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Polaris trailboss 04 User's Manual

1. 98 Battery Storage 0 99 Brake Lever 00 40 Brakelight Lamp Replacement 91 Brakes 00005 39 76 77 Break In Period 46 Cc Camber and Caster 80 Carburetor 0 00 81 Choker elena CAE eigen dale 42 Cleaning and Storage 101 104 Cleaning the ATV 101 CONTROLS 36 45 Crankcase Emission Control 63 D Drive Chain 000 88 Drive Chain Slack 86 87 Driving Downhill 57 Driving in Reverse 61 Driving on Slippery Surfaces 54 Driving Over Obstacles 60 Driving Procedures 52 Driving Safely 52 62 Driving Through Water 59 Driving Uphill 55 E Electrical Switches 36 EMISSION CONTROLS 63 Engine Fogging 103 Engine Oil Check 75 Equipment Modifications 11 Exhaust Emission Control System 63 116 F FEATURES 36 45 F el Filter cscs es eee eae es 42 Fuel Safety 0 000 43 Fuel Stabilizer 102 Fuel Tank pisec de sub bt gue ee a 42 Fuel Valve 04 42 G Gear Selector 44 H Handlebars 80 Hauling Cargo 50 51 Headlight Lamp Replacement 90 High Beam Adjustment 90 l Indicator Lamp Replacement
2. 91 Indicator Lights 38 K K T m eetere Bode Grek Gian 58 L Light Switches 0 38 TAH x24 2s nA ea iain 90 91 Lubrication Recommendations 70 75 M Main Switch 36 MAINTENANCE 64 104 Maintenance Record 69 Making Turns 53 N Noise Emission Control System 63 O Oil Change 0 8 71 72 Oil Filter Change 71 72 OPERATION 46 62 Operator Safety 7 31 Override Switch 36 P Parking Brake 2 40 Parking on an Incline 62 Periodic Maintenance Schedule 64 68 POLARIS PRODUCTS 108 Pre Ride Inspection 47 Premium 4 Synthetic Oil 71 PVT Drying 0 0 97 PVT System 00 96 97 R Rear Drive Chain Slack 86 87 Rear Spring 000 80 Recoil Housing 95 Recoil Starter 0 000 45 S Safe Riding Gear 35 SAFETY cceeeeveee 7 35 Safety Decals and Locations 32 34 Safety Training 7 Side Panel Removal 79 Sidehilling 00 56 Spark Arrestor 63 94 Spark Plug Removal Replacement 92 Spark Plugs 0 008 92 SPECIFICATIONS 105 107 Starting a Cold Engine 48 Starting a Warm Engine 49 Starting the Engine 48 49 Steeri
3. Driving in Reverse OPERATION Follow these precautions when operating in reverse 1 2 Always avoid backing downhill Back slowly When in reverse apply the brakes lightly for stopping Avoid turning at sharp angles in reverse Never open the throttle suddenly while backing AWARNING Failure to use caution when operating in reverse can result in serious injury or death Before shifting into reverse always check for obstacles or people behind the vehicle When it s safe to proceed back slowly Do not use the override switch unless additional power is required for vehicle movement Use with caution Avoid backing on inclines and avoid turning at sharp angles NOTE This Polaris ATV is equipped with a reverse speed limiter The override button should be used with caution as rearward vehicle speed is greatly increased Do not operate at wide open throttle Open the throttle just enough to maintain a desired speed CAUTION Excessive throttle operation while in the speed limit mode may cause fuel to build in the exhaust resulting in engine popping and or engine damage 61 OPERATION Driving Safely Parking on an Incline Avoid parking on an incline if possible If it s unavoidable follow these precautions 1 1 2 3 62 Turn the engine off Place the transmission in gear Set the parking brake Always block the rear wheels on the downhill side See illustration Shu
4. tion this warranty does not cover physical damage to paint or finish stress cracks tearing or puncturing of upholstery material corrosion or defects in parts components or the ATV due to fire explosions or any other cause beyond Polaris control This warranty does not cover the use of unauthorized lubricants chemicals or fuels that are not compatible with the ATV The exclusive remedy for breach of this warranty shall be at Polaris exclusive option repair or replacement of any defective materials or components or products THE REMEDIES SET FORTH IN THIS WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CON TRACT NEGLIGENCE OR OTHER TORT OR OTHERWISE Some states do not per mit the exclusion or limitation of incidental or consequential damages or implied warranties so the above limitations or exclusions may not apply to you if inconsistent with controlling state law 113 WARRANTY WARRANTY COVERAGE AND EXCLUSIONS LIMITATIONS OF WARRANTIES AND REMEDIES ALL IMPLIED WARRANTIES INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE LIMITED IN DURATION TO THE ABOVE SIX MONTH WARRAN TY PERIOD POLARIS FURTHER DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN T
5. Excessive throttle may cause tion loss of control and vehicle overturn Belt slippage from water Dry out the PVT as outlined on page 97 Inspect clutch or snow ingestion into the seals for damage if repeated leaking occurs PVT system Clutch malfunction Contact your Polaris dealer for inspection of clutch com ponents Poor engine performance Check for fouled plugs or foreign material in gas tank fuel lines or carburetor Contact your dealer for service 109 TROUBLESHOOTING Contact your Polaris dealer for service if you re unable to identify solutions using the following charts Engine Doesn t Turn Over Possible Cause Solution Low battery voltage Recharge battery to 12 8 VDC or higher Loose battery connections Check all connections and tighten Loose solenoid connections Check all connections and tighten Engine Turns Over Fails to Start Possible Cause Solution Turn fuel valve to reserve refuel Mechanical failure Engine Pings or Knocks Possible Cause Solution Poor quality or low octane fuel Replace with recommended fuel Incorrect ignition timing See your Polaris dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs 110 TROUBLESHOOTING Engine Backfires Possible Cause Solution Weak spark from spark plugs Inspect clean and or replace spark plugs Incorrect spark plug gap or heat range Set gap to specs or replace plugs Mechanical failure Engine
6. capacity 73 MAINTENANCE AND LUBRICATION Lubrication Recommendations Transmission Oil Change 1 74 Place a drain pan beneath the transmission oil drain plug area Loosen the jam nut A Turn the adjuster bolt B in to allow the removal of the drain plug C Remove the drain plug and wipe the magnetic end clean to remove accumulated metallic filings After the oil has drained completely install a new sealing washer and reinstall the drain plug Torque to 14 ft Ibs 19 Nm Turn the adjuster bolt B out until it touches the frame and then turn an additional 1 2 turn Tighten the jam nut securely while holding the adjuster bolt Add the recommended lubricant through the dipstick hole until the oil level is between the upper and lower limits Do not overfill Check for leaks MAINTENANCE AND LUBRICATION Lubrication Recommendations Engine Oil Check The oil fill is located on the left side of the vehicle 1 Position the machine on a level surface Start the engine and let it idle for 20 30 seconds Stop the engine Remove the dipstick and wipe it dry with a clean cloth Screw the dipstick completely in Remove the dipstick and read the oil level Maintain the oil level in the safe operating range 2 Do not overfill DLR Re 75 MAINTENANCE AND LUBRICATION Adjustments Brakes The front and rear brakes are hydraulic disc brakes activated by moving the single brake lever toward the hand
7. intervals SAFETY Operator Safety The following signal words and symbols appear throughout this manual and on your ATV Your safety is involved when these words and symbols are used Become familiar with their meanings before reading the manual The safety alert symbol on your ATV or in this manual alerts you to the potential for personal injury AWARNING The safety alert warning indicates a potential hazard that may result in serious injury or death 4 CAUTION The safety alert caution indicates a potential hazard that may result in minor personal injury or damage to the machine CAUTION A caution indicates a situation that may result in damage to the machine NOTE A note will alert you to important information or instructions SAFETY Operator Safety AWARNING Serious injury or death can result if you do not follow these instructions and procedures which are outlined in further detail within your owner s manual Read this manual and all labels carefully and follow the operating procedures described Never operate an ATV without proper instruction Take a training course Beginners should receive training from a certified instructor Contact an authorized Polaris ATV dealer or call Polaris at 1 800 342 3764 to find out about the training courses nearest you Never allow anyone under 16 years of age to operate this ATV Never permit a guest to operate the ATV unless the guest has read this manual and al
8. slippery or loose terrain WHAT CAN HAPPEN Operating on excessively rough slippery or loose terrain could cause loss of traction or loss of control which could result in an accident or overturn HOW TO AVOID THE HAZARD Do not operate on excessively rough slippery or loose terrain until you ve learned and practiced the skills necessary to control the ATV on such terrain Always use extra caution on rough slippery or loose terrain 21 SAFETY Operator Safety 4 WARNING POTENTIAL HAZARD Turning improperly WHAT CAN HAPPEN Improper turns could cause loss of control and lead to a collision or overturn HOW TO AVOID THE HAZARD Always follow proper procedures for turning as described in the owner s manual Practice turning at slow speeds before attempting to turn at faster speeds Never turn at excessive speed 4 WARNING POTENTIAL HAZARD Operating on excessively steep hills WHAT CAN HAPPEN The vehicle may overturn HOW TO AVOID THE HAZARD Never operate on hills too steep for the ATV or for your abilities Never operate the ATV on hills steeper than 25 Practice on smaller hills before attempting large hills 22 SAFETY Operator Safety 4 WARNING POTENTIAL HAZARD Climbing hills improperly WHAT CAN HAPPEN Improper hill climbing could cause loss of control or overturn HOW TO AVOID THE HAZARD Always follow proper procedures for climbing hills as described in the owner s man
9. 2872348 2871323 60 40 Coolant gal 2871534 60 40 Coolant qt 108 TROUBLESHOOTING Drive Belt and Cover Problems Driving the ATV onto a Avoid stopping on the ramp or creeping slowly up the pickup or tall trailer in ramp These practices may slip the clutch and belt high range Starting out going up a When starting out on an incline dismount the ATV after steep incline first applying the park brake and perform the K turn as described on page 58 Driving at low RPM or Drive at a slightly higher speed Avoid creeping low ground speed at about 3 7 MPH Insufficient warm up of Warm the engine at least 5 minutes With the transmission ATVs exposed to low am in neutral advance the throttle to about 1 8 throttle in bient temperatures short bursts 5 to 7 times The belt will become more flex ible and prevent belt burning Slow and easy clutch en Use the throttle quickly and effectively for efficient enga gagement gement Towing pushing at low Install a one tooth smaller counter shaft sprocket RPM low ground speed Utility use plowing snow Install a one tooth smaller counter shaft sprocket dirt etc Stuck in mud or snow Carefully use fast aggressive throttle application to engage clutch WARNING Excessive throttle may cause loss of control and vehicle overturn Climbing over large ob Carefully use fast brief aggressive throttle application to jects from a stopped posi engage clutch WARNING
10. PTVs e All Surface Loaders ASLs We believe Polaris sets a standard of excellence for all utility and recreational vehicles manufactured in the world today Many years of experience have gone into the engineering design and development of your Polaris vehicle making it the finest machine we ve ever produced For safe and enjoyable operation of your vehicle be sure to follow the instructions and recommendations in this owner s manual Your manual contains instructions for minor maintenance but information about major repairs is outlined in the Polaris Service Manual and should be performed only by a Factory Certified Master Service Dealer MSD Technician Your Polaris dealer knows your vehicle best and is interested in your total satisfaction Be sure to return to your dealership for all of your service needs during and after the warranty period We also take great pride in our Parts Apparel and Accessories PAA products available through our online store at www purepolaris com Have your accessories and clothing delivered right to your door Polaris Polaris The Way Out and Workmobiles are registered trademarks of Polaris Industries Inc LOCTITE is a registered trademark of LOCTITE Corporation TABLE OF CONTENTS WELCOME icc bing trane oni cued hued aed o 3 VEHICLE IDENTIFICATION NUMBERS 6 SAFETY oar EE paladin needed aa eat ian anata 7 FEATURES AND CONTROLS 36 OPERATION ri hienn iaaa baba
11. TO AVOID THE HAZARD Always wear an approved helmet that fits properly Always wear eye protection goggles or face shield gloves boots long sleeved shirt or jacket and long pants SAFETY Operator Safety 4 WARNING POTENTIAL HAZARD Operating the ATV after consuming alcohol or drugs WHAT CAN HAPPEN Consumption of alcohol and or drugs could seriously affect operator judgment Reaction time may be slower and operator balance and perception could be affected Consuming alcohol and or drugs before or while operating an ATV could result in an accident causing severe injury or death HOW TO AVOID THE HAZARD Never consume alcohol or drugs before or while operating an ATV 4 WARNING POTENTIAL HAZARD Operating the ATV at excessive speeds WHAT CAN HAPPEN Excessive speed increases the operator s chance of losing control of the ATV which can result in an accident HOW TO AVOID THE HAZARD Always operate the ATV at a speed that s proper for the terrain visibility and operating conditions and your experience 17 SAFETY Operator Safety 18 4 WARNING POTENTIAL HAZARD Attempting wheelies jumps and other stunts WHAT CAN HAPPEN Attempting stunts increases the chance of an accident including an overturn HOW TO AVOID THE HAZARD Never attempt wheelies jumps or other stunts Avoid exhibition driving SAFETY Operator Safety 4 WARNING POTENTIAL HAZARD Failure to inspect the ATV before
12. engine and shift the transmission into neutral Apply varying throttle for 10 15 seconds to expel the moisture and air dry the belt and clutches Do not hold the throttle wide open for more than 10 seconds Allow the engine RPM to settle to idle speed then shift the transmission to the lowest available range 4 Test for belt slippage If the belt slips repeat the process 5 Take the vehicle to your dealer for service as soon as possible 97 MAINTENANCE AND LUBRICATION Battery AWARNING Improperly connecting or disconnecting battery cables can result in an explosion and cause serious injury or death When removing the battery always disconnect the negative black cable first When reinstalling the battery always connect the negative black cable last Battery Removal 1 2 3 4 Disconnect the battery hold down strap and remove the battery cover Disconnect the black negative battery cable first Disconnect the red positive battery cable next Lift the battery out of the ATV Battery Installation When installing a new battery make sure it s fully charged prior to its initial use Using a new battery that has not been fully charged can damage the battery and result in a shorter life It can also hinder vehicle performance Follow the battery charging instructions on page 99 before installing the battery 1 EA a BS 98 Ensure that the battery is fully charged Set the battery in the battery
