2008 Polaris Sportsman 6x6 Owners Manual
2008 Polaris Sportsman 6x6 Manual
2008 Polaris Sportsman 6x6 manual content summary:
- 2008 Polaris Sportsman 6x6 | Owners Manual - Page 1
- 2008 Polaris Sportsman 6x6 | Owners Manual - Page 2
relax when used for more than 5 minutes. When parking on grades, leave shift in forward. LOCATE AND READ OWNER'S MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS. IF OWNER'S MANUAL IS MISSING, CONTACT A POLARIS DEALER FOR A REPLACEMENT. For your nearest Polaris dealer, call 1-800-POLARIS or visit www - 2008 Polaris Sportsman 6x6 | Owners Manual - Page 3
WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm. - 2008 Polaris Sportsman 6x6 | Owners Manual - Page 4
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 - 2008 Polaris Sportsman 6x6 | Owners Manual - Page 5
reprinting or reuse of the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited. Printed in U.S.A. 2008 Sportsman 6X6 Owner's Manual P/N 9921309 2 - 2008 Polaris Sportsman 6x6 | Owners Manual - Page 6
TABLE OF CONTENTS Know Your Vehicle ...5 Safety ...6 Features and Controls ...34 Operation ...50 Emission Control Systems ...69 Maintenance ...70 Adjustments ...115 Troubleshooting ...120 Specifications ...124 Polaris Products...126 Warranty ...127 Maintenance Log ...137 Index ...140 3 - 2008 Polaris Sportsman 6x6 | Owners Manual - Page 7
4 - 2008 Polaris Sportsman 6x6 | Owners Manual - Page 8
responsible for your personal safety, the safety of others, and the protection of our environment. Read and understand your owner's manual, which includes valuable information about all aspects of your vehicle, including safe operating procedures. Vehicle Identification Numbers Record your vehicle - 2008 Polaris Sportsman 6x6 | Owners Manual - Page 9
of the decals on the ATV carefully. If any of the decals depicted in this manual differ from the decals on your ATV, always read and follow the instructions of the decals on the ATV. If any decal becomes illegible or comes off, contact your Polaris dealer to purchase a replacement. Replacement - 2008 Polaris Sportsman 6x6 | Owners Manual - Page 10
hilly terrain, reduce speed and cargo. Do not block headlight. Be careful if load extends over the side of the rack or box. Read Owner's Manual for more detailed loading information. Front Rack/Box Warning WARNING DO NOT TOW FROM RACK OR BUMPER. Vehicle damage or tipover may result causing severe - 2008 Polaris Sportsman 6x6 | Owners Manual - Page 11
SAFETY Safety Decals and Locations Age 16 Warning Container/No Passenger Warning + + + Clutch Cover Warning Age 16 Warning WARNING Operating this ATV if you are under the age of 16 increases your chance of severe injury or death. NEVER operate this ATV if you are under age 16. Container/No - 2008 Polaris Sportsman 6x6 | Owners Manual - Page 12
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. Hitch Capacity Label TRAILER MAX WEIGHT: 1500 LBS. (682 KG) ON LEVEL GROUND 850 LBS. (386 KG) UP TO 15° GRADE HITCH MAX. VERTICAL WEIGHT - 2008 Polaris Sportsman 6x6 | Owners Manual - Page 13
SAFETY Safe Riding Gear Always wear appropriate clothing when riding an ATV. Wear protective clothing for comfort and to reduce the chance of injury. Eye Protection Gloves Long Pants Helmet Long Sleeves Boots Helmet Wearing a helmet can prevent a severe head injury. Whenever riding a Polaris - 2008 Polaris Sportsman 6x6 | Owners Manual - Page 14
Safe Riding Gear SAFETY Eye Protection Do not depend on eyeglasses or sunglasses for eye protection. Whenever riding a Polaris vehicle, always wear shatterproof goggles or use a shatterproof helmet face shield. Polaris recommends wearing approved Personal Protective Equipment (PPE) bearing - 2008 Polaris Sportsman 6x6 | Owners Manual - Page 15
routine maneuvers like turning, or driving on hills or over obstacles, if you fail to take proper precautions. Read and understand your owner's manual and all warnings before operating a Polaris ATV. Age Restrictions This vehicle is an ADULT VEHICLE ONLY. Operation is prohibited for anyone under 16 - 2008 Polaris Sportsman 6x6 | Owners Manual - Page 16
priority for Polaris. When you purchased your new ATV, your dealer instructed you on the authorized ATV RiderCoursesm available to you and your eligible follow the recommended maintenance program outlined in your owner's manual. This preventive maintenance program is designed to ensure that - 2008 Polaris Sportsman 6x6 | Owners Manual - Page 17
symbols are used. Become familiar with their meanings before reading the manual. The safety alert symbol, on your vehicle or in this manual, alerts you to the potential for injury. WARNING The safety alert to the vehicle. NOTE A note will alert you to important information or instructions. 14 - 2008 Polaris Sportsman 6x6 | Owners Manual - Page 18
Safety WARNING SAFETY Serious injury or death can result if you do not follow these instructions and procedures, which are outlined in further detail within your owner's manual. • Read this manual and all labels carefully, and follow the operating procedures described. • Never operate an ATV - 2008 Polaris Sportsman 6x6 | Owners Manual - Page 19
weight uphill. Never attempt to turn the ATV 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. • Always use proper procedures if you stall or roll backwards while climbing a hill. To avoid - 2008 Polaris Sportsman 6x6 | Owners Manual - Page 20
• Never exceed the stated load capacity for your ATV. Cargo must be properly distributed and securely attached. Reduce speed and follow the instructions in this manual for carrying cargo or towing. Allow a greater distance for braking. • Always remove the ignition key when the vehicle is not in use - 2008 Polaris Sportsman 6x6 | Owners Manual - Page 21
