Polaris Trail Boss 2007, Owner'S Manual

Page 1: ...tion This is an adult vehicle only Operation is prohibited for those under 16 years of age 2007 Trail Boss Owner s Manual for Maintenance and Safety 2007 Trail Boss Owner s Manual for Maintenance and...

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Page 3: ...he next page If you cannot locate this card or if it has been removed please call 1 800 342 3764 for assistance The engine exhaust from this product contains chemicals known to cause cancer birth defe...

Page 4: ...ation of your vehicle be sure to follow the instructions and recommendations in this owner s manual Your manual contains instructions for minor maintenance but information about major repairs is outli...

Page 5: ...t between the actual vehicle and the information presented in this publication Depictions and or procedures in this publication are intended for reference use only No liability can be accepted for omi...

Page 6: ...6 FEATURES AND CONTROLS 30 OPERATION 40 EMISSION CONTROL SYSTEMS 57 MAINTENANCE AND LUBRICATION 58 SPECIFICATIONS 97 POLARIS PRODUCTS 100 TROUBLESHOOTING 101 WARRANTY 105 MAINTENANCE LOG 109 INDEX 11...

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Page 8: ...ignition key can be duplicated only by ordering a Polaris key blank using your key number and mating it with one of your existing keys The ignition switch must be replaced if all keys are lost Vehicl...

Page 9: ...top priority for Polaris When you purchased your new ATV your dealer instructed you on the authorized ATV RiderCoursesm available to you and your eligible family members This training is included in t...

Page 10: ...al alerts you to the potential for personal injury WARNING The safety alert warning indicates a potential hazard that may result in serious injury or death CAUTION The safety alert caution indicates a...

Page 11: ...uding a dirt or gravel road S Never operate an ATV without wearing an approved helmet that fits properly Always wear eye protection goggles or face shield gloves boots a long sleeved shirt or jacket a...

Page 12: ...d on any hill until you ve mastered on level ground the turn ing technique outlined in this manual Avoid crossing the side of a steep hill when possible S Always use proper procedures if you stall or...

Page 13: ...ATV SAFETY call the Con sumer Product Safety Commission at 1 800 638 2772 or visit www cpsc gov visit www atvsafety org or call Polaris at 1 800 342 3764 Equipment Modifications We are concerned for t...

Page 14: ...es described in the Owner s Manual For more information about the ATV RiderCoursesm contact ATV Enrollment Express at 800 887 2887 or visit www atvsafety org WARNING POTENTIAL HAZARD Failure to follow...

Page 15: ...position as needed during operation It is not intended for carrying passengers WARNING POTENTIAL HAZARD Operating an ATV on paved surfaces including sidewalks paths parking lots and driveways WHAT CAN...

Page 16: ...his ATV without wearing an approved helmet eye protection and protective clothing WHAT CAN HAPPEN Operating an ATV without an approved helmet increases the risk of a severe head injury or death in the...

Page 17: ...TV could result in an accident causing severe injury or death HOW TO AVOID THE HAZARD Never consume alcohol or drugs before or while operating an ATV WARNING POTENTIAL HAZARD Operating the ATV at exce...

Page 18: ...iving WARNING POTENTIAL HAZARD Failure to inspect the ATV before operating Failure to properly maintain the ATV WHAT CAN HAPPEN Poor maintenance increases the possibility of an accident or equipment d...

Page 19: ...eels and lead to accident or injury HOW TO AVOID THE HAZARD Always keep both hands on the handlebars and both feet on the footrests of the ATV during operation WARNING POTENTIAL HAZARD Failure to use...

Page 20: ...ry or loose terrain until you ve learned and practiced the skills necessary to control the ATV on such terrain Always use extra caution on rough slippery or loose terrain WARNING POTENTIAL HAZARD Turn...

Page 21: ...e loss of control or overturn HOW TO AVOID THE HAZARD Always follow proper procedures for climbing hills as described in the owner s manual Always check the terrain carefully before ascending any hill...

