Polaris Trail Boss 9921784 Page 1 Owner'S Manual Download

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Summary of Contents for Trail Boss 9921784

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Page 2: ...For your nearest Polaris dealer call 1 800 POLARIS or visit www polarisindustries com Polaris Sales Inc 2100 Hwy 55 Medina MN 55340 Phone 1 888 704 5290 Part No 9921784 Rev 02 Printed in USA...

Page 3: ...r 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 WARNING The engine exhaust from this product contains chemicals known to...

Page 4: ...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 abou...

Page 5: ...and quality of production components some minor discrep ancies may result between the actual vehicle and the information presented in this publi cation Depictions and or procedures in this publicatio...

Page 6: ...TENTS Introduction 4 Safety 7 Features and Controls 26 Operation 36 Emission Control Systems 56 Maintenance 57 Polaris Products 103 Troubleshooting 104 Specifications 108 Warranty 110 Maintenance Log...

Page 7: ...l injury hazard WARNING A WARNING indicates a hazardous situation which if not avoided may result in death or serious injury CAUTION A CAUTION indicates a hazardous situation which if not avoided may...

Page 8: ...ty warnings precautions and operating procedures before operating a Polaris ATV Keep this manual with the ATV Never operate an ATV without proper instruction Take a training course Purchasers of a new...

Page 9: ...our key number and mating it with one of your existing keys The ignition switch must be replaced if all keys are lost Vehicle Model Number ___________________________________________________ Frame VIN...

Page 10: ...ATV you can take the ATV RiderCoursesm by calling ATV Enrollment Express at 800 887 2887 or by visiting www atvsafety org Purchasers of a used Polaris ATV will be charged for this training A Polaris...

Page 11: ...eds established safety standards Approved helmets in the USA and Canada bear a U S Department of Transportation DOT label Approved helmets in Europe Asia and Oceania bear the ECE 22 05 label The ECE m...

Page 12: ...protect arms and legs Riding pants with kneepads and a jersey with shoulder pads provide the best protection Equipment Modifications We strongly recommend that consumers do not install on a Polaris A...

Page 13: ...properly in different situations and on different types of terrain Beginning and inexperienced operators should complete the recommended safety training before operating this vehicle See page 7 Never...

Page 14: ...e off whenever the vehicle is stored or parked Exposure to Exhaust Engine exhaust fumes are poisonous and can cause loss of consciousness or death in a short time Never start the engine or let it run...

Page 15: ...ts properly and eye protection goggles or face shield Using Alcohol or Drugs Operating the ATV after consuming alcohol or drugs could adversely affect operator judgment reaction time balance and perce...

Page 16: ...sudden turns or stops Operating on Public Roads Operating this ATV on public streets roads or highways could result in a collision with another vehicle Never operate the ATV on any public street road...

Page 17: ...ng improperly could cause loss of traction loss of control accident or overturn Always follow proper procedures for turning as described in the owner s manual Never turn abruptly or at sharp angles Ne...

Page 18: ...a hill Shift your weight rearward Never travel down a hill at high speed Avoid traveling down a hill at an angle which would cause the vehicle to lean sharply to one side Travel straight down the hil...

Page 19: ...in the owner s manual See page 49 If the ATV begins rolling downhill Keep body weight uphill Never apply engine power Never apply the auxiliary rear brake while rolling backwards Apply the single lev...

Page 20: ...slippery or loose terrain Always use extra caution on rough slippery or loose terrain Operating in Unfamiliar Terrain Failure to use extra caution when operating on unfamiliar terrain could result in...

Page 21: ...Before shifting into reverse gear always check for obstacles or people behind the ATV When it s safe to proceed back slowly Improper Tire Maintenance Operating this ATV with improper tires or with im...

Page 22: ...a caution to reduce the chance of skidding or sliding Do not operate on excessively slippery surfaces Operating Through Deep Water Operating the ATV through deep or fast flowing water could cause the...

Page 23: ...argo or pull ing a trailer Operating on Frozen Bodies of Water Operating on frozen bodies of water may result in serious injury or death if the ATV and or the operator fall through the ice Never opera...

Page 24: ...disabilities who operate this vehicle have an increased risk of overturn and loss of control Hot Exhaust Systems Exhaust system components are very hot during and after use of the vehicle Hot compone...

