Polaris Trailboss 7174820 User Manual

1WELCOMEThank you for purchasing a P olaris vehicle, and welcome to ourworld-wide family of Polaris owners. We proudly produce an excitingline of util

10SAFETYOperator SafetyS Wet brakes may have reduced stopping ability. Test your brakes afterleaving water. If necessary, apply t hem lightly several

100MAINTENANCE AND LUBRICATIONCleaning and StorageStorage TipsCAUTIONStarting the engine during the storage period will disturb theprotective film cre

101MAINTENANCE AND LUBRICATIONCleaning and StorageStorage TipsFluid LevelsInspect the fluid levels. Add or change fluids as recommended in thePeriodic

102MAINTENANCE AND LUBRICATIONCleaning and StorageStorage TipsInspect and LubricateInspect all cables and lubricate all areas of the vehicle as recomm

103SPECIFICATIONS2008 Trail BossCapacitiesBody Style Gen IVMaximum Weight Capacity 415 lbs. (188 kg)Fuel Capacity 3.25 gal. (12.35 l)Transmission Oil

104SPECIFICATIONS2008 Trail BossDrive SystemDrive System Type PVTShift Type Side Lever (F-N-R)Gear Reduction - Reverse 3.05/1Gear Reduction - Forward

105SPECIFICATIONS2008 Trail BossJetting ChartAltitude AMBIENTTEMPERATUREBelow 40° F(Below 5° C)+40°F and above(+5°C and above)Meters(Feet)0-1800(0-600

106POLARIS PRODUCTSPart No. DescriptionEngine Lubricant2870791 Fogging Oil (12 oz. Aerosol)2871098 Premium Blue 2-Cycle Mineral Oil (qt.)2871097 Premi

107TROUBLESHOOTINGContact your Polaris dealer for service if you’re unable t o identifysolutions using the following charts.Drive Belt and Cover Probl

108TROUBLESHOOTINGEngine Doesn’t Turn OverPossible Cause SolutionLow battery voltage Recharge battery to 12.8 VDC or higherLoose battery connections C

109TROUBLESHOOTINGEngine BackfiresPossible Cause SolutionWeak spark from spark plugs Inspect, clean and/or replace spark plugsIncorrect spark plug gap

11SAFETYOperator SafetyWARNINGPOTENTIAL HAZARDOperating this ATV without proper instruction.WHAT CANHAPPENThe risk of an accident is greatly increased

110TROUBLESHOOTINGEngine Stops or Loses PowerPossible Cause SolutionOut o f fuel Turn fuel valve to reserve, refuelKinked or plugged fuel system vent

111WARRANTYLIMITED WARRANTYPolaris Sales Inc., 2100 Highway 55, Medina, MN 55340, gives a SIX MONTH LIMITEDWARRANTY on all components of the Polaris A

112WARRANTYWARRANTY COVERAGE AND EXCLUSIONS:LIMITATIONS OF WARRANTIES AND REMEDIESALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE IMPLIEDWARR

113WARRANTYExported VehiclesEXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE IS NO WAR-RANTY OR SERVICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOL

114WARRANTYU.S.A. EPA Emissions Limited WarrantyThis All Terrain Vehicle (ATV) or Off Road Utility Vehicle (ORUV) emissions limitedwarranty is in addi

115MAINTENANCE LOGPeriodic Mainten ance RecordUse the following chart to record periodic maintenance.DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / CO

116MAINTENANCE LOGDATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS

117MAINTENANCE LOGDATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS

12SAFETYOperator SafetyWARNINGPOTENTIAL HAZARDCarrying a passenger on anATV.WHAT CANHAPPENCarrying a passengergreatly reduces theoperator’s ability to

13SAFETYOperator SafetyWARNINGPOTENTIAL HAZARDOperating this ATV onpublic streets, roads orhighways.WHAT CANHAPPENThe ATV could collidewith another ve

14SAFETYOperator SafetyWARNINGPOTENTIAL HAZARDOperating the ATV after consumingalcohol or drugs.WHAT CANHAPPENConsumption of alcohol and/or drugscould

15SAFETYOperator SafetyWARNINGPOTENTIAL HAZARDAttempting wheelies, jumpsand other stunts.WHAT CANHAPPENAttempting stunts increasesthe chance of an acc

16SAFETYOperator SafetyWARNINGPOTENTIAL HAZARDRemoving hands from the handlebars or feet from the footrestsduring operation.WHAT CANHAPPENRemoving eve

17SAFETYOperator SafetyWARNINGPOTENTIAL HAZARDFailure to use extracaution when operating onexcessively rough,slippery or loose terrain.WHAT CANHAPPENO

18SAFETYOperator SafetyWARNINGPOTENTIAL HAZARDOperating on excessively steep hills.WHAT CANHAPPENThe vehicle may overturn.HOW TO AVOID THEHAZARDNever