SAFETY Operator Safety Equipment Modifications We are concerned for the safety of our customers and for the general public. Therefore, we strongly recommend that consumers do not install on a Polaris ATV any equipment that may increase the speed or power of the vehicle, or make any other - 2008 Polaris Sportsman 6x6 | Owners Manual - Page 22
WARNING SAFETY POTENTIAL HAZARD Operating this ATV without proper instruction. WHAT CAN HAPPEN The risk of an accident skills learned in the course and the operating techniques described in the Owner's Manual. For more information about the ATV RiderCoursesm contact ATV Enrollment Express at (800 - 2008 Polaris Sportsman 6x6 | Owners Manual - Page 23
SAFETY Operator Safety WARNING POTENTIAL HAZARD Carrying a passenger on an ATV. WHAT CAN HAPPEN Carrying a passenger greatly reduces the operator's ability to balance and control the ATV, which could cause an accident and injury to the operator and/or passenger. A passenger riding on a rack or in - 2008 Polaris Sportsman 6x6 | Owners Manual - Page 24
Operator Safety WARNING POTENTIAL HAZARD Operating this ATV on public streets, roads or highways. WHAT CAN HAPPEN The ATV could collide with another vehicle. HOW TO AVOID THE HAZARD Never operate the ATV on any public street, road or highway, including dirt and gravel roads. In many states it's - 2008 Polaris Sportsman 6x6 | Owners Manual - Page 25
SAFETY Operator Safety WARNING POTENTIAL HAZARD Operating the ATV 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/ - 2008 Polaris Sportsman 6x6 | Owners Manual - Page 26
ATV before each use to make sure it's in safe operating condition. Always follow the inspection and maintenance procedures and schedules described in the owner's manual. 23 - 2008 Polaris Sportsman 6x6 | Owners Manual - Page 27
SAFETY Operator Safety WARNING 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 ATV. If the operator's foot - 2008 Polaris Sportsman 6x6 | Owners Manual - Page 28
loss of control and lead to a collision or overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for turning as described in the owner's manual. Practice turning at slow speeds before attempting to turn at faster speeds. Never turn at excessive speed. 25 - 2008 Polaris Sportsman 6x6 | Owners Manual - Page 29
could cause loss of control or overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for climbing hills as described in the owner's manual. Always check the terrain carefully before ascending any hill. Never operate the ATV on hills steeper than 15 degrees. Never climb hills with - 2008 Polaris Sportsman 6x6 | Owners Manual - Page 30
procedures for traveling down hills as described in the owner's manual. NOTE: A special technique is required when braking while traveling ve mastered the turning technique (on level ground) as described in the owner's manual. See page 64. Use extra caution when turning on any hill. Avoid crossing - 2008 Polaris Sportsman 6x6 | Owners Manual - Page 31
If all forward speed is lost: Keep your weight uphill. Apply the service brakes. Lock the parking brake when fully stopped. Never back down a engine power. Never apply the rear brake while rolling backwards. Apply the service brake gradually. When fully stopped, apply the rear brake as well, and - 2008 Polaris Sportsman 6x6 | Owners Manual - Page 32
such as rocks and fallen trees when possible. If unavoidable, use extreme caution and always follow proper procedures as outlined in the owner's manual. WARNING POTENTIAL HAZARD Skidding or sliding. WHAT CAN HAPPEN Skidding or sliding can cause loss of control. If the tires regain traction - 2008 Polaris Sportsman 6x6 | Owners Manual - Page 33
SAFETY Operator Safety WARNING POTENTIAL HAZARD Operating the ATV through deep or fast-flowing water. WHAT CAN HAPPEN Tires may float, causing loss of traction and loss of control, which could lead to an accident or overturn. HOW TO AVOID THE HAZARD Avoid operating the ATV through deep or fast- - 2008 Polaris Sportsman 6x6 | Owners Manual - Page 34
tires specified for the ATV in the owner's manual. Always maintain proper tire pressure as described in the owner's manual and on safety decals. WARNING POTENTIAL HAZARD Operating installed and used according to approved instructions. See your authorized Polaris ATV dealer for more information. 31 - 2008 Polaris Sportsman 6x6 | Owners Manual - Page 35
and securely attached. Reduce speed when carrying cargo or pulling a trailer. Allow a greater distance for braking. Always follow the instructions in the owner's manual for carrying cargo or pulling a trailer. WARNING POTENTIAL HAZARD Operating on frozen bodies of water. WHAT CAN HAPPEN Severe - 2008 Polaris Sportsman 6x6 | Owners Manual - Page 36
SAFETY Operating a damaged ATV can result in an accident with serious injury or death. After any overturn or accident, have a qualified service dealer inspect the entire machine for possible damage, including (but not limited to) brakes, throttle and steering systems. WARNING Safe operation of - 2008 Polaris Sportsman 6x6 | Owners Manual - Page 37
FEATURES AND CONTROLS Switches Headlight Switch AWD Switch Mode/Reverse Override Switch Main Key Switch Engine Stop Switch WARNING Activating the override switch while the throttle is open can cause loss of control, resulting in severe injury or death. Do not activate the override switch while - 2008 Polaris Sportsman 6x6 | Owners Manual - Page 38
Switches FEATURES AND CONTROLS Engine Stop Switch Move the stop switch to the center (OFF) position to stop the engine quickly. The stop switch provides the operator with a quick means of engine shutdown in case of stuck throttle or other emergency. The engine will not start or run when the switch - 2008 Polaris Sportsman 6x6 | Owners Manual - Page 39
to severe injury or death. Never start or operate an ATV with a sticking or improperly operating throttle. Always contact your dealer for service if throttle problems arise. Failure to check or maintain proper operation of the throttle system can result in an accident if the throttle lever sticks - 2008 Polaris Sportsman 6x6 | Owners Manual - Page 40
