Polaris Trail Boss 9920770 manual

R ead this manual carefully . It contains important safety infor mation. This is an adult vehicle only . Operation is prohibited for those under 16 years of age. 2007 T rail Boss Owner's Manual for Maintenance and Safety 2007 T rail Boss Owner's Manual for Maintenance and Safety[...]

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A car d containing im portant A TV s afet y infor mation s hould be att ached to t he owner ’ s manual on t he next page. If you cannot locat e this c ard, or if it has been r emoved, please call 1-800- 342-3764 for assist ance. The engine exhaust from this product contains chemic als know n to cause cancer , bi rth defects or other reproductive [...]

1 WELC OME Thank you f or purc hasing a Polaris veh icle , and welc ome to our wor ld-wide f amily of Polaris owne rs. W e proudly produc e an exc iting line of utility and r ec r ea tional pr oducts. S Snowmobiles S All- ter ra in vehic le s (A TVs) S RANGER utility vehicle s S V ict ory mo torcy cles W e belie ve Pola ris sets a standa rd of exc [...]

2 Copyr ight 2006 Pola ri s Sal e s Inc . Al l inf or ma t ion c onta i ne d wi t hin t hi s publi c a t i on i s ba s e d on t he la te s t produc t i nfor m a t ion at t he t i me of publ i c a ti on. Due t o c ons t a nt imp rov emen ts in the desig n and q uality o f p r oduc t i on compone nt s , s ome mi nor d iscrepan cies may resu lt betw e[...]

3 TABLE OF CONTENTS VEHICLE IDENT IFI CA TION NUMBERS 5 ....... SA FETY 6 ................................... FEA TURES AND CONTROL S 30 ............... OPE RA TION 40 .............................. EMI SSION CONT ROL SYST EM S 57 ............ MAINTENANCE AND L UBRICA TION 58 ........ SPECIF ICA TIO NS 97 ......................... POLARIS PRODUCT S[...]

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5 VE HICLE IDENTIFICATION NUMBERS Recor d your A TV’ s identifica tion number s and ke y number in the sp aces prov ided . R emove t he sp are key and s tore i t i n a safe pl ace. An ignition key c an be duplica ted only by or de ring a Polaris key bla nk (using your ke y numbe r) a nd mating it with one of your e xisting ke ys. The ignition swi[...]

6 SA FETY Operator S afety W ARNING Failur e to f ollow the warnings c ontained in this m anual can result in serious injury or deat h. A Polaris A T V is not a toy and can be hazardous t o operate. T his vehicle handles diff erently t han other v ehicles, suc h as motorcycles and cars. A collision o r rollover can occur quickly , even during r out[...]

7 SA FETY Operator S afety The following signa l wor ds and symbols appe ar throughout this manua l and on your A TV . Y our sa fe ty is involved whe n these words and symbols ar e used. Become f a miliar with the ir mea nings befor e re ading the manua l. The safet y alert sy mbol , on y our vehicle or in t his manual, aler ts you t o the pot enti[...]

8 SA FETY Operator S afety W ARNING Serious injur y or deat h can result if you do not f ollow thes e inst ruct ions and procedur es, whic h are outlined in f urther det ail within your owner ’s manual. S Rea d this manua l and a ll labels c ar ef ully , and follow the opera ting proce dure s desc ribed. S Neve r oper ate a n A TV without proper [...]

9 SA FETY Operator S afety S Alway s have th e A TV i nspect ed by an aut hori zed Pol aris d ealer if it ’ s been invol ved in an accident. S Ne ver ope ra te on hills too stee p for the A TV or for your a bilities. Pra c tice on sma ller hills be for e atte mpting lar ger hills. S Alwa ys follow prope r pro ce dure s for climbing hills. Check t[...]

10 SA FETY Operator S afety S W et bra ke s may have re duce d stopping ability . T est your bra kes a fte r lea ving wa te r . If ne ce ssa ry , apply the m lightly seve ra l times to allow frict ion t o dry out the pads . S Always che ck for obsta cles or people be hind the A TV bef ore ope ra t- in g in revers e. When i t’ s s afe t o proceed [...]

11 SA FETY Operator S afety W ARNING POTENTI AL HAZA RD Oper ating this A T V without pr oper instr uction. WHA T CA N HAPPEN The r isk of an ac cident is gr eatly inc reased if t he operat or does not k now how to operat e the A T V properly in differ ent sit uations and on different types of t errain. HOW T O A VOID TH E HAZARD Beginning and inex[...]

12 SA FETY Operator S afety W ARNING POTENTI AL HAZA RD Carry ing a passenger on an AT V . WHA T CA N HAPPEN Carry ing a passenger great ly reduces t he operat or ’s ability t o balanc e and cont rol the A T V , whic h could caus e an accident and injury t o the operat or and/or pass enger . HOW T O A VOID TH E HAZARD Never c arry a pas senger . [...]

13 SA FETY Operator S afety W ARNING POTENTI AL HAZA RD Oper ating this A T V on public st reets , roads or highways. WHA T CA N HAPPEN The A T V could collide with anot her vehic le. HOW T O A VOID TH E HAZARD Never oper ate t he A TV on any public st reet, road or highway , including dirt and gravel roads . I n many st ates it’s illegal t o ope[...]

14 SA FETY Operator S afety W ARNING POTENTI AL HAZA RD Oper ating t he A TV af ter c onsuming alcohol or dr ugs. WHA T CA N HAPPEN Consumpt ion of alc ohol and/or dr ugs could ser iously affec t operat or judgment . React ion tim e may be slower and operat or balance and perc eption could be affec ted. Consuming alc ohol and/or dr ugs befor e or w[...]

