Polaris trailboss 04 User Manual
3
WARNING
The engine exhaust from this
product contains chemicals known
to cause cancer, birth defects or
other reproductive harm.
A card containing important ATV safety information should be attached
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.
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1
Copyright 2003 Polaris Sales Inc. All information contained within this publication is
based on the latest product information at the time of publication. Due to constant
improvements in the design and quality of production components, some minor
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 liability can be accepted for omissions or inaccuracies. Any reprinting or
reuse of the depictions and/or procedures contained within, whether whole or in part, is
expressly prohibited. Printed in U.S.A.
2
WELCOME
Thank you for purchasing a Polaris vehicle, and welcome to our
world-wide family of Polaris owners. We proudly produce an exciting
line of utility and recreational products.
Polaris Recreational and Utility Vehicles
S Snowmobiles
S All-terrain vehicles (ATVs)
S Wa tercraft
S Victory motorcycles
S RANGER utility vehicles
Polaris Professional Series Workmobilest
S Utility Task Vehiclest (UTVs)
S Personal Task Vehiclest (PTVs)
S All-Surface Loaders (ASLs)
We believe Polaris sets a standard of excellence for all utility and
recreational vehicles manufactured in the world today. Many years of
experience have gone into the engineering, design, and development of
your Polaris vehicle, making it the finest machine we’ve ever
produced.
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
about major repairs is outlined in the Polaris Service Manual and
should be performed only by a F actory Certified Master Service Dealer
(MSD) Technician.
Your Polaris dealer knows your vehicle best and is interested in your
total satisfaction. Be sure to return to your dealership for all of your
service needs during, and after, the warranty period.
We also take great pride in our Parts Apparel and Accessories (PAA)
products, available through our online store at www.purepolaris.com.
Have your accessories and clothing delivered right to your door!
Polaris, Polaris The Way Out, and Workmobiles are registered
trademarks of Polaris Industries Inc.
LOCTITE is a registered trademark of LOCTITE Corporation.
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4
TABLE OF CONTENTS
WELCOME 3.................................
VEHICLE IDENTIFICATION NUMBERS 6........
SAFETY 7...................................
FEATURES A ND CONTROLS 36...............
OPERATION 46..............................
EMISSION CONTROL SYSTEMS 63............
MAINTENANCE AND LUBRICATION 64.........
SPECIFICATIONS 105........................
POLARIS PRODUCTS 108.....................
TROUBLESHOOTING 109.....................
WARRANTY 113..............................
INDEX 116...................................
5
VEHICLE IDENTIFICATION NUMBERS
The vehicle frame vehicle identification number (VIN)(1) and engine
serial number are important for model identification when registering
your vehicle, when obtaining insurance, and when ordering
replacement parts. If your vehicle is stolen, these numbers are essential
to the recovery and identification of your vehicle.
Remove the spare key and store it in a safe place. Your key can be
duplicated only by mating a Polaris key blank with one of your
existing keys. If both keys are lost, the ignition switch must be
replaced. See your Polaris dealer.
NOTE: Record your vehicle’s ID numbers and key number (2) in the
spaces provided.
31XX
1
Frame VIN:
Vehicle Model Number:
Engine Serial Number (right front side of engine crankcase):
Key Number:
6
2
SAFETY
Operator Safety
WARNING
Failure to follow the warnings contained in this manual can result
in severe injury or death.
A Polaris ATV is not a toy and can be hazardous to operate. This
vehicle handles differently than other vehicles, such as
motorcycles and cars. A collision or rollover can occur quickly,
even during routine maneuvers like turning, or driving on hills or
over obstacles, if you fail to take proper precautions.
Read and understand your owner’s manual and all warnings
before operating a Polaris ATV.
Age Restrictions
This vehicle is an ADULT VEHICLE ONLY. Operation is prohibited
for anyone under 16 years of age.
Know Your Vehicle
As the operator of the vehicle, you are responsible for your personal
safety, the safety of others, and the protection of our environment.
