Polaris Trailboss 7174820 manual

1 WELC O ME Thank you f or purc ha sing a Polar is vehic le, and we lcome to our world- wide fa mily of Polaris owner s. W e proudly produc e an exc iting line of utility a nd re cr ea tiona l produc ts. S Snowmobiles S All- ter ra in vehic le s (A TVs) S RANGER utility vehicle s S V ict ory m ot or cycl es W e belie ve Polar is sets a standar d of[...]

2 Copyr ight 2007 Pola r i s Sa l e s I nc . Al l inf or ma t i on c onta i ne d wi t hi n t hi s publi c a ti on i s ba s e d on t he la t e s t pr oduc t i nf orm a t ion at t he t i me of publ i c a t ion. Due t o c ons t a nt imp ro v emen ts in the desig n an d q uality o f pr oduct i on compone nt s , s ome m inor d iscrepan cies may resu lt [...]

3 TABLE OF CONTE NTS VEHICLE IDENT IFI CA TION NUMBERS 5 ....... SA FE TY 6 ................................... FEA TURES AND CONTROL S 30 ............... OPE RA T ION 40 .............................. EMI SSION CONT ROL SYST EM S 57 ............ MAINTENANCE AND L UBRICA TION 58 ........ SPECIF ICA T IO NS 10 3 ........................ POLARIS PROD[...]

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5 VE HICLE IDENTIFICATION NUMBERS Recor d your A TV’ s ide ntific ation numbe rs and ke y number in the sp aces pro vi ded. Rem ov e the s pare k ey and st ore i t in a s afe pl ace. An ignition key c an be duplic ate d only by ord er ing a Polar is key bla nk (using your ke y numbe r) a nd mating it with one of your existing ke ys. The ignition [...]

6 SA FETY Operator S afety W ARNING Failur e to f ollow t he warnings c ontained in t his m anual can res ult in serious injury or deat h. A Polar is A T V is not a t oy and can be haz ardous t o operat e. T his vehicle handles diff erent ly t han other vehic les, s uch as motorcycles and cars. A collision o r r ollover can occur quickly , even dur[...]

7 SA FETY Operator S afety The f ollowing signal words a nd symbols appear throughout this manua l and on your A TV . Y our sa fety is involved w hen these words and symbols are use d. Bec ome fa miliar with their mea nings bef ore re ading the manua l. The safet y alert s ymbol , on your v ehicle or in t his m anual, aler ts you t o the pot ent ia[...]

8 SA FETY Operator S afety W ARNING Serious injur y or deat h can r esult if you do not follow t hese inst ruct ions and pr ocedures , whic h are out lined in fur ther det ail within y our owner ’s manual. S Rea d this manual and a ll labels c aref ully , and follow the ope rating proce dures desc ribed. S Neve r opera te an A TV without proper i[...]

9 SA FETY Operator S afety S Alway s have t he A T V ins pect ed by an au tho rized P o lari s deal er if it ’ s been i nvolved i n an accident. S Ne ver ope rate on hills too stee p for the A TV or for your abilitie s. Pra ctice on sma ller hills befor e attempting la r ger hills. S Alwa ys follow pr oper pro ce dure s for c limbing hills. Check[...]

10 SA FETY Operator S afety S W et bra kes may have reduc ed stopping a bility . T est your brake s afte r lea ving wate r . If nec essar y , apply them lightly se vera l times to allow frict io n to d ry out t he pad s. S Always che ck for obstac l es or people be hind the A TV bef ore opera t- in g in rev erse. Wh en it ’ s s afe to pro ceed in[...]

11 SA FETY Operator S afety W ARNING POTENTI AL HAZ ARD Oper ating t his A T V wit hout pr oper inst ruc tion. WHA T C AN HAPPEN The r isk of an accident is gr eatly inc reased if the oper ator does not k now how to oper ate t he A T V pr operly in diff erent sit uat ions and on different ty pes of t err ain. HOW T O A VOID THE HAZA RD Beginning an[...]

12 SA FETY Operator S afety W ARNING POTENTI AL HAZ ARD Carry ing a passenger on an AT V. WHA T C AN HAPPEN Carry ing a passenger great ly reduces t he operat or ’s ability to balance and cont rol t he A T V , whic h could caus e an accident and injury t o t he operat or and/or pas senger . HOW T O A VOID THE HAZA RD Never c arry a pas senger . T[...]

13 SA FETY Operator S afety W ARNING POTENTI AL HAZ ARD Oper ating t his A T V on public st reet s, r oads or highways. WHA T C AN HAPPEN The A TV c ould collide with anot her v ehicle. HOW T O A VOID THE HAZA RD Never oper ate t he A T V on any public st reet , r oad or highway , including dirt and gravel roads . I n many s tat es it’s illegal t[...]

14 SA FETY Operator S afety W ARNING POTENTI AL HAZ ARD Oper ating t he A T V af ter c onsuming alcohol or dr ugs. WHA T C AN HAPPEN Consumpt ion of alc ohol and/or drugs could ser iously aff ect oper ator judgment . Reac tion t ime m ay be slower and operat or balance and per cept ion could be affec ted. Consuming alc ohol and/or dr ugs bef ore or[...]

15 SA FETY Operator S afety W ARNING POTENTI AL HAZ ARD At tem pting wheelies , jum ps and other s tunt s. WHA T C AN HAPPEN At tem pting s tunt s inc reases the c hance of an ac cident , including an over tur n. HOW T O A VOID TH E HAZ ARD Never at tem pt wheelies, jumps, or other s tunt s. Avoid exhibit ion driving. W ARNING POTENTI AL HAZ ARD Fa[...]

16 SA FETY Operator S afety W ARNING POTENTI AL HAZ ARD Removing hands f rom t he handlebars or f eet f rom t he f ootr est s during operat ion. WHA T C AN HAPPEN Removing ev en one hand or f oot c an reduce abilit y t o cont rol t he vehicle or c ould cause los s of balance and ejec tion f rom t he A T V . If t he operator ’ s foot is not f irml[...]

