Polaris trailboss 04 manual

[...]

3[...]

A car d cont aining import ant A TV saf ety infor mat ion should be at tac hed to t he owner ’s manual on t he next page. If you c annot loc ate t his c ard, or if it has been rem oved, pleas e call 1-800- 342-3764 f or ass ist ance. The engine exhaust from this product contains chemic als know n to cause cancer , birth defects or other reproduct[...]

1 We’ve cr eated a Web sit e ju st f or you! S T echnical ti ps S New product introductions S Event schedules S Parts and Se rvice M anual information S Exciting details about The W ay Out Ch e c k it ou t... www .polar isindustr ies.com /owner[...]

2 Copyr ight 2003 Pol a ri s Sa l e s Inc . All inf or ma t i on c ont a i ne d wi t hi n t hi s publi c a t ion i s ba s e d on the l a t e s t pr oduc t i nf or ma t i on a t the t i me of publ i c a t i on. Due t o c ons t a nt imp ro v emen ts in th e desig n an d q uality o f pr oduct i on compone nt s , s ome m i nor d iscrepan cies may resu [...]

3 WELC O ME Thank you f or purc hasing a Polar is vehic le, and we lcome to our wor ld-wide f amily of Polaris owne rs. W e proudly produc e an exciting line of utility a nd re cre ational produc ts. Polar is Recr eatio nal and Utility V ehicles S Snowmobiles S All- ter rain ve hicle s (A T Vs) S W at ercraft S V ict ory m ot orcy cles S RANGER uti[...]

4[...]

5 TABLE OF CONTE NTS WELCO ME 3 ................................. VEHICL E IDENTI FICA TION NUM BERS 6 ........ SAFET Y 7 ................................... FEA TURES AND CONTROLS 36 ............... OPE RA TION 46 .............................. EMI SSION CONTRO L SYSTEMS 63 ............ MAINTENANCE AND LUBRICA TION 64 ......... SPECIF ICA TIO NS 1[...]

6 VE HICLE IDENTIFICATION NUMBERS The vehic le fra me vehic le identific ation number (VIN) (1) and engine ser ial numbe r a re impor tant f or mode l i dentif ication w hen re gistering your ve hicle, when obta i ning insura nce, and whe n ordering replacem ent part s. If your vehicl e is s tol en, t hese numbers are essenti al to the r ec overy a[...]

7 SA FETY Operator S afety Age Restr ictions This vehi cle is an ADUL T VEHICLE ONL Y . Operati on is prohi bited for anyone under 16 ye ars of age . Know Y our V e hicle As the opera tor of the vehicle , you are re sponsible for your persona l saf ety , the safe ty of others, and the prote ction of our environme nt. Read a nd understand your owner[...]

8 SA FETY Operator S afety The f ollowing signal wor ds and symbols appe ar throughout this manua l and on your A TV . Y our safe ty is involved whe n t hese words and symbols ar e used. Beco me fa miliar w ith their mea nings befor e re ading the manua l. The saf et y alert s ymbol, on your A T V or in this manual, aler ts you to t he pot ential f[...]

9 SA FETY Operator S afety S Rea d this manual and a ll l ab els ca ref ully , and f ollow the ope rating proce dures desc ribed. S Neve r oper ate a n A TV without proper instr uction. T ake a training course . B eginners shoul d recei ve training from a certi fied ins tructo r . Co nt act an aut ho rized P ol aris A T V deal er or cal l P ol ari [...]

10 SA FETY Operator S afety S Alway s have t he A TV i ns pected b y an aut hori zed P ol aris d ealer i f it ’ s b een invol ved in an accident . S Ne ver ope rate on hills too steep fo r the A TV or for your a bilities. Pra ctice o n smalle r hills befo re a ttempting lar ger hills. S Alwa ys follow prope r proc edures fo r climbing hills. C he[...]

11 SA FETY Operator S afety S W et bra kes may ha ve re duced stopping a bility . T est your br akes a fte r lea ving wate r . If ne cessa ry , apply the m lightly seve ra l times to allow frict io n to d ry out t he pad s. S Always che ck for obsta cles or people be hind the A TV bef ore oper at- in g in rev erse. When i t’ s s afe to proceed i [...]

12 SA FETY Operator S afety POTENTI AL HAZ ARD Oper ating t his A TV wit hout pr oper inst ruct ion. WHA T CAN H APPEN The r isk of an acc ident is great ly inc reased if t he operat or does not know how t o operat e the A T V pr operly in diff erent sit uations and on different t ypes of t errain. HOW T O A VOID TH E HAZ ARD Beginning and inexper [...]

13 SA FETY Operator S afety POTENTI AL HAZ ARD Carr ying a passenger on an A T V . WHA T CAN H APPEN Carr ying a passenger great ly reduc es the operat or ’s ability t o balance and cont rol t he A T V , which could c ause an accident and injury t o t he operat or and/ or pass enger . HOW T O A VOID TH E HAZ ARD Never c arry a passenger . T he pu[...]

14 SA FETY Operator S afety POTENTI AL HAZ ARD Oper ating an A T V on pav ed surf aces , inc luding sidewalks , paths , par king lot s, and driveway s. WHA T CAN H APPEN A TV tir es ar e designed for off- road use. O perat ing on paved surf aces may s eriously affect t he handling and cont rol of the A TV and could result in loss of contr ol, accid[...]

15 SA FETY Operator S afety POTENTI AL HAZ ARD Oper ating t his A TV on public st reet s, roads or highway s. WHA T CAN H APPEN The A T V c ould collide wit h another vehicle. HOW T O A VOID TH E HAZ ARD Never operat e the A T V on any public str eet, road or highway , including dirt and gr avel roads . In many st ates it’s illegal to operat e A [...]

