Polaris trailboss 04 - Manuals

5 TABLE OF CONTENTS WELCOME 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VEHICLE IDENTIFICATION NUMBERS 6 . . . . . . . . SAFETY 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FEATURES AND CONTROLS 36 . . . . . . . . . . . . . . . OPERATION 46 . . . . ...

6 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 essenti...

7 SAFETY Operator Safety Age Restrictions This vehicle is an ADULT VEHICLE ONLY. Operation is prohibited for anyone under 16 years of age. Know Your Vehicle As the operator of the vehicle, you are responsible for your personal safety, the safety of others, and the protection of our environment. Read...

8 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 ...

9 SAFETY Operator Safety 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. Contact an authorized Polaris ATV dealer or ...

11 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...

12 SAFETY Operator Safety 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 HAZARDBeginning...

13 SAFETY Operator Safety POTENTIAL HAZARDCarrying a passenger on an ATV.WHAT CAN HAPPENCarrying 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 HAZARDNever carry a passenger...

14 SAFETY Operator Safety POTENTIAL HAZARDOperating an ATV on paved surfaces, including sidewalks, paths, parking lots, and driveways.WHAT CAN HAPPENATV 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 ...

15 SAFETY Operator Safety POTENTIAL HAZARDOperating this ATV on public streets, roads or highways.WHAT CAN HAPPENThe ATV could collide with another vehicle.HOW TO AVOID THE HAZARDNever operate the ATV on any public street, road or highway, including dirt and gravel roads. In many states it’s illegal...

16 SAFETY Operator Safety POTENTIAL HAZARDOperating this ATV without wearing an approved helmet, eye protection and protective clothing.WHAT CAN HAPPENOperating 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 pro...

17 SAFETY Operator Safety 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 drugs b...

19 SAFETY Operator Safety POTENTIAL HAZARDFailure to inspect the ATV before operating.Failure to properly maintain the ATV.WHAT CAN HAPPENPoor maintenance increases the possibility of an accident or equipment damage.HOW TO AVOID THE HAZARDAlways inspect your ATV before each use to make sure it’s in ...

20 SAFETY Operator Safety POTENTIAL HAZARDFailure to use extra caution when operating the ATV on unfamiliar terrain.WHAT CAN HAPPENUnfamiliar terrain may contain hidden rocks, bumps, or holes that could cause loss of control or overturn.HOW TO AVOID THE HAZARDTravel slowly and use extra caution when...

21 SAFETY Operator Safety 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 overtur...

22 SAFETY Operator Safety POTENTIAL HAZARDTurning improperly.WHAT CAN HAPPENImproper turns could cause loss of control and lead to a collision or overturn.HOW TO AVOID THE HAZARDAlways follow proper procedures for turning as described in the owner’s manual.Practice turning at slow speeds before atte...

23 SAFETY Operator Safety POTENTIAL HAZARDClimbing hills improperly.WHAT CAN HAPPENImproper hill climbing could cause loss of control or overturn.HOW TO AVOID THE HAZARDAlways follow proper procedures for climbing hills as described in the owner’s manual.Always check the terrain carefully before asc...

24 SAFETY Operator Safety POTENTIAL HAZARDTraveling downhill improperly.WHAT CAN HAPPENImproperly descending a hill could cause loss of control or overturn.HOW TO AVOID THE HAZARDAlways follow proper procedures for traveling down hills as described in the owner’s manual. NOTE: A special technique is...

25 SAFETY Operator Safety 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 technique ...

26 SAFETY Operator Safety 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 single leve...

27 SAFETY Operator Safety 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 fallen trees...

30 SAFETY Operator Safety POTENTIAL HAZARDOverloading the ATV or carrying/towing cargo improperly.WHAT CAN HAPPENOverloading and towing can cause changes in vehicle handling, which could lead to loss of control or an accident.HOW TO AVOID THE HAZARDNever exceed the stated load capacity for this ATV....

32 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 instr...

34 SAFETY Safety Decals and Locations 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. WARNING 7078253 Chain Freeplay Is Important. Adjust Freeplay to 3/16 ″ - 3/8 ″ DO NOT Overtension. See Owner’s Manua...

35 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 injur...

36 FEATURES AND CONTROLS Electrical Switches 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. WARNING Override Switch (1) (Reverse Speed Limiter) - This vehicle is...

