Polaris Trail Blazer 9922460 manual

P antone 426C Owner's Manual for Maintenance and Safet y Read this manual carefully . It contains important safety information. This is an adult vehicle only . Operation is prohibited for those under 16 years of age. Trail Boss 330 Trail Blazer 330[...]

A card containi ng important A T V safety info rmation shou ld be attached to the owner's man ual on the next page. If you cannot locate th is card, or if it has been remove d, please call 1-8 00-342- 3764 for assistance. W ARNING The engine exhaust from th is product contains chemicals known to the Stat e of California to cause cancer , birth[...]

The text is printed on 100% recycled with 40% post-consume r waste (PCW).[...]

W ARNING Improper vehicle use can r esult in SEVERE INJUR Y or DEA TH. NEVER operate: S without pr oper training or instruction. S at speeds too fast for your skills or the conditions. S on public r oads - a collision can occur with another vehicle. S with a passenger - passengers affect balance and steering and incr ease risk of losing control. AL[...]

1 WELCOME Thank you for purch asing a Polaris vehicle, and welcome to our world- wide family of Polaris owners. W e proudly produce an excit ing line of utility and recreati onal products. • Snowmobiles • All-terrain vehicles (A TVs) • RANGER ® utility vehicles • V ictory Motorcycles ® W e believe Polaris sets a standard of excellence for[...]

2 POLARIS, THE W A Y OU T , TRAIL BOSS and TRAIL BLAZER are regist ered trade- marks of Polaris Industries Inc. Copyright 2009 Polaris Sales Inc. All inform ation contained within this publication is based on the latest product information at th e time of publication. Due to constant improvements in the design and quality of production compo nents,[...]

3 T ABLE OF CONTENTS Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 F eatures and Controls . . . . . . . . . . . . . . . . . . . 26 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Emission Control Systems . . . . . . . . . . . .[...]

4 INTRODUCTION The following signal words and symbol s appear througho ut this manual and on your veh icle. Y our safety is involved when these words and sym- bols are used. Become familiar with their meanings before reading t he manual. The safety ale rt symbol indicates a potential persona l injury hazard. W ARNING A W ARNING indicates a hazardou[...]

5 INTRODUCTION Failure to hee d the warnin gs and safety precaution s contained in this manual can result in severe injury or death. A Polaris A TV is not a toy and can be hazardous to operate. This vehicle handl es differently than other vehicles, such as motorcycles and cars. A collision or rollover can occur quickly , even during routine maneuve[...]

6 INTRODUCTION V ehicle Identification Numbers Record your vehicle's identificatio n 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 yo ur key number) and matin g it with one of yo ur existing keys. The ignition switc[...]

7 SAFETY Safety T raining A TV safety training is a top prior ity for Polaris. Polaris strongly encourages you and any family member s who will be riding the A T V to take a training course. If you purchased a new Polaris A TV in the United S tates, your dealer provided instruction to y ou about the authorized A TV RiderCourse sm that is available [...]

8 SAFETY Safe Riding Gear Always wear appropriate clothing when riding an A TV . W ear protective clothing for comfort an d to reduce the chan ce of injury . Helmet W earing a helmet can prevent a sever e head injury . Whenever riding a Polaris vehicle, always wear a helmet that meets or exceeds established safety standards. Approved helmets in the[...]

9 SAFETY Safe Riding Gear Eye Protection Do not depend on eyeglasses or sunglasses for eye protection. When- ever riding a Polaris vehicle, always wear shatterproof goggl es or use a shatterproof helmet face shield. Po laris recommends wearing approved Personal Protective Equ i pment (PPE) bearing markings such as VESC 8, V -8, Z87.1, or CE. Make s[...]

10 SAFETY Safety W arnings Failure to operate the A TV properly can re sul t 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 owne r ’s manual. See the OPERA TION section of the owner ’ s manual fo r proper operating procedures. Operating[...]

11 SAFETY Safety W arnings Handling Gasoline Gasoline is h ighly flammable and e xplosive under certain conditions. • Always exercise extreme cautio n whenever handling gasoline. • Always refuel with the engine stopped, and outdoors or in a well ventilated area. • Do not smoke or allow open flames or sparks in or near the area where refu- eli[...]

12 SAFETY Safety W arnings Protective App arel Riding in this vehicl e without wearing an approved helmet and protective eyewe ar increases the risk of a serious injuries in the event of an accident. Operator and passenger must always wear an approved helmet that fits properly and eye protection (goggles o r face shield). Using Alcohol or Drugs Ope[...]

13 SAFETY Safety W arnings Operating on Pavement Operating an A TV on paved surfaces (including sidewalks, paths, parking lot s and driveways) may adversely a ffect the handling of the A TV and could result in loss of control and accident or overturn. Avoid operating the A TV on p avement. A TV tires are design ed for off-road use. If it's una[...]

14 SAFETY Safety W arnings Physical Control of the A TV Removing a hand from the handlebars or feet from the foo trests during operation can reduce your a bility to contro l the vehicle o r cause loss of balance and ejection from the A TV . If the operator's foot is not firmly planted on the footrest, it could also contact the rear wheels. Nev[...]

15 SAFETY Safety W arnings Descending Hill s Impr operly Improperly descending a hill could cause loss of control or o verturn. • Always follow proper procedures fo r travel- ing dow n hills as describ ed in the owne r's manual. NOTE: A special techn ique is required when braking while traveling down- hill. See page 48. • Always descend a [...]