17 SA FETY Operator S afety W ARNING POTENTI AL HAZ ARD Failu re t o use e xtra caut ion when operat ing on exces sively r ough, slippery or loose t err ain. WHA T C AN HAPPEN Operatin g on excessive ly rough, s lippery or loose ter rain could c ause loss of tr act ion or loss of c ontr ol, which could r esult in an accident or over tur n. HOW T O [...]

18 SA FETY Operator S afety W ARNING POTENTI AL HAZ ARD Oper ating on ex cess ively s teep hills . WHA T C AN HAPPEN The v ehicle may ov ert urn. HOW T O A VOID THE HAZA RD Never oper ate on hills t oo st eep for t he A T V or f or y our abilit ies. Never oper ate t he A T V on hills st eeper t han 25 _ . Prac tic e on smaller hills bef ore at tem [...]

19 SA FETY Operator S afety W ARNING POTENTI AL HAZ ARD T rav eling downhill improper ly . WHA T C AN HAPPEN Im properly des cending a hill could caus e loss of cont rol or overt urn. HOW T O A VOID TH E HAZ ARD Always f ollow proper procedur es for t rav eling down hills as des cribed in the owner ’ s m anual. NO TE: A spec ial tec hnique is req[...]

20 SA FETY Operator S afety W ARNING POTENTI AL HAZ ARD Im properly c ross ing hills and tur ning on hills. WHA T C AN HAPPEN Im properly c ross ing or tur ning as hills c ould cause loss of cont rol or ov ert urn. HOW T O A VOID TH E HAZ ARD N e v e ra t t e m p t t ot u r nt h e A T V around on any hill unt il you’ve m ast ered t he tur ning te[...]

21 SA FETY Operator S afety W ARNING POTENTI AL HAZ ARD St alling, r olling backwar ds or improper ly dismount ing while climbing a hill. WHA T C AN HAPPEN The v ehicle could ov ert urn. HOW T O A VOID TH E HAZ ARD Maint ain st eady speed when climbing a hill. If all for ward speed is lost: Keep your weight uphill. Apply t he single lev er brak e g[...]

22 SA FETY Operator S afety W ARNING POTENTI AL HAZ ARD Im properly oper ating ov er obst acles . WHA T C AN HAPPEN Oper ating ov er obst acles c ould cause los s of cont rol or ov ert urn. HOW T O A VOID THE HAZA RD Bef ore operat ing in a new area, chec k for obs tac les. Avoid operating ov er large obs tac les suc h as roc ks and f allen tr ees [...]

23 SA FETY Operator S afety W ARNING POTENTI AL HAZ ARD Oper ating t he A T V t hrough deep or f ast -f lowing wat er . WHA T C AN HAPPEN T ir es may float , c ausing loss of t rac tion and loss of c ontr ol, which could lead t o an accident or ov ert urn. HOW T O A VOID THE HAZA RD Avoid operating t he A T V t hrough deep or f ast -f lowing water [...]

24 SA FETY Operator S afety W ARNING POTENTI AL HAZ ARD Oper ating t he A T V wit h improper m odific ations . WHA T C AN HAPPEN Im proper ins tallat ion of ac cess ories or modif icat ion of t he A T V may c ause changes in handling whic h could lead t o an accident . HOW T O A VOID THE HAZA RD Never m odify t he A T V t hrough impr oper inst alla[...]

25 SA FETY Operator S afety W ARNING Leaving t he keys in t he ignit ion can lead t o unauthor ized use of the v ehicle res ulting in s erious injur y or deat h. A lways r emove the ignit ion key when t he vehic le is not in use. W ARNING Af ter any over tur n or acc ident, hav e a qualified s ervic e dealer inspect the ent ire v ehicle f or poss i[...]

1 2 3 26 SA FETY Safety D ecals and Locations W arning d ecals have been pl aced on the A TV for your protecti on. R ead and fo ll ow th e ins tru cti on s of th e decals an d ot her warni ng s on t he A TV careful ly . If any o f the d ecals s how n in t hi s m anual d iffer from the decals on your A TV , al ways read and follo w the inst ructions[...]

27 SA FETY Safety D ecals and Locations Gene r al W ar ning (3) W ARNING Im proper A TV use can resul t in SEVERE I NJURY or DEA TH AL WA YS USE AN APPROVED HELMET AND PROTECTIVE GEAR NEVER USE ON PUBLIC ROADS NEVER CARR Y P ASSENGERS NEVER USE WITH DRUGS OR ALCOHOL NEVER operat e: S wit hout proper t raini ng or inst ruct ion S at speeds t oo fast[...]

6 7 5 4 4 28 SA FETY Safety D ecals and Locations Rack W arning (4) W ARNING S DO NOT TOW FROM RACK OR BUMPER. V ehicle dam age or t ipover may resul t causing severe inj ury or death. T ow only fr om tow hooks or hitch. S Max Rack Loads: Front 75 lbs. ( 34 kg) Rear 125 l bs. ( 57 kg) A g e1 6W a r n i n g( 5 ) W ARNING Oper ating t his A TV if you[...]

29 SA FETY Safe R iding Gear Always we ar c lothing suited to the t ype of riding. A TV riding re quires spec i al prote ctive c lothing for comf ort and to reduc e the chanc e of injury . 1. Helm et W eari ng a hel m et can prev ent a s evere head injury . Whe never r iding a Polaris vehic le, alway s wear a hel m et t hat m eet s or ex ceeds esta[...]

30 FEATURE S AND CONTROLS Electr ical S witches W ARNING Act ivat ing t he overr ide swit ch while t he thr ott le is open c an cause loss of cont rol, r esult ing in sever e injury or deat h. Do not act ivat e the ov erride s witc h while the t hrot t le is open. Ov errid e S wi tch (1 ) (Re ver se Speed Limite r) - This vehicle is equipped with a[...]

