Instruction/ maintenance manual of the product Trail Boss 9920770 Polaris
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R ead this manual carefully . It contains important safety infor mation. This is an adult vehicle only . Operation is prohibited for those under 16 years of age.
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A car d containing im portant A TV s afet y infor mation s hould be att ached to t he owner ’ s manual on t he next page. If you cannot locat e this c ard, or if it has been r emoved, please call 1-800- 342-3764 for assist ance.
1 WELC OME Thank you f or purc hasing a Polaris veh icle , and welc ome to our wor ld-wide f amily of Polaris owne rs. W e proudly produc e an exc iting line of utility and r ec r ea tional pr oducts.
2 Copyr ight 2006 Pola ri s Sal e s Inc . Al l inf or ma t ion c onta i ne d wi t hin t hi s publi c a t i on i s ba s e d on t he la te s t produc t i nfor m a t ion at t he t i me of publ i c a ti on.
3 TABLE OF CONTENTS VEHICLE IDENT IFI CA TION NUMBERS 5 ....... SA FETY 6 ................................... FEA TURES AND CONTROL S 30 ............... OPE RA TION 40 .............................. EMI SSION CONT ROL SYST EM S 57 ............ MAINTENANCE AND L UBRICA TION 58 .
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5 VE HICLE IDENTIFICATION NUMBERS Recor d your A TV’ s identifica tion number s and ke y number in the sp aces prov ided . R emove t he sp are key and s tore i t i n a safe pl ace. An ignition key c an be duplica ted only by or de ring a Polaris key bla nk (using your ke y numbe r) a nd mating it with one of your e xisting ke ys.
6 SA FETY Operator S afety W ARNING Failur e to f ollow the warnings c ontained in this m anual can result in serious injury or deat h. A Polaris A T V is not a toy and can be hazardous t o operate. T his vehicle handles diff erently t han other v ehicles, suc h as motorcycles and cars.
7 SA FETY Operator S afety The following signa l wor ds and symbols appe ar throughout this manua l and on your A TV . Y our sa fe ty is involved whe n these words and symbols ar e used. Become f a miliar with the ir mea nings befor e re ading the manua l.
8 SA FETY Operator S afety W ARNING Serious injur y or deat h can result if you do not f ollow thes e inst ruct ions and procedur es, whic h are outlined in f urther det ail within your owner ’s manual. S Rea d this manua l and a ll labels c ar ef ully , and follow the opera ting proce dure s desc ribed.
9 SA FETY Operator S afety S Alway s have th e A TV i nspect ed by an aut hori zed Pol aris d ealer if it ’ s been invol ved in an accident. S Ne ver ope ra te on hills too stee p for the A TV or for your a bilities. Pra c tice on sma ller hills be for e atte mpting lar ger hills.
10 SA FETY Operator S afety S W et bra ke s may have re duce d stopping ability . T est your bra kes a fte r lea ving wa te r . If ne ce ssa ry , apply the m lightly seve ra l times to allow frict ion t o dry out the pads . S Always che ck for obsta cles or people be hind the A TV bef ore ope ra t- in g in revers e.
11 SA FETY Operator S afety W ARNING POTENTI AL HAZA RD Oper ating this A T V without pr oper instr uction. WHA T CA N HAPPEN The r isk of an ac cident is gr eatly inc reased if t he operat or does not k now how to operat e the A T V properly in differ ent sit uations and on different types of t errain.
12 SA FETY Operator S afety W ARNING POTENTI AL HAZA RD Carry ing a passenger on an AT V . WHA T CA N HAPPEN Carry ing a passenger great ly reduces t he operat or ’s ability t o balanc e and cont rol the A T V , whic h could caus e an accident and injury t o the operat or and/or pass enger .
13 SA FETY Operator S afety W ARNING POTENTI AL HAZA RD Oper ating this A T V on public st reets , roads or highways. WHA T CA N HAPPEN The A T V could collide with anot her vehic le. HOW T O A VOID TH E HAZARD Never oper ate t he A TV on any public st reet, road or highway , including dirt and gravel roads .
14 SA FETY Operator S afety W ARNING POTENTI AL HAZA RD Oper ating t he A TV af ter c onsuming alcohol or dr ugs. WHA T CA N HAPPEN Consumpt ion of alc ohol and/or dr ugs could ser iously affec t operat or judgment . React ion tim e may be slower and operat or balance and perc eption could be affec ted.
15 SA FETY Operator S afety W ARNING POTENTI AL HAZA RD At tempt ing wheelies, jumps and other s tunt s. WHA T CA N HAPPEN At tempt ing st unts inc reases the c hance of an ac cident, including an over turn. HOW T O A VOID TH E HAZ ARD Never at tempt wheelies, jumps, or other st unts.
