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WARNING The engine exhaust from this product contains chemicals known to cause cancer, birth defects or other reproductive harm. A card containing important ATV safety information should be attached to the owner’s manual on the next page. If you cannot locate this card, or if it has been removed, please call 1-800-342-3764 for assistance.
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Copyright 2003 Polaris Sales Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this publication. Depictions and/or procedures in this publication are intended for reference use only. No liability can be accepted for omissions or inaccuracies.
WELCOME Thank you for purchasing a Polaris vehicle, and welcome to our world-wide family of Polaris owners. We proudly produce an exciting line of utility and recreational products.
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TABLE OF CONTENTS WELCOME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 VEHICLE IDENTIFICATION NUMBERS . . . . . . . . 6 SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 FEATURES AND CONTROLS . . . . . . . . . . . . . . . 36 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 EMISSION CONTROL SYSTEMS . . . . . . . . . . . . 63 MAINTENANCE AND LUBRICATION . . . . . . . . . 64 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . .
VEHICLE IDENTIFICATION NUMBERS The vehicle frame vehicle identification number (VIN)(1) and engine serial number are important for model identification when registering your vehicle, when obtaining insurance, and when ordering replacement parts. If your vehicle is stolen, these numbers are essential to the recovery and identification of your vehicle. Remove the spare key and store it in a safe place. Your key can be duplicated only by mating a Polaris key blank with one of your existing keys.
SAFETY Operator Safety WARNING Failure to follow the warnings contained in this manual can result in severe injury or death. A Polaris ATV is not a toy and can be hazardous to operate. This vehicle handles differently than other vehicles, such as motorcycles and cars. A collision or rollover can occur quickly, even during routine maneuvers like turning, or driving on hills or over obstacles, if you fail to take proper precautions.
SAFETY Operator Safety The following signal words and symbols appear throughout this manual and on your ATV. Your safety is involved when these words and symbols are used. Become familiar with their meanings before reading the manual. The safety alert symbol, on your ATV or in this manual, alerts you to the potential for personal injury. WARNING The safety alert warning indicates a potential hazard that may result in serious injury or death.
SAFETY Operator Safety WARNING Serious injury or death can result if you do not follow these instructions and procedures, which are outlined in further detail within your owner’s manual. S Read this manual and all labels carefully, and follow the operating procedures described. S Never operate an ATV without proper instruction. Take a training course. Beginners should receive training from a certified instructor.
SAFETY Operator Safety S Always have the ATV inspected by an authorized Polaris dealer if it’s been involved in an accident. S Never operate on hills too steep for the ATV or for your abilities. Practice on smaller hills before attempting larger hills. S Always follow proper procedures for climbing hills. Check the terrain carefully before ascend a hill. Never climb hills with excessively slippery or loose surfaces. Shift your weight forward. Never open the throttle suddenly or make sudden gear changes.
Operator Safety SAFETY S Wet brakes may have reduced stopping ability. Test your brakes after leaving water. If necessary, apply them lightly several times to allow friction to dry out the pads. S Always check for obstacles or people behind the ATV before operating in reverse. When it’s safe to proceed in reverse, move slowly and avoid turning at sharp angles. S Always use the size and type of tires specified for your ATV, and always maintain proper tire pressure.
SAFETY Operator Safety WARNING POTENTIAL HAZARD Operating this ATV without proper instruction. WHAT CAN HAPPEN The risk of an accident is greatly increased if the operator does not know how to operate the ATV properly in different situations and on different types of terrain. HOW TO AVOID THE HAZARD Beginning and inexperienced operators should complete the certified training course offered by Polaris.
SAFETY Operator Safety WARNING POTENTIAL HAZARD Carrying a passenger on an ATV. WHAT CAN HAPPEN Carrying a passenger greatly reduces the operator’s ability to balance and control the ATV, which could cause an accident and injury to the operator and/or passenger. HOW TO AVOID THE HAZARD Never carry a passenger. The purpose of the long seat is to allow the operator to shift position as needed during operation. It is not intended for carrying passengers.
SAFETY Operator Safety WARNING POTENTIAL HAZARD Operating an ATV on paved surfaces, including sidewalks, paths, parking lots, and driveways. WHAT CAN HAPPEN ATV tires are designed for off-road use. Operating on paved surfaces may seriously affect the handling and control of the ATV and could result in loss of control, accident, and/or injury. HOW TO AVOID THE HAZARD Avoid operating the ATV on pavement. If it’s unavoidable, travel slowly and avoid sudden turns or stops.
SAFETY Operator Safety WARNING POTENTIAL HAZARD Operating this ATV on public streets, roads or highways. WHAT CAN HAPPEN The ATV could collide with another vehicle. HOW TO AVOID THE HAZARD Never operate the ATV on any public street, road or highway, including dirt and gravel roads. In many states it’s illegal to operate ATVs on public streets, roads and highways.
SAFETY Operator Safety WARNING POTENTIAL HAZARD Operating this ATV without wearing an approved helmet, eye protection and protective clothing. WHAT CAN HAPPEN Operating an ATV without an approved helmet increases the risk of a severe head injury or death in the event of an accident. Operating without eye protection could result in an accident and could increase the chance of a severe injury in the event of an accident. HOW TO AVOID THE HAZARD Always wear an approved helmet that fits properly.
SAFETY Operator Safety WARNING POTENTIAL HAZARD Operating the ATV after consuming alcohol or drugs. WHAT CAN HAPPEN Consumption of alcohol and/or drugs could seriously affect operator judgment. Reaction time may be slower and operator balance and perception could be affected. Consuming alcohol and/or drugs before or while operating an ATV could result in an accident causing severe injury or death. HOW TO AVOID THE HAZARD Never consume alcohol or drugs before or while operating an ATV.
SAFETY Operator Safety WARNING POTENTIAL HAZARD Attempting wheelies, jumps and other stunts. WHAT CAN HAPPEN Attempting stunts increases the chance of an accident, including an overturn. HOW TO AVOID THE HAZARD Never attempt wheelies, jumps, or other stunts. Avoid exhibition driving.