16 SA FETY Operator S afety POTENTI AL HAZ ARD Oper ating t his A T V wit hout wearing an approv ed helmet , ey e prot ect ion and prot ect ive clot hing. WHA T CAN H APPEN Oper ating an A T V wit hout an approved helm et inc reases the ris k of a s evere head injur y or deat h in t he event of an accident . Oper ating wit hout eye prot ect ion cou[...]

17 SA FETY Operator S afety POTENTI AL HAZ ARD Oper ating t he A T V af ter consum ing alcohol or dr ugs. WHA T CAN H APPEN Consumpt ion of alcohol and/ or drugs could ser iously aff ect operat or judgment . React ion ti me may be slower and oper ator balance and perc eption c ould be affect ed. Consuming alc ohol and/or drugs bef ore or while oper[...]

18 SA FETY Operator S afety POTENTI AL HAZ ARD At tem pting wheelies , jum ps and ot her st unt s. WHA T CAN H APPEN At tem pting s tunt s inc reases the c hance of an accident , including an overt urn. HOW T O A VOID TH E HAZ ARD Never att empt wheelies , jumps, or ot her stunt s. Avoid exhibition driving. W ARNING[...]

19 SA FETY Operator S afety POTENTI AL HAZ ARD Failur e to ins pect the A T V bef ore oper ating. Failur e to pr operly m aintain t he A T V . WHA T CAN H APPEN Poor m aintenanc e increas es t he possibilit y of an acc ident or equipment dam age. HOW T O A VOID TH E HAZ ARD Always inspect your A TV befor e each use t o mak e sure it ’s in saf e o[...]

20 SA FETY Operator S afety POTENTI AL HAZ ARD Failur e to us e ext ra caut ion when operat ing t he A TV on unfam iliar terrai n. WHA T CAN H APPEN Unfamiliar t errain ma y cont ain hidden rocks, bumps, o r holes that could caus e loss of cont rol or overt urn. HOW T O A VOID TH E HAZ ARD T rav el slowly and us e ext ra caut ion when operat ing on[...]

21 SA FETY Operator S afety POTENTI AL HAZ ARD Failur e to us e ext ra caut ion when operat ing on exc essiv ely rough, s lippery or loose t err ain. WHA T CAN H APPEN Oper ating on ex cess ively r ough, s lippery or loose t err ain could cause los s of tr act ion or loss of c ontr ol, whic h could res ult in an accident or over tur n. HOW T O A VO[...]

22 SA FETY Operator S afety POTENTI AL HAZ ARD T urning im proper ly . WHA T CAN H APPEN Im proper t urns could caus e loss of cont rol and lead t o a collis ion or overt urn. HOW T O A VOID TH E HAZ ARD Always f ollow proper proc edures f or tur ning as described in the owner ’s manual. Prac tic e tur ning at s low speeds bef ore at t empt ing t[...]

23 SA FETY Operator S afety POTENTI AL HAZ ARD Climbing hills im properly . WHA T CAN H APPEN Im proper hill c limbing could c ause loss of c ontr ol or over tur n. HOW T O A VOID TH E HAZ ARD Always f ollow proper proc edures f or climbing hills as desc ribed in the owner ’ s manual. Always check the t err ain caref ully bef ore as cending any h[...]

24 SA FETY Operator S afety POTENTI AL HAZ ARD T rav eling downhill impr operly . WHA T CAN H APPEN Im proper ly descending a hill c ould cause los s of cont rol or overt urn. HOW T O A VOID TH E HAZ ARD Always f ollow proper proc edures f or tr aveling down hills as descr ibed in the owner ’ s manual. NO T E: A s pecial t echnique is r equired w[...]

25 SA FETY Operator S afety POTENTI AL HAZ ARD Im properly cros sing hills and t urning on hills . WHA T CAN H APPEN Im proper ly cros sing or turning as hills could caus e loss of cont rol or overt urn. HOW T O A VOID TH E HAZ ARD Never at t empt to t urn t he A T V around on any hill until y ou’ve mast ered t he t urning t echnique (on lev el g[...]

26 SA FETY Operator S afety POTENTI AL HAZ ARD St alling, r olling backwar ds or impr operly dis mount ing while climbing a hill. WHA T CAN H APPEN 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 f orwar d speed is lost: Keep your weight uphill. Apply t he single lev er brak e graduall[...]

27 SA FETY Operator S afety POTENTI AL HAZ ARD Im proper ly operat ing over obstac les. WHA T CAN H APPEN Oper ating ov er obst acles could caus e loss of cont rol or overt urn. HOW T O A VOID TH E HAZ ARD Bef ore operat ing in a new ar ea, chec k f or obst acles . Avoid operating ov er large obs tac les suc h as roc ks and f allen tr ees when poss[...]

28 SA FETY Operator S afety POTENTI AL HAZ ARD Oper ating t he A T V t hrough deep or f ast -f lowing wat er . WHA T CAN H APPEN T ires m ay float , c ausing loss of t rac tion and loss of c ontr ol, which could lead t o an acc ident or overt urn. HOW T O A VOID TH E HAZ ARD Avoid operating t he A T V t hrough deep or f ast -f lowing wat er . If it[...]

29 SA FETY Operator S afety POTENTI AL HAZ ARD Oper ating t his A TV wit h improper t ires , or wit h improper or uneven tire pre ssure. WHA T CAN H APPEN Use of impr oper tir es, or oper ation of the A T V wit h impr oper or uneven t ire pr essur e, could c ause loss of c ontr ol or acc ident. HOW T O A VOID TH E HAZ ARD Always use t he size and t[...]