16 SA FETY Operator S afety W ARNING POTENTI AL HAZA RD Removing hands f rom the handlebars or f eet f rom the f ootres ts during operat ion. WHA T CA N HAPPEN Removing ev en one hand or foot can reduce abilit y to c ontrol t he vehicle or c ould cause loss of balanc e and ejection f rom t he A T V .
17 SA FETY Operator S afety W ARNING POTENTI AL HAZA RD Failu re to use extra caut ion when operating on exces sively rough, slippery or loos e terrain. WHA T CA N HAPPEN Opera ting on e xcessi vely rough, s lippery or loose ter rain could caus e loss of tr action or loss of contr ol, which could r esult in an accident or overt urn.
18 SA FETY Operator S afety W ARNING POTENTI AL HAZA RD Oper ating on exc essively st eep hills. WHA T CA N HAPPEN The v ehicle may ov ertur n. HOW T O A VOID TH E HAZARD Never operat e on hills t oo steep f or the A T V or for your abilit ies. Never oper ate t he A TV on hills s teeper t han 25 _ .
19 SA FETY Operator S afety W ARNING POTENTI AL HAZA RD T raveling downhill improper ly . WHA T CA N HAPPEN Im properly des cending a hill could caus e loss of c ontrol or overt urn. HOW T O A VOID TH E HAZ ARD Always f ollow proper procedur es for t raveling down hills as des cribed in the owner ’s manual.
20 SA FETY Operator S afety W ARNING POTENTI AL HAZA RD Im properly cr ossing hills and tur ning on hills. WHA T CA N HAPPEN Im properly c rossing or tur ning as hills could c ause loss of c ontrol or over turn.
21 SA FETY Operator S afety W ARNING POTENTI AL HAZA RD St alling, rolling bac kwards or improper ly dismount ing while climbing a hill. WHA T CA N HAPPEN The v ehicle could over turn. HOW T O A VOID TH E HAZ ARD Maint ain steady s peed when climbing a hill.
22 SA FETY Operator S afety W ARNING POTENTI AL HAZA RD Im properly operat ing over obst acles. WHA T CA N HAPPEN Oper ating over obs tacles c ould cause loss of contr ol or overt urn. HOW T O A VOID TH E HAZARD Bef ore operat ing in a new area, c heck f or obstac les.
23 SA FETY Operator S afety W ARNING POTENTI AL HAZA RD Oper ating t he A TV t hrough deep or f ast -flowing wat er . WHA T CA N HAPPEN T ires may f loat, c ausing loss of t raction and loss of c ontrol, which could lead t o an accident or ov erturn. HOW T O A VOID TH E HAZARD Avoid operating t he A T V thr ough deep or fas t-f lowing water .
24 SA FETY Operator S afety W ARNING POTENTI AL HAZA RD Oper ating t he A TV wit h improper m odificat ions. WHA T CA N HAPPEN Im proper inst allation of ac cessor ies or modif icat ion of the A T V may c ause changes in handling whic h could lead to an ac cident.
25 SA FETY Operator S afety W ARNING Leaving t he keys in t he ignition c an lead to unauthor ized use of the v ehicle result ing in serious injur y or deat h.
1 2 3 26 SA FETY Safety D ecals and Locations W arning d ecals have been placed on t he A TV for your protecti on. Read and fo llo w the in stru ctio ns of th e d ecals and o ther warni ngs o n the A TV careful ly .
27 SA FETY Safety D ecals and Locations Gene r al W arni ng (3) W ARNI NG Im proper A TV use can resul t in SEVERE I NJUR Y or DEA TH AL W A YS USE AN APPROVED HELMET AND PROTECTIVE GEAR NEVER USE ON .
6 7 5 4 4 28 SA FETY Safety D ecals and Locations Rack W arning (4) W ARNI NG S DO NOT TOW FROM RACK OR BUMPER. V ehicl e damage or ti pover may resul t causing severe inj ur y or death. T ow only fr om t ow hooks or hitch. S Max Rack Loads: Front 75 lbs.
29 SA FETY Safe Ridi ng Gear Always we ar c lothing suited to the t ype of riding. A TV riding requir es spec ial protec tive c lothing for comf ort and to reduc e the cha nce of injury . 1. Helm et W eari ng a h elmet can prev ent a s evere head injury .
30 FEATURE S AND CONTRO LS Electr ical Switches W ARNING Act ivat ing the over ride switc h while the t hrott le is open can c ause loss of contr ol, res ulting in sever e injury or deat h. Do not ac tivat e the ov erride swit ch while t he throt tle is open.