19SAFETYOperator SafetyWARNINGPOTENTIAL HAZARDT raveling downhillimproperly.WHAT CANHAPPENImproperly descending a hillcould cause loss of controlor ov

2Copyright 2007 Polaris Sales Inc. All information contained with in this publication isbased on the latest product information at the time of publica

20SAFETYOperator SafetyWARNINGPOTENTIAL HAZARDImproperly crossing hills andturning on hills.WHAT CANHAPPENImproperly crossing orturning as hills could

21SAFETYOperator SafetyWARNINGPOTENTIAL HAZARDStalling, rolling backwardsor improperly dismountingwhile climbing a hill.WHAT CANHAPPENThe vehicle coul

22SAFETYOperator SafetyWARNINGPOTENTIAL HAZARDImproperly operating over obstacles.WHAT CANHAPPENOperating over obstacles could cause loss of control o

23SAFETYOperator SafetyWARNINGPOTENTIAL HAZARDOperating the ATV through deep or fast-flowing water.WHAT CANHAPPENT ires may float, causing loss of tra

24SAFETYOperator SafetyWARNINGPOTENTIAL HAZARDOperating the ATV with improper modifications.WHAT CANHAPPENImproper installation of accessories or modi

25SAFETYOperator SafetyWARNINGLeaving the keys in the ignition can lead to unauthorized use ofthe vehicle resulting in serious injury or death. Always

12326SAFETYSafety Decals and LocationsWarning decals have been placed on the ATV for your protection. Readand follow the instructions of the decals an

27SAFETYSafety Decals and LocationsGeneral Warning (3)WARNINGImproper ATV use can result in SEVERE INJURY or DEATHALWAYS USE AN APPROVED HELMET AND PR

6754428SAFETYSafety Decals and LocationsRack Warning (4)WARNINGS DO NOT TOW FROMRACK OR BUMPER.Vehicle damage or tipovermay result causing severeinjur

29SAFETYSafe Riding GearAlways wear clothing suited to the type of riding. ATV riding requiresspecial protective clothing for comfort and to reduce th

3TABLE OF CONTENTSVEHICLE IDENTIFICATION NUMBERS 5...SAFETY 6...FEATURES AND CONTROLS 30...OPERATION 4

30FEATURES AND CONTROLSElectrical SwitchesWARNINGActivating the override switch while the throttle is open can causeloss of control, resulting in seve

31FEATURES AND CONTROLSWARNINGDo not start or operate an ATV with sticking or improperlyoperating throttle controls, which could cause an accident and

32FEATURES AND CONTROLSWARNINGOperating the ATV on streets or roads, especially in darkness,could result in an accident and serious injury or death.Yo

33FEATURES AND CONTROLSBrakesCheck the brake fluid level in themaster cylinder before each use of theATV. The master cylinder (1) islocated on the lef

34FEATURES AND CONTROLSBrake LeverThe front and rear brakes are applied bysqueezing the brake lever (1) toward thehandlebar. The front and rear brakes

35FEATURES AND CONTROLSAuxiliary BrakeWARNINGAggressively applying the rear brake when backing downhill maycause rear tipover, which could result in s

36FEATURES AND CONTROLSChokeThe choke assists in starting a cold engine. Refer to the engine startingprocedure on page 42 for correct choke and t hrot

37FEATURES AND CONTROLSFuel SafetyWARNINGGasoline is highly flammable and explosive under certainconditions.S Always exercise extreme caution whenever

38FEATURES AND CONTROLSAutomatic Transmission Gear SelectorThe transmission gear selector (1)is located on the right side of the ATV.F: ForwardN: Neut

1239FEATURES AND CONTROLSRecoil StarterIf the battery is too weak tostart t he engine, use the recoilstarter (1). Follow the startingprocedures on pag

4

40OPERATIONBreak-In PeriodThe break-in period for your new Polaris ATV is defined as the first tenhours of operation, or the time it takes to use the

41OPERATIONPre-Ride InspectionWARNINGIf a proper inspection is not done before each use, severe injuryor death could result. Always inspect the vehicl

42OPERATIONStarting the EngineWARNINGEngine exhaust contains poisonous carbon monoxide and cancause loss of consciousness resulting in severe injury o

43OPERATIONStarting the Engine7. Move the engine stop switch to RUN.NOTE: Do not press the throttle while starting the engine.8. Turn the i gnition ke

44OPERATIONHauling CargoYour ATV has been designed to carry or tow a certain amount of load.Always read and understand the load distribution warning l

45OPERATIONHauling CargoWARNINGHauling cargo improperly can alter vehicle handling and maycause loss of control or brake instability and result in ser

46OPERATIONDriving SafelyDriving Procedures1. Sit upright with both feet on the footrests and both hands on thehandlebars.2. Start the engine and allo