30 SA FETY Operator S afety POTENTI AL HAZ ARD Ov erloading t he A TV or car rying/ t owing cargo im properly . WHA T CAN H APPEN Ov erloading and t owing can caus e changes in v ehicle handling, which could lead t o loss of c ontr ol or an acc ident. HOW T O A VOID TH E HAZ ARD Never ex ceed t he st ated load c apacit y f or t his A T V . Cargo sh[...]

31 SA FETY Operator S afety Af ter any over tur n or acc ident, have a qualif ied ser vice dealer inspect t he entir e vehicle f or pos sible damage, including ( but not limi t ed to) bra kes, throttle and stee ring syste ms. Saf e operat ion of t his r ider-ac tiv e vehicle r equires good judgem ent and physic al skills . Pers ons wit h cognit ive[...]

32 SA FETY Safety D ecals and Locations W arnin g decals h ave been placed 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 oth er warni ngs o n th e A T V careful ly . If an y of t he d ecals sho wn i n t hi s m anual di f fer fro m the decal s on your A TV , always read and fol low the ins truct ions [...]

33 SA FETY Safety D ecals and Locations W ARNING Improper A TV use can r esu lt i n SEVER E INJUR Y or DEA TH ALW A YS USE AN APPRO VED HELMET AND PROTECTIVE GEAR NEVER USE ON PUBLIC ROADS NEVER CARR Y P ASSENGERS NEVER USE WIT H DRUGS OR ALCOHOL NEVER o pera te : AL W A YS: S DO NOT T OW FROM RACK OR BUMP ER. V ehicle d amage or t ipover may resu [...]

34 SA FETY Safety D ecals and Locations Operat ing this A TV if you are under the age of 16 i ncreases your chan ce of severe i nj ury or d eat h. NEVER ope ra te t his ATV if y ou ar e under age 1 6. W ARNING 7078253 Chain Fr eepl ay Is Important. Adjust F ree play to 3/1 6 ″ -3 / 8 ″ DO NO T Overtension. See Owner’s Manual. T orque Nut on E[...]

35 SA FETY Safe Riding G ear Always we ar c lothing suited to the t ype of riding. A TV riding requir es spec i al prote ctive clothing for c omfor t and to reduc e the cha nce of injury . 1. Helm et Y our he lmet is the most importa nt piece of prote ctive ge ar for sa fe riding. A hel met can p revent a sev ere head i nj ury . S elect an app rov [...]

36 FEATURE S AND CONTROLS Electr ical S witches 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 esulting in s evere injur y or death. Do not act ivat e the ov erride s witc h while the t hrot t le is open. W ARNING Ov errid e S wi tch (1 ) (Re ver se Speed Limite r) - This vehicle is equipped with a [...]

37 FEATURE S AND CONTROLS Throttle Lever Eng in e speed an d veh icl e moveme nt are c ontrolle d by pre ssing the throttle leve r . The throttle le ver (1) is spring load ed. Engine spee d retur ns to i dle whe n th e lev er is rel eased . This A TV is equippe d with Polar i s Ele ctronic Throttle Contro l (ET C), whic h is designe d to reduc e th[...]

38 FEATURE S AND CONTROLS Light S witches The light sw itch is loca ted on the left h andl ebar (1). It ’ s us ed to t urn the lights on a nd of f and to switc h the lights fr om HI to LO on mode ls equippe d with HI-LO bea ms. NOTE: The lights won’ t work unless the key is in the ON position and the shut-of f switc h i s in the RUN position. I[...]

39 FEATURE S AND CONTROLS Br akes Ch eck th e brake flu id l evel i n th e mas ter cy li n der befo re each us e of t he A TV . The maste r cylinde r (1) is lo cated o n th e left h andl ebar . The f luid leve l ca n be se en thr ough an indica tor window (2) on the top of the mas ter cy li nd er . Thi s “ey e” wil l appe ar dar k when the f lu[...]

40 FEATURE S AND CONTROLS Br ake Lever The fro nt and rear brak es are ap pl ied b y sq ueezin g t he b rake lev er (1) t oward the han dl ebar . Th e front and rear brak es are hydra ulica lly activa t e d disc type brake s th at are acti vat ed by o nl y one l ever . Alway s tes t brake lev er t ravel an d mas ter cyli nder flui d level before ri[...]

41 FEATURE S AND CONTROLS Auxiliary Brake The a uxiliar y brake ( 1), is loca ted on the inside of the right floor boa rd and is opera ted by the right foot. The auxilia ry bra ke ser ves as a backup to the main bra ke system if the main system be come s inoperative . If the r ea r whee ls slide while using the a uxiliar y bra ke, r educe brak e pe[...]

42 FEATURE S AND CONTROLS Choke The choke a ssists i n starting a c old engine. Ref er to the engine sta rting proc edur e on page 48 for corr ect choke and throttle se ttings during star ting. Fuel V alve The fu el v alv e (1) i s l ocat ed on th e left si de o f the veh icle , either be low t he fe nder or on the side pane l. It has t hre e posit[...]

43 FEATURE S AND CONTROLS Fuel Safety Gas oline is highly f lamm able and explosiv e under cer tain condit ions. S Always exerc ise ext rem e caut ion whenever handling gas o- line. S Always ref uel with t he engine st opped, and outdoor s or in a well vent ilated ar ea. S Do not smok e or allow open f lames or spar ks in or near the area wher e re[...]

44 FEATURE S AND CONTROLS Autom atic T r ansm ission Gear Selector The tra nsmission gear se lector ( 1) is locate d on the right side of the A TV . F: For wa rd N: Neutral R: Rev er se Whe never the A TV is left unattende d, alwa ys place the tra nsmission in gea r with the parking bra ke locked. Mainta ining shift linkage adjustme nt is important[...]