is located on the left handlebar. This lever controls both front and rear wheel braking action. Use this lever for normal braking. Apply the service brakes by squeezing the left brake lever toward the handlebar. These brakes are hydraulically activated disc brakes. Always test brake lever travel and - 2008 Polaris Sportsman 6x6 | Owners Manual - Page 41
FEATURES AND CONTROLS Brake Systems Master Cylinders/Brake Fluid The master cylinders are located on the left and right handlebars. Check fluid levels before each use of the ATV. The fluid level can be seen Master Cylinder through an indicator window on the top of the master cylinder. This eye will - 2008 Polaris Sportsman 6x6 | Owners Manual - Page 42
Parking Brake FEATURES AND CONTROLS WARNING Operating the ATV while the parking brake is engaged could result in an accident and serious injury or death. Always check to be sure the parking brake is disengaged before operating. Locking the Parking Brake 1. Squeeze and release the brake lever two - 2008 Polaris Sportsman 6x6 | Owners Manual - Page 43
FEATURES AND CONTROLS Fuel Tank Cap Remove the fuel tank cap to add fuel to the fuel tank. Use either leaded or unleaded gasoline with a minimum pump octane number of 87=(R+ M/2) octane. Do not use E-85 fuel. Fuel Valve Fuel Tank Cap Fuel Valve The fuel valve is located on the left side panel. It - 2008 Polaris Sportsman 6x6 | Owners Manual - Page 44
left unattended. Maintaining shift linkage adjustment is important to assure proper transmission function. See your dealer if you experience any shifting problems. H L N R CAUTION Shifting gears with the engine speed above idle or while the vehicle is moving could cause transmission damage. To - 2008 Polaris Sportsman 6x6 | Owners Manual - Page 45
FEATURES AND CONTROLS Recoil Starter If the battery is too weak to start the engine, use the recoil starter. The recoil starter is located on the right side of the vehicle. Follow the starting procedures on page 53, cranking the engine with the recoil starter instead of the main key switch. 1. Grasp - 2008 Polaris Sportsman 6x6 | Owners Manual - Page 46
All Wheel Drive (AWD) System FEATURES AND CONTROLS The All Wheel Drive system is controlled by the AWD switch. When the switch is off, the vehicle is in rear wheel drive at all times. When the switch is on, the vehicle is in AWD and the front wheels will automatically engage any time the rear - 2008 Polaris Sportsman 6x6 | Owners Manual - Page 47
the vehicle and shift to forward gear. 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 AWD switch. See page 34. WARNING Operating with only - 2008 Polaris Sportsman 6x6 | Owners Manual - Page 48
Instrument Cluster FEATURES AND CONTROLS Your ATV is equipped with an instrument cluster that senses vehicle speed from the right front wheel. The instrument cluster measures distance in miles or kilometers as well as hours of operation. It also includes a reverse speed limiter function that - 2008 Polaris Sportsman 6x6 | Owners Manual - Page 49
8 1 2. AWD Indicator - This indicator illuminates when the electrical portion of the AWD system is enabled. 3. Engine Hour Display Indicator 4. Service Interval/Diagnostic Mode Indicator 5. Low Battery and Over Voltage - This warning usually indicates that the ATV is operating at an RPM too low to - 2008 Polaris Sportsman 6x6 | Owners Manual - Page 50
Instrument Cluster FEATURES AND CONTROLS Rider Information Center Standard Modes The rider information center has 4 standard modes. The reverse override button on the left handlebar is also the mode button. NOTE: If using the mode button to program the rider information center, or to toggle - 2008 Polaris Sportsman 6x6 | Owners Manual - Page 51
FEATURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode The diagnostic mode is for informational purposes only. Please return your ATV to your dealer for all major repairs. As long as the gauge is in the diagnostic mode, the wrench icon will remain lit. To leave the - 2008 Polaris Sportsman 6x6 | Owners Manual - Page 52
faster. When the desired time increment is displayed, release the button and wait for the wrench to stop flashing. When the wrench stops blinking, your service hours are set. NOTE: If you scroll past the intended number, hold the button down until the count turns over to 0. You can then reset - 2008 Polaris Sportsman 6x6 | Owners Manual - Page 53
OPERATION Fuel Safety WARNING Gasoline is highly flammable and explosive under certain conditions. • Always exercise extreme caution whenever handling gasoline. • Always refuel with the engine stopped, and outdoors or in a well ventilated area. • Do not smoke or allow open flames or sparks in or - 2008 Polaris Sportsman 6x6 | Owners Manual - Page 54
Break-In Period OPERATION The break-in period for your new Polaris ATV is the first ten hours of operation, or the time it takes to use the first two full tanks of gasoline. No single action on your part is as important as following the procedures for a proper break-in. Careful treatment of a new - 2008 Polaris Sportsman 6x6 | Owners Manual - Page 55
OPERATION Pre-Ride Checklist WARNING If a proper inspection is not done before each use, severe injury or death could result. Always inspect the vehicle before each use to ensure it's in proper operating condition. Item Brake system/lever travel Brake fluid Auxiliary brake Front suspension Rear - 2008 Polaris Sportsman 6x6 | Owners Manual - Page 56
Starting the Engine WARNING OPERATION Engine exhaust contains poisonous carbon monoxide and can cause loss of consciousness resulting in severe injury or death. Never run an engine in an enclosed area. 1. Position the vehicle on a level surface. 2. Place the transmission in neutral. 3. Lock the - 2008 Polaris Sportsman 6x6 | Owners Manual - Page 57
