Polaris 7174820 manual

1 WELC OME Thank you for purcha sing a Polaris ve hicle, and we lcome to our world-w ide family of Polaris owne rs. W e proudly produce a n exciting line of utility a nd re cre ationa l products. S Snowmobiles S All-te rra in vehic les (A TVs) S RANGER utility vehicle s S V ict ory m ot orcy cles W e belie ve Polaris sets a standa rd of exce llenc [...]

2 Copyri ght 2007 Pol a ri s Sa les Inc . All infor mati on c onta ine d withi n thi s public ati on is bas ed on t he la t es t produc t inf orm at ion at t he ti me of public a ti on. Due to cons tant imp ro vem ents in the desig n an d q uality o f pr oduct ion compone nts, s ome mi nor discrep an cies may result betw een th e actual vehicle and[...]

3 TABLE OF CONTENTS VEHICLE IDENTI FICA TION NUMBERS 5 ....... SA FETY 6 ................................... FEA TURES AND CONTROL S 30 ............... OPER A TION 40 .............................. EMISSI ON CONTRO L SYSTEMS 57 ............ MAINTENANCE AND LUBRICA TION 58 ........ SPECIF ICA TIO NS 10 3 ........................ POLARIS PRODUCTS 106[...]

4[...]

5 VEHICLE IDE NTIFICATION NUMBERS Recor d your A TV’ s identifica tion numbers a nd key number in the spaces prov id ed. R em ove t he s pare key and s tore i t in a s afe pl ace. An ignition key c an be duplic ated only by or der ing a Polaris ke y blank (using your ke y number) and mating it with one of your existing ke ys. The ignition switch [...]

6 SAFE TY Operator S afety W ARNING Failur e to f ollow the war nings cont ained in t his manual c an result in serious injury or deat h. A Polar is A T V is not a t oy and can be haz ardous t o operat e. T his vehicle handles different ly t han other vehicles , s uch as motorcycles and cars. A collision o r rollover c an occur quickly , even durin[...]

7 SAFE TY Operator S afety The following signa l words and symbols appe ar thr oughout this manual a nd on your A TV . Y our safe ty is involved whe n these words and symbols are use d. B ec ome familia r with their mea nings before rea ding the manual. The safety aler t sy mbol , on your v ehicle or in t his m anual, aler ts you to t he pot ential[...]

8 SAFE TY Operator S afety W ARNING Serious injury or deat h can r esult if y ou do not f ollow t hese instr uct ions and proc edures, which ar e outlined in f urt her det ail within your owner ’s manual. S Read this ma nual and a ll labels ca re fully , and follow the oper ating proce dures desc ribed. S Never ope rate a n A TV without proper in[...]

9 SAFE TY Operator S afety S Always hav e the A TV ins pect ed by an aut ho rized P ol ari s deal er if it’ s been i nvolved i n an accident. S Neve r opera te on hills too steep for the A TV or for your abilitie s. Pra ctice o n smaller hills bef ore a ttempting lar ger hills. S Always f ollow prope r proc edure s for c limbing hills. Check the [...]

10 SAFE TY Operator S afety S W et bra kes may ha ve reduc ed stopping a bility . T est your bra kes af ter lea ving wate r . If ne cessa ry , apply them lightly se vera l times to allow frict ion t o dry o ut t he pads . S Always chec k for obstacles or people be hind the A TV befor e operat- ing i n revers e. Wh en it ’ s safe to p roceed i n r[...]

11 SAFE TY Operator S afety W ARNING POTENTI AL HAZA RD Oper ating t his A T V wit hout proper inst ruc tion. WHA T C AN HAPPEN The r isk of an accident is gr eatly increas ed if t he operat or does not know how to operat e t he A T V proper ly in differ ent s ituat ions and on different ty pes of ter rain. HOW TO A VOID THE HAZ ARD Beginning and i[...]

12 SAFE TY Operator S afety W ARNING POTENTI AL HAZA RD Carry ing a passenger on an AT V. WHA T C AN HAPPEN Carry ing a passenger great ly reduces t he operat or ’s ability to balance and contr ol t he A TV , which could caus e an accident and injury t o the operat or and/or pass enger . HOW TO A VOID THE HAZ ARD Never c arry a passenger. The pur[...]

13 SAFE TY Operator S afety W ARNING POTENTI AL HAZA RD Oper ating t his A T V on public str eets , roads or highways. WHA T C AN HAPPEN The A T V c ould collide with anot her vehic le. HOW TO A VOID THE HAZ ARD Never oper ate t he A T V on any public st reet , r oad or highway , including dirt and gravel r oads. I n many st ates it’s illegal to [...]

14 SAFE TY Operator S afety W ARNING POTENTI AL HAZA RD Oper ating t he A T V af ter consuming alcohol or dr ugs. WHA T C AN HAPPEN Consumpt ion of alc ohol and/or drugs could ser iously aff ect operator judgment . Reac tion t ime m ay be slower and operat or balance and per cept ion could be affec ted. Consuming alc ohol and/or drugs bef ore or wh[...]

15 SAFE TY Operator S afety W ARNING POTENTI AL HAZA RD Att empt ing wheelies, jumps and other stunt s. WHA T C AN HAPPEN Att empt ing st unt s incr eases the c hance of an ac cident , including an over tur n. HOW TO A VOID THE HAZA RD Never att empt wheelies, jumps, or ot her st unt s. Avoid exhibiti on driving. W ARNING POTENTI AL HAZA RD Failur [...]