37 FEATURES AND CONTROLS Throttle Lever Engine speed and vehicle movement are controlled by pressing the throttle lever. The throttle lever (1) is spring loaded. Engine speed returns to idle when the lever is released.This ATV is equipped with Polaris Electronic Throttle Control (ETC), which is desi...

38 FEATURES AND CONTROLS Light Switches The light switch is located on the left handlebar (1). It’s used to turn the lights on and off and to switch the lights from HI to LO on models equipped with HI-LO beams. NOTE: The lights won’t work unless the key is in the ON position and the shut-off switch ...

39 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 ...

40 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...

41 FEATURES AND CONTROLS Auxiliary Brake The auxiliary brake (1), is located on the inside of the right floor board and is operated by the right foot. The auxiliary brake serves as a backup to the main brake system if the main system becomes inoperative.If the rear wheels slide while using the auxil...

42 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 pane...

43 FEATURES AND CONTROLS Fuel Safety Gasoline is highly flammable and explosive under certain conditions. S Always exercise extreme caution whenever handling gaso- line. S Always refuel with the engine stopped, and outdoors or in a well ventilated area. S Do not smoke or allow open flames or sparks ...

44 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 Whenever the ATV is left unattended, always place the transmission in gear with the parking brake locked.Maintaining shift linkage a...

45 FEATURES AND CONTROLS Recoil Starter 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 wi...

46 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...

47 OPERATION Pre-Ride Inspection 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. All brakes - Check operation, ...

48 OPERATION Starting the Engine Starting a Cold Engine 1. Place the transmission in neutral and lock the parking brake. Make sure the fuel tank valve is on. 2. Sit on the vehicle and pull the choke knob out until it stops (1). NOTE: If the knob doesn’t stay where positioned, increase the tension by...

49 OPERATION Starting the Engine 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...

50 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...

52 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...

53 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 tractio...

54 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...

55 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...

56 OPERATION Driving Safely Sidehilling 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. Lean into the hill, transferring your upper body weight toward th...

57 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...

58 OPERATION Driving Safely Turning Around on a Hill 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. Stop and lock the parking brake while keeping body weight uphill.2. L...

59 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 ...

60 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. Severe injury or death can result if your vehicle comes in contact with a hidden obstacle. Not all ...

61 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...

62 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...

63 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 ...

64 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 ...

65 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. Item Hours/ Miles Frequency Remarks Brake Syst...

69 MAINTENANCE AND LUBRICATION Periodic Maintenance Record Use the following chart to record periodic maintenance. Maintenance Interval Performed Servicing Date Servicing Dealer or Person Remarks 10 hrs.20 hrs.50 hrs. 100 hrs.

70 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, ...

71 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 lub...

72 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. 4. Place a drain pan beneath the engine crankcase and remove the...

73 MAINTENANCE AND LUBRICATION Lubrication Recommendations Transmission Oil Check The transmission dipstick (1) is 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 annu...

74 MAINTENANCE AND LUBRICATION Lubrication Recommendations Transmission 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 ...

75 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 clea...

76 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 mor...

78 MAINTENANCE AND LUBRICATION Adjustments 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. NOTE: The steering frog can be used as an indicator of whether ...

79 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.2. Grasp the rear of the side panel near the rear cab. With a quick and firm motion, pull the pa...

80 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-...

81 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 mixtu...

82 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...

83 MAINTENANCE AND LUBRICATION Adjustments Wheel Removal 1. Stop the engine, place the transmission in gear and lock the parking brake. 2. Loosen the wheel nuts slightly.3. Elevate the side of the vehicle by placing a suitable stand under the footrest frame. 4. Remove the wheel nuts and remove the w...

84 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 finge...

85 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 Always replace tires when tread depth is worn to 1/8 ″ (.3 cm) or le...

86 MAINTENANCE AND LUBRICATION Adjustments Rear Drive Chain Slack 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. At this point the cha...

88 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 miss...

89 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...

90 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. Headlight Lamp Replacement 1. Remove the wire harness connector from the back of the headlight....

91 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) and replac...