45 FEATURE S AND CONTROLS Recoil S tarter If the ba ttery has be en dra i ned or da mage d and c annot star t the engine , use of the re coil star ter (1) w ill a llow veh icle oper ation until re pairs c an be made . The r ec oil starte r is loca t ed on the right side of the mach in e. Polaris 4- cycle engine s are equippe d with automa tic decom[...]

46 OPERATION Br eak - In P er iod The br ea k-in period f or your new Polaris A TV is def ined a s the first te n hours of oper ation, or the time it takes to use the first two full t anks of gasoline . No single ac tion on your part is a s important a s following the proc edur es for a prope r break- i n. Caref ul t re atment of a new engine will [...]

47 OPERATION Pr e -Ride Inspection Use the f ollowing chec klist to verif y that your ve hicle is in prope r wor king condition be fore each use. Item /Insp ectio n Procedu re 1. T ires - Che ck condition a nd pre ssure s. 2. Fuel and oil tanks - Fill both tanks to their prope r leve l s. 3. All bra kes - Che ck oper ation, adjustme nt an d fluid l[...]

48 OPERATION Star ting the Engine S tar ting a Col d Engine 1. Place the tr ansmission in neutra l and lo ck t he park in g brak e. Mak e sure the fue l t ank valve is on. 2. Sit on the vehicle a nd pull t he choke knob out until it stops (1) . NOTE: If the knob doesn’ t stay where positione d, incre ase the tension by r otating the te nsion adju[...]

49 OPERATION Star ting the Engine S tar ting a W ar m Engine W ar m engines do not normally requir e the use of the choke. Exce ssive use of the choke ca n cause the spa rk plug to become we t foule d. 1. Position the vehicle on a le vel surfa ce with the tra nsmission in neutr al. 2. Lock the par king bra ke, turn the f uel tank valve to ON, sit o[...]

50 OPERATION Hauling Cargo Y our A TV has bee n designed to ca rry or tow a ce rtain a mount of load. Always r ea d and unde rstand the loa d distribution war ning labels on the veh icl e, an d never ex ceed th e weigh 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 i g[...]

51 OPERATION Hauling Cargo Hauling cargo im proper ly can alt er v ehicle handling and may cause loss of c ontr ol or brake inst ability and res ult in serious injur y or death. A lways f ollow t hese prec autions when hauling cargo: S REDUCE SPEED AN D ALLO W G REA TER DI ST ANCE F OR BRAKING WHEN HAULING C ARGO . S CARG O W EI G HT DI ST RI BUT I[...]

52 OPERATION Driving Safely Driving Pr o cedures 1. Sit upright with both fe et on the f ootre sts and both hands on the handle bar s. 2. Start the engine a nd allow it to war m up, then shift the tr ansmission into gea r . 3. Check your sur roundings and dete rmine your pa th of trave l . 4. Relea se t he par king brake . 5. Slowly depr ess the th[...]

53 OPERATION Driving Safely Making T urns Y our Pola ris A TV is equippe d with a solid r ear ax le tha t drives both re ar wh ee ls equally at a ll times. This me ans that the whe el on the outside of the turn must travel a gre ate r distanc e than the inside wheel whe n turning and the inside tir e must slip trac tion slightly . T o make a turn, [...]

54 OPERATION Driving Safely Dr iving on Slippe r y Sur f aces Whenev er ridi ng o n sl ip pery su rfaces su ch as wet trai l s or lo ose grav el, or du ring freezi ng weat her , fol lo w thes e precaut io ns: 1. Slow down when e nter ing slippery a rea s. 2. Mai nt ain a h ig h l evel o f al ert ness , read in g t he t rai l and avo id in g qui ck,[...]

55 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 footre sts. 4. T ransfe r your weight forwar d. 5. P roceed at a s tead y rat e of spee d and throttle ope ning. 6. Rem ai n alert an d be prep [...]

56 OPERATION Driving Safely Sidehilling Sidehilling ca n be a dange rous type of driving a nd should be avoided if at a ll possible. If you do e nter into a situa tion where sidehilling is neces sary , fol l ow t hes e precaut i ons : 1. Slow down. 2. Lea n into the hill, transf er ring your uppe r body weight towa rd the hill while kee ping your f[...]

57 OPERATION Driving Safely Driving Downh ill Whe never de scending a hill, follow these pr ecauti on s: 1. P roceed di rect ly d own h ill. 2. T ransf er your we ight to the re ar of the ve hicle. 3. Slow down. 4. Apply the brakes slightly to aid in slowing, using the single br ake leve r . NOTE: Fa miliar i z e yourse lf with opera tion of the au[...]

58 OPERATION Driving Safely T urning A round on a H ill If the ve hicle stalls while c limbing a hill, never ba ck it down the hill! One mane uver that c an be used whe n it’ s nece ssar y to turn ar ound while c limbing a hill is the K-turn: 1. Stop and lock the pa rking bra ke while ke eping body w eight uphill. 2. Lea ve transmission in f orwa[...]

59 OPERATION Driving Safely Dr iving Thr ough W ater Y our A TV can ope ra te through wa ter with a maximum r ecomme nded depth e qual to the bottom of the footr ests (1) . F ollow th ese pro cedu res when oper ating through wa ter: 1. De termine wa ter depths a nd cur rent bef ore c rossing. 2. Choose a crossing wher e both banks have gra dual inc[...]

60 OPERATION Driving Safely Dr ivin g Over Obstacles Be al ert! L ook ah ead and l earn to read t he terrai n yo u’re trav eli ng on . Be con st ant l y alert fo r hazards s uch as l og s, ro cks an d lo w hangi ng bran ches . Sever e injury or death c an result if your v ehicle com es in cont act with a hidden obs tac le. Not all obst acles are [...]

