Polaris trail boss 325 Owner'S Manual Download Page 7

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Additional Important Information...

Due to our concern for the safety of our customers and the general

public, Polaris hereby strongly recommends and requests that

consumers not have installed on a Polaris ATV any equipment

which is intended to increase the speed or power of the vehicle; or

make any other modifications to the vehicle for these purposes.

Any modifications to the original equipment of the ATV substantial-

ly increase the risk of bodily injury. Please be aware that these

modifications may create a substantial safety hazard.

Polaris hereby informs you that the warranty on your ATV is termi-

nated if any such equipment has been added to the ATV or any

modifications have been made to the ATV which increase its

speed or power.

We also advise you to strictly follow the recommended mainte-

nance program outlined in this manual. This preventive mainte-

nance program is designed to ensure that all critical components

on the ATV are thoroughly inspected by your dealer at various

mileage intervals.

NOTE:

The addition of certain accessories including (but not limited to)

mowers, blades, tires, sprayers, or large racks may change the

handling characteristics of the ATV.

Be certain any accessories added to this ATV have been approved

by Polaris.

Familiarize yourself with their function and affect on the ATV.

Summary of Contents for trail boss 325

Page 1: ...Universal Owner s Safety and Maintenance Manual ATV Read this manual carefully It contains important safety information This is an adult vehicle only Operation is prohibited for those under 16 years o...

Page 2: ...The engine exhaust from this product contains chemicals known to cause cancer birth defects or other reproductive harm WARNING...

Page 3: ...PROTECT YOUR SPORT Know all local state province riding laws Respect your vehicle Respect the environment and You will gain the respect of others We also advise you to strictly follow the recommended...

Page 4: ...out the training courses nearest you Never allow anyone under 16 years of age to operate this ATV Never permit a guest to operate this ATV unless the guest has read this manual and all product labels...

Page 5: ...ger hills Always follow proper procedures for climbing hills as described in this manual Check the terrain carefully before you start up any hill Never climb hills with excessively slippery or loose s...

Page 6: ...recommended maxi mum depth pg NO TAG go slowly balance your weight care fully avoiding sudden movements maintain a slow and steady forward motion do not make sudden turns or stops and do not make sudd...

Page 7: ...orms you that the warranty on your ATV is termi nated if any such equipment has been added to the ATV or any modifications have been made to the ATV which increase its speed or power We also advise yo...

Page 8: ...ber A colorful sticker of the PRO logo A PRO merchandise brochure and order form As a PRO Family member you re entitled to opportunities such as A free subscription to PRO Spirit the official magazine...

Page 9: ...be shipped di rectly to your home from the PRO merchandise fulfillment center Watch for your PRO membership packet and the next issue of PRO Spirit magazine This quarterly magazine will keep you in f...

Page 10: ......

Page 11: ...DENTIFICATION NUMBERS 34 CONTROL AND PARTS FUNCTIONS 35 65 STARTING THE ENGINE 66 VEHICLE BREAK IN PERIOD 67 69 RIDING GEAR 70 CARRYING LOADS 71 73 DAILY PRE RIDE INSPECTION 74 RIDING 75 88 PVT System...

Page 12: ...ronment SAFETY TRAINING When you purchased this vehicle your dealer presented a hands on safety training course covering all aspects of ATV safety In addition you were provided with certain printed ma...

Page 13: ...out this manual to convey the following messages This is the safety alert symbol When you see this symbol on your machine or in this manual be alert to the potential for personal injury Your safety is...

Page 14: ...ur protec tion Read and follow the instructions on each decal carefully In the event any decal becomes illegible or comes off contact your Polaris dealer for a replacement Any safety decal needing re...

Page 15: ...SAFETY WARNING AND OPERATION DECALS 1 7079083 E1997 IF OWNER S MANUAL IS MISSING CONTACT YOUR POLARIS DEALER FOR A REPLACEMENT WARNING...

Page 16: ...SAFETY WARNING AND OPERATION DECALS 2 3...

Page 17: ...To prevent flipover avoid sudden braking or sharp turns F Use OVERRIDE for reverse speed limiter with caution To prevent loss of control never activate override button with open throttle F PARKING BRA...

Page 18: ...SAFETY WARNING AND OPERATION DECALS 4 5 6...

Page 19: ...uce speed and allow greater distance for braking when carrying cargo Overloading or carrying tall off center or unsecured loads will increase your risk of losing control Loads should be centered carri...

Page 20: ...e v hicule sous li l ment filtre endommage s v rement le moteur DNettoyer souvent le filtre air surtout dans des situations poussiereuses 7072791 Under Seat 7 8 Moving parts hazard under belt clutch g...

Page 21: ...result causing severe injury or death Tow only from tow hooks or hitch Maximum Front Rack Load 90 lbs 7079102 DO NOT TOW FROM RACK OR BUMPER vehicle damage or tipover may result causing severe injury...

