Polaris Trail Blazer manual

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A car d cont aining import ant A TV saf ety infor mat ion should be at tac hed to t he owner ’s manual on t he next page. If you c annot loc ate t his c ard, or if it has been rem oved, please call 1- 800-342-3764 f or as sist ance. The engine exhaust from this product contains chemic als know n to cause cancer , birth defects or other reproducti[...]

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2 Copyr ight 2004 Pol a r is Sa l e s Inc . All inf or m a t i on c ont a ine d wi thi n t his publ i c a t ion i s ba se d on t he la te st pr oduct i nfor ma ti on a t the t ime of publ ic at ion. Due t o c ons t a nt imp ro v emen ts in the desig n and q u ality o f p r oduc ti on c omponent s, s ome mi nor d iscrepan cies may resu lt b etween t[...]

3 WELC O ME Thank you f or purcha sing a Polaris vehic le, and welc ome to our wor ld-wide fa mily of Pola ris owner s. W e proudly produc e an exciting line of utility an d re cre ationa l pr oducts. Polar is Recr eatio nal and Utility V ehicles S Snowmobiles S All- ter rain ve hicles ( A TVs) S W at ercraft S V ict ory m ot orcy cles S RANGER uti[...]

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5 TABLE OF CONTENTS WELCO ME 3 ................................. VEHICL E IDENT IF ICA TIO N NUMBERS 7 ........ SAFET Y 8 ................................... FEA TURES AND CONTROLS 32 ............... OPE RA T ION 44 .............................. EMI SSION CONTRO L SYSTEMS 63 ............ MAINTENANCE AND LUBRICA TION 64 ......... SPECIF ICA TIO NS [...]

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7 VE HICLE IDENTIFICATION NUMBERS Recor d your A TV’ s identif ication numbe rs an d key numbe r in the sp aces pr ovi ded . Rem ov e th e spare k ey and st ore i t i n a s afe pl ace. Y our ke y ca n be duplica ted only by ma ting a Polar is key blank w ith one of your ex isting keys, so if both ke ys are lost, the ignition switch mu st be rep l[...]

8 SA FETY Operator S afety W ARNING Failur e to f ollow t he warnings c ontained in t his m anual can res ult in serious injury or deat h. A Polar is A T V is not a t oy and can be haz ardous t o operat e. This vehicle handles differ ently than ot her v ehicles, suc h as motorcycles and cars. A collision o r rollover can occur quickly , even during[...]

9 SA FETY Operator S afety The f ollowing signal wor ds and symbols appe ar throughout this manua l and on your A TV . Y our saf ety is involve d when the se words and symbols ar e used. Become f amiliar w ith their mea nings be fore re ading the manual. The safet y alert s ymbol , on your vehic le or in t his manual, alert s you t o the pot ent ia[...]

10 SA FETY Operator S afety W ARNING Serious injury or deat h can res ult if you do not follow thes e inst ruct ions and pr ocedures , whic h are out lined in fur ther detail within y our owner ’s manual. S Rea d this manual and a ll lab els ca ref ully , and follow the oper ating proc edure s describe d. S Neve r operate a n A TV without proper [...]

11 SA FETY Operator S afety S Alway s have t he A TV i nsp ected b y an aut hori zed P ol aris d ealer i f it ’ s been involved i n an accident. S Ne ver ope rate on hills too steep for the A TV or for your a bilities. Pra ctice o n smalle r hills befo re a ttempting lar ger hills. S Alwa ys f ollow prope r proce dures for c limbing hills. Chec k[...]

12 SA FETY Operator S afety S W et br ake s may ha ve reduc ed stopping ability . T est your bra kes a fter lea ving wate r . If ne cessa ry , apply the m lightly se ver al times to allow frict io n to d ry out t he pad s. S Always che ck for obstac les or pe ople behind the A TV be fore oper at- in g in rev erse. When i t’ s s afe to pro ceed in[...]

13 SA FETY Operator S afety W ARNING POTENTI AL HAZ ARD Oper ating t his A T V wit hout proper ins tr uct ion. WHA T CAN H APPEN The r isk of an acc ident is great ly inc reased if t he operator does not k now how to oper ate t he A T V proper ly in differ ent s ituat ions and on different t ypes of t err ain. HOW T O A VOID TH E HA ZA RD Beginning[...]

14 SA FETY Operator S afety W ARNING POTENTI AL HAZ ARD Carry ing a passenger on an AT V . WHA T CAN H APPEN Carry ing a passenger great ly reduces t he operat or ’s ability to balance and cont rol t he A TV , which could caus e an accident and injury t o t he operat or and/or pas senger . HOW T O A VOID TH E HA ZA RD Never c arry a pass enger . [...]