31 FEATURE S AND CONTRO LS W ARNING Do not s tart or operat e an A TV wit h stic king or impr operly operat ing throt tle c ontrols , which could c ause an accident and lead to s evere injury or deat h. Always c ontact your dealer for ser vice repairs if throt tle problem s arise.
32 FEATURE S AND CONTRO LS W ARNING Oper ating t he A TV on s treet s or r oads, espec ially in darknes s, could res ult in an acc ident and ser ious injury or deat h. Y our A T V is not equipped wit h highway-appr oved lights . It ’ s designed f or and must be used for of f -road use only .
33 FEATURE S AND CONTRO LS Br akes Ch eck the brak e fl uid l evel i n the mas ter cyl in der befo re each use o f the A TV . The master c ylinde r (1) is lo cated on t he left h andl ebar . The fluid le ve l can be see n through a n indica tor window (2) on the top of the mas ter cy lin der .
34 FEATURE S AND CONTRO LS Br ake Lever The fro nt an d rear brak es are app li ed by sq ueezing t he brak e lever (1 ) toward t he han dleb ar . T he front and rear b rakes are hydra ulica lly ac tivated disc type bra ke s th at are activ ated by o nly o ne lever .
35 FEATURE S AND CONTRO LS Auxiliary Brake W ARNING Aggres sively apply ing the rear br ake when backing downhill may cause r ear tipov er , which c ould result in s erious injury or deat h. Use caut ion when applying t he auxiliary br ake. Do not aggress ively apply t he auxiliary br ake when going forwar d.
36 FEATURE S AND CONTRO LS Choke The choke a ssists in star ting a cold engine. Ref er to the engine sta rting proc edure o n page 42 for corr ec t choke and throttle settings during star ting. Fuel V alve The fu el val ve (1) i s l ocated o n th e left s ide of the vehic le , eithe r below the f ende r or on the side pane l.
37 FEATURE S AND CONTRO LS Fuel Safety W ARNING Gas oline is highly f lammable and explos ive under cer tain condit ions. S Always ex ercise ex trem e caution whenever handling gas oline. S Always r efuel wit h the engine st opped, and out doors or in a well vent ilated area.
38 FEATURE S AND CONTRO LS Autom atic T ransm ission Gear S elector The tra nsmission gear se lec tor (1) is locate d on the right side of the A TV . F: For w a rd N: Neutral R: Rev e rs e CAUTION Shif ting gears wit h the engine speed abov e idle or while the vehicle is m oving could caus e transm ission damage.
1 2 39 FEATURE S AND CONTRO LS Recoil S tarter If the ba tter y is too we a k to star t the engine, use the rec oil star ter ( 1). F ollow the sta rting proce dure s on page 42, cr anking the engine with the recoi l st arter i nst ead of t he main ke y switc h.
40 OPERATION Br eak-In Per iod The br ea k-in pe riod f or your ne w Polar is A TV is def ined a s the f irst ten hours of oper ation, or the time it takes to use the first two full tanks of gasoline . No single ac tion on your pa rt is as impor tant a s following the proc edur es for a prope r bre ak- in.
41 OPERATION Pr e - Ride Inspection W ARNING If a proper inspec tion is not done bef ore each us e, sev ere injury or deat h could result . A lways inspect the vehic le before eac h use to ens ure it’s in proper oper ating condit ion.
42 OPERATION Star ting the E ngine W ARNING Engine exhaus t cont ains poisonous car bon monoxide and can cause los s of c onsciousnes s result ing in severe injur y or deat h. Never r un an engine in an enclosed area. 1. Position the vehicle on a leve l su rface.
43 OPERATION Star ting the E ngine 7. Move the engine stop switch to RUN. NOT E: Do not pr ess the t hrot tle while st art ing the engine. 8. T urn the ignition key past the ON position to enga ge the star ter . Activa te the starte r for a ma ximum of five seconds, rele asing the key when the engine sta rts.
44 OPERATION Hauling Cargo Y our A TV has be en de signed to ca rr y or tow a ce rta in amount of loa d. Always re a d and unde rsta nd the loa d distribution wa rning la bels on the veh icle, and nev er exceed t he weig ht capac ities outlined in the sp ecificat io ns sect ion o f th e o wner ’ s m anual an d on th e s afety decal s.
45 OPERATION Hauling Cargo W ARNING Hauling cargo im properly c an alter v ehicle handling and may cause los s of c ontrol or br ake inst ability and res ult in ser ious injury or deat h. Alway s follow thes e pr ecautions when hauling cargo: S REDUCE SPEED AN D ALLO W GREA TER DI ST ANCE F OR BRAKING WHEN HAULING CAR GO.