Page 22: ...0 3000 feet 5 to 26 C at 0 900 meters 7073761 TRAILER MAX WEIGHT 850 LBS HITCH MAX VERTICAL WEIGHT 30 LBS POIDS MAX DE REMORQUE 386 KG POIDS MAX VERTICAL D ATTACHE 14 KG OVERRIDE SWITCH Reverse overr...

Page 23: ...unction 7 Wheels check for tightness of wheelnuts and axle nuts check that axle nuts are secured by cotter pins 8 Drive chain condition and slack refer to drive chain adjust ment 9 Air cleaner element...

Page 24: ...and the operating techniques described in the Owner s Manual For more information about the training course contact an authorized ATV dealer or call Polaris at 1 800 342 3764 POTENTIAL HAZARD Failure...

Page 25: ...uces your ability to balance and control this ATV Could cause an accident resulting in harm to you and or your passenger HOW TO AVOID THE HAZARD Never carry a passenger The long seat is to allow the o...

Page 26: ...HAPPEN The ATV tires are designed for off road use Paved surfaces may seriously affect handling and control of the ATV and may cause the vehicle to go out of control HOW TO AVOID THE HAZARD Avoid oper...

Page 27: ...roads or high ways WHAT CAN HAPPEN You can collide with another vehicle HOW TO AVOID THE HAZARD Never operate this ATV on any public street road or highway even a dirt or gravel one In many states it...

Page 28: ...ances of a severe head injury or death in the event of an accident Operating without eye protection can result in an accident and increases your chances of a severe injury in the event of an accident...

Page 29: ...ld result in an accident HOW TO AVOID THE HAZARD Never consume alcohol or drugs before or while driving this ATV POTENTIAL HAZARD Operating this ATV at excessive speeds WHAT CAN HAPPEN Increases your...

Page 30: ...L HAZARD Attempting wheelies jumps and other stunts WHAT CAN HAPPEN Increases the chance of an accident including an over turn HOW TO AVOID THE HAZARD Never attempt stunts such as wheelies or jumps Do...

Page 31: ...and schedules described in the Owner s Manual POTENTIAL HAZARD Removing hands from handlebars or feet from foot rests during operation WHAT CAN HAPPEN Removing even one hand or foot can reduce your ab...

Page 32: ...HAPPEN You can come upon hidden rocks bumps or holes with out enough time to react Could result in the ATV overturning or going out of con trol HOW TO AVOID THE HAZARD Go slowly and be extra careful...

Page 33: ...ld cause loss of traction or vehicle control which could result in an accident including an overturn HOW TO AVOID THE HAZARD Do not operate on excessively rough slippery or loose terrain until you hav...

Page 34: ...ow speeds before attempting to turn at faster speeds Do not turn at excessive speed POTENTIAL HAZARD Operating on excessively steep hills WHAT CAN HAPPEN The vehicle can overturn more easily on extrem...

Page 35: ...ed in the Owner s Manual See pages 79 through 82 Always check the terrain carefully before you start up any hill Never climb hills with excessively slippery or loose surfaces Shift your weight forward...

Page 36: ...down hills as described in the Owner s Manual See page 81 NOTE A special technique is required when braking as you go downhill Always check the terrain carefully before you start down any hill Shift...

Page 37: ...hill until you have mastered the turning technique as described in the Owner s Manual on level ground See page 82 Be very careful when turning on any hill Avoid crossing the side of a steep hill if po...

Page 38: ...l Apply the brakes Lock parking brake after you are stopped If you begin rolling backwards Keep weight uphill never apply engine power Never apply the rear brake while rolling backwards Apply the sing...

Page 39: ...obstacles such as large rocks or fallen trees If you cannot avoid obstacles always follow proper proce dures as described in the Owner s Manual POTENTIAL HAZARD Skidding or sliding WHAT CAN HAPPEN Yo...

Page 40: ...ding sudden movements maintain a slow and steady forward motion do not make sudden turns or stops and do not make sudden throttle changes Remember that wet brakes may have reduced stopping ability Tes...

Page 41: ...described in the Owner s Manual Supplement POTENTIAL HAZARD Operating this ATV with improper modifications WHAT CAN HAPPEN Improper installation of accessories or modification of this vehicle may cau...

Page 42: ...ing a trailer Allow greater distance for braking Always followthe instructions in the Owner s Manualfor carrying cargo or pulling a trailer See pages 71 and 73 POTENTIAL HAZARD Riding on frozen lakes...

Page 43: ...obstacles such as large rocks or fallen trees If you cannot avoid obstacles always follow proper proce dures as described in the Owner s Manual POTENTIAL HAZARD Skidding or sliding WHAT CAN HAPPEN Yo...

Page 44: ...possible damage Safe operation 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...

Page 45: ...na safe place Your key can be duplicated only by obtaining a key blank from Polaris and having it cut by mating it with your existing key The vehicle frame and engine serial numbers are important for...