OPERATION Starting the Engine 8. Turn the ignition key past the ON position to engage the starter. Activate the starter for a maximum of five seconds, releasing the key when the engine starts. 9. If the engine does not start, return the key to the OFF position and wait five seconds before - 2008 Polaris Sportsman 6x6 | Owners Manual - Page 58
the load distribution warning labels on the vehicle, and never exceed the weight capacities outlined in the specifications section of the owner's manual and on the safety decals. WARNING Overloading the vehicle or carrying or towing cargo improperly can alter vehicle handling and may cause loss - 2008 Polaris Sportsman 6x6 | Owners Manual - Page 59
OPERATION Hauling Cargo Dumping Cargo 1. Select a level site to dump the cargo. Do not attempt to dump or unload the vehicle while parked on an incline. 2. Lock the parking brake. 3. Dismount the vehicle. 4. Check cargo distribution. If cargo has shifted to the rear of the box, exercise caution. - 2008 Polaris Sportsman 6x6 | Owners Manual - Page 60
Hauling Cargo OPERATION Load Distribution Load cargo as far forward as possible 1. Never exceed the maximum capacities for hauling cargo as stated on the load distribution warning labels and on page 55. 2. Always load the cargo box with the load as far forward as possible. 3. Always operate the - 2008 Polaris Sportsman 6x6 | Owners Manual - Page 61
OPERATION Driving Safely Driving Procedures 1. Wear protective riding gear. See page 10. 2. Sit upright with both feet on the footrests and both hands on the handlebars. 3. Start the engine and allow it to warm up. See page 53. 4. Shift the transmission into gear. 5. Check your surroundings and - 2008 Polaris Sportsman 6x6 | Owners Manual - Page 62
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 - 2008 Polaris Sportsman 6x6 | Owners Manual - Page 63
OPERATION Driving Safely Driving on Slippery Surfaces Whenever riding on slippery surfaces such as wet trails or loose gravel, or during freezing weather, follow these precautions: 1. Slow down when entering slippery areas. 2. Engage AWD before wheels begin to lose traction. 3. Maintain a high - 2008 Polaris Sportsman 6x6 | Owners Manual - Page 64
injury or death. Avoid climbing steep hills (15° maximum). Use extreme caution when operating on hills, and follow proper operating procedures outlined in the owner's manual. 61 - 2008 Polaris Sportsman 6x6 | Owners Manual - Page 65
resulting in severe injury or death. Avoid crossing the side of a hill when possible. Follow proper procedures as outlined in the owner's manual. Sidehilling can dangerous and should be avoided if at all possible. If you encounter a situation where sidehilling is necessary, follow these precautions - 2008 Polaris Sportsman 6x6 | Owners Manual - Page 66
. 4. Apply the brakes slightly to gradually slow the vehicle. NOTE: Before operating your ATV, learn how to use the auxiliary brake for emergency situations (if service brakes become inoperable). 63 - 2008 Polaris Sportsman 6x6 | Owners Manual - Page 67
, or on the left if the vehicle is pointing straight uphill. 4. Staying uphill of the vehicle, turn the handlebars full left. 5. While holding the service brake, release the parking brake lock and slowly allow the vehicle to roll around to your right until it's pointing across the hill or slightly - 2008 Polaris Sportsman 6x6 | Owners Manual - Page 68
brakes by applying light pressure to the lever until braking action is normal. After running the vehicle in water, it's critical to have it serviced as outlined in the maintenance chart. See page 70. The following areas need special attention: engine oil, transmission oil, front and rear gearcases - 2008 Polaris Sportsman 6x6 | Owners Manual - Page 69
OPERATION Driving Safely Driving Over Obstacles Be alert! Look ahead and learn to read the terrain you're traveling on. Be constantly alert for hazards such as logs, rocks and low hanging branches. WARNING Severe injury or death can result if your vehicle comes in contact with a hidden obstacle. - 2008 Polaris Sportsman 6x6 | Owners Manual - Page 70
Driving Safely OPERATION Driving in Reverse Follow these precautions when operating in reverse: 1. Always check for obstacles or people behind the vehicle. 2. Always avoid backing downhill. 3. Back slowly. 4. Apply the brakes lightly for stopping. 5. Avoid turning at sharp angles. 6. Never open - 2008 Polaris Sportsman 6x6 | Owners Manual - Page 71
OPERATION Driving Safely Parking on an Incline Avoid parking on an incline if possible. If it's unavoidable, follow these precautions: 1. Stop the engine. 2. Place the transmission in gear. 3. Lock the parking brake. 4. Always block the rear wheels on the downhill side. 5. Turn the fuel valve off - 2008 Polaris Sportsman 6x6 | Owners Manual - Page 72
Public Lands in the U.S.A. Your Polaris vehicle has a spark arrestor that was tested and qualified to be in accordance with the USDA Forest Service Standard 5100-1C. Federal law requires that this spark arrestor be installed and functional when the vehicle is operated on public lands. Operation of - 2008 Polaris Sportsman 6x6 | Owners Manual - Page 73
upon average riding conditions and an average vehicle speed of approximately 10 miles per hour. Vehicles subjected to severe use must be inspected and serviced more frequently. Severe Use Definition • Frequent immersion in mud, water or sand • Racing or race-style high RPM use • Prolonged low speed - 2008 Polaris Sportsman 6x6 | Owners Manual - Page 74
Failure to conduct this maintenance will not void the emissions warranty but may affect emissions.) Q Have an authorized Polaris dealer perform these services. WARNING Improperly performing the procedures marked with a Q could result in component failure and lead to serious injury or death. Have an - 2008 Polaris Sportsman 6x6 | Owners Manual - Page 75