SAFETY Operator Safety WARNING POTENTIAL HAZARD Failure to inspect the ATV before operating. Failure to properly maintain the ATV. WHAT CAN HAPPEN Poor maintenance increases the possibility of an accident or equipment damage. HOW TO AVOID THE HAZARD Always inspect your ATV before each use to make sure it’s in safe operating condition. Always follow the inspection and maintenance procedures and schedules described in the owner’s manual.
SAFETY Operator Safety WARNING POTENTIAL HAZARD Failure to use extra caution when operating the ATV on unfamiliar terrain. WHAT CAN HAPPEN Unfamiliar terrain may contain hidden rocks, bumps, or holes that could cause loss of control or overturn. HOW TO AVOID THE HAZARD Travel slowly and use extra caution when operating on unfamiliar terrain. Always be alert to changing terrain conditions.
SAFETY Operator Safety WARNING POTENTIAL HAZARD Failure to use extra caution when operating on excessively rough, slippery or loose terrain. WHAT CAN HAPPEN Operating on excessively rough, slippery or loose terrain could cause loss of traction or loss of control, which could result in an accident or overturn. HOW TO AVOID THE HAZARD Do not operate on excessively rough, slippery or loose terrain until you’ve learned and practiced the skills necessary to control the ATV on such terrain.
SAFETY Operator Safety WARNING POTENTIAL HAZARD Turning improperly. WHAT CAN HAPPEN Improper turns could cause loss of control and lead to a collision or overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for turning as described in the owner’s manual. Practice turning at slow speeds before attempting to turn at faster speeds. Never turn at excessive speed. WARNING POTENTIAL HAZARD Operating on excessively steep hills. WHAT CAN HAPPEN The vehicle may overturn.
SAFETY Operator Safety WARNING POTENTIAL HAZARD Climbing hills improperly. WHAT CAN HAPPEN Improper hill climbing could cause loss of control or overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for climbing hills as described in the owner’s manual. Always check the terrain carefully before ascending any hill. Never operate the ATV on hills steeper than 25_. Never climb hills with excessively slippery or loose surfaces. Shift your weight forward.
SAFETY Operator Safety WARNING POTENTIAL HAZARD Traveling downhill improperly. WHAT CAN HAPPEN Improperly descending a hill could cause loss of control or overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for traveling down hills as described in the owner’s manual. NOTE: A special technique is required when braking while traveling downhill. See page 57. Always check the terrain carefully before you descending a hill. Shift your weight backward. Never travel down a hill at high speed.
SAFETY Operator Safety WARNING POTENTIAL HAZARD Improperly crossing hills and turning on hills. WHAT CAN HAPPEN Improperly crossing or turning as hills could cause loss of control or overturn. HOW TO AVOID THE HAZARD Never attempt to turn the ATV around on any hill until you’ve mastered the turning technique (on level ground) as described in the owner’s manual. See page 58. Use extra caution when turning on any hill. Avoid crossing the side of a steep hill.
SAFETY Operator Safety WARNING POTENTIAL HAZARD Stalling, rolling backwards or improperly dismounting while climbing a hill. WHAT CAN HAPPEN The vehicle could overturn. HOW TO AVOID THE HAZARD Maintain steady speed when climbing a hill. If all forward speed is lost: Keep your weight uphill. Apply the single lever brake gradually. When fully stopped, apply the auxiliary rear brake as well, then lock the parking brake. If the ATV begins rolling backwards: Keep weight uphill. Never apply engine power.
SAFETY Operator Safety WARNING POTENTIAL HAZARD Improperly operating over obstacles. WHAT CAN HAPPEN Operating over obstacles could cause loss of control or overturn. HOW TO AVOID THE HAZARD Before operating in a new area, check for obstacles. Avoid operating over large obstacles such as rocks and fallen trees when possible. If unavoidable, use extreme caution and always follow proper procedures as outlined in the owner’s manual. WARNING POTENTIAL HAZARD Skidding or sliding.
SAFETY Operator Safety WARNING POTENTIAL HAZARD Operating the ATV through deep or fast-flowing water. WHAT CAN HAPPEN Tires may float, causing loss of traction and loss of control, which could lead to an accident or overturn. HOW TO AVOID THE HAZARD Avoid operating the ATV through deep or fast-flowing water.
SAFETY Operator Safety WARNING POTENTIAL HAZARD Operating this ATV with improper tires, or with improper or uneven tire pressure. WHAT CAN HAPPEN Use of improper tires, or operation of the ATV with improper or uneven tire pressure, could cause loss of control or accident. HOW TO AVOID THE HAZARD Always use the size and type of tires specified for the ATV. Always maintain proper tire pressure as specified. WARNING POTENTIAL HAZARD Operating the ATV with improper modifications.
SAFETY Operator Safety WARNING POTENTIAL HAZARD Overloading the ATV or carrying/towing cargo improperly. WHAT CAN HAPPEN Overloading and towing can cause changes in vehicle handling, which could lead to loss of control or an accident. HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this ATV. Cargo should be properly distributed and securely attached. Reduce speed when carrying cargo or pulling a trailer. Allow a greater distance for braking.
SAFETY Operator Safety WARNING Leaving the keys in the ignition can lead to unauthorized use of the vehicle resulting in serious injury or death. Always remove the ignition key when the vehicle is not in use. WARNING After any overturn or accident, have a qualified service dealer inspect the entire vehicle for possible damage, including (but not limited to) brakes, throttle and steering systems. WARNING Safe operation of this rider-active vehicle requires good judgement and physical skills.
SAFETY Safety Decals and Locations Warning decals have been placed on the ATV for your protection. Read and follow the instructions of the decals and other warnings on the ATV carefully. If any of the decals shown in this manual differ from the decals on your ATV, always read and follow the instructions of the decals on the ATV. If any decal becomes illegible or comes off, contact your Polaris dealer to purchase a replacement. Replacement safety decals are provided by Polaris at no charge.
SAFETY Safety Decals and Locations WARNING S DO NOT TOW FROM RACK OR BUMPER. Vehicle damage or tipover may result causing severe injury or death. Tow only from tow hooks or hitch. S Max Rack Loads: Front 75 lbs. (34 kg) Rear 125 lbs.