Read and understand your owner’s manual, which includes valuable
information about all aspects of your vehicle, including safe operating
procedures.
Safety Training
When you purchased your new ATV, your dealer offered a hands-on
safety training course that covers all aspects of vehicle safety. You were
also provided with printed materials that explain safe operating
procedures. You should review this information on a regular basis.
If you purchased a used Polaris ATV from a party other than a Polaris
dealer, you can request this free safety training from any authorized
Polaris dealer.
A Polaris ATV is an off-road vehicle. Familiarize yourself with all laws
and regulations concerning the operation of t his vehicle in your area.
We strongly advise you to strictly follow the recommended
maintenance program outlined in your owner’s manual. This
preventive maintenance program is designed to ensure that all critical
components on your vehicle are thoroughly inspected at specific
intervals.
7
SAFETY
Operator Safety
The following signal words and symbols appear throughout this
manual and on your ATV. Your safety is involved when these words
and symbols are used. Become familiar with their meanings before
reading the manual.
The safety alert symbol, on your ATV 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 safety alert caution indicates a potential hazard that may result
in minor personal injury or damage to the machine.
CAUTION
A caution indicates a situation that may result in damage to the
machine.
NOTE
A note will alert you to important information or instructions.
8
SAFETY
Operator Safety
WARNING
Serious injury or death can result if you do not follow these
instructions and procedures, which are outlined in further detail
within your owner’s manual.
S Read this manual and all labels carefully, and follow the operating
procedures described.
S Never operate an ATV without proper instruction. Take a t raining
course. Beginners should receive training from a certified instructor.
Contact an authorized Polaris ATV dealer or call Polaris at
1-800-342-3764 to find out about the training courses nearest you.
S Never allow anyone under 16 years of age to operate this ATV.
S Never permit a guest to operate the ATV unless the guest has read
this manual and all product labels and has completed a certified safety training course.
S Always avoid operating an ATV on paved surfaces, including side-
walks, driveways, parking lots, and streets.
S Never operate an ATV on a public 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 long-sleeved shirt or jacket, and long pants.
S Never consume alcohol or drugs before or while operating an ATV.
S Never operate at excessive speeds. Travel at speeds appropriate for
the terrain, visibility and operating conditions, and your experience.
S Never attempt wheelies, jumps or other stunts.
S Always inspect your ATV before each use to make sure it’s in safe
operating condition. Always follow the inspection and maintenance
procedures and schedules outlined in your owner’s manual.
S Always keep both hands on the handlebars and both feet on the foot-
rests of the ATV during operation.
S Always travel slowly and use extra caution when operating on unfa-
miliar terrain. Be alert to changing terrain conditions.
S Never operate on excessively rough, slippery, or loose terrain.
S Always follow proper turning procedures as described in this manu-
al. Practice turning at low speeds before attempting to turn at faster
speeds. Do not turn at excessive speeds.
9
SAFETY
Operator Safety
S Always have the ATV inspected by an authorized Polaris dealer if
it’s been involved in an accident.
S Never operate on hills too steep for the ATV or for your abilities.
Practice on smaller hills before attempting larger hills.
S Always follow proper procedures for climbing hills. Check the ter-
rain carefully before ascend a hill. Never climb hills with excessively slippery or loose surfaces. Shift your weight forward. Never open
the throttle suddenly or make sudden gear changes. Never go over
the top of a hill at high speed.
S Always follow proper procedures for going downhill and for braking
on hills. Check the terrain carefully before you start down a hill.
Shift your weight backward. Never go down a hill at high speed.
Avoid going down a hill at an angle, which would cause the vehicle
to lean sharply to one side. Travel straight down the hill when possible.
S Always follow proper procedures for crossing the side of a hill.
Avoid hills with excessively slippery or loose surfaces. Shift your
weight to the uphill side of the ATV. Never attempt to turn the ATV
around on any hill until you’ve mastered (on level ground) the turning technique outlined in this manual. Avoid crossing the side of a
steep hill when possible.