16 SAFE TY Operator S afety W ARNING POTENTI AL HAZA RD Removing hands from the handlebar s or f eet fr om t he foot res ts during operat ion. WHA T C AN HAPPEN Removing ev en one hand or f oot c an reduce abilit y t o cont rol t he vehicle or could cause los s of balance and eject ion f rom t he A T V . If t he operator ’s foot is not firm ly pl[...]

17 SAFE TY Operator S afety W ARNING POTENTI AL HAZA RD Failu re to use extra caution w hen operat ing on exces sively r ough, slippery or loose t errain. WHA T C AN HAPPEN Operatin g on excessi vely rough, s lippery or loose terr ain could caus e loss of tr acti on or loss of cont rol, which could r esult in an accident or overt urn. HOW TO A VOID[...]

18 SAFE TY Operator S afety W ARNING POTENTI AL HAZA RD Operat ing on exc essiv ely st eep hills. WHA T C AN HAPPEN The v ehicle may overt urn. HOW TO A VOID THE HAZ ARD Never oper ate on hills t oo st eep f or t he A TV or f or your abilities . Never oper ate t he A T V on hills s teeper than 25 _ . Pract ice on s maller hills befor e att empt ing[...]

19 SAFE TY Operator S afety W ARNING POTENTI AL HAZA RD T raveling downhill improper ly . WHA T C AN HAPPEN Impr operly descending a hill could caus e loss of cont rol or overt urn. HOW TO A VOID THE HAZA RD Always f ollow proper procedur es for t rav eling down hills as des cribed in the owner ’s manual. NO T E: A special technique is required w[...]

20 SAFE TY Operator S afety W ARNING POTENTI AL HAZA RD Impr operly c rossi ng hills and turning on hills . WHA T C AN HAPPEN Im properly cross ing or turning as hills could c ause loss of cont rol or ov ert urn. HOW TO A VOID THE HAZA RD N e v e ra t t e m p tt ot u r nt h e A TV around on any hill unt il you’ve m aster ed the t urning tec hniqu[...]

21 SAFE TY Operator S afety W ARNING POTENTI AL HAZA RD Stalling, rolling bac kwards or improper ly dismount ing while climbing a hill. WHA T C AN HAPPEN The v ehicle could ov ertur n. HOW TO A VOID THE HAZA RD Maint ain steady speed when climbing a hill. If all for ward speed is lost: Keep your weight uphill. Apply t he single lev er brak e gradua[...]

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

23 SAFE TY Operator S afety W ARNING POTENTI AL HAZA RD Oper ating t he A T V t hrough deep or f ast -f lowing water. WHA T C AN HAPPEN T ires may f loat , caus ing loss of tr act ion and loss of cont rol, whic h could lead t o an accident or over tur n. HOW TO A VOID THE HAZ ARD Avoid operating t he A T V t hrough deep or f ast -f lowing wat er . [...]

24 SAFE TY Operator S afety W ARNING POTENTI AL HAZA RD Oper ating t he A T V wit h improper modifi cati ons. WHA T C AN HAPPEN Im proper ins tallat ion of ac cess ories or modif icat ion of t he A T V may c ause changes in handling which could lead t o an accident . HOW TO A VOID THE HAZ ARD Never m odify the A T V t hrough im proper ins tallat io[...]

25 SAFE TY Operator S afety W ARNING Leaving the k eys in t he ignit ion can lead t o unauthor ized use of the vehic le result ing in ser ious injury or deat h. Alway s rem ove the ignit ion key when the vehic le is not in use. W ARNING Aft er any overt urn or accident , have a qualif ied serv ice dealer inspect the ent ire v ehicle f or poss ible [...]

1 2 3 26 SAFE TY Safety D ecals and Locations W arning decal s have been placed on t he A TV for your protect ion. R ead and fol lo w th e ins tru cti ons o f the decal s and o th er warni ngs o n th e A TV carefull y . If any o f th e decals sh own i n t hi s m anual di ffer from the decals o n your A TV , always read and fol low the in struct ion[...]

27 SAFE TY Safety D ecals and Locations Gener al W ar ning (3) W ARNING Impr oper A TV use can result i n SEVERE INJUR Y or DEA TH AL W A YS USE AN APPROVED HELMET AND PROTECTIVE GEAR NEVER USE ON PUBLIC ROADS NEVER CARRY P ASSENGERS NEVER USE WITH DRUGS OR ALCOHOL NEVER operat e: S wit hout proper t rai ning or inst ruct ion S at speeds too fast f[...]

6 7 5 4 4 28 SAFE TY Safety D ecals and Locations Rack W arning (4) W ARNING S DO NOT TOW FROM RACK OR BUMPER. V ehicle damage or ti pover may result causi ng severe inj ury or death. T ow only fr om tow hooks or hit ch. S Max Rack Loads: Front 75 lbs. ( 34 kg) Rear 125 l bs. ( 57 kg) A g e1 6W a r n i n g( 5 ) W ARNING Operat ing t his A TV if you[...]

29 SAFE TY Safe R iding Gear Always wea r clothing suited to the t ype of r iding. A TV riding requir es specia l protective c lothing for comfort and to reduc e the chanc e of injury . 1. Helmet W eari ng a h elm et can prev ent a s evere h ead injury . Whene ver riding a Pola ris vehicle , always wear a hel met th at m eets or exceed s esta blish[...]

30 FEATURES AND CONTROLS Electr ical Switches W ARNING Act ivat ing the ov erride s witc h while the t hrot t le is open can c ause loss of cont rol, result ing in sev ere injury or death. Do not ac tiv ate the over ride swit ch while t he t hrot tle is open. Overri d e S witch (1) (Rever se Spee d Limiter) - This vehicle is equipped with a re vers[...]

