Polaris Trail Boss 9920770- Manuals

5 VEHICLE IDENTIFICATION NUMBERS Record your ATV’s identification numbers and key number in the spaces provided. Remove the spare key and store it in a safe place. An ignition key can be duplicated only by ordering a Polaris key blank (using your key number) and mating it with one of your existing k...

6 SAFETY Operator Safety WARNING Failure to follow the warnings contained in this manual can result in serious 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 o...

7 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 vehicle or in this manual, al...

8 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 ...

10 SAFETY Operator 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 operat- ing in reverse. When it’s safe to...

11 SAFETY Operator Safety WARNING POTENTIAL HAZARDOperating this ATV without proper instruction.WHAT CAN HAPPENThe 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 HAZARDB...

14 SAFETY Operator Safety WARNING POTENTIAL HAZARDOperating the ATV after consuming alcohol or drugs.WHAT CAN HAPPENConsumption 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...

15 SAFETY Operator Safety WARNING POTENTIAL HAZARDAttempting wheelies, jumps and other stunts.WHAT CAN HAPPENAttempting stunts increases the chance of an accident, including an overturn.HOW TO AVOID THE HAZARDNever attempt wheelies, jumps, or other stunts. Avoid exhibition driving. WARNING POTENTIAL...

17 SAFETY Operator Safety WARNING POTENTIAL HAZARDFailure to use extra caution when operating on excessively rough, slippery or loose terrain.WHAT CAN HAPPENOperating on excessively rough, slippery or loose terrain could cause loss of traction or loss of control, which could result in an accident or...

20 SAFETY Operator Safety WARNING POTENTIAL HAZARDImproperly crossing hills and turning on hills.WHAT CAN HAPPENImproperly crossing or turning as hills could cause loss of control or overturn.HOW TO AVOID THE HAZARDNever attempt to turn the ATV around on any hill until you’ve mastered the turning te...

21 SAFETY Operator Safety WARNING POTENTIAL HAZARDStalling, rolling backwards or improperly dismounting while climbing a hill.WHAT CAN HAPPENThe vehicle could overturn.HOW TO AVOID THE HAZARDMaintain steady speed when climbing a hill.If all forward speed is lost:Keep your weight uphill.Apply the sin...

22 SAFETY Operator Safety WARNING POTENTIAL HAZARDImproperly operating over obstacles.WHAT CAN HAPPENOperating over obstacles could cause loss of control or overturn.HOW TO AVOID THE HAZARDBefore operating in a new area, check for obstacles.Avoid operating over large obstacles such as rocks and fall...

23 SAFETY Operator Safety WARNING POTENTIAL HAZARDOperating the ATV through deep or fast-flowing water.WHAT CAN HAPPENTires may float, causing loss of traction and loss of control, which could lead to an accident or overturn.HOW TO AVOID THE HAZARDAvoid operating the ATV through deep or fast-flowing...

24 SAFETY Operator Safety WARNING POTENTIAL HAZARDOperating the ATV with improper modifications.WHAT CAN HAPPENImproper installation of accessories or modification of the ATV may cause changes in handling which could lead to an accident.HOW TO AVOID THE HAZARDNever modify the ATV through improper in...

1 2 3 26 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...

29 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 Wearing a helmet can prevent a severe head injury. Whenever riding a Polaris vehicle, always wear a helmet that meet...

30 FEATURES AND CONTROLS Electrical Switches 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) - This vehicle is...

31 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 oper...

32 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 s...

33 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 ...

34 FEATURES AND CONTROLS Brake Lever 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...

35 FEATURES AND CONTROLS Auxiliary Brake 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 ...

36 FEATURES AND CONTROLS Choke The choke assists in starting a cold engine. Refer to the engine starting procedure on page 42 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 pane...

37 FEATURES AND CONTROLS Fuel Safety 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 well ventilated area. S Do not smoke or allow open flames or s...

38 FEATURES AND CONTROLS Automatic Transmission Gear Selector The transmission gear selector (1) is located on the right side of the ATV.F: ForwardN: NeutralR: Reverse CAUTION Shifting gears with the engine speed above idle or while the vehicle is moving could cause transmission damage.To change gea...