16 SAFETY Safety W arnings S t alling While Climbing a Hill S talling, roll ing backwards or improperly dismounting while climbi ng a hill could cause an overturn. • Always maintain a steady speed when climbing a hill. If all forward speed is lost: • Keep body weight uphill. • Apply the single-le ver brake gradually . • Lock the parking bra[...]

17 SAFETY Safety W arnings Operating on Slippery T errain Failure to use extra caution when ope rating on excessively rough, sl ippery or loose te rrain could cause loss of traction, loss of control, accident or overturn. Do not operate on excessively rough, slippe ry or loose terrain. Always u se extra caution on rough, slippery or loose terrain. [...]

18 SAFETY Safety W arnings Operating Improperly in Reverse Improperly operating in reverse could result in a collision with an obstacle or person. Always follow prope r operating procedures as outlined in this manual. See page 52. Before shifting into reverse gear , always check for obstacles or people behind the A TV . W hen it's safe to proc[...]

19 SAFETY Safety W arnings Operating Over Obst acles Improperly operating over obstacles could cause loss of control or overturn. Before operating in a new area, check for obst acles. Avoid operating over large obstacles such as rocks and fallen trees. If unavoidable, use extreme caution and always follow proper ope rating proce dures as outlin ed [...]

20 SAFETY Safety W arnings Improper Cargo Loading Overloading the A TV or carrying/towing cargo improperly may cause changes in handling, which could cause loss of contro l or an accident. • Never exceed the stated load cap acity for this A TV . • Cargo should b e properly di stributed and secu rely attached. • Reduce speed when carrying carg[...]

21 SAFETY Safety W arnings Operating a Damaged A TV Operating a da maged A TV can result in a n accident. After any overturn or accident, have a qual ified service dealer insp ect the entire machine for possible damage, including (but not limited to) brakes, th rottle and steering systems. Physical Skills Safe operation of this rider-active veh icl[...]

22 SAFETY Safety Labels and Locations W arning labels hav e 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 ma nual dif fer from the la bels on your vehicle, always read and follow the instructio ns of the labels on the vehicle. If an informational or grap[...]

23 SAFETY Safety Labels and Locations Discretionary W arning W ARNING • Never operate this A TV on HILLS steeper than 25 degrees 25 ° . T o pre- vent overturn on hilly terrain, use throttle and brakes gradually , and shift weight uphill. • REVERSE operation can be dangerous even at low speeds. S teering becomes difficult. T o prevent loss of c[...]

24 SAFETY Safety Labels and Locations “No Passenger” W arning W ARNING NEVER ride as a p assenger . Passengers can cause a lo ss of control, resulti ng in SEVERE INJURY or DEA TH. 7175378 T ire Pressure/Load W a rning (TRAIL BOSS) W ARNING Improper tire pressure or overlo ading ca n cause loss of control. Loss of control can result in severe in[...]

25 SAFETY Safety Labels and Locations Age 16 W arning W ARNING Operating this A TV if you a re under the age of 16 increases your chance of severe injury or d eath. NEVER operate this A TV if you are under age 16. 7175374 Clutch Cover W arning W ARNING • Moving part s hazard und er belt-clutch gu ard. T o prevent seriou s injury , do not operate [...]

26 FEA TURES AND CONTROLS Switches Engine Stop Switch Move the stop switch eith er left or right to the OFF position to stop the engine quickly . The engine will not start or run when the switch is off. Both the main switch and the engine stop switch will shut off all electri- cal power to the vehicle, including lights. Main K ey Switch Use the mai[...]

27 FEA TURES AND CONTROLS Switches Override Switch This vehicle is equipped with a re verse sp eed limiter system. T o gain additional wheel speed while backing, release the throttle and press the override switch. W ARNING! Pressing the override switch while the throttle is open can ca use loss of control, wh ich may result in se ri ous injury or d[...]

28 FEA TURES AND CONTROLS Throttle Lever Operating an A TV wi th sticking or impr operly operating throttl e controls could cause an accident. N ever start or oper ate an A TV that has a sticking or improperly operating th rottle. Always c ontact your dealer for service before operating the vehicle. Failure to check or ma intain proper operation o [...]

29 FEA TURES AND CONTROLS Brake Lever Operating the A TV with a spongy brake leve r can result in loss of braking, which could cause an accident. Neve r operat e the A TV with a spongy-fee ling brake lever . Always contact your dealer for service before ope rating the vehicle. Squeeze the brake lever toward the ha ndlebar to apply the front and rea[...]

30 FEA TURES AND CONTROLS Auxiliary Foot Brake Aggressively applying the auxi liary brake when backing down a hill may cause rear tipover , w hich could result in seri ous injury or death. Never ba ck down a hill. Use caution when applying the auxili ary brake. Do not ag gressively apply the auxiliary brake when going forward. The rear wheels may s[...]

31 FEA TURES AND CONTROLS Brake Fluid An over-full master cylinder may ca use brake drag or b rake lock-up, which co uld result in an accident. Maintain brake fluid at the recommended level. Do not overfill. Never store or use a partial bottle of br ake fluid. Brake fluid is hygro scopic, meaning it rapidly absorbs moisture from the air . The moist[...]