31 FEATURE S AND CONTROLS W ARNING Do not s tar t or oper ate an A T V wit h st ick ing or impr operly operat ing thr ott le cont rols , whic h could caus e an accident and lead to s evere injur y or deat h. Always c ontac t your dealer f or ser vice repair s if t hrot tle problem s arise. Failur e to c heck or m aintain pr oper operat ion of t he [...]

32 FEATURE S AND CONTROLS W ARNING Oper ating t he A T V on st reet s or r oads, espec ially in dark ness, could res ult in an ac cident and s erious injur y or deat h. Y our A T V is not equipped wit h highway-appr oved light s. I t ’ s designed f or and mus t be us ed for of f - road us e only . Use ca ution and drive at reduced s peeds in cond[...]

33 FEATURE S AND CONTROLS Br akes Ch eck th e brake flu id l evel i n th e mas ter cy li nd er befo re each us e of t he A TV . The master c ylinder (1) is lo cated o n th e left han dl ebar . The f luid leve l can be seen thr ough an indica tor window (2) on the top of the mas ter cy li nd er . Th is “ey e” wil l appe ar dar k when the f luid [...]

34 FEATURE S AND CONTROLS Br ake Lever The fro nt an d rear b rakes are ap pl ied b y sq ueezin g t he brak e lev er (1) t oward t he hand leb ar . Th e front an d rear b rakes are hydra ulica lly ac tivated disc type bra kes th at are acti vat ed by on ly o ne lev er . Alway s tes t brake lev er travel an d mast er cyli nder flui d level before ri[...]

35 FEATURE S AND CONTROLS Auxiliary Brake W ARNING Aggres sively apply ing the r ear brak e when backing downhill m ay cause r ear t ipover , whic h could res ult in s erious injur y or deat h. Use caut ion when applying t he auxiliar y brak e. Do not aggress ively apply t he auxiliar y brak e when going for ward. T he rear wheels m ay sk id and sl[...]

36 FEATURE S AND CONTROLS Choke The choke a ssists in starting a cold engine . R ef er to the engine star ting proc edur e on page 42 for cor rect choke a nd throttle settings during star ting. Fuel V alve The fu el v alv e (1) i s l ocat ed o n th e left s i de of the vehic le, eithe r below the fende r or on the side pane l. It has three position[...]

37 FEATURE S AND CONTROLS Fuel Safety W ARNING Gas oline is highly f lamm able and explosiv e under cer tain condit ions. S Always ex ercis e ext reme c aution whenev er handling gasoline. S Always r efuel wit h t he engine st opped, and out doors or in a well vent ilated ar ea. S Do not s moke or allow open f lames or s parks in or near t he area [...]

38 FEATURE S AND CONTROLS Autom atic T r ansm ission Gear S elector The tra nsmission gear se lector (1) is located on the right side of the A TV . F: For wa rd N: Neutral R: Rev ers e CAUTION Shif ting gear s wit h the engine s peed above idle or while t he vehicle is m oving could c ause t ransm ission dam age. T o change gear s, st op t he vehic[...]

1 2 39 FEATURE S AND CONTROLS Recoil S tarter If the batte ry is too wea k to star t the engine, use the rec oil star ter (1). Follow the star ting proce dures on page 42, cr anking the engine with the recoi l s tart er in st ead of t he main ke y switch. 1. Gras p t he reco il s tart er rope ha ndle (2) tightly . 2. Pull slowly so you can fe el th[...]

40 OPERATION Br eak - In P er iod The br ea k-in period f or your new Pola ris A TV is def ined as the f irst ten hours of oper ation, or the time it take s to use the fir st two full tanks of gasoline . No single a ction on your par t is as importa nt as following the proc edur es for a prope r bre ak-in. Care ful tre atme nt of a new engine and d[...]

41 OPERATION Pr e -Ride Inspection W ARNING If a proper ins pect ion is not done bef ore eac h use, sev ere injury or deat h could res ult. Always ins pect t he vehicle bef ore eac h use to ens ure it ’ s in pr oper operat ing condit ion. Pre - Ride Che ck lis t Item Remarks See Page Brake syst em / br ake lever tr avel Ensure proper oper ati on [...]

42 OPERATION Star ting the E ngine W ARNING Engine exhaus t c ontains pois onous car bon monoxide and c an cause los s of c onscious ness r esult ing in sever e injury or deat h. Never r un an engine in an enclosed ar ea. 1. Position the vehicle on a leve l su rface. 2. Place the tr ansmission in neutr al. 3. Lock the par king brake . NOT E: T he s[...]

43 OPERATION Star ting the E ngine 7. Move the engine stop switch to R UN. NOT E: Do not pr ess t he t hrot tle while s tar ting t he engine. 8. T urn the ignition key pa st the ON position to enga ge the star ter . Activa t e the star ter for a ma ximum of five sec onds, relea sing the key whe n the engine starts. 9. If the engine doe s not start,[...]

44 OPERATION Hauling Cargo Y our A TV has bee n designed to ca rry or tow a c er tain a mount of load. Always re ad and unde rstand the loa d distribution war ning labe ls on the veh icl e, an d never exceed t he wei gh t capac ities outlined in the sp ecifi cati on s sect io n of th e owner ’ s m anu al and o n th e safety d ecals . Car go we ig[...]

45 OPERATION Hauling Cargo W ARNING Hauling cargo im properly c an alter vehic le handling and may cause los s of c ontr ol or brak e instabilit y and r esult in s erious injury or deat h. Alway s follow t hese precaut ions when hauling cargo: S REDUCE SPEED AN D ALLO W G REA T ER DIST ANCE F OR BRAKING WHEN HAULING C ARGO . S CARG O W EI G HT DI S[...]