Page 22: ...as described in the owner s manual NOTE A special technique is required when braking while traveling downhill See page 51 Always check the terrain carefully before descending a hill Shift your weight...

Page 23: ...ny hill until you ve mastered the turning technique on level ground as described in the owner s manual See page 52 Use extra caution when turning on any hill Avoid crossing the side of a steep hill Wh...

Page 24: ...uxiliary rear brake as well then lock the parking brake If the ATV begins rolling backwards Keep weight uphill Never apply engine power Never apply the auxiliary rear brake while rolling backwards App...

Page 25: ...Skidding or sliding WHAT CAN HAPPEN Skidding or sliding can cause loss of control If the tires regain traction unexpectedly the ATV could overturn HOW TO AVOID THE HAZARD On slippery surfaces such as...

Page 26: ...teady forward motion Do not make sudden turns or stops and do not make sudden throttle changes Wet brakes may have reduced stopping ability Always test the brakes after leaving water If necessary appl...

Page 27: ...TIAL HAZARD Overloading the ATV or carrying towing cargo improperly WHAT CAN HAPPEN Overloading and towing can cause changes in vehicle handling which could lead to loss of control or an accident HOW...

Page 28: ...tion of this rider active vehicle requires good judgement and physical skills Persons with cognitive or physical disabilities who operate this vehicle have an increased risk of overturn and loss of co...

Page 29: ...To prevent flipover on hilly terrain when going up or down use throttle and brakes gradually S REVERSE operation can be dangerous even at low speeds Steering becomes difficult To prevent flipover avo...

Page 30: ...he conditions S on public roads a collision can occur with another vehicle S with a passenger passengers affect balance and steering and increase risk of losing control ALWAYS S use proper riding tech...

Page 31: ...IRE PRESSURE OR OVERLOADING can cause loss of control resulting in SEVERE INJURY OR DEATH TIRE PRESSURE IN PSI KPa FRONT 4 27 6 REAR 3 20 7 MAXIMUM WEIGHT CAPACITY Gross Vehicle Weight INCLUDING MACHI...

Page 32: ...approval number and serial number will also be displayed on the label 2 Eye Protection Do not depend on eyeglasses or sunglasses for eye protection Whenever riding a Polaris vehicle always wear shatt...

Page 33: ...he engine starts NOTE Turning off the main switch will shut off all electrical power to the vehicle including the lights WARNING Leaving the keys in the ignition can lead to unauthorized use of the ve...

Page 34: ...nd 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 Electr...

Page 35: ...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...

Page 36: ...rake fluid at the recommended level Do not overfill NOTE When checking the fluid level the ATV must be on level ground with the handlebars straight If the fluid level is low add DOT 4 brake fluid only...

Page 37: ...ng the ATV while the parking brake is engaged could result in an accident and serious injury or death Always check to be sure the parking brake is disengaged before operating Setting the Parking Brake...

Page 38: ...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 inoper...

Page 39: ...bout a 7 to 10 mile 11 2 to 16 km range on reserve gas Always refill the gas tank as soon as possible after using the reserve supply Always return valve to ON position after refueling Fuel Tank The fu...

Page 40: ...nk Do not fill the tank neck S If gasoline spills on your skin or clothing immediately wash it off with soap and water and change clothing S Never start the engine or let it run in an enclosed area En...

Page 41: ...hifting gears with the engine speed above idle or while the vehicle is moving could cause transmission damage To change gears stop the vehicle and with the engine idling move the lever to the desired...

Page 42: ...ngine rolls past the stroke then stop pulling immediately 3 Allow the recoil rope to rewind into the recoil assembly then pull the rope abruptly and forcefully to start the engine 4 Repeat all steps u...

Page 43: ...Polaris Premium 4 Synthetic Oil if necessary to maintain the oil level in the safe operating range 1 3 Drive slowly at first Select an open area that allows room to familiarize yourself with vehicle...