SAFETY Safety Decals and Locations WARNING Operating this ATV if you are under the age of 16 increases your chance of severe injury or death. NEVER operate this ATV if you are under age 16. 7078253 Under Seat Chain Freeplay Is Important. Adjust Freeplay to 3/16″ - 3/8″ DO NOT Overtension. See Owner’s Manual. Torque Nut on Eccentric Bolts: To 30 Ft. Lbs. (For models without a hitch). To 40 Ft. Lbs. (For models with a hitch). 7078572 MANUFACTURED BY: POLARIS IND. INC.
SAFETY Safe Riding Gear Always wear clothing suited to the type of riding. ATV riding requires special protective clothing for comfort and to reduce the chance of injury. 1. Helmet Your helmet is the most important piece of protective gear for safe riding. A helmet can prevent a severe head injury. Select an approved helmet that meets or exceeds your state’s safety standards and bears either the Department of Transportation (DOT) label, the American National Standards Institute label (ANSI z90.
FEATURES AND CONTROLS Electrical Switches 3 2 1 WARNING Activating the override switch while the throttle is open can cause loss of control, resulting in severe injury or death. Do not activate the override switch while the throttle is open. Override Switch (1) (Reverse Speed Limiter) OFF RUN OFF This vehicle is equipped with a reverse speed limiter system. To gain additional power while backing, depress the override switch.
FEATURES AND CONTROLS WARNING Do not start or operate an ATV with sticking or improperly operating throttle controls, which could cause an accident and lead to severe injury or death. Always contact your dealer for service repairs if throttle problems arise. Failure to check or maintain proper operation of the throttle system can result in an accident if the throttle lever sticks during operation. Always check the lever for free movement and return before starting the engine.
FEATURES AND CONTROLS WARNING Operating the ATV on streets or roads, especially in darkness, could result in an accident and serious injury or death. Your ATV is not equipped with highway-approved lights. It’s designed for and must be used for off-road use only. Use caution and drive at reduced speeds in conditions of reduced visibility such as fog, rain and darkness. Light Switches The light switch is located on the left handlebar (1).
FEATURES AND CONTROLS Brakes Check the brake fluid level in the master cylinder before each use of the ATV. The master cylinder (1) is located on the left handlebar. The fluid level can be seen through an indicator window (2) on the top of the master cylinder. This “eye” will appear dark when the fluid level is full. When fluid needs to be added, the eye will be clear. 1 2 WARNING An over-full master cylinder may cause brake drag or brake lock-up, which could result in serious injury or death.
FEATURES AND CONTROLS Brake Lever 2 1 The front and rear brakes are applied by squeezing the brake lever (1) toward the handlebar. The front and rear brakes are hydraulically activated disc type brakes that are activated by only one lever. Always test brake lever travel and master cylinder fluid level before riding. When squeezed, the lever should feel firm. Any sponginess would indicate a possible fluid leak or low master cylinder fluid level, which must be corrected before riding.
Auxiliary Brake FEATURES AND CONTROLS WARNING Aggressively applying the rear brake when backing downhill may cause rear tipover, which could result in serious injury or death. Use caution when applying the auxiliary brake. Do not aggressively apply the auxiliary brake when going forward. The rear wheels may skid and slide sideways, causing loss of control and serious injury or death. The auxiliary brake (1), is located on the inside of the right floor board and is operated by the right foot.
FEATURES AND CONTROLS Choke The choke assists in starting a cold engine. Refer to the engine starting procedure on page 48 for correct choke and throttle settings during starting. Fuel Valve The fuel valve (1) is located on the left side of the vehicle, either below the fender or on the side panel. It has three positions: OFF: For vehicle storage and when transporting. ON: For normal operation. RES: For reserve supply if main supply is exhausted. NOTE: There’s about a 7 to 10 mile 1 (11.
Fuel Safety FEATURES AND CONTROLS WARNING Gasoline is highly flammable and explosive under certain conditions. S Always exercise extreme caution whenever handling gasoline. S Always refuel with the engine stopped, and outdoors or in a S S S S S well ventilated area. Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored. Do not overfill the tank. Do not fill the tank neck.
FEATURES AND CONTROLS Automatic Transmission Gear Selector The transmission gear selector (1) is located on the right side of the ATV. F: Forward N: Neutral R: Reverse 1 F N R CAUTION Shifting gears with the engine speed above idle or while the vehicle is moving could cause transmission damage. To change gears, stop the vehicle, and with the engine idling, move the lever to the desired gear. Whenever the ATV is left unattended, always place the transmission in gear with the parking brake locked.
Recoil Starter FEATURES AND CONTROLS 2 1 If the battery has been drained or damaged and cannot start the engine, use of the recoil starter (1) will allow vehicle operation until repairs can be made. The recoil starter is located on the right side of the machine. Polaris 4-cycle engines are equipped with automatic decompressors. This makes recoil starting possible by reducing the amount of compression during starting.
OPERATION Break-In Period The break-in period for your new Polaris ATV is defined as the first ten hours of operation, or the time it takes to use the first two full tanks of gasoline. No single action on your part is as important as following the procedures for a proper break-in. Careful treatment of a new engine will result in more efficient performance and longer life for the engine. Perform the following procedures carefully.
Pre-Ride Inspection OPERATION WARNING If a proper inspection is not done before each use, severe injury or death could result. Always inspect the vehicle before each use to ensure it’s in proper operating condition. Use the following checklist to verify that your vehicle is in proper working condition before each use. Item/Inspection Procedure 1. Tires - Check condition and pressures. 2. Fuel and oil tanks - Fill both tanks to their proper levels. 3.
OPERATION Starting the Engine Starting a Cold Engine WARNING Engine exhaust contains poisonous carbon monoxide and can cause loss of consciousness resulting in severe injury or death. Never run an engine in an enclosed area. CAUTION Operating the vehicle immediately after starting could cause engine damage. Allow the engine to warm up for several minutes before operating the vehicle. 1. Place the transmission in neutral and lock the parking brake. Make sure the fuel tank valve is on. 2.