47OPERATIONDriving SafelyTurning the VehicleYour Polaris ATV is equipped with a solid rear axle that drives bothrear wheels equally at all times. This

48OPERATIONDriving SafelyDriving o n Slippery SurfacesWhenever riding on slippery surfaces such as wet trails or loose gravel,or during freezing weath

49OPERATIONDriving SafelyDriving UphillWhenever traveling uphill, followthese precautions:1. Always travel straight uphill.2. Avoid steep hills (25_ m

5VEHICLE IDENTIFICATION NUMBERSRecord your ATV’s identification numbers and key number in thespaces provided. Remove the spare key and store it in a s

50OPERATIONDriving SafelySidehillingWARNINGImproperly crossing hills or turning on hills can result in loss ofcontrol or vehicle overturn, resulting i

51OPERATIONDriving SafelyDriving DownhillWhenever descending a hill, follow these precautions:1. Proceed directly downhill.2. Transfer your weight to

8’ (2.4 m)52OPERATIONDriving SafelyTurning Around on a HillIf the vehicle stalls while climbing a hill, never back it down t he hill!Use the K-turn to

53OPERATIONDriving SafelyDriving Through WaterYour ATV can operatethrough water with amaximum recommendeddepth equal to the bottom ofthe footrests (1)

54OPERATIONDriving SafelyDriving Over ObstaclesBe alert! Look ahead and learn to read the terrain you’re traveling on.Be constantly alert for hazards

55OPERATIONDriving SafelyDriving in ReverseFollow these precautions when operating in reverse:1. Always avoidbacking downhill.2. Back slowly.3. When i

56OPERATIONDriving SafelyParkingonanInclineAvoid parking on an incline if possible. If it’s unavoidable, followthese precautions:1. Turn the engine of

57EMISSION CONTROL SYSTEMSNoise Emission Control SystemDo not modify the engine, intake or exhaust components, as doing somay affect compliance with U

58MAINTENANCE AND LUBRICATIONPeriodic Maintenance ChartCareful periodic maintenance will help keep your vehicle in t he safest,most reliable condition

59MAINTENANCE AND LUBRICATIONPeriodic Maintenance ChartMaintenance Chart Key" Perform these procedures more frequently for vehicles subjected tos

6SAFETYOperator SafetyWARNINGFailure to follow the warnings contained in this manual can resultin serious injury or death.A Polaris ATV is not a toy a

60MAINTENANCE AND LUBRICATIONPeriodic Maintenance ChartPerform all services at whichever maintenance interval is reached first.Item Maintenance Interv

61MAINTENANCE AND LUBRICATIONPeriodic Maintenance ChartItem Maintenance Interval(whichever comes first)RemarksHours Calendar Miles(Km)Carburetor float

62MAINTENANCE AND LUBRICATIONPeriodic Maintenance ChartItem Maintenance Interval(whichever comes first)RemarksHours Calendar Miles(Km)JClutches(drive

63MAINTENANCE AND LUBRICATIONLubrication RecommendationsCheck and lubricate all components at the intervals outlined in thePeriodic Maintenance Chart

64MAINTENANCE AND LUBRICATIONEngine OilAlways check and change the engine oil at t he intervals outlined in thePeriodic Maintenance Chart beginning on

65MAINTENANCE AND LUBRICATIONEngine OilOil and F ilter Chan ge1. Position the vehicle on a level surface.2. Clean the area around the drain plug.3. Ru

66MAINTENANCE AND LUBRICATIONTransmission OilOil CheckThe transmission dipstick (1) islocated on the right side of themachine near the recoil handle.C

67MAINTENANCE AND LUBRICATIONTransmission OilOil Change1. Place a drain pan beneath thetransmission oil drain plugarea.2. Loosen the jam nut (A).3. Tu

68MAINTENANCE AND LUBRICATIONBrakesThe front and rear brakes are hydraulic disc brakes, activated bymoving the single brake lever toward the handlebar

69MAINTENANCE AND LUBRICATIONBrakes2. Check the brake system for fluid leaks.3. Check the brakes for excessive travel orspongy feel.4. Check the frict

7SAFETYOperator SafetyThe following signal words and symbols appear throughout thismanual and on your ATV. Your safety is involved when these wordsand

AB70MAINTENANCE AND LUBRICATIONToe AlignmentWARNINGSevere injury or death can result from improper toe alignment andadjustment. Do not attempt to adju

71MAINTENANCE AND LUBRICATIONSide Panel RemovalNOTE: Side panel removal may be difficult until the locking tabs andreceivers have been snapped and uns

72MAINTENANCE AND LUBRICATIONCamber and CasterThe camber and caster are non-adjustable.Rear SpringThe rear shock absorber spring isadjusted by rotatin