Page 46: ...tch This key switch must be turned clockwise to the on position to start the engine includes start feature on some models 3 Emergency Engine Stop Switch The engine will not start or run when the switc...

Page 47: ...ddition to turning the lights on and off it also switches the lights from Hi to Lo on models equipped with Hi Lo beams NOTE Will not light unless the main switch is on Backing your ATV can be dangerou...

Page 48: ...mission Neutral Green 2 Transmission Reverse Yellow 3 Oil Warning Red On 2 cycle models this light in dicates a low oil level 4 High Temp Red Will light only if engine overheats 5 All Wheel Drive Red...

Page 49: ...s 00000 0 M Trip Miles 000 0 M Hours 00000 0 H To reset Trip Miles 1 Toggle to Trip Miles 2 Hold down button approximately 4 seconds The speedometer also has additional features accessed through a sub...

Page 50: ...tton once to scroll through the four available functions Each function will be displayed as follows Service Hours SET hr Service Distance SETdIS Miles to Kilometers COnvrT No Menu Changes DOnE Changin...

Page 51: ...vice setting example from above the speedometer will take the 50 hour setting and add it to the val ue of the hour meter This will be the value displayed when the operator checks when service is due f...

Page 52: ...E REMINDER FROM THE DIS PLAY The reminder will remain in the LCD window until the button is pushed or it is reprogrammed for the next service interval When this is done the display will return to the...

Page 53: ...s will cease when the operator releases the throttle lever Choke Refer to the engine starting procedure on page 65 for correct choke 2 and throttle settings during starting Do not start or operate an...

Page 54: ...ng the fluid level the ATV must be on level ground the the handlebars straight If the fluid lev el is low add DOT 3 PN 2870990 only The Electronic Throttle Control ETC stops the engine in the event of...

Page 55: ...brake levertravel and reservoir fluid level before riding When squeezed the lever should feel firm Any sponginess would indicate a possible fluid leak or low master cylinderfluid levelwhich must be c...

Page 56: ...to the notches on the mas ter cylinder body Release the brake lever 3 To release the parking brake lock squeeze the brake le ver It will return to its re leased position Always check to be sure that t...

Page 57: ...ause an accident D Do not leave the vehicle on a hill depending on the park ing brake for more than five minutes D Always block the downhill side of the wheels if leaving the ATV on a hill or park the...

Page 58: ...to brake the rearwheels without skidding Aggressively applying the rearbrake when backing down a hill may cause rear tip over Brake Fluid Level It will be necessary to check the brake fluid level for...

Page 59: ...r s Manual Supplement for specification NOTE To extend belt life use low forward gear in heavy pulling situations and in situations where you are operating below 7 miles per hour for extended periods...

Page 60: ...verse to find neutral Refer to the gear shift pedal illustrated on this page Once the vehicle is in neutral start the en gine by engaging the start button Brake Start Feature This model also has a bra...

Page 61: ...p follow this procedure 1 With the transmission in neutral hold the brake lever 2 With the throttle closed raise the gear shift pedal one full stroke to shift into first gear 3 Release the brake lever...

Page 62: ...ngage neutral depress gearshift pedalone fullstroke fromthe 1st gear position To Decelerate When slowing down or stopping release the throttle and apply the brakes smoothly and evenly As you slow down...

Page 63: ...gage anytime the rear wheels lose traction When the rear wheels regain traction the front wheels will automatically disengage NOTE The override switch also allows activation of De mand 4 Drive AWD in...

Page 64: ...erse Then proceed in forward again You can tell if only one front hub is engaged if the handlebars pull to one side If both front wheel hubs are engaged steering effort increases but remains balanced...

Page 65: ...creases the contracting cooled coolant is drawn back up from the tank past the pressure cap and into the radia tor NOTE Some coolant level drop on new machines is normal as the system is purging itsel...

Page 66: ...n III A To access the pressure cap clean the area around the oil cap and re move the oil cap 2 cycle models Remove front cover by placing your fingers under the front of the cover and pull ing upward...

Page 67: ...ely drained every two years and a fresh mixture of antifreeze and water be added Polaris recommends the use of Polaris Premium 60 40 anti freeze coolant or a 50 50 mixture of high quality aluminum com...

Page 68: ...ere gasoline is stored D Do not over fill the tank Do not fill the tank neck D If you get gasoline on your skin or clothing immediately wash it off with soap and water and change clothing D Never star...

Page 69: ...and has three posi tions OFF For vehicle storage and whenever transport ing ON For normal opera tion RES For reserve supply in the event of main supply exhaustion NOTE There is about a 7 to 10 mile 11...

Page 70: ...er to your Owner s Manual Supplement to determine the type of engine your vehicle has The tank ca pacity is 2 quarts 1 9 l On models with a two cycle engine use only Polaris injection oil Never substi...