15 SA FETY Operator S afety W ARNING POTENTI AL HAZ ARD Oper ating t his A T V on public st reet s, r oads or highways. WHA T CAN H APPEN The A T V c ould collide with anot her v ehicle. HOW T O A VOID TH E HA ZA RD Never oper ate t he A T V on any public st reet , road or highway , including dirt and gr avel roads . In many st ates it’s illegal [...]

16 SA FETY Operator S afety W ARNING POTENTI AL HAZ ARD Oper ating t he A T V af ter consum ing alcohol or dr ugs. WHA T CAN H APPEN Consumpt ion of alcohol and/ or drugs could ser iously aff ect operat or judgment . Reac tion t ime m ay be slower and operat or balance and per cept ion could be affec ted. Consuming alc ohol and/or drugs befor e or [...]

17 SA FETY Operator S afety W ARNING POTENTI AL HAZ ARD At tem pting wheelies , jum ps and other st unts . WHA T CAN H APPEN At tem pting s tunt s inc reases the c hance of an acci dent, including an over tur n. HOW T O A VOID TH E HAZ ARD Never at tem pt wheelies, jumps, or ot her st unts . Avoid exhibit ion driving. W ARNING POTENTI AL HAZ ARD Fa[...]

18 SA FETY Operator S afety W ARNING POTENTI AL HAZ ARD Removing hands f rom t he handlebars or f eet f rom the f oot rest s during operat ion. WHA T CAN H APPEN Removing ev en one hand or f oot c an reduce abilit y t o cont rol t he vehicle or could c ause loss of balanc e and eject ion fr om t he A T V . If t he operator ’ s foot is not f irml [...]

19 SA FETY Operator S afety W ARNING POTENTI AL HAZ ARD Failu re t o use e xtra caut ion when operat ing on exces sively r ough, slippery or loos e ter rain. WHA T CAN H APPEN Operatin g on excessi vely rough, s lippery or loose ter rain could c ause loss of tr act ion or loss of c ontr ol, which could r esult in an accident or ov ert urn. HOW T O [...]

20 SA FETY Operator S afety W ARNING POTENTI AL HAZ ARD Oper ating on ex cess ively s teep hills . WHA T CAN H APPEN The v ehicle may over tur n. HOW T O A VOID TH E HA ZA RD Never oper ate on hills too s teep f or t he A T V or f or y our abilit ies. Never oper ate t he A T V on hills s teeper than 25 _ . Prac tic e on smaller hills bef ore at tem[...]

21 SA FETY Operator S afety W ARNING POTENTI AL HAZ ARD T rav eling downhill improper ly . WHA T CAN H APPEN Im properly descending a hill could caus e loss of cont rol or overt urn. HOW T O A VOID TH E HAZ ARD Always follow pr oper procedur es for t rav eling down hills as des cribed in the owner ’ s m anual. NOT E: A special t echnique is requi[...]

22 SA FETY Operator S afety W ARNING POTENTI AL HAZ ARD Im properly c ross ing hills and tur ning on hills. WHA T CAN H APPEN Im properly cr ossing or tur ning as hills c ould cause loss of cont rol or overt urn. HOW T O A VOID TH E HAZ ARD N e v e ra t t e m p tt ot u r nt h e A TV around on any hill unt il you’ve m ast ered t he tur ning tec hn[...]

23 SA FETY Operator S afety W ARNING POTENTI AL HAZ ARD St alling, r olling backwar ds or improper ly dismount ing while climbing a hill. WHA T CAN H APPEN The v ehicle could ov ert urn. HOW T O A VOID TH E HAZ ARD Maint ain st eady speed when climbing a hill. If all f orward s peed is lost: Keep your weight uphill. Apply t he single lev er brak e [...]

24 SA FETY Operator S afety W ARNING POTENTI AL HAZ ARD Im properly operat ing over obst acles. WHA T CAN H APPEN Oper ating ov er obst acles could c ause loss of c ontr ol or over tur n. HOW T O A VOID TH E HA ZA RD Bef ore operat ing in a new ar ea, chec k f or obst acles . Avoid operating ov er lar ge obst acles s uch as r ocks and fallen tr ees[...]

25 SA FETY Operator S afety W ARNING POTENTI AL HAZ ARD Oper ating t he A T V t hrough deep or f ast -f lowing wat er . WHA T CAN H APPEN T ires m ay float , c ausing loss of t rac tion and loss of c ontr ol, which could lead t o an accident or overt urn. HOW T O A VOID TH E HA ZA RD Avoid operating t he A T V t hrough deep or f ast -f lowing wat e[...]

26 SA FETY Operator S afety W ARNING POTENTI AL HAZ ARD Oper ating t he A T V wit h improper modif icat ions. WHA T CAN H APPEN Im proper ins tallat ion of acces sories or m odific ation of t he A T V may c ause changes in handling which c ould lead to an ac cident . HOW T O A VOID TH E HA ZA RD Never m odify the A T V t hrough im proper ins tallat[...]