46 OPERATION Driving Safely Driving Pr o cedures 1. Sit upright with both fe et on the footre sts and both hands on the handle bars. 2. Start the engine and allow it to war m up, then shift the tran smission into gea r . 3. Check your surroundings and de termine your path of tra vel. 4. Relea se t he par king bra ke. 5. Slowly depre ss the throttle[...]

47 OPERATION Driving Safely T urning the V ehic le Y our Polar is A TV is equippe d with a solid r ear axle that drive s both re ar whe els equa lly at all time s. This mea ns that the whee l on the outside of the turn must trave l a grea ter distance tha n the inside whee l whe n turning and the inside tire must slip tra ction slightly . T o make [...]

48 OPERATION Driving Safely Dr iving on Slipp er y Sur f aces Whenev er ridi ng o n sl ip pery su rfaces su ch as wet t rail s or lo os e gravel, or du rin g freezing weat her , fo ll ow t hese precau ti on s: 1. Slow down when e ntering slippe ry are as. 2. Mai nt ain a h igh lev el o f al ertn ess , readi ng th e trai l and avo id in g qui ck, sh[...]

49 OPERATION Driving Safely Driving Uphill Whe neve r trave ling uphill, follow th ese p recaut io ns: 1. Alwa ys trave l straight uphill. 2. A void stee p hills (25 _ ma ximum). 3. Kee p both feet on the f ootrests. 4. T ransfer your we ight forwa rd. 5. P roceed at a st eady rat e of spee d and throttle ope ning. 6. Rem ai n alert an d be prepare[...]

50 OPERATION Driving Safely Sidehilling W ARNING Im properly c ross ing hills or t urning on hills can r esult in loss of cont rol or v ehicle over tur n, r esult ing in sever e injury or deat h. Avoid cross ing the s ide of a hill when pos sible. F ollow proper procedur es as out lined in t he owner ’s manual. Sidehilling ca n be a dange rous ty[...]

51 OPERATION Driving Safely Driving Downh ill Whe never de scending a hill, follow these pr ecau ti on s: 1. P roceed di rect ly do wnh ill. 2. T ransfe r your weight to the re ar of the vehic le. 3. Slow down. 4. Apply the brakes slightly to aid in slowing, using the single br ake leve r . NOT E: F amiliar ize your self wit h operat ion of t he au[...]

8’ (2. 4 m) 52 OPERATION Driving Safely T urning A round on a Hill If the ve hicle stalls while c limbing a hill, ne ver ba ck it down the hill! Use the K- turn to turn around. 1. Stop and lock the pa rking bra ke while keeping body we ight uphill. 2. Lea ve the tra nsmission in for war d and shut of f the engine . 3. Dismount on the uphill side [...]

53 OPERATION Driving Safely Dr iving Thr ough W ater Y our A TV c an oper ate through wa ter w ith a maximum r ecomme nded depth e qual to the bottom of the footr ests (1). Follow th ese pro cedur es when oper ating through wa ter : 1. De termine wa ter depths a nd curr ent bef ore c rossing. 2. Choose a crossing wher e both banks have gra dual inc[...]

54 OPERATION Driving Safely Dr iving Over Obstacles Be al ert! Lo ok ahead an d learn t o read t he terrai n you ’re travel i ng on . Be con st ant ly al ert fo r hazards s uch as l ogs , r ocks an d lo w hang in g bran ches . W ARNING Sever e injury or deat h can r esult if your vehic le comes in c ontact with a hidden obs tac le. Not all obs ta[...]

55 OPERATION Driving Safely Dr iving in Reverse F oll ow t hese precau ti on s when op erati ng i n revers e: 1. Always avoid bac king downhill. 2. Back slowly . 3. When i n reverse, apply the brake s lightly for stopping. 4. A void turning at sh arp angl es i n reverse. 5. Never ope n the throttle sudde nly while ba cking. W ARNING Failur e to us [...]

56 OPERATION Driving Safely P a r k i n go na nI n c l i n e A void parking on a n incline if possible . If it’ s unavoidable , follow th ese p recaut io ns: 1. T urn the engine of f. 1. Place the tr ansmission in gea r . 2. Set t he par king brake . 3. Always block the rea r wheels on the downhill side. See illustra tion. 4. Shut of f the fuel s[...]

57 EMISSION C ON TR OL SYST EMS Noise E mi ssion Contr ol System Do not modify the engine , intake o r exha ust components, as doing so may af fe ct compliance w ith U.S .A. EP A noise control re quire ments (40 CFR 205) and loc al noise le vel requir ements. Operation on Public Land s in the U.S.A. Y our Polar is vehic le has a spa rk ar re stor t[...]

58 MAINTENANCE AND LUBRICATION Per iodic Maintenance C hart Care ful periodic mainte nance will help kee p your vehicle in the safe st, most relia ble condition. Inspec tion, adjustment a nd lubric ation of importa nt components ar e expla ined in t he per iodic m ainte nance c hart. Ins pect , clean, l ub ricat e, adj us t and replace part s as n [...]

59 MAINTENANCE AND LUBRICATION Per iodic Maintenance C hart Maintena nce Cha rt Key " P erform t hes e proced ures m ore frequ ent ly fo r veh icl es s ubj ected t o seve re use . E Emission-r ela ted servic e (Failur e to conduc t this mainte nance will not void the emissions warr ant y but may af fec t emissions.) J Have an aut ho rized P ol[...]

60 MAINTENANCE AND LUBRICATION Per iodic Maintenance C hart P erform all s ervi ces at whi chever mai nt enance in terval i s reached fi rst . Item Maint enance Inter val (w hichev er c omes f irs t) Remarks Hours C alendar Miles (Km) J Steer ing -- Pre- Ride -- Mak e adjustments as need- e d S e e P r e R i d e C h e c k l i s t " Front s us [...]