Page 25: ...the label General Warning WARNING Improper ATV use can result in SEVERE INJURY or DEATH ALWAYS USE AN APPROVED HELMET AND PROTECTIVE GEAR NEVER USE ON PUBLIC ROADS NEVER CARRY PASSENGERS NEVER USE WIT...

Page 26: ...ration can be dangerous even at low speeds Steering becomes difficult To prevent loss of control avoid sudden braking or sharp turns 7175511 Rack Warning Front and Rear WARNING DO NOT TOW FROM RACK OR...

Page 27: ...DEATH 7175378 Tire Pressure Load Warning WARNING Improper tire pressure or overloading can cause loss of control Loss of control can result in severe injury or death Cold tire pressure Front 4 0 psi...

Page 28: ...h guard To prevent serious injury do not operate vehicle with guard removed Do not modify engine or clutch Doing so can cause part failure possible imbalance and excessive engine RPM which can result...

Page 29: ...ssing the override switch The override switch also allows activation of All Wheel Drive in reverse if the AWD switch is on Engine Stop Switch Move the stop switch either left or right to the OFF posit...

Page 30: ...position and the engine stop switch must be in the RUN position to operate the headlights Indicator Lights With the engine running verify the function of all indicator lights before each use of the ve...

Page 31: ...c throttle control could result in failure to perform as designed which could result in an accident Do not attempt to modify the throttle control system or replace it with any after market throttle me...

Page 32: ...diagnosis and repairs Parking Brake Locking the Parking Brake 1 Place the transmission in gear 2 Squeeze and release the brake lever two or three times then squeeze and hold 3 Push the parking brake l...

Page 33: ...ear wheels may skid and slide sideways causing loss of control which may result in serious injury or death The auxiliary brake system is intended to be used as a backup for the main brake sys tem Shou...

Page 34: ...ibility of brake failure which could result in an accident After opening a bottle of brake fluid always discard any unused portion Always maintain brake fluid at the recommended level Do not overfill...

Page 35: ...ars are straight 2 View the fluid level through the indicator window eye on the top of the master cylinder The eye will appear dark when the fluid level is full When fluid is low the eye will be clear...

Page 36: ...mp octane number of 87 R M 2 octane Do not use E 85 fuel Fuel Valve The fuel valve is located on the left side of the vehicle below the fender ON For normal operation OFF For vehicle storage and when...

Page 37: ...Neutral R Reverse To shift gears brake to a complete stop When the engine is idling move the lever to the desired gear NOTICE Shifting gears with the engine speed above idle or while the vehicle is m...

Page 38: ...st 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 the engine 4 Repe...

Page 39: ...of operation or the time it takes to use the first two full tanks of gasoline No single action on your part is as important as following the proce dures for a proper break in Careful treatment of a n...

Page 40: ...e throttle positions Do not operate at sustained idle 5 Perform regular checks on fluid levels controls and areas outlined on the daily pre ride inspection checklist See page 40 6 Pull only light load...

Page 41: ...d visibility such as fog rain and darkness Clean headlights fre quently and replace burned out headlamps promptly 8 Drive in a manner appropriate for your skills and operating condi tions Never operat...

Page 42: ...icle use As an off road enthusiast you represent the sport and can set a good example or a poor example for others to follow Tread lightly Operate with respect for the terrain avoid littering and alwa...

Page 43: ...tion Tires Inspect condition and pressure 71 Wheels fasteners Inspect ensure fastener tightness 71 Frame nuts bolts fasteners Inspect ensure tightness Fuel and oil Ensure proper levels 33 62 Throttle...

Page 44: ...ecome wet fouled 6 If the engine is cold pull the choke knob out until it stops If the knob doesn t stay where positioned increase the ten sion by rotating the tension adjusting nut clockwise Tip The...

Page 45: ...ve seconds if necessary Repeat this procedure until the engine starts Tip If a warm engine has cooled to a point where it does not readily start inter mittent use of the choke knob pulled half way out...

Page 46: ...n the handlebars 3 Start the engine and allow it to warm up 4 Shift the transmission into gear 5 Check your surroundings and determine your path of travel 6 Release the parking brake 7 Slowly depress...

Page 47: ...in the direction of the turn leaning your upper body to the inside of the turn while supporting your weight on the outer footrest This tech nique alters the balance of trac tion between the rear whee...