Page 44: ...condition and pressure 77 Wheels fasteners Inspect ensure fastener tightness 76 Frame nuts bolts fasteners Inspect ensure tightness Fuel and oil Ensure proper levels 64 Throttle Ensure proper operati...

Page 45: ...he choke if starting a warm engine Excessive use of the choke can cause the spark plug to become wet fouled 6 If the engine is cold pull the choke knob out until it stops 1 NOTE The variable choke is...

Page 46: ...hoke button pulled half way out may be necessary If the engine is over choked when warm depress the throttle lever fully while cranking to aid in starting Release the throttle lever immediately after...

Page 47: ...d in the specifications section of the owner s manual and on the safety decals Cargo weight should be evenly distributed 1 3 on the front rack and 2 3 on the rear rack and mounted as low as possible W...

Page 48: ...NG Unsecured loads can create unstable operating conditions which could result in loss of control of the vehicle S OPERATE ONLY WITH STABLE AND SAFELY ARRANGED LOADS When handling off centered loads t...

Page 49: ...ansmission into gear 3 Check your surroundings and determine your path of travel 4 Release the parking brake 5 Slowly depress the throttle with your right thumb and begin driving Vehicle speed is cont...

Page 50: ...our upper body to the inside of the turn while supporting your weight on the outer footrest This technique alters the balance of traction between the rear wheels allowing the turn to be made smoothly...

Page 51: ...arp turns which can cause skids 3 Correct a skid by turning the handlebars in the direction of the skid and shifting your body weight forward WARNING Failure to exercise care when operating on slipper...

Page 52: ...Keep your weight uphill Never apply engine power Never apply the auxiliary rear brake while rolling backwards Apply the single lever brake gradually When fully stopped apply the auxiliary rear brake a...

Page 53: ...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 upp...

Page 54: ...the brakes slightly to aid in slowing using the single brake lever NOTE Familiarize yourself with operation of the auxiliary rear brake pedal for additional braking in the event of normal service brak...

Page 55: ...t uphill 4 Staying uphill of the vehicle turn the handlebars full left 5 While holding the brake lever release the parking brake lock and slowly allow the vehicle to roll around to your right until it...

Page 56: ...rease fittings CAUTION Major engine damage can result if the vehicle is not thoroughly inspected after operation in water Perform the services outlined in the maintenance chart If your vehicle becomes...

Page 57: ...on Be constantly alert for hazards such as logs rocks and low hanging branches WARNING Severe injury or death can result if your vehicle comes in contact with a hidden obstacle Not all obstacles are i...

Page 58: ...e When it s safe to proceed back slowly Do not use the override switch unless additional power is required for vehicle movement Use with caution Avoid backing on inclines and avoid turning at sharp an...

Page 59: ...ssible 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...

Page 60: ...Crankcase Emission Control System This engine is equipped with a closed crankcase system Blow by gases are forced back to the combustion chamber by the intake system All exhaust gases exit through the...

Page 61: ...cedures have a qualified dealer perform these operations Maintenance intervals in the following chart are based upon average riding conditions and an average vehicle speed of approximately 10 miles pe...

Page 62: ...to conduct this maintenance will not void the emissions warranty but may affect emissions J Have an authorized Polaris dealer perform these services WARNING Improperly performing the procedures marked...

Page 63: ...box sediment tube Daily Drain deposits when visible Headlamp tail lamp Daily Check operation apply dielectric grease if replacing E Air filter main element Weekly Inspect replace as needed Recoil hou...

Page 64: ...r change 100 H 6 M 1000 1600 Replace with oil change J E Valve clearance 100 H 12 M 1000 1600 Inspect adjust J E Fuel system 100 H 12 M 1000 1600 Check for leaks at tank cap lines fuel valve filter pu...