13. engine in an enclosed area Exhaust contains poisonous carbon monoxide gas Never go under the vehicle while it s inclined Remove the arrestor clean out plug 1 from the bottom of the muffler Place the transmission in neutral and start the engine Purge carbon from the system by momentarily revving the engine several times If carbon is expelled cover or plug the exhaust outlet 2 and rap on the pipe around the cleanout plug while revving the engine several more times If particles are still suspected to be in the muffler elevate the rear of the vehicle one foot higher than the front Set the parking brake and block the wheels Make sure the vehicle is in neutral and repeat steps 3 and 4 until no more particles are expelled when the engine is revved Stop the engine and allow the arrestor to cool Reinstall the arrestor plug and remove the outlet cover or plug MAINTENANCE AND LUBRICATION Recoil Housing To prevent possible engine damage always drain the recoil housing 1 after operating the ATV in very wet conditions This should also be done before storing the ATV Water will enter the recoil housing if the starter handle is disengaged from the rope guide when under water The drain screw is located at the bottom of the recoil housing Use a wrench to remove the screw Be sure to reinstall the screw after draining the housing NOTE Do not open the crankcase drain unless the engine has ingested wate
14. holder Connect and tighten the red positive cable first Connect and tighten the black negative cable last Reinstall the battery cover and attach the hold down strap Verify that cables are properly routed MAINTENANCE AND LUBRICATION Battery Battery Storage Whenever the vehicle is not used for a period of three months or more remove the battery from the vehicle ensure that it s fully charged and store it out of the sun in a cool dry place Check battery voltage each month during storage and recharge as needed to maintain a full charge NOTE Battery charge can be maintained by using a Polaris Battery Tender charger PN 2871076 or by charging about once a month to make up for normal self discharge Battery Tender can be left connected during the storage period and will automatically charge the battery if the voltage drops below a pre determined point Battery Charging The following battery charging instructions apply only to the installation of a YUASA activated sealed battery Read all instructions before proceeding with the installation of this battery The YUASA activated sealed battery is already filled with electrolyte and has been sealed and fully charged at the factory Never pry the sealing strip off or add any other fluid to this battery The single most important thing about maintaining a sealed battery is to keep it fully charged Since the battery is sealed and the sealing strip cannot be removed you
15. injury or death Always follow these precautions when hauling cargo REDUCE SPEED AND ALLOW GREATER DISTANCE FOR BRAKING WHEN HAULING CARGO CARGO WEIGHT DISTRIBUTION should be 1 3 on the front rack and 2 3 on the rear rack When operating over rough or hilly terrain reduce speed and cargo to maintain stable driving condi tions Carrying loads on one rack only increases the possibility of vehicle overturn LOADS MUST BE CARRIED AS LOW ON THE RACKS AS POSSIBLE Carrying loads high on the racks raises the center of gravity of the vehicle and creates a less stable operating condi tion When cargo loads are carried high on the racks the weight of the loads must be reduced to maintain stable operating condi tions ALL LOADS MUST BE SECURED BEFORE OPERATING Un secured loads can create unstable operating conditions which could result in loss of control of the vehicle OPERATE ONLY WITH STABLE AND SAFELY ARRANGED LOADS When handling off centered loads that cannot be cen tered securely fasten load and operate with extra caution Al ways attach the tow load to the hitch point designated for your vehicle HEAVY LOADS CAN CAUSE BRAKING AND CONTROL PROB LEMS Use extreme caution when applying brakes with a loaded vehicle Avoid terrain or situations that may require backing downhill EXTREME CAUTION MUST BE USED when operating with loads extending over the rack sides Stability and maneuverabili ty may be adversely affected causing
16. must use a voltmeter or multimeter to measure DC voltage For a refresh charge follow all instructions carefully 1 Check the battery voltage with a voltmeter or multimeter A fully charged battery will register 12 8 V or higher 2 Ifthe voltage is less than 12 8 volts recharge the battery at 1 2 amps or less until the battery voltage is 12 8 or greater NOTE When using an automatic charger refer to the charger manufacturer s instructions for recharging When using a constant current charger use the following guidelines for recharging AWARNING An overheated battery may explode causing severe injury or death Always watch charging times carefully Stop charging if the battery becomes very warm to the touch Allow it to cool before resuming charging 99 MAINTENANCE AND LUBRICATION Battery Battery Charging NOTE Always verify battery condition before and 1 2 hours after the end of charging Voltage Charge Time Using constant current charger standard amps specified on top of battery 100 12 8 13 0 volts None check at None required 3 mos from date of manufacture 50 75 12 0 12 5 volts Needs charge 5 11 hours 25 50 11 5 12 0 volts Needs charge At least 13 hours verify state of charge 0 25 11 5 volts or less Needs charge with At least 20 hours desulfating charger 75 100 12 5 12 8 volts May need slight 3 6 hours charge if no charge given check in 3 months 100 MAINTENANCE AND LUBRICATION C
17. next page If you cannot locate this card or if it has been removed please call 1 800 342 3764 for assistance We ve created a Web site just for you Technical tips New product introductions Event schedules Parts and Service Manual information Exciting details about The Way Out Check it out www polarisindustries com owner POLARIS The Way Out Copyright 2003 Polaris Sales Inc All information contained within this publication is based on the latest product information at the time of publication Due to constant improvements in the design and quality of production components some minor discrepancies may result between the actual vehicle and the information presented in this publication Depictions and or procedures in this publication are intended for reference use only No liability can be accepted for omissions or inaccuracies Any reprinting or reuse of the depictions and or procedures contained within whether whole or in part is expressly prohibited Printed in U S A 2 WELCOME Thank you for purchasing a Polaris vehicle and welcome to our world wide family of Polaris owners We proudly produce an exciting line of utility and recreational products Polaris Recreational and Utility Vehicles e Snowmobiles e All terrain vehicles ATVs e Watercraft e Victory motorcycles e RANGER utility vehicles Polaris Professional Series Workmobiles e Utility Task Vehicles UTVs e Personal Task Vehicles
18. of the disc NOTE Pads should be changed when worn to 3 64 1 cm or about the thickness of a U S dime 3 64 1 cm Auxiliary Brake The auxiliary brake system is intended to be used as a backup for the main brake system Should the main system fail the rear brake can be activated by depressing the foot pedal on the inside of the right footrest The hydraulic auxiliary brake system requires no adjustment NOTE Since this is a rear brake only it will not be as effective as the all wheel single lever system 77 MAINTENANCE AND LUBRICATION Adjustments AWARNING Severe injury or death can result from improper toe alignment and adjustment Do not attempt to adjust tie rod alignment All tie rod adjustments should be performed by an authorized Polaris dealer Toe Alignment Use the following procedure to check the toe alignment of the vehicle The recommended toe alignment is 1 8 to 1 4 toe out 1 Set the handlebars in a straight ahead position es NOTE The steering frog ee al can be used as an indicator We 7 of whether the handlebars are See straight The frog should sy always point straight back from the steering post 2 Place stands 1 in front of the vehicle perpendicular to the rear tires See illustration 3 Tie an elastic string around the stands making sure the string just touches the side surface of the rear tires on ea
19. or exceeds your state s safety standards and bears either the Department of Transportation DOT label the American National Standards Institute label ANSI 290 1 or the Snell Memorial Foundation label 2 Eye Protection Do not depend on sunglasses for proper eye protection A pair of goggles or a helmet face shield offer the best protection for your eyes They should be kept clean and be of shatterproof design bearing the markings z2 1 or VESC 8 3 Gloves Off road style gloves with knuckle pads are the best for comfort and protection 4 Boots The best footwear is a pair of strong over the calf boots with heels like moto cross boots 5 Clothing Always wear long sleeves and long pants to protect arms and legs Riding pants with kneepads and a jersey with shoulder pads provide the best protection 35 FEATURES AND CONTROLS Electrical Switches AWARNING Activating the override switch while the throttle is open can cause loss of control resulting in severe injury or death Do not activate the override switch while the throttle is open Override Switch 1 Reverse Speed Limiter This vehicle is equipped with a reverse speed limiter system To gain additional power while Valen backing depress the override switch Main Switch 2 To start the engine slide the stop switch to the center RUN position and turn the main key switch clockwise past the ON position Release the key when the en
20. position e Never depend on the parking brake alone if the ATV is parked on a hill Always block the wheels to prevent rolling 40 FEATURES AND CONTROLS Auxiliary Brake AWARNING Aggressively applying the rear brake when backing downhill may cause rear tipover which could result in serious injury or death Use caution when applying the auxiliary brake Do not aggressively apply the auxiliary brake when going forward The rear wheels may skid and slide sideways causing loss of control and serious injury or death The auxiliary brake 1 is located on the inside of the right floor board and is operated by the right foot The auxiliary brake serves as a backup to the main brake system if the main system becomes inoperative If the rear wheels slide while using the auxiliary brake reduce brake pedal pressure to brake the rear wheels without skidding Check the brake fluid level frequently for the auxiliary brake system The reservoir is located under the seat or near the foot brake Maintain the fluid level between the maximum and minimum marks 41 FEATURES AND CONTROLS Choke The choke assists in starting a cold engine Refer to the engine starting procedure on page 48 for correct choke and throttle settings during starting Fuel Valve The fuel valve 1 is located on the left side of RES the vehicle either below the fender or on the side panel It has three positions em n OFF For vehicle storage and when
21. procedures for a proper break in Careful treatment of a new engine will result in more efficient performance and longer life for the engine Perform the following procedures carefully CAUTION Excessive heat build up during the first three hours of operation will damage close fitted engine parts Do not operate at full throttle or high speeds for extended periods during the first three hours of use Use of any oils other than those recommended by Polaris may cause serious engine damage We recommend the use of Polaris Premium 4 Synthetic Oil for your 4 cycle engine 1 Fill the fuel tank with gasoline See page 42 2 Check the oil level on the dipstick See page 75 Add Polaris Premium 4 Synthetic Oil if necessary to maintain the oil level in the safe operating range 1 3 Drive slowly at first Select an open area that allows room to familiarize yourself with vehicle operation and handling 4 Vary throttle positions Do not operate at sustained idle 5 Perform regular checks on fluid levels controls and areas outlined on the daily pre ride inspection checklist See page 47 6 Pull only light loads 7 During the break in period change both the oil and the filter at 20 hours or 200 miles 46 OPERATION Pre Ride Inspection AWARNING If a proper inspection is not done before each use severe injury or death could result Always inspect the vehicle before each use to ensure it s in proper operating condit
22. should be avoided if at all possible If you do enter into a situation where sidehilling is necessary follow these precautions 1 Slow down 2 Lean into the hill transferring your upper body weight toward the hill while keeping your feet on the footrests 3 Steer slightly into the hill to maintain vehicle directions NOTE If the vehicle begins to tip quickly turn the front wheel downhill if possible or dismount on the uphill side immediately 56 OPERATION Driving Safely Driving Downhill Whenever descending a hill follow these precautions 1 Proceed directly downhill 2 Transfer your weight to the rear of the vehicle 3 Slow down 4 Apply the brakes slightly to aid in slowing using the single brake lever NOTE Familiarize yourself with operation of the auxiliary rear brake pedal for additional braking in the event of normal service brake loss AWARNING Excessive speed can cause loss of control and lead to serious injury or death Always operate slowly when traveling downhill 57 OPERATION Driving Safely Turning Around on a Hill AWARNING Improper hill climbing procedures could cause loss of control or overturn and result in serious injury or death Avoid climbing steep hills 25 maximum Use extreme caution when operating on hills and follow proper operating procedures outlined in the owner s manual If the vehicle stalls while climbing a hill never back it down the hill One mane
23. transporting ON For normal operation ON RES For reserve supply if main supply is exhausted NOTE There s about a 7 to 10 mile 11 2 to 16 km range on reserve gas Always refill the gas tank as soon as possible after using the reserve supply Always return valve to ON position after refueling Fuel Tank The fuel tank filler cap 2 is located directly below the handlebar Use either leaded or unleaded gasoline with a minimum pump octane number of 87 R M 2 octane Refer to the specifications beginning on page 105 for capacities Fuel Filter The in line fuel filter should be replaced by your dealer after every 100 hours of operation or annually Do not attempt to clean the fuel filter 42 FEATURES AND CONTROLS Fuel Safety AWARNING Gasoline is highly flammable and explosive under certain conditions Always exercise extreme caution whenever handling gaso line Always refuel with the engine stopped and outdoors or ina well ventilated area Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored Do not overfill the tank Do not fill the tank neck If gasoline spills on your skin or clothing immediately wash it off with soap and water and change clothing Never start the engine or let it run in an enclosed area Engine exhaust fumes are poisonous and can cause loss of consciousness or death in a short time Turn the fu
