilizer 7 5 19 cm travel Engine Oil Capacity Two quarts 1 89 liters Coolant Capacity 2 25 quarts 2 13 liters Engine EH50PLE10 Displacement 499cc Bore x Stroke 92 x 75 mm Pilot Jet 40 Main Jet 142 5 Needle Jet Q 4 829 Jet Needle 4HB41 3 Pilot Sc...

Page 109: ...aliper Parking Brake Hydraulic lock all wheel Headlight 12v 60w Taillights 12v 5w Clutching and Jetting Charts Altitude AMBIENT TEMPERATURE Below 40 F Below 5 C 40 F and above 5 C and above Meters Feet 0 1800 0 6000 150 145 1800 3700 6000 12000 142 5 137 5 Altitude Shift Weight Drive Clutch Spring Driven Clutch Spring Helix Spring Setting Meters Feet 0 1800 0 6000 20 56 PN 5631215 Blue Green PN 70...

Page 110: ... 8 oz 2871654 Premium Drive Hub Fluid 8 oz Grease Specialized Lubricants 2871312 Grease Gun Kit Premium All Season 3 oz 2871322 Premium All Season Grease 3 oz cartridge 2871423 Premium All Season Grease 14 oz cartridge 2871460 Starter Drive Grease 2 oz 2871515 Premium U Joint Lube 3 oz 2871551 Premium U Joint Lube 14 oz 2871329 Dielectric Grease Nyogelt Coolant 2871323 60 40 Coolant gal 2871534 60...

Page 111: ...or effi cient engagement Stuck in mud or snow Carefully use fast aggressive throttle application to engage clutch WARNING Excessive throttle may cause loss of control and vehicle overturn Climbing over large objects from a stopped position Carefully use fast brief aggressive throttle ap plication to engage clutch WARNING Exces sive throttle may cause loss of control and ve hicle overturn Belt slip...

Page 112: ... is turned off Turn the fuel valve on Old or non recommended fuel Replace with new fuel Fouled or defective spark plug s Inspect plug s replace if necessary No spark to spark plug Inspect plug s verify stop switch is on Crankcase filled with water or fuel Immediately see your Polaris dealer Overuse of choke Inspect clean and or replace spark plugs Clogged fuel filter Replace the filter Low battery...

Page 113: ...se ignition connections Check all connections and tighten Water present in fuel Replace with new fuel Low battery voltage Recharge battery to 12 5 VDC Kinked or plugged fuel vent line Inspect and replace Incorrect fuel Replace with recommended fuel Clogged air filter Inspect and clean or replace Reverse speed limiter malfunction See your Polaris dealer Electronic throttle control malfunction See y...

Page 114: ... battery voltage Recharge battery to 12 5 VDC Incorrect fuel Replace with recommended fuel Clogged air filter Inspect and clean or replace Reverse speed limiter malfunction See your Polaris dealer Electronic throttle control malfunction See your Polaris dealer Other mechanical failure See your Polaris dealer Overheated engine Clean radiator screen and core if equipped Clean engine exterior See you...

Page 115: ...ntitlement If you have not signed the original registration and received the customer copy please contact your dealer immediately NO WARRANTY COVERAGE WILL BE ALLOWED UNLESS YOUR VEHICLE IS REGISTERED WITH POLARIS Initial dealer preparation and set up of your vehicle is very important in ensuring trouble free operation Purchasing a machine in the crate or without proper dealer set up will void you...

Page 116: ...CLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY Some states do not allow limitations on how long an implied warranty lasts so the above limitation may not apply to you if inconsistent with controlling state law HOW TO OBTAIN WARRANTY SERVICE If your vehicle requires warranty service you must take it to a Polaris Servicing Dealer When requesting warranty service you must present your copy...

Page 117: ...e RPM Adjustment 88 Equipment Modifications 11 F FEATURES 35 36 Filter Systems 81 82 Front Gearcase Lubrication 74 Front Wheel and Middle Axle Brake 85 Front Wheel Hub Tightening 86 Fuel Safety 32 Fuel System 43 G Gear Selector Operation 44 Gearcase Oil Changing 74 H Handlebar Adjustment 84 Hauling Cargo 50 51 Headlight Adjustment 101 Headlight Housing Replacement 102 Headlight Lamp Replacement 10...

Page 118: ...g the Vehicle 105 Suspension Springs 84 Switches and Indicators 37 38 T TABLE OF CONTENTS 5 Taillight Brakelight Lamp Replacement 103 Throttle Lever 39 T Tire Specifications 93 Tires 92 Toe Alignment 83 Tool Kit 66 Torque Specifications 93 Towing Capacities 50 Transmission Lubrication 73 Transmission Oil Change 73 Transporting the Vehicle 105 TROUBLESHOOTING 109 112 Turning Around on a Hill 59 V V...

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Polaris PTV 6x6 SERIES 10, Owner'S Manual

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