Polaris Trail Boss 9920770 Owner'S Manual Download

Page: 72 / 122

MAINTENANCE AND LUBRICATION

Brakes

2. Check the brake system for fluid leaks.
3. Check the brakes for excessive travel or

spongy feel.

4. Check the friction pads for wear,

damage and looseness.

5. Check the security and surface

condition of the disc.

NOTE:

Pads should be changed when

worn to 3/64

″

(.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 foot pedal on the inside of the right

footrest. The hydraulic auxiliary brake system requires no adjustment.

NOTE:

Since this is a rear brake only, it will not be as effective as

the all-wheel single lever system.

3/64

″

(.1 cm)

Summary of Contents for Trail Boss 9920770

Page 1: ...ins important safety information 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...

Page 2: ...R02...

Page 3: ...ed to the owner s manual on the 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 kno...

Page 4: ...For safe and enjoyable operation 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...

Page 5: ...inor discrepancies may result 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 liabi...

Page 6: ...ENTIFICATION NUMBERS 5 SAFETY 6 FEATURES AND CONTROLS 30 OPERATION 40 EMISSION CONTROL SYSTEMS 57 MAINTENANCE AND LUBRICATION 58 SPECIFICATIONS 97 POLARIS PRODUCTS 100 TROUBLESHOOTING 101 WARRANTY 105...

Page 7: ...4...

Page 8: ...d store it in a safe place An ignition key can be duplicated only by ordering a Polaris key blank using your key number and mating it with one of your existing keys The ignition switch must be replace...

Page 9: ...ng ATV safety training is a 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 Th...

Page 10: ...your vehicle or in this manual 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 safe...

Page 11: ...street road or highway including 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 lo...

Page 12: ...attempt to turn the ATV around 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 prope...

Page 13: ...FOR MORE INFORMATION ABOUT 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 Modifica...

Page 14: ...e and the operating techniques 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 POTENT...

Page 15: ...allow the operator to shift 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...

Page 16: ...POTENTIAL HAZARD Operating this 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...

Page 17: ...fore or while operating an ATV 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 HAZA...

Page 18: ...r stunts Avoid exhibition driving WARNING POTENTIAL HAZARD Failure to inspect the ATV before operating Failure to properly maintain the ATV WHAT CAN HAPPEN Poor maintenance increases the possibility o...

Page 19: ...into contact with the rear wheels 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 POT...

Page 20: ...e on excessively rough slippery 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...

Page 21: ...per hill climbing could cause 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 careful...

Page 22: ...res for traveling down hills 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 descend...

Page 23: ...t to turn the ATV around on any 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 crossin...

Page 24: ...en fully stopped apply the auxiliary 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...

Page 25: ...nual WARNING POTENTIAL HAZARD 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...

Page 26: ...nts and maintain a slow and steady 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 le...

Page 27: ...re information WARNING POTENTIAL 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...

Page 28: ...ng systems WARNING 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 ri...

Page 29: ...S steeper than 25 degrees 25 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 diffi...

Page 30: ...too fast for your skills or the 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 AL...

Page 31: ...Warning 7 WARNING IMPROPER TIRE 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 Ve...

Page 32: ...ich has granted approval The 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 Polar...

Page 33: ...sition Release the key when the 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...

Page 34: ...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...

Page 35: ...ed 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 pos...

Page 36: ...us injury or death Maintain brake 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 l...

Page 37: ...Parking Brake WARNING Operating 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 operat...

Page 38: ...serious injury or death 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 th...

Page 39: ...y is exhausted NOTE There s about 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 aft...

Page 40: ...red S Do not overfill the tank 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 i...

Page 41: ...N Neutral R Reverse CAUTION Shifting 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 m...

Page 42: ...ing the rope just until the engine 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 th...

Page 43: ...the dipstick See page 64 Add 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 famil...

Page 44: ...free operation Tires Inspect 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 T...

Page 45: ...the vehicle NOTE Do not use the 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...

Page 46: ...art intermittent use of the choke 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 thro...

Page 47: ...he weight capacities outlined 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...

Page 48: ...UST BE SECURED BEFORE OPERATING 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...

Page 49: ...to warm up then shift 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...

Page 50: ...rection of the turn leaning your 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...

Page 51: ...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 WARNING Failure to exercise ca...

Page 52: ...TV begins rolling backwards 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 appl...

Page 53: ...dehilling 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 t...

Page 54: ...vehicle 3 Slow down 4 Apply 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...

Page 55: ...vehicle is pointing straight 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 a...

Page 56: ...and rear gearcases and all grease 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...

Page 57: ...the terrain you re traveling on Be constantly alert for hazards such as logs rocks and low hanging branches WARNING Severe injury or death can result if your vehicle comes in contact with a hidden obs...

Page 58: ...s or people behind the vehicle 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...

Page 59: ...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 dow...

Page 60: ...e at www gpoaccess gov ecfr 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 ex...