27 SA FETY Operator S afety W ARNING Leaving t he keys in the ignit ion can lead t o unaut horized us e of the v ehicle res ulting in s erious injur y or deat h. Alway s rem ove the ignit ion key when the v ehicle is not in us e. W ARNING Af ter any over tur n or acc ident, have a qualif ied ser vice dealer inspect t he entir e vehicle f or pos sib[...]

28 SA FETY Safety D ecals and Locations W arning d ecals have been pl aced on the A TV for your protection. R ead and fo ll ow th e ins tru cti on s of th e decals an d ot her warni ng s on t he A TV careful ly . If an y of t he d ecals s ho wn i n t his man ual di f fer fro m the decal s on your A TV , al ways read and foll ow the inst ructi ons o[...]

29 SA FETY Safety D ecals and Locations Improper A TV use can r esult in SEVERE INJU R Y or DEA TH ALW A YS USE AN APPRO VED HELMET AND PROTECTIVE GEAR NEVER USE ON PUBLIC ROADS NEVER CARR Y P ASSENGERS NEVER USE WIT H DRUGS OR ALCOHOL NEVER o pe rate : AL W A YS: 7172560 W ARNING[...]

30 SA FETY Safety D ecals and Locations Chain Fr eepl ay Is Important. Adjust F re epla y to 3/ 16 ″ -3 / 8 ″ DO NO T Overtension. See Owner’s Manual. T orque Nut on Eccentric B olts: T o 30 Ft. Lbs. (For m odels without a hitc h). T o 40 Ft. Lbs. (For m odels with ah i t c h ) . 7078572 MANUF ACTURE D BY : POLARIS IND. INC. DA TE : VIN: THI [...]

31 SA FETY Safe Ridi ng Gear Always we ar c lothing suited to the t ype of riding. A TV riding re quire s spec i al prote ctive clothing for comf ort and to reduc e the cha nce of injury . 1. Helm et Y our he lmet is the most impor tant pie ce of prote ctive ge ar for sa fe riding. A hel met can p revent a s evere head in ju ry . S elect an app rov[...]

32 FEATURE S AND CO NTROLS Electr ical S witches W ARNING Act ivat ing t he overr ide swit ch while t he thr ott le is open c an cause loss of cont rol, res ulting in s evere injur y or deat h. Do not act ivat e the ov erride s witc h while the t hrot t le is open. Ov errid e S wi tch (1 ) (Re ve rse Spe ed Limiter ) - This vehicle is equipped with[...]

33 FEATURE S AND CO NTROLS W ARNING Do not s tar t or operat e an A T V wit h st ick ing or impr operly operat ing thr ott le cont rols , whic h could caus e an accident and lead to s evere injur y or deat h. Always c ontac t your dealer f or ser vice repair s if t hrot tle problem s arise. Failur e to c heck or maint ain proper oper ation of t he [...]

34 FEATURE S AND CO NTROLS W ARNING Oper ating t he A T V on st reet s or roads, espec ially in dark ness, could res ult in an ac cident and ser ious injury or deat h. Y our A T V is not equipped wit h highway-appr oved light s. I t’s designed f or and mus t be us ed for of f -road use only . Use cau t ion and drive at reduc ed speeds in c onditi[...]

35 FEATURE S AND CO NTROLS Br akes Ch eck t he b rake fl uid lev el i n t he m ast er cyl in der b efore each u se o f th e A TV . The ma ster c ylinder (1) is loca ted on th e left han dl ebar . 1. Position the A TV on leve l ground with the handle bars stra ight. 2. V iew the fluid le vel through the indica t or window (2) on the top of the maste[...]

36 FEATURE S AND CO NTROLS Br ake Lever The fro nt and rear brak es are app li ed b y sq ueezin g t he brak e lev er (1) t oward t he han dleb ar . The fro nt and rear brak es are hydra ulically ac tivated disc type bra kes th at are acti vat ed by o nly o ne lev er . Alway s tes t brake lev er travel an d mast er cylinde r fluid level bef ore r id[...]

37 FEATURE S AND CO NTROLS Park in g Brak e W ARNING Oper ating t he A T V while t he parking br ake is engaged c ould result in an accident and ser ious injury or deat h. Always c heck t o be sure t he park ing brake is disengaged bef ore oper ating. Setting the P arking Br ake 1. S queeze an d rel ease t he b rake leve r (1) two or thre e times, [...]

38 FEATURE S AND CO NTROLS Auxiliary Brake W ARNING Aggres sively applying t he rear brake when bac king downhill may cause r ear t ipover , which c ould result in ser ious injury or deat h. Use caut ion when applying t he auxiliar y brak e. Do not aggress ively apply t he auxiliary brake when going f orwar d. T he rear wheels may skid and s lide s[...]