24. 004 Trail Boss Shit Type Gear Reduction Reverse Gear Reduction Forward Final Drive ato Drive Chain Front Suspension Mac Strut Rear Suspension Progressive Rate 9 in 22 9 cm travel Swing Arm Shook Adjustment Front Brake Fixed disc hydraulic floating caliper Rear Brake Hydraulic opposed piston caliper rear axle fixed disc Auxiliary Brake Hydraulic opposed piston caliper rear axle fixed disc Park Brake Headlight Tait Brake Ligh Battery DC Plugin Read DC Socket Forward Plecire Sta High Beam Inicio High Temp Indicator Windshield Low Of Ligh Neutral Indicator Speedometer Fuel Gauge Too Kit 106 SPECIFICATIONS 2004 Trail Boss Jetting Chart Altitude AMBIENT Below 40 F 40 F and above TEMPERATURE Below 5 C 5 C and above Meters 0 1800 127 5 Feet 0 6000 1800 3700 6000 12000 Clutching Chart Altitude Shift Drive Clutch Driven Clutch Helix Spring Weight Spring Spring Setting Meters 0 1800 10RH Blue Green Black 40 Feet 0 6000 5630709 7041157 7041782 5131446 2 2 1800 3700 20 40 Blue Green Black 40 6000 12000 5631356 7041157 7041782 5131446 2 2 107 POLARIS PRODUCTS Part No Description 287079 2571098 2871281 2871844 2871567 Premium 4 Synthetic OW 40 4 Cycle Engine Oil 16 gal Gearcase Transmission Lubricants aara 2871478 2871653 2572278 2570465 2571654 2872277 2871322 2871423 2871460 2871515 2871551 2871312 2871320 2872073
25. 02 MAINTENANCE AND LUBRICATION Cleaning and Storage Storage Tips See page 108 for the part numbers of Polaris products Fluid Levels Inspect the following fluid levels and change if necessary engine oil transmission oil brake fluid change every two years or as needed if fluid looks dark or contaminated Engine 1 Remove the spark plug and pour 2 3 tablespoons of Premium 4 Synthetic OW40 engine oil into the hole Use a section of clear 1 4 hose and a small plastic squeeze bottle filled with the pre measured amount of oil NOTE Do this carefully If you miss the plug hole oil will drain from the spark plug cavity into the hole at the front of the cylinder head and appear to be an oil leak 2 Reinstall the spark plug 3 With the ignition off turn the engine over several times using the recoil starter This will ensure coverage of the piston rings cylinder walls and crankshaft bearings 4 Apply dielectric grease to the inside of the spark plug cap and install the cap onto the plug 5 Treat the fuel system with Polaris Carbon Clean 6 If Polaris fuel system additive is not used drain all fuel from the fuel tank fuel lines and carburetor Eliminate any fuel remaining in the carburetor by running the engine until it stops Lubricate Inspect all cables and lubricate with Polaris Cable Lubricant Follow lubrication guidelines in the maintenance section of the service or owner s manual to completely grease an
26. 70952 4 WARNING Improper ATV use can result in SEVERE INJURY or DEATH DOO ALWAYS USE NEVER USE NEVER CARRY NEVER USE AN APPROVED ON PUBLIC PASSENGERS WITH DRUGS HELMET AND ROADS OR ALCOHOL PROTECTIVE GEAR NEVER operate without proper training or instruction at speeds too fast for your skills or the conditions on public roads a collision can occur with another vehicle with a passenger passengers affect balance and steering and increase risk of losing control ALWAYS use proper riding techniques to avoid vehicle overturns on hills and rough terrain and in turns avoid paved surfaces pavement may seriously affect handling and control LOCATE AND READ OWNER S MANUAL FOLLOW ALL INSTRUCTIONS AND WARNINGS IF OWNER S MANUAL IS MISSING CONTACT A POLARIS DEALER FOR A REPLACEMENT 1997 2000 7079083 33 SAFETY Safety Decals and Locations 4 WARNING Operating this ATV if you are under the age of 16 increases your chance of severe injury or death NEVER operate this ATV if you are under age 16 7078253 Under Seat ATTENTION Specific carburetor jetting and adjustments are required depending on temperature and altitude See your Owner s Manual Factory setting 40 to 80 F at 0 3000 feet 8 to 27 C at 0 900 meters 7470007 Operation of this vehicie without the air filter element will severely damage the engine Clean pre filter el
27. HIS WARRANTY Some states do not allow limitations on how long an im plied warranty lasts so the above limitation may not apply to you if inconsistent with con trolling state law HOW TO OBTAIN WARRANTY SERVICE If your ATV requires warranty service you must take it to a Polaris dealer authorized to re pair Polaris ATVs When requesting warranty service you must present your copy of the Warranty Registration form to the dealer THE COST OF TRANSPORTATION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY Polaris suggests that you use your original selling dealer however you may use any Polaris Servicing Dealer to perform war ranty service Please work with your dealer to resolve any warranty issues Should your dealer require any additional assistance they will contact the appropriate personnel at Polaris This warranty gives you specific legal rights and you may also have other rights which vary from state to state If any of the above terms are void because of state or federal law all other warranty terms will remain in effect Engine Oil 1 Mixing oil brands or using non recommended oil may cause engine damage We recom mend the use of Polaris engine oil 2 Damage resulting from the use of non recommended lubricants may not be covered by warranty 114 WARRANTY Exported Vehicles EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW THERE IS NO WAR RANTY OR SERVICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD OUTSIDE THE CO
28. Improperly operating in reverse WHAT CAN HAPPEN The ATV could collide with an obstacle or person resulting in severe injury HOW TO AVOID THE HAZARD Before shifting into reverse gear always check for obstacles or people behind the ATV When it s safe to proceed back slowly 28 SAFETY Operator Safety A WARNING POTENTIAL HAZARD Operating this ATV with improper tires or with improper or uneven tire pressure WHAT CAN HAPPEN Use of improper tires or operation of the ATV with improper or uneven tire pressure could cause loss of control or accident HOW TO AVOID THE HAZARD Always use the size and type of tires specified for the ATV Always maintain proper tire pressure as specified 4 WARNING POTENTIAL HAZARD Operating the ATV with improper modifications WHAT CAN HAPPEN Improper installation of accessories or modification of the ATV may cause changes in handling which could lead to an accident HOW TO AVOID THE HAZARD Never modify the ATV through improper installation or use of accessories All parts and accessories added to the vehicle must be genuine Polaris Industries Inc or equivalent components designed for use on this ATV and should be installed and used according to approved instructions See your authorized Polaris ATV dealer for more information 29 SAFETY Operator Safety 30 4 WARNING POTENTIAL HAZARD Overloading the ATV or carrying towing cargo improperly WHAT CAN HAPPE
29. N Overloading and towing can cause changes in vehicle handling which could lead to loss of control or an accident HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this ATV Cargo should be properly distributed and securely attached Reduce speed when carrying cargo or pulling a trailer Allow a greater distance for braking Always follow the instructions in the owner s manual for carrying cargo or pulling a trailer See page 50 4 WARNING POTENTIAL HAZARD Operating on frozen bodies of water WHAT CAN HAPPEN Severe injury or death can result if the ATV and or the operator fall through the ice HOW TO AVOID THE HAZARD Never operate the ATV on a frozen body of water If you re confident that the ice is thick enough and sound enough to support the machine and its operator as well as the force created by a moving vehicle exercise extreme caution SAFETY Operator Safety AWARNING Leaving the keys in the ignition can lead to unauthorized use of the vehicle resulting in serious injury or death Always remove the ignition key when the vehicle is not in use AWARNING After any overturn or accident have a qualified service dealer inspect the entire vehicle for possible damage including but not limited to brakes throttle and steering systems AWARNING Safe operation of this rider active vehicle requires good judgement and physical skills Persons with cognitive or physical disabilities who
30. PAA SBT oe EITA PR actos ya sJ P KERN nce oy Ses SA Read this manual carefully It contains important safety information This is an adult vehicle only Operation is prohibited for those under 16 years of age A ue E POLARIS The Way Out r paa A YA Sa A y Po C r 5 ERIE 4 7 A FS f g P P amp oe F i AWARNING Improper vehicle use can result in SEVERE INJURY or DEATH DH ALWAYS USE NEVER USE NEVER CARRY NEVER USE AN APPROVED ON PUBLIC PASSENGERS WITH DRUGS HELMET AND ROADS OR ALCOHOL PROTECTIVE GEAR NEVER Operate without proper training or instruction e Operate on public roads A collision can occur with another vehicle e Operate at speeds too fast for your skills or the conditions e Use ALCOHOL or DRUGS before or while operating this vehicle e Carry Passengers ALWAYS e Avoid paved surfaces which may adversely affect handling and control e Use proper RIDING TECHNIQUES to avoid vehicle overturns on hills and rough terrain and in turns e Wear eye protection helmet and protective apparel READ OWNER S MANUAL FOLLOW ALL INSTRUCTIONS AND WARNINGS Part No 9918757 Rev 03 3 POSLaRisS PRINTED IN THE USA The Way Out AWARNING The engine exhaust from this product contains chemicals known to cause cancer birth defects or other reproductive harm A card containing important ATV safety information should be attached to the owner s manual on the
31. PVT components belt cover etc NOTE Avoid heavy pulling and extended low speed operation 96 MAINTENANCE AND LUBRICATION PVT System AWARNING Failure to comply with the instructions in this warning can result in severe injury or death Do not modify any component of the PVT system Doing so may reduce its strength so that a failure may occur at a high speed The PVT system has been precision balanced Any modification will cause the system to be out of balance creating vibration and additional loads on components The PVT system rotates at high speeds creating large amounts of force on clutch components Extensive engineering and testing has been conducted to ensure the safety of this product However as the owner you have the following responsibilities to make sure this system remains safe Always follow all recommended maintenance procedures See your dealer as outlined in the owner s manual This PVT system is intended for use on Polaris products only Do not install it in any other product Always make sure the PVT housing is securely in place during operation PVT Drying There may be some instances when water is accidently ingested into the PVT system Use the following instructions to dry it out before operating 1 3 Move the ATV to dry land or to water that is at least three inches below the footwell Remove the PVT drain plug and allow the water to drain Reinstall the drain plug Start the
32. Runs Irregularly Stalls or Misfires Possible Weak Spark Cause Solution Other mechanical failure Possible Lean Fuel Mixture Cause Solution Possible Rich Fuel Mixture Cause Solution Kinked or plugged fuel vent line Inspect and replace 111 TROUBLESHOOTING Engine Stops or Loses Power Possible Cause Solution Kinked or plugged fuel system vent lines Water present in fuel Overuse of choke Fouled or defective spark plugs Worn or defective spark plug wires Incorrect spark plug gap or heat range Loose ignition connections Low battery voltage Clogged or wet air filter Reverse speed limiter malfunction Electronic throttle control malfunction Other mechanical failure Overheated engine Clean radiator screen and core if equipped Clean engine exterior See your Polaris dealer 112 WARRANTY LIMITED WARRANTY Polaris Sales Inc 2100 Highway 55 Medina MN 55340 gives a SIX MONTH LIMITED WARRANTY on all components of the Polaris All Terrain Vehicle ATV against defects in material or workmanship Polaris also gives a one year limited warranty on the final drive chain for failure due to defects This warranty covers the parts and labor charges for repair or replacement of defective parts which are covered by this warranty This warranty begins on the date of purchase This warranty is transferrable to another consumer during the war ranty period through a Polaris dealer REGISTRATION At the time of sale the Warranty Re
33. T CAN HAPPEN The risk of an accident is greatly increased if the operator does not know how to operate the ATV properly in different situations and on different types of terrain HOW TO AVOID THE HAZARD Beginning and inexperienced operators should complete the certified training course offered by Polaris Operators should regularly practice the skills learned in the course and the operating techniques described in the owner s manual For more information about the training course contact an authorized ATV dealer or call Polaris at 1 800 342 3764 4 WARNING POTENTIAL HAZARD Failure to follow the age recommendations for this ATV WHAT CAN HAPPEN Severe injury and or death could occur if a child under the minimum age recommendation operates an ATV Even though a child may be within the recommended age group for operating some ATVs he she may not have the skills abilities or judgment needed to operate an ATV safely and could be susceptible to accident or injury HOW TO AVOID THE HAZARD No one under the age of 16 should operate a Polaris ATV SAFETY Operator Safety A WARNING POTENTIAL HAZARD Carrying a passenger on an ATV WHAT CAN HAPPEN Carrying a passenger greatly reduces the operator s ability to balance and control the ATV which could cause an accident and injury to the operator and or passenger HOW TO AVOID THE HAZARD Never carry a passenger The purpose of the long seat is to allow the operator to
34. UNTRY OF THE SELLING DEALER S AUTHORIZED LOCA TION This policy does not apply to vehicles that have received authorization for export from Polaris Industries Dealers may not give authorization for export You should consult an authorized dealer to determine this vehicle s warranty or service bulletin coverage if you have any questions This policy does not apply to vehicles registered to government officials or military per sonnel on assignment outside the country of the selling dealer s authorized location This policy does not apply to Safety Recalls How to Get Service In the Country where your vehicle was purchased Warranty or Service Bulletin repairs must be done by an authorized Polaris dealer If you move or are traveling within the country where your vehicle was purchased Warranty or Service Bulletin repairs may be requested from any authorized Polaris dealer who sells the same line as your vehicle Outside the Country where your vehicle was purchased If you are traveling temporarily outside the country where your vehicle was purchased you should take your vehicle to an authorized Polaris dealer You must show the dealer photo identification from the country of the selling dealer s authorized location as proof of residence Upon residence verification the servicing dealer will be authorized to per form the warranty repair If You Move If you move to another country be sure to contact Polaris Customer Assistance a