15 SA FETY Operator S afety W ARNING POTENTI AL HAZA RD At tempt ing wheelies, jumps and other s tunt s. WHA T CA N HAPPEN At tempt ing st unts inc reases the c hance of an ac cident, including an over turn. HOW T O A VOID TH E HAZ ARD Never at tempt wheelies, jumps, or other st unts. A void exhibit ion driving. W ARNING POTENTI AL HAZA RD Failur e[...]

16 SA FETY Operator S afety W ARNING POTENTI AL HAZA RD Removing hands f rom the handlebars or f eet f rom the f ootres ts during operat ion. WHA T CA N HAPPEN Removing ev en one hand or foot can reduce abilit y to c ontrol t he vehicle or c ould cause loss of balanc e and ejection f rom t he A T V . If t he operator ’s foot is not f irmly plante[...]

17 SA FETY Operator S afety W ARNING POTENTI AL HAZA RD Failu re to use extra caut ion when operating on exces sively rough, slippery or loos e terrain. WHA T CA N HAPPEN Opera ting on e xcessi vely rough, s lippery or loose ter rain could caus e loss of tr action or loss of contr ol, which could r esult in an accident or overt urn. HOW T O A VOID [...]

18 SA FETY Operator S afety W ARNING POTENTI AL HAZA RD Oper ating on exc essively st eep hills. WHA T CA N HAPPEN The v ehicle may ov ertur n. HOW T O A VOID TH E HAZARD Never operat e on hills t oo steep f or the A T V or for your abilit ies. Never oper ate t he A TV on hills s teeper t han 25 _ . Prac tice on s maller hills bef ore att empt ing [...]

19 SA FETY Operator S afety W ARNING POTENTI AL HAZA RD T raveling downhill improper ly . WHA T CA N HAPPEN Im properly des cending a hill could caus e loss of c ontrol or overt urn. HOW T O A VOID TH E HAZ ARD Always f ollow proper procedur es for t raveling down hills as des cribed in the owner ’s manual. NOT E: A spec ial technique is required[...]

20 SA FETY Operator S afety W ARNING POTENTI AL HAZA RD Im properly cr ossing hills and tur ning on hills. WHA T CA N HAPPEN Im properly c rossing or tur ning as hills could c ause loss of c ontrol or over turn. 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 aster ed the t urning tec hn[...]

21 SA FETY Operator S afety W ARNING POTENTI AL HAZA RD St alling, rolling bac kwards or improper ly dismount ing while climbing a hill. WHA T CA N HAPPEN The v ehicle could over turn. HOW T O A VOID TH E HAZ ARD Maint ain steady s peed when climbing a hill. If all forwar d speed is lost: Keep your weight uphill. Apply t he single lever br ake grad[...]

22 SA FETY Operator S afety W ARNING POTENTI AL HAZA RD Im properly operat ing over obst acles. WHA T CA N HAPPEN Oper ating over obs tacles c ould cause loss of contr ol or overt urn. HOW T O A VOID TH E HAZARD Bef ore operat ing in a new area, c heck f or obstac les. Avoid operating ov er large obst acles s uch as roc ks and fallen tr ees when po[...]

23 SA FETY Operator S afety W ARNING POTENTI AL HAZA RD Oper ating t he A TV t hrough deep or f ast -flowing wat er . WHA T CA N HAPPEN T ires may f loat, c ausing loss of t raction and loss of c ontrol, which could lead t o an accident or ov erturn. HOW T O A VOID TH E HAZARD Avoid operating t he A T V thr ough deep or fas t-f lowing water . I f i[...]

24 SA FETY Operator S afety W ARNING POTENTI AL HAZA RD Oper ating t he A TV wit h improper m odificat ions. WHA T CA N HAPPEN Im proper inst allation of ac cessor ies or modif icat ion of the A T V may c ause changes in handling whic h could lead to an ac cident. HOW T O A VOID TH E HAZARD Never modif y the A TV t hrough improper ins tallat ion or[...]

25 SA FETY Operator S afety W ARNING Leaving t he keys in t he ignition c an lead to unauthor ized use of the v ehicle result ing in serious injur y or deat h. Always r emove the ignit ion key when t he vehicle is not in us e. W ARNING Af ter any ov erturn or ac cident, have a qualified ser vice dealer inspect the ent ire vehicle f or possible dam [...]

1 2 3 26 SA FETY Safety D ecals and Locations W arning d ecals have been placed on t he A TV for your protecti on. Read and fo llo w the in stru ctio ns of th e d ecals and o ther warni ngs o n the A TV careful ly . If an y of th e decals s hown i n th is m anual d if fer from the decals o n your A TV , al ways read and follow the in structi ons of[...]

27 SA FETY Safety D ecals and Locations Gene r al W arni ng (3) W ARNI NG Im proper A TV use can resul t in SEVERE I NJUR Y or DEA TH AL W A 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 pr oper t rai ni ng or instr uct i on S at speeds too[...]

6 7 5 4 4 28 SA FETY Safety D ecals and Locations Rack W arning (4) W ARNI NG S DO NOT TOW FROM RACK OR BUMPER. V ehicl e damage or ti pover may resul t causing severe inj ur y or death. T ow only fr om t ow 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 ARNI NG Oper ati ng t hi s A TV [...]

29 SA FETY Safe Ridi ng Gear Always we ar c lothing suited to the t ype of riding. A TV riding requir es spec ial protec tive c lothing for comf ort and to reduc e the cha nce of injury . 1. Helm et W eari ng a h elmet can prev ent a s evere head injury . Whene ver r iding a Polar is vehicle , alway s wear a hel met t hat m eets o r exceeds esta bl[...]

30 FEATURE S AND CONTRO LS Electr ical Switches W ARNING Act ivat ing the over ride switc h while the t hrott le is open can c ause loss of contr ol, res ulting in sever e injury or deat h. Do not ac tivat e the ov erride swit ch while t he throt tle is open. Ov errid e Swi tch (1 ) ( Reve rse Spe e d Limiter ) - This vehicle is equipped with a re [...]