31 FEATURES AND CONTROLS W ARNING Do not st art or oper ate an A T V wit h st ick ing or impr operly operat ing throt t le cont rols, which c ould cause an ac cident and lead to sev ere injur y or deat h. Always cont act your dealer f or ser vice repair s if t hrot tle problem s arise. Failur e to chec k or m aintain pr oper oper ation of the t hro[...]

32 FEATURES AND CONTROLS W ARNING Oper ating t he A T V on st reet s or r oads, especially in darknes s, could res ult in an ac cident and s erious injur y or deat h. Y our A TV is not equipped with highway- approv ed lights. It ’s designed f or and mus t be us ed for off -road use only . Use caution and drive at reduced s peeds in condit ions of[...]

33 FEATURES AND CONTROLS Br akes Ch eck the brak e flui d l evel i n th e mas ter cy li nd er before each use o f th e A TV . The master cylinde r (1) is locat ed on t he l eft han dl ebar . The fluid le vel ca n be see n through an indicator window (2) o n the top of the mas ter cy li nd er . Th is “eye” wi ll appea r dar k when the fluid leve[...]

34 FEATURES AND CONTROLS Br ake Lever The fro nt an d rear b rakes are appl ied by squ eezin g th e brak e lever (1 ) to ward t he hand leb ar . Th e front and rear brak es are hydraulic ally ac tivated disc type bra kes that are acti vat ed by o nl y one lev er . Always t est b rake lever t ravel and m ast er cylinder fl uid l evel before ri di ng[...]

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

36 FEATURES AND CONTROLS Choke The choke assists in starting a co ld engine. Refe r to the engine star ting proce dure on page 42 for cor rec t choke and throttle settings during starting. Fuel V alve The fu el v alve (1 ) i s l ocat ed on th e left si de of the vehic le, either below the fe nder or on the side panel. I t has three positions: OFF: [...]

37 FEATURES AND CONTROLS Fuel Safety W ARNING Gasoline is highly f lammable and ex plosive under cert ain conditi ons. S Always ex ercis e ext reme c aution whenev er handling gasoline. S Always r efuel wit h t he engine st opped, and out doors or in a well ventilat ed area. S Do not sm oke or allow open f lames or spar ks in or near t he area wher[...]

38 FEATURES AND CONTROLS Automatic T ransmission Gear Se lector The transmission gea r sele ctor (1) is located on the right side of the A TV . F: For wa rd N: Neutral R: Rev ers e CAUTION Shift ing gears with t he engine speed abov e idle or while t he vehicle is m oving c ould cause t ransm iss ion damage. T o change gears , s top t he vehic le, [...]

1 2 39 FEATURES AND CONTROLS Recoil Star ter If the batte ry is too we ak to start the engine , use the reco il starte r (1). Follow the starting proce dures on page 42, cra nking the engine with the recoil st art er in st ead of t he main ke y switch. 1. Grasp t he recoi l st arter rope handle ( 2) tightly . 2. Pull slowly so you ca n fee l the en[...]

40 OPERATION Br eak-In Per iod The bre ak-in pe riod for your new Pola ris A TV is defined a s the fir st ten hours of opera tion, or the time it takes to use the first two full tanks of gasoline. No single action o n your part is as impor tant as following the proce dures for a prope r brea k-in. C are ful treatme nt of a new engine and drive c om[...]

41 OPERATION Pr e -Ride Inspection W ARNING If a proper ins pect ion is not done befor e each use, sev ere injury or deat h could res ult. A lways ins pect the v ehicle bef ore each us e to ens ure it ’s in proper operat ing condit ion. Pre - Ride Che ck lis t Item Remarks See Page Brake syst em / br ake lever tr avel Ensure proper oper ati on 34[...]

42 OPERATION Star ting the E ngine W ARNING Engine exhaus t cont ains pois onous car bon monoxide and c an cause los s of c onscious ness r esult ing in sever e injury or death. Never r un an engine in an enclosed ar ea. 1. Position the vehic le on a level surface. 2. Pla ce the transmission in neutr al. 3. Loc k the par king brake. NOT E: T he st [...]

43 OPERATION Star ting the E ngine 7. Move the e ngine stop switch to RUN. NOT E: Do not press the t hrot tl e while star ti ng the engine. 8. T urn the ignition key past the ON position to enga ge the sta rter . Activate the sta rter for a ma ximum of five seconds, relea sing the key when the engine sta rts. 9. I f the engine does not start, relea[...]

44 OPERATION Hauling Cargo Y our A TV ha s been de signed to car ry or tow a cer tain amount of loa d. Always re ad and unde rstand the load distribution w arning labe ls on the vehi cl e, and n ever exceed t he wei ght capac ities outlined in the speci fi cati ons sect io n of t he owner ’ s m anu al and on t he safet y decal s. Car go we ight s[...]

45 OPERATION Hauling Cargo W ARNING Hauling cargo im properly c an alter vehicle handling and m ay cause los s of c ontr ol or brak e inst ability and result in ser ious injury or deat h. Always f ollow thes e precaut ions when hauling cargo: S REDUCE SPEED AN D ALLOW GREA T ER DIST ANCE FO R BRAKING WHEN H AULING CAR GO. S CARGO W EI GHT DI STRI B[...]

46 OPERATION Driving Safely Driving Pr ocedu res 1. Sit upright with both feet on the footrests and both hands on the handleba rs. 2. Star t the engine and allow it to war m up, then shift the transmission into gea r . 3. Che ck your surr oundings and dete rmine your pa th of tra vel. 4. Re lease the par king brake. 5. Slowly de press the throttle [...]