Page 71: ...ey excel in meeting the lubrication demands of today s high perfor mance 2 cycle engines These are optimumoils recommended for liquid cooled and air cooled 2 cycle engines We believe these oils are th...

Page 72: ...temperatures from 40 F to 120 F Its ex ceptional frictional properties result in more efficient operation more power output lower fuel consumption and easier starting in cold temperatures Although Po...

Page 73: ...nds 3 Stop the engine remove dipstick and wipe dry with a clean cloth 4 Screw in the dipstick completely remove it and read the oil level NOTE The dipstick must be screwed in to keep the angle and dep...

Page 74: ...e is spinning fast enough to start and restores compression for starting 1 Be certain your vehicle is on a level surface and the parking brake is set See page 45 2 Take the machine out of gear 3 Grasp...

Page 75: ...ter travelling in wet areas the recoil housing and starter should always be drained completely by removing the recoil Do not open the crankcase drain unless the engine has ingested water On 4 cycle en...

Page 76: ...tch to RUN 6 Turn the ignition key to ON and press the starter button 7 On models with a push pull choke the choke is on FULL when the knob is pulled out all the way The choke is OFF when the knob is...

Page 77: ...move the choke to OFF 3 Cold Weather Operation 4 Cycle Engines Polaris offers the following kits for cold weather operation Oil Tank Cover Engine Heater and Oil Tank Heater These kits re duce moistur...

Page 78: ...s outlined on page 58 2 Fill the oil tank with Polaris injection oil 3 Drive slowly at first Select an area which is open and will give you room to familiarize yourself with vehicle operation and han...

Page 79: ...ter the first tank of pre mixed fuel has been used please verify that the oil level in the oil tank has dropped indicating that the oil pump is functioning properly If the level has not dropped see yo...

Page 80: ...rive slowly at first Select an area which is open and will give you room to familiarize yourself with vehicle operation and han dling 4 Vary the throttle positions Do not operate at sustained idle CAU...

Page 81: ...t of Transportation DOT label the American National Standards Institute label ANSI z90 1 or the Snell Memorial Foundation label 2 Eye Protection Do not depend on sunglasses for proper eye protection A...

Page 82: ...30 lbs 14 kg Select models may tow up to 1225 556 kg on level ground only with a maximum vertical hitch weight of 35 lbs 16 kg Refer to your Owner s Manual Supplement to determine your machine s capa...

Page 83: ...tions Carrying loads on one rack only increases the possibility of vehicle tip over D HEAVY LOADS CAN CAUSE BRAKING AND CON TROL PROBLEMS Use extreme caution when apply ing brakes with a loaded vehicl...

Page 84: ...fasten load and op erate with extra caution Always attach the tow load to the hitch point designated for your ATV D EXTREME CAUTION MUST BE USED when operating with loads extending over the rack sides...

Page 85: ...nction 7 Wheels check for tightness of wheel nuts and axle nuts check that axle nuts are secured by cotter pins 8 Drive chain condition and slack refer to drive chain adjust ment 9 Air cleaner element...

Page 86: ...hift the transmission into gear 3 Check your surroundings and determine your path of travel 4 Release the parking brake 5 Slowly depress the throttle with your right thumb and begin driv ing Vehicle s...

Page 87: ...l when turning and the inside tire must slip traction slightly To turn steer in the direction of the turn leaning your upper body to the inside of the turn while supporting your weight on the outer fo...

Page 88: ...eading the trail and avoiding quick sharp turns which can cause skids 3 Correct a skid by turning the handlebars in the direction of the skid and shifting your body weight forward 4 Driving with Deman...

Page 89: ...wheels are spinning as severe damage to drive train may occur Failure to exercise care when operating the ATV on slippery surfaces can be dangerous Loss of tire traction and vehicle control can result...

Page 90: ...your weight forward 4 Proceed at a steady rate of speed and throttle opening 5 Remain alert and be prepared to take emergency action This may include quick dismounting of the ATV Exercise extreme cau...

Page 91: ...transferring your upper body weight toward the hill while keeping your feet on the footrests 3 Steer slightly into the hill to maintain vehicle directions If vehicle begins to tip quickly turn the fr...

Page 92: ...the vehicle 3 Slow down 4 Apply the brakes slightly to aid in slowing Familiarize yourself with the auxiliary rear brake pedal and its use in the event loss of normal service brakes occurs Do not trav...

Page 93: ...TV 4 Staying uphill of ATV turn handlebars full left while facing front of ATV 5 While holding service brake release parking brake lock and slowly allow ATV to roll around to your right until ATV is p...

Page 94: ...ng action is normal D Avoid operating the ATV through deep or fast flowing water If you cannot avoid water which exceeds the recommended maximum depth go slowly balance your weight carefully avoid sud...

Page 95: ...ectric start D Dry the spark plug and reinstall or replace with a new plug D Tighten the carburetor drain screw 1 or reinstall carburetor drain 2 D Reinstall crankcase drain D Turn the fuel valve to O...