32 FEA TURES AND CONTROLS Brake Fluid Hand Brake Check the brake fluid level in the master cylinder be fore each use of the vehicl e. The maste r cylinder is located on the left handlebar . Maintain the fluid level 1/4" (6 mm) below the top edge of the master cylinder . Do not overfill. 1. Position the vehicle on a level surface. Make sure the[...]

33 FEA TURES AND CONTROLS Choke The choke assists in starting a cold engine. Refer to the engine start- ing procedure on page 41 for cor- rect choke and throttle settings during starting. Fuel T ank Cap Always refuel with the engine stopped, and outdoo rs or in a well ventilated area. Refuel on a level surface. Remove the fuel tank cap to add fuel [...]

34 FEA TURES AND CONTROLS Automatic T ransmission Gear Selector The transmission gear selector is located on the right side of the vehicle. F: Forward Gear N: Neutral R: Reverse T o shift gears, brake to a complete stop. When the engine is id ling, move the lever to the desired gear . NOTICE: Shifting gears with the engine speed above idle or while[...]

35 FEA TURES AND CONTROLS Recoil St arter If the battery is too weak to start the engin e, use the rec oil starter . Follow the starting procedures on page 41, cran king the engine with the recoil starter instead of the main key switc h. 1. Grasp the recoil starte r rope handle tightly . 2. Pull slowly so you can feel the engine strokes. Tip : The [...]

36 OPERA TION Failure to operate the A TV properly can re sul t in a collision, loss of control, accident or overturn, which may result in serious injury or death . Read and understand all safety warnings outlined in the safety section of this owner ’s manual. Break-In Period The break-in period fo r your new Polaris A TV is the first ten hours o[...]

37 OPERA TION Break-In Period Engine and Drivetrain Break-in 1. Fill the fuel tank with gasoline. See page 33. Always exercise extreme caution whenever handling gasoline. 2. Check the oil level on the dipstick. See page 62. Add oil if neces- sary to maintain the level in the safe operating range. 3. Drive slowly at first. Select an op en area t hat[...]

38 OPERA TION Safe Operation Practices 1. Complete the recommen ded safety training be fore operating this vehicle. See page 7. 2. Do not allow any one under 16 year s of age to operate this vehicle. Do not allow anyone w ith cognitive or physical di sabilities to oper- ate this vehicl e. 3. Never carry a passenger on this A TV . 4. Engine ex haust[...]

39 OPERA TION Know Y our Riding Area/T read Lightly Familiarize yourself with all laws and regulations concerning the opera- tion of this of f-road vehicle in your area. Respect the environment in which you ri de. Find out where the d e signated riding areas are by con- tacting your Polaris dealer , a loca l riding club or local officials. Help kee[...]

40 OPERA TION Pre-Ride Checklist Failure to inspect and verify that th e A TV is in safe operating condition before operating increases the risk of an accident. Always inspect the A T V before each use to make sure it's in safe operating condition. Item Remarks P age Brake system/lever travel Ensure proper operation 29 66 Brake fluid Ensure pr[...]

41 OPERA TION S t arting the Engine 1. Position the vehicle on a level su rface outdoors or in a well-venti- lated area. 2. Place the transmission in neutral. 3. Lock the parking br ake. Tip : The starter interlock will prevent the eng ine from starting if the transmission is in gear and the brake is not engaged. 4. T urn the fuel valve on. 5. Sit [...]

42 OPERA TION S t arting the Engine 9. T u rn 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 en gine starts. NOTICE: Operating the vehicle immediate ly af ter starting could cause engine damage. Allow the engine to warm up for several minutes before operat[...]

43 OPERA TION Driving Procedures 1. W ear a helmet and eye protection. See page 8. 2. Sit uprigh t with both feet on the footrests and both hand s on the handlebars. 3. S tart the engine and allow it to warm up. 4. Shift the transmission into gear . 5. Check you r surroundings and determine your p ath of travel. 6. Release the parking brake. 7. Slo[...]

44 OPERA TION T urning the V ehicle Y our A TV is equipped with a solid rear axle, which drives both rear wheels equally at all times. This means that the wheel on the outside of the turn must travel a greater distance than the inside wheel when turn- ing and the inside tire must slip traction sl ightly . T o turn, steer in the direction of the tur[...]

45 OPERA TION Driving on Slippery Surfaces Whenever riding on slippery surfaces such as wet trai ls or loose gravel, or during freezin g weather , follow these precautions: 1. Do not operate on excessively ro ugh, slippery or loos e terrain. 2. Slow down when entering slippery areas. 3. Maintain a high level of alertne ss, reading the trail and avo[...]

46 OPERA TION Driving Uphill Braking and handling are greatly af fe cted when operating in hilly ter- rain. Imprope r procedure coul d cause loss of control or overturn. When- ever traveling uphill, fo llow these precautions: 1. Drive straight uphill. 2. A void steep hills (25 ° maximum) . 3. Always check the terrain care fully before ascending an[...]

47 OPERA TION Driving on a Sidehill (Sidehilling) Driving on a sidehill is not recommended. Improper proced ure could cause loss of control or overturn. A v oid crossing the side of any hill unless absolutely necessary . If crossing a sidehill is unavoidab le , follow these precautions: 1. Slow down. 2. A void crossing the side of a steep hill. 3. [...]

48 OPERA TION Driving Downhill When driving downhill, follow these precautions: 1. A void steep hills (25 ° maximum) . 2. Shift body weight uph ill. 3. Drive straight downhill. 4. Slow down. Excessive speed wh en traveling downhill can cause loss of control. 5. Squeeze the brake lever gradually . Applying the b rakes too firmly may cause the rear [...]