31 FEATURE S AND CONTRO LS W ARNING Do not s tart or operat e an A TV wit h stic king or impr operly operat ing throt tle c ontrols , which could c ause an accident and lead to s evere injury or deat h. Always c ontact your dealer for ser vice repairs if throt tle problem s arise. Failur e to chec k or maint ain proper oper ation of t he throt tle [...]

32 FEATURE S AND CONTRO LS W ARNING Oper ating t he A TV on s treet s or r oads, espec ially in darknes s, could res ult in an acc ident and ser ious injury or deat h. Y our A T V is not equipped wit h highway-appr oved lights . It ’ s designed f or and must be used for of f -road use only . Use ca utio n and drive at reduced speeds in c ondition[...]

33 FEATURE S AND CONTRO LS Br akes Ch eck the brak e fl uid l evel i n the mas ter cyl in der befo re each use o f the A TV . The master c ylinde r (1) is lo cated on t he left h andl ebar . The fluid le ve l can be see n through a n indica tor window (2) on the top of the mas ter cy lin der . Thi s “ey e” will appe ar dark w hen the fluid le v[...]

34 FEATURE S AND CONTRO LS Br ake Lever The fro nt an d rear brak es are app li ed by sq ueezing t he brak e lever (1 ) toward t he han dleb ar . T he front and rear b rakes are hydra ulica lly ac tivated disc type bra ke s th at are activ ated by o nly o ne lever . Alway s test br ake lev er trav el and mast er cyli nder fluid level before ri di n[...]

35 FEATURE S AND CONTRO LS Auxiliary Brake W ARNING Aggres sively apply ing the rear br ake when backing downhill may cause r ear tipov er , which c ould result in s erious injury or deat h. Use caut ion when applying t he auxiliary br ake. Do not aggress ively apply t he auxiliary br ake when going forwar d. T he rear wheels m ay skid and s lide s[...]

36 FEATURE S AND CONTRO LS Choke The choke a ssists in star ting a cold engine. Ref er to the engine sta rting proc edure o n page 42 for corr ec t choke and throttle settings during star ting. Fuel V alve The fu el val ve (1) i s l ocated o n th e left s ide of the vehic le , eithe r below the f ende r or on the side pane l. It has three positions[...]

37 FEATURE S AND CONTRO LS Fuel Safety W ARNING Gas oline is highly f lammable and explos ive under cer tain condit ions. S Always ex ercise ex trem e caution whenever handling gas oline. S Always r efuel wit h the engine st opped, and out doors or in a well vent ilated area. S Do not smok e or allow open f lames or sparks in or near t he area wher[...]

38 FEATURE S AND CONTRO LS Autom atic T ransm ission Gear S elector The tra nsmission gear se lec tor (1) is locate d on the right side of the A TV . F: For w a rd N: Neutral R: Rev e rs e CAUTION Shif ting gears wit h the engine speed abov e idle or while the vehicle is m oving could caus e transm ission damage. T o change gear s, s top the v ehic[...]

1 2 39 FEATURE S AND CONTRO LS Recoil S tarter If the ba tter y is too we a k to star t the engine, use the rec oil star ter ( 1). F ollow the sta rting proce dure s on page 42, cr anking the engine with the recoi l st arter i nst ead of t he main ke y switc h. 1. Gras p th e recoil start er rope ha ndle (2) tightly . 2. Pull slowly so you can fe e[...]

40 OPERATION Br eak-In Per iod The br ea k-in pe riod f or your ne w Polar is A TV is def ined a s the f irst ten hours of oper ation, or the time it takes to use the first two full tanks of gasoline . No single ac tion on your pa rt is as impor tant a s following the proc edur es for a prope r bre ak- in. Caref ul treatme nt of a new engine and dr[...]

41 OPERATION Pr e - Ride Inspection W ARNING If a proper inspec tion is not done bef ore each us e, sev ere injury or deat h could result . A lways inspect the vehic le before eac h use to ens ure it’s in proper oper ating condit ion. Pre - Ride Chec kli st Item Remarks See Page Brake syst em / br ake l ever tr avel Ensure proper oper at i on 34,[...]

42 OPERATION Star ting the E ngine W ARNING Engine exhaus t cont ains poisonous car bon monoxide and can cause los s of c onsciousnes s result ing in severe injur y or deat h. Never r un an engine in an enclosed area. 1. Position the vehicle on a leve l su rface. 2. Place the tr ansmission in neutr al. 3. Lock the parking br ake . NOT E: T he s tar[...]

43 OPERATION Star ting the E ngine 7. Move the engine stop switch to RUN. NOT E: Do not pr ess the t hrot tle while st art ing the engine. 8. T urn the ignition key past the ON position to enga ge the star ter . Activa te the starte r for a ma ximum of five seconds, rele asing the key when the engine sta rts. 9. If the engine doe s not start, relea[...]

44 OPERATION Hauling Cargo Y our A TV has be en de signed to ca rr y or tow a ce rta in amount of loa d. Always re a d and unde rsta nd the loa d distribution wa rning la bels on the veh icle, and nev er exceed t he weig ht capac ities outlined in the sp ecificat io ns sect ion o f th e o wner ’ s m anual an d on th e s afety decal s. Car go weig[...]

45 OPERATION Hauling Cargo W ARNING Hauling cargo im properly c an alter v ehicle handling and may cause los s of c ontrol or br ake inst ability and res ult in ser ious injury or deat h. Alway s follow thes e pr ecautions when hauling cargo: S REDUCE SPEED AN D ALLO W GREA TER DI ST ANCE F OR BRAKING WHEN HAULING CAR GO. S CARG O W EIG HT DI STRI [...]