/flange X Front hub bearings (if equipped) Drive belt Cooling system (if applicable) X Perform these procedures more often for vehicles subjected to severe use. E Emission-Related Service Q Have an authorized Polaris dealer perform these - 2008 Polaris Sportsman 6x6 | Owners Manual - Page 76
Q Brake fluid Spark arrestor Idle speed Q Toe adjustment X Auxiliary brake Q Headlight aim X Perform these procedures more often for vehicles subjected to severe use. E Emission-Related Service Q Have an authorized Polaris dealer perform these - 2008 Polaris Sportsman 6x6 | Owners Manual - Page 77
MAINTENANCE Lubrication Recommendations Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart beginning on page 70. Items not listed in the chart should be lubricated at the general lubrication interval. NOTE: The a-arms and lower control arms are lubricated - 2008 Polaris Sportsman 6x6 | Owners Manual - Page 78
Lubrication Recommendations Front Prop Shaft Yoke MAINTENANCE Tie Rod Ends Swing Arm Bushings AWD Hubs Middle Axle Bearings Ball Joint 4:00 Position Center Swing Arm Housing Rear Strut Rear Axle Bearing 75 - 2008 Polaris Sportsman 6x6 | Owners Manual - Page 79
MAINTENANCE Engine Oil Oil Recommendations Polaris recommends the use of Polaris PS-4 PLUS Performance Synthetic 2W-50 4-cycle oil or a similar oil for this engine. Oil may need to be changed more frequently if Polaris oil is not used. Always use 2W-50 oil. Follow the manufacturer's recommendations - 2008 Polaris Sportsman 6x6 | Owners Manual - Page 80
Engine Oil Oil Level The oil dipstick is on the left side of the ATV. 1. Position the vehicle on a level surface. 2. Start the engine. Allow it to idle for 20-30 seconds. Stop the engine. 3. Remove the dipstick. Wipe it dry with a clean cloth. 4. Reinstall the dipstick securely. NOTE: The dipstick - 2008 Polaris Sportsman 6x6 | Owners Manual - Page 81
MAINTENANCE Oil and Filter Change CAUTION Hot oil can cause serious burns to skin. Do not allow hot oil to contact skin. If the ATV is left without oil in the system for extended periods, the oil pump may lose its prime, which could result in engine damage. Always replace the oil and filter within - 2008 Polaris Sportsman 6x6 | Owners Manual - Page 82
Oil and Filter Change MAINTENANCE 8. Reinstall the screen fitting and rotate the fitting clockwise a minimum of 2 1/2 turns into the tank threads. Continue to rotate the fitting until the nipple of the fitting aligns with the mark on the tank. NOTE: Do not over-tighten. Maximum torque for the - 2008 Polaris Sportsman 6x6 | Owners Manual - Page 83
MAINTENANCE Oil Pump Priming Oil and Filter Change This priming procedure must be Tank performed whenever the oil hose 2" connection between the oil tank and (5 cm) pump inlet has been disconnected. 1. Clamp or pinch off the vent line approximately 2" (5 cm) from the oil tank, between the end of - 2008 Polaris Sportsman 6x6 | Owners Manual - Page 84
Transmission Oil MAINTENANCE Always check and change the transmission oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 70. Maintain the oil level at the bottom of the fill plug hole threads. We recommend the use of Polaris Premium AGL Synthetic Gearcase Lubricant. - 2008 Polaris Sportsman 6x6 | Owners Manual - Page 85
MAINTENANCE Front Gearcase Oil Always check and change the front gearcase oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 70. Maintain the oil level at the bottom of the fill hole threads. We recommend the use of Polaris Premium ATV Angle Drive Fluid. See page 126 - 2008 Polaris Sportsman 6x6 | Owners Manual - Page 86
Cooling System MAINTENANCE 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 ( - 2008 Polaris Sportsman 6x6 | Owners Manual - Page 87
MAINTENANCE Cooling System Radiator Coolant To ensure that the coolant maintains its ability to protect the engine, Polaris recommends that you drain the system completely every two years and add a fresh mixture of antifreeze and water. Replace the coolant any time the cooling system has been - 2008 Polaris Sportsman 6x6 | Owners Manual - Page 88
Brakes MAINTENANCE Rear Brake The transmission brake is a hydraulic disc brake. This brake is activated by the left brake lever, which also activates the front brakes. The transmission brake system is selfadjusting. Periodically check the brake pads for wear. Replace brake pads when they are worn - 2008 Polaris Sportsman 6x6 | Owners Manual - Page 89
) toe out alignment. 5. Repeat the measurement procedure on the other side of the vehicle. NOTE: If you discover improper alignment, see your Polaris dealer for service. 86 - 2008 Polaris Sportsman 6x6 | Owners Manual - Page 90
assembly of the ATV should be checked periodically for loose nuts and bolts. If loose nuts and bolts are found, see your Polaris dealer for service before operating the vehicle. Side Panel Removal 1. Remove the seat. 2. Grasp the rear of the side panel near the rear cab. With a quick and firm - 2008 Polaris Sportsman 6x6 | Owners Manual - Page 91
proper tire pressure as described on the decal on your ATV and in the owner's manual. Always use original equipment size and type when replacing tires. Make sure the wheels spindle nut retention are critical component operations. All service must be performed by your authorized Polaris dealer. 88 - 2008 Polaris Sportsman 6x6 | Owners Manual - Page 92
to specification. Tapered Nut Axle and Wheel Nut Torque Specifications Check the following nuts for tightness occasionally and when they've been loosened for service. Nut Type Front Spindle Nut(s) Front Wheel Nuts Center and Rear Axle Nut(s) Center and Rear Wheel Nuts Torque 100 in. lbs. (11 Nm - 2008 Polaris Sportsman 6x6 | Owners Manual - Page 93