47 OPERATION Driving Safely T urning the V ehicl e Y our Polaris A TV is equipped w ith a solid re ar a xle that dr ives both rea r wh eels e qually a t all times. Th is means that the whe el on the outside of the turn must travel a grea ter distanc e than the inside whee l whe n turning and the inside tire must slip trac tion slightly . T o make a[...]

48 OPERATION Driving Safely Driving on Slippery S urfaces Whenev er ridi ng o n sl ipp ery su rfaces such as wet t rail s or lo os e gravel, or duri ng freezi ng weat her , fol l ow th ese precaut i ons : 1. Slow down whe n enter ing slippery ar eas. 2. Mai nt ain a h ig h level of al ert nes s, read in g the t rai l and av oi di ng qui ck, sh arp [...]

49 OPERATION Driving Safely Driving Uphill Whe neve r trav eling uphill, follow thes e precau ti on s: 1. A lways tr avel str aight uphill. 2. A void steep hills ( 25 _ maximum) . 3. Ke ep both fe et on the footr ests. 4. T ransf er your weight forwa rd. 5. Pro ceed at a st eady rate o f speed a nd throttle ope ning. 6. Rem ain al ert and b e prepa[...]

50 OPERATION Driving Safely Sidehilling W ARNING Impr operly c ross ing hills or t urning on hills can res ult in los s of contr ol or v ehicle over tur n, r esulting i n sever e injury or deat h. Avoid cross ing the s ide of a hill when pos sible. F ollow proper procedur es as out lined in the owner ’s manual. Sidehilling can be a dange rous typ[...]

51 OPERATION Driving Safely Driving Downhill Whe never de scending a hill, follow these pr ecauti ons : 1. Pro ceed di rectl y do wnh ill. 2. T ra nsfer your we ight to the rear of the ve hicle . 3. Slow down. 4. Apply the brake s slightly to aid in slowing, using the single brake leve r . NOT E: F amiliariz e yours elf wit h operat ion of the aux [...]

8’ (2. 4 m) 52 OPERATION Driving Safely T urning A round on a Hill If the ve hicle stalls while c limbing a hill, never ba ck it down the hill! Use the K-tur n to turn around. 1. Stop and loc k the park ing brake w hile kee ping body weight uphill. 2. Le ave the transmission in f orwa rd and shut of f the e ngine. 3. Dismount on the uphill side o[...]

53 OPERATION Driving Safely Dr iving Thr ough W ater Y our A TV can ope rate through wate r with a maximum re comme nded depth equa l to the bottom of the footre sts (1). Follow thes e pro cedures when opera ting through water : 1. D eter mine wate r depths and c urrent befor e crossing. 2. Choose a cr ossing where both banks have gradua l inclines[...]

54 OPERATION Driving Safely Driving Over Obstacles Be alert ! Loo k ahead and l earn t o read th e terrain y ou’re t ravel in g on. Be con st ant ly al ert for hazard s su ch as lo gs , ro cks and l ow h angi ng branch es. W ARNING Severe injur y or deat h can r esult if y our vehic le comes in cont act with a hidden obst acle. Not all obs tac le[...]

55 OPERATION Driving Safely Driving in Rever se Fo ll ow th ese precau ti ons when op erati ng i n revers e: 1. Alwa ys avoid back ing downhill. 2. Ba ck slowly . 3. When in rev erse, apply the brake s lightly for stopping. 4. A void turning at sharp an gl es in reverse. 5. Ne ver open the throttle sudde nly while bac king. W ARNING Failur e to use[...]

56 OPERATION Driving Safely P a r k i n go na nI n c l i n e A void pa rking on an inc line if possible. I f it’ s unavoidable, follow thes e precau ti on s: 1. T urn the engine of f. 1. Plac e the transmission in gea r . 2. Set the parking bra ke. 3. Alwa ys block the rear whee ls on t he downhill side. See illustration. 4. Shut of f the fuel su[...]

57 EMISSION C ONT RO L SYST EMS Noise Em ission C ontrol System Do not modify the engine, intake o r exhaust components, as doing so may af fect complianc e with U.S. A. EP A noise control re quireme nts (40 CFR 205) and loca l noise le vel re quireme nts. Operation on Public Land s in the U.S .A. Y our Polaris veh icle ha s a spar k arr estor tha [...]

58 MAINTENANCE AND LUBRICATION Per iodic Maintenance Char t Care ful periodic mainte nance will help kee p your vehicle in the safe st, most relia ble condition. I nspection, ad justment and lubric ation of important compone nts are expla ined in the periodic maintena nce cha rt. Insp ect, cl ean, l ub ricat e, adj us t and replace parts as necess [...]

59 MAINTENANCE AND LUBRICATION Per iodic Maintenance Char t Maintenanc e Char t Key " Perfo rm t hese p roced ures m ore freq uent ly for veh icl es s ubj ect ed to sever e use. E Emission-re late d service ( Failure to conduc t this maintenanc e will not void the emissions warrant y but may a f fec t emissions.) J Have an au th ori zed P ol a[...]

60 MAINTENANCE AND LUBRICATION Per iodic Maintenance Char t Perfo rm all s ervices at wh ich ever main ten ance int erval i s reached firs t. Item Maintenance I nter val (whic hev er c omes fir s t) Remarks Hours Calendar Miles (Km) J Steering -- P re-R ide -- Mak e adjustments as need- e d S e e P r e R i d e C h e c k l i s t " Front s us pe[...]