35. air fuel mixture becomes overly rich and the engine loses approximately 3 of its power for each 1000 foot 304 8 m increase in elevation Although this power cannot be regained adjustments to the carburetor and drive system can be made to allow more efficient operation Optional jets available from your Polaris dealer are required for operation above 6 000 feet and temperatures below 40 degrees F 4 degrees C NOTE Continuous operation of the engine without proper jetting when required can cause poor performance overheating or engine damage See your Polaris dealer for more information about jetting the ATV for conditions in your area If the engine idle speed is not satisfactory and all other conditions are favorable the carburetor can be adjusted 1 Warm up the engine by running the vehicle for approximately five minutes 2 Place the transmission in gear with the parking brake applied 3 Adjust the carburetor idle screw 1 either in or out until the desired idle RPM is reached Turning the screw in clockwise will raise RPM Turning the screw out counterclockwise will lower RPM 81 MAINTENANCE AND LUBRICATION Adjustments Throttle Cable Freeplay Throttle cable freeplay is adjusted at the handlebar 1 Slide the boots 1 off the inline cable adjuster sleeve 2 Loosen the adjuster locknut 3 2 Turn the adjuster until 1 16 to 1 8 freeplay is achieved at the thumb lever NOTE While adjusting free
36. akes are applied by squeezing the brake lever 1 toward the handlebar The front and rear brakes are hydraulically activated disc type brakes that are activated by only one lever Always test brake lever travel and master cylinder fluid level before riding When squeezed the lever should feel firm Any sponginess would indicate a possible fluid leak or low master cylinder fluid level which must be corrected before riding Contact your dealer for proper diagnosis and repairs AWARNING Operating the ATV with a spongy brake lever can result in loss of braking which could cause an accident Never operate the ATV with a spongy feeling brake lever Parking Brake AWARNING Operating the ATV while the parking brake is engaged could result in an accident and serious injury or death Always check to be sure the parking brake is disengaged before operating Setting the Parking Brake 1 Squeeze and release the brake lever two or three times then squeeze and hold 2 Push the park brake lock 2 forward to engage the brake Release the brake lever 3 To release the parking brake lock squeeze and release the brake lever It will return to its unlocked position Important Safeguards e The parking brake may relax if left on for a long period of time Al ways block the wheels to prevent rolling e Always block the wheels on the downhill side of the ATV if leaving it parked on a hill Another option is to park the ATV in a sidehill
37. allowing the turn to be made smoothly The same leaning technique should be used for turning in reverse NOTE Practice making turns at slow speeds before attempting to turn at faster speeds AWARNING Turning at sharp angles or at excessive speeds can result in vehicle overturn and lead to serious injury Avoid turning at sharp angles Never turn at high speeds 53 OPERATION Driving Safely Driving on Slippery Surfaces Whenever riding on slippery surfaces such as wet trails or loose gravel or during freezing weather follow these precautions 1 2 3 54 Slow down when entering slippery areas Maintain a high level of alertness reading the trail and avoiding quick sharp turns which can cause skids Correct a skid by turning the handlebars in the direction of the skid and shifting your body weight forward AWARNING Failure to exercise care when operating on slippery surfaces can result in loss of tire traction and cause loss of control accident and serious injury or death Never apply the brakes during a skid Do not operate on excessively slippery surfaces Always reduce speed and use additional caution OPERATION Driving Safely Driving Uphill Whenever traveling uphill follow these precautions 1 Always travel straight uphill 2 Avoid steep hills 25 maximum 3 Keep both feet on the footrests 4 Transfer your weight forward 5 Proceed at a steady rate of speed and throttle openi
38. aneuvers like turning or driving on hills or over obstacles if you fail to take proper precautions Read and understand your owner s manual and all warnings before operating a Polaris ATV Age Restrictions This vehicle is an ADULT VEHICLE ONLY Operation is prohibited for anyone under 16 years of age Know Your Vehicle As the operator of the vehicle you are responsible for your personal safety the safety of others and the protection of our environment Read and understand your owner s manual which includes valuable information about all aspects of your vehicle including safe operating procedures Safety Training When you purchased your new ATV your dealer offered a hands on safety training course that covers all aspects of vehicle safety You were also provided with printed materials that explain safe operating procedures You should review this information on a regular basis If you purchased a used Polaris ATV from a party other than a Polaris dealer you can request this free safety training from any authorized Polaris dealer A Polaris ATV is an off road vehicle Familiarize yourself with all laws and regulations concerning the operation of this vehicle in your area We strongly advise you to strictly follow the recommended maintenance program outlined in your owner s manual This preventive maintenance program is designed to ensure that all critical components on your vehicle are thoroughly inspected at specific
39. atanite ta 46 EMISSION CONTROL SYSTEMS 63 MAINTENANCE AND LUBRICATION 64 SPECIFICATIONS hee sles acca iw neeeckitecaal ein enon 105 POLARIS PRODUCTS 05 108 TROUBLESHOOTING 2 005 109 WARRANTY assy Gon ned cee pena wenen 113 INDEX sige takin Ga eras a a ee aaa eters 116 VEHICLE IDENTIFICATION NUMBERS The vehicle frame vehicle identification number VIN 1 and engine serial number are important for model identification when registering your vehicle when obtaining insurance and when ordering replacement parts If your vehicle is stolen these numbers are essential to the recovery and identification of your vehicle Remove the spare key and store it in a safe place Your key can be duplicated only by mating a Polaris key blank with one of your existing keys If both keys are lost the ignition switch must be replaced See your Polaris dealer NOTE Record your vehicle s ID numbers and key number 2 in the spaces provided Frame VIN Vehicle Model Number Engine Serial Number right front side of engine crankcase Key Number SAFETY Operator Safety AWARNING Failure to follow the warnings contained in this manual can result in severe injury or death A Polaris ATV is not a toy and can be hazardous to operate This vehicle handles differently than other vehicles such as motorcycles and cars A collision or rollover can occur quickly even during routine m
40. ch side of the vehicle and goes around the stands in front of the vehicle 2 4 Measure the distance from the string to the rim at the 1 front and rear of the front rim 3 Rear measurement should be 1 16 1 8 2 to 3 cm more than the front measurement NOTE If you discover improper alignment see your Polaris dealer for service MET 78 MAINTENANCE AND LUBRICATION Adjustments Side Panel Removal NOTE Side panel removal may be difficult until the locking tabs and receivers have been snapped and unsnapped a few times 1 Remove the seat l Step 2 2 Grasp the rear of the side panel near the rear cab With a quick and firm motion pull the panel forward and outward to disengage the two rear tabs 3 Place your hand on top of the side panel behind the fuel tank With a quick and firm motion Step 3 push down on the side panel to disengage the top rear two tabs Then pull up on the side panel to disengage the front upper and gt lower tabs 4 To reinstall the side panel align the panel tabs with the slots on the front cab Push the panel Step 4 upward and forward until the tabs lock Bend the rear of the side panel and insert the two tabs into the rear cab 79 MAINTENANCE AND LUBRICATION Adjustments Steering Assembly The steering assembly of the ATV should be checked periodically for loose nuts and bolts If loose nuts and bolts are found see your P
41. d as outlined in the maintenance chart See page 64 The following areas need special attention engine oil transmission oil front and rear gearcases and all grease fittings 4 CAUTION Major engine damage can result if the vehicle is not thoroughly inspected after operation in water Perform the services outlined in the maintenance chart If your vehicle becomes immersed or is operated in water that exceeds the footrest level take it to your dealer for service before starting the engine NOTE Avoid operating the vehicle through deep or fast flowing water If you cannot avoid water that exceeds the recommended maximum depth go slowly balance your weight carefully avoid sudden movements and maintain a slow and steady forward motion Do not make sudden turns or stops and do not make sudden throttle changes If your vehicle becomes immersed and it s impossible to take it to a dealer before starting it follow the steps described on page 93 Have the vehicle serviced by your dealer at the first opportunity 59 OPERATION Driving Safely Driving Over Obstacles Be alert Look ahead and learn to read the terrain you re traveling on Be constantly alert for hazards such as logs rocks and low hanging branches AWARNING Severe injury or death can result if your vehicle comes in contact with a hidden obstacle Not all obstacles are immediately visible Travel with caution in unfamiliar terrain 60 Driving Safely
42. d lubricate the entire vehicle with Polaris Premium All Season Grease Apply Polaris O Ring Chain Lube to the drive chain Storage Area Covers Set the tire pressure and safely support the ATV with the tires 1 2 off the ground Be sure the storage area is well ventilated and cover the machine with a genuine Polaris ATV cover NOTE Do not use plastic or coated materials They do not allow enough ventilation to prevent condensation and may promote corrosion and oxidation 103 MAINTENANCE AND LUBRICATION Cleaning and Storage Transporting an ATV Follow these procedures when transporting an ATV 1 Turn off the engine and remove the key to prevent loss during transporting 2 Turn the fuel valve off 3 Be sure the fuel cap oil cap and seat are installed correctly and securely 4 Always tie the frame of the ATV to the transporting unit securely using suitable straps or rope The rack bumper or handlebars do not offer enough support for tie down while transporting the unit 5 Always place the transmission in gear and lock the parking brake 104 SPECIFICATIONS 2004 Trail Boss Body Sk Gross Vehicle Weighi Fuel Capacity Transmission O 1 7 qts 1 6 I oil change only Front Rack Rear Rack Tongue Weigh Hich Towing Rating Unbraked Trailer Towing Capacity Tum Radius Ground Clearance Hegh Length Wii Seat Hea Dry Weigh Wheel Base Based on EU Directive 76 432 EC 105 SPECIFICATIONS 2
43. e Using a clean dry cloth clean the filter sealing surface on the crankcase Lubricate the gasket on the new filter with a film of engine oil Check to make sure the gasket is in good condition Install the new filter and turn by hand until the filter gasket contacts the sealing surface then turn and additional 1 2 turn Remove the dipstick and fill the sump with 1 7 quarts 1 6 1 of Polaris Premium 4 synthetic oil Place the gear selector in neutral and set the parking brake Start the engine and let it idle for one to two minutes Stop the engine and inspect for leaks Recheck the oil level and add oil as necessary to bring the level to the upper mark on the dipstick Dispose of used filter and oil properly MAINTENANCE AND LUBRICATION Lubrication Recommendations Transmission Oil Check The transmission dipstick 1 is located on the right side of the machine near the recoil handle Check the lubricant level monthly or every 1000 miles 1600 km whichever comes first Change the transmission oil annually NOTE We recommend the use of Polaris Premium Synthetic Gearcase Lubricant See page 108 for the part numbers of Polaris products 1 Position the ATV on a level surface Remove the dipstick and wipe it clean 2 Reinstall the dipstick completely then remove it and check the level Add the recommended lubricant to bring the level into the safe operating range See Specifications beginning on page 105 for
44. e loss of control or overturn HOW TO AVOID THE HAZARD Before operating in a new area check for obstacles Avoid operating over large obstacles such as rocks and fallen trees when possible If unavoidable use extreme caution and always follow proper procedures as outlined in the owner s manual 4 WARNING POTENTIAL HAZARD Skidding or sliding WHAT CAN HAPPEN Skidding or sliding can cause loss of control If the tires regain traction unexpectedly the ATV could overturn HOW TO AVOID THE HAZARD On slippery surfaces such as ice travel slowly and use extra caution to reduce the chance of skidding or sliding out of control 27 SAFETY Operator Safety 4 WARNING POTENTIAL HAZARD Operating the ATV through deep or fast flowing water WHAT CAN HAPPEN Tires may float causing loss of traction and loss of control which could lead to an accident or overturn HOW TO AVOID THE HAZARD Avoid operating the ATV through deep or fast flowing water If it s unavoidable to enter water that exceeds the recommended maximum depth see page 59 travel slowly balance your weight carefully avoid sudden movements and maintain a slow and steady forward motion Do not make sudden turns or stops and do not make sudden throttle changes Wet brakes may have reduced stopping ability Always test the brakes after leaving water If necessary apply them several times to let friction dry out the pads 4 WARNING POTENTIAL HAZARD
45. e often under severe use such as dirty or wet conditions Emission Control System Service California E Dealer service item s required Periodic inspection adjust when parts are replaced Adjust as needed 68 MAINTENANCE AND LUBRICATION Periodic Maintenance Record Use the following chart to record periodic maintenance Maintenance Servicing Servicing Interval Date Dealer Performed or Person 10 hrs 69 MAINTENANCE AND LUBRICATION Lubrication Recommendations NOTE Hours are based on 10 mph average If service is due at 20 hours the equivalent odometer reading would be 200 miles Perform all services at whichever reading is reached first Lubrication Chart Key gt More often under severe use such as wet or dusty conditions Polaris Premium All Season Grease or grease conforming to NLG No 2 such as Conoco Superlube M or Mobilegrease Special A When suspension action becomes stiff or after washing 4 Cycle Polaris Premium 4 Add to proper level on dip Check level daily Engine Synthetic OW40 stick Brakes DOT 3 fluid only Maintain level between fill As required change lines See page 39 every two years or 200 hours Drive chain s O ring chain lube Lubricate as often as re As required or SAE 80 90 quired and before each ride in wet conditions Transmission Polaris Premium See Page 73 Check every 6 Synthetic Gear months 1000 miles case Lube Change annually or at 100 hours Ball Joint p G