cover and the seat. CAUTION Operation of your vehicle without a pre-filter can cause engine damage. Always reinstall the pre-filter after removing it for service. Air Box Drain Periodically check the air box drain tube located on the bottom rear of the air box. Empty the drain tube if necessary - 2008 Polaris Sportsman 6x6 | Owners Manual - Page 94
. CAUTION Operation of your vehicle without both the pre-filter and breather filter can cause engine damage. Always reinstall both filters after removing them for service. 91 - 2008 Polaris Sportsman 6x6 | Owners Manual - Page 95
normal operation. Wash the headlights frequently to maintain lighting quality. Hot components can cause serious burns to skin. Allow lamps to cool before servicing. Headlight Lamp Replacement 1. Remove the two screws on the lower front corners of the headlight pod. 2. Remove the screw from the rear - 2008 Polaris Sportsman 6x6 | Owners Manual - Page 96
Lights MAINTENANCE High Beam Adjustment The headlight beam can be adjusted slightly upward or downward. Use the following procedure to make the adjustment. 25 ft. (7.6 m) 2" (5 cm) 1. Position the vehicle on a level surface with the headlight approximately 25 ft. (7.6 m) from a wall. Lock the - 2008 Polaris Sportsman 6x6 | Owners Manual - Page 97
MAINTENANCE Lights Headlight Housing Replacement 1. Remove the two screws on the lower front corners of the headlight pod. 2. Lift the pod slightly while depressing the tabs at the rear of the pod. 3. Lift the pod cover and disconnect the speedometer harnesses from the speedometer. 4. Unplug the - 2008 Polaris Sportsman 6x6 | Owners Manual - Page 98
Lights MAINTENANCE Taillight/Brakelight Lamp Replacement 1. Remove the taillight lens cover mounting screws. Remove the lens cover and gasket and set aside for reassembly. 2. Remove the lamp. 3. Apply dielectric grease to the socket and install the new lamp. 4. Test the light for proper operation. - 2008 Polaris Sportsman 6x6 | Owners Manual - Page 99
MAINTENANCE Spark Plugs Spark Plug Recommendations CAUTION Using non-recommended spark plugs can result in serious engine damage. Always use Polaris-recommended spark plugs. Refer to the specifications section beginning on page 124 for the recommended spark plug type and gap for your vehicle. - 2008 Polaris Sportsman 6x6 | Owners Manual - Page 100
will be few combustion deposits. The electrodes are not burned or eroded. This indicates the proper type and heat range for the engine and the service. NOTE: The tip should not be flaky and white. A white insulator tip indicates overheating, caused by use of an improper spark plug or incorrect fuel - 2008 Polaris Sportsman 6x6 | Owners Manual - Page 101
fuel valve on. Drain Screw 11. Attempt to start the engine. If necessary, repeat the drying procedure. 12. Take the ATV to your dealer for service as soon as possible, whether you succeed in starting it or not. 13. If water has been ingested into the PVT, follow the procedure on - 2008 Polaris Sportsman 6x6 | Owners Manual - Page 102
the spark arrestor could result in serious injury or death. The exhaust system can get extremely hot. Do not perform service on the spark arrestor while the system is hot. Allow components to cool sufficiently before proceeding. Remove any combustible materials from the area. Wear eye - 2008 Polaris Sportsman 6x6 | Owners Manual - Page 103
PVT System WARNING Failure to comply with the instructions in this warning can result in severe injury safe: • Always follow all recommended maintenance procedures. See your dealer as outlined in the owner's manual. • This PVT system is intended for use on Polaris products only. Do not install it - 2008 Polaris Sportsman 6x6 | Owners Manual - Page 104
PVT System MAINTENANCE The basic operation of the Polaris PVT system is dependent on engine speed and vehicle torque requirements. As engine speed increases, the force exerted on the movable drive sheave by the flyweights also increases. This, in turn, increases the amount of pinch applied to the - 2008 Polaris Sportsman 6x6 | Owners Manual - Page 105
Drying There may be some instances when water is accidently ingested into the PVT system. Use the following instructions to dry it out before operating. 1. Remove the drain plug. Allow the water to drain completely the process. 5. Take the vehicle to your dealer for service as soon as possible. 102 - 2008 Polaris Sportsman 6x6 | Owners Manual - Page 106
Battery MAINTENANCE Your ATV may have either a sealed battery, which requires little maintenance, or a conventional battery. A sealed battery can be identified by its flat covers on the top of the battery. A conventional battery has six filler caps on the top of the battery. Conventional Battery - 2008 Polaris Sportsman 6x6 | Owners Manual - Page 107
MAINTENANCE Battery WARNING Improperly connecting or disconnecting battery cables can result in an explosion and cause serious injury or death. When removing the battery, always disconnect the negative (black) cable first. When reinstalling the battery, always connect the negative (black) cable last - 2008 Polaris Sportsman 6x6 | Owners Manual - Page 108
has not been fully charged can damage the battery and result in a shorter life. It can also hinder vehicle performance. Follow the battery charging instructions on page 107 before installing the battery. 1. Ensure that the battery is fully charged. 2. Place the battery in the battery holder. 3. With - 2008 Polaris Sportsman 6x6 | Owners Manual - Page 109
MAINTENANCE Battery Battery Storage Whenever the vehicle is not used for a period of three months or more, remove the battery from the vehicle, ensure that it's fully charged, and store it out of the sun in a cool, dry place. Check battery voltage each month during storage and recharge as needed to - 2008 Polaris Sportsman 6x6 | Owners Manual - Page 110