49 OPERA TION T urning Around on a Hill (K-T urn) If the vehicle stalls while climbing a hill, never back it down the hill! Use the K-turn to turn around. 1. S top and lock the parking brake while keeping body weight up hill. 2. Leave the transmission in forward and shut off the engine. 3. Dismount on the uphill side of the ve hi cle, or on the lef[...]

50 OPERA TION Driving Through W ater Y our A TV can operate through water with a maxi- mum recommended depth equal to the bottom of the footrests. Follow these pro- cedures when operating through water: 1. Determine water depths and cu rrent before entering water . 2. Choose a crossing where both banks have gradual inclines. 3. A void op erating th[...]

51 OPERA TION Driving Over Obst acles 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 haz- ards such as logs, rocks and low hanging branches. 3. T ravel slow ly and use extra cau tion when operating on unfamilia[...]

52 OPERA TION Driving in Reverse Follow these precautions when operating in reverse: 1. Always check for obstacles or people behind the vehicle. 2. Always avoid ba cking downhill. 3. Back slowly . 4. Apply the brakes lightly for stopping. 5. A void turning at sh arp angles. 6. Never open the throttle suddenly . 7. Do not use the override switch unl[...]

53 OPERA TION Parking on an Incline A void parking on an incl ine if poss ible. If it's unavoidable, follow these precautions: 1. S top the engine. 2. Place the transmission in gear . 3. Lock the parking br ake. 4. Always block the rear wh eels on the downhill side. 5. T urn the fuel valve of f. 25 ° maximum[...]

54 OPERA TION Hauling Cargo Overloading the vehi cle or carrying o r to wing ca rgo improperly ca n alter vehicle handling and may cause loss of control or brake instability , which can re sult in serious injury or death. Always follo w these p recautions when hau ling cargo: REDUCE SPEED AND ALLOW GREA TER DIST ANCES FOR BRAKING WHEN HAULING CARGO[...]

55 OPERA TION Hauling Cargo Never exceed the weight capacitie s sp ecified for your A TV on warning labels and in the specificati ons section of this manual. Always read and understand the load distribut ion warnings on the rack and hitch warning labels. Never carry car go on the fr ont of the TRAIL BLAZER. Cargo shoul d be evenly distributed and m[...]

56 EMISSION CONTROL SYSTEMS Noise Emission Control System Do not modify the engine, intake or exhaust components, as doing so may af fect compliance with U.S.A. EP A noise control requirements (40 CFR 205) and local noise level requirements. Operation on Public Lands in the U.S.A. Y our Polaris vehicle has a spark arrestor that was teste d and qual[...]

57 MAINTENANCE Periodic Maintenance Chart Careful periodic maintenance will help keep your vehicle in the safest, most reliable condition. Inspectio n, adjustment and lubrication of important components are explained in the periodic ma intenance ch art. Inspect, clean, lubricate, adjust and replace parts as nece ssary . When inspection reveals the [...]

58 MAINTENANCE Periodic Maintenance Chart Improperly performing the procedures marked wi th a  could result i n component failure an d cause an accid ent, which may result in serious injury o r death. Always have an authorize d Pola ris dealer perform these services. Maintenance Chart Key X Perform these operations more of ten for vehicles subje[...]

59 MAINTENANCE Periodic Maintenance Chart Perform all services at whiche ver main tenance interval is r eached first. Item Maintenance Interval (whichever comes first) Remarks Hours Calendar Miles (Km) Q Steering - Pre- Ride - Make adjustments as need ed. See Pre-Ride Checklist on page 40. X F ront suspension - Pre- Ride - X Rear su spensi on - Pre[...]

60 MAINTENANCE Periodic Maintenance Chart X Perform these procedures more often fo r vehicles subjected to severe use. E Emission-Related Service Q Have an authorized Polaris dealer perform these services. Item Maintenance Interval (whichever comes first) Remarks Hours Calendar Miles (Km) E Carburetor air intake ducts/flange 50 H 6 M 500 (800 Inspe[...]

61 MAINTENANCE Lubrication Guide Check and lubricate all components at the intervals outlined in the Peri- odic Maintenance Chart beginning on page 57. Items not listed in the chart should be lubric ated at the Ge neral Lubrication interval. See page 103 for the part numbers of Polaris products. The a-arms and lower control arms are lubricated at t[...]

62 MAINTENANCE Engine Oil Oil Recommendations Always change the oil filter whenever changing oil. Polaris recommends the use of Polaris PS-4 PLUS Performance Syn- thetic 2W -50 4-cycle oil or a similar oil for this engine. Oil may need to be changed more frequently if Polari s oil is not used. Always use 2W -50 oil. Follow the manufacturer's r[...]

63 MAINTENANCE Oil and Filter Change Always change the oil and filter at th e intervals outlined in the Periodic Maintenance Chart beginning on page 57. Always change the oil filter whenever changi ng oil. 1. Position the vehicle on a level su rface. Place the tr ansmission in neutral. Lock the parking brake. 2. Clean the area around the drain plug[...]

64 MAINTENANCE T ransmission Oil Always check and change the transmission oil at the intervals outlined in the Periodic Maintenance Char t beginning on page 57. Pol aris recommends the use of Pola ris Pr emium AGL Synthetic Gearcase Lube. See page 103 for the p art numbers of Polari s products. T ransmission Oil Recommendations Oil Check The dipsti[...]