Page 61: ...fe service and adjustment procedures have a qualified dealer perform these operations Maintenance intervals in the following chart are based upon average riding conditions and an average vehicle speed...

Page 62: ...ion related service Failure 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 perf...

Page 63: ...n often replace as needed Air 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...

Page 64: ...hange at one month Oil filter 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 ca...

Page 65: ...gs 100 H 12 M 1000 1600 Inspect 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 I...

Page 66: ...such as wet or dusty conditions 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...

Page 67: ...not used Follow the manufacturer 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 caus...

Page 68: ...Nm 8 Place shop towels beneath 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 Lubr...

Page 69: ...Chart beginning on page 60 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...

Page 70: ...o remove accumulated metallic 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...

Page 71: ...an lead to early brake fade 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 72: ...E Pads should be changed when 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 b...

Page 73: ...Set the handlebars in a straight 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 stri...

Page 74: ...ith a quick and firm motion push 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 alig...

Page 75: ...ng or loosening of the handlebars 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...

Page 76: ...ealer are required for operation 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 performanc...

Page 77: ...1 and slide it far enough to 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 lev...

Page 78: ...on the decal on your ATV and 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 dep...

Page 79: ...l 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 finger tighten On vehicles with tapered rear whe...

Page 80: ...e maneuverability and cause loss 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...

Page 81: ...ions by moving the vehicle slightly 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 procedu...

Page 82: ...ut the hitch and 45 ft lbs 61 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 place...

Page 83: ...s or damaged rollers Also check 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 ri...

Page 84: ...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 pre filter over the main filter Replace the main filte...

Page 85: ...bulb socket before installing 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...

Page 86: ...e new lamp 4 Test the taillight 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...

Page 87: ...Previously Installed Spark Plug 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 w...

Page 88: ...bon layer over the entire nose 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...

Page 89: ...e airbox for any water and dry 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 scre...

Page 90: ...r the vehicle while it s inclined 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 momen...

Page 91: ...only about 1500 RPM with an 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 t...

Page 92: ...outlined in the owner s manual 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 operati...

Page 93: ...off with clean shop towels Coat 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 i...

Page 94: ...moval 1 Disconnect the hold down 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 f...

Page 95: ...and securely installed Route 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...

Page 96: ...echarge as needed to maintain 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 T...

Page 97: ...ains minerals that are harmful 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 9...

Page 98: ...sealed and the sealing strip 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 cha...

Page 99: ...nt current charger standard 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 g...

Page 100: ...se types of products to come 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 washi...

Page 101: ...your Polaris dealer for free 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 syst...

Page 102: ...detergent Never use abrasive 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...

Page 103: ...mbustion chamber and the exhaust 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 rem...

Page 104: ...of Premium 4 Synthetic 0W40 engine 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...

Page 105: ...olaris cover NOTE Do not use plastic or coated materials They do not allow enough ventilation to prevent condensation and may promote corrosion and oxidation Transporting an ATV Follow these procedure...

Page 106: ...rance 5 5 in 14 cm Height 46 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 T...

Page 107: ...AM Front Brake Fixed disc hydraulic floating caliper Rear Brake Hydraulic opposed piston caliper rear axle fixed disc Auxiliary Brake Hydraulic opposed piston caliper rear axle fixed disc Park Brake H...

Page 108: ...rs 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 Spring Setting Meters Feet 0 1800 0 6000 10RH 563070...

Page 109: ...mium ATV Angle Drive Fluid 2 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...

Page 110: ...ng Use low range only Stuck in 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 cont...

Page 111: ...e fuel valve on Old or non recommended 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 Cr...

Page 112: ...ition connections Check all 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...

Page 113: ...your Polaris dealer Incorrect 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...

Page 114: ...MEDIES The Polaris limited warranty 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 improp...

Page 115: ...ESPONSIBILITY Polaris suggests 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 warra...

Page 116: ...ized Polaris dealer You must 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 wi...

Page 117: ...of any defective materials components 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 LIABIL...

Page 118: ...115 MAINTENANCE LOG Periodic Maintenance Record Use the following chart to record periodic maintenance DATE MILES KM TECHNICIAN SERVICE PERFORMED COMMENTS...

Page 119: ...116 MAINTENANCE LOG DATE MILES KM TECHNICIAN SERVICE PERFORMED COMMENTS...

Page 120: ...117 MAINTENANCE LOG DATE MILES KM TECHNICIAN SERVICE PERFORMED COMMENTS...

Page 121: ...Driving Downhill 51 Driving 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...

Page 122: ...28 Safety Training 6 Side Panel 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 10...

Search results

Summary of Contents for Trail Boss 9920770

Reviews:

Related manuals for Trail Boss 9920770

Brands by name

Popular brands

Polaris Trail Boss 9920770, Owner'S Manual

Search results

Summary of Contents for Trail Boss 9920770

Reviews:

Related manuals for Trail Boss 9920770

Brands by name

Popular brands