and the sealing strip cannot be removed, you must use a voltmeter or multimeter to measure DC voltage. For a refresh charge, follow all instructions carefully. 1. Check the battery voltage with a voltmeter or multimeter. A fully charged battery will register 12.8 V or higher. 2. If the voltage is - 2008 Polaris Sportsman 6x6 | Owners Manual - Page 111
MAINTENANCE Battery Battery Charging (Sealed Battery) NOTE: Always verify battery condition before and 1-2 hours after the end of charging. State of Charge 100% 75%-100% Voltage 12.8-13.0 volts 12.5-12.8 volts Action None, check at 3 mos. from date of manufacture May need slight charge, if no - 2008 Polaris Sportsman 6x6 | Owners Manual - Page 112
Cleaning and Storage Washing the Vehicle MAINTENANCE Keeping your Polaris vehicle clean will not only improve its appearance but it can also extend the life of various components. CAUTION High water pressure may damage components. Polaris recommends washing the vehicle by hand or with a garden - 2008 Polaris Sportsman 6x6 | Owners Manual - Page 113
the Vehicle Polaris recommends the use of common household aerosol furniture polish for polishing the finish on your Polaris vehicle. Follow the instructions on the container. Polishing Tips • Avoid the use of automotive products, some of which can scratch the finish of your vehicle. • Always - 2008 Polaris Sportsman 6x6 | Owners Manual - Page 114
the engine during the storage period. Clean the Exterior Make any necessary repairs and clean the vehicle as recommended. See page 109. Fog the Engine 1. Support the front end of the machine so the engine is level or tilted slightly rearward. 2. Remove the spark plug. Rotate the piston to BDC and - 2008 Polaris Sportsman 6x6 | Owners Manual - Page 115
(test strength/fill) Stabilize the Fuel 1. Fill the fuel tank. 2. Add Polaris Carbon Clean Fuel Treatment or Polaris Fuel Stabilizer. Follow the instructions on the container for the recommended amount. NOTE: Carbon clean will also reduce the possibility of bacterial growth in the fuel system - 2008 Polaris Sportsman 6x6 | Owners Manual - Page 116
coolant every two years. Battery Storage See pages 106-107 for storage and charging procedures. Storage Area/Covers Set the tire pressure and safely support the ATV with the tires slightly off the ground. Be sure the storage area is well ventilated. Cover the vehicle with a genuine Polaris cover - 2008 Polaris Sportsman 6x6 | Owners Manual - Page 117
MAINTENANCE Transporting the Vehicle Follow these procedures when transporting the vehicle. 1. Stop the engine. 2. Place the transmission in gear. 3. Lock the parking brake. 4. Secure the fuel cap, oil cap and seat. 5. Always tie the frame of the ATV to the transporting unit securely with suitable - 2008 Polaris Sportsman 6x6 | Owners Manual - Page 118
in loss of control and possible serious personal injury or death. Follow the adjustment procedures exactly, or see your Polaris dealer for service. 1. Remove the upper headlight pod. 2. Loosen the four handlebar bolts. 3. Adjust the handlebar to the desired height. NOTE: Be sure the handlebars - 2008 Polaris Sportsman 6x6 | Owners Manual - Page 119
ADJUSTMENTS Throttle Cable Freeplay Adjust throttle cable freeplay at the handlebar. 1. Locate the throttle cable adjuster at the handlebar. 2. Squeeze the end of the rubber boot and slide it far enough to expose the end of the inline cable adjuster. 3. Loosen the adjuster lock nut. 4. Rotate the - 2008 Polaris Sportsman 6x6 | Owners Manual - Page 120
. If the chain needs adjustment, use the following procedure. Proper splicelink clip 1. Remove the chain guard and opening position loosen the chain guide. 2. Loosen the two eccentric locking bolts. 3. Loosen the caliper mount bolts. Pin Punch 4. Insert a pin punch through the sprocket hub and into - 2008 Polaris Sportsman 6x6 | Owners Manual - Page 121
ADJUSTMENTS Rear Axle Drive Chain To adjust the rear axle drive chain, loosen the rearmost eccentric locking bolts and rotate using the same method as outlined for the front chain adjustment. Total slack for the rear chain should be adjusted to 3/6"-3/8" (6-9 mm) at the tightest point in the chain. - 2008 Polaris Sportsman 6x6 | Owners Manual - Page 122
for more information about jetting the ATV for conditions in your area. Polaris dealers. NOTE: Pilot screws are sealed with metal plugs and are serviceable only by Carburetor/Engine Idle RPM Adjustment Recommended engine idle RPM is 1200 +/- 200. If the engine idle speed is unsatisfactory and all - 2008 Polaris Sportsman 6x6 | Owners Manual - Page 123
TROUBLESHOOTING Drive Belt Wear/Burn Possible Cause Driving onto a pickup or tall trailer in high range Starting out going up a steep incline Driving at low RPM - 2008 Polaris Sportsman 6x6 | Owners Manual - Page 124
Engine Doesn't Turn Over Possible Cause Low battery voltage Loose battery connections Loose solenoid connections TROUBLESHOOTING Solution Recharge the battery to 12.8 VDC Check all connections and tighten Check all connections and tighten Engine Turns Over, Fails to Start Possible Cause - 2008 Polaris Sportsman 6x6 | Owners Manual - Page 125
TROUBLESHOOTING Engine Pings or Knocks Possible Cause Poor quality or low octane fuel Incorrect ignition timing Incorrect spark plug gap or heat range Solution Replace with - 2008 Polaris Sportsman 6x6 | Owners Manual - Page 126
voltage Incorrect fuel Clogged air filter Reverse speed limiter malfunction Electronic throttle control malfunction Other mechanical failure Overheated engine TROUBLESHOOTING Solution Refuel, cycle key to ON position three times for 5 seconds each, then start Inspect and replace Inspect, clean - 2008 Polaris Sportsman 6x6 | Owners Manual - Page 127
SPECIFICATIONS Sportsman 500 6X6 Maximum Weight Capacity Fuel Capacity Engine Oil Capacity Coolant Capacity Transmission Oil Capacity Front Gearcase Oil Capacity Front Rack/Storage Box Capacity Cargo Box Capacity Hitch Tongue Capacity Hitch Towing Rating Unbraked Trailer Towing Capacity* Overall - 2008 Polaris Sportsman 6x6 | Owners Manual - Page 128