46. ealer if it s been involved in an accident e Never operate on hills too steep for the ATV or for your abilities Practice on smaller hills before attempting larger hills e Always follow proper procedures for climbing hills Check the ter rain carefully before ascend a hill Never climb hills with excessive ly slippery or loose surfaces Shift your weight forward Never open the throttle suddenly or make sudden gear changes Never go over the top of a hill at high speed e Always follow proper procedures for going downhill and for braking on hills Check the terrain carefully before you start down a hill Shift your weight backward Never go down a hill at high speed Avoid going down a hill at an angle which would cause the vehicle to lean sharply to one side Travel straight down the hill when pos sible e Always follow proper procedures for crossing the side of a hill Avoid hills with excessively slippery or loose surfaces Shift your weight to the uphill side of the ATV Never attempt to turn the ATV around on any hill until you ve mastered on level ground the turn ing technique outlined in this manual Avoid crossing the side of a steep hill when possible e Always use proper procedures if you stall or roll backwards while climbing a hill To avoid stalling maintain a steady speed when climbing a hill If you stall or roll backwards follow the special pro cedure for braking described in this manual Always dismount on the u
47. ed p gt Air filter Weekly Weekly Inspect replace as needed main element m Brake pad wear Monthly Inspect periodically eee oil 20 hrs Monthly Inspect monthly change level annually Battery Monthly Check terminals clean i CCE breather 20 hrs Monthly Inspect replace annually filter and as needed Engine cylinder 25 hrs 3 months Inspect re torque required head and cylinder at first service only base fasteners General lubrication 50 hrs 3 months Lubricate all fittings pivots cables etc Engine oil level oil 100 hrs 6 months Check level daily break in change i service at one month change oil more often in cold weather Oil Filter 100 hrs 6 months Replace with oil change 1000 mi Engine breather 100 hrs 6 months Inspect hose p More often under severe use such as dirty or wet conditions n Emission Control System Service California m Dealer service item 66 MAINTENANCE AND LUBRICATION Periodic Maintenance Schedule Hours Frequency Miles Carburetor float 50 hrs 6 months Drain bowl periodically and bowl prior to storage Throttle Cable ETC 50 hrs 6 months Inspect adjust lubricate Switch replace if necessary Choke enricher 50 hrs 6 months Inspect adjust lubricate cable replace if necessary iil Shift linkage Inspect adjust m Drive belt Inspect replace as needed gt Steering Inspect daily lubricate aE suspension 50 hrs 6 months Inspect
48. el valve off whenever the ATV is stored or parked AWARNING The engine exhaust from this product contains chemicals known to cause cancer birth defects or other reproductive harm Operate this vehicle only outdoors or in well ventilated areas 43 FEATURES AND CONTROLS Automatic Transmission Gear Selector The transmission gear selector 1 is located on the right side of the ATV F Forward N Neutral R Reverse CAUTION Shifting gears with the engine speed above idle or while the vehicle is moving could cause transmission damage To change gears stop the vehicle and with the engine idling move the lever to the desired gear Whenever the ATV is left unattended always place the transmission in gear with the parking brake locked Maintaining shift linkage adjustment is important to assure proper transmission function See your dealer if you experience any shifting problems 44 FEATURES AND CONTROLS Recoil Starter If the battery has been drained or damaged and cannot start the engine use of the recoil starter 1 will allow vehicle operation until repairs can be made The recoil starter is located on the right side of the E machine L Polaris 4 cycle engines are REE ex equipped with automatic BEES EERE decompressors This makes recoil starting possible by reducing the amount of compression during starting The decompressor senses when the engine is spinning fast enoug
49. ement often more frequent cleaning required in dusty conditions Do not operate vehicle without pre filter Chain Freeplay Is Important Adjust Freeplay to 3 16 3 8 DO NOT Overtension See Owner s Manual Torque Nut on Eccentric Bolts To 30 Ft Lbs For models without a hitch To 40 Ft Lbs For models with a hitch 7078572 MANUFACTURED BY POLARIS IND INC DATE OVERRIDE SWITCH Reverse Speed is limited VIN THIS VEHICLE IS AN ALL TERRAIN VEHICLE AND IS NOT INTENDED FOR USE ON PUBLIC ROADS CE V HICULE EST UN V HICULE TOUT TERRAIN QUI N EST PAS DESTIN TRE UTILIS SUR LES CHEMINS PUBLICS Reverse override is controlled by the PATENT NOTICE Mfd by Al Terrain Vehicle Division j E MSY An Terran le Oyisini override switch Polaris Industries Inc under one or more of the following patents Other patents pending U S Patents 4697665 5036939 5975624 6016943 6092877 6149540 6224134 6270106 6340186 0378080 0389440 0400143 Canadian Certification Decal 34 See your Owner s Manual es 7079906 SAFETY Safe Riding Gear Always wear clothing suited to the type of riding ATV riding requires special protective clothing for comfort and to reduce the chance of injury 1 Helmet Your helmet is the most important piece of protective gear for safe riding A helmet can prevent a severe head injury Select an approved helmet that meets
50. essive use of the choke can cause the spark plug to become wet fouled 1 2 Position the vehicle on a level surface with the transmission in neutral Lock the parking brake turn the fuel tank valve to ON sit on the vehicle and turn the engine stop switch to RUN If the engine has cooled to a point where it does not readily start intermittent use of the choke pulled half way out may be necessary If the engine is over choked when warm depress the throttle lever fully while cranking to aid in starting Release the throttle lever immediately after the engine starts If the engine does not start and all conditions are favorable change the spark plug and try again 49 OPERATION Hauling Cargo 1 3 Your ATV has been designed to carry or tow a certain amount of load Always read and understand the load distribution warning labels on the vehicle and never exceed the weight capacities outlined in the specifications section of the owner s manual and on the safety decals Cargo weight should be evenly distributed 1 3 on the front rack and 2 3 on the rear rack and mounted as low as possible When operating over rough or hilly terrain reduce speed and cargo weight to maintain stable driving conditions Do not obstruct the headlight beam with cargo 50 OPERATION Hauling Cargo AWARNING Hauling cargo improperly can alter vehicle handling and may cause loss of control or brake instability and result in serious
51. ever is released 1 This ATV is equipped with Polaris Electronic Throttle Control ETC which is designed to reduce the risk of a frozen or stuck throttle If the throttle cable should stick in an open position when the operator releases the throttle lever the engine will stop and power to the rear wheels will cease AWARNING The Electronic Throttle Control ETC stops the engine in the event of a throttle system malfunction and is provided for your safety Do not attempt to modify the ETC system or replace it with any after market throttle mechanisms 37 FEATURES AND CONTROLS AWARNING Operating the ATV on streets or roads especially in darkness could result in an accident and serious injury or death Your ATV is not equipped with highway approved lights It s designed for and must be used for off road use only Use caution and drive at reduced speeds in conditions of reduced visibility such as fog rain and darkness Light Switches The light switch is located on the left handlebar 1 It s used to turn the lights on and off and to switch the lights from HI to LO on models equipped with HI LO beams NOTE The lights won t work unless the key is in the ON position and the shut off switch is in the RUN position Indicator Lights With the engine running verify the function of all indicator lights each time the ATV is used NOTE The taillight is on whenever the main switch key is on Turn the key off to
52. g and Storage Storage Tips See page 108 for the part numbers of Polaris products CAUTION Starting the engine during the storage period will disturb the protective film created by fogging and damage could occur Never start the engine during the storage period Exterior Make necessary repairs and then clean the ATV thoroughly with mild soap and warm water to remove all dirt and grime Don t use harsh detergents or high pressure washers Some detergents deteriorate rubber parts Use dish soap type cleaners only High pressure washers may force water past seals Fuel Stabilizer Polaris Carbon Clean is a fuel stabilizer and fuel system dryer It cleans the fuel system the combustion chamber and the exhaust ports It also prevents bacterial growth and promotes better starting after the storage period 1 Fill the fuel tank with fuel and add Polaris Carbon Clean or Fuel Stabilizer Follow the instructions on the container for the recommended amounts 2 Start the engine and allow it to run for 15 20 minutes so the stabilizer can disperse through the fuel in the tank and carburetor 3 Stop the engine turn the fuel valve off and drain the carburetor bowl Oil and Filter Warm the engine and change the oil and filter Air Filter Air Box Inspect and clean or replace the pre cleaner and air filter Clean the air box and drain the sediment tube Recoil Housing Remove the recoil housing drain plug and drain any moisture 1
53. ghten the clamp Do not over tighten the clamp as filter damage could occur 89 MAINTENANCE AND LUBRICATION Lights When servicing a halogen lamp don t touch the lamp with bare fingers Oil from your skin leaves a residue causing a hot spot that will shorten the life of the lamp AWARNING Poor lighting while driving can result in severe injury or death Headlight and taillight lenses become dirty during normal operation Wash the headlights frequently to maintain lighting quality Hot components can cause serious burns to skin Do not service the headlamps until they ve cooled sufficiently Headlight Lamp Replacement 1 Remove the wire harness connector from the back of the headlight 2 Grasp the bulb housing and turn it counterclockwise to remove the bulb 3 Apply dielectric grease to the light bulb socket before installing a new bulb Install the replacement bulb into the headlight housing and rotate clockwise firmly NOTE The bulb must be positioned so the harness installs into the lamp at the bottom 4 Reinstall the connector to the back of the headlight High Beam Adjustment The headlight beam can be adjusted vertically 1 Position the ATV on a level surface with the headlight approximately 25 ft 7 6 m from a flat wall 2 Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height 3 Start the engine and turn the headlight switch to high bea
54. gine starts NOTE Turning off the main switch will shut off all electrical power to the vehicle including the lights AWARNING Leaving the keys in the ignition can lead to unauthorized use of the vehicle resulting in serious injury or death Always remove the ignition key when the vehicle is not in use OFF RUN _ OFF Engine Stop Switch 3 The engine will not start or run when the switch is in the OFF position Its purpose is to provide the operator with a quick means of engine shutdown in case of an emergency To stop the engine slide the stop switch either right or left to the OFF position NOTE Turning off the engine stop switch will shut off all electrical power to the vehicle including the lights 36 FEATURES AND CONTROLS AWARNING Do not start or operate an ATV with sticking or improperly operating throttle controls which could cause an accident and lead to severe injury or death Always contact your dealer for service repairs if throttle problems arise Failure to check or maintain proper operation of the throttle system can result in an accident if the throttle lever sticks during operation Always check the lever for free movement and return before starting the engine Also check occasionally during operation Throttle Lever Engine speed and vehicle movement are controlled by pressing the throttle lever The throttle lever 1 is spring loaded Engine speed returns to idle when the l
55. gistration Form must be completed by your dealer and submitted to Polaris within ten days Upon receipt of this registration Polaris will record the registration for warranty THE PURCHASER MUST COMPLETEAN ATV SAFETY TRAINING COURSE PROVIDED BY THE DEALER IN ORDER TO HAVE VALID WARRANTY ON THE ATV No verification of registration will be sent to the purchaser as the copy of the Warranty Registration Form will be the warranty entitlement If you have not signed the original registration and received the customer copy please contact your dealer immediately NO WARRANTY COVERAGE WILL BE ALLOWED UNLESS YOUR ATV IS REGISTERED WITH POLARIS Initial dealer preparation and set up of your ATV is very important in ensuring trouble free operation Purchasing a machine in the crate or without proper dealer set up will void your warranty coverage WARRANTY COVERAGE AND EXCLUSIONS LIMITATIONS OF WARRANTIES AND REMEDIES The Polaris limited warranty excludes any failures that are not caused by a defect in material or workmanship This warranty does not cover accidental damage normal wear and tear abuse or improper handling This warranty also does not cover any ATV that has been al tered structurally modified neglected improperly maintained used for racing or used for purposes other than for which it was manufactured or for any damages which occur during trailer transit or as a result of unauthorized service or the use of unauthorized parts In addi
56. h to start and restores compression when running 1 Position the vehicle on a level surface and lock the parking brake see page 40 2 Shift the transmission into neutral 3 Make sure the engine stop switch is set to RUN and the main key switch is in the ON position NOTE If the engine is cold use the choke as outlined on page 48 4 Grasp the recoil starter rope handle 2 firmly and pull slowly so you can feel the engine strokes NOTE Every other stroke will be a compression stroke and will make the rope harder to pull When a compression stroke is found continue pulling the rope just until the engine rolls past the stroke then stop pulling immediately 5 Allow the recoil rope to rewind into the recoil assembly then pull the rope abruptly and forcefully to start the engine 6 Repeat steps 4 5 if necessary CAUTION Extending the recoil starter rope until it stops can cause damage to the recoil assembly Do not extend the starter rope so far that it stops If the starter rope handle is not seated properly water may enter the recoil housing and damage components Make sure the handle is fully seated on the recoil housing especially when traveling in wet areas 45 OPERATION Break In Period The break in period for your new Polaris ATV is defined as the first ten hours of operation or the time it takes to use the first two full tanks of gasoline No single action on your part is as important as following the