65 MAINTENANCE T ransmission Oil Oil Change 1. Position the vehicle on a level surface. 2. Place a drain pan beneath the transmission oil drain plug area. 3. Loosen the jam nut. 4. T u rn the adjuster bolt in to allow the removal of the drain plug. 5. Remove the d rain plug an d wipe the magnetic end clean to remove accumulated metallic filings. 6.[...]

66 MAINTENANCE Brakes The front and rear brakes are hydraulic disc brakes, activated by moving the single brake lever toward the hand lebar . The auxiliary foot brake is also hydraulic. Both brake systems are self-adjusting. Brake Inspections The following checks are recommende d to keep the brake system in good operating condition. Check more ofte[...]

67 MAINTENANCE Side Panel Removal Tip : Side panel removal may be d if ficult 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 rear[...]

68 MAINTENANCE T oe Alignment Use the following procedure to check the toe alignment of the vehicle. The recommended toe alig nment is 1/8" to 1/4" (3-6 mm) to e out. W ARNING! Severe injury or death can result fro m improper toe alignment and adjustment. Do not attemp t to adjust tie rod alignment. All tie rod adjustments should be perfo[...]

69 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 rub- ber 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" t[...]

70 MAINTENANCE Camber and Caster The camber and caster are non-adjustable. Rear S pring 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 de aler . Handlebars The handlebars can be adjusted for rider pr[...]

71 MAINTENANCE Ti r e s Operating your A TV with worn tires, impr operly i nflated tires, non-standard tires or improperly installed tires will affect vehicle handling and cou ld cause an accident resulting in serious injury or death . Always follow all tire maintenance procedures as outlined in this manua l a nd on the labels on the vehicle. Alway[...]

72 MAINTENANCE Ti r e s Wheel Removal 1. Position the vehicle on a level su rface. Place the tr ansmission in gear . Lock the parking brake. 2. Loosen the wheel nuts slightly . W ARNING! Do not service axle nuts that have a cotter pin installed. See your Polaris deale r . 3. Place a suitable stand under the footrest frame to raise the wheel slightl[...]

73 MAINTENANCE Ti r e s Wheel Nut T orque Specifications Check the wheel nut torques occasional ly and when they 've been loos- ened for service. Item T orque Spe cification F ront Wheel Nuts 27 ft. lbs. (37 Nm) Rear Wheel Nuts 50 ft. lbs. (68 Nm) Rear 50 ft. lbs. (68 Nm) Fr o n t 27 ft. lbs. (37 Nm)[...]

74 MAINTENANCE Air Filter 1. Position the vehicle on a level su rface. Place the tr ansmission in gear . Lock the parking brake. 2. Remove the seat. 3. Release the air box cover clips, and remove the air box cover . 4. Loosen the clamp and remove the filter . 5. Remove the pre-filter from the main filter . 6. W ash the pre-filter in soapy water , t[...]

75 MAINTENANCE Recoil Housing Always drain the recoil housing after operating the vehicle in wet condi- tions. Drain the h ousing before storing the v ehicle. Make sure the hou s- ing is completely dry before reinstalling the drain plug. W ater will enter the reco il housing if the starter handle is disengaged from the rope guide when under water .[...]

76 MAINTENANCE Carburetor Y our Polaris A TV is calibrate d at the factory for optim al performance at altitudes ranging from zero to 6,000 feet (1800 m) and temperatures of +40 degrees F . (4 degrees C.) or higher . Above 6000 feet (1800 m) the engine air/fuel mixture becomes overly rich and the engine loses approximately 3% of its power for ea ch[...]

77 MAINTENANCE Drive Chain Drive Chain Lubrication Polaris A T V drive chains are equipped with o-ring-sea led, 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 dama ged rollers. Also check for [...]

78 MAINTENANCE Drive Chain Rear Drive Chain Slack Check the amount of chain slack in three dif ferent locations by moving the vehicle slightly forward to gain slack at the top side of the rear chain. Measure the chain slack at th e tightest of the three positions. At this point the chain should have 3/16" -3/8" (5 mm - 10 mm) deflection. [...]

79 MAINTENANCE Drive Chain Rear Drive Chain Slack 6. Roll the A TV forward or backward to adjust the chain slack to the proper tension. See the illustration for proper splice link clip opening position . 7. T i ghten the eccentric locking bolts to 30 ft. lbs. (41 Nm) for machines without the hitch and 45 ft. lbs. (61 Nm) for machines with a hitch. [...]

80 MAINTENANCE Light s Headlight Beam Adjustment The headlight beam can be adjusted slightly upward or downward. Use the following procedure to make the adjustment. 1. Position the vehicle on a level su rface with the headlight approxi- mately 25 ft. (7.6 m) from a wall. 2. Place the transmission in neutral. 3. Lock the parking br ake. 4. Measure t[...]

81 MAINTENANCE Light s Poor lighting can result in reduced visibility when driving. Headlight and taillight lenses become dirty duri ng normal operation. Clean lights frequently and rep lace burned out lamps promptly . Always make sure lights are adjusted properly for best visibility . Headlamp Replacement When servicing a ha logen lamp, don't[...]

82 MAINTENANCE Light s Indicator Lamp Replacement 1. Remove the instrument panel or front cover , if nec essary , to access the back of the in dicator panel. 2. Using a small, straight-blade scre wdriver , turn the base of the bulb 1/4 turn counterclockwise. 3. Using a needle-nose pliers or sim ilar tool, pull the l amp out of the indicator panel h[...]