46 OPERATION Driving Safely Driving Pr ocedures 1. Sit upright with both fee t on the footrests a nd both hands on the handle bar s. 2. Start the engine and a llow it to war m up, then shift the tra nsmission into gea r . 3. Check your surr oundings and dete rmine your pa th of trave l. 4. Relea se the par king brake . 5. Slowly depre ss the thrott[...]

47 OPERATION Driving Safely T urning the V ehicl e Y our Polar is A TV is equippe d with a solid re ar axle that drive s both re ar whe els e qually at all time s. This me ans that the w hee l on the outside of the turn must trave l a grea ter dista nce tha n the inside whee l whe n turning a nd the inside tire must slip trac tion slightly . T o ma[...]

48 OPERATION Driving Safely Dr iving on Slippe r y S urfaces Whenev er ridi ng on sl ipp ery surfaces s uch as wet t rails o r loos e g ravel, or dur ing freezi ng weath er , foll ow th ese precauti ons : 1. Slow down when e nter ing slippery a re as. 2. Mai ntai n a hi gh lev el of alert ness , read ing t he trai l and av oid ing qui ck, s harp tu[...]

49 OPERATION Driving Safely Driving Uphill Whe ne ve r tra veling uphill, follow th ese precau tio ns: 1. Alwa ys tra ve l stra ight uphill. 2. A void ste ep hills ( 25 _ maximum) . 3. Kee p both fe et on the f ootre sts. 4. T ransf er your weight for war d. 5. P roceed at a s teady rat e of spee d and thr ottle ope ning. 6. Rem ain al ert and be p[...]

50 OPERATION Driving Safely Sidehilling W ARNING Im properly c rossing hills or t urning on hills can r esult in los s of cont rol or vehic le overt urn, r esulting in sev ere injury or deat h. Avoid cross ing the side of a hill when possible. Follow proper procedur es as out lined in the owner ’ s m anual. Sidehilling ca n be a d ange rous type [...]

51 OPERATION Driving Safely Driving Downh ill Whe ne ver de sce nding a hill, follow these pr ecauti ons : 1. P roceed di rectly d ownh ill. 2. T ran sfe r your weight to the rea r of the veh icle . 3. Slow down. 4. Apply the brakes slightly to aid in slowing, using the single br ake leve r . NOT E: F amiliarize y ourself wit h operation of the aux[...]

8’ (2. 4 m) 52 OPERATION Driving Safely T urning A r ound on a H il l If the ve hic le stalls while c limbing a hill, neve r bac k it down t he hill! Use the K- turn to turn a round. 1. Stop and lock the pa rking b rake while ke e ping body we ight uphill. 2. Lea ve the transmission in f orw ar d and shut of f the engine . 3. Dismount on the uphi[...]

53 OPERATION Driving Safely Dr i ving Thr ough W ater Y our A TV can oper ate through wa ter with a maximum r ec omme nded depth e qual to the bottom of the footr ests (1). Follow th ese proced ures wh en oper ating through wa ter : 1. De ter mine wa ter depths a nd curr ent bef ore c rossing. 2. Choose a crossing wher e both banks have gra dual in[...]

54 OPERATION Driving Safely Dr iving Over Ob stacles Be al ert! Loo k ahead and l earn to read t he terrain y ou’re trav elin g on. Be con st antl y alert fo r hazard s such as l ogs , rock s and lo w hangi ng bran ches. W ARNING Sever e injury or deat h can res ult if y our vehicle com es in cont act with a hidden obs tacle. Not all obst acles a[...]

55 OPERATION Driving Safely Dr iving in Reverse Fo ll ow thes e p recauti ons wh en operati ng i n reverse: 1. Always avoid bac king downhill. 2. Bac k slowly . 3. Wh en in revers e, apply the brake s lightly for stopping. 4. A void turning at sh arp angl es in reverse. 5. Never ope n the throttle sudde nly while ba cking. W ARNING Failur e to use [...]

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

57 EMISSION C ONT RO L SYSTEMS Noise E mission C ontrol S ystem Do not modify the engine, intake o r exhaust compone nts, as doing so may af fec t complianc e with U.S. A. EP A noise control requir eme nts (40 CFR 205) and loc al noise leve l re quire ments. Operation on Public Lan ds in the U.S.A. Y our Polar is vehic le has a spa rk a r re stor t[...]

58 MAINTENANCE AND LUBRICATION Per iodic Maintenance Char t Care fu l periodic mainte nanc e will help kee p your vehicle in the safe st, most relia ble condition. Inspe ction, adjustme nt and lubr ica tion of importa nt components ar e expla ined in the periodic mainte nanc e ch ar t. Ins pect, cl ean, lu bricat e, adj ust and repl ace p arts as n[...]

59 MAINTENANCE AND LUBRICATION Per iodic Maintenance Char t Maintena nce C har t Ke y " Perfo rm t hese pro cedures m ore frequen tly fo r vehi cles s ubj ected t o seve re use . E Emission-r ela ted se rvic e (Failur e to conduct this maintena nc e will not void the emissions warr ant y but may af fec t emissions.) J Have an au tho rized P ol[...]

60 MAINTENANCE AND LUBRICATION Per iodic Maintenance Char t Perfo rm all serv ices at whi chever mai ntenan ce in terval i s reached first . Item Maint enance Int er val (w hichev er comes fir st) Remarks Hours C ale ndar Miles (Km) J Steer ing -- Pre-R ide -- Make 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 pen[...]

61 MAINTENANCE AND LUBRICATION Per iodic Maintenance Char t Item Maint enance Int er val (w hichev er comes fir st) Remarks Hours C ale ndar Miles (Km) Car buretor float bowl 50 H 6M 500 (800) Dr ain bowl periodic ally and prior t o stor age J E Thrott le Cable/ ETC Switc h 50 H 6M 500 (800) Ins pect; adjus t; lubric ate; replac e if nec ess ary J [...]