S Always use proper procedures if you stall or roll backwards while
climbing a hill. To avoid stalling, maintain a steady speed when
climbing a hill. If you stall or roll backwards, follow the special procedure for braking described in this manual. Always dismount on the
uphill side, or to either side if the ATV is pointed straight uphill.
Turn the ATV around and remount following the procedure described in this manual.
S Always check for obstacles before operating in a new area. Never
attempt to operate over large obstacles, such as rocks or fallen trees.
Always follow proper procedures when operating over obstacles as
described in this manual.
S Always be careful of skidding or sliding. On slippery surfaces like
ice, travel slowly and use extra caution to reduce the chance of skidding or sliding out of control.
S Avoid operating the ATV through deep or fast-flowing water. If it’s
unavoidable, travel slowly, balance your weight carefully, avoid sudden movements, and maintain a slow and steady forward motion. Do
not make sudden turns or stops, and do not make sudden throttle
changes.
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SAFETY
Operator Safety
S Wet brakes may have reduced stopping ability. Test your brakes after
leaving water. If necessary, apply them lightly several times to allow
friction to dry out the pads.
S Always check for obstacles or people behind the ATV before operat-
ing in reverse. When it’s safe to proceed in reverse, move slowly and
avoid turning at sharp angles.
S Always use t he size and t ype of tires specified for your ATV, and
always maintain proper tire pressure.
S Never modify an ATV through improper installation or use of acces-
sories.
S Never exceed the stated load capacity for your ATV. Cargo must be
properly distributed and securely attached. Reduce speed and follow
the instructions in this manual for carrying cargo or towing. Allow a
greater distance for braking.
S Always remove the ignition key when the vehicle is not in use to
prevent unauthorized use or accidental starting.
FOR MORE INFORMATION ABOUT ATV SAFETY, call the Consumer Product Safety Commission at 1-800-638-2772, or call
Polaris at 1-800-342-3764.
Equipment Modifications
We are concerned for the safety of our customers and for t he general
public. Therefore, we strongly recommend that consumers do not
install on a Polaris ATV any equipment that may 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
vehicle create a substantial safety hazard and increase the risk of bodily
injury.
The warranty on your Polaris ATV is terminated if any equipment has
been added to the vehicle, or if any modifications have been made to
the vehicle, that increase its speed or power.
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 vehicle. Use only P olaris-approved
accessories, and familiarize yourself with their function and effect on
the vehicle.
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SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD
Operating this ATV without proper instruction.
WHAT CAN
The risk of an accident is greatly increased if the operator
does not know how to operate the ATV properly in different
situations and on different types of terrain.
HOW TO AVOID THE
Beginning and inexperienced operators should complete the
certified training course offered by Polaris. Operators should
regularly practice the skills learned in the course 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.
HAPPEN
HAZARD
WARNING
POTENTIAL
Failure to follow the age recommendations for this ATV.
WHAT CAN
Severe injury and/or death could occur if a child under the
minimum age recommendation operates an ATV.
Even though a child may be within the recommended age group
for operating some ATVs, he/she may not have the skills,
abilities, or judgment needed to operate an ATV safely and could
be susceptible to accident or injury.
HOW TO AVOID THE
No one under the age of 16 should operate a Polaris ATV.
12
HAZARD
HAPPEN
HAZARD
Operator Safety
WARNING
POTENTIAL HAZARD
Carrying a passenger on an ATV.
WHAT CAN
Carrying a passenger greatly reduces the operator’s ability to
balance and control the ATV, which could cause an accident
and injury to the operator and/or passenger.
HOW TO AVOID THE
Never carry a passenger. The purpose of the long seat is to
allow the operator to shift position as needed during operation.
It is not intended for carrying passengers.
HAPPEN
HAZARD
SAFETY
13
SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD
Operating an ATV on paved surfaces, including sidewalks,
paths, parking lots, and driveways.
WHAT CAN
ATV tires are designed for off-road use. Operating on paved
surfaces may seriously affect the handling and control of the
ATV and could result in loss of control, accident, and/or injury.
