Pantone 425 C WARNING Improper vehicle 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 WITH DRUGS OR ALCOHOL NEVER operate: S without proper training or instruction. S at speeds 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.
The text is printed on 100% recycled with 40% post-consumer waste (PCW).
WELCOME Thank you for purchasing a Polaris vehicle, and welcome to our worldwide family of Polaris owners. We proudly produce an exciting line of utility and recreational products. • Snowmobiles • All-terrain vehicles (ATVs) • RANGER® utility vehicles • Victory Motorcycles® Always follow the instructions and recommendations in this manual.
POLARIS, THE WAY OUT, TRAIL BOSS and TRAIL BLAZER are registered trademarks of Polaris Industries Inc. Copyright 2009 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.
TABLE OF CONTENTS Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Features and Controls . . . . . . . . . . . . . . . . . . . 20 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Emission Control Systems . . . . . . . . . . . . . . . 48 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 Polaris Products. . . . . . . . . . . . . . . . . . . . . . . . 97 Troubleshooting . .
INTRODUCTION The following signal words and symbols appear throughout this manual and on your vehicle. Your safety is involved when these words and symbols are used. Become familiar with their meanings before reading the manual. The safety alert symbol indicates a potential personal injury hazard. WARNING A WARNING indicates a hazardous situation which, if not avoided, may result in death or serious injury.
INTRODUCTION WARNING Failure to follow the warnings in this manual can result in serious injury or death. This Polaris vehicle is not a toy and can be hazardous to operate. A collision or rollover can occur quickly, even during routine maneuvers, if you fail to take proper precautions. Read and understand your owner's manual and all warnings before operating this Polaris vehicle. Safety Training When you purchased your new Polaris vehicle, your dealer offered a hands-on safety training course.
INTRODUCTION Vehicle Identification Numbers Record your vehicle's identification numbers and key number in the spaces provided. Remove the spare key and 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 replaced if all keys are lost.
SAFETY WARNING Failure to operate the vehicle properly can result in a collision, loss of control, accident or overturn, which may result in serious injury or death. Heed all safety warnings outlined in this section of the owner’s manual. See the OPERATION section of the owner’s manual for proper operating procedures.
SAFETY Safe Riding Gear Always wear appropriate clothing when riding a Polaris vehicle. Wear protective clothing for comfort and to reduce the chance of injury. Eye Protection Long Sleeves Helmet Gloves Long Pants Boots Helmet Wearing a helmet can prevent a severe head injury. Whenever riding a Polaris vehicle, always wear a helmet that meets or exceeds established safety standards. Approved helmets in the USA and Canada bear a U.S. Department of Transportation (DOT) label.
SAFETY Safe Riding Gear Eye Protection Do not depend on eyeglasses or sunglasses for eye protection. Whenever riding a Polaris vehicle, always wear shatterproof goggles or use a shatterproof helmet face shield. Polaris recommends wearing approved Personal Protective Equipment (PPE) bearing markings such as VESC 8, V-8, Z87.1, or CE. Make sure protective eye wear is kept clean. Gloves Off-road style gloves with knuckle pads are the best for comfort and protection.
SAFETY Operator Safety Read and understand all warnings, cautions and operating procedures in this manual and on the safety labels before operating the vehicle. Never operate this vehicle without proper instruction. Take a training course. Beginners should receive training from a certified instructor. Contact an authorized Polaris dealer or visit the Polaris web site at www.polarisindustries.com.
SAFETY Operator Safety Always wear an approved helmet that fits properly. Wear eye protection (goggles or face shield), gloves, boots, long sleeves and long pants. Never consume alcohol or drugs before or while operating this vehicle. Never operate at excessive speeds. Travel and turn at speeds appropriate for the terrain, visibility, operating conditions and your experience. Never attempt jumps or other stunts.
SAFETY Operator Safety Always inspect your Polaris vehicle before each use to verify that it's in safe operating condition. Follow the inspection and maintenance procedures outlined in this manual. See page 31. Keep both hands on the handlebars. Keep your feet on the footrests. Always travel slowly when operating on unfamiliar terrain. Use extra caution. Use caution when operating on rough, slippery or loose terrain. Always follow the procedures outlined in this manual for turning. See page 35.
SAFETY Operator Safety If the vehicle has been involved in an accident, always have an authorized Polaris dealer inspect the entire vehicle for possible damage, including (but not limited to) brake, throttle and steering systems. Never operate on hills too steep for the vehicle or for your abilities. Practice on smaller hills before attempting larger hills. Avoid climbing hills steeper than 25°. Always follow the procedures outlined in this manual for climbing hills. See page 37.
SAFETY Operator Safety Always follow the procedures outlined in this manual for operating over obstacles. See page 42. Always follow the procedures outlined in this manual for operating on slippery or loose surfaces. Use extra caution. Always avoid skidding or sliding. See page 36. Always follow the procedures outlined in this manual for driving through water. Never drive through deep or fast-flowing water. See page 41. Always follow the procedures outlined in this manual for driving in reverse.
SAFETY Operator Safety Never exceed the stated load capacity for your vehicle. 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. Never operate this vehicle on a frozen body of water. Always remove the ignition key when the vehicle is not in use to prevent unauthorized use or accidental starting. Always unlock the steering before starting the engine. See page 26.
SAFETY Safety Labels and Locations Warning labels have been placed on the vehicle for your protection. Read and follow the instructions on each label carefully. If any of the labels shown in this manual differ from the labels on your vehicle, always read and follow the instructions of the labels on the vehicle. If an informational or graphic label becomes illegible or comes off, contact your Polaris dealer to purchase a replacement. Replacement safety labels are provided by Polaris at no charge.