Page 96: ...ide Stay on the right side of the trail if possible and be constantly alert for hazards such as logs rocks and low hanging branches Not all obstacles are visible Travel with caution on trails severe i...

Page 97: ...trol may result NOTE Most Polaris ATVs are equipped with a reverse speed limit er The override button should be used with caution as rearward vehicle speed is greatly increased Do not operate at wide...

Page 98: ...RIDING Parking on an Incline...

Page 99: ...the engine off 2 Place the transmission in gear or in park 3 Set the parking brake 4 Avoid parking on an incline If it is necessary to park on an in cline always block the rear wheels on the down hil...

Page 100: ...e engi neering and testing has been conducted to insure the safety of this product However as the owner you have the follow ing responsibilities to make sure this system remains safe D Do not modify a...

Page 101: ...elts and causes outer clutch covers to fail By switching to low range while operating at low ground speeds the air temperature in the clutch cover is reduced by almost 160 degrees Reducing the tempera...

Page 102: ...ide a guideline for when to use low range rather than high Low Range S Basic operation at speeds less than 7 MPH S Heavy pulling S Riding through rough terrain swamps mountains etc at low ground speed...

Page 103: ...sult causing serious injury or death Battery electrolyte is poisonous It contains sulfuric acid Se rious burns can result from contact with skin eyes or clothing Antidote External Flush with water Int...

Page 104: ...ro sion If cleaning is necessary remove the corrosion with a stiff wire brush Wash with a solution of one tablespoon baking soda and one cup water Rinse well with tap water and dry off with clean rags...

Page 105: ...tery cover and attach the hold down strap 6 Verify that cables are properly routed NOTE D When your ATV is placed in storage for three months or more the battery should be removed charged to proper le...

Page 106: ...W INCLUDE BUT ARE NOT LIMITED TO THE FOLLOWING 1 Removal or alteration or the puncturing of the muffler or any en gine component which conducts removal of engine exhaust gases 2 Removal or alteration...

Page 107: ...en cleaning the spark arrestor you must follow the safe guards listed below to avoid serious injury or death D Do not perform this operation immediately after the en gine has been run because the exha...

Page 108: ...and 3 Spark Arrestor cont 5 If particles are stillsus pected to be in the muffler drive the ma chine onto the incline so the front of the ma chine is one foot high er than the rear Set the parking br...

Page 109: ...ver D wrench D tire pressure gauge D spanner wrench for adjusting rear shock spring preload se lected models 4 cycle engines D screwdriver D open end wrench 8 10 mm D open end wrench 12 14 mm D box en...

Page 110: ...ricate adjust or replace parts as necessary NOTE Inspection may reveal the need for replacement parts Al ways use genuine Polaris parts available from your Polaris dealer Service and adjustments are c...

Page 111: ...Coolant Level In spection Daily Daily Replace engine coolant every two years Air Box Sediment Tube Daily Daily Drain deposits whenev er visible Headlamp Inspec tion Daily Daily Check operation daily a...

Page 112: ...hicle Item Hours or Miles When Remarks L Engine breather fil ter 4 cycle 20 hrs Monthly Inspect replace annual ly and as needed J Brake pad wear 10 hrs Monthly Inspect periodically Front and Rear Gear...

Page 113: ...50 hrs 6 months Drain bowl periodically and prior to storage J Throttle Cable ETC Switch 50 hrs 6 months Inspect adjust lubri cate replace if neces sary pre ride inspection item L Choke Enricher Cable...

Page 114: ...spension 50 hrs 6 months Inspect lubricate tight en fasteners Rear Suspension 50 hrs 6 months Inspect tighten fasten ers Drive Chain s 50 hrs 6 months Inspect daily adjust and lubricate if needed L Sp...

Page 115: ...12 months Inspect Adjust J Injector Oil Filter 2 Cycle 100 hrs 12 months Replace J Shift selector box H L R 200 hrs 24 months Change lubricant every two years J Brake fluid 200 hrs 24 months Change e...

Page 116: ...s Premium Synthetic gear case lube See Page 141 Change annually or at 100 hours 5 Front Gearcase Oil GL5 80 90 Weight Gear Lube See Page 146 Change annually or at 100 hours 6 Front Prop Shaft U joints...

Page 117: ...MAINTENANCE Lubrication Recommendations Operating Range Full 4 Transmission dipstick 6 Front Prop Shaft U Joint Fill plug 5 Front Gear Case 4 Transmission plug 7 Propshaft Yoke Fill plug...

Page 118: ...se gun Every 3 months or 50 hours 12 Front A Arm Pivot Shaft L Grease Locate fitting on pivot shaft and grease with grease gun Every 3 months or 50 hours 13 Counter Balance Housing 400 SAE 10 30 Check...