46 OPERATION Driving Safely Driving Pr ocedures 1. Sit upright with both fee t on the footrests a nd both hands on the handle bar s. 2. Start the engine and a llow it to war m up, then shift the tra nsmission into gea r . 3. Check your surr oundings and dete rmine your pa th of trave l.
47 OPERATION Driving Safely T urning the V ehicl e Y our Polar is A TV is equippe d with a solid re ar axle that drive s both re ar whe els e qually at all time s. This me ans that the w hee l on the outside of the turn must trave l a grea ter dista nce tha n the inside whee l whe n turning a nd the inside tire must slip trac tion slightly .
48 OPERATION Driving Safely Dr iving on Slippe r y S urfaces Whenev er ridi ng on sl ipp ery surfaces s uch as wet t rails o r loos e g ravel, or dur ing freezi ng weath er , foll ow th ese precauti ons : 1. Slow down when e nter ing slippery a re as.
49 OPERATION Driving Safely Driving Uphill Whe ne ve r tra veling uphill, follow th ese precau tio ns: 1. Alwa ys tra ve l stra ight uphill. 2. A void ste ep hills ( 25 _ maximum) . 3. Kee p both fe et on the f ootre sts. 4. T ransf er your weight for war d.
50 OPERATION Driving Safely Sidehilling W ARNING Im properly c rossing hills or t urning on hills can r esult in los s of cont rol or vehic le overt urn, r esulting in sev ere injury or deat h. Avoid cross ing the side of a hill when possible. Follow proper procedur es as out lined in the owner ’ s m anual.
51 OPERATION Driving Safely Driving Downh ill Whe ne ver de sce nding a hill, follow these pr ecauti ons : 1. P roceed di rectly d ownh ill. 2. T ran sfe r your weight to the rea r of the veh icle . 3. Slow down. 4. Apply the brakes slightly to aid in slowing, using the single br ake leve r .
8’ (2. 4 m) 52 OPERATION Driving Safely T urning A r ound on a H il l If the ve hic le stalls while c limbing a hill, neve r bac k it down t he hill! Use the K- turn to turn a round. 1. Stop and lock the pa rking b rake while ke e ping body we ight uphill.
53 OPERATION Driving Safely Dr i ving Thr ough W ater Y our A TV can oper ate through wa ter with a maximum r ec omme nded depth e qual to the bottom of the footr ests (1). Follow th ese proced ures wh en oper ating through wa ter : 1. De ter mine wa ter depths a nd curr ent bef ore c rossing.
54 OPERATION Driving Safely Dr iving Over Ob stacles Be al ert! Loo k ahead and l earn to read t he terrain y ou’re trav elin g on. Be con st antl y alert fo r hazard s such as l ogs , rock s and lo w hangi ng bran ches. W ARNING Sever e injury or deat h can res ult if y our vehicle com es in cont act with a hidden obs tacle.
55 OPERATION Driving Safely Dr iving in Reverse Fo ll ow thes e p recauti ons wh en operati ng i n reverse: 1. Always avoid bac king downhill. 2. Bac k slowly . 3. Wh en in revers e, apply the brake s lightly for stopping. 4. A void turning at sh arp angl es in reverse.
56 OPERATION Driving Safely P a r k i n go na nI n c l i n e A void par king on an inc line if possible. If it’ s unavoidable , follow th ese precau tio ns: 1. T urn the engine of f. 1. Place the tr ansmission in gear . 2. Set the parking brake . 3.
57 EMISSION C ONT RO L SYSTEMS Noise E mission C ontrol S ystem Do not modify the engine, intake o r exhaust compone nts, as doing so may af fec t complianc e with U.S. A. EP A noise control requir eme nts (40 CFR 205) and loc al noise leve l re quire ments.
58 MAINTENANCE AND LUBRICATION Per iodic Maintenance Char t Care fu l periodic mainte nanc e will help kee p your vehicle in the safe st, most relia ble condition. Inspe ction, adjustme nt and lubr ica tion of importa nt components ar e expla ined in the periodic mainte nanc e ch ar t.
59 MAINTENANCE AND LUBRICATION Per iodic Maintenance Char t Maintena nce C har t Ke y " Perfo rm t hese pro cedures m ore frequen tly fo r vehi cles s ubj ected t o seve re use . E Emission-r ela ted se rvic e (Failur e to conduct this maintena nc e will not void the emissions warr ant y but may af fec t emissions.
60 MAINTENANCE AND LUBRICATION Per iodic Maintenance Char t Perfo rm all serv ices at whi chever mai ntenan ce in terval i s reached first . Item Maint enance Int er val (w hichev er comes fir st) Rem.