SAFETY Safety Labels and Locations Discretionary Warning WARNING • Never operate this ATV on HILLS steeper than 25 degrees 25°. To prevent overturn on hilly terrain, use throttle and brakes gradually, and shift weight uphill. • REVERSE operation can be dangerous even at low speeds. Steering becomes difficult. To prevent loss of control, avoid sudden braking or sharp turns.
SAFETY Safety Labels and Locations “No Passenger” Warning Tire Pressure/Load Warning Age 16 Warning ++ + + Clutch Cover Warning “No Passenger” Warning WARNING NEVER ride as a passenger. Passengers can cause a loss of control, resulting in SEVERE INJURY or DEATH. 7175378 Tire Pressure/Load Warning (Trail Boss) 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 (27.6 kPa) Rear: 3.0 psi (20.
SAFETY Safety Labels and Locations Age 16 Warning WARNING Operating this ATV if you are under the age of 16 increases your chance of severe injury or death. NEVER operate this ATV if you are under age 16. 7175374 Clutch Cover Warning WARNING • Moving parts hazard under belt-clutch guard. To prevent serious injury, do not operate vehicle with guard removed. • Do not modify engine or clutch.
FEATURES AND CONTROLS Switches Engine Stop Switch The engine will not start or run when the switch is in the OFF position. OFF Headlight Switch Engine RUN Stop Switch Push the stop switch down to stop the engine Override quickly. Pull the stop Hazard Switch switch up to the RUN Switch position before attemptHorn ing to start the engine. Switch Both the main switch and the engine stop switch will shut off all electrical power to the vehicle, including lights.
FEATURES AND CONTROLS Switches Headlight Switch The lights do not operate unless the main key switch is on and the engine stop switch is in the RUN position. High Beam Low Beam Turn Signal Switch Push the toggle switch either left or right to activate the corresponding turn signal light. The indicator on the pod will also flash. Return the toggle to the center position and push it inward to end the signal. Hazard Switch Push the hazard warning switch to cause all turn signal lights to flash simultaneously.
FEATURES AND CONTROLS Mirrors Use the mirrors to assist in traffic maneuvers. Always check and adjust the mirrors before driving the vehicle. Indicator Lights With the engine running, verify the function of all indicator lights before each use of the vehicle. Tip: The taillight is on whenever the main switch (key) is on. Turn the key off to prevent battery drain.
FEATURES AND CONTROLS Throttle Lever Press the throttle lever to increase engine speed and vehicle movement. Release the lever to reduce engine speed and vehicle movement. Failure to check or maintain proper operation of the throttle system can result in an accident if the throttle lever sticks during operation. Check the lever for proper operation before starting the engine. Check occasionally during operation. Do not start or operate a vehicle with sticking or improperly operating throttle controls.
FEATURES AND CONTROLS Brakes Aggressively applying the brakes when backing down a hill may cause rear tipover. Aggressively applying the brakes while moving forward may cause the rear wheels to skid and result in loss of control. Read this owner's manual and understand the operation of all brake systems on this vehicle. Always use caution whenever applying the brakes. Foot Brake The all-wheel foot brake is located on the right footrest. The foot brake operates both front and rear brakes.
FEATURES AND CONTROLS Brakes 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 lock forward to engage the lock. 4. Release the brake lever. 5. To release the parking brake lock, squeeze and release the brake lever. It will return to its unlocked position. Operating the vehicle while the parking brake is engaged could result in an accident and serious injury or death.
FEATURES AND CONTROLS Steering Lock Lock the steering to prevent unauthorized use or theft of the vehicle. Tip: Place the steering lock keys in a safe place. The lock must be replaced if the keys are lost. 1. Turn the handlebars to the full left position. 2. Insert the steering lock key and turn it clockwise. 3. Remove the key. 4. Reverse the procedure to unlock the steering. The handlebars are locked in the full left position when the steering is locked.
FEATURES AND CONTROLS Choke The choke assists in starting a cold engine. Refer to the engine starting procedure on page 32 for correct choke and throttle settings during starting. Fuel Tank Cap Fuel Gauge Choke Always refuel with the engine stopped, and outdoors or in a well ventilated area. Refuel on a level surface. Remove the fuel tank cap to add fuel to the fuel tank. Use either leaded or unleaded gasoline with a minimum pump octane number of 87=(R+ M/2) octane.
FEATURES AND CONTROLS Transmission Gear Selector The transmission gear selector is located on the right side of the vehicle. F: Forward Gear N: 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 moving could cause transmission damage. Whenever the vehicle is left unattended, always place the transmission in gear and lock the parking brake.
FEATURES AND CONTROLS Recoil Starter If the battery is too weak to start the engine, use the recoil starter. Follow the starting procedures on page 32, cranking the engine with the recoil starter instead of the main key switch. 1. Grasp the recoil starter rope handle tightly. 2. Pull slowly so you can feel the engine strokes. Handle Recoil Starter Tip: The rope will be harder to pull when the engine is on a compression stroke.
OPERATION Break-In Period The break-in period for your new Polaris vehicle is the first ten hours of operation, or the time it takes to use the first two full tanks of gasoline. No single action on your part will increase the life and performance of your vehicle more than following the procedures for a proper break-in. Careful treatment of a new engine and drive components will result in more efficient performance and longer life for these components.
OPERATION Pre-Ride Checklist Failure to inspect and verify that the vehicle is in safe operating condition before operating increases the risk of an accident. Always inspect the vehicle before each use to make sure it's in safe operating condition.
OPERATION Starting the Engine Engine exhaust contains poisonous carbon monoxide and can cause loss of consciousness resulting in severe injury or death. Never run an engine in an enclosed area. 1. Position the vehicle on a level surface. 2. Place the transmission in neutral. 3. Lock the parking brake. Tip: The starter interlock will prevent the engine from starting if the transmission is in gear and the brake is not engaged. 4. Turn the fuel valve on. 5. Sit on the vehicle.