61 OPERATION Driving Safely Dr ivin g in Rever se F oll ow t hese precau ti on s when op erati ng i n revers e: 1. Always a void bac king downhill. 2. Bac k slowly . 3. When i n reverse, apply the brake s lightly for stopping. 4. A void turning at sh arp angl es i n revers e. 5. Never ope n t he throttle sudde nly while ba cking. NOTE: T his Polar [...]

62 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 unavoida ble, follow th ese p recaut io ns : 1. T urn the engine of f. 1. Place the tr ansmission in gear . 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 fue l s[...]

63 EMISSION C ON TR OL SYST EMS Noise E mi ssion Contr ol System Do not modify the engine, i ntake o r e xhaust components, as doing so may af fec t complianc e with state and loca l noise level requir ements. Spar k Ar r estor Y our Polaris ve hicle ha s a spar k arre stor that was te sted a nd appr oved in accordance wi th the US DA F or est S er[...]

64 MAINTENANCE AND LUBRICATION Accessor ies Auxilia ry powe r outlets provide 12V powe r for oper ating access ori es such a s hand held spot lights. Acce ssory outlets a re a vailable for all models. Contac t your P olar is dealer f or more informa tion. Po laris h as a wid e range of additi onal access ories avai lable for your A TV . See your Po[...]

65 MAINTENANCE AND LUBRICATION Per iodi c Maintenance S chedule Hours of ope ration ar e based o n a 10 mph a vera ge. If ser vice is due a t 20 hours, the e quivale nt odomete r rea ding would be 200 mile s. P erform all s ervi ces at whi chever readi ng is reach ed first . Item Hours/ Mile s Frequency Remar ks Brake S ystem Pre- Ride Pr e-Ride In[...]

66 MAINTENANCE AND LUBRICATION Per iodi c Maintenance S chedule Item Hours/ Mile s Frequency Remar ks T a illigh t/b rak e ligh t Pre- Ride Pr e-Ri de Check operat ion daily; ap- ply P olar is di electr ic gr ease to socket when r eplaced " L Air filte r , mai n elem ent W eekly W eekly Inspect ; repl ace as needed J Brake pad wear 10 hr s. Mo[...]

67 MAINTENANCE AND LUBRICATION Per iodi c Maintenance S chedule Item Hours/ Mile s Frequency Remar ks Carbur etor f loat bowl 50 hr s. 6 mont hs Drai n bowl peri odicall y and pri or to stor age J Throt tl e Cable/ ETC Swit ch 50 hr s. 6 mont hs Inspect ; adjust ; lubr icat e; r eplace if necessar y L Choke (enr icher ) cable 50 hr s. 6 mont hs Ins[...]

68 MAINTENANCE AND LUBRICATION Per iodi c Maintenance S chedule Item Hours/ Mile s Frequency Remar ks Radiat or/ Oil Cool er 100 hr s. 12 mont hs In spect; cl ean exter nal sur- fac e Cool ing syst em hoses 100 hr s. 12 mont hs In spect J Clut ches (dr ive and dri ven) 100 hr s. 12 mont hs In spect; cl ean Engine m ounts 100 hrs. 12 months Inspect [...]

69 MAINTENANCE AND LUBRICATION Per iodic Maintenance R ecord Use t he fol l owi ng ch art t o reco rd peri od ic m ain ten ance. Maintenance In terval Perfo rmed Se rv icing Date Ser vic ing Dealer or Pe rs on Remarks 10 hrs. 20 hrs. 50 hrs. 100 hrs.[...]

70 MAINTENANCE AND LUBRICATION Lubr ication Recom m endations NOTE: Hour s are ba sed on 10 mph aver age. If se rvice is due a t 20 hours, the e quivale nt odomete r rea ding would be 200 mile s. P er form all serv ices at whi chev er readin g is reach ed firs t. Lubr ica tion C har t Key " More ofte n under seve re use, such a s wet or dusty [...]

71 MAINTENANCE AND LUBRICATION Lubr ication Recom m endations Pr emium 4 S ynth etic Oil Polaris Pre mium 4 All Sea son Synthetic e ngine oil has bee n specia lly for mulated for use in Polar i s 4-c ycle e ngines. It’ s a fully synthetic , high per forma nce , multi-visc osity oil designed to pr ovide the ultima te in lu bri cati on perfo rman c[...]

72 MAINTENANCE AND LUBRICATION Lubr ication Recom m endations Oil an d Filter Chang e 1. Position the vehicle on a leve l surf ace. 2. Clean the a re a around the dra in plug. 3. Run the engine for two to three minutes until wa rm. Stop t he engine . 4. Place a dr ain pan bene ath the engine cr ankc ase a nd remove the dra in plug. 5. Allow the oil[...]

73 MAINTENANCE AND LUBRICATION Lubr ication Recom m endations T ransm issio n Oil Check The tr ansmission dipstic k (1) is loca t ed on the right side of the mach in e near t he reco il han dl e. Ch eck t he l ub rican t l evel monthly or e ver y 1000 miles (1600 km), whicheve r comes first. Change the tr ansmission oil annua lly . NOTE: We re comm[...]

74 MAINTENANCE AND LUBRICATION Lubr ication Recom m endations T ransm issio n Oil Chang e 1. P lace a drain p an ben eath t he tra nsmission oil drain plug area. 2. Loosen the jam nut ( A). 3. T urn the adjuste r bolt (B) in to allow the re moval of the drain plug (C). 4. Remove the dr ain plug and wipe the magne tic end cle an to remo ve accu mu l[...]

75 MAINTENANCE AND LUBRICATION Lubr ication Recom m endations E ngine Oi l Chec k The oil fill is locate d on the left side of the vehicle ( 1). 1. Position the mach ine on a level surf ace. 2. Start the engine and let it idle for 20-30 seconds. Stop the engine. 3. Remove the dipstic k and wipe it dry with a c lea n cloth. 4. Scre w the dipstick c [...]