1 2 39 FEATURES AND CONTROLS Recoil Starter If the battery is too weak to start the engine, use the recoil starter (1). Follow the starting procedures on page 42, cranking the engine with the recoil starter instead of the main key switch.1. Grasp the recoil starter rope handle (2) tightly. 2. Pull s...

40 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 treatme...

41 OPERATION Pre-Ride Inspection 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. Pre-Ride Checklist Item Remarks See Page Brake system / brake lever travel Ensure...

42 OPERATION Starting the 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. 1. Position the vehicle on a level surface. 2. Place the transmission in neutral.3. Lock the pa...

44 OPERATION Hauling Cargo 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...

46 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 brak...

47 OPERATION Driving Safely Turning the Vehicle 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 ...

48 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...

49 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...

50 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. Sidehilli...

51 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...

8’ (2.4 m) 52 OPERATION Driving Safely Turning Around on a Hill If the vehicle stalls while climbing a hill, never back it down the hill! Use the K-turn to turn around. 1. Stop and lock the parking brake while keeping body weight uphill.2. Leave the transmission in forward and shut off the engine.3....

53 OPERATION Driving Safely Driving Through Water Your ATV can operate through water with a maximum recommended depth equal to the bottom of the footrests (1). Follow these procedures when operating through water:1. Determine water depths and current before crossing. 2. Choose a crossing where both ...

54 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. ...

55 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...

56 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 o...

57 EMISSION CONTROL SYSTEMS Noise Emission Control System Do not modify the engine, intake or exhaust components, as doing so may affect compliance with U.S.A. EPA noise control requirements (40 CFR 205) and local noise level requirements. Operation on Public Lands in the U.S.A. Your Polaris vehicle...

58 MAINTENANCE AND LUBRICATION Periodic Maintenance Chart Careful periodic maintenance will help keep your vehicle in the safest, most reliable condition. Inspection, adjustment and lubrication of important components are explained in the periodic maintenance chart.Inspect, clean, lubricate, adjust ...

59 MAINTENANCE AND LUBRICATION Periodic Maintenance Chart Maintenance Chart Key " Perform these procedures more frequently for vehicles subjected to severe use. E Emission-related service (Failure to conduct this maintenance will not void the emissions warranty but may affect emissions.) J Have ...

63 MAINTENANCE AND LUBRICATION Lubrication Recommendations Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart beginning on page 60. Items not listed in the chart should be lubricated at the General Lubrication interval. NOTE: The a-arms and lower control a...

64 MAINTENANCE AND LUBRICATION Engine Oil Always check and change the engine oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 58. Always change the oil filter whenever changing oil. Premium 4 Synthetic Oil Polaris Premium 4 All Season Synthetic engine oil has been sp...

65 MAINTENANCE AND LUBRICATION Engine Oil 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...

66 MAINTENANCE AND LUBRICATION Transmission Oil Oil Check The transmission dipstick (1) is located on the right side of the machine near the recoil handle. Check and change the lubricant at the intervals outlined in the Periodic Maintenance Chart beginning on page 60. NOTE: We recommend the use of P...

67 MAINTENANCE AND LUBRICATION Transmission Oil Oil Change 1. Place a drain pan beneath the transmission oil drain plug area. 2. Loosen the jam nut (A).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 remove accu...

68 MAINTENANCE AND LUBRICATION 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 b...

69 MAINTENANCE AND LUBRICATION 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 ...

70 MAINTENANCE AND LUBRICATION Toe Alignment 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. Use the following procedure to check the toe ali...

71 MAINTENANCE AND LUBRICATION 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.2. Grasp the rear of the side panel near the rear cab. With a quick and firm motion, pull the panel forward...

72 MAINTENANCE AND LUBRICATION Camber and Caster The camber and caster are non-adjustable. Rear Spring The rear shock absorber spring is adjusted by rotating the adjuster (1) either clockwise or counterclockwise to increase or decrease spring tension. NOTE: Accessory springs are available through yo...