Starting the Engine OPERATION Starting a Warm Engine Warm engines do not normally require the use of the choke. Excessive use of the choke can cause the spark plug to become wet fouled. 1. Position the vehicle on a level surface with the transmission in neutral. 2. Lock the parking brake, turn the fuel tank valve to ON, sit on the vehicle, and turn the engine stop switch to RUN. 3.
OPERATION Hauling Cargo 2/3 1/3 Your ATV has been designed to carry or tow a certain amount of load. Always read and understand the load distribution warning labels on the vehicle, and never exceed the weight capacities outlined in the specifications section of the owner’s manual and on the safety decals. Cargo weight should be evenly distributed (1/3 on the front rack and 2/3 on the rear rack) and mounted as low as possible.
OPERATION Hauling Cargo WARNING Hauling cargo improperly can alter vehicle handling and may cause loss of control or brake instability and result in serious injury or death. Always follow these precautions when hauling cargo: S REDUCE SPEED AND ALLOW GREATER DISTANCE FOR BRAKING WHEN HAULING CARGO. S CARGO WEIGHT DISTRIBUTION should be 1/3 on the front rack and 2/3 on the rear rack. When operating over rough or hilly terrain, reduce speed and cargo to maintain stable driving conditions.
OPERATION Driving Safely Driving Procedures 1. Sit upright with both feet on the footrests and both hands on the handlebars. 2. Start the engine and allow it to warm up, then shift the transmission into gear. 3. Check your surroundings and determine your path of travel. 4. Release the parking brake. 5. Slowly depress the throttle with your right thumb and begin driving. Vehicle speed is controlled by the amount of throttle opening. 6. Drive slowly.
OPERATION Driving Safely Making Turns Your Polaris ATV is equipped with a solid rear axle that drives both rear wheels equally at all times. This means that the wheel on the outside of the turn must travel a greater distance than the inside wheel when turning and the inside tire must slip traction slightly. To make a turn, steer in the direction of the turn, leaning your upper body to the inside of the turn while supporting your weight on the outer footrest.
OPERATION Driving Safely Driving on Slippery Surfaces Whenever riding on slippery surfaces such as wet trails or loose gravel, or during freezing weather, follow these precautions: 1. Slow down when entering slippery areas. 2. Maintain a high level of alertness, reading the trail and avoiding quick, sharp turns which can cause skids. 3. Correct a skid by turning the handlebars in the direction of the skid and shifting your body weight forward.
OPERATION Driving Safely Driving Uphill Whenever traveling uphill, follow these precautions: 1. Always travel straight uphill. 2. Avoid steep hills (25_ maximum). 3. Keep both feet on the footrests. 4. Transfer your weight forward. 5. Proceed at a steady rate of speed and throttle opening. 6. Remain alert and be prepared to take emergency action. 25_ Maximum This may include quick dismounting of the vehicle. If all forward speed is lost: Keep your weight uphill. Apply the single lever brake, gradually.
OPERATION Driving Safely Sidehilling WARNING Improperly crossing hills or turning on hills can result in loss of control or vehicle overturn, resulting in severe injury or death. Avoid crossing the side of a hill when possible. Follow proper procedures as outlined in the owner’s manual. Sidehilling can be a dangerous type of driving and should be avoided if at all possible. If you do enter into a situation where sidehilling is necessary, follow these precautions: 1. Slow down. 2.
OPERATION Driving Safely Driving Downhill Whenever descending a hill, follow these precautions: 1. Proceed directly downhill. 2. Transfer your weight to the rear of the vehicle. 3. Slow down. 4. Apply the brakes slightly to aid in slowing, using the single brake lever. NOTE: Familiarize yourself with operation of the auxiliary rear brake pedal for additional braking in the event of normal service brake loss. WARNING Excessive speed can cause loss of control and lead to serious injury or death.
OPERATION Driving Safely Turning Around on a Hill WARNING Improper hill climbing procedures could cause loss of control or overturn and result in serious injury or death. Avoid climbing steep hills (25_ maximum). Use extreme caution when operating on hills, and follow proper operating procedures outlined in the owner’s manual. If the vehicle stalls while climbing a hill, never back it down the hill! One maneuver that can be used when it’s necessary to turn around while climbing a hill is the K-turn: 1.
OPERATION Driving Safely Driving Through Water Your ATV can operate through water with a maximum recommended depth equal to the bottom of the footrests (1). Follow these procedures when operating through water: 1. Determine water depths and current before crossing. 1 2. Choose a crossing where both banks have gradual inclines. 3. Proceed slowly, avoiding rocks and obstacles if possible. 4. After crossing, dry the brakes by applying light pressure to the lever until braking action is normal.
OPERATION Driving Safely Driving Over Obstacles Be alert! Look ahead and learn to read the terrain you’re traveling on. Be constantly alert for hazards such as logs, rocks and low hanging branches. WARNING Severe injury or death can result if your vehicle comes in contact with a hidden obstacle. Not all obstacles are immediately visible. Travel with caution in unfamiliar terrain.
OPERATION Driving Safely Driving in Reverse Follow these precautions when operating in reverse: 1. Always avoid backing downhill. 2. Back slowly. 3. When in reverse, apply the brakes lightly for stopping. 4. Avoid turning at sharp angles in reverse. 5. Never open the throttle suddenly while backing. WARNING Failure to use caution when operating in reverse can result in serious injury or death. Before shifting into reverse, always check for obstacles or people behind the vehicle.
OPERATION Driving Safely Parking on an Incline Avoid parking on an incline if possible. If it’s unavoidable, follow these precautions: 1. Turn the engine off. 1. Place the transmission in gear. 2. Set the parking brake. 3. Always block the rear wheels on the downhill side. See illustration. 4. Shut off the fuel supply.
EMISSION CONTROL SYSTEMS Noise Emission Control System Do not modify the engine, intake or exhaust components, as doing so may affect compliance with state and local noise level requirements. Spark Arrestor Your Polaris vehicle has a spark arrestor that was tested and approved in accordance with the USDA Forest Service Standard 5100-1C. Federal law requires that this spark arrestor be installed and functional when the vehicle is operated on public lands.