61 MAINTENANCE AND LUBRICATION Per iodic Maintenance Char t Item Maintenance I nter val (whic hev er c omes fir s t) Remarks Hours Calendar Miles (Km) Carbur etor float bowl 50 H 6M 500 (800) Drain bowl per iodically and prior to s tor age J E Throttle C able/ ETC Switch 50 H 6M 500 (800) Inspec t; adjus t; lubric ate; replac e if nec ess ar y J E [...]

62 MAINTENANCE AND LUBRICATION Per iodic Maintenance Char t Item Maintenance I nter val (whic hev er c omes fir s t) Remarks Hours Calendar Miles (Km) J Clutc hes (driv e and driv en) 100 H 12 M 1000 (1600) Ins pect ; c lean; replac e wor n parts J Front w heel bearings 100 H 12 M 1000 (1600) Ins pect ; replac e as needed J Brak e fluid 200 H 24 M [...]

63 MAINTENANCE AND LUBRICATION Lubricati on Recom m endations Chec k and lubric ate a ll components a t the interva ls outlined in the Periodic Mainte nance Cha rt beginning on page 60. Items not listed in the char t should be lubricate d at the Genera l Lubrication inter val. NOT E: T he a-arm s and lower c ontr ol arms are lubric ated at t he fac[...]

64 MAINTENANCE AND LUBRICATION Engi ne Oil Always che ck and cha nge the engine oil at the interva ls outlined in the Peri od ic M ain ten ance C hart b egi nning on page 58. Always change the oil filter whe never c hanging oil. Pr emium 4 S ynth etic Oil Polaris Pre mium 4 All Season Synthetic e ngine oil has bee n spec ially formula ted f or use [...]

65 MAINTENANCE AND LUBRICATION Engi ne Oil Oil and Filter Chang e 1. Position the vehic le on a level surf ace. 2. Clea n the area a round the drain plug. 3. Run the e ngine for two to three minute s until warm. Stop the engine. CAUTION Contact wit h hot oil may result in serious burns. Do not allow hot oil to c ome int o contac t wit h sk in. 4. P[...]

66 MAINTENANCE AND LUBRICATION T ransmission Oil Oil Check The tra nsmission dipstick (1) is locate d on the right side of the mach in e near t he recoi l hand le. Check and cha nge the lubricant at the inte rvals outline d in the Peri od ic M ain ten ance C hart beginning on page 60. NOT E: We recomme nd the use of Pola ris Premiu m AGL Synt hetic[...]

67 MAINTENANCE AND LUBRICATION T ransmission Oil Oil Chang e 1. Pl ace a drain pan b eneat h th e tran smission oil drain plug area. 2. Loose n the jam nut ( A). 3. T urn the a djuster bolt (B) in to allow the remova l of the drain plug (C). 4. Re move the drain plug and wipe the magne tic end cle an to remov e accum ul ated met a llic filings. 5. [...]

68 MAINTENANCE AND LUBRICATION Br akes The front and re ar brake s are hydra ulic disc brake s, activate d by moving the single brake leve r toward the handleba r . The se brakes ar e self- adjusting. The fo ll owi ng ch ecks are reco mm end ed to keep t he b rake s yst em i n good opera ting condition. Chec k more of ten if bra kes ar e used he av[...]

69 MAINTENANCE AND LUBRICATION Br akes 2. Ch eck th e brak e sys tem for f lui d l eaks . 3. Ch eck t he brak es fo r exces si ve t ravel or spongy fee l. 4. Check t he fri cti on pad s for wear , damage a nd looseness. 5. Ch eck the s ecurit y and s urface condition of the disc. NOT E: Pads should be changed when worn t o 3/64 ″ (.1 cm). Auxilia[...]

A B 70 MAINTENANCE AND LUBRICATION T oe Al ignm ent W ARNING Sever e injury or deat h can r esult fr om impr oper t oe alignment and adjustm ent. Do not at t empt to adjust t ie rod alignment . A ll tie r od adjustm ents should be perf orm ed by an aut horized P olaris dealer. Use the following proce dure to check the toe alignme nt of t he vehicle[...]

71 MAINTENANCE AND LUBRICATION Side P anel R emoval NOT E: Side panel r emoval m ay be diffic ult unt il t he locking t abs and receiv ers hav e been snapped and unsnapped a f ew t imes. 1. Re move the seat. 2. Grasp t he rear o f th e si de pan el near t he rear cab . W it h a q ui ck and f irm motion, pull the pane l forward and ou tward t o dise[...]

72 MAINTENANCE AND LUBRICATION Cam ber and C aster The cambe r and caste r are non- adjustable . Rear S pring The rea r shock absorbe r spring is adjuste d by rotating the adjuste r (1) either c lockwise or counte rclockwise to increas e or d ecrease s pri ng tens i on. NOT E: Accessory sprin gs are available thr ough your Polaris dealer. W ARNING [...]

73 MAINTENANCE AND LUBRICATION Car bur etor IMPOR T ANT : Y our Pola ris A TV is calibr ated a t the fa ctory for optimal per forma nce a t altitudes ra nging from z ero to 6,000 fee t (1800 m) and te mperatur es of +40 degr ees F . (4 degree s C. ) or highe r . Above 6000 fee t (1800 m) the e ngine air /fuel mixture become s overly r ich and the e[...]

1 2 3 74 MAINTENANCE AND LUBRICATION Throttl e Cable Fr eeplay Throttle c able f ree play is adjusted at the handle bar . 1. L ocate the thr ottle ca ble adj ust er on th e handleba r . 2. Squeeze the e nd of t he rubber boot (1) a nd slide it f ar enough to expose the end of the inline cab le adjuster ( 2). 3. Loose n the locknut (3). 4. Rota te t[...]