57. imately 3 8 10mm deflection 11 Position the chain guide to allow 1 8 3mm clearance and tighten the retaining bolt to 5 ft lbs 7 Nm 12 Reinstall the chain guard if applicable 87 MAINTENANCE AND LUBRICATION Adjustments Drive Chain Polaris ATV drive chains are equipped with o ring sealed permanently greased pins and rollers However the outer surfaces of the roller must be lubricated Always inspect the drive chain prior to operating the vehicle Check for damaged or missing o rings or damaged rollers Also check for correct slack adjustment Maintain the stone guard to rear sprocket clearance at 1 8 3 cm Regularly lubricate the drive chain with SAE 80 90 lube or an approved o ring chain spray lube See page 108 for the part numbers of Polaris products CAUTION Washing the drive chain with a high pressure washer or gasoline can cause damage to the o rings causing premature wear and drive chain failure Don t use a high pressure washer or gasoline to clean the drive chain 88 MAINTENANCE AND LUBRICATION Air Filter 1 2 Remove the seat release the clips and remove the air box cover Loosen the clamp and remove the filter Remove the fabric type pre filter 1 from the main filter 2 Wash the pre filter in soapy water then rinse and let dry Reinstall the pre filter over the main filter Replace the main filter if needed Reinstall the filter into the air box and ti
58. ing the vehicle 1 Place the transmission in neutral and lock the parking brake Make sure the fuel tank valve is on 2 Sit on the vehicle and pull the choke knob out until it stops 1 NOTE If the knob doesn t stay where positioned increase the tension by rotating the tension adjusting nut 2 clockwise 5 C NOTE The variable choke is fully on when the knob is pulled completely out The choke is off when the knob is pushed completely in The choke can be adjusted gradually depending on how much choke is needed for starting Be sure the choke is off during operation as excess fuel washing into the engine oil will increase wear on engine components 3 Move the engine stop switch to RUN NOTE Do not press the throttle while starting the engine 4 Turn the ignition key past the ON position to engage the starter Activate the starter for a maximum of five seconds releasing the key when the engine starts If the engine does not start release the key and wait five seconds Activate the starter for another five seconds Repeat this procedure until the engine starts 5 Ifthe engine slows position the choke knob half way in to allow proper engine warm up 6 Vary the engine RPM slightly with the throttle to aid in warm up When the engine idles smoothly push the choke all the way in 48 OPERATION Starting the Engine Starting a Warm Engine Warm engines do not normally require the use of the choke Exc
59. ion Use the following checklist to verify that your vehicle is in proper working condition before each use Item Inspection Procedure 1 2 3 9 10 11 12 Tires Check condition and pressures Fuel and oil tanks Fill both tanks to their proper levels All brakes Check operation adjustment and fluid level includes auxiliary brake Throttle Check for free operation and closing Headlight Taillight Brakelight Check operation of all indicator lights and switches Engine stop switch Check for proper function Wheels Check for tightness of wheel nuts and axle nuts check that axle nuts are secured by cotter pins Drive chain Check condition and slack refer to drive chain adjustment section lubricate when needed Air cleaner element Check for dirt clean or replace Steering Check for free operation noting any unusual looseness in any area Loose parts Visually inspect vehicle for any damaged components or loose nuts bolts or fasteners Riding gear Wear a helmet goggles and protective clothing 47 OPERATION Starting the Engine Starting a Cold Engine AWARNING Engine exhaust contains poisonous carbon monoxide and can cause loss of consciousness resulting in severe injury or death Never run an engine in an enclosed area CAUTION Operating the vehicle immediately after starting could cause engine damage Allow the engine to warm up for several minutes before operat
60. l product labels and has completed a certified safe ty training course Always avoid operating an ATV on paved surfaces including side walks driveways parking lots and streets Never operate an ATV on a public street road or highway including a dirt or gravel road Never operate an ATV without wearing an approved helmet that fits properly Always wear eye protection goggles or face shield gloves boots a long sleeved shirt or jacket and long pants Never consume alcohol or drugs before or while operating an ATV Never operate at excessive speeds Travel at speeds appropriate for the terrain visibility and operating conditions and your experience Never attempt wheelies jumps or other stunts Always inspect your ATV before each use to make sure it s in safe operating condition Always follow the inspection and maintenance procedures and schedules outlined in your owner s manual Always keep both hands on the handlebars and both feet on the foot rests of the ATV during operation Always travel slowly and use extra caution when operating on unfa miliar terrain Be alert to changing terrain conditions Never operate on excessively rough slippery or loose terrain Always follow proper turning procedures as described in this manu al Practice turning at low speeds before attempting to turn at faster speeds Do not turn at excessive speeds SAFETY Operator Safety e Always have the ATV inspected by an authorized Polaris d
61. leaning and Storage See page 108 for the part numbers of Polaris products Cleaning the ATV Keeping your ATV clean will not only improve its appearance but it can also extend the life of various components With a few precautions your ATV can be cleaned much like an automobile Washing the ATV The best and safest way to clean your ATV is with a garden hose and a pail of mild soap and water Use a professional type washing mitten cleaning the upper body first and the lower parts last Rinse with water frequently and dry with a chamois to prevent water spots NOTE If warning and safety labels are damaged contact your Polaris dealer for free replacements Polaris does not recommend the use of a high pressure type car wash system for washing the ATV If a high pressure system is used exercise extreme care to avoid water damage to the wheel bearings transmission seals body panels brakes and warning labels NOTE Grease all zerk fittings immediately after washing and allow the vehicle to run for a while to evaporate any water that may have entered the engine or exhaust system Waxing the ATV Your ATV can be waxed with any non abrasive automotive paste wax Avoid the use of harsh cleaners since they can scratch the body finish CAUTION Certain products including insect repellants and chemicals will damage plastic surfaces Use caution when using these products near plastic surfaces 101 MAINTENANCE AND LUBRICATION Cleanin
62. lebar These brakes are self adjusting The following checks are recommended to keep the brake system in good operating condition Check more often if brakes are used heavily under normal operation AWARNING Never store or use a partial bottle of brake fluid Brake fluid is hygroscopic meaning it rapidly absorbs moisture from the air The moisture causes the boiling temperature of the brake fluid to drop which can lead to early brake fade and the possibility of accident or severe injury After opening a bottle of brake fluid always discard any unused portion 1 Always keep brake fluid at an adequate level see page 39 AWARNING An over full master cylinder may cause brake drag or brake lock up which could result in serious injury or death Maintain brake fluid at the recommended level Do not overfill NOTE Under normal operation the diaphragm extends into the reservoir as fluid level drops If the fluid level is low and the diaphragm is not extended a leak is likely and the diaphragm should be replaced Always fill the reservoir as needed whenever the cover is loosened or removed to ensure proper diaphragm operation Use Polaris DOT 3 brake fluid Do not overfill 76 MAINTENANCE AND LUBRICATION Adjustments Brakes 2 Check the brake system for fluid leaks 3 Check the brakes for excessive travel or spongy feel 4 Check the friction pads for wear damage and looseness 5 Check the security and surface condition
63. ls Contact your Polaris dealer for more information Polaris has a wide range of additional accessories available for your ATV See your Polaris dealer Periodic Maintenance Schedule Careful periodic maintenance will help keep your vehicle in the safest most reliable condition Inspection adjustment and lubrication of important components are explained in the periodic maintenance schedule Maintenance intervals in the following charts are based upon average riding conditions and an average vehicle speed of approximately 10 miles per hour Vehicles subjected to severe use such as operation in wet or dusty areas should be inspected and serviced more frequently Inspect clean lubricate adjust and replace parts as necessary When inspection reveals the need for replacement parts use genuine Polaris parts available from your Polaris dealer NOTE Service and adjustments are critical If you re not familiar with safe service and adjustment procedures have a qualified dealer perform these operations Maintenance Chart Key p Perform these operations more often under severe use such as in dirty or wet conditions to purge water or dirt contamination from grease fittings and other critical components Emission Control System Service California 4 Cycle NOTE Some 4 Cycle models may have an additional California only emissions warranty m Dealer service item 64 MAINTENANCE AND LUBRICATION Periodic Maintenance Sched
64. lubricate tighten fasteners ere chain s 50 hrs 6 months ira daily adjust and lu bricate if needed Ae E Smo postbeangsr abe Spark plug 100 hrs Inspect replace as needed Ignition Timing 100 hrs 12 months Inspect adjust as needed E Fuel system 100 hrs 12 months Check for leaks at tank cap lines fuel valve filter pump and carburetor re place lines every two years Cl Fuel filter 100 hrs 12 months Replace annually gt More often under severe use such as dirty or wet conditions K Emission Control System Service California E Dealer service item 67 MAINTENANCE AND LUBRICATION Periodic Maintenance Schedule AWARNING Improperly performing the procedures marked with a m could result in component failure and lead to serious injury or death Have an authorized Polaris dealer perform these services Hours Frequency Miles Radiator Oil Cooler 100 hrs 12 months Inspect clean external sur face Cooling system 100 hrs 12 months Inspect hoses Clutches drive and 100 hrs 12 months Inspect clean driven E Valve clearance 100 hrs 12 months Inspect adjust Fi Shift selector 200 hrs 24 months Change lubricant every two years m Brake fluid 200 hrs Change every two years Front wheel 300 hrs 36 months Inspect replace as needed bearings Recoil housing As required Drain moisture out after rid ing in water F Toe adjustment a A i j Headlight aim gt Mor
65. m 4 Observe the headlight aim on the wall The most intense part of the headlight beam should be aimed 2 5 1 cm below the mark placed on the wall NOTE Include rider weight on the seat when measuring 5 Loosen the pivot bolt and adjust the beam to the desired position 6 Tighten the bolt and torque to 60 in Ibs 90 MAINTENANCE AND LUBRICATION Lights Taillight Brakelight Lamp Replacement If the taillight brakelight does not work the lamp may need to be replaced 1 4 Remove the taillight lens cover mounting screws Remove the lens cover and gasket and set aside for reassembly Remove the lamp 1 and replace it with a new lamp Test the taillight brakelight to see that it s working Reinstall the gasket and lens cover Indicator Lamp Replacement 1 2 3 Remove the instrument panel if necessary to access the back of the indicator panel Using a small straight blade screwdriver turn the base of the bulb 1 4 turn counterclockwise Using a needle nose plier or similar tool pull the lamp out of the indicator panel housing Insert the new bulb and seat it by turning it 1 4 turn clockwise Reassemble the pod or front cover 91 MAINTENANCE AND LUBRICATION Spark Plugs CAUTION Using non recommended spark plugs can result in serious engine damage Always use Polaris recommended spark plugs See Specifications beginning on page 105 Spark plug condition is indicative of engi
66. mage to the transmission and drive components Always make sure the slack is within the stated specifications Check the amount of chain slack in three different locations by moving the vehicle slightly forward to gain slack at the top side of the rear chain Measure the chain slack at the tightest of the three positions At this point the chain should have 3 16 3 8 48 cm 95 cm deflection Use the following procedure if adjustment is required 3 16 3 8 48 cm 95 cm 1 Remove the chain guard if applicable 2 Loosen the chain guide 3 Loosen the two eccentric locking bolts 1 4 Loosen the caliper mounting bracket bolts located under the axle 5 Insert a pin punch 2 through the sprocket hub and into the eccentric housing 86 MAINTENANCE AND LUBRICATION Adjustments Rear Drive Chain Slack 6 Roll the ATV forward or backward to adjust the chain slack to the proper tension See the illustration for proper splice link clip opening position 1 7 Tighten the eccentric locking bolts 2 to 30 ft Ibs 41 Nm for machines CA 1 without the hitch and 45 ft Ibs 61 Nm for machines with a hitch 8 Tighten the caliper mount bolts to 10 12 ft lbs 14 17 Nm 9 Remove the pin punch 10 Roll the ATV forward checking chain tension in several places around the chain NOTE The chain is adjusted correctly when the tightest portion of the chain has approx
67. mix oil brands Oil and Filter Change The recommended oil change interval is 100 hours 1000 miles or every six months whichever comes first Suggested break in oil change is at 20 hours 200 miles or one month whichever comes first Severe use operation requires more frequent service Severe use includes continuous duty in dusty or wet conditions and cold weather riding NOTE Severe use cold weather riding is all riding below 10 F and riding between 10 F and 30 F when most trips are slow speed and less than 5 miles Be sure to change the oil filter whenever changing oil 71 MAINTENANCE AND LUBRICATION Lubrication Recommendations Oil and Filter Change 1 2 3 10 11 12 13 14 15 16 72 Position the vehicle on a level surface Clean the area around the drain plug Run the engine for two to three minutes until warm Stop the engine 4 CAUTION Contact with hot oil may result in serious burns Do not allow hot oil to come into contact with skin Place a drain pan beneath the engine crankcase and remove the drain plug Allow the oil to drain completely Install a new sealing washer on the drain plug NOTE The sealing surfaces on the drain plug and crankcase should be clean and free of burrs nicks or scratches Reinstall the drain plug and torque to 14 ft lbs 19 Nm Place shop towels beneath the oil filter Using an oil filter wrench turn the filter counterclockwise to remov