OPERATION Starting the Engine 8. Do not press the throttle while starting the engine. Turn the ignition key past the ON position to engage the starter. Activate the starter for a maximum of five seconds, releasing the key when the engine starts. 9. If the engine does not start, release the starter and wait five seconds. 10. Repeat steps 8 and 9 until the engine starts. Operating the vehicle immediately after starting could cause engine damage.
OPERATION Driving Procedures 1. Wear a helmet and eye protection. See page 8. 2. Sit upright. Keep your feet on the footrests. Keep both hands on 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 squeeze the throttle lever toward the handlebar to begin driving. 8. Drive slowly. Practice maneuvering and using the throttle and brakes on level surfaces.
OPERATION Turning the Vehicle 1. Before turning, activate a turn signal to alert others of your intentions. Activate the left signal before a left turn. Activate the right signal before a right turn. 2. Steer in the direction of the turn, leaning your upper body to the inside of the turn while supporting your weight on the outer footrest. Use the same leaning technique for turning in reverse. 3. Practice turning at slow speeds before attempting to turn at faster speeds.
OPERATION Driving on Slippery Surfaces Sideways skid Turn in direction of skid Whenever riding on slippery surfaces such as wet trails or loose gravel, or during freezing weather, follow these precautions: 1. Do not operate on excessively rough, slippery or loose terrain. 2. Slow down when entering slippery areas. 3. Be alert. 4. Watch the trail. 5. Avoid quick, sharp turns. Tip: To correct a rear wheel skid, turn the handlebars in the same direction as the skid and shift body weight forward.
OPERATION Driving Uphill Whenever traveling uphill, follow these precautions: 1. Avoid steep hills (25° maximum). 2. Check the terrain carefully. 3. Avoid hills with excessively slippery or loose surfaces. 4. Shift your weight uphill. 5. Drive straight uphill. 25° Maximum 6. Keep your feet on the footrests. 7. Drive at a steady rate of speed to avoid stalling. 8. Be alert. Be prepared to take emergency action. This may include dismounting quickly. 9.
OPERATION Driving on a Sidehill (Sidehilling) Avoid crossing the side of a hill (sidehilling) if possible. If sidehilling is necessary, follow these precautions: 1. Slow down. 2. Avoid hills with excessively slippery or loose surfaces. 3. Avoid crossing the sides of steep hills. 4. Shift your weight uphill. 5. Keep your feet on the footrests. 6.
OPERATION Driving Downhill 25° Maximum When driving downhill, follow these precautions: 1. Check the terrain carefully. 2. Avoid hills with excessively slippery or loose surfaces. 3. Never drive downhill at high speed. 4. Slow down. 5. Avoid driving downhill at an angle, which can cause the vehicle to pitch sharply to one side. Drive straight downhill. 6. Shift your weight rearward. 7. Apply the brakes slightly to aid in slowing.
OPERATION Turning Around on a Hill (K-Turn) If the vehicle stalls while climbing a hill, never back it down the hill! Use the K-turn to turn around. 8 ft. (2.4 m) 1. Stop the vehicle. Keep your weight uphill. 2. Lock the parking brake. Leave the transmission in forward gear. Turn the engine off. 3. Dismount on the uphill side of the vehicle, or on the left if the vehicle is pointing straight uphill. 4. Staying uphill of the vehicle, turn the handlebars full left.
OPERATION Driving Through Water Your Polaris vehicle can operate through water with a maximum recommended depth equal to the bottom of the footrests. Follow these procedures when operating through water: 1. Determine water depths and current before entering water. 2. Choose a crossing where both banks have gradual inclines. 3. Avoid operating through deep or fastflowing water. Maximum Depth NOTICE: Major engine damage can result if the vehicle is not thoroughly inspected after operation in water.
OPERATION Driving Over Obstacles Follow these precautions when operating over obstacles: 1. Always check for obstacles before operating in a new area. 2. Look ahead and learn to read the terrain. Be constantly alert for hazards such as logs, rocks and low hanging branches. 3. Travel slowly and use extra caution when operating on unfamiliar terrain. Not all obstacles are immediately visible. 4. Never attempt to operate over large obstacles, such as rocks or fallen trees.
OPERATION Driving in Reverse Follow these precautions when operating in reverse: 1. Always check for obstacles or people behind the vehicle. 2. Always avoid backing downhill. 3. Back slowly. 4. Apply the brakes lightly for stopping. 5. Avoid turning at sharp angles. 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 increased.
OPERATION Parking on an Incline 25° maximum Avoid 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 downhill side. 5. Turn the fuel valve off.
OPERATION Hauling Cargo Overloading the vehicle or carrying or towing cargo improperly can alter vehicle handling and may cause loss of control or brake instability, which can result in serious injury or death. Always follow these precautions when hauling cargo: REDUCE SPEED AND ALLOW GREATER DISTANCES FOR BRAKING WHEN HAULING CARGO. NEVER EXCEED THE MAXIMUM WEIGHT CAPACITY of the vehicle.
OPERATION Hauling Cargo Load Distribution Read and understand the load distribution warnings listed on warning labels. Never exceed the specified weights. Never carry cargo on the front of the Trail Blazer model. Cargo should be evenly distributed and mounted as low as possible on the rear rack. On the Trail Boss model, cargo weight should be evenly distributed (1/3 on the front rack and 2/3 on the rear rack) and mounted as low as possible.
OPERATION Hauling Cargo Towing Loads Some models are equipped with a hitch. Accessory hitch kits are available for other models. Towing is approved OFF-ROAD ONLY. Do not exceed the maximum capacities when towing. Do not tow any trailer on a grade steeper than 15°. Always attach a towed load to the hitch point. Remove the hitch when not towing a trailer. If towing a load, reduce rear rack cargo weight by the amount of tongue weight.