HOW TO AVOID THE
Avoid operating the ATV on pavement. If it’s unavoidable,
travel slowly and avoid sudden turns or stops.
HAPPEN
HAZARD
14
Operator Safety
WARNING
POTENTIAL HAZARD
Operating this ATV on public streets, roads or highways.
WHAT CAN
The ATV could collide with another vehicle.
HOW TO AVOID THE
Never operate the ATV on any public street, road or highway,
including dirt and gravel roads. In many states it’s illegal to
operate ATVs on public streets, roads and highways.
HAPPEN
HAZARD
SAFETY
15
SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD
Operating this ATV without wearing an approved helmet, eye
protection and protective clothing.
WHAT CAN
Operating an ATV without an approved helmet increases the
risk of a severe head injury or death in the event of an
accident.
Operating without eye protection could result in an accident
and could increase the chance of a severe injury in the event
of an accident.
HOW TO AVOID THE
Always wear an approved helmet that fits properly.
Always wear eye protection (goggles or face shield), gloves,
boots, long-sleeved shirt or jacket, and long pants.
HAPPEN
HAZARD
16
Operator Safety
WARNING
POTENTIAL HAZARD
Operating the ATV after consuming alcohol or drugs.
WHAT CAN
Consumption of alcohol and/or drugs could seriously affect
operator judgment. Reaction time may be slower and operator
balance and perception could be affected.
Consuming alcohol and/or drugs before or while operating an
ATV could result in an accident causing severe injury or death.
HOW TO AVOID THE
Never consume alcohol or drugs before or while operating an
ATV.
HAPPEN
HAZARD
WARNING
SAFETY
POTENTIAL
Operating the ATV at excessive speeds.
WHAT CAN
Excessive speed increases the operator’s chance of losing
control of the ATV, which can result in an accident.
HOW TO AVOID THE
Always operate the ATV at a speed that’s proper for the terrain,
visibility and operating conditions, and your experience.
HAZARD
HAPPEN
HAZARD
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SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD
Attempting wheelies, jumps and other stunts.
WHAT CAN
Attempting stunts increases the chance of an accident, including
an overturn.
HOW TO AVOID THE
Never attempt wheelies, jumps, or other stunts. Avoid exhibition
driving.
HAPPEN
HAZARD
18
Operator Safety
WARNING
POTENTIAL HAZARD
Failure to inspect the ATV before operating.
Failure to properly maintain the ATV.
WHAT CAN
Poor maintenance increases the possibility of an accident or
equipment damage.
HOW TO AVOID THE
Always inspect your ATV before each use to make sure it’s in
safe operating condition.
Always follow the inspection and maintenance procedures and
schedules described in the owner’s manual.
HAPPEN
HAZARD
WARNING
SAFETY
POTENTIAL
Removing hands from the handlebars or feet from the
footrests during operation.
WHAT CAN
Removing even one hand or foot can reduce ability to
control the vehicle or could cause loss of balance and
ejection from the ATV.
If the operator’s foot is not firmly planted on the footrest, it
could come into contact with the rear wheels and lead to
accident or injury.
HOW TO AVOID THE
Always keep both hands on the handlebars and both feet
on the footrests of the ATV during operation.
HAZARD
HAPPEN
HAZARD
19
SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD
Failure to use extra caution when operating the ATV on unfamiliar
terrain.
WHAT CAN
Unfamiliar terrain may contain hidden rocks, bumps, or holes that
could cause loss of control or overturn.
HOW TO AVOID THE
Travel slowly and use extra caution when operating on unfamiliar
terrain. Always be alert to changing terrain conditions.
HAPPEN
HAZARD
20
Operator Safety
WARNING
POTENTIAL HAZARD
Failure to use extra caution when operating on excessively
rough, slippery or loose terrain.
WHAT CAN
Operating on excessively rough, slippery or loose terrain could
cause loss of traction or loss of control, which could result in an
accident or overturn.