76 MAINTENANCE AND LUBRICATION Adju stment s Br akes The front and re ar brake s are hydra ulic disc brakes, activa ted by moving the single brake le ver towar d t he handle bar . These br ake s are self -a djusting. The fo ll owi ng checks are recom men ded t o k eep th e brak e sys tem i n good oper ating c ondition. Check mor e often if bra kes [...]

77 MAINTENANCE AND LUBRICATION Adju stment s Br akes 2. Ch eck t he b rake sy st em fo r fl ui d l eaks. 3. Ch eck t he b rakes for ex cess iv e trav el o r spongy fe el. 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. NOTE: Pads should be cha nged when worn to 3/64 ″[...]

78 MAINTENANCE AND LUBRICATION Adju stment s T oe Alignm ent Use the following proce dure to chec k the t oe alignme nt of t he vehic le. The re comme nded toe alignment is 1/8 ″ to 1/4 ″ toe out. 1. Set t he handle bars in a stra ight-a head position. NOTE: The st eerin g frog can be us ed as an in di cato r of whether the ha ndleba rs are str[...]

79 MAINTENANCE AND LUBRICATION Adju stment s S ide P anel Rem oval NOTE: Side pane l re moval may be dif ficult until the locking ta bs and receiv ers have been s napp ed and un sn apped a few times. 1. Remove the sea t . 2. Grasp the rear of t he si de p anel near t he rear cab . W it h a q ui ck and firm motion, pull the pa nel forward and o utwa[...]

80 MAINTENANCE AND LUBRICATION Adju stment s Steer in g Assem b ly The ste er ing assembly of the A TV should be che cked pe riodically f or loose nuts and bolts. If loose nuts and bolts are f ound, see your Polaris dea ler for se rvice bef ore ope ra ting the vehicle. Cam b er and Caster The ca m ber a nd caste r are non-a djustable. Rear S pring [...]

81 MAINTENANCE AND LUBRICATION Adju stment s Ca r bur etor IMPOR T ANT : Y our Polar i s A TV is c alibr ate d at the fa ctory for optimal pe rf orma nce at a ltitudes r anging f rom ze ro to 6,000 fee t (1800 m) and temper atures of +40 degr ee s F . (4 degr ee s C .) or higher . Above 6000 fe et (1800 m) the e ngine air/f uel mixture be comes ove[...]

82 MAINTENANCE AND LUBRICATION Adju stment s Thr ottle C able Fr eeplay Thr ottle ca ble fre eplay is adjuste d at the handleba r . 1. Slide the boots (1) of f the inline cable a djuster slee ve (2) . Loosen the adjuste r locknut (3). 2. T urn the adjuste r until 1/16 ″ to 1/8 ″ freepl ay is ach iev ed at th e th um b lev er . NOTE: While a dju[...]

83 MAINTENANCE AND LUBRICATION Adju stment s Wheel Rem o val 1. Stop the engine , plac e the tra nsmission in gear a nd lock the par king bra ke. 2. Loosen the whe el nuts slightly . 3. Eleva te t he side of the veh icle by plac i ng a suitable sta nd under the foot rest fram e. 4. Remove the whe el nuts and remove the whe el. Oper ating y our A T [...]

84 MAINTENANCE AND LUBRICATION Adju stment s Wheel Installation 1. Place the tr ansmission in gear and loc k the par king bra ke. 2. P lace t he wh eel o n t he wh eel hub with the valve stem towar d the outside and rota tion arro ws on the tire pointing toward for wa rd r otation. 3. Insta ll the whee l nuts and finge r tighten. 4. Lower the vehic[...]

85 MAINTENANCE AND LUBRICATION Adju stment s Fr ont Whee l Hub T ightening Front whee l bea ring tightne ss and spindle nut rete ntion are cr itical compone nt opera tions. All servic e must be pe rforme d by your aut ho rized P ol ari s deal er . Tire s Alway s repl ace tires wh en tread depth is wor n t o 1/8 ″ ( .3 cm) or le ss. Use of non-st [...]

86 MAINTENANCE AND LUBRICATION Adju stment s Rear Dr ive Chain Slack Chec k the a mount of cha in slack in thr ee dif fe re nt locations by moving the ve hicle slightly f orwa rd to ga i n sla ck a t the top side of the r ear chai n. M easur e th e chai n sl ack at t he t ig ht est of t he t hree p os it io ns . At this point the chain should have [...]

87 MAINTENANCE AND LUBRICATION Adju stment s Rear Dr ive Chain Slack 6. R ol l t he A TV forward or back ward to adjust the cha in slack 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 bo lt s to 30 ft. lbs. (41 Nm) for ma chines without the hitc h and 45 ft[...]

88 MAINTENANCE AND LUBRICATION Adju stment s Drive Chain Polaris A TV drive cha ins are e quipped with o-r ing-sea led, perma nently greas ed pi ns and rol lers . Ho wever , th e out er su rfaces o f th e rol ler m us t be lubric ate d. Always inspe ct the dr i ve c hain prior to oper ating the vehic l e. Chec k for dama ged or missing o-r ings or [...]

89 MAINTENANCE AND LUBRICATION Air Filter 1. Rem ov e th e seat , rel ease t he cl ip s, and re move the air box cover . 2. Loosen the cla mp and re m ove the filte r . 3. Remove the f abric type pre -filter (1) f rom the main filter ( 2). W ash the pr e-f ilter in soapy w ate r , then rinse a nd let dry . 4. Reinsta ll the pre -filter ove r the ma[...]

