Benutzeranleitung / Produktwartung trailboss 04 des Produzenten Polaris
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A car d cont aining import ant A TV saf ety infor mat ion should be at tac hed to t he owner ’s manual on t he next page. If you c annot loc ate t his c ard, or if it has been rem oved, pleas e call 1-800- 342-3764 f or ass ist ance.
1 We’ve cr eated a Web sit e ju st f or you! S T echnical ti ps S New product introductions S Event schedules S Parts and Se rvice M anual information S Exciting details about The W ay Out Ch e c k it ou t.
2 Copyr ight 2003 Pol a ri s Sa l e s Inc . All inf or ma t i on c ont a i ne d wi t hi n t hi s publi c a t ion i s ba s e d on the l a t e s t pr oduc t i nf or ma t i on a t the t i me of publ i c a t i on.
3 WELC O ME Thank you f or purc hasing a Polar is vehic le, and we lcome to our wor ld-wide f amily of Polaris owne rs. W e proudly produc e an exciting line of utility a nd re cre ational produc ts.
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5 TABLE OF CONTE NTS WELCO ME 3 ................................. VEHICL E IDENTI FICA TION NUM BERS 6 ........ SAFET Y 7 ................................... FEA TURES AND CONTROLS 36 ............... OPE RA TION 46 .............................. EMI SSION CONTRO L SYSTEMS 63 .
6 VE HICLE IDENTIFICATION NUMBERS The vehic le fra me vehic le identific ation number (VIN) (1) and engine ser ial numbe r a re impor tant f or mode l i dentif ication w hen re gistering your ve hicle, when obta i ning insura nce, and whe n ordering replacem ent part s.
7 SA FETY Operator S afety Age Restr ictions This vehi cle is an ADUL T VEHICLE ONL Y . Operati on is prohi bited for anyone under 16 ye ars of age . Know Y our V e hicle As the opera tor of the vehicle , you are re sponsible for your persona l saf ety , the safe ty of others, and the prote ction of our environme nt.
8 SA FETY Operator S afety The f ollowing signal wor ds and symbols appe ar throughout this manua l and on your A TV . Y our safe ty is involved whe n t hese words and symbols ar e used. Beco me fa miliar w ith their mea nings befor e re ading the manua l.
9 SA FETY Operator S afety S Rea d this manual and a ll l ab els ca ref ully , and f ollow the ope rating proce dures desc ribed. S Neve r oper ate a n A TV without proper instr uction. T ake a training course . B eginners shoul d recei ve training from a certi fied ins tructo r .
10 SA FETY Operator S afety S Alway s have t he A TV i ns pected b y an aut hori zed P ol aris d ealer i f it ’ s b een invol ved in an accident . S Ne ver ope rate on hills too steep fo r the A TV or for your a bilities. Pra ctice o n smalle r hills befo re a ttempting lar ger hills.
11 SA FETY Operator S afety S W et bra kes may ha ve re duced stopping a bility . T est your br akes a fte r lea ving wate r . If ne cessa ry , apply the m lightly seve ra l times to allow frict io n to d ry out t he pad s. S Always che ck for obsta cles or people be hind the A TV bef ore oper at- in g in rev erse.
12 SA FETY Operator S afety POTENTI AL HAZ ARD Oper ating t his A TV wit hout pr oper inst ruct ion. WHA T CAN H APPEN The r isk of an acc ident is great ly inc reased if t he operat or does not know how t o operat e the A T V pr operly in diff erent sit uations and on different t ypes of t errain.
13 SA FETY Operator S afety POTENTI AL HAZ ARD Carr ying a passenger on an A T V . WHA T CAN H APPEN Carr ying a passenger great ly reduc es the operat or ’s ability t o balance and cont rol t he A T V , which could c ause an accident and injury t o t he operat or and/ or pass enger .
14 SA FETY Operator S afety POTENTI AL HAZ ARD Oper ating an A T V on pav ed surf aces , inc luding sidewalks , paths , par king lot s, and driveway s.
15 SA FETY Operator S afety POTENTI AL HAZ ARD Oper ating t his A TV on public st reet s, roads or highway s. WHA T CAN H APPEN The A T V c ould collide wit h another vehicle. HOW T O A VOID TH E HAZ ARD Never operat e the A T V on any public str eet, road or highway , including dirt and gr avel roads .
16 SA FETY Operator S afety POTENTI AL HAZ ARD Oper ating t his A T V wit hout wearing an approv ed helmet , ey e prot ect ion and prot ect ive clot hing. WHA T CAN H APPEN Oper ating an A T V wit hout an approved helm et inc reases the ris k of a s evere head injur y or deat h in t he event of an accident .