EMISSION CONTROL SYSTEMS Noise Emission Control System Do not modify the engine, intake or exhaust components, as doing so may affect compliance with governmental noise level requirements. Spark Arrestor Your Polaris vehicle has a spark arrestor that was designed for on-road and off-road operation. It is required that this spark arrestor remain installed and functional when the vehicle is operated.
MAINTENANCE Periodic Maintenance Chart Careful periodic maintenance will help keep your vehicle in the safest, most reliable condition. Inspection, adjustment and lubrication of important components are explained in the periodic maintenance chart. Inspect, clean, lubricate, adjust and replace parts as necessary. When inspection reveals the need for replacement parts, use genuine Polaris parts available from your Polaris dealer. Record maintenance and service in the Maintenance Log beginning on page 111.
MAINTENANCE Periodic Maintenance Chart Improperly performing the procedures marked with a could result in component failure and cause an accident, which may result in serious 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 service (Failure to conduct this maintenance will not void the emissions warranty but may affect emissions.
MAINTENANCE Periodic Maintenance Chart Item Maintenance Interval (whichever comes first) Hours Calendar Battery Remarks Miles (Km) 20 H Monthly 200 (320) X Transmission oil 25 H Monthly 250 (400) Inspect level; change yearly X Engine breather E filter (if equipped) 25 H Monthly 250 (400) Inspect; clean if needed X General lubrication 50 H 3M 500 (800) Lubricate all fittings, pivots, cables, etc.
MAINTENANCE Periodic Maintenance Chart Item Maintenance Interval Hours Calendar X Engine mounts Remarks (whichever comes first) Miles (Km) 100 H 12 M 1000 (1600) Inspect 100 H 12 M 1000 (1600) Inspect Q Spark plug 100 H 12 M 1000 (1600) Inspect; replace as needed Q Ignition Timing 100 H 12 M 1000 (1600) Inspect X Wiring 100 H 12 M 1000 (1600) Inspect for wear, routing, security; apply dielectric grease to connectors subjected to water, mud, etc.
MAINTENANCE Lubrication Guide Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart beginning on page 49. Items not listed in the chart should be lubricated at the General Lubrication interval. The a-arms and lower control arms are lubricated at the factory, and no additional lubrication will be needed. However, if these components are subjected to severe use, grease zerks have been provided for additional lubrication at the user's discretion.
MAINTENANCE Engine Oil Oil Recommendations Always change the oil filter whenever changing oil. Polaris recommends the use of Polaris PS-4 PLUS Performance Synthetic 2W-50 4-cycle oil or a similar oil for this engine. Oil may need to be changed more frequently if Polaris oil is not used. Always use 2W-50 oil. Follow the manufacturer's recommendations for ambient temperature operation. See page 97 for the part numbers of Polaris products.
MAINTENANCE Engine Oil Oil and Filter Change Always change the oil and filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 49. Always change the oil filter whenever changing oil. 1. Position the vehicle on a level surface. Place the transmission in neutral. Lock the parking brake. 2. Clean the area around the drain plug. 3. Start the engine. Allow it to idle for two to three minutes. Stop the engine. 4. Place a drain pan under the engine crankcase. Remove the drain plug.
MAINTENANCE Transmission Oil Always check and change the transmission oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 49. Polaris recommends the use of Polaris Premium AGL Synthetic Gearcase Lube. See page 97 for the part numbers of Polaris products. Transmission Oil Recommendations Gearcase Lubricant Capacity Drain Plug Torque Transmission Premium AGL Synthetic Gearcase Lubricant 11.3 oz. (335 ml) 14 ft. lbs.
MAINTENANCE Transmission Oil Oil Change 1. Position the vehicle on a level Adjuster Jam surface. Bolt Nut 2. Place a drain pan beneath the transmission oil drain plug area. 3. Loosen the jam nut. 4. Turn the adjuster bolt in to allow the removal of the drain plug. 5. Remove the drain plug and wipe the magnetic end clean to remove accumulated metallic filings. 6. Allow the oil to drain completely. 7. Reinstall the drain plug with a new sealing washer. Torque to Drain Plug specification. 8.
MAINTENANCE Brake Fluid Check brake fluid levels for both brake systems before each ride. Always maintain brake fluid at the recommended level. Do not overfill. The brakes should feel firm when they're applied. Spongy or weak brakes may indicate a fluid leak or low fluid level. A low fluid level may also mean that brake pads are worn and need to be replaced. Do not operate the vehicle with spongy or weak brakes. See your dealer for service.
MAINTENANCE Brake Fluid Hand Brake The master cylinder is located on the left handlebar. Maintain the fluid level 6 mm below the top edge of the master cylinder. Do not overfill. Master Cylinder Indicator Window 1. Position the vehicle on a level surface. Make sure the handlebars 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. 3.
MAINTENANCE Brakes The front and rear brakes are hydraulic disc brakes. Both brake systems are self-adjusting. Brake Inspections Perform the following checks to keep the brake systems 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 58. 2. Check the brake systems regularly for fluid leaks. 3. Check the brakes for excessive travel or spongy feel. 4.
MAINTENANCE Side Panel Removal Tip: Side panel removal may be difficult until the locking tabs and receivers have been snapped and unsnapped a few times. 1. Remove the seat. 2. Remove the push-pins at the front and rear of the side panel. 3. Grasp the rear of the side panel near the rear cab. Pull the panel slightly outward, downward and rearward to disengage the upper front section. 4. To reinstall the side panel, align the upper and lower front section with the mating front cab tabs.