90 MAINTENANCE AND LUBRICATION Lights Whe n servic ing a halogen la mp, don’ t t ouch the lamp with ba re finger s. Oil from your skin le aves a re s idue , causing a hot spot tha t will shorten the life o f the lamp. Headlight L am p Replacement 1. Remove the wir e harness conne ctor from the bac k of the headlight. 2. Gra sp the bulb housing an[...]

91 MAINTENANCE AND LUBRICATION Lights T aillight /Br akelig ht Lamp Replacement If the taillight/br akelight does not wo rk the lamp may ne ed to be repl aced. 1. Remove the ta illight lens cove r mounting scre ws. Remove the lens c over a nd gasket and se t aside f or re asse mbly . 2. Remove the lamp (1) and re place it with a ne w lamp. 3. T est[...]

92 MAINTENANCE AND LUBRICATION Spar k P lugs Spar k plug condition is indic ative of e ngine ope ra tion. The spar k plug firing e nd condition should be re ad af ter the engine ha s bee n wa rmed up an d th e vehi cle has b een dri ven at h ig her sp eeds . Imm edi at ely check t he spark p lu g for correct co lo r . 1. Normal The norma l i nsulat[...]

93 MAINTENANCE AND LUBRICATION V eh ic le Imme rsi o n If it’ s impossible to take your A TV to a deale r befor e starting it, follow the steps outlined below . 1. Move the A TV to dry land o r at the ver y least, to wa ter b elow the foot re sts. 2. Check the air box for any wa ter and dry it i f water i s p resen t. 3. T urn the fuel valve of f[...]

94 MAINTENANCE AND LUBRICATION Spar k Ar r estor 1. Remove the ar restor cle an- out plug (1) fr om the bottom of the muf fle r . 2. Place the tr ansmission in neutra l and star t the engine. 3. Pur ge carbon fr om the system by momenta rily revving the e ngine seve ral time s. 4. If c ar bon is expelle d, cover or plug the exha ust outlet (2) and [...]

95 MAINTENANCE AND LUBRICATION Recoil Hou sing T o preve nt possible engine dama ge, always dr ain the r ec oil housing (1) a f t e ro p e r a t i n gt h eA T Vi nv e r yw e t conditions. This should also be done bef ore storing the A TV . W ate r will ente r the re coil housing if the star ter ha ndle is disengage d from the rope guide when under [...]

96 MAINTENANCE AND LUBRICATION PV T System The basic ope ra tion of the P olar is P VT system is depende nt on engine sp eed and vehi cle t orq ue requ irem ent s. As engi ne s peed i ncreas es, t he for ce e xerte d on the m ovable d rive shea ve by the flyweights also incr ea ses. This, in turn, incr ease s the amount of “pinc h” applie d t o[...]

97 MAINTENANCE AND LUBRICATION PV T System PVT Dryi ng There m ay be som e ins tan ces when wat er is acci dent ly i ng est ed in to the PVT system. Use the following instruc tions to dry it out befor e oper ating: 1. Move the A TV to dry land, or to water that is at least three inche s below the footwe ll. Remove the PVT drain plug and allow the w[...]

98 MAINTENANCE AND LUBRICATION Batter y Batt ery Remov al 1. Disconne ct the batte ry hold-down stra p and re move the ba ttery c over . 2. Di sco nnect t he bl ack (n egat iv e) batt ery cab le fi rst . 3. Disc onnec t the red (positive ) batte ry ca ble next. 4. Lift the batter y out of the A TV . Battery Installation Whe n installing a ne w batt[...]

99 MAINTENANCE AND LUBRICATION Batter y Batter y Stor age Whe never the ve hicle is not used for a per iod of three months or more, remo ve t he bat tery from th e vehi cle, en sure t hat i t’ s fu ll y ch ar g ed, and st ore it ou t of t he sun i n a cool , d ry pl ace. C heck b att ery vo lt age each mo nt h du rin g st orag e and recharge as n[...]

100 MAINTENANCE AND LUBRICATION Batter y Batt ery Cha rgin g NOTE: A lways ve rify batter y condition bef ore a nd 1-2 hours af ter the end of cha r ging. 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 mos. fr om date of [...]

101 MAINTENANCE AND LUBRICATION Cleaning a nd Stor age See page 108 for the pa rt numbers of Polaris products. Cleaning th e A TV Kee ping your A TV cle an will not only improve its appe ara nce but it ca n also exte nd the life of va rious components. W ith a f ew precauti ons, your A TV can be cleaned m uch li ke an a utom obile. W ashin g the A [...]

102 MAINTENANCE AND LUBRICATION Cleaning a nd Stor age Sto ra ge Ti ps See page 108 for the pa rt numbers of Polaris products. Exterio r Make nec essar y re pair s and then c lean the A TV thoroughly with mild soap a nd warm w ater to re move all dirt a nd grime . Don’ t use harsh dete rg ents or high pressure wa shers. S ome de ter gen ts deter [...]

103 MAINTENANCE AND LUBRICATION Cleaning a nd Stor age Sto ra ge Ti ps See page 108 for the pa rt numbers of Polaris products. Flu id Levels Inspe ct the following fluid levels and cha nge if nece ssar y: engine oil; tran sm is si on oi l ; brak e flui d (chang e every two y ears or as needed i f fluid looks dark or conta minated). Engine 1 . Remov[...]

104 MAINTENANCE AND LUBRICATION Cleaning a nd Stor age T r anspor ting an A TV Follow these proce dures when tra nsporting an A TV . 1. T urn off the e ngine and remo ve t he k ey t o prev ent loss during tra nsporting. 2. T urn the fuel valve of f. 3. Be s ure t he fu el cap , oi l cap and seat are in st all ed correct ly an d secu rely . 4. Alwa [...]