17 SA FETY Operator S afety POTENTI AL HAZ ARD Oper ating t he A T V af ter consum ing alcohol or dr ugs. WHA T CAN H APPEN Consumpt ion of alcohol and/ or drugs could ser iously aff ect operat or judgment . React ion ti me may be slower and oper ator balance and perc eption c ould be affect ed.
18 SA FETY Operator S afety POTENTI AL HAZ ARD At tem pting wheelies , jum ps and ot her st unt s. WHA T CAN H APPEN At tem pting s tunt s inc reases the c hance of an accident , including an overt urn. HOW T O A VOID TH E HAZ ARD Never att empt wheelies , jumps, or ot her stunt s.
19 SA FETY Operator S afety POTENTI AL HAZ ARD Failur e to ins pect the A T V bef ore oper ating. Failur e to pr operly m aintain t he A T V . WHA T CAN H APPEN Poor m aintenanc e increas es t he possibilit y of an acc ident or equipment dam age.
20 SA FETY Operator S afety POTENTI AL HAZ ARD Failur e to us e ext ra caut ion when operat ing t he A TV on unfam iliar terrai n. WHA T CAN H APPEN Unfamiliar t errain ma y cont ain hidden rocks, bumps, o r holes that could caus e loss of cont rol or overt urn.
21 SA FETY Operator S afety POTENTI AL HAZ ARD Failur e to us e ext ra caut ion when operat ing on exc essiv ely rough, s lippery or loose t err ain. WHA T CAN H APPEN Oper ating on ex cess ively r ough, s lippery or loose t err ain could cause los s of tr act ion or loss of c ontr ol, whic h could res ult in an accident or over tur n.
22 SA FETY Operator S afety POTENTI AL HAZ ARD T urning im proper ly . WHA T CAN H APPEN Im proper t urns could caus e loss of cont rol and lead t o a collis ion or overt urn. HOW T O A VOID TH E HAZ ARD Always f ollow proper proc edures f or tur ning as described in the owner ’s manual.
23 SA FETY Operator S afety POTENTI AL HAZ ARD Climbing hills im properly . WHA T CAN H APPEN Im proper hill c limbing could c ause loss of c ontr ol or over tur n. HOW T O A VOID TH E HAZ ARD Always f ollow proper proc edures f or climbing hills as desc ribed in the owner ’ s manual.
24 SA FETY Operator S afety POTENTI AL HAZ ARD T rav eling downhill impr operly . WHA T CAN H APPEN Im proper ly descending a hill c ould cause los s of cont rol or overt urn. HOW T O A VOID TH E HAZ ARD Always f ollow proper proc edures f or tr aveling down hills as descr ibed in the owner ’ s manual.
25 SA FETY Operator S afety POTENTI AL HAZ ARD Im properly cros sing hills and t urning on hills . WHA T CAN H APPEN Im proper ly cros sing or turning as hills could caus e loss of cont rol or overt urn.
26 SA FETY Operator S afety POTENTI AL HAZ ARD St alling, r olling backwar ds or impr operly dis mount ing while climbing a hill. WHA T CAN H APPEN The v ehicle could ov ert urn. HOW T O A VOID TH E HAZ ARD Maint ain st eady speed when climbing a hill.
27 SA FETY Operator S afety POTENTI AL HAZ ARD Im proper ly operat ing over obstac les. WHA T CAN H APPEN Oper ating ov er obst acles could caus e loss of cont rol or overt urn. HOW T O A VOID TH E HAZ ARD Bef ore operat ing in a new ar ea, chec k f or obst acles .
28 SA FETY Operator S afety POTENTI AL HAZ ARD Oper ating t he A T V t hrough deep or f ast -f lowing wat er . WHA T CAN H APPEN T ires m ay float , c ausing loss of t rac tion and loss of c ontr ol, which could lead t o an acc ident or overt urn. HOW T O A VOID TH E HAZ ARD Avoid operating t he A T V t hrough deep or f ast -f lowing wat er .
29 SA FETY Operator S afety POTENTI AL HAZ ARD Oper ating t his A TV wit h improper t ires , or wit h improper or uneven tire pre ssure. WHA T CAN H APPEN Use of impr oper tir es, or oper ation of the A T V wit h impr oper or uneven t ire pr essur e, could c ause loss of c ontr ol or acc ident.
30 SA FETY Operator S afety POTENTI AL HAZ ARD Ov erloading t he A TV or car rying/ t owing cargo im properly . WHA T CAN H APPEN Ov erloading and t owing can caus e changes in v ehicle handling, which could lead t o loss of c ontr ol or an acc ident.
31 SA FETY Operator S afety Af ter any over tur n or acc ident, have a qualif ied ser vice dealer inspect t he entir e vehicle f or pos sible damage, including ( but not limi t ed to) bra kes, throttle and stee ring syste ms. Saf e operat ion of t his r ider-ac tiv e vehicle r equires good judgem ent and physic al skills .