83 MAINTENANCE Spar k P l u g s S p ark Plug Recommendations Refer to the sp ecifications section beginn ing on page 108 for the recom- mended spark plug type and gap for your v ehicle. T orque spark plugs to specification. NOTICE: Using non-recommended spark plugs can result in serious engine damage. Always use Po laris-recommended spark plugs. S [...]

84 MAINTENANCE Spar k P l u g s S p ark Plug Condition Normal S park Pl ug The normal insulator tip is gray , ta n or light brown. There will be few combustion deposits. The electrodes are not burned or eroded. This indi- cates the proper type and heat range for the engine and the service. The tip should not be flaky and wh ite. A white insulator t[...]

85 MAINTENANCE V ehicle Immersion If your vehicle bec omes immersed, majo r engine damage ca n result if the machine is not thorou ghly inspected. T ake the vehicle to your deal er before starting the engine. If it's impossible to take your A TV to a dealer before starting it, follow the steps outlined below . 1. Move the vehicle out of the wa[...]

86 MAINTENANCE S p ark Arrestor Failure to heed the followi ng warnings while servicing the spark arrestor could result in serious injury or death. Ne ver run the engine in an enclosed area. Remove any comb ustible materials fro m the area. W ear eye protect ion and leather work gloves. Do not stand behind or in front of the vehicle while purging. [...]

87 MAINTENANCE P VT System Failure to comply with the instructions in this warning can resul t in severe injury or death. Do not modify any component of the PVT system. Doing so may reduce its strength so that a failure ma y occur at a high speed. The PVT system has been precision balanced. Any modification will cause the system to be out of balanc[...]

88 MAINTENANCE P VT System The basic operation of the Polaris PVT system is dependent on engine speed and vehicle torque requiremen ts. As engine speed increases, the force exerted on the movable drive sheave by the flyweights also increases. This, in turn, increases th e amount of pinch applied to the drive belt. Similarly , if the engine speed de[...]

89 MAINTENANCE P VT System P VT Drying There may be some instance s when wate r is accidently ingested into the PVT system. Use the following instructions to dry it out before operat- ing. 1. Move the vehicle out of the water . 2. Remove the PVT drain plug. Allo w the water to drain completely . Reinstall the dra in plug. 3. S tart the engine. Plac[...]

90 MAINTENANCE Battery Improperly connecting or discon necting battery cables can result in an explosion and cause serious injury or death. When removing the battery , always disconnect the negative (bl ack) cable first. When reinstalling the battery , always connect the negative (black) cable last. Battery electrolyte is poisono us. It contains su[...]

91 MAINTENANCE Battery Battery Removal 1. Place the transmission in gear . 2. Lock the parking br ake. 3. Remove the seat. 4. Disconnect the battery hold-down strap. 5. On conventional batteries, re move the battery vent tube. 6. Disconnect the black (negative) battery cable first. 7. Disconnect the red (positive) battery cable last. 8. Lift the ba[...]

92 MAINTENANCE Battery Battery Inst allation Using a new battery that has not been fully char ged can damage the bat- tery and result in a shorter life. It ca n also hinder vehicle performance. Follow the battery charging instructions on page 94 before installing the battery . 1. Ensure that the battery is fully char ged. 2. Place the batte ry in t[...]

93 MAINTENANCE Battery Batter y S torage 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 char ged, and store it out of the sun in a cool, dry place. Check battery voltage each month during s torage and recharge as needed to maintain a full charge. Tip : Power pl[...]

94 MAINTENANCE Battery Battery Charging (Conventional Battery) 1. Remove the battery from the vehi cle to prevent d amage from leak- ing or spilled ele ctrolyte during charging. See page 9 1. 2. Char ge the battery with a charging output no lar ger than 1/10 of the battery’ s amp/hr rating. Charge as needed to raise the specific grav- ity to 1.27[...]

95 MAINTENANCE Battery Battery Charging (Sealed Battery) Always verify battery condition befo re and 1-2 hours after the end of charging. State of Charge V oltage Action Charge T ime (Using constant current charger @ standard amps specifi ed on top of battery) 100% 12.8-13.0 volts None, check at 3 mos. from date of manufacture None required 75%-100[...]

96 MAINTENANCE Cleaning and S torage W ashing th e V ehicle Keeping your Polaris vehicle clean will not only improve its appearance but it can also extend the life of various components. NOTICE: High water pre ssure may damage co mponents. Polaris recommends washing the vehicle by hand or with a g arden hose, using mild soap. Certain products, incl[...]

97 MAINTENANCE Cleaning and S torage W ash ing the V ehicle If a high pressure water system is u sed for cleaning (n ot recommended), exercise extreme caution. The w ate r may damage components and could remove paint and decals. A void direc ting the water stream at the follow- ing items: If an informational or graphic label becomes illegible or co[...]

98 MAINTENANCE Cleaning and S torage Chrome Wheel Care (if equipped) Proper maintenance will protect chrome wheels from corrosion, pre- serve wheel life and ensure a “like new” appearance for many ye ars. Chrome wheels exposed to road salt (or salt in the air in coastal areas) are more susceptible to corrosion if not properly cleaned. C lean ch[...]