61 MAINTENANCE AND LUBRICATION Per iodic Maintenance C hart Item Maint enance Inter val (w hichev er c omes f irs t) Remarks Hours C alendar Miles (Km) Car buretor float bowl 50 H 6M 500 ( 800) Drain bowl per iodic ally and prior t o st orage J E Thrott le Cable/ ETC Switc h 50 H 6M 500 ( 800) Inspec t; adjus t; lubric ate; replac e if nec es sar y[...]

62 MAINTENANCE AND LUBRICATION Per iodic Maintenance C hart Item Maint enance Inter val (w hichev er c omes f irs t) Remarks Hours C alendar Miles (Km) J Clutc hes (driv e and dr iven) 100 H 12 M 1000 (1600) Ins pec t; c lean; replac e w orn parts J Front w heel bearings 100 H 12 M 1000 (1600) Ins pec t; replac e as needed J Brak e fluid 200 H 24 M[...]

63 MAINTENANCE AND LUBRICATION Lubr ication Recom m endations Chec k and lubric ate a ll components a t the inter vals outlined in the Periodic Ma intenan ce Char t beginning on page 60. Ite ms not listed in the cha rt should be lubrica t ed at the Ge ner al Lubric ation interval. NOT E: T he a-ar ms and lower cont rol ar ms are lubr icat ed at t h[...]

64 MAINTENANCE AND LUBRICATION Engi ne Oil Alwa ys che ck and cha nge the engine oil at the inter vals outlined in the P eriod ic M ain ten ance C hart b egi nning on page 58. Always change the oil filter whe never c hanging oil. Pr emium 4 S ynth etic Oil Polaris Pre mium 4 All Season Synthetic engine oil has be en spec ially for m ula ted f or us[...]

65 MAINTENANCE AND LUBRICATION Engi ne Oil Oil an d F ilter Chang e 1. Position the vehicle on a leve l surf ace. 2. Clean the ar ea around the dra in plug. 3. Run the engine for two to three minutes until warm. Stop the engine . CAUTION Contac t with hot oil may result in serious burns. Do not allow hot oil to c ome int o cont act wit h sk in. 4. [...]

66 MAINTENANCE AND LUBRICATION T r ansmission Oil Oil Check The tra nsmission dipstick (1) is loca t ed on the right side of the mach in e near t he reco il h and le. Check and c hange the lubric ant at the inte rvals outline d in the P eriod ic M ain ten ance C hart beginning on pa ge 60. NOT E: We reco mmend the u se of Pola ris Premium AGL Synt [...]

67 MAINTENANCE AND LUBRICATION T r ansmission Oil Oil Chan ge 1. P lace a drain p an beneat h t he tra nsmission oil dra in plug area. 2. Loosen the j am nut ( A). 3. T urn the adjuste r bolt (B) in to allow the re moval of the drain plug (C). 4. Remove the dra in plug and wipe the magne tic end cle an to remo ve accu mul at ed m eta llic filings. [...]

68 MAINTENANCE AND LUBRICATION Br akes The front and re ar brake s are hydr aulic disc brak es, activa ted by moving the single brake le ver towar d the handleba r . These br ake s are self -a djusting. The fo ll owi ng check s are reco mm ended t o keep t he b rake sy st em i n good oper ating c ondition. Chec k more ofte n if brake s are use d he[...]

69 MAINTENANCE AND LUBRICATION Br akes 2. Ch eck t he brak e sy st em fo r flu id l eaks . 3. Ch eck t he b rakes f or exces si ve t ravel o r spongy fee l. 4. Ch eck th e fricti on p ads fo r wear , dama ge and looseness. 5. Ch eck th e securi ty an d su rface condition of the disc. NOT E: P ads should be c hanged when worn t o 3/64 ″ (. 1 cm). [...]

A B 70 MAINTENANCE AND LUBRICATION T oe A lignm ent W ARNING Sever e injury or deat h can r esult f rom im proper t oe alignment and adjust ment . Do not at tem pt t o adjust tie r od alignment . All t ie rod adjust ment s should be per for med by an aut horiz ed Polaris dealer . Use the following proce dure to che ck the t oe alignme nt of the veh[...]

71 MAINTENANCE AND LUBRICATION Si de Panel R emoval NOT E: S ide panel remov al may be diff icult unt il t he locking t abs and receiv ers hav e been snapped and unsnapped a f ew t imes. 1. Remove the sea t. 2. Grasp t he rear of t he s id e pan el near t he rear cab . W i th a q ui ck and f irm motion, pull t he pane l forward and o utward t o dis[...]

72 MAINTENANCE AND LUBRICATION Cam ber and C aster The ca m ber a nd ca s ter a re non-adjusta ble. Rear S pri ng The re ar shoc k absorbe r spring is adjuste d by rotating the adjuster ( 1) eithe r clockwise or c ountercloc kwise t o in crease o r decreas e spri ng t ens io n. NOT E: Accessory spri ngs a re available t hrough your Polaris dealer .[...]

73 MAINTENANCE AND LUBRICATION Car bur etor IMPOR T ANT : Y our Pola ris A TV is ca librated a t the fac tory for optimal pe rfo rmanc e at altitude s ranging fr om ze ro to 6,000 fee t (1800 m) an d tempera tures of +40 de gre es F . (4 degre es C. ) or highe r . Above 6000 fe et (1800 m) the engine a ir/fuel mixture become s overly ric h and the [...]

1 2 3 74 MAINTENANCE AND LUBRICATION Thr ottle Cable Fr eepla y Thr ottle ca ble fre eplay is adjusted at the handle bar . 1. Loc ate the throttle ca ble adj us ter o n t he handle bar . 2. S queeze the e nd of t he rubber boot (1) and slide it far enough to e xpose the e nd of the inline ca ble adjuster ( 2). 3. Loosen the locknut (3). 4. Rotate t[...]