32 SA FETY Safety D ecals and Locations W arnin g decals h ave been placed on the A TV for your protecti on. R ead and fo ll ow th e ins tru cti on s of th e decals an d oth er warni ngs o n th e A T V careful ly .
33 SA FETY Safety D ecals and Locations W ARNING Improper A TV use can r esu lt i n SEVER E INJUR Y or DEA TH ALW A YS USE AN APPRO VED HELMET AND PROTECTIVE GEAR NEVER USE ON PUBLIC ROADS NEVER CARR Y P ASSENGERS NEVER USE WIT H DRUGS OR ALCOHOL NEVER o pera te : AL W A YS: S DO NOT T OW FROM RACK OR BUMP ER.
34 SA FETY Safety D ecals and Locations Operat ing this A TV if you are under the age of 16 i ncreases your chan ce of severe i nj ury or d eat h. NEVER ope ra te t his ATV if y ou ar e under age 1 6. W ARNING 7078253 Chain Fr eepl ay Is Important. Adjust F ree play to 3/1 6 ″ -3 / 8 ″ DO NO T Overtension.
35 SA FETY Safe Riding G ear Always we ar c lothing suited to the t ype of riding. A TV riding requir es spec i al prote ctive clothing for c omfor t and to reduc e the cha nce of injury . 1. Helm et Y our he lmet is the most importa nt piece of prote ctive ge ar for sa fe riding.
36 FEATURE S AND CONTROLS Electr ical S witches Act ivat ing t he overr ide swit ch while t he thr ott le is open c an cause loss of cont rol, r esulting in s evere injur y or death. Do not act ivat e the ov erride s witc h while the t hrot t le is open.
37 FEATURE S AND CONTROLS Throttle Lever Eng in e speed an d veh icl e moveme nt are c ontrolle d by pre ssing the throttle leve r . The throttle le ver (1) is spring load ed.
38 FEATURE S AND CONTROLS Light S witches The light sw itch is loca ted on the left h andl ebar (1). It ’ s us ed to t urn the lights on a nd of f and to switc h the lights fr om HI to LO on mode ls equippe d with HI-LO bea ms. NOTE: The lights won’ t work unless the key is in the ON position and the shut-of f switc h i s in the RUN position.
39 FEATURE S AND CONTROLS Br akes Ch eck th e brake flu id l evel i n th e mas ter cy li n der befo re each us e of t he A TV . The maste r cylinde r (1) is lo cated o n th e left h andl ebar . The f luid leve l ca n be se en thr ough an indica tor window (2) on the top of the mas ter cy li nd er .
40 FEATURE S AND CONTROLS Br ake Lever The fro nt and rear brak es are ap pl ied b y sq ueezin g t he b rake lev er (1) t oward the han dl ebar . Th e front and rear brak es are hydra ulica lly activa t e d disc type brake s th at are acti vat ed by o nl y one l ever .
41 FEATURE S AND CONTROLS Auxiliary Brake The a uxiliar y brake ( 1), is loca ted on the inside of the right floor boa rd and is opera ted by the right foot. The auxilia ry bra ke ser ves as a backup to the main bra ke system if the main system be come s inoperative .
42 FEATURE S AND CONTROLS Choke The choke a ssists i n starting a c old engine. Ref er to the engine sta rting proc edur e on page 48 for corr ect choke and throttle se ttings during star ting. Fuel V alve The fu el v alv e (1) i s l ocat ed on th e left si de o f the veh icle , either be low t he fe nder or on the side pane l.
43 FEATURE S AND CONTROLS Fuel Safety Gas oline is highly f lamm able and explosiv e under cer tain condit ions. S Always exerc ise ext rem e caut ion whenever handling gas o- line. S Always ref uel with t he engine st opped, and outdoor s or in a well vent ilated ar ea.
44 FEATURE S AND CONTROLS Autom atic T r ansm ission Gear Selector The tra nsmission gear se lector ( 1) is locate d on the right side of the A TV . F: For wa rd N: Neutral R: Rev er se Whe never the A TV is left unattende d, alwa ys place the tra nsmission in gea r with the parking bra ke locked.
45 FEATURE S AND CONTROLS Recoil S tarter If the ba ttery has be en dra i ned or da mage d and c annot star t the engine , use of the re coil star ter (1) w ill a llow veh icle oper ation until re pairs c an be made . The r ec oil starte r is loca t ed on the right side of the mach in e.
46 OPERATION Br eak - In P er iod The br ea k-in period f or your new Polaris A TV is def ined a s the first te n hours of oper ation, or the time it takes to use the first two full t anks of gasoline . No single ac tion on your part is a s important a s following the proc edur es for a prope r break- i n.
47 OPERATION Pr e -Ride Inspection Use the f ollowing chec klist to verif y that your ve hicle is in prope r wor king condition be fore each use. Item /Insp ectio n Procedu re 1. T ires - Che ck condition a nd pre ssure s. 2. Fuel and oil tanks - Fill both tanks to their prope r leve l s.