68. nd the customs department of the destination country before you move Vehicles importation rules vary considerably from country to country You may be required to present docu mentation of your move to Polaris Industries in order to continue your warranty cover age You may also be required to obtain documentation from Polaris Industries in order to register your vehicle in your new country How to Get Service If Purchased From A Private Party If you purchase a Polaris product from a private citizen outside of the country in which the vehicle was originally purchased all warranty coverage will be denied Notice If your vehicle is registered outside of the country where it was purchased and you have not followed the procedure set out above your vehicle will no longer be eligible for war ranty or service bulletin coverage of any kind Vehicles registered to Government offi cials or military personnel on assignment outside of the country where the vehicle was purchased will continue to be covered by the basic warranty For questions call Polaris Customer Assistance United States 1 763 417 8650 Canada 1 204 925 7100 115 INDEX A ACCESSOTIES 2 ee ee eee 64 Adjustments 76 88 Age Restrictions 7 Aur Filter see 08g tas geese 89 Auxiliary Brake 41 77 B Battery ss saws aa bes 98 100 Battery Charging 99 100 Battery Installation 98 Battery Removal
69. ne operation The spark plug firing end condition should be read after the engine has been warmed up and the vehicle has been driven at higher speeds Immediately check the spark plug for correct color AWARNING A hot exhaust system and engine can cause serious burns Wear protective gloves when removing a spark plug for inspection 1 Normal The normal insulator tip is gray tan or light brown There will be few combustion deposits The electrodes are not burned or eroded This indicates the proper type and heat range for the engine and the service NOTE The tip should not be white A white insulator tip indicates overheating caused by use of an improper spark plug or incorrect carburetion adjustments 2 Wet Fouled The wet fouled insulator tip is black A damp oil film covers the firing end There may be a carbon layer over the entire nose Generally the electrodes are not worn General causes of fouling are excessive oil use of non recommended injection oil improper use of the choke or incorrect carburetion adjustments Spark Plug Removal and Replacement 1 Remove the spark plug cap 2 Using the special wrench provided in the tool pouch rotate the spark plug counterclockwise to remove 3 Reverse the procedure for spark plug installation Torque to 14 ft Ibs 19 Nm 92 MAINTENANCE AND LUBRICATION Vehicle Immersion CAUTION If your vehicle becomes immersed major engine damage can result if the machine is no
70. ng 6 Remain alert and be prepared to take emergency action 25 Maximu This may include quick dismounting of the vehicle If all forward speed is lost Keep your weight uphill Apply the single lever brake gradually When fully stopped apply the auxiliary brake as well then lock the park brake If the ATV begins rolling backwards Keep your weight uphill Never apply engine power Never apply the auxiliary rear brake while rolling backwards Apply the single lever brake gradually When fully stopped apply the auxiliary rear brake as well and then lock the parking brake Dismount on uphill side or to either side if ATV is pointed straight uphill Turn the ATV around and remount following the procedure described on page 58 AWARNING Braking and handling are greatly affected when operating in hilly terrain Improper procedure could cause loss of control or overturn and result in serious injury or death Avoid climbing steep hills 25 maximum Use extreme caution when operating on hills and follow proper operating procedures outlined in the owner s manual 55 OPERATION Driving Safely Sidehilling AWARNING Improperly crossing hills or turning on hills can result in loss of control or vehicle overturn resulting in severe injury or death Avoid crossing the side of a hill when possible Follow proper procedures as outlined in the owner s manual Sidehilling can be a dangerous type of driving and
71. ng Assembly 80 Stop Switch 0 0 00 0 000 36 Storage Tips 102 103 T TABLE OF CONTENTS 5 Taillight Lamp Replacement 91 Throttle Cable Freeplay 82 Throttle Lever 37 TIES wees ese nee eee ae es eh 85 Toe Alignment 78 Transmission Gear Selector 44 Transmission Oil Change 74 Transmission Oil Check 73 Transporting an ATV 104 TROUBLESHOOTING 109 112 Turning Around ona Hill 58 Vv VEHICLE ID NUMBERS 6 Vehicle Immersion 93 W WARRANTY 113 115 Washing the ATV 101 Waxing the ATV 101 WELCOME 0008 3 Wheel Hub Tightening 85 Wheel Installation 84 Wheel Nut Torque Specifications 84 Wheel Removal 83 117
72. nique on level ground as described in the owner s manual See page 58 Use extra caution when turning on any hill Avoid crossing the side of a steep hill When crossing the side of a hill Always follow proper procedures as described in the owner s manual Avoid hills with excessively slippery or loose surfaces Shift your weight to the uphill side of the ATV 25 SAFETY Operator Safety 4 WARNING POTENTIAL HAZARD Stalling rolling backwards or improperly dismounting while climbing a hill WHAT CAN HAPPEN The vehicle could overturn HOW TO AVOID THE HAZARD Maintain steady speed when climbing a hill If all forward speed is lost Keep your weight uphill Apply the single lever brake gradually When fully stopped apply the auxiliary rear brake as well then lock the parking brake If the ATV begins rolling backwards Keep weight uphill Never apply engine power Never apply the auxiliary rear brake while rolling backwards Apply the single lever brake gradually When fully stopped apply the auxiliary rear brake as well and then lock the parking brake Dismount on uphill side or to either side if ATV is pointed straight uphill Turn the ATV around and remount following the procedure described in the owner s manual See page 58 26 SAFETY Operator Safety 4 WARNING POTENTIAL HAZARD Improperly operating over obstacles WHAT CAN HAPPEN Operating over obstacles could caus
73. ol resulting in SEVERE INJURY OR DEATH TIRE PRESSURE IN PS KPa FRONT 4 27 6 REAR 3 20 7 MAXIMUM WEIGHT CAPACITY Gross Vehicle Weight INCLUDING MACHINE DRIVER AND CARGO IS 845 LBS 383 kg Reduce speed and allow greater distance for braking when carrying cargo Overloading or carrying talt off center or unsecured loads will increase your risk of losing control Loads should be centered cartied as low as possible and firmly secured to the racks With dual racks load distribution 1 3 front 2 3 rear is best For stabllity on rough or hifly terrain reduce speed and cargo Do not block headlight Be carefut if load extends over the side of the rack Read Owner s Manual for more detailed loading information 7079088 A WARNING NEVER ride as a passenger Passengers can cause a loss of control resulting in SEVERE INJURY or DEATH 4 WARNING Moving parts hazard under belt clutch guard To prevent serious injury do not operate vehicle with guard removed e Do not modify engine or clutch Doing so can cause part failure possible imbalance and excessive engine RPM which can result in serious injury or death N O STE P 7078689 7077920 32 SAFETY Safety Decals and Locations 4 WARNING e DO NOT TOW FROM RACK OR BUMPER Vehicle damage or tipover may result causing severe injury or death Tow only from tow hooks or hitch Max Rack Loads Front 75 Ibs 34 kg Rear 125 Ibs 57 kg 71
74. olaris dealer for service before operating the vehicle Camber and Caster The camber and caster are non adjustable Rear Spring The rear shock absorber spring is adjusted by rotating the adjuster 1 either clockwise or counterclockwise to increase or decrease spring tension NOTE Accessory springs are available through your Polaris dealer AWARNING Improper adjustment of the handlebars or incorrect torquing of the adjuster block tightening bolts can cause limited steering or loosening of the handlebars resulting in loss of control and possible serious personal injury or death Follow the adjustment procedures exactly or see your Polaris dealer for service Handlebars The handlebars can be adjusted for rider preference 1 Remove the handlebar cover and locate the handlebar bolts 1 2 Loosen the four bolts 3 Adjust the handlebar to the desired height Be sure the handlebars do not contact the gas tank or any other part of the machine when turned fully to the left or right 4 Torque the front two bolts to 10 12 ft lbs 14 17 Nm then torque the rear two bolts A gap of up to 1 8 will remain at the rear bolts 80 MAINTENANCE AND LUBRICATION Adjustments Carburetor IMPORTANT Your Polaris ATV is calibrated at the factory for optimal performance at altitudes ranging from zero to 6 000 feet 1800 m and temperatures of 40 degrees F 4 degrees C or higher Above 6000 feet 1800 m the engine
75. ons chart NOTE All nuts that have a cotter pin installed must be serviced by an authorized Polaris dealer Wheel Nut Torque Specifications Check the wheel nut torques occasionally and when they ve been loosened for maintenance service Bolt Size Specification Front 3 8 20 ft Ibs 27 Nm Rear 3 8 20 ft Ibs 27 Nm Rear 1 2 50 ft Ibs 68 Nm 84 MAINTENANCE AND LUBRICATION Adjustments Front Wheel Hub Tightening Front wheel bearing tightness and spindle nut retention are critical component operations All service must be performed by your authorized Polaris dealer Tires AWARNING Use of non standard size or type of tires or improper tire inflation may adversely affect vehicle maneuverability and cause loss of control resulting in serious injury or death Maintain proper tire pressure as outlined in the specifications section of this manual When replacing a tire always use original equipment size and type AWARNING Operating the vehicle with worn tires will increase the possibility of skidding which could lead to loss of control and serious injury or death Always replace tires when the tread depth measures 1 8 3 cm or less Always replace tires when tread depth is worn to 1 8 3 cm or less 1 8 3 cm 85 MAINTENANCE AND LUBRICATION Adjustments Rear Drive Chain Slack CAUTION Adjusting or operating the ATV with improper rear drive chain slack can result in severe da
76. operate this vehicle have an increased risk of overturn and loss of control which could result in severe injury or death CAUTION Always keep combustible materials away from the exhaust system Exposure to the hot components could result in a fire 31 SAFETY Safety Decals and Locations Warning decals have been placed on the ATV for your protection Read and follow the instructions of the decals and other warnings on the ATV carefully If any of the decals shown in this manual differ from the decals on your ATV always read and follow the instructions of the decals on the ATV If any decal becomes illegible or comes off contact your Polaris dealer to purchase a replacement Replacement safety decals are provided by Polaris at no charge The part number is printed on the decal AWARNING eNever operate this vehicle on HILLS steeper than 25 degrees 25 To prevent flipover on hilly terrain when going up or down use throttle and brakes gradually eREVERSE operation can be dangerous even at low speeds Steering be comes difficult To prevent flipover avoid sudden braking or sharp turns eUse OVERRIDE for reverse speed limiter with caution To prevent loss of control never activate override button with open throttle ePARKING BRAKE may relax when used for more than 5 minutes When parking on grades leave shift in forward 7079085 A WARNING IMPROPER TIRE PRESSURE OR OVERLOADING can cause loss of contr
77. operating Failure to properly maintain the ATV WHAT CAN HAPPEN Poor maintenance increases the possibility of an accident or equipment damage HOW TO AVOID THE HAZARD Always inspect your ATV before each use to make sure it s in safe operating condition Always follow the inspection and maintenance procedures and schedules described in the owner s manual 4 WARNING POTENTIAL HAZARD Removing hands from the handlebars or feet from the footrests during operation WHAT CAN HAPPEN Removing even one hand or foot can reduce ability to control the vehicle or could cause loss of balance and ejection from the ATV If the operator s foot is not firmly planted on the footrest it could come into contact with the rear wheels and lead to accident or injury HOW TO AVOID THE HAZARD Always keep both hands on the handlebars and both feet on the footrests of the ATV during operation 19 SAFETY Operator Safety 4 WARNING POTENTIAL HAZARD Failure to use extra caution when operating the ATV on unfamiliar terrain WHAT CAN HAPPEN Unfamiliar terrain may contain hidden rocks bumps or holes that could cause loss of control or overturn HOW TO AVOID THE HAZARD Travel slowly and use extra caution when operating on unfamiliar terrain Always be alert to changing terrain conditions 20 SAFETY Operator Safety 4 WARNING POTENTIAL HAZARD Failure to use extra caution when operating on excessively rough
78. operly distributed and securely attached Reduce speed and follow the instructions in this manual for carrying cargo or towing Allow a greater distance for braking e Always remove the ignition key when the vehicle is not in use to prevent unauthorized use or accidental starting FOR MORE INFORMATION ABOUT ATV SAFETY call the Con sumer Product Safety Commission at 1 800 638 2772 or call Polaris at 1 800 342 3764 Equipment Modifications We are concerned for the safety of our customers and for the general public Therefore we strongly recommend that consumers do not install on a Polaris ATV any equipment that may increase the speed or power of the vehicle or make any other modifications to the vehicle for these purposes Any modifications to the original equipment of the vehicle create a substantial safety hazard and increase the risk of bodily injury The warranty on your Polaris ATV is terminated if any equipment has been added to the vehicle or if any modifications have been made to the vehicle that increase its speed or power NOTE The addition of certain accessories including but not limited to mowers blades tires sprayers or large racks may change the handling characteristics of the vehicle Use only Polaris approved accessories and familiarize yourself with their function and effect on the vehicle 11 SAFETY Operator Safety 12 4 WARNING POTENTIAL HAZARD Operating this ATV without proper instruction WHA
79. phill side or to either side if the ATV is pointed straight uphill Turn the ATV around and remount following the procedure de scribed in this manual e Always check for obstacles before operating in a new area Never attempt to operate over large obstacles such as rocks or fallen trees Always follow proper procedures when operating over obstacles as described in this manual e Always be careful of skidding or sliding On slippery surfaces like ice travel slowly and use extra caution to reduce the chance of skid ding or sliding out of control e Avoid operating the ATV through deep or fast flowing water If it s unavoidable travel slowly balance your weight carefully avoid sud den movements and maintain a slow and steady forward motion Do not make sudden turns or stops and do not make sudden throttle changes 10 SAFETY Operator Safety e Wet brakes may have reduced stopping ability Test your brakes after leaving water If necessary apply them lightly several times to allow friction to dry out the pads e Always check for obstacles or people behind the ATV before operat ing in reverse When it s safe to proceed in reverse move slowly and avoid turning at sharp angles e Always use the size and type of tires specified for your ATV and always maintain proper tire pressure e Never modify an ATV through improper installation or use of acces sories e Never exceed the stated load capacity for your ATV Cargo must be pr