75 MAINTENANCE AND LUBRICATION Wheels W ARNING Oper ating y our A T V wit h worn t ires, improper ly inf lated t ires , non-st andard t ires or impr operly inst alled tir es will affect v ehicle handling and could caus e an accident result ing in ser ious injury or death. Maint ain proper t ire pr essur e as desc ribed on t he decal on your A T V a[...]

76 MAINTENANCE AND LUBRICATION Wheels Wheel Installation 1. Place the transmission in ge ar and loc k the par king brake . W ARNING Im properly ins talled wheels can adv ersely aff ect t ire wear and vehicle handling, which can r esult in s erious injur y or deat h. Always ens ure t hat all nut s ar e torqued t o spec ific ation. Do not serv ice ax[...]

77 MAINTENANCE AND LUBRICATION Wheels Fr ont Whee l Hub T ightening Front whee l bear ing tightness and spindle nut rete ntion are cr itical compone nt operations. All serv ice must be pe rforme d by your aut hor ized P ol aris d ealer . Tire s W ARNING Use of non- st andard siz e or ty pe of t ires or impr oper t ire inf lation may adver sely affe[...]

78 MAINTENANCE AND LUBRICATION Rear D rive C hain Slack CAUTION Adjust ing or oper ating t he A T V wit h improper r ear driv e chain slack c an result in s evere dam age to t he t ransm ission and dr ive component s. Always m ake sur e the slac k is wit hin t he st ated specif icat ions. Chec k the a mount of cha in slack in thre e dif fer ent loc[...]

79 MAINTENANCE AND LUBRICATION Rear D rive C hain Slack 6. R ol l t he A TV forward or b ackward to adjust the chain sla ck to the prope r tension. See the illustra tion for pr oper splice link clip ope ning position (1) . 7. T ig ht en t he eccen tri c lo cki ng b ol ts to 30 ft. lbs. (41 Nm) for machine s without the hitch a nd 45 ft. lbs. (61 Nm[...]

80 MAINTENANCE AND LUBRICATION Drive Chain Polaris A TV drive chains ar e equipped with o-ring- sealed, perma nently greas ed pi ns an d ro ll ers. Howev er , t he ou ter s urfaces o f th e rol ler m us t be lubric ated . Always inspe ct the dr i ve c hain prior to oper ating the vehic le. Check f or dama ged or missing o-r i ngs or da mage d rolle[...]

81 MAINTENANCE AND LUBRICATION Air Filter 1. Rem ov e th e seat , rel ease t he cl i ps , and re move the air box cover . 2. Loosen the clamp a nd re move the filte r . 3. Remove the f abric type pre -filter (1) f rom the main filter ( 2). W ash the pr e-filte r in soapy wa ter , then rinse a nd let dry . 4. Reinsta ll the pre- filte r over the mai[...]

82 MAINTENANCE AND LUBRICATION Lights Whe n servic ing a haloge n lamp, don’t touch the lamp with bare finger s. Oil f rom your skin le ave s a re sidue, ca using a hot spot tha t will shorten the life of the la mp. W ARNING Poor light ing while driv ing can res ult in s evere injur y or deat h. Headlight and t aillight lens es becom e dirty dur [...]

83 MAINTENANCE AND LUBRICATION Lights T aillight/Brakelight L am p Replacement If the taillight/bra kelight does not wor k the lamp may ne ed to be repl aced. 1. Remove the ta illight lens cover mounting scre ws. Remove the lens c over a nd gasket and se t aside f or re assembly . 2. Remove the lamp (1). 3. Apply dielec tric grea se to t he so cket[...]

84 MAINTENANCE AND LUBRICATION Spar k P lugs S par k Plug Re com mendati ons CAUTION Using non-r ecomm ended spark plugs can r esult in s erious engine damage. A lways us e Polaris -rec ommended s park plugs . S ee Specif icat ions beginning on page 103. Refe r to the specif ications se ction beginning on pa ge 103 fo r the re comme nded spa rk plu[...]

85 MAINTENANCE AND LUBRICATION Spar k P lugs Spar k Plug Inspectio n Normal Plug The norma l i nsulator tip is gray , tan or light brown. There will be fe w combustion deposits. The elec trodes ar e not burned or er oded. This indica tes the proper type a nd heat range f or t he engine a nd the servic e. NOT E: T he t ip should not be whit e. A whi[...]

86 MAINTENANCE AND LUBRICATION V eh icl e Immers io n CAUTION If your v ehicle becom es imm ersed, major engine damage c an result if t he mac hine is not t horoughly i nspect ed. T ak e the vehicle t o your dealer bef ore st art ing t he engine. If it’ s impossible to take your A TV to a dea ler befor e starting it, follow the steps outlined bel[...]

87 MAINTENANCE AND LUBRICATION Spar k Ar r estor W ARNING Failur e to heed t he f ollowing warnings while s ervic ing the s park arres tor c ould result in serious injur y or deat h. Do no t perform service o n t he spa rk arrestor wh ile the system is hot. E xhaust system t em peratures ca n r each 1000 ° F . Allow component s t o cool s ufficien[...]

88 MAINTENANCE AND LUBRICATION PV T System The basic ope ration of the P olar i s PVT system is dependent on engine sp eed and v ehicl e t orqu e requi rem ents . As en gin e sp eed i ncreases , t he forc e exerte d on the movable drive shea ve by the flyweights also incr ea ses. This, in turn, incre ase s the amount of “pinc h” applie d to the[...]

89 MAINTENANCE AND LUBRICATION PV T System W ARNING Failur e to c omply wit h t he inst ruct ions in t his warning c an result in sever e injury or deat h. Do not modify any component of th e PVT system. Doing so may reduce it s s tr ength s o that a failur e may oc cur at a high speed. The PVT syst em has been precisio n balanced. Any modif icatio[...]