48 OPERATION Star ting the Engine S tar ting a Col d Engine 1. Place the tr ansmission in neutra l and lo ck t he park in g brak e. Mak e sure the fue l t ank valve is on.
49 OPERATION Star ting the Engine S tar ting a W ar m Engine W ar m engines do not normally requir e the use of the choke. Exce ssive use of the choke ca n cause the spa rk plug to become we t foule d. 1. Position the vehicle on a le vel surfa ce with the tra nsmission in neutr al.
50 OPERATION Hauling Cargo Y our A TV has bee n designed to ca rry or tow a ce rtain a mount of load. Always r ea d and unde rstand the loa d distribution war ning labels on the veh icl e, an d never ex ceed th e weigh t capac ities outlined in the sp ecifi cati on s sect io n of th e owner ’ s m anu al and o n th e safety d ecals .
51 OPERATION Hauling Cargo Hauling cargo im proper ly can alt er v ehicle handling and may cause loss of c ontr ol or brake inst ability and res ult in serious injur y or death. A lways f ollow t hese prec autions when hauling cargo: S REDUCE SPEED AN D ALLO W G REA TER DI ST ANCE F OR BRAKING WHEN HAULING C ARGO .
52 OPERATION Driving Safely Driving Pr o cedures 1. Sit upright with both fe et on the f ootre sts and both hands on the handle bar s. 2. Start the engine a nd allow it to war m up, then shift the tr ansmission into gea r . 3. Check your sur roundings and dete rmine your pa th of trave l .
53 OPERATION Driving Safely Making T urns Y our Pola ris A TV is equippe d with a solid r ear ax le tha t drives both re ar wh ee ls equally at a ll times. This me ans that the whe el on the outside of the turn must travel a gre ate r distanc e than the inside wheel whe n turning and the inside tir e must slip trac tion slightly .
54 OPERATION Driving Safely Dr iving on Slippe r y Sur f aces Whenev er ridi ng o n sl ip pery su rfaces su ch as wet trai l s or lo ose grav el, or du ring freezi ng weat her , fol lo w thes e precaut io ns: 1. Slow down when e nter ing slippery a rea s.
55 OPERATION Driving Safely Driving Uphill Whe neve r trave ling uphill, follow th ese p recaut io ns : 1. Alwa ys trave l straight uphill. 2. A void stee p hills (25 _ ma ximum). 3. Kee p both feet on the footre sts. 4. T ransfe r your weight forwar d.
56 OPERATION Driving Safely Sidehilling Sidehilling ca n be a dange rous type of driving a nd should be avoided if at a ll possible. If you do e nter into a situa tion where sidehilling is neces sary , fol l ow t hes e precaut i ons : 1. Slow down. 2.
57 OPERATION Driving Safely Driving Downh ill Whe never de scending a hill, follow these pr ecauti on s: 1. P roceed di rect ly d own h ill. 2. T ransf er your we ight to the re ar of the ve hicle. 3. Slow down. 4. Apply the brakes slightly to aid in slowing, using the single br ake leve r .
58 OPERATION Driving Safely T urning A round on a H ill If the ve hicle stalls while c limbing a hill, never ba ck it down the hill! One mane uver that c an be used whe n it’ s nece ssar y to turn ar ound while c limbing a hill is the K-turn: 1. Stop and lock the pa rking bra ke while ke eping body w eight uphill.
59 OPERATION Driving Safely Dr iving Thr ough W ater Y our A TV can ope ra te through wa ter with a maximum r ecomme nded depth e qual to the bottom of the footr ests (1) . F ollow th ese pro cedu res when oper ating through wa ter: 1. De termine wa ter depths a nd cur rent bef ore c rossing.
60 OPERATION Driving Safely Dr ivin g Over Obstacles Be al ert! L ook ah ead and l earn to read t he terrai n yo u’re trav eli ng on . Be con st ant l y alert fo r hazards s uch as l og s, ro cks an d lo w hangi ng bran ches . Sever e injury or death c an result if your v ehicle com es in cont act with a hidden obs tac le.
61 OPERATION Driving Safely Dr ivin g in Rever se F oll ow t hese precau ti on s when op erati ng i n revers e: 1. Always a void bac king downhill. 2. Bac k slowly . 3. When i n reverse, apply the brake s lightly for stopping. 4. A void turning at sh arp angl es i n revers e.
62 OPERATION Driving Safely P a r k i n go na nI n c l i n e A void parking on a n incline if possible . If it’ s unavoida ble, follow th ese p recaut io ns : 1. T urn the engine of f. 1. Place the tr ansmission in gear . 2. Set t he par king brake.