Page 119: ...Lubrication Recommendations 10 Axle Cardan Front Drive AWD Models 13 Counterbalance Dipstick 14 Steering Post Bushings 11 Ball Joint 12 Front A Arm Pivot Shaft Upper 9 4 O clock position 9 Demand 4 Hu...

Page 120: ...Locate fitting and grease Semi annually 20 Rear Anti Roll Bar L Grease Locate fitting and grease Semi annually L More often under severe use such as wet or dusty conditions Polaris Premium all Season...

Page 121: ...rication Recommendations 16 Swing Arm Bushings 15 Rear Axle Bearing 17 Upper Control Arm 19 Rear Wheel Hub Bearing Carrier 20 Rear Anti Roll Bar 18 Lower Control Arm INDEPENDENT REAR SUSPENSION 18 Low...

Page 122: ...Periodic Maintenance Record Use the following chart to record periodic maintenance work Maintenance Interval Performed Servicing Date Servicing Dealer or Person Remarks First 5 Hrs 25 Hrs 50 Hrs 75 H...

Page 123: ...re han dlebars do not hit gas tank or any other part of ma chine when turned fully to left or right 4 Torque handlebar adjuster block bolts to 10 to 12 ft lbs NOTE Tighten bolts so there is an equal g...

Page 124: ...Bolt Size Specification Front 3 8 20 Ft Lbs Rear 3 8 20 Ft Lbs Rear 1 2 50 Ft Lbs NOTE All nuts that have a cotter pin installed must be ser viced by an authorized Polaris Dealer Front Wheel Hub Tigh...

Page 125: ...ar shock absorber spring is adjusted by rotating the adjuster in the direction required to increase or decrease spring tension NOTE Accessory springs are available through your Polaris dealer Rear Spr...

Page 126: ...panel forward and outward to disengage the two rear tabs 2 Place hand on top of side panel behind the fuel tank With a quick and firm motion push down on the side panel to disengage the top rear two t...

Page 127: ...in soapy water rinse and let dry 6 Re install pre filter over main filter Replace main filter if re quired Filter Installation Procedure 1 Check condition of airbox and replace if necessary 2 Replace...

Page 128: ...a dispersion type nozzle to prevent filter damage and clean from the inside to the outside NOTE Replace the air filter every 50 hours and possibly more often in very dirty conditions Air Filter Servic...

Page 129: ...or debris Blow through gently in direction of arrow on filter to check for clogging Replace as needed 3 Check hoses for cracks deterioration abrasion or leaks Replace as needed 4 Reinstall filter and...

Page 130: ...nt You can check the toe alignment of the vehicle using the following meth od The recommended toe alignment is 1 8 to 1 4 3 to 6 cm toe out If you discover improper adjustment have your dealer correct...

Page 131: ...g sure string just touches side surface of the rear tires on each side of machine and goes around the stands in front of the machine 4 Measure from string to rim at front and rear of front rim Rear ri...

Page 132: ...gm is not extended a leak is in dicated and the diaphragm should be replaced Always fill the reservoir as indicated whenever the cover is loosened or removed to insure proper diaphragm operation Use P...

Page 133: ...which is about the thickness of a dime D Inspect the brake disc spline and pad wear surface for ex cessive wear Auxiliary Brake Systems Your ATV s auxiliary brake system is intended to be used as a ba...

Page 134: ...sure on the throttle lever until all freeplay is removed from throttle cable to the point where the carb slide is just starting to rise 4 Lift boot up off adjuster sleeve Remove the oil pump cover Loo...

Page 135: ...r s Manual Sup plement 3 Place very slight pressure on the throttle lever until all freeplay is removed from throttle cable to the point where the carb slide is just starting to rise 4 Loosen locknut...

Page 136: ...onds Tighten bleed screw CAUTION Never run the engine with the bleed screw loose Loss of oil will cause serious engine damage 3 Start the engine and rotate the oil pump lever to its full open position...

Page 137: ...the engine will be hard starting when cold and the half on choke position used for intermittent applications will not function Choke Adjustment Procedure 1 Flip choke toggle to the full off position 2...

Page 138: ...crew in or out until the desired idle RPM is reached Turning the screw in clockwise will raise RPM Turning the screw out counterclock wise will lower RPM The following variations to air screw adjustme...

Page 139: ...adjusting nut clockwise on in line ad juster until 1 8 3 cm or more choke toggle free play is evident 4 Turn the cable sleeve adjusting nut counterclockwise on the in line cable adjuster until the to...

Page 140: ...er and loosen adjustment locknut 4 Turn adjuster until the choke knob pushes out over 1 4 5 Push on the choke knob lightly while turning the adjuster the opposite way 6 Turn the adjuster until the kno...

Page 141: ...d idle RPM is reached Turning the screw in clockwise will raise RPM Turning the screw out counterclockwise will lowerRPM Throttle Cable Free Play Adjustment Throttle cable free play is adjusted at the...