90 MAINTENANCE AND LUBRICATION Batter y Y our A TV may ha ve e ither a seale d batter y , which r equires little mainte nance , or a conve ntional batte ry . A sea l ed ba ttery c an be identif ied by its flat c over s on the top of the batter y . A conventiona l batte ry has six fille r ca ps on the top of t he ba ttery . Conve n tional B atter y [...]

91 MAINTENANCE AND LUBRICATION Batter y W ARNING Im properly c onnect ing or disc onnect ing batt ery cables c an result in an explosion and c ause ser ious injury or deat h. W hen remov ing the bat t ery , alway s disc onnect t he negativ e (black ) cable f irst . W hen reinst alling t he batt ery , always c onnect t he negativ e (black ) cable la[...]

92 MAINTENANCE AND LUBRICATION Batter y Battery Installation Using a ne w ba ttery tha t has not been f ully cha r ged c an da mage the bat tery an d resu lt i n a sho rter l ife. It can al so hi nd er vehi cle per forma nce. Follow the batte ry char ging instructions on page s 94-96 bef ore installing the batte ry . 1. Ensur e that the batte ry is[...]

93 MAINTENANCE AND LUBRICATION Batter y Batter y Stor age Whe never the ve hicle is not used for a per i od of three months or more, remo ve t he bat tery fro m t he v ehicl e, en su re that it ’ s fu ll y ch ar g ed, an d st ore it o ut o f the su n in a coo l, dry p lace. Ch eck bat tery v ol tage each mo nt h du rin g st orage and r echarge as[...]

94 MAINTENANCE AND LUBRICATION Batter y Batte ry Fluid (C onventiona l Batte r y) A poorly ma intained ba ttery will dete riorate r apidly . Check the batte ry fluid le vel of ten. Maintain the fluid leve l between the upper a nd lower leve l mar ks (1). Add only distille d wate r . T ap w ater conta i ns miner als that are harmful to a batte ry . [...]

95 MAINTENANCE AND LUBRICATION Batter y Batter y Charging (S ealed Batter y) The f ollowing batte ry c har ging instruc tions apply only to the in st all ati on o f a sealed bat t ery . R ead all i ns tr ucti on s befo re proceedi ng with the i nsta llation of this batter y . The seale d batter y is alr eady f illed with e lec trolyte a nd has bee [...]

96 MAINTENANCE AND LUBRICATION Batter y Batter y Charging (S ealed Batter y) NOT E: A lways v erif y bat ter y condit ion bef ore and 1-2 hour s af ter t he end of c harging. Stat e of Char ge Vo l t a g e Acti on Charge T ime* (Us ing cons tant cur rent char ger @ standard amps spec ified on top of battery) 100% 12.8- 13.0 volt s None, check at 3 [...]

97 MAINTENANCE AND LUBRICATION Cleaning a nd Stor age See page 106 for the pa rt numbers of Polaris products. W ashin g the V ehicle Kee ping your A TV clea n will not only improve its appe ara nce but it ca n also exte nd the life of var ious components. CAUTION High water pr essur e may dam age A TV c omponent s. P olaris recom mends was hing the[...]

98 MAINTENANCE AND LUBRICATION Cleaning a nd Stor age W ashin g the V ehicle If a high pre ssure wa ter syste m is used for c leaning (not recom men ded) , ex ercis e ext reme cau ti on . T he wat er m ay dam age components and coul d remove pain t and decals. A void di recting t he wa ter strea m at the f ollowing ite ms: S Wheel b earing s S Radi[...]

99 MAINTENANCE AND LUBRICATION Cleaning a nd Stor age Chr ome W heel Ca r e (if equippe d) P roper mai nt enance wil l pro tect ch rome wheel s from corro si on, pres erve wheel l i fe and en sure a ”l i ke new” ap pearance fo r man y years . NOT E: Chr ome wheels ex posed t o road salt ( or salt in the air in coast al areas ) are m ore sus cep[...]

100 MAINTENANCE AND LUBRICATION Cleaning a nd Stor age Sto ra ge Ti ps CAUTION St art ing the engine dur ing the s tor age period will dist urb t he prot ect ive f ilm cr eated by f ogging and damage c ould occur . Nev er st art t he engine during t he st orage per iod. Clean t he Exterio r Mak e any necess ary repai rs and cl ean th e vehi cle as [...]

101 MAINTENANCE AND LUBRICATION Cleaning a nd Stor age Sto ra ge Ti ps Flu id Levels Inspe ct the fluid le vels. Add or c hange fluids a s rec ommended in the Periodic Mainte nance Char t beginning on page 60. S Dema nd drive unit (front gea rcase ) S Rear g earcase (i f equ ip ped) S T ransmission S Bra ke fluid (c hange e ver y two year s and any[...]

102 MAINTENANCE AND LUBRICATION Cleaning a nd Stor age Sto ra ge Ti ps Inspe ct a nd Lubric ate Ins pect al l cab les an d l ubri cat e all areas o f th e vehi cl e as recom m ended in the Periodic Mainte nanc e C har t beginning on page 60. Batte ry S tora ge See pa ges 93-96 for stor age and c har ging procedur es. Sto rage A rea/Co vers Set the [...]

103 SPECIFIC ATIO NS 2008 T r ail Boss Capac ities Body Styl e Gen I V Ma ximum W ei ght Capa ci ty 415 lbs . ( 188 kg) F uel C ap acity 3.25 ga l. ( 12.35 l ) Transm issio n Oi l 1 1.3 oz . ( 335 ml) Engine O il Ca pa c it y 1.9 qts . (1. 8 l) (i ncl . oil c oole r ) 1.7 qt s. ( 1.6 l )( oil cha nge only) Front Ra ck 75 lbs . ( 34.1 kg) Rear R ack[...]