Page 48: ...e traction NOTICE Severe damage to drive train may occur if AWD is engaged while the wheels are spinning Allow the rear wheels to stop spinning before engaging AWD or engage AWD before wheels begin to...

Page 49: ...hills 25 maximum 3 Always check the terrain carefully before ascending any hill 4 Never climb hills with excessively slippery or loose surfaces 5 Keep both feet on the footrests 6 Shift body weight up...

Page 50: ...ssing the side of any hill unless absolutely necessary If crossing a sidehill is unavoidable follow these precautions 1 Slow down 2 Avoid crossing the side of a steep hill 3 Shift body weight uphill 4...

Page 51: ...p hills 25 maximum 2 Shift body weight uphill 3 Drive straight downhill 4 Slow down Excessive speed when traveling downhill can cause loss of control 5 Squeeze the brake lever gradually Applying the b...

Page 52: ...ointing 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 around to your...

Page 53: ...if equipped and all grease fittings If the vehicle tips or overturns in water or if the engine stops during or after operating in water restarting can result in serious engine damage Transport the ve...

Page 54: ...ing in a new area 2 Look ahead and learn to read the terrain Be constantly alert for haz ards such as logs rocks and low hanging branches 3 Travel slowly and use extra caution when operating on unfami...

Page 55: ...6 Never open the throttle suddenly 7 Do not use the override switch unless additional wheel speed is required for vehicle movement Use the override with caution as rearward vehicle speed is greatly in...

Page 56: ...oid parking on an incline if possible If it s unavoidable follow these precautions 1 Stop the engine 2 Place the transmission in gear 3 Lock the parking brake 4 Always block the rear wheels on the dow...

Page 57: ...racks raises the center of gravity of the vehicle and creates a less stable operating condition SECURE ALL LOADS BEFORE OPERATING Unsecured loads can create unstable operating conditions which could r...

Page 58: ...hitch from the ATV when not towing a trailer If towing a load reduce rear rack cargo weight by the amount of tongue weight The combination of rear rack cargo weight and tongue weight must not exceed t...

Page 59: ...cess 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 exhaust gases ex...

Page 60: ...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 of approx...

Page 61: ...ous injury or death Always have an authorized Polaris dealer perform these services Maintenance Chart Key X Perform these operations more often for vehicles subjected to severe use E Emission related...

Page 62: ...amp tail lamp Daily Check operation apply dielectric grease if replacing X E Air filter main element Weekly Inspect replace as needed Recoil housing if applicable Weekly Drain water as needed check of...

Page 63: ...system filter 100 H 12 M 1000 1600 Check for leaks at tank cap lines fuel valve filter pump carburetor replace lines every two years X Engine mounts 100 H 12 M 1000 1600 Inspect Exhaust muffler pipe 1...

Page 64: ...ese components are subjected to severe use grease zerks have been provided for additional lubrication at the user s discretion Item Lube Method Engine Oil PS 4 PLUS Performance Synthetic 2W 50 See pag...

Page 65: ...brands Oil Specifications Oil Level The oil dipstick is located on the left side of the vehicle 1 Position the vehicle on a level surface Place the transmission in neutral Lock the parking brake 2 Sta...

Page 66: ...ing surfaces on the drain plug and crankcase should be clean and free of burrs nicks or scratches 6 Place towels under the oil filter Using an oil filter wrench turn the filter counterclockwise to rem...

Page 67: ...ns Oil Check The dipstick is located on the right side of the vehicle near the recoil handle 1 Position the vehicle on a level surface 2 Remove the dipstick Wipe it dry with a clean cloth 3 Reinstall...

Page 68: ...umulated metallic filings 6 Allow the oil to drain com pletely 7 Reinstall the drain plug with a new sealing washer Torque to specification 8 Turn the adjuster bolt out until it touches the frame and...

Page 69: ...ecommended to keep the brake system in good operating condition Check more often if brakes are used heavily under normal operation 1 Always keep brake fluid at an adequate level See page 31 2 Check th...

Page 70: ...disengage the two rear tabs 3 Place your hand on top of the side panel behind the fuel tank With a quick and firm motion push down on the side panel to disengage the top rear two tabs Then pull up on...

Page 71: ...nd secure them in this position 3 Place a chalk mark on the center line of the front tires approximately 10 25 4 cm from the floor or as close to the hub axle center line as possible Make sure both ma...