63 EMISSION C ON TR OL SYST EMS Noise E mi ssion Contr ol System Do not modify the engine, i ntake o r e xhaust components, as doing so may af fec t complianc e with state and loca l noise level requir ements.
64 MAINTENANCE AND LUBRICATION Accessor ies Auxilia ry powe r outlets provide 12V powe r for oper ating access ori es such a s hand held spot lights. Acce ssory outlets a re a vailable for all models. Contac t your P olar is dealer f or more informa tion.
65 MAINTENANCE AND LUBRICATION Per iodi c Maintenance S chedule Hours of ope ration ar e based o n a 10 mph a vera ge. If ser vice is due a t 20 hours, the e quivale nt odomete r rea ding would be 200 mile s. P erform all s ervi ces at whi chever readi ng is reach ed first .
66 MAINTENANCE AND LUBRICATION Per iodi c Maintenance S chedule Item Hours/ Mile s Frequency Remar ks T a illigh t/b rak e ligh t Pre- Ride Pr e-Ri de Check operat ion daily; ap- ply P olar is di electr ic gr ease to socket when r eplaced " L Air filte r , mai n elem ent W eekly W eekly Inspect ; repl ace as needed J Brake pad wear 10 hr s.
67 MAINTENANCE AND LUBRICATION Per iodi c Maintenance S chedule Item Hours/ Mile s Frequency Remar ks Carbur etor f loat bowl 50 hr s. 6 mont hs Drai n bowl peri odicall y and pri or to stor age J Throt tl e Cable/ ETC Swit ch 50 hr s. 6 mont hs Inspect ; adjust ; lubr icat e; r eplace if necessar y L Choke (enr icher ) cable 50 hr s.
68 MAINTENANCE AND LUBRICATION Per iodi c Maintenance S chedule Item Hours/ Mile s Frequency Remar ks Radiat or/ Oil Cool er 100 hr s. 12 mont hs In spect; cl ean exter nal sur- fac e Cool ing syst em hoses 100 hr s. 12 mont hs In spect J Clut ches (dr ive and dri ven) 100 hr s.
69 MAINTENANCE AND LUBRICATION Per iodic Maintenance R ecord Use t he fol l owi ng ch art t o reco rd peri od ic m ain ten ance. Maintenance In terval Perfo rmed Se rv icing Date Ser vic ing Dealer or Pe rs on Remarks 10 hrs.
70 MAINTENANCE AND LUBRICATION Lubr ication Recom m endations NOTE: Hour s are ba sed on 10 mph aver age. If se rvice is due a t 20 hours, the e quivale nt odomete r rea ding would be 200 mile s. P er form all serv ices at whi chev er readin g is reach ed firs t.
71 MAINTENANCE AND LUBRICATION Lubr ication Recom m endations Pr emium 4 S ynth etic Oil Polaris Pre mium 4 All Sea son Synthetic e ngine oil has bee n specia lly for mulated for use in Polar i s 4-c ycle e ngines.
72 MAINTENANCE AND LUBRICATION Lubr ication Recom m endations Oil an d Filter Chang e 1. Position the vehicle on a leve l surf ace. 2. Clean the a re a around the dra in plug. 3. Run the engine for two to three minutes until wa rm. Stop t he engine . 4.
73 MAINTENANCE AND LUBRICATION Lubr ication Recom m endations T ransm issio n Oil Check The tr ansmission dipstic k (1) is loca t ed on the right side of the mach in e near t he reco il han dl e. Ch eck t he l ub rican t l evel monthly or e ver y 1000 miles (1600 km), whicheve r comes first.
74 MAINTENANCE AND LUBRICATION Lubr ication Recom m endations T ransm issio n Oil Chang e 1. P lace a drain p an ben eath t he tra nsmission oil drain plug area. 2. Loosen the jam nut ( A). 3. T urn the adjuste r bolt (B) in to allow the re moval of the drain plug (C).
75 MAINTENANCE AND LUBRICATION Lubr ication Recom m endations E ngine Oi l Chec k The oil fill is locate d on the left side of the vehicle ( 1). 1. Position the mach ine on a level surf ace. 2. Start the engine and let it idle for 20-30 seconds. Stop the engine.
76 MAINTENANCE AND LUBRICATION Adju stment s Br akes The front and re ar brake s are hydra ulic disc brakes, activa ted by moving the single brake le ver towar d t he handle bar . These br ake s are self -a djusting. The fo ll owi ng checks are recom men ded t o k eep th e brak e sys tem i n good oper ating c ondition.
77 MAINTENANCE AND LUBRICATION Adju stment s Br akes 2. Ch eck t he b rake sy st em fo r fl ui d l eaks. 3. Ch eck t he b rakes for ex cess iv e trav el o r spongy fe el. 4. Ch eck th e fricti on p ads fo r wear , dama ge and looseness. 5. Ch eck th e securi ty an d su rface condition of the disc.