Page 65: ...ct replace as needed J Brake fluid 200 H 24 M 2000 3200 Change every two years Spark arrestor 300 H 36 M 3000 4800 Clean out Idle speed Adjust as needed J Toe adjustment Inspect periodically adjust wh...

Page 66: ...ions L Polaris Premium All Season Grease or grease conforming to NLG No 2 such as Conoco Superlube M or Mobilegrease Special Item Lube Method 4 Cycle Engine Polaris Premium 4 Synthetic 0W40 Add to pro...

Page 67: ...urer s recommendations for ambient temperature operation See page 106 for the part numbers of Polaris products CAUTION Mixing brands or using a non recommended oil may cause serious engine damage We r...

Page 68: ...ath the oil filter Using an oil filter wrench turn the filter counterclockwise to remove 9 Using a clean dry cloth clean the filter sealing surface on the crankcase 10 Lubricate the gasket on the new...

Page 69: ...NOTE We recommend the use of Polaris Premium AGL Synthetic Gearcase Lube See page 106 for the part numbers of Polaris products 1 Position the ATV on a level surface Remove the dipstick and wipe it cle...

Page 70: ...c filings 5 After the oil has drained completely install a new sealing washer and reinstall the drain plug Torque to 14 ft lbs 19 Nm 6 Turn the adjuster bolt B out until it touches the frame and then...

Page 71: ...and the possibility of accident or severe injury After opening a bottle of brake fluid always discard any unused portion 1 Always keep brake fluid at an adequate level see page 33 WARNING An over full...

Page 72: ...worn to 3 64 1 cm Auxiliary Brake The auxiliary brake system is intended to be used as a backup for the main brake system Should the main system fail the rear brake can be activated by depressing the...

Page 73: ...ight ahead position 2 Place stands 1 in front of the vehicle perpendicular to the rear tires See illustration 3 Tie an elastic string around the stands making sure the string just touches the side sur...

Page 74: ...ush down on the side panel to disengage the top rear two tabs Then pull up on the side panel to disengage the front upper and lower tabs 4 To reinstall the side panel align the panel tabs with the slo...

Page 75: ...ebars resulting in loss of control and possible serious personal injury or death Follow the adjustment procedures exactly or see your Polaris dealer for service Handlebars The handlebars can be adjust...

Page 76: ...tion above 6 000 feet and temperatures below 40 degrees F 4 degrees C NOTE Continuous operation of the engine without proper jetting when required can cause poor performance overheating or engine dama...

Page 77: ...o expose the end of the inline cable adjuster 2 3 Loosen the locknut 3 4 Rotate the boot to turn the adjuster until 1 16 to 1 8 2 3 mm freeplay is achieved at the thumb lever NOTE While adjusting free...

Page 78: ...in your owner s manual Always use original equipment size and type when replacing tires Make sure the wheels are installed properly Always replace tires when the tread depth measures 1 8 3 cm or less...

Page 79: ...alve stem toward the outside and rotation arrows on the tire pointing toward forward rotation 3 Install the wheel nuts and finger tighten On vehicles with tapered rear wheel nuts make sure the tapered...

Page 80: ...oss of control resulting in serious injury or death Maintain proper tire pressure as outlined in the specifications section of this manual When replacing a tire always use original equipment size and...

Page 81: ...ightly forward Measure the chain slack at the tightest of the three positions At this point the chain should have 3 16 3 8 48 cm 95 cm deflection Use the following procedure if adjustment is required...

Page 82: ...Nm for machines with a hitch 8 Tighten the caliper mounting bolt to 15 ft lbs 20 Nm 9 Remove the pin punch 10 Roll the ATV forward checking chain tension in several places around the chain NOTE The c...

Page 83: ...ck for correct slack adjustment Maintain the stone guard to rear sprocket clearance at 1 8 3 cm Regularly lubricate the drive chain with SAE 80 90 lube or an approved o ring chain spray lube See page...