75 MAINTENANCE AND LUBRICATION Wheels W ARNING Operat ing your A T V with wor n tir es, improper ly inf lated t ires , non-st andard tir es or improper ly inst alled tires will affec t vehic le handling and could caus e an accident result ing in ser ious injury or death. Maint ain proper t ire pr essur e as desc ribed on t he decal on your A TV and[...]

76 MAINTENANCE AND LUBRICATION Wheels Wheel Installation 1. Plac e the tr ansmission in gea r and lock the parking br ake. W ARNING Im properly ins talled wheels can adver sely aff ect tir e wear and vehicle handling, which can r esult in serious injury or death. Always ens ure t hat all nut s ar e tor qued to s pecif icat ion. Do not serv ice axle[...]

77 MAINTENANCE AND LUBRICATION Wheels Front W heel Hub T ighteni ng Front wheel be aring tightne ss and spindle nut re tention ar e cr itical component ope rations. A ll servic e must be pe rfor med by your auth ori zed P ol aris d ealer . Tire s W ARNING Use of non- st andard siz e or t ype of tir es or im proper t ire inf lat ion may adver sely a[...]

78 MAINTENANCE AND LUBRICATION Rear Drive C hain Slack CAUTION Adjust ing or operat ing t he A T V with i mproper r ear driv e chain slack c an result in sev ere damage t o t he tr ansmis sion and driv e component s. Always make s ure t he slack is within t he st at ed specif icat ions. Check the amount of c hain slac k in three dif fer ent loca ti[...]

79 MAINTENANCE AND LUBRICATION Rear Drive C hain Slack 6. Rol l t he A TV forward o r backward to adjust the c hain sla ck to the proper te nsion. See the illustration for prope r splice link clip ope ning position (1). 7. T igh ten th e eccent ric l ock in g bo lt s to 30 ft. lbs. (41 Nm) for mac hines without the hitch a nd 45 ft. lbs. (61 Nm) fo[...]

80 MAINTENANCE AND LUBRICATION Drive Chain Polaris A TV drive chains are e quipped with o-ring-se aled, perma nently greased pi ns an d ro ll ers. Howev er , t he o uter surfaces of t he ro ll er mu st be lubrica ted. Always inspec t the drive c hain prior to ope rating the ve hicle. Check f or damage d or missing o-r ings or damage d roller s. Als[...]

81 MAINTENANCE AND LUBRICATION Air Filter 1. Rem ov e th e seat , r eleas e th e cli ps , and remove the a ir box cover . 2. Loose n the cla mp and re move the filte r . 3. Re move the fab ric type pre- filter (1) f rom the main filte r (2). W ash the pre -filte r in soapy w ater , then rinse and let dry . 4. Re install the pre-f ilter over the mai[...]

82 MAINTENANCE AND LUBRICATION Lights Whe n servic ing a haloge n lamp, don’t touch the lamp with bar e finger s. Oil from your skin leave s a r esidue, ca using a hot spot tha t will shorten the life of the la mp. W ARNING Poor light ing while driv ing can result in sev ere injury or deat h. Headlight and t aillight lens es becom e dirt y during[...]

83 MAINTENANCE AND LUBRICATION Lights T aillig ht/Brakelight Lamp Replacement If the taillight/bra kelight does not wor k the lamp may ne ed to be replaced . 1. Re move the taillight lens cover mounting scre ws. Remove the lens cove r and ga sket and set aside for r easse mbly . 2. Re move the lamp (1). 3. Apply diele ctric gr ease to the sock et a[...]

84 MAINTENANCE AND LUBRICATION Spar k Pl ugs Spar k Plug Recom mendations CAUTION Using non-r ecomm ended spark plugs can res ult in s erious engine damage. A lways us e Polaris -rec ommended s park plugs . See Specif icat ions beginning on page 103. Refer to the spec ifications sec tion beginning on pa ge 103 for the rec ommended spa rk plug type [...]

85 MAINTENANCE AND LUBRICATION Spar k Pl ugs Spark P lug Insp ection Normal Plug The normal insulator tip is gray , tan or light brown. There will be few combustion deposits. The e lectrode s are not burned or erode d. This indicate s the proper type and heat ra nge for the engine and the ser vice. NOT E: T he tip s hould not be whit e. A white ins[...]

86 MAINTENANCE AND LUBRICATION V eh icle I mmers io n CAUTION If your v ehicle becom es imm ersed, major engine damage can result if t he mac hine is not thor oughly inspec ted. T ake t he vehicle t o your dealer befor e st art ing the engine. If it’ s impossible to take your A TV to a dealer be fore sta rting it, follow the steps outlined below [...]

87 MAINTENANCE AND LUBRICATION Spar k Ar restor W ARNING Failur e to heed t he following war nings while ser vicing t he spar k arres tor c ould result in serious injury or death. Do no t perform service on the spa rk arrestor whil e the system is hot. Exhaust system t em peratures ca n reach 1000 ° F . Allow component s t o cool suff icient ly be[...]

88 MAINTENANCE AND LUBRICATION PV T System The basic oper ation of the Polaris PVT system is dependent on engine speed and v ehi cle t orq ue requ irem ent s. As en gi ne sp eed i ncreas es, th e forc e exer ted on the m ovable drive she ave by the flyweights also incre ases. This, in turn, incre ase s the amount of “ pinch” a pplied to the dri[...]

89 MAINTENANCE AND LUBRICATION PV T System W ARNING Failure t o com ply wit h the ins tr uct ions in t his warning can r esult in sever e injury or deat h. Do not modify any component of th e PVT syst em. Doing so may reduce it s s tr ength so t hat a failur e may oc cur at a high speed. The PVT syst em has been precisio n balanced. Any modif icati[...]