78 MAINTENANCE AND LUBRICATION Adju stment s T oe Alignm ent Use the following proce dure to chec k the t oe alignme nt of t he vehic le. The re comme nded toe alignment is 1/8 ″ to 1/4 ″ toe out. 1. Set t he handle bars in a stra ight-a head position.
79 MAINTENANCE AND LUBRICATION Adju stment s S ide P anel Rem oval NOTE: Side pane l re moval may be dif ficult until the locking ta bs and receiv ers have been s napp ed and un sn apped a few times. 1. Remove the sea t . 2. Grasp the rear of t he si de p anel near t he rear cab .
80 MAINTENANCE AND LUBRICATION Adju stment s Steer in g Assem b ly The ste er ing assembly of the A TV should be che cked pe riodically f or loose nuts and bolts. If loose nuts and bolts are f ound, see your Polaris dea ler for se rvice bef ore ope ra ting the vehicle.
81 MAINTENANCE AND LUBRICATION Adju stment s Ca r bur etor IMPOR T ANT : Y our Polar i s A TV is c alibr ate d at the fa ctory for optimal pe rf orma nce at a ltitudes r anging f rom ze ro to 6,000 fee t (1800 m) and temper atures of +40 degr ee s F .
82 MAINTENANCE AND LUBRICATION Adju stment s Thr ottle C able Fr eeplay Thr ottle ca ble fre eplay is adjuste d at the handleba r . 1. Slide the boots (1) of f the inline cable a djuster slee ve (2) . Loosen the adjuste r locknut (3). 2. T urn the adjuste r until 1/16 ″ to 1/8 ″ freepl ay is ach iev ed at th e th um b lev er .
83 MAINTENANCE AND LUBRICATION Adju stment s Wheel Rem o val 1. Stop the engine , plac e the tra nsmission in gear a nd lock the par king bra ke. 2. Loosen the whe el nuts slightly . 3. Eleva te t he side of the veh icle by plac i ng a suitable sta nd under the foot rest fram e.
84 MAINTENANCE AND LUBRICATION Adju stment s Wheel Installation 1. Place the tr ansmission in gear and loc k the par king bra ke. 2. P lace t he wh eel o n t he wh eel hub with the valve stem towar d the outside and rota tion arro ws on the tire pointing toward for wa rd r otation.
85 MAINTENANCE AND LUBRICATION Adju stment s Fr ont Whee l Hub T ightening Front whee l bea ring tightne ss and spindle nut rete ntion are cr itical compone nt opera tions. All servic e must be pe rforme d by your aut ho rized P ol ari s deal er . Tire s Alway s repl ace tires wh en tread depth is wor n t o 1/8 ″ ( .
86 MAINTENANCE AND LUBRICATION Adju stment s Rear Dr ive Chain Slack Chec k the a mount of cha in slack in thr ee dif fe re nt locations by moving the ve hicle slightly f orwa rd to ga i n sla ck a t the top side of the r ear chai n. M easur e th e chai n sl ack at t he t ig ht est of t he t hree p os it io ns .
87 MAINTENANCE AND LUBRICATION Adju stment s Rear Dr ive Chain Slack 6. R ol l t he A TV forward or back ward to adjust the cha in slack to the prope r tension. See the illustra tion for pr oper splice link clip ope ning position (1) . 7. T ig ht en t he eccen tri c lo cki ng bo lt s to 30 ft.
88 MAINTENANCE AND LUBRICATION Adju stment s Drive Chain Polaris A TV drive cha ins are e quipped with o-r ing-sea led, perma nently greas ed pi ns and rol lers . Ho wever , th e out er su rfaces o f th e rol ler m us t be lubric ate d. Always inspe ct the dr i ve c hain prior to oper ating the vehic l e.
89 MAINTENANCE AND LUBRICATION Air Filter 1. Rem ov e th e seat , rel ease t he cl ip s, and re move the air box cover . 2. Loosen the cla mp and re m ove the filte r . 3. Remove the f abric type pre -filter (1) f rom the main filter ( 2). W ash the pr e-f ilter in soapy w ate r , then rinse a nd let dry .
90 MAINTENANCE AND LUBRICATION Lights Whe n servic ing a halogen la mp, don’ t t ouch the lamp with ba re finger s. Oil from your skin le aves a re s idue , causing a hot spot tha t will shorten the life o f the lamp. Headlight L am p Replacement 1.
91 MAINTENANCE AND LUBRICATION Lights T aillight /Br akelig ht Lamp Replacement If the taillight/br akelight does not wo rk the lamp may ne ed to be repl aced. 1. Remove the ta illight lens cove r mounting scre ws. Remove the lens c over a nd gasket and se t aside f or re asse mbly .