Page 72: ...he adjuster until 1 16 to 1 8 1 5 3 mm of freeplay is achieved at the thumb lever While adjusting freeplay be sure to flip the throttle lever back and forth 5 Tighten the lock nut 6 Squeeze the end of...

Page 73: ...k tightening bolts can cause limited steering or loosening of the handlebars resulting in loss of control and serious injury or death Follow the adjustment procedures exactly or see your Polaris deale...

Page 74: ...manual and on the labels on the vehicle Always use original equipment size and type when replacing tires Refer to the specifications section beginning on page 108 for recom mended tire type size and...

Page 75: ...e the wheel Wheel Installation 1 Place the wheel on the wheel hub with the valve stem toward the outside and the rotation arrows on the tire pointing toward forward rotation 2 Install the wheel nuts f...

Page 76: ...e Specifications Check the wheel nut torques occasionally and when they ve been loos ened for service Item Torque Specification Front Wheel Nuts 27 ft lbs 37 Nm Rear Wheel Nuts 50 ft lbs 68 Nm Rear 50...

Page 77: ...oosen the clamp and remove the filter 5 Remove the pre filter from the main filter 6 Wash the pre filter in soapy water then rinse and let dry 7 Reinstall the pre filter over the main filter Replace t...

Page 78: ...Water will enter the recoil housing if the starter handle is disengaged from the rope guide when under water 1 Place the transmission in gear 2 Lock the parking brake 3 Stop the engine 4 Remove the d...

Page 79: ...our Polaris dealer are required for operation above 6 000 feet and temperatures below 40 degrees F 4 degrees C Tip Continuous operation of the engine without proper jetting when required can cause poo...

Page 80: ...maged rollers Also check for correct slack adjustment Maintain the stone guard to rear sprocket clearance at 1 8 3 mm Regularly lubricate the drive chain with Polaris Chain Lube an SAE 80 90 lube or a...

Page 81: ...r operating the ATV with improper rear drive chain slack can result in severe damage to the transmission and drive components Always make sure the slack is within the stated specifications Use the fol...

Page 82: ...hitch and 45 ft lbs 61 Nm for machines with a hitch 8 Tighten the caliper mount bolt to 15 ft lbs 20 Nm 9 Remove the pin punch 10 Roll the ATV forward checking chain tension in several places around t...

Page 83: ...arking brake 4 Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height Include rider weight on the seat when measuring 5 Start the engine Turn...

Page 84: ...residue causing a hot spot that will shorten the life of the lamp 1 Remove the wire harness connector from the back of the headlight CAUTION Hot components can cause burns to skin Allow lamps to cool...

Page 85: ...proper operation 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 panel 2 Using a small s...

Page 86: ...le has been driven at higher speeds Immediately check the spark plug for correct color See page 84 CAUTION A hot exhaust system and engine can cause burns Wear protective gloves when removing a spark...

Page 87: ...hould not be flaky and white A white insulator tip indicates overheating caused by use of an improper spark plug or incorrect carbu retion adjustments Wet Fouled Spark Plug The wet fouled insulator ti...

Page 88: ...air box and replace the filter with a new filter 4 Remove the spark plug 5 Loosen the carburetor drain screw and drain the carburetor 6 Turn the engine over several times using the electric start 7 Dr...

Page 89: ...he vehicle on a level surface 2 Place the transmission in neutral 3 Lock the parking brake 4 Remove the arrestor clean out plug from the bottom of the muffler 5 Start the engine 6 Quickly squeeze and...

Page 90: ...oads on components The PVT system rotates at high speeds creating large amounts of force on clutch components Extensive engineering and testing has been conducted to ensure the safety of this product...

Page 91: ...be running at only about 1500 RPM with an engagement speed of about 1400 RPM Whenever operating this close to the engage ment speed the engine may be running at a speed too low to provide the pinch n...

Page 92: ...completely Reinstall the drain plug 3 Start the engine Place the transmission in neutral 4 Apply varying throttle for 10 15 seconds to expel the moisture and air dry the belt and clutches Do not hold...

Page 93: ...duce explosive gases Keep sparks flame cigarettes etc away Ventilate when charging or using in an enclosed space Always shield eyes when working near batteries KEEP OUT OF REACH OF CHILDREN Your ATV m...

Page 94: ...move the battery vent tube 6 Disconnect the black negative battery cable first 7 Disconnect the red positive battery cable last 8 Lift the battery out of the ATV Be careful not to tip a conventional b...