73 MAINTENANCE AND LUBRICATION 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 o...

1 2 3 74 MAINTENANCE AND LUBRICATION Throttle Cable Freeplay Throttle cable freeplay is adjusted at the handlebar.1. Locate the throttle cable adjuster on the handlebar. 2. Squeeze the end of the rubber boot (1) and slide it far enough to expose the end of the inline cable adjuster (2). 3. Loosen th...

75 MAINTENANCE AND LUBRICATION Wheels 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 th...

76 MAINTENANCE AND LUBRICATION Wheels Wheel Installation 1. Place the transmission in gear and lock the parking brake. WARNING Improperly installed wheels can adversely affect tire wear and vehicle handling, which can result in serious injury or death. Always ensure that all nuts are torqued to spec...

77 MAINTENANCE AND LUBRICATION Wheels 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 inflat...

78 MAINTENANCE AND LUBRICATION 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 t...

79 MAINTENANCE AND LUBRICATION 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 without the hit...

80 MAINTENANCE AND LUBRICATION 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 ...

81 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 pr...

82 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 taillig...

83 MAINTENANCE AND LUBRICATION Lights 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).3. Apply d...

84 MAINTENANCE AND LUBRICATION Spark Plugs Spark Plug Recommendations CAUTION Using non-recommended spark plugs can result in serious engine damage. Always use Polaris-recommended spark plugs. See Specifications beginning on page 103. Refer to the specifications section beginning on page 103 for the...

85 MAINTENANCE AND LUBRICATION Spark Plugs Spark Plug Inspection Normal Plug The normal insulator tip is gray, tan or light brown. There will be few combustion deposits. The electrodes are not burned or eroded. This indicates the proper type and heat range for the engine and the service. NOTE: The t...

86 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...

87 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 componen...

88 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 “pin...

89 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 precisio...

90 MAINTENANCE AND LUBRICATION Battery Your ATV may have either a sealed battery, which requires little maintenance, or a conventional battery. A sealed battery can be identified by its flat covers on the top of the battery. A conventional battery has six filler caps on the top of the battery. Conve...

91 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...

92 MAINTENANCE AND LUBRICATION Battery Battery Installation Using a new battery that has not been fully charged can damage the battery and result in a shorter life. It can also hinder vehicle performance. Follow the battery charging instructions on pages 94-96 before installing the battery.1. Ensure...

93 MAINTENANCE AND LUBRICATION Battery Battery Storage Whenever the vehicle is not used for a period of three months or more, remove the battery from the vehicle, ensure that it’s fully charged, and store it out of the sun in a cool, dry place. Check battery voltage each month during storage and rec...

95 MAINTENANCE AND LUBRICATION Battery Battery Charging (Sealed Battery) The following battery charging instructions apply only to the installation of a sealed battery. Read all instructions before proceeding with the installation of this battery.The sealed battery is already filled with electrolyte...

96 MAINTENANCE AND LUBRICATION Battery Battery Charging (Sealed Battery) NOTE: Always verify battery condition before and 1-2 hours after the end of charging. State of Charge Voltage Action Charge Time* (Using constant current charger @ standard amps specified on top of battery) 100% 12.8-13.0 volts...

97 MAINTENANCE AND LUBRICATION Cleaning and Storage See page 106 for the part numbers of Polaris products. Washing the Vehicle Keeping your ATV clean will not only improve its appearance but it can also extend the life of various components. CAUTION High water pressure may damage ATV components. Pol...

98 MAINTENANCE AND LUBRICATION Cleaning and Storage Washing the Vehicle If a high pressure water system is used for cleaning (not recommended), exercise extreme caution. The water may damage components and could remove paint and decals. Avoid directing the water stream at the following items: S Whee...

99 MAINTENANCE AND LUBRICATION Cleaning and Storage Chrome Wheel Care (if equipped) Proper maintenance will protect chrome wheels from corrosion, preserve wheel life and ensure a ”like new” appearance for many years. NOTE: Chrome wheels exposed to road salt (or salt in the air in coastal areas) are ...