99 MAINTENANCE Cleaning and S torage Sto r a g e Ti ps NOTICE: S t arting the engine during the storage perio d will disturb the protective film created by fogging and damage coul d occur . Never start the engine during the stora ge period. Clean the Exterior Make any necessary re pairs and clean the vehicle as rec ommended. See page 96. Stabilize [...]

100 MAINTENANCE Cleaning and S torage Sto r a g e Ti ps Fluid Levels Inspect the fluid levels. Chan ge fluids as recomm ended in the Period ic Maintenance Chart beg inning on page 57. • Demand drive unit (if equipped) • T ra nsmission • Brake fluid (change every two years and any time the fluid looks dark or contaminated) F og the Engine 1. T[...]

101 MAINTENANCE Cleaning and S torage Sto r a g e Ti ps Inspect and Lubricate Inspect all cable s and lubricate al l areas of the vehicle as recommended in the Periodic Maintenance Chart beginn ing on page 57. Battery Storage See pages 93-94 for storage and charging procedures. Storage Area/Covers Set the tire pressure and safely support the A TV w[...]

102 MAINTENANCE T ransporting the V ehicle Follow these procedures when transporting the vehicle. 1. S top the engine. 2. Place the transmission in gear . 3. Lock the parking br ake. 4. T urn the fuel valve of f. 5. Secure the fuel cap, oil cap and seat. 6. Remove the key to prevent loss during transporting. 7. Always tie the frame of the A TV to t[...]

103 POLARIS PRODUCTS P art # D escr iption Engine L ubricant 2870791 Fogging Oil (12 oz. Aerosol) 2876244 PS-4 PLUS Performance Synthetic 2W-50 4-Cycle Oil (qt./.95 l) 2876245 PS-4 PLUS Performance Synthet ic 2W-50 4-Cycle Oil (gal./3.8 l) Gearcase / T ransmission Lubricants 2873602 Premium AGL Synthetic Gea rcase Lubricant (qt./.95 l) 2873603 Prem[...]

104 TROUBLESHOOTING Drive Belt Wear/Burn Possible Cause Solution Starting out going up a steep in cline Use low range (if equipped) or turn around using the K- turn (see page 49). Driving at l ow RPM or ground speed (3-7 MPH) Drive at a higher speed or u se low range (if equipped) more frequently . Insufficient warm-up at low ambie nt tempera- ture[...]

105 TROUBLESHOOTING Engine Doesn't T urn Over Engine T urns Over , Fails to S t art Engine Backfires Possible Cause Solution Low battery voltage Rechar ge the battery to 12.8 VDC Loose battery connections Chec k all connections and tighten Loose solenoid connections Chec k all connections and tighten Possible Cause Solution Out of fuel T urn f[...]

106 TROUBLESHOOTING Engine Pings or Knocks Engine Runs Irregularl y , S t alls or Misfires Possible Cause Solution Poor quality or low octane fu el Replace w ith recommende d fuel Incorrect ignition timing See your dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs Idle set too low Adjust idle speed Possible Cause Solut[...]

107 TROUBLESHOOTING Engine S top s or Loses Power Possible Cause Solution Out of fuel T urn fuel valve to reserve, refuel Kinked or plugged fuel vent line Inspect and replace W ater is present in fuel Replace wi th new fuel Overuse of choke Ins pect, cl ean a nd/or replace spark plugs Fouled or defective spark plugs Inspec t, clean and/or replace s[...]

108 SPECIFICA TIONS * Based on EU Directiv e 76/432/EC TRAIL BOS S 330 Maximum W eigh t Capacity 415 lbs. (188 kg) (includes weight of operator , cargo and accessories) Dry W eight 531 lbs. (241 kg) Fuel Capacity 4 gal. (15.1 l) Engine Oil Capacity 1.9 qts. (1.8 l) (with oil cooler) 1.7 qts. (1.6 l) (oil change only) T ransmission Oil 1 1.3 oz. (33[...]

109 SPECIFICA TIONS Jetting Chart Clutching Ch art TRAIL BOS S 330 Driving System T ype Automatic PVT (Polaris V ariable T ransmission) Shift T ype Side Lever (F/N/R) Gear Reduction, Reverse 3 .05:1 Gear Reduction, Forward 2.68:1 Drive Ratio, Final 3.64:1 Drive Chain 520 O-Ring T ires/Pressure, Front 23 x 7-10 (4 psi/27.6 kPa) T ires/Pressure, Rear[...]

110 SPECIFICA TIONS * Based on EU Directiv e 76/432/EC TRAIL BL AZER 330 Maximum W eigh t Capacity 275 lbs. (125 kg) (includes weight of opera- tor , car go and accessories) Dry W eight 492 lbs. (223 kg) Fuel Capacity 4 gal. (15.1 l) Engine Oil Capacity 1.9 qts. (1.8 l) (with oil cooler) 1.7 qts. (1.6 l) (oil change only) T ransmission Oil 1 1.3 oz[...]

111 SPECIFICA TIONS Jetting Chart Clutching Ch art TRAIL BL AZER 330 Driving System T ype Automatic PVT (Polaris V ariable T ransmission) Shift T ype Side Lever (F/N/R) Gear Reduction, Reverse 3 .05:1 Gear Reduction, Forward 2.68:1 Drive Ratio, Final 3.64:1 Drive Chain 520 O-Ring T ires/Pressure, Front 23 x 7-10 (4 psi/27.6 kPa) T ires/Pressure, Re[...]