Page 84: ...ic type pre filter 1 from the main filter 2 Wash the pre filter in soapy water then rinse and let dry 4 Reinstall the pre filter over the main filter Replace the main filter if needed 5 Reinstall the...

Page 85: ...g a new bulb Install the replacement bulb into the headlight housing and rotate clockwise firmly NOTE The bulb must be positioned so the harness installs into the lamp at the bottom 4 Reinstall the co...

Page 86: ...ht brakelight to see that it s working 5 Reinstall the gasket and lens cover Indicator Lamp Replacement 1 Remove the instrument panel or front cover if necessary to access the back of the indicator pa...

Page 87: ...ug 17 20 ft lbs 23 27 Nm Spark Plug Inspection Spark plug condition is indicative of engine operation Check the spark plug firing end condition after the engine has been warmed up and the vehicle has...

Page 88: ...se Generally the electrodes are not worn General causes of fouling are excessive oil use of non recommended injection oil improper use of the choke or incorrect carburetion adjustments Recoil Housing...

Page 89: ...ry it if water is present 3 Turn the fuel valve off 4 Remove the spark plug 5 Turn the engine over several times using the electric start 6 Loosen the carburetor drain screw 1 7 Dry the spark plug and...

Page 90: ...lined 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 se...

Page 91: ...engagement speed of about 1400 RPM Whenever operating this close to the engagement point the engine may be running at a speed too low to provide the adequate pinch needed to prevent incomplete engagem...

Page 92: ...al This PVT system is intended for use on Polaris products only Do not install it in any other product Always make sure the PVT housing is securely in place during operation PVT Drying There may be so...

Page 93: ...oat the terminals with dielectric grease or petroleum jelly Be careful not to allow cleaning solution or tap water into a conventional battery WARNING Battery electrolyte is poisonous It contains sulf...

Page 94: ...own strap holding the battery in position and remove battery cover 2 On conventional batteries remove the battery vent tube 3 Disconnect the black negative battery cable first 4 Disconnect the red pos...

Page 95: ...e the tube away from the frame and vehicle body to prevent contact with electrolyte WARNING Battery gases could accumulate in an improperly installed vent tube and cause an explosion resulting in seri...

Page 96: ...a full charge NOTE Power plug leads may need to be bent down so that the battery cover can be installed NOTE Battery charge can be maintained by using a Polaris Battery Tender charger or by charging...

Page 97: ...ul to a battery Battery Charging Conventional Battery 1 Remove the battery from the vehicle to prevent damage from leaking or spilled electrolyte during charging See page 91 2 Charge the battery with...

Page 98: ...cannot be removed you must use a voltmeter or multimeter to measure DC voltage WARNING An overheated battery could explode causing severe injury or death Always watch charging times carefully Stop ch...

Page 99: ...amps specified on top of battery 100 12 8 13 0 volts None check at 3 mos from date of manufacture None required 75 100 12 5 12 8 volts May need slight charge if no charge given check in 3 months 3 6 h...

Page 100: ...into contact with the vehicle The best and safest way to clean your Polaris vehicle is with a garden hose and a pail of mild soap and water 1 Use a professional type washing cloth cleaning the upper b...

Page 101: ...replacement Grease all zerk fittings immediately after washing Allow the engine to run for a while to evaporate any water that may have entered the engine or exhaust system Polishing the Vehicle Pola...

Page 102: ...cleaners on plated or painted surfaces 2 Rinse well with clear water Soap detergents salt dirt mud and other elements can cause corrosion 3 Polish the clean chrome wheels periodically Use an automoti...

Page 103: ...aust ports It also prevents bacterial growth and promotes better starting after the storage period NOTE Carbon Clean removes water from fuel systems stabilizes fuel and removes carbon deposits from pi...

Page 104: ...ngine oil into the hole NOTE Use a section of small hose and a small plastic squeeze bottle filled with the pre measured amount of oil 4 Reinstall the spark plug Torque to specification 5 Apply dielec...