62 MAINTENANCE AND LUBRICATION Per iodic Maintenance Char t Item Maint enance Int er val (w hichev er comes fir st) Remarks Hours C ale ndar Miles (Km) J Clutc hes (driv e and driv en) 100 H 12 M 1000 (1600) Ins pect; c lean; replace w orn parts J Front w heel bearings 100 H 12 M 1000 (1600) Ins pect; replac e as needed J Brak e fluid 200 H 24 M 20[...]

63 MAINTENANCE AND LUBRICATION Lubr ication Recom mendations Chec k an d lubric ate a ll co mponents a t the inter vals outline d in the Periodic Ma intena nce Cha rt beginning on page 60. Items not listed in the cha rt should be lubrica ted at the Gene ra l Lubrica tion interva l. NOT E: T he a-arms and lower cont rol arm s are lubric ated at t he[...]

64 MAINTENANCE AND LUBRICATION Engi ne Oil Alwa ys chec k and cha nge the engine oil at the interva ls outlined in the P eriodi c Mai nten ance Ch art beg i nning on page 58. Always change the oil filter whe ne ver c hanging oil. Pr emium 4 Synth etic Oil Polaris Pre mium 4 All Season Synthetic engine oil has bee n spec ially for mulate d fo r use [...]

65 MAINTENANCE AND LUBRICATION Engi ne Oil Oil an d F ilter Change 1. Position the vehicle on a leve l surf ace. 2. Clean the ar ea a round the dra in plug. 3. Run the engine for two to thre e minute s until warm. Stop the engine . CAUTION Contac t with hot oil m ay result in serious burns. Do not allow hot oil to c ome into c ontact wit h skin. 4.[...]

66 MAINTENANCE AND LUBRICATION T ransm ission Oil Oil Check The tra nsmission dipstic k (1) is loca ted on the right side of the mach ine n ear the r ecoil h andl e. Check and c hange the lubric ant at the inte rva ls outline d in the P eriodi c Mai nten ance Ch art beginning on pa ge 60. NOT E: We re commen d the use of Pol aris Pre mium AGL Synt [...]

67 MAINTENANCE AND LUBRICATION T ransm ission Oil Oil Chan ge 1. P lace a drai n pan ben eath th e tra nsmission oil dra in plug area. 2. Loosen the jam nut (A) . 3. T urn the a djuster bolt (B) in to allow the re moval of the drain plug (C). 4. Remove the dr ain plug and wipe the magne tic e nd cle an to remo ve accum ulat ed m eta llic filings. 5[...]

68 MAINTENANCE AND LUBRICATION Br akes The front and re ar br ake s are hydra ulic disc bra kes, activa ted by moving the single brake le ver towar d the handleba r . These bra kes ar e self -a djusting. The fo ll owing ch ecks are recom men ded to k eep th e brake sy stem i n good oper ating c ondition. Check mor e of ten if brake s ar e use d hea[...]

69 MAINTENANCE AND LUBRICATION Br akes 2. Ch eck th e brake s yst em for f lui d leak s. 3. Ch eck th e brakes fo r excess iv e travel o r spongy fee l. 4. C heck t he fricti on pad s for wear , dama ge and loosene ss. 5. Ch eck the secu rit y and su rface condition of the disc. NOT E: Pads s hould be changed when worn t o 3/64 ″ (.1 cm). Auxilia[...]

70 MAINTENANCE AND LUBRICATION T oe A lignm ent W ARNING Sever e injury or deat h can res ult f rom impr oper toe alignment and adjust ment. Do not at tempt to adjust t ie rod alignment . A ll tie rod adjust ments s hould be perfor med by an author ized Polaris dealer . Use the following proce dure to che ck the toe alignmen t of t he ve hicle . Th[...]

71 MAINTENANCE AND LUBRICATION Si de Panel Rem oval NOT E: Side panel r emoval may be diff icult unt il the lock ing tabs and receiv ers have been s napped and unsnapped a few t imes. 1. Remove the sea t. 2. Gras p t he rear of t he si de panel near t he rear cab. W ith a q uick and f irm motion, pull the pa ne l forward and o utward t o disenga ge[...]

72 MAINTENANCE AND LUBRICATION Cam ber and Caster The ca mber a nd caste r ar e non-a djustable . Rear S pring The re ar shoc k absorbe r spring is adjuste d by ro tating the adjuste r ( 1) eithe r clockwise or c ounter cloc kwise to in crease or d ecrease sp ring t ens ion . NOT E: Accessory sp ring s are available t hrough your Polaris dealer . W[...]

73 MAINTENANCE AND LUBRICATION Car bur etor IMPOR T ANT : Y our Polaris A TV is calibr ate d a t the fa ctor y for optimal pe rf orman ce at altitude s ra nging fr om ze ro to 6,000 fee t (1800 m) and temper atur es of +40 degre es F . (4 degree s C. ) or highe r . Above 6000 fe et (1800 m) the e ngine a ir/fue l mixture be c omes ove rly ric h a n[...]

1 2 3 74 MAINTENANCE AND LUBRICATION Thr ottle Cable Fr eeplay Thr ottle ca ble f re epla y is adjusted at the handle bar . 1. Loc ate the thr ottle ca ble adj ust er on t he handle bar . 2. S queeze the e nd of the rubber boot (1) and slide it far enough to e xpose the e nd of the inline ca ble a djuster ( 2). 3. Loosen the locknut (3). 4. Rotate [...]

75 MAINTENANCE AND LUBRICATION Wheels W ARNING Oper ating your A T V with wor n tires, improperly inf lated t ires, non-st andard tir es or improperly ins talled tir es will aff ect vehic le handling and could caus e an accident r esulting in ser ious injury or death. Maint ain proper t ire press ure as desc ribed on the dec al on your A T V and in[...]