MAINTENANCE Handlebars The handlebars can be adjusted for rider preference. Improper adjustment of the handlebars or incorrect torquing of the adjuster block tightening bolts can cause limited steering or loosening of the handlebars, resulting in loss of control. Follow the adjustment procedures exactly, or see your Polaris dealer for service. 1. Remove the handlebar cover to Handlebar Bolts access the handlebar bolts. 2. Loosen the four handlebar bolts. 3. Adjust the handlebar to the desired height. 4.
MAINTENANCE Toe Alignment Do not attempt to adjust tie rod alignment. All tie rod adjustments should be performed by an authorized Polaris dealer. Use the following procedure to check the toe alignment of the vehicle. The recommended toe alignment is 3-6 mm toe out. 1. Position the vehicle on a level surface. 2. Set the handlebars in a straight-ahead position and secure them in this position. 3. Place a chalk mark on the center line of the front tires approximately 10" (25.
MAINTENANCE Throttle Cable Freeplay Adjust throttle cable freeplay at the handlebar. 1. Locate the throttle cable adjuster at the handlebar. 2. Squeeze the end of the rubber boot and slide it far enough to expose the end of the inline cable adjuster. 3. Loosen the adjuster lock nut. 4. Rotate the boot to turn the 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.
MAINTENANCE Steering Assembly The steering assembly of the ATV should be checked periodically for loose nuts and bolts. If loose nuts and bolts are found, see your Polaris dealer for service before operating the vehicle. Camber and Caster The camber and caster are non-adjustable. Rear Spring The rear shock absorber spring is adjusted by rotating the adjuster either clockwise or counterclockwise to increase or decrease spring tension. Accessory springs are available through your Polaris dealer.
MAINTENANCE Tires WARNING Operating your vehicle with worn tires, improperly inflated tires, non-standard tires or improperly installed tires will affect vehicle handling and could cause an accident. • Maintain proper tire pressure as described on the label on your vehicle and in the specifications section of the owner's manual. • Use only original equipment size and type when replacing tires. • Make sure the wheels are installed properly. • Replace tires when the tread depth measures 3 mm or less.
MAINTENANCE Tires Wheel Removal 1. Position the vehicle on a level surface. Place the transmission in gear. Lock the parking brake. 2. Loosen the wheel nuts slightly. Do not service axle nuts that have a cotter pin installed. See your Polaris dealer. 3. Place a suitable stand under the footrest frame to raise the wheel slightly off the ground. 4. Remove the wheel nuts. 5. Remove the wheel. Wheel Installation 1.
MAINTENANCE Tires Wheel Nut Torque Specifications Front 27 ft. lbs. (37 Nm) Rear 50 ft. lbs. (68 Nm) Check the wheel nut torques occasionally and when they've been loosened for service. 68 Item Torque Specification Front Wheel Nuts 27 ft. lbs. (37 Nm) Rear Wheel Nuts 50 ft. lbs.
MAINTENANCE Air Filter 1. Remove the seat. 2. Release the air box cover clips, and remove the air box cover. 3. Loosen the clamp and remove the filter. 4. Remove the fabric type pre-filter from the main filter. Wash the pre-filter in soapy water, then rinse and let dry. 5. Reinstall the pre-filter over the main filter. Install a new main filter if needed. 6. Reinstall the filter into the air box and tighten the clamp. Do not over-tighten the clamp, as filter damage could occur. 7.
MAINTENANCE Recoil Housing Always drain the recoil housing after operating the vehicle in wet conditions. Drain the housing before storing the vehicle. Make sure the housing is completely dry before reinstalling the drain plug. 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 drain screw on the bottom of the recoil housing. 5. Reinstall the drain screw.
MAINTENANCE Carburetor Your Polaris vehicle is calibrated at the factory for optimal performance at altitudes ranging from zero to 1800 meters and at temperatures of 4 degrees C. or higher. Above 1800 meters the engine air/fuel mixture becomes too rich and the engine loses approximately 3% of its power for each 300 meter increase in elevation. Although this power cannot be regained, adjustments to the carburetor and drive system can be made to allow more efficient operation.
MAINTENANCE Drive Chain Drive Chain Lubrication The drive chains are equipped with o-ring-sealed, permanently greased pins and rollers. However, the outer surfaces of the roller must be lubricated. Always inspect the drive chain prior to operating the vehicle. Check for damaged or missing o-rings or damaged rollers. Also check for correct slack adjustment. Maintain the stone guard to rear sprocket clearance at 1/8” (3 mm).
MAINTENANCE Drive Chain Rear Drive Chain Slack Check the amount of chain slack in three different locations by moving the vehicle slightly forward to gain slack at the top side of the rear chain. Measure the chain slack at the tightest of the three positions. At this point the chain should have 3/16"-3/8" (5 mm - 10 mm) deflection. Adjusting or operating the vehicle with improper rear drive chain slack can result in severe damage to the transmission and drive components.
MAINTENANCE Drive Chain Rear Drive Chain Slack 6. Roll the vehicle forward or backward to adjust the chain slack to the proper tension. See the illustration for proper splice link clip opening position. 7. Tighten the eccentric locking bolts to 30 ft. lbs. (41 Nm) for machines without the hitch and 45 ft. lbs. (61 Clip Nm) for machines with a hitch. Position 8. Tighten the caliper mount bolt to 15 ft. lbs. (20 Nm). 9. Remove the pin punch. 10.
MAINTENANCE Lights Headlight Beam Adjustment The headlight beam can be adjusted slightly upward or downward. Use the following procedure to make the adjustment. 25 ft. (7.6 m) X X 2" (5 cm) 1. Position the vehicle on a level surface with the headlight approximately 25 ft. (7.6 m) from a wall. 2. Place the transmission in neutral. 3. Lock the parking 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.