104 SPECIFIC ATIO NS 2008 T r ail Boss Drive S ystem Dr ive Sys te m T ype PVT Shif t T ype Side Le ver ( F-N- R) Ge ar Re ducti on - Reve rs e 3.05/ 1 Gear R ed u ction - F orw ard 2.68/ 1 Fin al D riv e (ratio) 1 1/40 78P Driv e C hain 520 O- Ring Fr ont T ire s 2 3x7 - 1 0( 4p s i ) Rear Tires 22 x 1 1-10 ( 3 ps i) Sus pens ion and Br akes Fr on[...]

105 SPECIFIC ATIO NS 2008 T r ail Boss Jetting Chart Altitu d e AMBIENT TEMPERA TURE Below 40 ° F (B elow 5 ° C) +40 ° F and above (+5 ° C and above) Meters (Feet ) 0-1800 (0- 6000) 127.5 122. 5 1800-3700 (6000- 12000) 120 11 5 Cl utching C hart Altitude Shi ft W eight Driv e C lutch Sprin g Driven Cl utch Sprin g Helix /Spring Setting Meters ([...]

106 POLARIS PRODUCTS Part No. Descr ipti on Engine Lubr icant 2870791 Fogging O il ( 12 oz. Aer osol) 2871098 Prem ium Blue 2-Cycl e Miner al Oil ( qt. ) 2871097 Prem ium Blue 2-Cycl e Miner al Oil ( gal. ) 2871721 Prem ium Gol d Syntheti c 2-Cycl e Oil ( qt. ) 2871722 Prem ium Gol d Syntheti c 2-Cycl e Oil ( gal. ) 2871281 Prem ium 4 Synt heti c 0[...]

107 TROUB LE SH OOTING Contact your Polar is deale r for se rvic e if you’r e unable to identif y solutions using the follow i ng cha rts. Dr ive Belt and Cover Pr o blems Possibl e Cause Solut ion Dr ivi ng onto a pi ckup or tall trailer in h ig h ran g e Shif t t ra nsm is si on to l ow ra nge dur ing l oadi ng of t he A TV to pr e ve nt be lt [...]

108 TROUB LE SH OOTING Engine Doesn’t T urn Over Po ssibl e Cause Sol uti on Lo w b attery v o ltag e Re c ha r ge bat te ry t o 12.8 VDC or hi ghe r Loos e ba tt er y conne ct ions Ch eck all con n ectio n s and tig h ten Loos e s ole noid conne c ti ons Ch eck all con n ectio n s and tig h ten Engine T urns Over , F ails to Star t Po ssibl e Ca[...]

109 TROUB LE SH OOTING Engine Backfires Po ssibl e Cause Sol uti on W ea k s pa rk f rom spa rk pl ugs In sp ect, clean and /o r replace spark p lu gs In correct sp ark plu g g ap o r heat rang e Se t ga p to s pec s or r epl ac e pl ugs Ol d or non- r e c omme nded f uel Re pla ce w it h new fue l In correctly in stalled sp ark p lug w ires See yo[...]

11 0 TROUB LE SH OOTING E ngine S tops or Loses P ower Po ssibl e Cause Sol uti on Out of fuel Tu rn fuel v alve to reserve, refu el Ki nked or plugge d fue l sys te m vent l ine s Insp ect an d r eplace W ater p resen t in fu el Repl ac e wit h new fue l Ove rus e of choke In sp ect, clean and /o r replace spark p lu gs Foule d or def ec ti ve s p[...]

111 WARRANTY LI MIT ED W ARRANTY Pola ri s Sal es I nc. , 2100 Hi ghway 55, Me dina , M N 55340, give s a SIX MON TH LI MITED W ARRANTY on a ll c ompone nts of t he Pol a ri s Al l T er ra in V e hic le ( A TV) aga ins t def ec ts in m at er ia l or wor kmans hip. Pola ri s a ls o give s a one ye ar l imi te d war ra nty on t he f ina l dr ive c ha[...]

11 2 WARRANTY W ARRANT Y COVERAGE AND EXCL USIONS: LIMI T A TIO NS OF W ARRANTI ES AND REME DIE S ALL IM PLIED W ARRANTIES ( INCLUDI NG BUT NOT LIMI TED TO THE IMPLI ED W ARRANTIES OF MERCHANT ABILI TY AND FITNESS FOR A P AR TICULAR PURPOSE) ARE LI MITED I N DURA TION TO THE ABOVE SIX MONTH W ARRAN- TY PERI OD. POLARI S FUR THER DISCLAI MS ALL EXPR[...]

11 3 WARRANTY Exported V ehicles EXCEPT WHERE SPECIFI CALL Y REQUIRED B Y LA W , THERE I S NO W AR- RANTY OR SER VICE BULLETI N COVERAGE ON THI S VEHICLE I F IT IS SOLD OUTSIDE THE COUNTR Y OF THE SELLING DEALER’S AUTHORI ZED LOCA- TION. Th is po licy d o es no t app ly to v eh icles th at hav e received au th o rization fo r e xpor t fr om Pola [...]

11 4 WARRANTY U. S.A. EP A Emi ss io n s L imi t ed W arra n ty Th is A ll T errain V eh icle (A T V) o r Off Ro ad Utility V ehi cle (OR UV ) emissio n s limited warran ty is in add itio n to the Po laris stand ard limited w arrant y for this veh icle. Po laris w arran ts th at thi s veh icle is; (1 ) d esig ned , b u ilt, an d equ ip ped to con f[...]

11 5 MAINTENANCE LOG Per iod ic Maintenan ce Record Use t he fol lo win g chart t o reco rd p eriod ic m ain ten ance. DA TE MILES ( KM) TECHNICIAN SER VICE PER FORMED / CO MM E NTS[...]

11 6 MAINTENANCE LOG DA TE MILES ( KM) TECHNICIAN SER VICE PER FORMED / CO MM E NTS[...]

11 7 MAINTENANCE LOG DA TE MILES ( KM) TECHNICIAN SER VICE PER FORMED / CO MM E NTS[...]