61 MAINTENANCE AND LUBRICATION Per iodic Maintenance Char t Item Maint enance Int er val (w hichev er comes fir st) Remarks Hours C ale ndar Miles (Km) Car buretor float bowl 50 H 6M 500 (800) Dr ain .
62 MAINTENANCE AND LUBRICATION Per iodic Maintenance Char t Item Maint enance Int er val (w hichev er comes fir st) Remarks Hours C ale ndar Miles (Km) J Clutc hes (driv e and driv en) 100 H 12 M 1000.
63 MAINTENANCE AND LUBRICATION Lubr ication Recom mendations Chec k an d lubric ate a ll co mponents a t the inter vals outline d in the Periodic Ma intena nce Cha rt beginning on page 60. Items not listed in the cha rt should be lubrica ted at the Gene ra l Lubrica tion interva l.
64 MAINTENANCE AND LUBRICATION Engi ne Oil Alwa ys chec k and cha nge the engine oil at the interva ls outlined in the P eriodi c Mai nten ance Ch art beg i nning on page 58.
65 MAINTENANCE AND LUBRICATION Engi ne Oil Oil an d F ilter Change 1. Position the vehicle on a leve l surf ace. 2. Clean the ar ea a round the dra in plug. 3. Run the engine for two to thre e minute s until warm. Stop the engine . CAUTION Contac t with hot oil m ay result in serious burns.
66 MAINTENANCE AND LUBRICATION T ransm ission Oil Oil Check The tra nsmission dipstic k (1) is loca ted on the right side of the mach ine n ear the r ecoil h andl e. Check and c hange the lubric ant at the inte rva ls outline d in the P eriodi c Mai nten ance Ch art beginning on pa ge 60.
67 MAINTENANCE AND LUBRICATION T ransm ission Oil Oil Chan ge 1. P lace a drai n pan ben eath th e tra nsmission oil dra in plug area. 2. Loosen the jam nut (A) . 3. T urn the a djuster bolt (B) in to allow the re moval of the drain plug (C). 4. Remove the dr ain plug and wipe the magne tic e nd cle an to remo ve accum ulat ed m eta llic filings.
68 MAINTENANCE AND LUBRICATION Br akes The front and re ar br ake s are hydra ulic disc bra kes, activa ted by moving the single brake le ver towar d the handleba r . These bra kes ar e self -a djusting. The fo ll owing ch ecks are recom men ded to k eep th e brake sy stem i n good oper ating c ondition.
69 MAINTENANCE AND LUBRICATION Br akes 2. Ch eck th e brake s yst em for f lui d leak s. 3. Ch eck th e brakes fo r excess iv e travel o r spongy fee l. 4. C heck t he fricti on pad s for wear , dama ge and loosene ss. 5. Ch eck the secu rit y and su rface condition of the disc.
70 MAINTENANCE AND LUBRICATION T oe A lignm ent W ARNING Sever e injury or deat h can res ult f rom impr oper toe alignment and adjust ment. Do not at tempt to adjust t ie rod alignment . A ll tie rod adjust ments s hould be perfor med by an author ized Polaris dealer .
71 MAINTENANCE AND LUBRICATION Si de Panel Rem oval NOT E: Side panel r emoval may be diff icult unt il the lock ing tabs and receiv ers have been s napped and unsnapped a few t imes. 1. Remove the sea t. 2. Gras p t he rear of t he si de panel near t he rear cab.
72 MAINTENANCE AND LUBRICATION Cam ber and Caster The ca mber a nd caste r ar e non-a djustable . Rear S pring The re ar shoc k absorbe r spring is adjuste d by ro tating the adjuste r ( 1) eithe r clockwise or c ounter cloc kwise to in crease or d ecrease sp ring t ens ion .
73 MAINTENANCE AND LUBRICATION Car bur etor IMPOR T ANT : Y our Polaris A TV is calibr ate d a t the fa ctor y for optimal pe rf orman ce at altitude s ra nging fr om ze ro to 6,000 fee t (1800 m) and temper atur es of +40 degre es F . (4 degree s C. ) or highe r .
1 2 3 74 MAINTENANCE AND LUBRICATION Thr ottle Cable Fr eeplay Thr ottle ca ble f re epla y is adjusted at the handle bar . 1. Loc ate the thr ottle ca ble adj ust er on t he handle bar . 2. S queeze the e nd of the rubber boot (1) and slide it far enough to e xpose the e nd of the inline ca ble a djuster ( 2).
75 MAINTENANCE AND LUBRICATION Wheels W ARNING Oper ating your A T V with wor n tires, improperly inf lated t ires, non-st andard tir es or improperly ins talled tir es will aff ect vehic le handling and could caus e an accident r esulting in ser ious injury or death.