MAINTENANCE Lights Poor lighting can result in loss of control or an accident. Lights become dirty during normal operation. Wash the headlights and taillights frequently. Hot components can cause burns to skin. Allow lamps to cool before servicing. Headlamp Replacement When servicing a halogen lamp, do not touch the lamp with bare fingers. Oil from your skin leaves a residue, causing a hot spot that will shorten the life of the lamp. Hold the plastic part of the lamp. 1.
MAINTENANCE Lights Indicator Lamp Replacement 1. Remove the instrument panel, if necessary, to access the back of the indicator panel. 2. Using a small, straight-blade screwdriver, turn the base of the bulb 1/4 turn counterclockwise. 3. Using a needle-nose pliers or similar tool, pull the lamp out of the indicator panel housing. 4. Insert the new bulb and seat it by turning it 1/4 turn clockwise. 5. Reinstall the instrument panel if removed. Taillight/Brakelight Lamp Replacement 1.
MAINTENANCE Spark Plugs Spark Plug Recommendations Refer to the specifications section beginning on page 102 for the recommended spark plug type and gap for your vehicle. NOTICE: Using non-recommended spark plugs can result in serious engine damage. Always use Polaris-recommended spark plugs.
MAINTENANCE Spark Plugs Spark Plug Condition Normal Spark Plug The normal insulator tip is gray, tan or light brown. There will be few combustion deposits. The electrodes are not burned or eroded. This indicates the proper type and heat range for the engine and the service. The tip should not be flaky and white. A white insulator tip indicates overheating, caused by use of an improper spark plug or incorrect carburetion adjustments. Wet Fouled Spark Plug The wet fouled insulator tip is black.
MAINTENANCE Vehicle Immersion If your vehicle becomes immersed, major engine damage can result if the machine is not thoroughly inspected. Take the vehicle to your dealer before starting the engine. If it's impossible to take your vehicle to a dealer before starting it, follow the steps outlined below. 1. Move the vehicle out of the water. 2. Turn the fuel valve off. 3. Check the air box. If water is present, dry the air box and replace the filter with a new filter. 4. Remove the spark plug. 5.
MAINTENANCE Spark Arrestor WARNING Failure to heed the following warnings while servicing the spark arrestor could result in serious injury or death. Never run the engine in an enclosed area. Remove any combustible materials from the area. Wear eye protection and leather work gloves. Do not stand behind or in front of the vehicle while purging. Never go under the vehicle while it's inclined. The exhaust system can get extremely hot. Do not perform service on the spark arrestor while the system is hot.
MAINTENANCE PVT System WARNING Failure to comply with the instructions in this warning can result in severe injury or death. Do not modify any component of the PVT system. Doing so may reduce its strength so that a failure may occur at a high speed. The PVT system has been precision balanced. Any modification will cause the system to be out of balance, creating vibration and additional loads on components. The PVT system rotates at high speeds, creating large amounts of force on clutch components.
MAINTENANCE PVT System The basic operation of the Polaris PVT system is dependent on engine speed and vehicle torque requirements. As engine speed increases, the force exerted on the movable drive sheave by the flyweights also increases. This, in turn, increases the amount of pinch applied to the drive belt. Similarly, if the engine speed decreases, the amount of centrifugal force decreases, reducing the amount of belt pinch.
MAINTENANCE PVT System PVT Drying There may be some instances when water is accidently ingested into the PVT system. Use the following instructions to dry it out before operating. 1. Move the vehicle out of the water. 2. Remove the PVT drain plug. Allow the water to drain 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.
MAINTENANCE Battery WARNING Improperly connecting or disconnecting battery cables can result in an explosion and cause serious injury or death. When removing the battery, always disconnect the negative (black) cable first. When reinstalling the battery, always connect the negative (black) cable last. WARNING Battery electrolyte is poisonous. It contains sulfuric acid. Serious burns can result from contact with skin, eyes or clothing. Antidote: External: Flush with water.
MAINTENANCE Battery Battery Removal 1. 2. 3. 4. 5. 6. 7. 8. 9. Place the transmission in gear. Lock the parking brake. Remove the seat. Disconnect the battery hold-down strap. Remove the battery cover (if equipped). On conventional batteries, remove the battery vent tube. Disconnect the black (negative) battery cable first. Disconnect the red (positive) battery cable last. Lift the battery out of the vehicle. Be careful not to tip a conventional battery sideways, which could spill electrolyte.
MAINTENANCE Battery Battery Installation Using a new battery that has not been fully charged can damage the battery and result in a shorter life. It can also hinder vehicle performance. Follow the battery charging instructions on page 89 before installing the battery. 1. Ensure that the battery is fully charged. 2. Place the battery in the battery holder. 3. With conventional batteries, install the battery vent tube (sealed batteries do not have a vent tube).
MAINTENANCE Battery Battery Storage Whenever the vehicle is not used for a period of three months or more, remove the battery from the vehicle, ensure that it's fully charged, and store it out of the sun in a cool, dry place. Check battery voltage each month during storage and recharge as needed to maintain a full charge. Tip: Power plug leads may need to be bent down so that the battery cover can be installed.
MAINTENANCE Battery Battery Charging (Conventional Battery) 1. Remove the battery from the vehicle to prevent damage from leaking or spilled electrolyte during charging. See page 86. 2. Charge the battery with a charging output no larger than 1/10 of the battery’s amp/hr rating. Charge as needed to raise the specific gravity to 1.270 or greater. 3. Reinstall the battery. See page 87. Make sure the positive terminal is toward the front of the vehicle.
MAINTENANCE Battery Battery Charging (Sealed Battery) Always verify battery condition before and 1-2 hours after the end of charging. Charge Time State of Charge Voltage Action (Using constant current charger @ standard amps specified on top of battery) 100% 12.8-13.0 volts None required 75%-100% 12.5-12.8 volts 50%-75% 25%-50% 12.0-12.5 volts 11.5-12.0 volts None, check at 3 mos.