76 MAINTENANCE AND LUBRICATION Wheels Wheel Installation 1. Place the tra nsmission in gea r a nd lock the parking br ake . W ARNING Im properly inst alled wheels can adversely aff ect t ire wear and vehicle handling, which can res ult in ser ious injury or deat h. Always ens ure that all nut s are t orqued to s pecificat ion. Do not serv ice axle [...]

77 MAINTENANCE AND LUBRICATION Wheels Fr ont Whee l Hub T ighte ning Front whee l bear ing tightness a nd spindle nut r ete ntion ar e c ritic al compone nt oper ations. All se rvic e must be per forme d by your aut hori zed Po laris d ealer . Tire s W ARNING Use of non- standar d size or t ype of t ires or im proper t ire inflat ion may adver sely[...]

78 MAINTENANCE AND LUBRICATION Rear Dr ive Chain Sl ack CAUTION Adjust ing or operat ing the A T V with im proper rear dr ive chain slack c an result in sev ere damage t o the t ransmis sion and drive component s. A lways mak e sure the s lack is wit hin the s tat ed specif icat ions. Chec k the a mount of cha in slac k in thre e dif fer ent loc at[...]

79 MAINTENANCE AND LUBRICATION Rear Dr ive Chain Sl ack 6. R oll t he A TV forward o r backward to adjust the cha in slac k to the prope r tension. See the illustra tion for pr oper splic e link clip opening position (1) . 7. T i ght en t he eccent ric l ocki ng bo lt s to 30 ft. lbs. (41 Nm) for mac hines without the hitch a nd 45 ft. lbs. (61 Nm)[...]

80 MAINTENANCE AND LUBRICATION Drive Chain Polaris A TV drive cha ins are e quipped with o-r ing-sea led, per mane ntly greas ed pi ns and ro ll ers. Howev er , the o uter s urfaces o f the rol ler m ust be lubric ate d. Always inspe ct the dr ive ch ain prior to ope ra ting the ve hicle. Chec k for dama ged or missing o-rings or damage d rolle rs.[...]

81 MAINTENANCE AND LUBRICATION Air Filter 1. Rem ove t he s eat, rel ease t he cli ps, and re move the air box cover . 2. Loosen the cla mp and r emove the filte r . 3. Remove the f abr ic type pre -filte r (1) f rom the ma in filter ( 2). W a sh the pr e- filte r in soa py wa ter , then rinse and le t dry . 4. Reinsta ll the pre- filte r over the [...]

82 MAINTENANCE AND LUBRICATION Lights Whe n ser vic ing a ha logen lamp, don’ t touch the lamp with ba re finger s. Oil from your skin lea ve s a r esidue , ca using a hot spot that will shorten the life o f the lamp. W ARNING Poor light ing while driving c an result in s evere injury or deat h. Headlight and t aillight lens es become dir ty dur [...]

83 MAINTENANCE AND LUBRICATION Lights T aillight/Brakelight Lamp Replacement If the taillight/br ake light does not work 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 gaske t and se t aside f or re asse mbly . 2. Remove the lamp (1). 3. Apply dielec tric gre ase to the so cket [...]

84 MAINTENANCE AND LUBRICATION Spar k Pl ugs S par k P lug Re com m endati ons CAUTION Using non-r ecommended s park plugs c an result in s erious engine damage. Always us e Polaris- recomm ended spark plugs. See Specif icat ions beginning on page 103. Refe r to the spe cific ations se ction be ginning on page 103 for the re comme nded spa rk plug [...]

85 MAINTENANCE AND LUBRICATION Spar k Pl ugs Spar k Plug Inspectio n Normal Plug The norma l i nsula tor tip is gra y , tan or light brown. Ther e will be few combustion deposits. The ele ctrode s are not burne d or eroded. This indica tes the proper type a nd heat range f or the engine a nd the service . NOT E: T he tip should not be whit e. A whi[...]

86 MAINTENANCE AND LUBRICATION V eh i c le I mmers i o n CAUTION If your vehic le becomes im mersed, m ajor engine damage can result if t he machine is not thoroughly inspec ted. T ake t he vehicle t o your dealer bef ore st arting t he engine. If it’ s impossible to t a ke your A TV t o a dea le r bef ore sta rting it, follow the steps outlined [...]

87 MAINTENANCE AND LUBRICATION Spar k Ar restor W ARNING Failur e to heed t he following warnings while serv icing the s park arres tor could res ult in serious injury or deat h. Do no t perform service o n the spa rk arrestor whi le the system is hot. Exhaust syst em tem peratures ca n r each 1000 ° F . A llow component s t o cool suffic iently b[...]

88 MAINTENANCE AND LUBRICATION PV T System The basic ope ra tion of the P ola ris PVT system is dependent on engine sp eed and v ehicl e torq ue requi rement s. As en gin e speed i ncreases , t he forc e e xerte d on the m ova ble drive shea ve by the flyweights also incr ea ses. This, in turn, incre ase s the a mount of “p inch” applie d to th[...]

89 MAINTENANCE AND LUBRICATION PV T System W ARNING Failur e to com ply with t he instr uctions in t his warning c an result in sever e injury or death. Do not modify any component of th e PVT system. Doing so may reduce it s st rengt h so that a f ailure may oc cur at a high s peed. The PVT syst em has been precisio n balanced. Any modif ication w[...]

90 MAINTENANCE AND LUBRICATION Batter y Y our A TV may ha ve e ithe r a se a led ba tter y , which r equir es little mainte nanc e, or a conve ntional ba tter y . A seale d batte ry c an be identif ied by its f lat c over s on the top of the batte ry . A conve ntional batte ry ha s six fille r c a ps on the top of the batte r y . Conve ntional B at[...]

91 MAINTENANCE AND LUBRICATION Batter y W ARNING Im properly connec ting or disconnec ting batt ery cables can r esult in an explosion and c ause serious injur y or death. When remov ing the bat tery , alway s disconnect the negat ive (black ) cable f irst . W hen reinst alling the batt ery , alway s connect the negativ e (black) c able last. Batt [...]