76 MAINTENANCE AND LUBRICATION Wheels Wheel Installation 1. Place the tra nsmission in gea r a nd lock the parking br ake . W ARNING Im properly inst alled wheels can adversely aff ect t ire wear and vehicle handling, which can res ult in ser ious injury or deat h.
77 MAINTENANCE AND LUBRICATION Wheels Fr ont Whee l Hub T ighte ning Front whee l bear ing tightness a nd spindle nut r ete ntion ar e c ritic al compone nt oper ations.
78 MAINTENANCE AND LUBRICATION Rear Dr ive Chain Sl ack CAUTION Adjust ing or operat ing the A T V with im proper rear dr ive chain slack c an result in sev ere damage t o the t ransmis sion and drive component s. A lways mak e sure the s lack is wit hin the s tat ed specif icat ions.
79 MAINTENANCE AND LUBRICATION Rear Dr ive Chain Sl ack 6. R oll t he A TV forward o r backward to adjust the cha in slac k to the prope r tension. See the illustra tion for pr oper splic e link clip opening position (1) . 7. T i ght en t he eccent ric l ocki ng bo lt s to 30 ft.
80 MAINTENANCE AND LUBRICATION Drive Chain Polaris A TV drive cha ins are e quipped with o-r ing-sea led, per mane ntly greas ed pi ns and ro ll ers. Howev er , the o uter s urfaces o f the rol ler m ust be lubric ate d. Always inspe ct the dr ive ch ain prior to ope ra ting the ve hicle.
81 MAINTENANCE AND LUBRICATION Air Filter 1. Rem ove t he s eat, rel ease t he cli ps, and re move the air box cover . 2. Loosen the cla mp and r emove the filte r . 3. Remove the f abr ic type pre -filte r (1) f rom the ma in filter ( 2). W a sh the pr e- filte r in soa py wa ter , then rinse and le t dry .
82 MAINTENANCE AND LUBRICATION Lights Whe n ser vic ing a ha logen lamp, don’ t touch the lamp with ba re finger s. Oil from your skin lea ve s a r esidue , ca using a hot spot that will shorten the life o f the lamp. W ARNING Poor light ing while driving c an result in s evere injury or deat h.
83 MAINTENANCE AND LUBRICATION Lights T aillight/Brakelight Lamp Replacement If the taillight/br ake light does not work the lamp may ne ed to be repl aced. 1. Remove the ta illight lens cover mounting scre ws. Remove the lens c over a nd gaske t and se t aside f or re asse mbly .
84 MAINTENANCE AND LUBRICATION Spar k Pl ugs S par k P lug Re com m endati ons CAUTION Using non-r ecommended s park plugs c an result in s erious engine damage. Always us e Polaris- recomm ended spark plugs. See Specif icat ions beginning on page 103.
85 MAINTENANCE AND LUBRICATION Spar k Pl ugs Spar k Plug Inspectio n Normal Plug The norma l i nsula tor tip is gra y , tan or light brown. Ther e will be few combustion deposits. The ele ctrode s are not burne d or eroded. This indica tes the proper type a nd heat range f or the engine a nd the service .
86 MAINTENANCE AND LUBRICATION V eh i c le I mmers i o n CAUTION If your vehic le becomes im mersed, m ajor engine damage can result if t he machine is not thoroughly inspec ted.
87 MAINTENANCE AND LUBRICATION Spar k Ar restor W ARNING Failur e to heed t he following warnings while serv icing the s park arres tor could res ult in serious injury or deat h. Do no t perform service o n the spa rk arrestor whi le the system is hot.
88 MAINTENANCE AND LUBRICATION PV T System The basic ope ra tion of the P ola ris PVT system is dependent on engine sp eed and v ehicl e torq ue requi rement s. As en gin e speed i ncreases , t he forc e e xerte d on the m ova ble drive shea ve by the flyweights also incr ea ses.
89 MAINTENANCE AND LUBRICATION PV T System W ARNING Failur e to com ply with t he instr uctions in t his warning c an result in sever e injury or death. Do not modify any component of th e PVT system. Doing so may reduce it s st rengt h so that a f ailure may oc cur at a high s peed.
90 MAINTENANCE AND LUBRICATION Batter y Y our A TV may ha ve e ithe r a se a led ba tter y , which r equir es little mainte nanc e, or a conve ntional ba tter y . A seale d batte ry c an be identif ied by its f lat c over s on the top of the batte ry .
91 MAINTENANCE AND LUBRICATION Batter y W ARNING Im properly connec ting or disconnec ting batt ery cables can r esult in an explosion and c ause serious injur y or death. When remov ing the bat tery , alway s disconnect the negat ive (black ) cable f irst .