MAINTENANCE Cleaning and Storage Washing the Vehicle Keeping your Polaris vehicle clean will not only improve its appearance but it can also extend the life of various components. NOTICE: High water pressure may damage components. Polaris recommends washing the vehicle by hand or with a garden hose, using mild soap. Certain products, including insect repellents and chemicals, will damage plastic surfaces. Do not allow these types of products to contact the vehicle.
MAINTENANCE Cleaning and Storage Washing the Vehicle If a high pressure water system is used for cleaning (not recommended), exercise extreme caution. The water may damage components and could remove paint and decals.
MAINTENANCE Cleaning and Storage Chrome Wheel Care (if equipped) Proper maintenance will protect chrome wheels from corrosion, preserve wheel life and ensure a “like new” appearance for many years. Chrome wheels exposed to road salt (or salt in the air in coastal areas) are more susceptible to corrosion if not properly cleaned. Clean chrome wheels more often if they're exposed to salt or other corrosive elements. 1. Wash chrome wheels frequently. Use a mild detergent.
MAINTENANCE Cleaning and Storage Storage Tips NOTICE: Starting the engine during the storage period will disturb the protective film created by fogging and damage could occur. Never start the engine during the storage period. Clean the Exterior Make any necessary repairs and clean the vehicle as recommended. See page 91. Stabilize the Fuel 1. Fill the fuel tank. 2. Add Polaris Carbon Clean Fuel Treatment or Polaris Fuel Stabilizer. Follow the instructions on the container for the recommended amount.
MAINTENANCE Cleaning and Storage Storage Tips Fluid Levels Inspect the fluid levels. Change fluids as recommended in the Periodic Maintenance Chart beginning on page 49. • Demand drive unit (if equipped) • Transmission • Brake fluid (change every two years and any time the fluid looks dark or contaminated) Fog the Engine 1. Treat the fuel system with Polaris Carbon Clean. See page 94. 2. Support the front end of the machine so the engine is level or tilted slightly rearward. 3. Remove the spark plug.
MAINTENANCE Cleaning and Storage Storage Tips Inspect and Lubricate Inspect all cables and lubricate all areas of the vehicle as recommended in the Periodic Maintenance Chart beginning on page 49. Battery Storage See pages 88-89 for storage and charging procedures. Storage Area/Covers Set the tire pressure and safely support the vehicle with the tires slightly off the ground. Be sure the storage area is well ventilated. Cover the vehicle with a genuine Polaris cover. Do not use plastic or coated materials.
POLARIS PRODUCTS Part Number 2870791 2876244 2876245 2873602 2873603 2871653 2872276 2870465 2871312 2871322 2871423 2871460 2871515 2871551 2871329 2872073 2872348 2871326 2870652 2872189 2871956 2859044 Description Engine Lubricant Fogging Oil (12 oz. Aerosol) PS-4 PLUS Performance Synthetic 2W-50 4-Cycle Oil (qt./.95 l) PS-4 PLUS Performance Synthetic 2W-50 4-Cycle Oil (gal./3.8 l) Gearcase / Transmission Lubricants Premium AGL Synthetic Gearcase Lubricant (qt./.
TROUBLESHOOTING Drive Belt Wear/Burn Possible Cause Starting out going up a steep incline Driving at low RPM or ground speed (3-7 MPH) Insufficient warm-up at low ambient temperatures Solution Use low range (if equipped) or turn around using the Kturn (see page 40). Drive at a higher speed or use low range (if equipped) more frequently. Warm the engine at least 5 minutes. With the transmission in neutral, advance the throttle to about 1/8 throttle in short bursts, 5 to 7 times.
TROUBLESHOOTING Engine Doesn't Turn Over Possible Cause Low battery voltage Loose battery connections Loose solenoid connections Solution Recharge the battery to 12.
TROUBLESHOOTING Engine Pings or Knocks Possible Cause Poor quality or low octane fuel Incorrect ignition timing Incorrect spark plug gap or heat range Idle set too low Solution Replace with recommended fuel See your dealer Set gap to specs or replace plugs Adjust idle speed Engine Runs Irregularly, Stalls or Misfires Possible Cause Fouled or defective spark plugs Worn or defective spark plug wires Incorrect spark plug gap or heat range Loose ignition connections Water present in fuel Low battery voltage K
TROUBLESHOOTING Engine Stops or Loses Power Possible Cause Out of fuel Kinked or plugged fuel vent line Water is present in fuel Overuse of choke Fouled or defective spark plugs Worn or defective spark plug wires Incorrect spark plug gap or heat range Loose ignition connections Low battery voltage Incorrect fuel Clogged air filter Reverse speed limiter malfunction Electronic throttle control malfunction Other mechanical failure Overheated engine Solution Turn fuel valve to reserve, refuel Inspect and repla
SPECIFICATIONS Trail Boss 330 Maximum Weight Capacity Dry Weight Fuel Capacity Engine Oil Capacity Transmission Oil Front Rack Capacity Rear Rack Capacity Hitch Tongue Weight Capacity Hitch Towing Rating Unbraked Trailer Towing Capacity* Overall Length Overall Width Overall Height Wheelbase Ground Clearance Minimum Turning Radius Engine Model Number/Type Lubrication Engine Cooling Displacement Bore x Stroke Alternator Output Compression Ratio Carburetor Pilot Jet Main Jet Needle Jet Jet Needle Pilot Air Jet
SPECIFICATIONS Trail Boss 330 Driving System Type Shift Type Gear Reduction, Reverse Gear Reduction, Forward Drive Ratio, Final Drive Chain Tires/Pressure, Front Tires/Pressure, Rear Front Suspension Rear Suspension Shock Adjustment Brakes, Front and Rear Brake, Auxiliary Brake, Parking Headlight Taillights Brake Light Battery Indicators Automatic PVT (Polaris Variable Transmission) Side Lever (F/N/R) 3.05:1 2.68:1 3.64:1 520 O-Ring 23 x 7-10 (4 psi/27.6 kPa) 22 x 11-10 (3 psi/20.