92 MAINTENANCE AND LUBRICATION Spark Plugs 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. 1. Normal Th...

93 MAINTENANCE AND LUBRICATION Vehicle Immersion 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. T...

94 MAINTENANCE AND LUBRICATION Spark Arrestor 1. Remove the arrestor clean-out plug (1) from the bottom of the muffler. 2. Place the transmission in neutral and start the engine. 3. Purge carbon from the system by momentarily revving the engine several times. 4. If carbon is expelled, cover or plug ...

95 MAINTENANCE AND LUBRICATION Recoil Housing To prevent possible engine damage, 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 g...

96 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...

97 MAINTENANCE AND LUBRICATION PVT System PVT Drying There may be some instances when water is accidently ingested into the PVT system. Use the following instructions to dry it out before operating:1. Move the ATV to dry land, or to water that is at least three inches below the footwell. Remove the ...

98 MAINTENANCE AND LUBRICATION Battery Battery Removal 1. Disconnect the battery hold-down strap and remove the battery cover.2. Disconnect the black (negative) battery cable first.3. Disconnect the red (positive) battery cable next.4. Lift the battery out of the ATV. Battery Installation When insta...

99 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...

100 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 Action Charge Time* (Using constant current charger @ standard amps specified on top of battery) 100% 12.8-13.0 volts None, check at ...

101 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...

102 MAINTENANCE AND LUBRICATION Cleaning and Storage Storage Tips See page 108 for the part numbers of Polaris products. 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. ...

103 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 cont...

104 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 se...

105 SPECIFICATIONS 2004 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...

107 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) 127.5 122.5 1800-3700 (6000-12000) 120 115 Clutching Chart Altitude Shift Weight Drive Clutch Spring Driven Clutch Spring Helix/...

108 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-Cyc...

109 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 ...

110 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 12.8 VDC or higher Loose battery connections Check all connections and tighten Loose...

111 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...

112 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...

113 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...

114 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...

115 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...

116 INDEX A Accessories 64 . . . . . . . . . . . . . . . . . . . Adjustments 76-88 . . . . . . . . . . . . . . . . Age Restrictions 7 . . . . . . . . . . . . . . . . Air Filter 89 . . . . . . . . . . . . . . . . . . . . . Auxiliary Brake 41, 77 . . . . . . . . . . . . B Battery 98-100 . . . . . . . ...

5 TABLE OF CONTENTS WELCOME 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VEHICLE IDENTIFICATION NUMBERS 6 . . . . . . . . SAFETY 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FEATURES AND CONTROLS 36 . . . . . . . . . . . . . . . OPERATION 46 . . . . ...

6 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 essenti...

7 SAFETY Operator Safety Age Restrictions This vehicle is an ADULT VEHICLE ONLY. Operation is prohibited for anyone under 16 years of age. Know Your Vehicle As the operator of the vehicle, you are responsible for your personal safety, the safety of others, and the protection of our environment. Read...

8 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 ...

9 SAFETY Operator Safety 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. Contact an authorized Polaris ATV dealer or ...

11 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...

12 SAFETY Operator Safety 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 HAZARDBeginning...

13 SAFETY Operator Safety POTENTIAL HAZARDCarrying a passenger on an ATV.WHAT CAN HAPPENCarrying 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 HAZARDNever carry a passenger...

14 SAFETY Operator Safety POTENTIAL HAZARDOperating an ATV on paved surfaces, including sidewalks, paths, parking lots, and driveways.WHAT CAN HAPPENATV 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 ...

15 SAFETY Operator Safety POTENTIAL HAZARDOperating this ATV on public streets, roads or highways.WHAT CAN HAPPENThe ATV could collide with another vehicle.HOW TO AVOID THE HAZARDNever operate the ATV on any public street, road or highway, including dirt and gravel roads. In many states it’s illegal...

16 SAFETY Operator Safety POTENTIAL HAZARDOperating this ATV without wearing an approved helmet, eye protection and protective clothing.WHAT CAN HAPPENOperating 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 pro...

17 SAFETY Operator Safety 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 drugs b...

19 SAFETY Operator Safety POTENTIAL HAZARDFailure to inspect the ATV before operating.Failure to properly maintain the ATV.WHAT CAN HAPPENPoor maintenance increases the possibility of an accident or equipment damage.HOW TO AVOID THE HAZARDAlways inspect your ATV before each use to make sure it’s in ...