90 MAINTENANCE AND LUBRICATION Batter y Y our A TV ma y have e ither a seale d batte ry , which r equire s little maintena nce , or a conventiona l batte ry . A sea led batte ry c an be identifie d by its flat c overs on the top of the ba ttery . A conventional batte ry has six fille r ca ps on the top of the batte ry . Conventi onal Batter y Alway[...]

91 MAINTENANCE AND LUBRICATION Batter y W ARNING Im properly c onnect ing or disc onnect ing batt ery cables c an result in an explosion and c ause ser ious injury or death. W hen remov ing the bat ter y , always dis connect the negat ive ( black) cable fir st . W hen reins talling t he bat ter y , alway s connec t t he negative ( black) cable last[...]

92 MAINTENANCE AND LUBRICATION Batter y Battery Installation Using a new batter y that has not bee n fully ch ar ged c an dama ge the batt ery and res ul t i n a shor ter li fe. It can al so hi nd er vehi cle perf ormanc e. Follow the batter y char ging instructions on page s 94-96 befo re installing the batte ry . 1. E nsure that the batte ry is f[...]

93 MAINTENANCE AND LUBRICATION Batter y Batter y Stor age Whe never the ve hicle is not used for a period of three months or more , remov e th e bat tery from t he v ehi cle, ens ure t hat it ’ s fu ll y charged, and st ore it o ut o f the su n in a coo l, dry p lace. C heck bat t ery vol tag e each mo nth d uri ng s to rage and rech arge as need[...]

94 MAINTENANCE AND LUBRICATION Batter y Batter y Flui d (Conventional B atter y) A poorly ma intained ba ttery will dete riorate r apidly . Check the batter y fluid leve l often. Ma intain the f luid level betwee n the upper and lower leve l mark s (1). Add only distille d wate r . T ap w ate r contains mine rals that a re ha rmful to a batte ry . [...]

95 MAINTENANCE AND LUBRICATION Batter y Batter y Charging (S ealed Batter y) The following ba ttery c har ging instructions apply only to the ins tal l ati on of a seal ed bat tery . R ead all i nst ruct i ons b efore proceed in g with the insta llation of this b atter y . The se ale d batter y is alr eady f illed w ith elec trolyte a nd ha s been [...]

96 MAINTENANCE AND LUBRICATION Batter y Batter y Charging (S ealed Batter y) NOT E: Alway s ver ify batt ery condit ion befor e and 1-2 hours af t er t he end of c harging. Stat e of Charge Vo l t a g e Action Char ge T ime* (Us ing cons tant cur rent char ger @ s tandard amps spec ified on top of battery) 100% 12.8- 13.0 volt s None, check at 3 mo[...]

97 MAINTENANCE AND LUBRICATION Cleaning and S tor age See page 106 for the par t numbers of Polaris products. W ashin g the V ehicle Keep ing your A TV clean will not only improve its appea ran ce but it can a lso exte nd the life of var ious components. CAUTION High water pr essur e may dam age A T V com ponents . Polar is recom mends was hing the[...]

98 MAINTENANCE AND LUBRICATION Cleaning and S tor age W ashin g the V ehicle If a high pre ssure wa ter system is used for cle aning (not recomm end ed), exerci se ex trem e caut i on. Th e wat er may damag e components and could remove pain t and decal s. A void d irecting t he wate r str eam a t the f ollowing items: S Wheel beari ng s S Radiator[...]

99 MAINTENANCE AND LUBRICATION Cleaning and S tor age Chr ome W heel C are (i f equipped) Pro per mai nten ance wil l prot ect chro me wheels fro m corros io n, preserv e wheel li fe and en su re a ”li ke new” ap pearance fo r man y y ears. NOT E: Chrom e wheels expos ed to r oad salt (or s alt in t he air in coast al areas ) are m ore sus cept[...]

100 MAINTENANCE AND LUBRICATION Cleaning and S tor age Sto rag e Tip s CAUTION Star ting t he engine during t he st orage per iod will dist urb t he prot ecti ve film creat ed by f ogging and damage c ould occur. Never star t t he engine during t he st orage per iod. Clean t he Exterio r Make any n ecess ary repai rs and cl ean th e vehi cle as rec[...]

101 MAINTENANCE AND LUBRICATION Cleaning and S tor age Sto rag e Tip s Flu id Levels Inspec t the fluid le vels. Add or cha nge fluids a s rec ommended in the Periodic Maintena nce Char t beginning on page 60. S Demand drive unit (f ront gea rcase ) S Rear g earcase (i f equi pp ed) S T ransmission S Brak e fluid (c hange ever y two yea rs and a ny[...]

102 MAINTENANCE AND LUBRICATION Cleaning and S tor age Sto rag e Tip s Inspe ct and Lubric ate Insp ect al l cab les and lub ri cate al l areas of t he veh icl e as reco mm end ed in the Periodic Maintena nce Char t beginning on page 60. Batte ry S torage See page s 93-96 for stor age a nd char ging procedure s. Sto rage A rea/Co vers Set the tire [...]

103 SPECIFICA TIO NS 2008 T rail Boss Capac ities Body Styl e Gen I V Ma ximum W eight Ca pa ci ty 415 lbs . ( 188 kg) Fu el C apacity 3.25 ga l . ( 12.35 l ) Transm issio n Oil 11. 3 oz. (335 ml ) Engine Oi l Ca pac i ty 1.9 qts . ( 1.8 l) (i nc l. oi l cool e r ) 1.7 qt s. (1. 6 l )( oil cha nge only) Front Ra c k 75 lbs . ( 34.1 kg) Rear R ack 1[...]