92 MAINTENANCE AND LUBRICATION Batter y Battery Installation Using a ne w ba tter y that has not be en f ully cha r ged ca n dama ge the bat tery and res ult in a sho rter li fe. It can al so hi nder veh icle per forma nce . Follow the batte ry c har ging instructions on pa ges 94-96 bef ore insta lling the batte ry .
93 MAINTENANCE AND LUBRICATION Batter y Batter y S tor age Whe ne ver the ve hicle is not used for a per iod of three months or more, remo ve th e batt ery from t he vehi cle, en sure t hat i t’ s fu ll y charged, and st ore it o ut of th e s un in a coo l, d ry place.
94 MAINTENANCE AND LUBRICATION Batter y Batte r y Fluid (Conv entional B atter y) A poorly ma inta ined ba tter y will dete rior ate r ap idly . Check the batte ry fluid le vel of ten. Mainta in the f luid leve l between the upper a nd lower leve l mar ks (1) .
95 MAINTENANCE AND LUBRICATION Batter y Batter y C harging (S ealed B attery ) The f ollowing batte ry c har ging instructions a pply only to the in stal lat ion o f a seal ed batt ery . Read all ins truct ion s before proceed ing with the installa tion of this ba tte ry .
96 MAINTENANCE AND LUBRICATION Batter y Batter y C harging (S ealed B attery ) NOT E: Alway s verif y batter y condition bef ore and 1-2 hours aft er the end of c harging. Stat e of Charge Vo l t a g e Acti on Char ge T i me* (Us ing constant c urr ent char ger @ s tandard amps spec ifi ed on top of battery ) 100% 12.
97 MAINTENANCE AND LUBRICATION Cleaning a nd Stor age See page 106 for the pa rt numbers of Polaris products. W ashing the V ehicle Kee ping your A TV cle an will not only improve its a ppea ra nc e but it ca n also e xtend the life o f va rious c omponents.
98 MAINTENANCE AND LUBRICATION Cleaning a nd Stor age W ashing the V ehicle If a high pre ssur e wa ter syste m is used for c lea ning (not recom mend ed), ex ercise ex trem e cauti on. The wat er may d amage components and could rem ove pain t and decal s.
99 MAINTENANCE AND LUBRICATION Cleaning a nd Stor age Chr om e W heel Car e (if equi pped) Pr oper main tenan ce wi ll pr otect chro me wheels from co rrosi on, pres erve wheel l ife and ens ure a ”li ke new” ap pearance for m any y ears.
100 MAINTENANCE AND LUBRICATION Cleaning a nd Stor age Sto rag e Tip s CAUTION St arting t he engine during t he stor age period will distur b the prot ectiv e film c reated by f ogging and damage could oc cur . Never st art t he engine during t he stor age period.
101 MAINTENANCE AND LUBRICATION Cleaning a nd Stor age Sto rag e Tip s Flu id Levels Inspe ct the fluid leve ls. Add or c hange fluids as r ec ommende d in the Periodic Mainte nanc e Chart beginning on page 60.
102 MAINTENANCE AND LUBRICATION Cleaning a nd Stor age Sto rag e Tip s Inspe ct and Lubri cate Ins pect al l cabl es an d lu bricat e all areas o f the v ehicl e as reco mmen ded in the Periodic Mainte nanc e Char t beginning on page 60. Batte ry Stor age See pa ges 93- 96 for stor age and c har ging procedur es.
103 SPECIFIC ATIO NS 2007 T rail Boss Capac ities Body Styl e Gen I V Gro ss V ehicle W eig ht 845 l bs . ( 383 kg) Fu el C apacity 3.25 ga l. (12. 35 l ) Transm ission O il 1 1. 3 oz . (335 ml ) Engine O i l Ca pa c it y 1.9 qts . (1. 8 l) (i nc l . oi l c ool e r ) 1.
104 SPECIFIC ATIO NS 2007 T rail Boss Drive S ystem Dr i ve Sys t e m T ype PVT Shif t T ype Side Le ver (F- N- R) Ge a r Re duc ti on - Reve r s e 3.05/ 1 Gear R edu ctio n - F orw ard 2.
105 SPECIFIC ATIO NS 2007 T rail Boss Jetting Chart Altitu de AMBIENT TEMPERA TURE Below 40 ° F (B elow 5 ° C) +40 ° F and above (+5 ° C and above) Meters (Feet ) 0-1800 (0- 6000) 127.
106 POLARIS PRODUCTS Part No. Descri pt i on Engine Lubr i cant 2870791 Fogging O il ( 12 oz. Aerosol ) 2871098 Prem ium Bl ue 2-Cycl e Miner al Oi l ( qt .) 2871097 Prem ium Bl ue 2-Cycl e Miner al Oi l ( gal .) 2871721 Prem ium Gold S ynthet i c 2- Cycle Oi l ( qt.