MAINTENANCE AND LUBRICATION Accessories Auxiliary power outlets provide 12V power for operating accessories such as hand held spot lights. Accessory outlets are available for all models. Contact your Polaris dealer for more information. Polaris has a wide range of additional accessories available for your ATV. See your Polaris dealer. Periodic Maintenance Schedule Careful periodic maintenance will help keep your vehicle in the safest, most reliable condition.
MAINTENANCE AND LUBRICATION Periodic Maintenance Schedule Hours of operation are based on a 10 mph average. If service is due at 20 hours, the equivalent odometer reading would be 200 miles. Perform all services at whichever reading is reached first. WARNING Improperly performing the procedures marked with a J could result in component failure and lead to serious injury or death. Have an authorized Polaris dealer perform these services.
MAINTENANCE AND LUBRICATION Periodic Maintenance Schedule WARNING Improperly performing the procedures marked with a J could result in component failure and lead to serious injury or death. Have an authorized Polaris dealer perform these services. Item Hours/ Miles Taillight/brakelight Pre-Ride Pre-Ride Check operation daily; apply Polaris dielectric grease to socket when replaced " Air filter, Weekly Weekly Inspect; replace as needed J Brake pad wear 10 hrs.
MAINTENANCE AND LUBRICATION Periodic Maintenance Schedule Item Hours/ Miles Frequency Remarks Carburetor float bowl 50 hrs. 6 months Drain bowl periodically and prior to storage J Throttle Cable/ETC 50 hrs. 6 months Inspect; adjust; lubricate; replace if necessary L Choke (enricher) 50 hrs. 6 months Inspect; adjust; lubricate; replace if necessary Shift linkage 50 hrs. 6 months Inspect; adjust J Drive belt 50 hrs. 6 months Inspect; replace as needed " Steering 50 hrs.
MAINTENANCE AND LUBRICATION Periodic Maintenance Schedule WARNING Improperly performing the procedures marked with a J could result in component failure and lead to serious injury or death. Have an authorized Polaris dealer perform these services. Item Hours/ Miles Frequency Remarks Radiator/Oil Cooler 100 hrs. 12 months Inspect; clean external surface Cooling system hoses 100 hrs. 12 months Inspect J Clutches (drive and 100 hrs. 12 months Inspect; clean Engine mounts 100 hrs.
MAINTENANCE AND LUBRICATION Periodic Maintenance Record Use the following chart to record periodic maintenance. Maintenance Interval Performed Servicing Servicing Date Dealer or Person Remarks 10 hrs. 20 hrs. 50 hrs. 100 hrs.
MAINTENANCE AND LUBRICATION Lubrication Recommendations NOTE: Hours are based on 10 mph average. If service is due at 20 hours, the equivalent odometer reading would be 200 miles. Perform all services at whichever reading is reached first. Lubrication Chart Key " More often under severe use, such as wet or dusty conditions ∆ No.
MAINTENANCE AND LUBRICATION Lubrication Recommendations Premium 4 Synthetic Oil Polaris Premium 4 All Season Synthetic engine oil has been specially formulated for use in Polaris 4-cycle engines. It’s a fully synthetic, high performance, multi-viscosity oil designed to provide the ultimate in lubrication performance and protection. NOTE: See page 108 for the part numbers of Polaris products. Premium 4 possesses unsurpassed film strength over the widest possible temperature range.
MAINTENANCE AND LUBRICATION Lubrication Recommendations Oil and Filter Change 1. Position the vehicle on a level surface. 2. Clean the area around the drain plug. 3. Run the engine for two to three minutes until warm. Stop the engine. CAUTION Contact with hot oil may result in serious burns. Do not allow hot oil to come into contact with skin. 4. Place a drain pan beneath the engine crankcase and remove the drain plug. 5. Allow the oil to drain completely. 6.
MAINTENANCE AND LUBRICATION Lubrication Recommendations Transmission Oil Check The transmission dipstick (1) is 1 located on the right side of the machine near the recoil handle. Check the lubricant level monthly or every 1000 miles (1600 km), whichever comes first. Change the transmission oil annually. NOTE: We recommend the use of Polaris Premium Synthetic Gearcase Lubricant. See page 108 for the part numbers of Polaris products. 1. Position the ATV on a level surface.
MAINTENANCE AND LUBRICATION Lubrication Recommendations Transmission Oil Change 1. Place a drain pan beneath the transmission oil drain plug A area. 2. Loosen the jam nut (A). B 3. Turn the adjuster bolt (B) in to allow the removal of the drain plug (C). 4. Remove the drain plug and wipe the magnetic end clean to C remove accumulated metallic filings. 5. After the oil has drained completely, install a new sealing washer and reinstall the drain plug. Torque to 14 ft. lbs. (19 Nm). 6.
MAINTENANCE AND LUBRICATION Lubrication Recommendations Engine Oil Check The oil fill is located on the left side of the vehicle (1). 1. Position the machine on a level surface. 2. Start the engine and let it idle for 20-30 seconds. Stop the engine. 3. Remove the dipstick and wipe it dry with a clean cloth. 4. Screw the dipstick completely in. 5. Remove the dipstick and read the oil level. Maintain the oil level in the safe operating range (2). Do not overfill.
MAINTENANCE AND LUBRICATION Adjustments Brakes The front and rear brakes are hydraulic disc brakes, activated by moving the single brake lever toward the handlebar. These brakes are self-adjusting. The following checks are recommended to keep the brake system in good operating condition. Check more often if brakes are used heavily under normal operation. WARNING Never store or use a partial bottle of brake fluid. Brake fluid is hygroscopic, meaning it rapidly absorbs moisture from the air.
MAINTENANCE AND LUBRICATION Adjustments Brakes 2. Check the brake system for fluid leaks. 3. Check the brakes for excessive travel or spongy feel. 4. Check the friction pads for wear, damage and looseness. 5. Check the security and surface condition of the disc. NOTE: Pads should be changed when worn to 3/64″ (.1 cm), or about the thickness of a U.S. dime. 3/64″ (.1 cm) Auxiliary Brake The auxiliary brake system is intended to be used as a backup for the main brake system.