SPECIFICATIONS Sportsman 500 6X6 Transmission Gear Reduction, Low Gear Reduction, Reverse Gear Reduction, Forward Drive Ratio, Front Drive Ratio, Final Tires/Pressure, Front Tires/Pressure, Center Tires/Pressure, Rear Brakes, Front Brakes, Rear Brake, Auxiliary Brake, Parking Headlight Taillights - 2008 Polaris Sportsman 6x6 | Owners Manual - Page 129
POLARIS PRODUCTS Part Number 2870791 2876244 2876245 2873602 2873603 2871653 2872276 2870465 2871654 2872277 2871323 2871534 2871312 2871322 2871423 2871460 2871515 2871551 2871329 2872073 2872348 2871326 2870652 2872189 2871956 2859044 Description Engine Lubricant Fogging Oil (12 oz. Aerosol) PS-4 - 2008 Polaris Sportsman 6x6 | Owners Manual - Page 130
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 your warranty coverage. 127 - 2008 Polaris Sportsman 6x6 | Owners Manual - Page 131
for purposes other than for which it was manufactured, or for any damages which occur during trailer transit or as a result of unauthorized service or the use of unauthorized parts. In addition, this warranty does not cover physical damage to paint or finish, stress cracks, tearing or puncturing - 2008 Polaris Sportsman 6x6 | Owners Manual - Page 132
THE DEALER IS YOUR RESPONSIBILITY). Polaris suggests that you use your original selling dealer; however, you may use any Polaris Servicing Dealer to perform warranty service. Please work with your dealer to resolve any warranty issues. Should your dealer require any additional assistance they will - 2008 Polaris Sportsman 6x6 | Owners Manual - Page 133
must be done by an authorized Polaris dealer. If you move or are traveling within the country where your vehicle was purchased, Warranty or Service Bulletin repairs may be requested from any authorized Polaris dealer who sells the same line as your vehicle. Outside the Country where your vehicle - 2008 Polaris Sportsman 6x6 | Owners Manual - Page 134
where it was purchased, and you have not followed the procedure set out above, your vehicle will no longer be eligible for warranty or service bulletin coverage of any kind. (Vehicles registered to Government officials or military personnel on assignment outside of the country where the vehicle was - 2008 Polaris Sportsman 6x6 | Owners Manual - Page 135
maintenance listed in your Owner's Safety and Maintenance Manual (herein "Owner's Manual"). POLARIS recommends that you retain all receipts covering your LSI engine to a dealer authorized by POLARIS as soon as a problem exists. The warranty repairs should be completed in a reasonable amount of time - 2008 Polaris Sportsman 6x6 | Owners Manual - Page 136
California Emission Control Warranty Statement Limited Warranty WARRANTY California Only POLARIS warrants to the owner of 2006 and later LSI engines that the LSI engine (1) has been designed, built, and equipped at the time of manufacture so as to conform with the applicable regulations of the - 2008 Polaris Sportsman 6x6 | Owners Manual - Page 137
such as changing, adding, or removing parts. When the LSI engine is being serviced under warranty, POLARIS and any of its authorized dealers shall not be liable to follow the maintenance and operating instructions specified in the 2006 and later Owner's Manual including: (a) Improper or inadequate - 2008 Polaris Sportsman 6x6 | Owners Manual - Page 138
. These replacement parts will be provided at no charge if the part is still under warranty. How to File a Warranty Claim/Where to Get Warranty Service All repairs qualifying under this Limited Warranty must be performed by a dealer who sold you the LSI engine or a dealer authorized by POLARIS. In - 2008 Polaris Sportsman 6x6 | Owners Manual - Page 139
WARRANTY U.S.A. EPA Emissions Limited Warranty This All Terrain Vehicle (ATV) or Off Road Utility Vehicle (ORUV) emissions limited warranty is in addition to the Polaris standard limited warranty for this vehicle. Polaris warrants that this vehicle is; (1) designed, built, and equipped to conform - 2008 Polaris Sportsman 6x6 | Owners Manual - Page 140
MAINTENANCE LOG Present this section of your manual to your dealer each time your vehicle is serviced. This will provide you and future owners with an accurate log of maintenance and services performed. DATE MILES (KM) OR HOURS TECHNICIAN SERVICE PERFORMED / COMMENTS 137 - 2008 Polaris Sportsman 6x6 | Owners Manual - Page 141
MAINTENANCE LOG DATE MILES (KM) OR HOURS TECHNICIAN SERVICE PERFORMED / COMMENTS 138 - 2008 Polaris Sportsman 6x6 | Owners Manual - Page 142
MAINTENANCE LOG DATE MILES (KM) OR HOURS TECHNICIAN SERVICE PERFORMED / COMMENTS 139 - 2008 Polaris Sportsman 6x6 | Owners Manual - Page 143
...105 Removal...104 Storage ...106 Belt Life ...41 Boots ...11 Brake Fluid, Main Brake System...38 Brake Lever, Auxiliary ...37 Brake Lever, Service ...37 Brake Systems ...37- 38 Brake, Front Wheel ...85 Brake, Middle Axle ...85 Brake, Parking ...39 Brake, Rear ...85 Brakelight ...95 Brakes - 2008 Polaris Sportsman 6x6 | Owners Manual - Page 144
INDEX I Idle RPM Adjustment ...119 Immersion ...98 Instrument Cluster...45-49 P Parking Brake ...39 Parking on an Incline ...68 Periodic Maintenance Chart ...70-73 Polaris Product List...126 Polishing the Vehicle ...110 Pre-Ride Checklist ...52 PVT Break-In ...51 PVT Drying ...102 PVT System ...100 - 2008 Polaris Sportsman 6x6 | Owners Manual - Page 145
INDEX T Taillight ...95 Throttle Body Adjustment ...116 Throttle Cable Freeplay ...116 Throttle Lever ...36 Tire Tread Depth ...88 Tires ...88-89 Front Wheel Hub Tightening. . 88 Wheel Installation ...89 Wheel Nut Torque ...89 Wheel Removal ...88 Toe Alignment ...86 Towing Capacities ...55 Training
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