Page 142: ...or tip indicates overheating caused by use of an improper spark plug or incorrect carburetion adjustments 2 Wet Fouled The insulator tip is black A damp oil film covers the firing end There may be a c...

Page 143: ...Suggested break in oil change is at 20 hours 200 miles or one month whichever comes first Severe use operation requires more frequent service Se vere use includes continuous duty in dusty or wet condi...

Page 144: ...e sealing surfaces on the drain plug and the oil tank should be clean and free of burrs nicks or scratches 7 Reinstall drain plug and torque to 14 17 ft lbs 1 93 2 35 kg m 8 Disconnect the lower oil d...

Page 145: ...wer right side of crankcase NOTE The sealing surfaces on the drain plug and crankcase should be clean and free of burrs nicks or scratches 14 Reinstall drain plug 15 Remove dipstick and add the amount...

Page 146: ...w oil to drain completely 6 Replace sealing washer on drain plug NOTE The sealing surfaces on drain plug and crankcase should be clean and free of burrs nicks or scratches 7 Reinstall drain plug and t...

Page 147: ...brake 14 Start the engine and let it idle for one to two minutes Stop the engine and inspect for leaks 15 Re check the oil level on the dipstick and add oil as necessary to bring the level to the uppe...

Page 148: ...her on drain plug NOTE The sealing surfaces on drain plug and crankcase should be clean and free of burrs nicks or scratches 7 Reinstall drain plug and torque to 14 ft lbs 1 9 kgm 8 Place shop towels...

Page 149: ...nutes Stop the engine and inspect for leaks 15 Re check the oil level on the dipstick and add oil as necessary to bring the level to the upper mark on the dipstick 16 Dispose of used filter and oil pr...

Page 150: ...her on drain plug NOTE The sealing surfaces on drain plug and crankcase should be clean and free of burrs nicks or scratches 7 Reinstall drain plug and torque to 14 ft lbs 1 9 kgm 8 Place shop towels...

Page 151: ...the engine and let it idle for one to two minutes Stop the engine and inspect for leaks 15 Re check the oil level on the dipstick and add oil as necessary to bring the level to the upper mark on the...

Page 152: ...1600 km whichever comes first Transmis sion oil should be changed annually With the ATV on a level sur face remove fill plug 1 and check the lubricant level Use the il lustration and the chart below...

Page 153: ...nsmission drain plug located on the bottom left hand side and drain the oil refer to page for the location of the Mag num drain plug Catch and discard used oil properly 4 Clean and reinstall the drain...

Page 154: ...the rear brake disc The transmission lubricant level should be checked monthly or 1000 miles 1600 km whichever comes first Transmission oil should be changed annually With the ATV on a level surface r...

Page 155: ...w the removal of drain plug C 5 Remove the drain plug and wipe the magnetic end clean to remove accumulated metallic filings 6 After the oil has drained completely install a new sealing washer and ins...

Page 156: ...move transmission drain plug side and drain the oil Catch and discard used oil properly 3 Clean and reinstall the drain plug 4 Add 32 oz 948 ml Polaris Premium Synthetic Gearcase Lubricant PN 2871478...

Page 157: ...plug thread The cor rect gearcase lubricant to use is GL5 80 90 Weight Gear Lube Type B The lubricant level in this type of gearcase cannot be checked You must periodically drain it and refill it acc...

Page 158: ...gearcase lubricant to use is GL5 80 90 Weight Gear Lube Oil Changing Procedure 1 Remove drain plug 3 Catch and discard used oil properly 2 Clean and reinstall the drain plug with a new sealing washer...

Page 159: ...anged as nec essary The oil should be changed annually espe cially before off season storage If the machine is used in wet conditions the oil should be checked more frequently If the oil has a milky a...

Page 160: ...ver filled excess oil will be ex pelled through the vent hose 4 Reinstall dipstick NOTE Recommended Oil Level 2 Counter Balance Oil Changing Procedure 1 Remove skid plate 2 Remove counter balance drai...

Page 161: ...d tire wear Wheel Removal Procedure 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...

Page 162: ...oint toward forward rotation 2 Attach the wheel nuts and finger tighten them 3 Lower the vehicle to the ground 4 Securely tighten the wheel nuts according to the chart found on page 113 Tire Inspectio...

Page 163: ...nspect the drive chain prior to operating the vehicle checking for damaged or missing O rings rollers and correct slack adjustment Maintain the stone guard to rear sprocket clearance at 1 8 3 cm Regul...

Page 164: ...slack at the top side of the rear chain At this point the chain should have 3 16 3 8 48 cm 95 cm deflection 1 If the chain needs adjustment use the following procedure Never adjust or operate the vehi...

Page 165: ...forward or back to adjust chain slack to the proper tension 6 Tighten caliper mount bolts 10 12 ft lbs 1 4 1 7 kg m 7 Tighten the eccentric locking bolts to 30 ft lbs 9 kg m for machines without the h...