Page 105: ...plastic or coated materials They do not allow enough ventilation to prevent condensation and may promote corrosion and oxidation Transporting an ATV Follow these procedures when transporting an ATV 1...

Page 106: ...in 116 8 cm Length 75 in 190 5 cm Width 46 in 116 8 cm Seat Height 34 in 86 4 cm Dry Weight 505 lbs 229 kg Wheel Base 49 5 in 125 7 cm Engine Cooling Engine Model Number Type ES 32PFE 103 4 Cycle Sing...

Page 107: ...draulic floating caliper Rear Brake Hydraulic opposed piston caliper rear axle fixed disc Auxiliary Brake Hydraulic opposed piston caliper rear axle fixed disc Park Brake Hydraulic lock all wheel Feat...

Page 108: ...22 5 1800 3700 6000 12000 120 115 Clutching Chart Altitude Shift Weight Drive Clutch Spring Driven Clutch Spring Helix Spring Setting Meters Feet 0 1800 0 6000 10RH 5630709 Blue Green 7041157 Black 70...

Page 109: ...5 gal 2870465 Pump for Gallon Jug 2871654 Premium Demand Drive Hub Fluid 8 oz 2872277 Premium Demand Drive Hub Fluid 2 5 gal Grease Specialized Lubricants 2871322 Premium All Season Grease 3 oz cartri...

Page 110: ...n mud or snow Shift the transmission to low range and carefully use fast aggressive throttle application to engage clutch WARNING Excessive throttle may cause loss of control and vehicle overturn Clim...

Page 111: ...commended fuel Replace with new fuel Fouled or defective spark plug s Inspect plug s replace if necessary No spark to spark plug Inspect plug s verify stop switch is on Crankcase filled with water or...

Page 112: ...connections and tighten Water present in fuel Replace with new fuel Low battery voltage Recharge battery to 12 8 VDC or higher Kinked or plugged fuel vent line Inspect and replace Incorrect fuel Repla...

Page 113: ...ct spark plug gap or heat range Set gap to specs or replace plugs Loose ignition connections Check all connections and tighten Low battery voltage Recharge battery to 12 8 VDC or higher Incorrect fuel...

Page 114: ...arranty excludes any failures that are not caused by a defect in material or workmanship This warranty does not cover accidental damage normal wear and tear abuse or improper handling This warranty al...

Page 115: ...ts that you use your original selling dealer however you may use any Polaris Servicing Dealer to perform war ranty service Please work with your dealer to resolve any warranty issues Should your deale...

Page 116: ...show the dealer photo identification from the country of the selling dealer s authorized location as proof of residence Upon residence verification the servicing dealer will be authorized to per form...

Page 117: ...mponents or products THE REMEDIES SET FORTH IN THIS LIMITED WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDEN...

Page 118: ...INTENANCE LOG Periodic Maintenance Record Use the following chart to record periodic maintenance DATE MILES KM TECHNICIAN SERVICE PERFORMED COMMENTS Downloaded from www Manualslib com manuals search e...

Page 119: ...116 MAINTENANCE LOG DATE MILES KM TECHNICIAN SERVICE PERFORMED COMMENTS Downloaded from www Manualslib com manuals search engine...

Page 120: ...117 MAINTENANCE LOG DATE MILES KM TECHNICIAN SERVICE PERFORMED COMMENTS Downloaded from www Manualslib com manuals search engine...

Page 121: ...in Reverse 55 Driving on Slippery Surfaces 48 Driving Over Obstacles 54 Driving Procedures 46 Driving Safely 46 56 Driving Through Water 53 Driving Uphill 49 E Electrical Switches 30 Emission Control...

Page 122: ...el Removal 71 Sidehilling 50 Spark Arrestor 87 S Spark Plugs 84 85 Specifications 103 105 Starting the Engine 42 43 Steering Assembly 71 Stop Switch 30 Storage Tips 100 102 T Taillight Brakelight Lamp...