20 SAFETY Operator Safety POTENTIAL HAZARDFailure to use extra caution when operating the ATV on unfamiliar terrain.WHAT CAN HAPPENUnfamiliar terrain may contain hidden rocks, bumps, or holes that could cause loss of control or overturn.HOW TO AVOID THE HAZARDTravel slowly and use extra caution when...

21 SAFETY Operator Safety 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 overtur...

22 SAFETY Operator Safety POTENTIAL HAZARDTurning improperly.WHAT CAN HAPPENImproper turns could cause loss of control and lead to a collision or overturn.HOW TO AVOID THE HAZARDAlways follow proper procedures for turning as described in the owner’s manual.Practice turning at slow speeds before atte...

23 SAFETY Operator Safety POTENTIAL HAZARDClimbing hills improperly.WHAT CAN HAPPENImproper hill climbing could cause loss of control or overturn.HOW TO AVOID THE HAZARDAlways follow proper procedures for climbing hills as described in the owner’s manual.Always check the terrain carefully before asc...

24 SAFETY Operator Safety POTENTIAL HAZARDTraveling downhill improperly.WHAT CAN HAPPENImproperly descending a hill could cause loss of control or overturn.HOW TO AVOID THE HAZARDAlways follow proper procedures for traveling down hills as described in the owner’s manual. NOTE: A special technique is...

25 SAFETY Operator Safety 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 technique ...

26 SAFETY Operator Safety 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 single leve...

27 SAFETY Operator Safety 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 fallen trees...

30 SAFETY Operator Safety POTENTIAL HAZARDOverloading the ATV or carrying/towing cargo improperly.WHAT CAN HAPPENOverloading and towing can cause changes in vehicle handling, which could lead to loss of control or an accident.HOW TO AVOID THE HAZARDNever exceed the stated load capacity for this ATV....

32 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 instr...

34 SAFETY Safety Decals and Locations 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. WARNING 7078253 Chain Freeplay Is Important. Adjust Freeplay to 3/16 ″ - 3/8 ″ DO NOT Overtension. See Owner’s Manua...

35 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 injur...

36 FEATURES AND CONTROLS Electrical Switches 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. WARNING Override Switch (1) (Reverse Speed Limiter) - This vehicle is...

37 FEATURES AND CONTROLS Throttle Lever Engine speed and vehicle movement are controlled by pressing the throttle lever. The throttle lever (1) is spring loaded. Engine speed returns to idle when the lever is released.This ATV is equipped with Polaris Electronic Throttle Control (ETC), which is desi...

38 FEATURES AND CONTROLS Light Switches The light switch is located on the left handlebar (1). It’s used to turn the lights on and off and to switch the lights from HI to LO on models equipped with HI-LO beams. NOTE: The lights won’t work unless the key is in the ON position and the shut-off switch ...

39 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 ...

40 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...

41 FEATURES AND CONTROLS Auxiliary Brake The auxiliary brake (1), is located on the inside of the right floor board and is operated by the right foot. The auxiliary brake serves as a backup to the main brake system if the main system becomes inoperative.If the rear wheels slide while using the auxil...

42 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 pane...

43 FEATURES AND CONTROLS Fuel Safety Gasoline is highly flammable and explosive under certain conditions. S Always exercise extreme caution whenever handling gaso- line. S Always refuel with the engine stopped, and outdoors or in a well ventilated area. S Do not smoke or allow open flames or sparks ...

44 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 Whenever the ATV is left unattended, always place the transmission in gear with the parking brake locked.Maintaining shift linkage a...

45 FEATURES AND CONTROLS Recoil Starter 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 wi...

46 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...

47 OPERATION Pre-Ride Inspection 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. All brakes - Check operation, ...

48 OPERATION Starting the Engine Starting a Cold Engine 1. Place the transmission in neutral and lock the parking brake. Make sure the fuel tank valve is on. 2. Sit on the vehicle and pull the choke knob out until it stops (1). NOTE: If the knob doesn’t stay where positioned, increase the tension by...

49 OPERATION Starting the Engine 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...

50 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...

52 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...

53 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 tractio...

54 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...

55 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...

56 OPERATION Driving Safely Sidehilling 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. Lean into the hill, transferring your upper body weight toward th...

57 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...

58 OPERATION Driving Safely Turning Around on a Hill 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. Stop and lock the parking brake while keeping body weight uphill.2. L...