92 MAINTENANCE AND LUBRICATION Spar k P lugs Spar k plug condition is indic ative of e ngine ope ra tion. The spar k plug firing e nd condition should be re ad af ter the engine ha s bee n wa rmed up an d th e vehi cle has b een dri ven at h ig her sp eeds .
93 MAINTENANCE AND LUBRICATION V eh ic le Imme rsi o n If it’ s impossible to take your A TV to a deale r befor e starting it, follow the steps outlined below . 1. Move the A TV to dry land o r at the ver y least, to wa ter b elow the foot re sts. 2.
94 MAINTENANCE AND LUBRICATION Spar k Ar r estor 1. Remove the ar restor cle an- out plug (1) fr om the bottom of the muf fle r . 2. Place the tr ansmission in neutra l and star t the engine. 3. Pur ge carbon fr om the system by momenta rily revving the e ngine seve ral time s.
95 MAINTENANCE AND LUBRICATION Recoil Hou sing T o preve nt possible engine dama ge, always dr ain the r ec oil housing (1) a f t e ro p e r a t i n gt h eA T Vi nv e r yw e t conditions.
96 MAINTENANCE AND LUBRICATION PV T System The basic ope ra tion of the P olar is P VT system is depende nt on engine sp eed and vehi cle t orq ue requ irem ent s. As engi ne s peed i ncreas es, t he for ce e xerte d on the m ovable d rive shea ve by the flyweights also incr ea ses.
97 MAINTENANCE AND LUBRICATION PV T System PVT Dryi ng There m ay be som e ins tan ces when wat er is acci dent ly i ng est ed in to the PVT system. Use the following instruc tions to dry it out befor e oper ating: 1. Move the A TV to dry land, or to water that is at least three inche s below the footwe ll.
98 MAINTENANCE AND LUBRICATION Batter y Batt ery Remov al 1. Disconne ct the batte ry hold-down stra p and re move the ba ttery c over . 2. Di sco nnect t he bl ack (n egat iv e) batt ery cab le fi rst . 3. Disc onnec t the red (positive ) batte ry ca ble next.
99 MAINTENANCE AND LUBRICATION Batter y Batter y Stor age Whe never the ve hicle is not used for a per iod of three months or more, remo ve t he bat tery from th e vehi cle, en sure t hat i t’ s fu ll y ch ar g ed, and st ore it ou t of t he sun i n a cool , d ry pl ace.
100 MAINTENANCE AND LUBRICATION Batter y Batt ery Cha rgin g NOTE: A lways ve rify batter y condition bef ore a nd 1-2 hours af ter the end of cha r ging. Stat e of Char ge Vo l t a g e Acti on Charge T ime* (Us ing cons tant cur rent char ger @ standard amps spec ified on top of battery ) 100% 12.
101 MAINTENANCE AND LUBRICATION Cleaning a nd Stor age See page 108 for the pa rt numbers of Polaris products. Cleaning th e A TV Kee ping your A TV cle an will not only improve its appe ara nce but it ca n also exte nd the life of va rious components.
102 MAINTENANCE AND LUBRICATION Cleaning a nd Stor age Sto ra ge Ti ps See page 108 for the pa rt numbers of Polaris products. Exterio r Make nec essar y re pair s and then c lean the A TV thoroughly with mild soap a nd warm w ater to re move all dirt a nd grime .
103 MAINTENANCE AND LUBRICATION Cleaning a nd Stor age Sto ra ge Ti ps See page 108 for the pa rt numbers of Polaris products. Flu id Levels Inspe ct the following fluid levels and cha nge if nece ssar y: engine oil; tran sm is si on oi l ; brak e flui d (chang e every two y ears or as needed i f fluid looks dark or conta minated).
104 MAINTENANCE AND LUBRICATION Cleaning a nd Stor age T r anspor ting an A TV Follow these proce dures when tra nsporting an A TV . 1. T urn off the e ngine and remo ve t he k ey t o prev ent loss during tra nsporting. 2. T urn the fuel valve of f. 3.
105 SPECIFIC ATIO NS 2004 T r ail B oss Capac ities Body Styl e Gen I V Gro ss V ehicle W eig h t 845 lbs . ( 383 kg) Fu el C ap acity 3.25 ga l. (12. 35 l) Transm issio n Oil 1 1.3 oz . ( 335 ml ) Engine O il Ca pac it y 1.9 qts . (1. 8 l )( inc l. oi l cool er ) 1.
106 SPECIFIC ATIO NS 2004 T r ail Boss Drive S ystem Dr ive Sys te m T ype PVT Shi ft T ype Side Le ver ( F-N- R) Ge ar Re duct ion - Reve rs e 3.05/ 1 Gear R ed u ction - F o rward 2.
107 SPECIFIC ATIO NS 2004 T r ail Boss Jetting Chart Altitu d e AMBIENT TEMPERA TURE Below 40 ° F (B elow 5 ° C) +40 ° F and above (+5 ° C and above) Meters (F eet) 0-1800 (0- 6000) 127.