SPECIFICATIONS Trail Blazer 330 Maximum Weight Capacity Dry Weight Fuel Capacity Engine Oil Capacity Transmission Oil Front Rack Capacity (Accessory) Rear Rack Capacity (Accessory) Hitch Tongue Weight Capacity Hitch Towing Rating Unbraked Trailer Towing Capacity* Overall Length Overall Width Overall Height Wheelbase Ground Clearance Minimum Turning Radius Engine Model Number/Type Lubrication Engine Cooling Displacement Bore x Stroke Alternator Output Compression Ratio Carburetor Pilot Jet Main Jet Needle Je
SPECIFICATIONS Trail Blazer 330 Driving System Type Shift Type Gear Reduction, Reverse Gear Reduction, Forward Drive Ratio, Final Drive Chain Tires/Pressure, Front Tires/Pressure, Rear Front Suspension Rear Suspension Shock Adjustment Brakes, Front and Rear Brake, Auxiliary Brake, Parking Headlight Taillights Brake Light Battery Indicators Automatic PVT (Polaris Variable Transmission) Side Lever (F/N/R) 3.05:1 2.68:1 3.64:1 520 O-Ring 23 x 7-10 (4 psi/27.6 kPa) 22 x 11-10 (3 psi/20.
DECLARATION OF CONFORMITY Polaris Industries Inc., 2100 Hwy 55, Medina, MN 55340 U.S.A. Telephone 763-542-0500 We, Polaris Industries Inc., declare that the vehicles listed below conform to the essential health and safety requirements applicable to off-road all-terrain vehicles. APPLICABLE EUROPEAN DIRECTIVES 98/37/EC as amended (Machinery Directive) TEST / EVALUATION METHODS EN 1050 hazard analysis CD 77/311/EEC driver-perceived noise level CISPR 12:2001 EN 55012:2002 CAN/CSA-C108.
WARRANTY LIMITED WARRANTY Polaris Industries Inc., 2100 Highway 55, Medina, MN 55340, gives a TWO YEAR LIMITED WARRANTY on all components of the Polaris vehicle against defects in material or workmanship. This warranty covers the parts and labor charges for repair or replacement of defective parts which are covered by this warranty. This warranty begins on the date of purchase. This warranty is transferable to another consumer during the warranty period through a Polaris dealer.
WARRANTY WARRANTY COVERAGE AND EXCLUSIONS: LIMITATIONS OF WARRANTIES AND REMEDIES 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 improper handling.
WARRANTY LIMITATIONS OF WARRANTIES AND REMEDIES This warranty also excludes failures resulting from improper lubrication; improper engine timing; improper fuel; surface imperfections caused by external stress, heat, cold or contamination; operator error or abuse; improper component alignment, tension, adjustment or altitude compensation; failure due to snow, water, dirt or other foreign substance ingestion/contamination; improper maintenance; modified components; use of aftermarket components resulting in f
WARRANTY ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE) ARE LIMITED IN DURATION TO THE ABOVE TWO YEAR WARRANTY PERIOD. POLARIS FURTHER DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY. Some states do not allow limitations on how long an implied warranty lasts, so the above limitation may not apply to you if inconsistent with controlling state law.
MAINTENANCE LOG Present this 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 services performed.
MAINTENANCE LOG DATE 112 MILES (KM) OR HOURS TECHNICIAN SERVICE PERFORMED / COMMENTS
INDEX A Age Restrictions . . . . . . . . . . . . . . . . . 5 Air Filter . . . . . . . . . . . . . . . . . . . . . . 69 B Battery . . . . . . . . . . . . . . . . . . . . 85-90 Charging (Conventional) . . . . . . . 89 Charging (Sealed) . . . . . . . . . 89-90 Fluid (Conventional) . . . . . . . . . . 88 Installation . . . . . . . . . . . . . . . . . . 87 Removal . . . . . . . . . . . . . . . . . . . . 86 Storage . . . . . . . . . . . . . . . . . . . . . 88 Boots . . . . . . . . . . . . . . . . . . . . . . . .
INDEX I P Idle RPM Adjustment . . . . . . . . . . . 71 Immersion . . . . . . . . . . . . . . . . . . . . 80 Indicator Lights . . . . . . . . . . . . . . . . 22 Parking Brake . . . . . . . . . . . . . . . . . . 25 Parking on an Incline. . . . . . . . . . . . . 44 Periodic Maintenance Chart . . . . 49-52 Polaris Product List . . . . . . . . . . . . . . 97 Polishing the Vehicle. . . . . . . . . . . . . 92 Pre-Ride Checklist. . . . . . . . . . . . . . . 31 PVT Break-In . . . . . . . . . . . . . . . . . .
INDEX S T Stop Switch . . . . . . . . . . . . . . . . . . . . 20 Storage . . . . . . . . . . . . . . . . . . . . 91-96 Switches . . . . . . . . . . . . . . . . . . . 20-21 Engine Stop Switch . . . . . . . . . . . 20 Hazard Switch . . . . . . . . . . . . . . . 21 Headlight Switch . . . . . . . . . . . . . 21 Horn Switch . . . . . . . . . . . . . . . . . 21 Main Key Switch . . . . . . . . . . . . . 21 Override Switch . . . . . . . . . . . . . . 20 Turn Signal Switch. . . . . . . . . . . . 21 Towing Loads .