92 MAINTENANCE AND LUBRICATION Batter y Battery Installation Using a ne w ba tter y that has not be en f ully cha r ged ca n dama ge the bat tery and res ult in a sho rter li fe. It can al so hi nder veh icle per forma nce . Follow the batte ry c har ging instructions on pa ges 94-96 bef ore insta lling the batte ry . 1. Ensur e that the batte ry i[...]

93 MAINTENANCE AND LUBRICATION Batter y Batter y S tor age Whe ne ver the ve hicle is not used for a per iod of three months or more, remo ve th e batt ery from t he vehi cle, en sure t hat i t’ s fu ll y charged, and st ore it o ut of th e s un in a coo l, d ry place. Check b attery v olt age each mo nth d urin g st orage and recharge as needed [...]

94 MAINTENANCE AND LUBRICATION Batter y Batte r y Fluid (Conv entional B atter y) A poorly ma inta ined ba tter y will dete rior ate r ap idly . Check the batte ry fluid le vel of ten. Mainta in the f luid leve l between the upper a nd lower leve l mar ks (1) . Add only distille d w ate r . T ap w ate r conta ins minera ls that ar e ha rmful to a b[...]

95 MAINTENANCE AND LUBRICATION Batter y Batter y C harging (S ealed B attery ) The f ollowing batte ry c har ging instructions a pply only to the in stal lat ion o f a seal ed batt ery . Read all ins truct ion s before proceed ing with the installa tion of this ba tte ry . The sea led ba tte ry is a lre a dy fille d w ith ele ctr olyte and h as be [...]

96 MAINTENANCE AND LUBRICATION Batter y Batter y C harging (S ealed B attery ) NOT E: Alway s verif y batter y condition bef ore and 1-2 hours aft er the end of c harging. Stat e of Charge Vo l t a g e Acti on Char ge T i me* (Us ing constant c urr ent char ger @ s tandard amps spec ifi ed on top of battery ) 100% 12.8- 13. 0 volt s None, check at [...]

97 MAINTENANCE AND LUBRICATION Cleaning a nd Stor age See page 106 for the pa rt numbers of Polaris products. W ashing the V ehicle Kee ping your A TV cle an will not only improve its a ppea ra nc e but it ca n also e xtend the life o f va rious c omponents. CAUTION High water pr essure m ay damage A T V com ponents. Polar is recom mends washing t [...]

98 MAINTENANCE AND LUBRICATION Cleaning a nd Stor age W ashing the V ehicle If a high pre ssur e wa ter syste m is used for c lea ning (not recom mend ed), ex ercise ex trem e cauti on. The wat er may d amage components and could rem ove pain t and decal s. A void d irecting the wa ter stre am a t the f ollowing ite ms: S Wheel b earing s S Radiato[...]

99 MAINTENANCE AND LUBRICATION Cleaning a nd Stor age Chr om e W heel Car e (if equi pped) Pr oper main tenan ce wi ll pr otect chro me wheels from co rrosi on, pres erve wheel l ife and ens ure a ”li ke new” ap pearance for m any y ears. NOT E: Chrom e wheels exposed t o road salt ( or salt in t he air in coast al areas) ar e more sus ceptible[...]

100 MAINTENANCE AND LUBRICATION Cleaning a nd Stor age Sto rag e Tip s CAUTION St arting t he engine during t he stor age period will distur b the prot ectiv e film c reated by f ogging and damage could oc cur . Never st art t he engine during t he stor age period. Clean t h e Exterio r Mak e an y necess ary repairs an d clean t he vehi cle as reco[...]

101 MAINTENANCE AND LUBRICATION Cleaning a nd Stor age Sto rag e Tip s Flu id Levels Inspe ct the fluid leve ls. Add or c hange fluids as r ec ommende d in the Periodic Mainte nanc e Chart beginning on page 60. S Dema nd drive unit (fr ont gea rc ase ) S Rear g earcase (i f equi pped) S T ra nsmission S Bra ke f luid (c hange eve r y two yea rs a n[...]

102 MAINTENANCE AND LUBRICATION Cleaning a nd Stor age Sto rag e Tip s Inspe ct and Lubri cate Ins pect al l cabl es an d lu bricat e all areas o f the v ehicl e as reco mmen ded in the Periodic Mainte nanc e Char t beginning on page 60. Batte ry Stor age See pa ges 93- 96 for stor age and c har ging procedur es. Sto rag e Ar ea/Co vers Set the tir[...]

103 SPECIFIC ATIO NS 2007 T rail Boss Capac ities Body Styl e Gen I V Gro ss V ehicle W eig ht 845 l bs . ( 383 kg) Fu el C apacity 3.25 ga l. (12. 35 l ) Transm ission O il 1 1. 3 oz . (335 ml ) Engine O i l Ca pa c it y 1.9 qts . (1. 8 l) (i nc l . oi l c ool e r ) 1.7 qt s . (1. 6 l ) ( oi l cha nge only) Front Ra ck 75 lbs . ( 34.1 kg) Rear R a[...]

104 SPECIFIC ATIO NS 2007 T rail Boss Drive S ystem Dr i ve Sys t e m T ype PVT Shif t T ype Side Le ver (F- N- R) Ge a r Re duc ti on - Reve r s e 3.05/ 1 Gear R edu ctio n - F orw ard 2.68/ 1 Fin al Driv e (ratio ) 1 1/ 40 78P Driv e Ch ain 520 O- Ri ng Front T ir e s 2 3x7 - 1 0( 4p s i ) Rear Tires 22 x 1 1- 10 ( 3 psi ) Sus pe nsi on and Br ak[...]