73MAINTENANCE AND LUBRICATIONCarburetorIMPORTANT: Your Polaris ATV is calibrated at the factory foroptimal performance at altitudes ranging from zero

12374MAINTENANCE AND LUBRICATIONThrottle Cable FreeplayThrottle cable freeplay is adjusted at the handlebar.1. Locate t he throttle cableadjuster on t

75MAINTENANCE AND LUBRICATIONWheelsWARNINGOperating your ATV with worn tires, improperly inflated tires,non-standard tires or improperly installed tir

76MAINTENANCE AND LUBRICATIONWheelsWheel In stallation1. Place the transmission in gear and lock the parking brake.WARNINGImproperly installed wheels

77MAINTENANCE AND LUBRICATIONWheelsFront Wheel Hub TighteningFront wheel bearing tightness and spindle nut retention are criticalcomponent operations.

78MAINTENANCE AND LUBRICATIONRear Drive Chain SlackCAUTIONAdjusting or operating the ATV with improper rear drive chainslack can result in severe dama

79MAINTENANCE AND LUBRICATIONRear Drive Chain Slack6. Roll the ATV forward or backwardto adjust the chain slack to theproper tension. See the illustra

8SAFETYOperator SafetyWARNINGSerious injury or death can result if you do not follow theseinstructions and procedures, which are outlined in further d

80MAINTENANCE AND LUBRICATIONDrive ChainPolaris ATV drive chains are equipped with o-ring-sealed, permanentlygreased pins and rollers. However , the o

81MAINTENANCE AND LUBRICATIONAir Filter1. Remove the seat, release the clips,and remove the air box cover.2. Loosen the clamp and remove thefilter.3.

82MAINTENANCE AND LUBRICATIONLightsWhen servicing a halogen lamp, don’t touch the lamp with barefingers. Oil from your skin leaves a residue, causing

83MAINTENANCE AND LUBRICATIONLightsTaillig ht/Brakelight Lamp ReplacementIf the t aillight/brakelight does not work the lamp may need to bereplaced.1.

84MAINTENANCE AND LUBRICATIONSpark PlugsSpark Plug RecommendationsCAUTIONUsing non-recommended spark plugs can result in serious enginedamage. Always

85MAINTENANCE AND LUBRICATIONSpark PlugsSpark Plug InspectionNormal PlugThe normal insulator tip is gray, tan or light brown. There will be fewcombust

86MAINTENANCE AND LUBRICATIONVehicle ImmersionCAUTIONIf your vehicle becomes immersed, major engine damage canresult if the machine is not thoroughly

87MAINTENANCE AND LUBRICATIONSpark ArrestorWARNINGFailure to heed the following warnings while servicing the sparkarrestor could result in serious inj

88MAINTENANCE AND LUBRICATIONPVT SystemThe basic operation of the Polaris PVT system is dependent on enginespeed and vehicle torque requirements. As e

89MAINTENANCE AND LUBRICATIONPVT SystemWARNINGFailure to comply with the instructions in this warning can result insevere injury or death.Do not modif

9SAFETYOperator SafetyS Always have the ATV inspected by an authorized Polaris dealer ifit’s been involved in an accident.S Never operate on hills too

90MAINTENANCE AND LUBRICATIONBatteryYour ATV may have either a sealed battery, which requires littlemaintenance, or a conventional battery. A sealed b

91MAINTENANCE AND LUBRICATIONBatteryWARNINGImproperly connecting or disconnecting battery cables can resultin an explosion and cause serious injury or

92MAINTENANCE AND LUBRICATIONBatteryBattery Installatio nUsing a new battery that has not been fully charged can damage thebattery and result in a sho

93MAINTENANCE AND LUBRICATIONBatteryBattery StorageWhenever the vehicle is not used for a period of three months or more,remove the battery from the v

94MAINTENANCE AND LUBRICATIONBatteryBattery Fluid (Conventional Battery)A poorly maintained battery willdeteriorate rapidly. Check the batteryfluid le

95MAINTENANCE AND LUBRICATIONBatteryBattery Charging (Sealed Battery)The following battery charging instructions apply only to theinstallation of a se

96MAINTENANCE AND LUBRICATIONBatteryBattery Charging (Sealed Battery)NOTE: Always verify battery condition before and 1-2 hours after theend of chargi

97MAINTENANCE AND LUBRICATIONCleaning and StorageSee page 106 for the part numbers of P olaris products.Washin g the VehicleKeeping your ATV clean wil

98MAINTENANCE AND LUBRICATIONCleaning and StorageWashin g the VehicleIf a high pressure water system i s used for cleaning (notrecommended), exercise

99MAINTENANCE AND LUBRICATIONCleaning and StorageChrome Wheel Care (if equipped)Proper maintenance will protect chrome wheels from corrosion,preserve