Instruction/ maintenance manual of the product 7174820 Polaris
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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.
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.
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 .
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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.
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.
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.
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.
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.
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.
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.
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 .
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.
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.
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.
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 .
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.
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 _ .
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.
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.
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.
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.
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.
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 .
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.
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 .
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 PUB.
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.
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 .
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.
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.
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 .
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 .
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 .
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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 .
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.
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.
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.
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 .
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.
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.
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.
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.
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.
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.
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.
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.
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) R.
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 bo.
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 .
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.
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.
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.
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.
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.
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.
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.
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.
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 .
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.
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 .
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).
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.
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.
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.
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.
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.
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.
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 .
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.
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 .
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.
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.
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.
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.
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.
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.
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 .
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 .
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 .
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.
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).
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 .
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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 ect.
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.
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.
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.
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.
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.
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.
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.
An important point after buying a device Polaris 7174820 (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Polaris 7174820 yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Polaris 7174820 - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Polaris 7174820 you will learn all the available features of the product, as well as information on its operation. The information that you get Polaris 7174820 will certainly help you make a decision on the purchase.
If you already are a holder of Polaris 7174820, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Polaris 7174820.
However, one of the most important roles played by the user manual is to help in solving problems with Polaris 7174820. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Polaris 7174820 along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