108 POLARIS PRODUCTS Part No. Descr ipt ion Engine Lubr icant 2870791 Fogging O il ( 12 oz. Aer osol) 2871098 Prem ium 2- Cycle Engi ne Oi l ( qt. ) 2871281 Prem ium 4 Synt heti c 0W -40 ( 4-Cycl e) Engi ne Oil ( qt. ) 2871844 Prem ium 4 Synt heti c 0W -40 ( 4-Cycl e) Engi ne Oil ( gal.
109 TROUB LES HOOTIN G Dr ive Belt and Cover Pr o blems Po ssib l e Cause Solution Dr ivi ng t he A TV ont o a p icku p o r tall trailer in hi gh ra nge . A void s toppi ng on the ra mp or c r e e ping s low l y up the ramp . Th ese practices may slip the clutch an d b elt.
11 0 TROUB LES HOOTIN G Contac t your P olar is dealer f or servic e if you’re una ble to identify solutions using the follow i ng ch ar ts. Engine Doesn’t T urn Over Po ssibl e Cause Solut io n Lo w b attery v o ltag e Re cha r ge ba tt er y to 12.
111 TROUB LES HOOTIN G Engine Backfir es Po ssibl e Cause Solut io n W ea k spa r k fr om s par k plugs In spect, clean an d/ or repl ace spark p lu g s In correct sp ark plu g g ap o r heat rang e Se.
11 2 TROUB LES HOOTIN G E ngine S tops or Loses P ower Po ssibl e Cause Solut io n Out of fuel Tu rn fuel v alve to reserv e, refu el Ki nked or plugge d fue l sys te m ve nt li nes Insp ect an d rep .
11 3 WARRANTY LIM IT ED W ARRANT Y Pol a ri s Sal es I nc ., 2100 Highwa y 55, Me dina , MN 55340, gi ves a SIX MONTH LI MI TED W ARRANTY on al l com pone nts of t he Pol a ri s Al l T e rr ai n V ehi cl e (A TV) aga ins t def ec ts i n ma te ri al or wor kma nshi p.
11 4 WARRANTY W ARRANT Y COVERAGE AND EXCL USIONS: LIMI T A TIO NS OF W ARRANTI ES AND REME DIE S ALL IM P LI ED W ARRANTIES (I NCLUDING BUT NOT LIM ITED T O THE IM P LI ED W ARRANTIES OF MERCHANT ABILI TY AND FITNESS FOR A P AR TICULAR PURPOSE) ARE LI MITED I N DURA TION TO THE ABOVE SIX MONTH W ARRAN- TY PERI OD.
11 5 WARRANTY Exported V ehicles EXCEPT WHERE SPECI FICALL Y REQUIRED BY LA W , THERE IS NO W AR- RANTY OR SER VICE BULLETIN COVERAGE ON THIS VEHICLE I F IT I S SOLD OUTSIDE THE COUNTR Y OF THE SELLING DEALER’ S AUTHORIZED LOCA- TION.
11 6 INDEX A Accesso ries 6 4 ................... Adj ust ment s 76-88 ................ Ag e R estrictio ns 7 ................ Air F ilter 8 9 ..................... Au x iliary B rake 4 1, 7 7 ............ B Ba tt er y 98-100 ................... Ba tt er y Char ging 99-100 .
11 7 INDEX P Park in g B rake 4 0 ................. P a r k i n go na nI n c l i n e 6 2 ........... Pe ri odic M ai nte nanc e Sche dule 64- 68 . POLARIS PRODUCTS 108 ....... P re-Rid e In sp ectio n 4 7 ............. Pr e mi um 4 Synt he ti c Oil 71 .
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Wenn Sie aber schon Polaris trailboss 04 besitzen, und noch keine Gelegenheit dazu hatten, die Bedienungsanleitung zu lesen, sollten Sie es aufgrund der oben beschriebenen Gründe machen. Sie erfahren dann, ob Sie die zugänglichen Funktionen richtig genutzt haben, aber auch, ob Sie keine Fehler begangen haben, die den Nutzungszeitraum von Polaris trailboss 04 verkürzen könnten.
Jedoch ist die eine der wichtigsten Rollen, die eine Bedienungsanleitung für den Nutzer spielt, die Hilfe bei der Lösung von Problemen mit Polaris trailboss 04. Sie finden dort fast immer Troubleshooting, also die am häufigsten auftauchenden Störungen und Mängel bei Polaris trailboss 04 gemeinsam mit Hinweisen bezüglich der Arten ihrer Lösung. Sogar wenn es Ihnen nicht gelingen sollte das Problem alleine zu bewältigen, die Anleitung zeigt Ihnen die weitere Vorgehensweise – den Kontakt zur Kundenberatung oder dem naheliegenden Service.