100 MAINTENANCE AND LUBRICATION Cleaning and Storage Storage Tips 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. Clean the Exterior Make any necessary repairs and clea...

101 MAINTENANCE AND LUBRICATION Cleaning and Storage Storage Tips Fluid Levels Inspect the fluid levels. Add or change fluids as recommended in the Periodic Maintenance Chart beginning on page 60. S Demand drive unit (front gearcase) S Rear gearcase (if equipped) S Transmission S Brake fluid (change...

102 MAINTENANCE AND LUBRICATION Cleaning and Storage Storage Tips Inspect and Lubricate Inspect all cables and lubricate all areas of the vehicle as recommended in the Periodic Maintenance Chart beginning on page 60. Battery Storage See pages 93-96 for storage and charging procedures. Storage Area/C...

103 SPECIFICATIONS 2007 Trail Boss Capacities Body Style Gen IV Gross Vehicle Weight 845 lbs. (383 kg) Fuel Capacity 3.25 gal. (12.35 l) Transmission Oil 11.3 oz. (335 ml) Engine Oil Capacity 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...

105 SPECIFICATIONS 2007 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) 127.5 122.5 1800-3700 (6000-12000) 120 115 Clutching Chart Altitude Shift Weight Drive Clutch Spring Driven Clutch Spring Helix/...

106 POLARIS PRODUCTS Part No. Description Engine Lubricant 2870791 Fogging Oil (12 oz. Aerosol) 2871098 Premium Blue 2-Cycle Mineral Oil (qt.) 2871097 Premium Blue 2-Cycle Mineral Oil (gal.) 2871721 Premium Gold Synthetic 2-Cycle Oil (qt.) 2871722 Premium Gold Synthetic 2-Cycle Oil (gal.) 2871281 Pr...

107 TROUBLESHOOTING Contact your Polaris dealer for service if you’re unable to identify solutions using the following charts. Drive Belt and Cover Problems Possible Cause Solution Driving onto a pickup or tall trailer in high range Shift transmission to low range during loading of the ATV to preven...

108 TROUBLESHOOTING Engine Doesn’t Turn Over Possible Cause Solution Low battery voltage Recharge battery to 12.8 VDC or higher Loose battery connections Check all connections and tighten Loose solenoid connections Check all connections and tighten Engine Turns Over, Fails to Start Possible Cause So...

109 TROUBLESHOOTING Engine Backfires Possible Cause Solution Weak spark from spark plugs Inspect, clean and/or replace spark plugs Incorrect spark plug gap or heat range Set gap to specs or replace plugs Old or non-recommended fuel Replace with new fuel Incorrectly installed spark plug wires See you...

110 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 defecti...

111 WARRANTY LIMITED WARRANTY Polaris Sales Inc., 2100 Highway 55, Medina, MN 55340, gives a SIX MONTH LIMITED WARRANTY on all components of the Polaris All Terrain Vehicle (ATV) against defects in material or workmanship. Polaris also gives a one year limited warranty on the final drive chain for f...

112 WARRANTY WARRANTY COVERAGE AND EXCLUSIONS: LIMITATIONS OF WARRANTIES AND REMEDIES ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE) ARE LIMITED IN DURATION TO THE ABOVE SIX MONTH WARRAN- TY PERIOD. POLARIS FURTHER...

113 WARRANTY Exported Vehicles EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE IS NO WAR- RANTY OR SERVICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD OUTSIDE THE COUNTRY OF THE SELLING DEALER’S AUTHORIZED LOCA- TION.This policy does not apply to vehicles that have received authorization for ex...

115 MAINTENANCE LOG Periodic Maintenance Record Use the following chart to record periodic maintenance. DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS

118 INDEX A Age Restrictions 6 . . . . . . . . . . . . . . . . Air Filter 81 . . . . . . . . . . . . . . . . . . . . . Auxiliary Brake 35, 69 . . . . . . . . . . . . B Battery 91-96 . . . . . . . . . . . . . . . . . . . . Battery (Conventional) 90 . . . . . . . . . . Battery Charging (Conventional) ...