MAINTENANCE AND LUBRICATION Adjustments WARNING Severe injury or death can result from improper toe alignment and adjustment. Do not attempt to adjust tie rod alignment. All tie rod adjustments should be performed by an authorized Polaris dealer. Toe Alignment Use the following procedure to check the toe alignment of the vehicle. The recommended toe alignment is 1/8″ to 1/4″ toe out. 1. Set the handlebars in a straight-ahead position.
MAINTENANCE AND LUBRICATION Adjustments Side Panel Removal NOTE: Side panel removal may be difficult until the locking tabs and receivers have been snapped and unsnapped a few times. 1. Remove the seat. Step 2 2. Grasp the rear of the side panel near the rear cab. With a quick and firm motion, pull the panel forward and outward to disengage the two rear tabs. 3. Place your hand on top of the side panel behind the fuel tank.
MAINTENANCE AND LUBRICATION Adjustments Steering Assembly The steering assembly of the ATV should be checked periodically for loose nuts and bolts. If loose nuts and bolts are found, see your Polaris dealer for service before operating the vehicle. Camber and Caster The camber and caster are non-adjustable. Rear Spring The rear shock absorber spring is adjusted by rotating the adjuster (1) either clockwise or counterclockwise to increase or decrease spring tension.
MAINTENANCE AND LUBRICATION Adjustments Carburetor IMPORTANT: Your Polaris ATV is calibrated at the factory for optimal performance at altitudes ranging from zero to 6,000 feet (1800 m) and temperatures of +40 degrees F. (4 degrees C.) or higher. Above 6000 feet (1800 m) the engine air/fuel mixture becomes overly rich and the engine loses approximately 3% of its power for each 1000-foot (304.8 m) increase in elevation.
MAINTENANCE AND LUBRICATION Adjustments Throttle Cable Freeplay Throttle cable freeplay is adjusted at the handlebar. 1. Slide the boots (1) off the inline cable adjuster sleeve (2). Loosen the adjuster locknut (3). 2. Turn the adjuster until 1/16″ to 1/8″ freeplay is achieved at the thumb lever. NOTE: While adjusting freeplay, be sure to flip the throttle lever back and forth. 3. Tighten the locknut and slide the boots over the cable adjuster until they touch at the midpoint of the adjuster.
MAINTENANCE AND LUBRICATION Adjustments WARNING Operating your ATV with worn tires, improperly inflated tires, non-standard tires or improperly installed tires will affect vehicle handling and could cause an accident resulting in serious injury or death. Maintain proper tire pressure as described on the decal on your ATV and in your owner’s manual. Always use original equipment size and type when replacing tires. Make sure the wheels are installed properly.
MAINTENANCE AND LUBRICATION Adjustments Wheel Installation 1. Place the transmission in gear and lock the parking brake. 2. Place the wheel on the wheel hub with the valve stem toward the outside and rotation arrows on the tire pointing toward forward rotation. 3. Install the wheel nuts and finger tighten. 4. Lower the vehicle to the ground. 5. Torque the wheel nuts according to the wheel nut torque specifications chart.
MAINTENANCE AND LUBRICATION Adjustments Front Wheel Hub Tightening Front wheel bearing tightness and spindle nut retention are critical component operations. All service must be performed by your authorized Polaris dealer. Tires WARNING Use of non-standard size or type of tires or improper tire inflation may adversely affect vehicle maneuverability and cause loss of control resulting in serious injury or death. Maintain proper tire pressure as outlined in the specifications section of this manual.
MAINTENANCE AND LUBRICATION Adjustments Rear Drive Chain Slack CAUTION Adjusting or operating the ATV with improper rear drive chain slack can result in severe damage to the transmission and drive components. Always make sure the slack is within the stated specifications. Check the amount of chain slack in three different locations by moving the vehicle slightly forward to gain slack at the top side of the rear chain. Measure the chain slack at the tightest of the three positions.
MAINTENANCE AND LUBRICATION Adjustments Rear Drive Chain Slack 6. Roll the ATV forward or backward to adjust the chain slack to the proper tension. See the illustration for proper splice link clip opening position (1). 7. Tighten the eccentric locking bolts to 30 ft. lbs. (41 Nm) for machines 1 without the hitch and 45 ft. lbs. (61 Nm) for machines with a hitch. 8. Tighten the caliper mount bolts to 10-12 ft. lbs. (14-17 Nm) 9. Remove the pin punch. 10.
MAINTENANCE AND LUBRICATION Adjustments Drive Chain Polaris ATV drive chains are equipped with o-ring-sealed, permanently greased pins and rollers. However, the outer surfaces of the roller must be lubricated. Always inspect the drive chain prior to operating the vehicle. Check for damaged or missing o-rings or damaged rollers. Also check for correct slack adjustment. Maintain the stone guard to rear sprocket clearance at 1/8″ (.3 cm).
MAINTENANCE AND LUBRICATION Air Filter 1. Remove the seat, release the clips, and remove the air box cover. 2. Loosen the clamp and remove the filter. 3. Remove the fabric type pre-filter (1) from the main filter (2). Wash the pre-filter in soapy water, then rinse and let dry. 4. Reinstall the pre-filter over the main filter. (Replace the main filter if needed.) 5. Reinstall the filter into the air box and tighten the clamp. Do not over tighten the clamp, as filter damage could occur.
MAINTENANCE AND LUBRICATION Lights When servicing a halogen lamp, don’t touch the lamp with bare fingers. Oil from your skin leaves a residue, causing a hot spot that will shorten the life of the lamp. WARNING Poor lighting while driving can result in severe injury or death. Headlight and taillight lenses become dirty during normal operation. Wash the headlights frequently to maintain lighting quality. Hot components can cause serious burns to skin.