59 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 ...

60 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. Severe injury or death can result if your vehicle comes in contact with a hidden obstacle. Not all ...

61 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...

62 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...

63 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 ...

64 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 ...

65 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. Item Hours/ Miles Frequency Remarks Brake Syst...

69 MAINTENANCE AND LUBRICATION Periodic Maintenance Record Use the following chart to record periodic maintenance. Maintenance Interval Performed Servicing Date Servicing Dealer or Person Remarks 10 hrs.20 hrs.50 hrs. 100 hrs.

70 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, ...

71 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 lub...

72 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. 4. Place a drain pan beneath the engine crankcase and remove the...

73 MAINTENANCE AND LUBRICATION Lubrication Recommendations Transmission Oil Check The transmission dipstick (1) is 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 annu...

74 MAINTENANCE AND LUBRICATION Lubrication Recommendations Transmission 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 ...

75 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 clea...

76 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 mor...

78 MAINTENANCE AND LUBRICATION Adjustments 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. NOTE: The steering frog can be used as an indicator of whether ...

79 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.2. Grasp the rear of the side panel near the rear cab. With a quick and firm motion, pull the pa...

80 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-...

81 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 mixtu...

82 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...

83 MAINTENANCE AND LUBRICATION Adjustments Wheel Removal 1. Stop the engine, place the transmission in gear and lock the parking brake. 2. Loosen the wheel nuts slightly.3. Elevate the side of the vehicle by placing a suitable stand under the footrest frame. 4. Remove the wheel nuts and remove the w...

84 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 finge...

85 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 Always replace tires when tread depth is worn to 1/8 ″ (.3 cm) or le...

86 MAINTENANCE AND LUBRICATION Adjustments Rear Drive Chain Slack 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. At this point the cha...

88 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 miss...

89 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...

90 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. Headlight Lamp Replacement 1. Remove the wire harness connector from the back of the headlight....

91 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) and replac...

92 MAINTENANCE AND LUBRICATION Spark Plugs 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. 1. Normal Th...

93 MAINTENANCE AND LUBRICATION Vehicle Immersion 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. T...

94 MAINTENANCE AND LUBRICATION Spark Arrestor 1. Remove the arrestor clean-out plug (1) from the bottom of the muffler. 2. Place the transmission in neutral and start the engine. 3. Purge carbon from the system by momentarily revving the engine several times. 4. If carbon is expelled, cover or plug ...

95 MAINTENANCE AND LUBRICATION Recoil Housing To prevent possible engine damage, 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 g...

96 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...

97 MAINTENANCE AND LUBRICATION PVT System PVT Drying There may be some instances when water is accidently ingested into the PVT system. Use the following instructions to dry it out before operating:1. Move the ATV to dry land, or to water that is at least three inches below the footwell. Remove the ...

98 MAINTENANCE AND LUBRICATION Battery Battery Removal 1. Disconnect the battery hold-down strap and remove the battery cover.2. Disconnect the black (negative) battery cable first.3. Disconnect the red (positive) battery cable next.4. Lift the battery out of the ATV. Battery Installation When insta...

99 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...

100 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 Action Charge Time* (Using constant current charger @ standard amps specified on top of battery) 100% 12.8-13.0 volts None, check at ...

101 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...

102 MAINTENANCE AND LUBRICATION Cleaning and Storage Storage Tips See page 108 for the part numbers of Polaris products. 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. ...

103 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 cont...

104 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 se...

105 SPECIFICATIONS 2004 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...

107 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) 127.5 122.5 1800-3700 (6000-12000) 120 115 Clutching Chart Altitude Shift Weight Drive Clutch Spring Driven Clutch Spring Helix/...

108 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-Cyc...

109 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 ...

110 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 12.8 VDC or higher Loose battery connections Check all connections and tighten Loose...

111 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...

112 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...

113 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...

114 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...

115 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...

116 INDEX A Accessories 64 . . . . . . . . . . . . . . . . . . . Adjustments 76-88 . . . . . . . . . . . . . . . . Age Restrictions 7 . . . . . . . . . . . . . . . . Air Filter 89 . . . . . . . . . . . . . . . . . . . . . Auxiliary Brake 41, 77 . . . . . . . . . . . . B Battery 98-100 . . . . . . . ...