112 DECLARA TION OF CONFORMITY Polaris Industries Inc., 2100 Hwy 55, Medina, MN 55340 U.S.A. T elephone 763-542- 0500 W e, Polaris Industries Inc., declare that the vehicles listed below conform to the essential health and safety requirements ap plicable to off-road all-terrain vehicles. PRODUCT IDENTIFICA TION APPLICABLE EUROPEAN DIRECTIVES TEST /[...]

113 W ARRANTY LIMITED W ARRANTY Polaris Sales Inc., 2100 Highway 55, Me dina, MN 55340, gives a SIX MONTH LIM- ITED W ARRANTY on all components of the Po laris All T errain V ehicle (A TV) against defects in material or work manship. Polaris also gives a one year limited warranty on the final drive chain for failure due to defect s. This warranty c[...]

114 W ARRANTY W ARRANTY COVERAGE AND EXCLUSIONS: LIMIT A TIONS OF W ARRANTIE S AND REMEDIES The Polaris l imited warranty exc ludes any failu res that are not caused by a def ect in material or workmanship. Th is warranty does not cover acci dental damage, normal wear and tear , abuse o r improper handling. This warranty also does not cover any A T[...]

115 W ARRANTY LIMIT A TIONS OF W ARRANTIE S AND REMEDIES This warranty also excludes failures resu lting from improper lubrication; improper engine timing; improper fuel; su rface imperfect ions caused by external stress, heat, col d or contamination; operator error or abuse; improper component alignment, tension, adjustment or altitude compensat i[...]

116 W ARRANTY ALL IMPLIED W ARRANTIES (INCLU DING BUT NOT LIMITED TO THE IMPLIED W A RRANTIES OF MERCHANT ABILITY AND FITNESS FOR A P AR- TICULAR PURPOSE) ARE LIMITED IN DURA TION TO THE ABOVE SIX MONTH W ARRANTY PERIOD. POLARIS FUR T HER DISCLAIMS ALL EXPRESS W ARRANTIES NOT ST A TED IN THIS W ARR ANTY . Some states do not allow limi- tations on h[...]

117 W ARRANTY Exported V ehicles EXCEP T WHERE SPECIFICALL Y REQUIRED BY LA W , THERE IS NO W AR- RANTY OR SER VICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD OUTSIDE THE COUNTR Y OF THE SELLING DEALER'S AUTHORIZED LOCA- TION. This policy does not apply to vehicles that hav e received authorization for export from Polaris Industries. Deal[...]

118 W ARRANTY Exported V ehicles How to Get Service If Purchased From A Pr ivate Party: If you purchase a Polaris product from a private ci tizen, to be kept and used outside of the country in which the vehicle was o riginally purchased, all warrant y coverage will be denied. Notice If your vehicle is registered outside of the country where it was [...]

119 W ARRANTY U.S.A. EP A Emission s Limited W arranty This emissions limited warrant y is in additi on to the Polaris sta ndard limited warran ty for your vehicle. Polaris Industrie s Inc. warrants that at the time it is first purchased, this emissions-certified vehicle is designed, built and equipped so it conform s with applica- ble U.S. Environ[...]

120 W ARRANTY U.S.A. EP A Emission s Limited W arranty The exclusive rem edy for breach of this limited warrant y shall be, at the exclusive option of Polaris, repair or replacement of any defective materials, components or prod- ucts. THE REMEDIES SET FOR TH IN THIS LIMITED W ARRANTY AR E THE ONL Y REMEDIES A V AILABLE T O ANY PERSON FOR BREACH OF[...]

121 MAINTENANCE LOG Present this section of your ma nual to your dealer each ti me your vehicle is serviced. This will provide you and future owners with an accurate log of maintenance and ser- vices performed. DA TE MILES (KM) OR HOURS TECHNICIAN SERVICE PERFORMED / COMMEN TS[...]

122 MAINTENANCE LOG DA TE MILES (KM) OR HOURS TECHNICIAN SERVICE PERFORMED / COMMEN TS[...]

123 INDEX A Air Filt er . . . . . . . . . . . . . . . . . . . . . . 74 Apparel, P rotective . . . . . . . . . . . . . 12 B Battery . . . . . . . . . . . . . . . . . . . . 90-95 Charging (Convent ional) . . . . . . . 94 Charging (Sealed) . . . . . . . . . 94-95 Fluid (Conventional) . . . . . . . . . . 93 Installat ion . . . . . . . . . . . . . . . .[...]

124 INDEX I Idle RPM Adjus tment . . . . . . . . . . . 76 Immersion . . . . . . . . . . . . . . . . . . . . 85 Indicator L ights . . . . . . . . . . . . . . . . 27 J Jetting Chart, TRAIL BOSS . . . . . 109 Jetting Chart, TRAIL BLAZER . . 111 K Key Switch. . . . . . . . . . . . . . . . . . . . 26 K-Turn . . . . . . . . . . . . . . . . . . . . . . . [...]

125 INDEX T Training . . . . . . . . . . . . . . . . . . . . . . . . 7 Transm ission Oil . . . . . . . . . . . . . 64-65 Transporting the Vehicle . . . . . . . . 102 Tread Light ly . . . . . . . . . . . . . . . . . . 39 Turning Around on a Hill . . . . . . . . . 49 Turning th e Vehicle . . . . . . . . . . . . . 44 V Vehicle Identi fication Numbers [...]