HOW TO AVOID THE
Do not operate 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.
HAPPEN
HAZARD
SAFETY
21
SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD
Turning improperly.
WHAT CAN
Improper turns could cause loss of control and lead to a collision
or overturn.
HOW TO AVOID THE
Always follow proper procedures for turning as described in the
owner’s manual.
Practice turning at slow speeds before attempting to turn at
faster speeds.
Never turn at excessive speed.
HAPPEN
HAZARD
WARNING
POTENTIAL
Operating on excessively steep hills.
WHAT CAN
The vehicle may overturn.
HOW TO AVOID THE
Never operate on hills too steep for the ATV or for your
abilities. Never operate the ATV on hills steeper than 25_.
Practice on smaller hills before attempting large hills.
22
HAZARD
HAPPEN
HAZARD
SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD
Climbing hills improperly.
WHAT CAN
Improper hill climbing could cause loss of control or overturn.
HOW TO AVOID THE
Always follow proper procedures for climbing hills as described
in the owner’s manual.
Always check the terrain carefully before ascending any hill.
Never operate the ATV on hills steeper than 25_.
Never climb hills with excessively slippery or loose surfaces.
Shift your weight forward.
Never open the throttle suddenly while traveling uphill. The ATV
could flip over backwards.
Never go over the top of any hill at high speed. An obstacle, a
sharp drop, or another vehicle or person could be on the other
side of the hill.
HAPPEN
HAZARD
23
SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD
Traveling downhill improperly.
WHAT CAN
Improperly descending a hill could cause loss of control or
overturn.
HOW TO AVOID THE
Always follow proper procedures for traveling down hills as
described in the owner’s manual. NOTE: A special technique
is required when braking while traveling downhill. See page
57.
Always check the terrain carefully before you descending a hill.
Shift your weight backward.
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
hill when possible.
HAPPEN
HAZARD
24
SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD
Improperly crossing hills and turning on hills.
WHAT CAN
Improperly crossing or turning as hills could cause loss of control
or overturn.
HOW TO AVOID THE
Never attempt 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 58. Use extra caution when
turning on any hill.
Avoid crossing the side of a steep hill.
When crossing the side of a
Always follow proper procedures as described in the owner’s
manual.
Avoid hills with excessively slippery or loose surfaces.
Shift your weight to the uphill side of the ATV.
HAPPEN
HAZARD
hill:
25
SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD
Stalling, rolling backwards or
improperly dismounting while
climbing a hill.
WHAT CAN
The vehicle could overturn.
HOW TO AVOID
HAZARD
Maintain steady speed when
climbing a hill.
If all forward speed is
Keep your weight uphill.
Apply the single lever brake gradually.
When fully stopped, apply the auxiliary rear brake as well, then
lock the parking brake.
If the ATV begins rolling
Keep weight uphill.
Never apply engine power.
Never apply the auxiliary rear brake while rolling backwards.
Apply the single-lever brake gradually.
When fully stopped, apply the auxiliary rear brake as well, and
then lock the parking brake.
Dismount on uphill side, or to either side if ATV is pointed
straight uphill.
Turn the ATV around and remount, following the procedure
described in the owner’s manual. See page 58.
HAPPEN
THE
lost:
backwards:
26
SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD
Improperly operating over obstacles.
WHAT CAN
Operating over obstacles could cause loss of control or overturn.
HOW TO AVOID THE
Before operating in a new area, check for obstacles.
Avoid operating over large obstacles such as rocks and fallen
trees when possible. If unavoidable, use extreme caution and
always follow proper procedures as outlined in the owner’s
manual.
HAPPEN
HAZARD
WARNING
POTENTIAL
Skidding or sliding.
WHAT CAN
Skidding or sliding can cause loss of control.
If the tires regain traction unexpectedly, the ATV could overturn.
HOW TO AVOID THE
On slippery surfaces such as ice, travel slowly and use extra
caution to reduce the chance of skidding or sliding out of control.
HAZARD
HAPPEN
HAZARD
27
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