Lights MAINTENANCE AND LUBRICATION Taillight/Brakelight Lamp Replacement If the taillight/brakelight does not work the lamp may need to be replaced. 1. Remove the taillight lens cover mounting screws. Remove the lens cover and gasket and set aside for reassembly. 2. Remove the lamp (1) and replace it with a new lamp. 3. Test the taillight/brakelight to see that it’s working. 1 4. Reinstall the gasket and lens cover. Indicator Lamp Replacement 1.
MAINTENANCE AND LUBRICATION Spark Plugs CAUTION Using non-recommended spark plugs can result in serious engine damage. Always use Polaris-recommended spark plugs. See Specifications beginning on page 105. Spark plug condition is indicative of engine operation. The spark plug firing end condition should be read after the engine has been warmed up and the vehicle has been driven at higher speeds. Immediately check the spark plug for correct color.
MAINTENANCE AND LUBRICATION Vehicle Immersion CAUTION If your vehicle becomes immersed, major engine damage can result if the machine is not thoroughly inspected. Take the vehicle to your dealer before starting the engine. If it’s impossible to take your ATV to a dealer before starting it, follow the steps outlined below. 1. Move the ATV to dry land or at the very least, to water below the foot rests. 2. Check the airbox for any water and dry it if water is present. 3. Turn the fuel valve off. 4.
MAINTENANCE AND LUBRICATION Spark Arrestor WARNING Failure to heed the following warnings while servicing the spark arrestor could result in serious injury or death. Do not perform service on the spark arrestor while the system is hot. Exhaust system temperatures can reach 1000° F. Allow components to cool sufficiently before proceeding. Remove any combustible materials from the area. Wear eye protection and leather work gloves. Do not stand behind or in front of the vehicle while purging.
MAINTENANCE AND LUBRICATION Recoil Housing To prevent possible engine damage, 1 always drain the recoil housing (1) after operating the ATV in very wet conditions. This should also be done before storing the ATV. Water will enter the recoil housing if the starter handle is disengaged from the rope guide when under water. The drain screw is located at the bottom of the recoil housing. Use a wrench to remove the screw. Be sure to reinstall the screw after draining the housing.
MAINTENANCE AND LUBRICATION PVT System The basic operation of the Polaris PVT system is dependent on engine speed and vehicle torque requirements. As engine speed increases, the force exerted on the movable drive sheave by the flyweights also increases. This, in turn, increases the amount of “pinch” applied to the drive belt. Similarly, if the engine speed decreases, the amount of centrifugal force decreases, reducing the amount of belt “pinch.
MAINTENANCE AND LUBRICATION PVT System WARNING Failure to comply with the instructions in this warning can result in severe injury or death. Do not modify any component of the PVT system. Doing so may reduce its strength so that a failure may occur at a high speed. The PVT system has been precision balanced. Any modification will cause the system to be out of balance, creating vibration and additional loads on components.
MAINTENANCE AND LUBRICATION Battery WARNING Improperly connecting or disconnecting battery cables can result in an explosion and cause serious injury or death. When removing the battery, always disconnect the negative (black) cable first. When reinstalling the battery, always connect the negative (black) cable last. Battery Removal 1. 2. 3. 4. Disconnect the battery hold-down strap and remove the battery cover. Disconnect the black (negative) battery cable first.
Battery MAINTENANCE AND LUBRICATION Battery Storage Whenever the vehicle is not used for a period of three months or more, remove the battery from the vehicle, ensure that it’s fully charged, and store it out of the sun in a cool, dry place. Check battery voltage each month during storage and recharge as needed to maintain a full charge. NOTE: Battery charge can be maintained by using a Polaris Battery Tendert charger (PN 2871076) or by charging about once a month to make up for normal self-discharge.
MAINTENANCE AND LUBRICATION Battery Battery Charging NOTE: Always verify battery condition before and 1-2 hours after the end of charging. State of Charge Voltage 100% 12.8-13.0 volts None, check at 3 mos. from date of manufacture None required 75%-100% 12.5-12.8 volts May need slight charge, if no charge given, check in 3 months 3-6 hours 50%-75% 12.0-12.5 volts Needs charge 5-11 hours 25%-50% 11.5-12.0 volts Needs charge At least 13 hours, verify state of charge 0%-25% 11.
MAINTENANCE AND LUBRICATION Cleaning and Storage See page 108 for the part numbers of Polaris products. Cleaning the ATV Keeping your ATV clean will not only improve its appearance but it can also extend the life of various components. With a few precautions, your ATV can be cleaned much like an automobile. Washing the ATV The best and safest way to clean your ATV is with a garden hose and a pail of mild soap and water.
MAINTENANCE AND LUBRICATION Cleaning and Storage Storage Tips See page 108 for the part numbers of Polaris products. CAUTION Starting the engine during the storage period will disturb the protective film created by fogging and damage could occur. Never start the engine during the storage period. Exterior Make necessary repairs and then clean the ATV thoroughly with mild soap and warm water to remove all dirt and grime. Don’t use harsh detergents or high pressure washers.
MAINTENANCE AND LUBRICATION Cleaning and Storage Storage Tips See page 108 for the part numbers of Polaris products. Fluid Levels Inspect the following fluid levels and change if necessary: engine oil; transmission oil; brake fluid (change every two years or as needed if fluid looks dark or contaminated). Engine 1. Remove the spark plug and pour 2-3 tablespoons of Premium 4 Synthetic 0W40 engine oil into the hole.
MAINTENANCE AND LUBRICATION Cleaning and Storage Transporting an ATV Follow these procedures when transporting an ATV. 1. Turn off the engine and remove the key to prevent loss during transporting. 2. Turn the fuel valve off. 3. Be sure the fuel cap, oil cap and seat are installed correctly and securely. 4. Always tie the frame of the ATV to the transporting unit securely using suitable straps or rope. The rack, bumper or handlebars do not offer enough support for tie-down while transporting the unit. 5.