Page 95: ...rely 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 explosio...

Page 96: ...ning battery charge by using a Polaris Bat tery Tender charger or by charging about once a month to make up for normal self discharge Battery Tender can be left connected during the storage period and...

Page 97: ...the sealing strip off or add any other fluid to this battery The single most important thing about maintaining a sealed battery is to keep it fully charged Since the battery is sealed and the sealing...

Page 98: ...dard 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...

Page 99: ...to contact 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 body fi...

Page 100: ...ashing Allow the engine to run for a while to evaporate any water that may have entered the engine or exhaust system Polishing the Vehicle Polaris recommends the use of common household aerosol furnit...

Page 101: ...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 periodical...

Page 102: ...bilizer Follow the instructions on the container for the recommended amount Carbon Clean removes water from fuel systems stabilizes fuel and removes carbon deposits from pistons rings valves and exhau...

Page 103: ...Pour 2 3 tablespoons 30 40 ml of engine oil into the hole Tip 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 Torq...

Page 104: ...ery Storage See pages 93 94 for storage and charging procedures Storage Area Covers Set the tire pressure and safely support the ATV with the tires slightly off the ground Be sure the storage area is...

Page 105: ...ission in gear 3 Lock the parking brake 4 Turn the fuel valve off 5 Secure the fuel cap oil cap and seat 6 Remove the key to prevent loss during transporting 7 Always tie the frame of the ATV to the t...

Page 106: ...Angle Drive Fluid 2 5 gal 9 5 l 2870465 Pump for Gallon Jug Grease Specialized Lubricants 2871312 Grease Gun Kit Premium All Season 3 oz 2871322 Premium All Season Grease 3 oz cartridge 2871423 Premiu...

Page 107: ...ow range only if equipped Stuck in mud or snow Shift the transmission to low range if equipped Care fully use fast aggressive throttle application to engage clutch WARNING Excessive throttle may cause...

Page 108: ...fresh recommended fuel Fouled or defective spark plug s Inspect plugs and replace if necessary No spark to spark plug Inspect plugs verify stop switch is on Overuse of choke Inspect clean and or repl...

Page 109: ...tighten Water present in fuel Replace with new fuel Low battery voltage Recharge battery to 12 8 VDC Kinked or plugged fuel tank vent line Inspect and replace Incorrect fuel Replace with recommended f...

Page 110: ...Worn or defective spark plug wires See your dealer Incorrect spark plug gap or heat range Set gap to specs or replace plug Loose ignition connections Check all connections and tighten Low battery vol...

Page 111: ...ing Rating 850 lbs 385 6 kg Unbraked Trailer Towing Capacity 1263 lbs 573 kg Overall Length 75 in 190 5 cm Overall Width 46 in 117 cm Overall Height 46 in 117 cm Wheelbase 49 5 in 125 7 cm Ground Clea...

Page 112: ...Brakes Front and Rear Single Control Hydraulic Disc Brake Auxiliary Foot Activated Hydraulic Disc Rear Wheel Brake Parking Hydraulic lock all wheel Headlight 2 Dual Beam 30w 30w Taillights 12V 8 26W...

Page 113: ...laris dealer REGISTRATION At the time of sale the Warranty Registration Form must be completed by your dealer and submitted to Polaris within ten days Upon receipt of this registration Polaris will re...

Page 114: ...osion 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...

Page 115: ...your original selling dealer however you may use any Polaris Servicing Dealer to perform warranty service Please work with your dealer to resolve any warranty issues Should your dealer require any ad...

Page 116: ...ling within the country where your vehicle was purchased Warranty or Service Bulletin repairs may be requested from any authorized Polaris dealer who sells the same line as your vehicle Outside the Co...

Page 117: ...ed outside of the country where it was purchased and you have not followed the procedure set out above your vehicle will no longer be eligible for war ranty or service bulletin coverage of any kind Ve...

Page 118: ...replacement of any defective materials components or prod ucts THE REMEDIES SET FORTH IN THIS LIMITED WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WAR RANTY POLARIS SHALL...

Page 119: ...section of your manual to your dealer each time your vehicle is serviced This will provide you and future owners with an accurate log of maintenance and ser vices performed DATE MILES KM OR HOURS TECH...

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

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Polaris Trail Boss 9921784, Owner'S Manual

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