104 SPECIFICA TIO NS 2008 T rail Boss Drive S ystem Dri ve Syste m T ype PVT Shif t T ype Side Le ver ( F-N -R) Gea r Reduct ion - Reve rs e 3.05/1 Gear R edu ctio n - Fo rward 2.68/ 1 Fin al D rive (ratio ) 1 1/40 78P Driv e Ch ain 520 O-Ri ng Front T ire s 2 3x7 - 1 0( 4p s i ) Rear Tires 22 x 11- 10 (3 psi ) Suspe ns ion and Br akes Front Sus pe[...]

105 SPECIFICA TIO NS 2008 T rail Boss Jetting Chart Altitu de AMBIENT TEMPERA TURE Below 40 ° F (Bel ow 5 ° C) +40 ° F and above (+5 ° C and above) Meters (Feet ) 0-1800 (0- 6000) 127.5 122. 5 1800-3700 (6000- 12000) 120 11 5 Clutc hing Char t Altitude Shif t Weight Driv e Clutc h Spring Driven Clu tch Spring Helix /Spring Setting Meters (Feet)[...]

106 POLARIS PRODUCTS Part No. Descri pti on Engine Lubr icant 2870791 Fogging Oi l ( 12 oz. Aer osol) 2871098 Premi um Blue 2-Cycl e Miner al Oil ( qt. ) 2871097 Premi um Blue 2-Cycl e Miner al Oil ( gal. ) 2871721 Premi um Gol d Synthet ic 2- Cycle Oi l ( qt. ) 2871722 Premi um Gol d Synthet ic 2- Cycle Oi l ( gal. ) 2871281 Premi um 4 Synt heti c[...]

107 TROUBLE S HOOTING Contact your Polaris dea ler for se rvice if you’ re unable to identify solutions using the following c harts. Drive Belt and Cover Pr oblems Possibl e Cause Solut ion Dri ving onto a pic kup or tall trailer in h ig h ran g e Shif t t r ans mi ss ion t o l ow ra nge duri ng loa ding of the A TV to pre ve nt bel t burni ng. S[...]

108 TROUBLE S HOOTING Engine Doesn’t T urn Over Possi bl e Cause Sol uti on Lo w b attery v o ltage Re cha r ge ba tt er y to 12. 8 VDC or highe r Loose ba tte ry conne c ti ons Ch eck all con n ection s and tig h ten Loose s olenoi d connec tions Ch eck all con n ection s and tig h ten Engine T u rns Over , Fails to Start Possi bl e Cause Sol ut[...]

109 TROUBLE S HOOTING Engine Backfires Possi bl e Cause Sol uti on W e a k spa rk f r om spa rk plugs Inspect, clean and /o r replace spark p lu g s Inco rrect spark p lu g g ap o r heat rang e Set ga p to s pecs or r e pla ce plugs Old or non-r ecom mende d fuel Repl a ce wi th new fue l Inco rrectly in stalled sp ark plu g w ires Se e your Pola r[...]

11 0 TROUBLE S HOOTING Engi ne Stops or Loses Pow er Possi bl e Cause Sol uti on Out of fuel Turn fu el valv e to reserve, refuel Kinke d or plugge d fue l s yst em ve nt li ne s Insp ect and rep lace W ater presen t in fuel Repl a ce wi th new fue l Ove rus e of choke Insp ect, clean and /o r replace spark p lu g s Foule d or def ec ti ve spa r k [...]

111 WARRANTY LIM ITED W ARRANTY Pola r is Sa le s I nc. , 2100 Highw ay 55, M edi na, MN 55340, gi ves a SIX MONTH LI MI TED W ARRANTY on all c ompone nts of t he Pol ar is A ll T err a in V ehi cl e (A TV) aga ins t defe c ts in m at er i al or wor kma nshi p. Pola ri s al so gi ves a one yea r l im it ed w ar ra nty on the fi nal drive cha in for[...]

11 2 WARRANTY W ARRANTY COVERAGE AND EXCL USIONS: LIMIT A TIO NS OF W ARRANTIES AND REME DIE S ALL IMPLI ED W ARRANTIES (INCLUDI NG BUT NOT LIMI TED TO THE IMPLI ED W ARRANTIES OF MERCHANT ABILITY AND FITNESS FOR A P AR TICULAR PURPOSE) ARE LI MITED I N DURA TION TO THE ABOVE SIX MONTH W ARRAN- TY PERIOD. POLARIS FUR THER DISCLAI MS ALL EXPRESS W A[...]

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

11 4 WARRANTY U.S. A. EP A Emiss io n s L i mit ed W arra n ty Th is Al l T errain V eh icle (A TV ) or O ff Road Utility V eh icle (O RU V) em issio ns lim ited warran ty is in add ition to th e Po laris standard lim ited warran ty fo r this veh icle. Po laris w arrants t hat th is v eh icle is; (1 ) d esign ed , b u ilt, and equ ip p ed to con fo[...]

11 5 MAINTENANCE LOG Per iodic Main tenance Record Use th e fol lo wing chart to r ecord p eriod ic m ain ten ance. DA TE MIL ES (K M) TECHNI CIAN SERVICE PERFORMED / COMMENTS[...]

11 6 MAINTENANCE LOG DA TE MIL ES (K M) TECHNI CIAN SERVICE PERFORMED / COMMENTS[...]

11 7 MAINTENANCE LOG DA TE MIL ES (K M) TECHNI CIAN SERVICE PERFORMED / COMMENTS[...]