105 SPECIFIC ATIO NS 2007 T rail Boss Jetting Chart Altitu de 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 har t Altitude Shi ft W eight Driv e Clutc h Sprin g Driven Cl ut ch Sprin g Helix /Spring Setting Meters ([...]

106 POLARIS PRODUCTS Part No. Descri pt i on Engine Lubr i cant 2870791 Fogging O il ( 12 oz. Aerosol ) 2871098 Prem ium Bl ue 2-Cycl e Miner al Oi l ( qt .) 2871097 Prem ium Bl ue 2-Cycl e Miner al Oi l ( gal .) 2871721 Prem ium Gold S ynthet i c 2- Cycle Oi l ( qt. ) 2871722 Prem ium Gold S ynthet i c 2- Cycle Oi l ( gal. ) 2871281 Prem ium 4 Syn[...]

107 TROUB LE SH OOTIN G Contact your Polar is deale r for se rvic e if you’r e unable to identify solutions using the follow ing cha rts. Dr ive Belt an d Cover Problem s Possibl e Cause Solut i on Dr i ving ont o a pi c kup or tall trailer in h ig h rang e Shif t t ra nsmi s s i on t o l ow r a nge duri ng l oa ding of t he A TV to pr e ve nt be[...]

108 TROUB LE SH OOTIN G Engine Doesn’t T u r n Over Po ssibl e Cause Solut ion Lo w b attery vo ltag e Re c ha r ge ba t t e r y t o 12.8 V DC or highe r Loos e ba tt e r y conne c t i ons Ch eck all con nectio n s and tig hten Loos e s ole noid c onne c t ions Ch eck all con nectio n s and tig hten Engine T ur ns Over , Fails to Star t Po ssibl [...]

109 TROUB LE SH OOTIN G Engine Backfir es Po ssibl e Cause Solut ion W e a k s pa r k f r om s pa r k pl ugs Insp ect, clean an d/o r rep lace spark p lug s In correct spark p lug g ap o r heat rang e Se t ga p to spe c s or r e pl a c e pl ugs Ol d or non-r e c omme nded f ue l Re pla ce wi t h ne w fue l In correctly in stalled spark p lug w ires[...]

11 0 TROUB LE SH OOTIN G E ngine S tops or Loses P ower Po ssibl e Cause Solut ion Out of fuel Tu rn fuel valv e to reserv e, refuel Ki nke d or plugge d fue l s ys t e m vent l i ne s Insp ect an d rep lace W ater p resen t in fu el Repl a c e wi th new fue l Ove r us e of c hoke In sp ect, clean and /o r replace spark p lu gs Foule d or de f e c [...]

111 WARRANTY LIM ITED W ARRANT Y Pola ri s Sa l e s Inc ., 2100 Hi ghwa y 55, M e dina , MN 55340, gi ve s a SI X M ONTH LIMI TED W ARRANTY on a ll c om ponent s of t he Pol a r i s Al l T e r r a in V ehi c le ( A TV) aga i ns t de f e c t s in m a t e r ia l or workm a ns hip. Pola r is a l s o gi ve s a one ye a r li mi t e d wa r r a nt y on t [...]

11 2 WARRANTY W ARRANTY C OVERAGE AND EXCLUSIONS: LIMI T A TIONS O F W ARRANTI ES AND REMEDI ES ALL IM PLIED W ARRANTIES ( INCLUDI NG BUT NOT LIM ITED TO THE IMPLI ED W ARRANTIES OF MERCHANT ABI LITY AND FITNESS FOR A P AR TI CULAR PURPOSE) ARE LI MI TED 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 BY LA W , THERE IS NO W AR- RANTY OR SER VICE BULLETI N COVERAGE ON THI S VEHI CLE IF I T I S SOLD OUTSIDE THE COUNTR Y OF THE SELLING DEALER’ S AUTHORI ZED LOCA- TION. Th is po licy do es no t ap ply to v ehicles that hav e receiv ed auth orizatio n for e xport f rom Pola ri s[...]

11 4 WARRANTY U. S.A. EP A Emis sio n s Li mit ed W arran t y Th is All T errain V eh icle (A T V) o r Off Ro ad U tility V eh icle (ORU V) em ission s limited warran ty is in add ition to t he Po laris stan d ard limited warran ty for this veh icle. Po laris w arrants th at thi s veh icle is; (1) d esig ned , bu ilt, an d eq uip p ed to co nfo rm [...]

11 5 MAINTENANCE LOG Per iodic Mainten ance Recor d Use t he fol lowi ng chart to reco rd perio dic m aint enance. DA TE MILE S (K M) TECHNI CIAN SER VICE PERFO RMED / COMMENTS[...]

11 6 MAINTENANCE LOG DA TE MILE S (K M) TECHNI CIAN SER VICE PERFO RMED / COMMENTS[...]

11 7 MAINTENANCE LOG DA TE MILE S (K M) TECHNI CIAN SER VICE PERFO RMED / COMMENTS[...]

11 8 INDEX A Ag e Restrictio n s 6 ................ Air F ilter 8 1 ..................... Au x iliary B rake 3 5, 6 9 ............ B Ba tt e r y 91- 96 .................... Ba tt e r y ( Conve nt i ona l ) 90 .......... Ba tt e r y Cha r gi ng (C onve nti ona l ) 94 .. Ba tt e r y Cha r gi ng (Se al e d) 95-96 ...... Ba tt e r y Fl ui d ( Conve nt [...]

11 9 INDEX O Oi l Cha nge 65 ................... Oi l Ch eck 6 4 .................... Oil F ilter Ch ang e 6 5 .............. Oi l , Engi ne 64- 65 ................. Oi l , T r a ns mi s s i on 66- 67 ............ Ope r a t or Sa f e ty 6- 25 ............... Ov errid e Sw itch 30 ............... P Park in g Brak e 3 4 ................. P a r k i n [...]