107 TROUB LE SH OOTIN G Contact your Polar is deale r for se rvic e if you’r e unable to identify solutions using the follow ing cha rts. Dr ive Belt an d Cover Problem s Possibl e Cause Solut i on .
108 TROUB LE SH OOTIN G Engine Doesn’t T u r n Over Po ssibl e Cause Solut ion Lo w b attery vo ltag e Re c ha r ge ba t t e r y t o 12.8 V DC or highe r Loos e ba tt e r y conne c t i ons Ch eck al.
109 TROUB LE SH OOTIN G Engine Backfir es Po ssibl e Cause Solut ion W e a k s pa r k f r om s pa r k pl ugs Insp ect, clean an d/o r rep lace spark p lug s In correct spark p lug g ap o r heat rang e.
11 0 TROUB LE SH OOTIN G E ngine S tops or Loses P ower Po ssibl e Cause Solut ion Out of fuel Tu rn fuel valv e to reserv e, refuel Ki nke d or plugge d fue l s ys t e m vent l i ne s Insp ect an d r.
111 WARRANTY LIM ITED W ARRANT Y Pola ri s Sa l e s Inc ., 2100 Hi ghwa y 55, M e dina , MN 55340, gi ve s a SI X M ONTH LIMI TED W ARRANTY on a ll c om ponent s of t he Pol a r i s Al l T e r r a in V ehi c le ( A TV) aga i ns t de f e c t s in m a t e r ia l or workm a ns hip.
11 2 WARRANTY W ARRANTY C OVERAGE AND EXCLUSIONS: LIMI T A TIONS O F W ARRANTI ES AND REMEDI ES ALL IM PLIED W ARRANTIES ( INCLUDI NG BUT NOT LIM ITED TO THE IMPLI ED W ARRANTIES OF MERCHANT ABI LITY AND FITNESS FOR A P AR TI CULAR PURPOSE) ARE LI MI TED I N DURA TION TO THE ABOVE SIX MONTH W ARRAN- TY PERI OD.
11 3 WARRANTY Exported V ehicles EXCEPT WHERE SPECIFI CALL Y REQUIRED BY LA W , THERE IS NO W AR- RANTY OR SER VICE BULLETI N COVERAGE ON THI S VEHI CLE IF I T I S SOLD OUTSIDE THE COUNTR Y OF THE SELLING DEALER’ S AUTHORI ZED LOCA- TION.
11 4 WARRANTY U. S.A. EP A Emis sio n s Li mit ed W arran t y Th is All T errain V eh icle (A T V) o r Off Ro ad U tility V eh icle (ORU V) em ission s limited warran ty is in add ition to t he Po laris stan d ard limited warran ty for this veh icle.
11 5 MAINTENANCE LOG Per iodic Mainten ance Recor d Use t he fol lowi ng chart to reco rd perio dic m aint enance. DA TE MILE S (K M) TECHNI CIAN SER VICE PERFO RMED / COMMENTS.
11 6 MAINTENANCE LOG DA TE MILE S (K M) TECHNI CIAN SER VICE PERFO RMED / COMMENTS.
11 7 MAINTENANCE LOG DA TE MILE S (K M) TECHNI CIAN SER VICE PERFO RMED / COMMENTS.
11 8 INDEX A Ag e Restrictio n s 6 ................ Air F ilter 8 1 ..................... Au x iliary B rake 3 5, 6 9 ............ B Ba tt e r y 91- 96 .................... Ba tt e r y ( Conve nt i ona l ) 90 .......... Ba tt e r y Cha r gi ng (C onve nti ona l ) 94 .
11 9 INDEX O Oi l Cha nge 65 ................... Oi l Ch eck 6 4 .................... Oil F ilter Ch ang e 6 5 .............. Oi l , Engi ne 64- 65 ................. Oi l , T r a ns mi s s i on 66- 67 ............ Ope r a t or Sa f e ty 6- 25 ........
An important point after buying a device Polaris Trail Boss 9920770 (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 Trail Boss 9920770 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 Trail Boss 9920770 - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Polaris Trail Boss 9920770 you will learn all the available features of the product, as well as information on its operation. The information that you get Polaris Trail Boss 9920770 will certainly help you make a decision on the purchase.
If you already are a holder of Polaris Trail Boss 9920770, 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 Trail Boss 9920770.
However, one of the most important roles played by the user manual is to help in solving problems with Polaris Trail Boss 9920770. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Polaris Trail Boss 9920770 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