105 SPECIFIC ATIO NS 2004 T r ail B oss Capac ities Body Styl e Gen I V Gro ss V ehicle W eig h t 845 lbs . ( 383 kg) Fu el C ap acity 3.25 ga l. (12. 35 l) Transm issio n Oil 1 1.3 oz . ( 335 ml ) Engine O il Ca pac it y 1.9 qts . (1. 8 l )( inc l. oi l cool er ) 1.7 qt s. (1. 6 l) (oi l c hange only) Front Ra ck 75 lbs . ( 34.1 kg) Rear R ack 125[...]

106 SPECIFIC ATIO NS 2004 T r ail Boss Drive S ystem Dr ive Sys te m T ype PVT Shi ft T ype Side Le ver ( F-N- R) Ge ar Re duct ion - Reve rs e 3.05/ 1 Gear R ed u ction - F o rward 2.68/ 1 Fi nal D riv e (ratio) 1 1/40 78P Driv e C hain 520 O-Ri ng Fr ont 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 Brake s Fr [...]

107 SPECIFIC ATIO NS 2004 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 (F eet) 0-1800 (0- 6000) 127.5 122. 5 1800-3700 (6000- 12000) 120 11 5 Cl utching C hart Altitude Shi ft W eight Dr ive C lutch Sprin g Driven Cl utch Sprin g Helix /Spring Setting Meter s [...]

108 POLARIS PRODUCTS Part No. Descr ipt ion Engine Lubr icant 2870791 Fogging O il ( 12 oz. Aer osol) 2871098 Prem ium 2- Cycle Engi ne Oi l ( qt. ) 2871281 Prem ium 4 Synt heti c 0W -40 ( 4-Cycl e) Engi ne Oil ( qt. ) 2871844 Prem ium 4 Synt heti c 0W -40 ( 4-Cycl e) Engi ne Oil ( gal.) 2871567 Prem ium 4 Synt heti c 0W -40 ( 4-Cycl e) Engi ne Oil[...]

109 TROUB LES HOOTIN G Dr ive Belt and Cover Pr o blems Po ssib l e Cause Solution Dr ivi ng t he A TV ont o a p icku p o r tall trailer in hi gh ra nge . A void s toppi ng on the ra mp or c r e e ping s low l y up the ramp . Th ese practices may slip the clutch an d b elt. St a rt ing out going up a steep in cline. Whe n st ar ti ng out on a n inc[...]

11 0 TROUB LES HOOTIN G Contac t your P olar is dealer f or servic e if you’re una ble to identify solutions using the follow i ng ch ar ts. Engine Doesn’t T urn Over Po ssibl e Cause Solut io n Lo w b attery v o ltag e Re cha r ge ba tt er y to 12. 8 VDC or highe r Loos e ba t te ry conne c t ions Ch eck all con n ectio n s an d tigh ten Loos [...]

111 TROUB LES HOOTIN G Engine Backfir es Po ssibl e Cause Solut io n W ea k spa r k fr om s par k plugs In spect, clean an d/ or repl ace spark p lu g s In correct sp ark plu g g ap o r heat rang e Se t ga p to spe c s or re pla c e plugs Ol d or non- re comm e nde d f ue l Re pla c e wi th new fue l In correctly in stalled sp ark p lu g wires Se e[...]

11 2 TROUB LES HOOTIN G E ngine S tops or Loses P ower Po ssibl e Cause Solut io n Out of fuel Tu rn fuel v alve to reserv e, refu el Ki nked or plugge d fue l sys te m ve nt li nes Insp ect an d rep lace W ater p resent in fu el Repl ac e wit h new fue l Ove rus e of choke In spect, clean an d/ or repl ace spark p lu g s Foul e d or de f e c ti ve[...]

11 3 WARRANTY LIM IT ED W ARRANT Y Pol a ri s Sal es I nc ., 2100 Highwa y 55, Me dina , MN 55340, gi ves a SIX MONTH LI MI TED W ARRANTY on al l com pone nts of t he Pol a ri s Al l T e rr ai n V ehi cl e (A TV) aga ins t def ec ts i n ma te ri al or wor kma nshi p. Pol a r is al so gi ves a one yea r l imi te d war ra nty on t he f ina l dr ive c[...]

11 4 WARRANTY W ARRANT Y COVERAGE AND EXCL USIONS: LIMI T A TIO NS OF W ARRANTI ES AND REME DIE S ALL IM P LI ED W ARRANTIES (I NCLUDING BUT NOT LIM ITED T O THE IM P LI 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 [...]

11 5 WARRANTY Exported V ehicles EXCEPT WHERE SPECI FICALL Y REQUIRED BY LA W , THERE IS NO W AR- RANTY OR SER VICE BULLETIN COVERAGE ON THIS VEHICLE I F IT I S SOLD OUTSIDE THE COUNTR Y OF THE SELLING DEALER’ S AUTHORIZED LOCA- TION. Th is po licy d o es no t app ly to v eh icles th at h ave received au th o rizatio n for e xpor t fr om Pol a ri[...]

11 6 INDEX A Accesso ries 6 4 ................... Adj ust ment s 76-88 ................ Ag e R estrictio ns 7 ................ Air F ilter 8 9 ..................... Au x iliary B rake 4 1, 7 7 ............ B Ba tt er y 98-100 ................... Ba tt er y Char ging 99-100 ............ Battery In stallatio n 9 8 ............. Ba tt er y Remova l 98[...]

11 7 INDEX P Park in g B rake 4 0 ................. P a r k i n go na nI n c l i n e 6 2 ........... Pe ri odic M ai nte nanc e Sche dule 64- 68 . POLARIS PRODUCTS 108 ....... P re-Rid e In sp ectio n 4 7 ............. Pr e mi um 4 Synt he ti c Oil 71 ......... PVT Dryi ng 97 .................. PVT Sys te m 96- 97 ................ R Re a r Dr ive C[...]