2004 Trail Boss SPECIFICATIONS Capacities Gen IV 845 lbs. (383 kg) 3.25 gal. (12.35 l) 11.3 oz. (335 ml) 1.9 qts. (1.8 l)(incl. oil cooler ) 1.7 qts. (1.6 l)(oil change only) Front Rack 75 lbs. (34.1 kg) Rear Rack 125 lbs. (56.7 kg) Tongue Weight 85 lbs. (38.6 kg) Hitch Towing Rating 850 lbs.(386 kg) Unbraked Trailer Towing Capacity* 1263 lbs. (573 kg) Turn Radius 75 in. (190.5 cm) Ground Clearance 5.5 in. (14 cm) Height 46 in. (116.8 cm) Length 75 in. (190.5 cm) Width 46 in. (116.8 cm) Seat Height 34 in.
SPECIFICATIONS 2004 Trail Boss Drive System Type Shift Type Gear Reduction - Reverse Gear Reduction - Forward Final Drive (ratio) Drive Chain Front Tires Rear Tires Drive System PVT Side Lever (F-N-R) 3.05/1 2.68/1 11/40 78P 520 O-Ring 23 x 7-10 (4 psi) 22 x 11-10 (3 psi) Suspension and Brakes Front Suspension: Mac Strut 6.7 in. (17 cm) travel Rear Suspension: Progressive Rate 9 in. (22.
SPECIFICATIONS 2004 Trail Boss Jetting Chart Altitude AMBIENT TEMPERATURE Below 40° F (Below 5° C) +40°F and above (+5°C and above) Meters (Feet) 0-1800 (0-6000) 127.5 122.
POLARIS PRODUCTS Part No. Description Engine Lubricant 2870791 Fogging Oil (12 oz. Aerosol) 2871098 Premium 2-Cycle Engine Oil (qt.) 2871281 Premium 4 Synthetic 0W-40 (4-Cycle) Engine Oil (qt.) 2871844 Premium 4 Synthetic 0W-40 (4-Cycle) Engine Oil (gal.) 2871567 Premium 4 Synthetic 0W-40 (4-Cycle) Engine Oil (16 gal.) Gearcase / Transmission Lubricants 2871477 Premium Synthetic Gearcase Lubricant (1 gal.) 2871478 Premium Synthetic Gearcase Lubricant (12 oz.
TROUBLESHOOTING Drive Belt and Cover Problems Possible Cause Solution Driving the ATV onto a pickup or tall trailer in high range. Avoid stopping on the ramp or creeping slowly up the ramp. These practices may slip the clutch and belt. Starting out going up a steep incline. When starting out on an incline, dismount the ATV (after first applying the park brake) and perform the K-turn as described on page 58. Driving at low RPM or low ground speed (at about 3-7 MPH). Drive at a slightly higher speed.
TROUBLESHOOTING Contact your Polaris dealer for service if you’re unable to identify solutions using the following charts. Engine Doesn’t Turn Over Possible Cause Solution Low battery voltage Recharge battery to 12.
Engine Backfires TROUBLESHOOTING Possible Cause Solution Weak spark from spark plugs Inspect, clean and/or replace spark plugs Incorrect spark plug gap or heat range Set gap to specs or replace plugs Old or non-recommended fuel Replace with new fuel Incorrectly installed spark plug wires See your Polaris dealer Incorrect ignition timing See your Polaris dealer Mechanical failure See your Polaris dealer Engine Runs Irregularly, Stalls or Misfires Possible Weak Spark Cause Solution Fouled or
TROUBLESHOOTING Engine Stops or Loses Power Possible Cause Solution Out of fuel Turn fuel valve to reserve, refuel Kinked or plugged fuel system vent lines Inspect and replace Water present in fuel Replace with new fuel Overuse of choke Inspect, clean and/or replace spark plugs Fouled or defective spark plugs Inspect, clean and/or replace spark plugs Worn or defective spark plug wires See your Polaris dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs Loose igni
LIMITED WARRANTY WARRANTY Polaris Sales Inc., 2100 Highway 55, Medina, MN 55340, gives a SIX MONTH LIMITED WARRANTY on all components of the Polaris All Terrain Vehicle (ATV) against defects in material or workmanship. Polaris also gives a one year limited warranty on the final drive chain for failure due to defects. This warranty covers the parts and labor charges for repair or replacement of defective parts which are covered by this warranty. This warranty begins on the date of purchase.
WARRANTY WARRANTY COVERAGE AND EXCLUSIONS: LIMITATIONS OF WARRANTIES AND REMEDIES ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE) ARE LIMITED IN DURATION TO THE ABOVE SIX MONTH WARRANTY PERIOD. POLARIS FURTHER DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY.
Exported Vehicles WARRANTY EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE IS NO WARRANTY OR SERVICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD OUTSIDE THE COUNTRY OF THE SELLING DEALER’S AUTHORIZED LOCATION. This policy does not apply to vehicles that have received authorization for export from Polaris Industries. Dealers may not give authorization for export. You should consult an authorized dealer to determine this vehicle’s warranty or service bulletin coverage if you have any questions.
INDEX A F Accessories . . . . . . . . . . . . . . . . . . . 64 Adjustments . . . . . . . . . . . . . . . . 76-88 Age Restrictions . . . . . . . . . . . . . . . . 7 Air Filter . . . . . . . . . . . . . . . . . . . . . 89 Auxiliary Brake . . . . . . . . . . . . 41, 77 FEATURES . . . . . . . . . . . . . . . . 36-45 Fuel Filter . . . . . . . . . . . . . . . . . . . . 42 Fuel Safety . . . . . . . . . . . . . . . . . . . 43 Fuel Stabilizer . . . . . . . . . . . . . . . . 102 Fuel Tank . . . . . . . . . . . . .
INDEX P T Parking Brake . . . . . . . . . . . . . . . . . 40 Parking on an Incline . . . . . . . . . . . 62 Periodic Maintenance Schedule . 64-68 POLARIS PRODUCTS . . . . . . . 108 Pre-Ride Inspection . . . . . . . . . . . . . 47 Premium 4 Synthetic Oil . . . . . . . . . 71 PVT Drying . . . . . . . . . . . . . . . . . . 97 PVT System . . . . . . . . . . . . . . . . 96-97 TABLE OF CONTENTS . . . . . . . . 5 Taillight Lamp Replacement . . . . . . 91 Throttle Cable Freeplay . . . . . . . . . .