Page 166: ...ckwise firmly NOTE Bulb is to be positioned so the harness installs into the lamp at the bottom 4 Reinstall connector Keep you headlights and taillights clean Poor lighting while riding can result in...

Page 167: ...o the center of the head light and make a mark on the wall at the same height 3 Start the engine and turn the headlight switch to high beam 4 Observe headlight aim The most intense part of the headlig...

Page 168: ...t approxi mately 25 7 6 m from a wall 2 Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height 3 Start the engine and turn on headlight 4 Obs...

Page 169: ...e removal of the seat 5 Disengage the tabs at the front of the upper panel where they snap into the low er panel surrounding the headlight assembly Also dis engage the tabs on the upper panel which en...

Page 170: ...eadlight Adjustment The headlight beam can be adjusted to any position desired by turning the four screws at the outer corners of the lamp housing 1 Place the vehicle on a level surface with the headl...

Page 171: ...Disconnect speedometer harnesses from speedometer Unplug indicator light harness and remove pod cover 5 Unplug headlamp from wiring harness 6 Remove boot and locking collar from back of lamp housing 7...

Page 172: ...i mately 25 7 6 m from a wall 2 Measure the distance from the floor to the center of the head light and make a mark on the wall at the same height 3 Start the engine and turn the headlight switch to h...

Page 173: ...Disconnect speedometer harnesses from speedometer Unplug indicator light harness and remove pod cover 6 Unplug headlamp from wiring harness 7 Remove O Ring from headlight pivot pins 8 Pull headlight h...

Page 174: ...cement Style I 1 Remove the upperheadlight pod Gen 4 or the front cover Gen 2 to access the back of the indicator panel 2 Using a small straight blade screwdriver turn the base of the bad bulb 1 4 tur...

Page 175: ...after washing Also run the vehicle to evaporate any water that might have entered the engine or exhaust system The best and safest way to clean your ATV is with a garden hose and a pail of mild soap a...

Page 176: ...zer to disperse through the fuel in the tank and carburetor Turn the fuel valve to OFF and drain the carburetor bowl completely Oil And Filter Change 4 Strokes Warm the engine and change oil and filte...

Page 177: ...e chain s Battery Maintenance Remove the battery and add distilled wa ter as required to the proper level Do not use tap water which may contain minerals that reduce battery life Apply Polaris Di Elec...

Page 178: ...Polaris Carbon Clean 5 If Polaris fuel system additive is not used fuel tank fuel lines and carburetor should be completely drained of gasoline to eliminate any fuel remaining in the carburetor run t...

Page 179: ...ate foraltitude and ortempera ture changes 2 Transmission convertor modification to adjust for engine horse power loss during high altitude operation Contact your dealer 3 On 2 cycle models air screw...

Page 180: ...of Low Range is highly recommended for cooler PVT operating temperatures and longer component life Insufficient warm up of ATVs exposed to low am bient temperatures Warm engine at least 5 min then wi...

Page 181: ...Repeat sev eral times as required During this procedure the throttle should not be held at the full position for more than 10 seconds Clutch seals should be inspected for damage if repeated leaking oc...

Page 182: ...es for questions you may have about the operation of your ATV See your Polaris dealer with any additional questions you may have ENGINE TURNS OVER BUT FAILS TO START No Fuel Water in Fuel Spark Plug F...

Page 183: ...ruse of Choke Spark Plug Fouled Engine Overheated Clean Engine Exterior Turn Fuel Valve to Res Water in Fuel Air Filter Clogged Reverse Speed Limiter Malfunction Electronic Throttle Control Malfunctio...

Page 184: ...time of sale the Warranty Registration Form must be com pleted by your dealer and submitted to Polaris within ten days Upon receipt of this registration Polaris will record the registration for warran...

Page 185: ...n or defects in parts components or the ATV due to fire explosions or any other cause beyond Polaris control This warranty does not cover the use of unauthorized lubricants chemicals or fuels that are...

Page 186: ...you must present your copy of the Warranty Registra tion form to the dealer THE COST OF TRANSPORTATION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY Polaris suggests that you use your original sellin...

Page 187: ...ly Pre ride Inspection 12 74 Disengaging Wheel Hubs 53 Drive Chain Adjustment 152 Engine Choke Adjustment 130 Engine Choke Engine Idle Rpm Adjustment 128 130 Filter Change 132 140 Fuel Safety 58 Fuel...

Page 188: ...e Alignment 119 120 Tool Kit 98 Torque Specifications 113 Trail Obstacles 85 Transmission Gear Selector Operation 48 Transmission Lubrication 141 143 Transmission Oil Changing Procedure 142 145 Transp...

Page 189: ...nual before operation Severe injury or death can result from ignoring warnings or improper use Never permit a guest to operate this vehicle unless the guest has read and understands all warning labels...

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Polaris trail boss 325, Owner'S Manual

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