80. play be sure to flip the throttle lever back and forth 3 Tighten the locknut and slide the boots over the cable adjuster until they touch at the midpoint of the adjuster 1 2 3 1 fe 82 MAINTENANCE AND LUBRICATION Adjustments AWARNING Operating your ATV with worn tires improperly inflated tires non standard tires or improperly installed tires will affect vehicle handling and could cause an accident resulting in serious injury or death Maintain proper tire pressure as described on the decal on your ATV and in your owner s manual Always use original equipment size and type when replacing tires Make sure the wheels are installed properly Always replace tires when the tread depth measures 1 8 3 cm or less Wheel Removal 1 Stop the engine place the transmission in gear and lock the parking brake Loosen the wheel nuts slightly Elevate the side of the vehicle by placing a suitable stand under the footrest frame Remove the wheel nuts and remove the wheel 83 MAINTENANCE AND LUBRICATION Adjustments Wheel Installation 1 Place the transmission in gear and lock the parking brake 2 Place the wheel on the wheel hub with the valve stem toward the outside and rotation arrows on the tire pointing toward forward rotation 3 Install the wheel nuts and finger tighten 4 Lower the vehicle to the ground 5 Torque the wheel nuts according to the wheel nut torque specificati
81. prevent battery drain 1 E DAAA 3 2 1 Transmission Neutral Indicator 2 Transmission Reverse Indicator 3 High Temp Warning This light will display if the engine overheats 38 FEATURES AND CONTROLS Brakes Check the brake fluid level in the master cylinder before each use of the ATV The master cylinder 1 is located on the left handlebar The fluid level can be seen through an indicator window 2 on the top of the master cylinder This eye will appear dark when the fluid level is full When fluid needs to be added the eye will be clear f fle gs AWARNING An over full master cylinder may cause brake drag or brake lock up which could result in serious injury or death Maintain brake fluid at the recommended level Do not overfill NOTE When checking the fluid level the ATV must be on level ground with the handlebars straight If the fluid level is low add DOT 3 brake fluid only DO NOT OVERFILL See page 108 for the part numbers of Polaris products AWARNING Never store or use a partial bottle of brake fluid Brake fluid is hygroscopic meaning it rapidly absorbs moisture from the air The moisture causes the boiling temperature of the brake fluid to drop which can lead to early brake fade and the possibility of accident or severe injury After opening a bottle of brake fluid always discard any unused portion 39 FEATURES AND CONTROLS Brake Lever The front and rear br
82. r On 4 cycle engines some engine oil will be lost if the crankcase drain is opened 95 MAINTENANCE AND LUBRICATION PVT System The basic operation of the Polaris PVT system is dependent on engine speed and vehicle torque requirements As engine speed increases the force exerted on the movable drive sheave by the flyweights also increases This in turn increases the amount of pinch applied to the drive belt Similarly if the engine speed decreases the amount of centrifugal force decreases reducing the amount of belt pinch This begins to occur at speeds of less than 5 MPH due to the system s dependence on engine speed For example when operating at a ground speed of 3 MPH the engine would be running at only about 1500 RPM with an engagement speed of about 1400 RPM Whenever operating this close to the engagement point the engine may be running at a speed too low to provide the adequate pinch needed to prevent incomplete engagement Incomplete engagement creates excessive heat that can destroy belts and clutch covers In some cases excessive clutch wear and damage may result If the ATV will be operated for extended periods below 5 MPH or for towing loads we recommend that you install a one tooth smaller counter shaft sprocket to raise the operating RPM far enough above the engagement RPM to reduce heat caused by incomplete engagement Reducing the temperature inside the clutch cover extends the life of the
83. rease Locate fitting on back side of Every 3 months or struts and grease with 50 hours grease gun 1 2 Swing Arm p Grease Locate fittings on swing arm Monthly or at 20 Bushings and grease with grease gun hours 70 MAINTENANCE AND LUBRICATION Lubrication Recommendations Premium 4 Synthetic Oil Polaris Premium 4 All Season Synthetic engine oil has been specially formulated for use in Polaris 4 cycle engines It s a fully synthetic high performance multi viscosity oil designed to provide the ultimate in lubrication performance and protection NOTE See page 108 for the part numbers of Polaris products Premium 4 possesses unsurpassed film strength over the widest possible temperature range It resists viscosity and frictional breakdown in ambient temperatures from 40 F to 120 F Its exceptional frictional properties result in more efficient operation more power output and lower fuel consumption Although Polaris Premium 4 is the only oil recommended for use in this engine use of any API certified SH oil is allowable as long as it s OW 40 Oil may need to be changed more frequently if Polaris Premium 4 is not used Follow the manufacturer s recommendations for ambient temperature operation CAUTION Mixing brands or using a non recommended oil may cause serious engine damage We recommend the use of Polaris Premium 4 All Season synthetic oil or API certified SH oil OW 40 Never substitute or
84. shift position as needed during operation It is not intended for carrying passengers 13 SAFETY Operator Safety 4 WARNING POTENTIAL HAZARD Operating an ATV on paved surfaces including sidewalks paths parking lots and driveways WHAT CAN HAPPEN ATV tires are designed for off road use Operating on paved surfaces may seriously affect the handling and control of the ATV and could result in loss of control accident and or injury HOW TO AVOID THE HAZARD Avoid operating the ATV on pavement If it s unavoidable travel slowly and avoid sudden turns or stops 14 SAFETY Operator Safety 4 WARNING 7 w SE N i POTENTIAL HAZARD Operating this ATV on public streets roads or highways WHAT CAN HAPPEN The ATV could collide with another vehicle HOW TO AVOID THE HAZARD Never operate the ATV on any public street road or highway including dirt and gravel roads In many states it s illegal to operate ATVs on public streets roads and highways 15 SAFETY Operator Safety 16 4 WARNING POTENTIAL HAZARD Operating this ATV without wearing an approved helmet eye protection and protective clothing WHAT CAN HAPPEN Operating an ATV without an approved helmet increases the risk of a severe head injury or death in the event of an accident Operating without eye protection could result in an accident and could increase the chance of a severe injury in the event of an accident HOW
85. t off the fuel supply EMISSION CONTROL SYSTEMS Noise Emission Control System Do not modify the engine intake or exhaust components as doing so may affect compliance with state and local noise level requirements Spark Arrestor Your Polaris vehicle has a spark arrestor that was tested and approved in accordance with the USDA Forest Service Standard 5100 1C Federal law requires that this spark arrestor be installed and functional when the vehicle is operated on public lands Crankcase Emission Control System This engine is equipped with a closed crankcase system Blow by gases are forced back to the combustion chamber by the intake system The system does not allow the blow by gases to enter the atmosphere Exhaust Emission Control System The emissions from the exhaust of this vehicle are controlled by engine design including factory set carburetion and ignition The engine and related components must be maintained at Polaris specifications to achieve optimal performance Adjustment to engine idle is the 1 only adjustment Polaris G A recommends that the operator on 4 eZ perform Any other adjustments AR eo 4 should be performed by an authorized Polaris dealer The emissions label 1 is located on the recoil cover 63 MAINTENANCE AND LUBRICATION Accessories Auxiliary power outlets provide 12V power for operating accessories such as hand held spot lights Accessory outlets are available for all mode
86. t thoroughly inspected Take the vehicle to your dealer before starting the engine If it s impossible to take your ATV to a dealer before starting it follow the steps outlined below 1 8 9 10 11 Move the ATV to dry land or at the very least to water below the foot rests Check the airbox for any water and dry it if water is present Turn the fuel valve off Remove the spark plug Turn the engine over several times using the electric start Loosen the carburetor drain screw 1 Dry the spark plug and reinstall or replace it with a new plug Tighten the carburetor drain screw Turn the fuel valve on Attempt to start the engine If necessary repeat the drying procedure Take the ATV to your dealer for service as soon as possible whether you succeed in starting it or not NOTE If water has been ingested into the PVT follow the procedure on page 97 for drying out the PVT 93 MAINTENANCE AND LUBRICATION Spark Arrestor 94 AWARNING Failure to heed the following warnings while servicing the spark arrestor could result in serious injury or death Do not perform service on the spark arrestor while the system is hot Exhaust system temperatures can reach 1000 F Allow components to cool sufficiently before proceeding Remove any combustible materials from the area Wear eye protection and leather work gloves Do not stand behind or in front of the vehicle while purging Never run the
87. the machine to overturn DO NOT BLOCK THE FRONT HEADLIGHT BEAM when carry ing loads on the front rack DO NOT TRAVEL FASTER THAN THE RECOMMENDED SPEEDS Vehicle should never exceed 10 mph 16 kph while towing a load on a level grass surface Vehicle speed should never exceed 5 mph 8 kph when towing loads in rough terrain while cornering or while ascending or descending a hill 51 OPERATION Driving Safely Driving Procedures 52 Sit upright with both feet on the footrests and both hands on the handlebars Start the engine and allow it to warm up then shift the transmission into gear Check your surroundings and determine your path of travel Release the parking brake Slowly depress the throttle with your right thumb and begin driving Vehicle speed is controlled by the amount of throttle opening Drive slowly Practice maneuvering and using the throttle and brakes on level surfaces OPERATION Driving Safely Making Turns Your Polaris ATV is equipped with a solid rear axle that drives both rear wheels equally at all times This means that the wheel on the outside of the turn must travel a greater distance than the inside wheel when turning and the inside tire must slip traction slightly To make a turn steer in the direction of the turn leaning your upper body to the inside of the turn while supporting your weight on the outer footrest This technique alters the balance of traction between the rear wheels
88. ual Always check the terrain carefully before ascending any hill Never operate the ATV on hills steeper than 25 Never climb hills with excessively slippery or loose surfaces Shift your weight forward Never open the throttle suddenly while traveling uphill The ATV could flip over backwards Never go over the top of any hill at high speed An obstacle a sharp drop or another vehicle or person could be on the other side of the hill 23 SAFETY Operator Safety 24 4 WARNING POTENTIAL HAZARD Traveling downhill improperly WHAT CAN HAPPEN Improperly descending a hill could cause loss of control or overturn HOW TO AVOID THE HAZARD Always follow proper procedures for traveling down hills as described in the owner s manual NOTE A special technique is required when braking while traveling downhill See page 57 Always check the terrain carefully before you descending a hill Shift your weight backward Never travel down a hill at high speed Avoid traveling down a hill at an angle which would cause the vehicle to lean sharply to one side Travel straight down the hill when possible SAFETY Operator Safety 4 WARNING POTENTIAL HAZARD Improperly crossing hills and turning on hills WHAT CAN HAPPEN Improperly crossing or turning as hills could cause loss of control or overturn HOW TO AVOID THE HAZARD Never attempt to turn the ATV around on any hill until you ve mastered the turning tech
89. ule Hours of operation are based on a 10 mph average If service is due at 20 hours the equivalent odometer reading would be 200 miles Perform all services at whichever reading is reached first AWARNING Improperly performing the procedures marked with a m could result in component failure and lead to serious injury or death Have an authorized Polaris dealer perform these services Hours Frequency Miles Tres Preige a mee PreRige Preide Inspect Frame nuts bolts Pre Ride Pre Ride Inspect fasteners p gt Air filter Pre Ride Pre Ride Inspect clean Pre cleaner ia Fuel and oil tanks Fill to proper levels xz Engine stop switch Check operation Steering Check for free operation fee box sediment Pre Ride Pre Ride Drain deposits whenever tube visible Headlamp Pre Ride Pre Ride Check operation daily ap ply Polaris dielectric grease to connector when replaced p More often under severe use such as dirty or wet conditions K Emission Control System Service California E Dealer service item 65 MAINTENANCE AND LUBRICATION Periodic Maintenance Schedule AWARNING Improperly performing the procedures marked with a m could result in component failure and lead to serious injury or death Have an authorized Polaris dealer perform these services Hours Frequency Miles Taillight brakelight Pre Ride Pre Ride Check operation daily ap ply Polaris dielectric grease to socket when replac
90. uver that can be used when it s necessary to turn around while climbing a hill is the K turn 1 Stop and lock the parking brake while keeping body weight uphill 2 Leave transmission in forward and shut off the engine 3 Dismount on the uphill side of the vehicle or on the left if the vehicle is pointing straight uphill 4 Staying uphill of the vehicle turn the handlebars full left 5 While holding the brake lever release the parking brake lock and slowly allow the vehicle to roll around to your right until it s pointing across the hill or slightly downward 6 Lock the parking brake and remount the vehicle from the uphill side keeping body weight uphill 7 Restart the engine with the transmission still in forward 8 Release the parking brake and proceed slowly controlling speed with the brake until the vehicle is on more level ground 58 OPERATION Driving Safely Driving Through Water Your ATV can operate through water with a maximum recommended depth equal to the bottom of the footrests 1 Follow these procedures when operating through water 1 Determine water depths and current before crossing 2 Choose a crossing where both banks have gradual inclines 3 Proceed slowly avoiding rocks and obstacles if possible 4 After crossing dry the brakes by applying light pressure to the lever until braking action is normal After running the vehicle in water it s critical to have it service

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