39 FEATURE S AND CO NTROLS Choke The choke a ssists in star ting a cold engine . Refer to the engine sta rting proc edur e on page 47 for cor rec t choke and throttle settings during star ting. Fuel V alve The f uel v alv e (1) i s l ocat ed o n t he left s ide o f the vehic le, below the fende r . It has t hre e positions: OFF: For vehicle stor ag[...]

40 FEATURE S AND CO NTROLS Fuel Safety W ARNING Gas oline is highly f lamm able and explosiv e under cer tain condit ions. S Always exerc ise ex tr eme caut ion whenever handling gasoline. S Always ref uel with t he engine st opped, and outdoor s or in a well vent ilated ar ea. S Do not s moke or allow open fl ames or spark s in or near the area wh[...]

41 FEATURE S AND CO NTROLS Oil Injection T ank CAUTION Mixi ng brands or using a non-r ecomm ended oil may c ause serious engine damage. We rec ommend t he use of Polar is Premiu m Synthetic 2-cycl e oi l for your 2 -cycle Po laris A TV . Never subs tit ut e or mix oil brands. T o avoid s erious engine dam age, alway s t op off t he oil level when [...]

42 FEATURE S AND CO NTROLS Autom atic T r ansm ission Gear Selector The tra nsmission gear se lector (1 ) is locate d on the right side of the A TV . F: For wa rd N: Neutral R: Rev er se CAUTION Shif ting gear s wit h the engine s peed above idle or while t he vehicle is mov ing could caus e tr ansmis sion damage. T o change gear s, st op the v ehi[...]

43 FEATURE S AND CO NTROLS Recoil S tarter If the ba tter y has be en draine d or dama ged and ca nnot start the engine , use of the re coil starte r (1) will allow ve hicle ope ration until re pairs can be ma de. The rec oil star ter is locate d on the right side of t he m achi ne. 1. Position the vehicle on a leve l surfa ce and lock the parking [...]

44 OPERATION Br eak - In P er iod The bre ak-in per iod for your new Polaris A TV i s def ined as the time it take s t o use the fir st ta nk of fu el. No single a ction on your pa rt is as importa nt as following the proce dure s for a proper br ea k-in. Care ful treat m ent o f a new en gi ne wi ll resu lt in mo re ef fi cien t p erform ance and [...]

45 OPERATION Br eak - In P er iod The fi rst t ank of fuel m ust be pre-m ix ed accordi ng t o th e foll owi ng instruc tions. Afte r the brea k-in period, the oil injection syste m will provide the ne cessa ry engine lubr ica tion without pre -mixing. 1. Pre mix the rec ommended oil with gasoline in a suitable ga s con tai ner . R efer to t he ch [...]

46 OPERATION Pr e -Ride Inspection W ARNING If a proper inspec tion is not done bef ore eac h use, sever e injury or deat h could res ult. A lways ins pect the v ehicle bef ore each us e to ens ure it ’ s in proper operat ing condit ion. Pre - Ride Che ck li st Item Remarks See Page Br ake system / lever t ravel Ensure proper oper ati on 36, 75 B[...]

47 OPERATION Star ti ng the Engi ne S tar ting a Col d Engine W ARNING Engine exhaus t c ontains poisonous c arbon monox ide and can cause los s of consc iousnes s res ulting in s evere injur y or deat h. Never r un an engine in an enclosed ar ea. CAUTION Oper ating t he vehic le immediat ely af t er st art ing could c ause engine damage. Allow t h[...]

48 OPERATION Star ti ng the Engi ne S tar ting a W arm E ngine W ar m engines do not nor mally re quire the use of the c hoke. Exce ssive use of the choke ca n cause the spa rk plug to become we t fouled. 1. Position the vehicle on a leve l surfac e and plac e the t ra nsmission in neutr al. 2. Lock the parking br ake, turn the f uel tank valve to [...]

49 OPERATION Driving Safely Driving Pr o cedures 1. Sit upright with both feet on the footre sts and both hands on the handle bars. 2. Start the engine a nd allow it to warm up, then shif t the tra nsmission into gea r . 3. Check your surr oundings and de t er mine your path of tra vel. 4. Relea se t he par king brake. 5. Slowly depre ss the thrott[...]

50 OPERATION Driving Safely Making T urns Y our Pola ris A TV is equippe d with a solid re ar a xle tha t drive s both re ar wh ee ls equally a t all times. This me ans that the whe el on the outside of the turn must tra vel a greate r distance tha n the inside wheel whe n turning and the inside tir e must slip trac tion slightly . T o make a turn,[...]

51 OPERATION Driving Safely Dr iving on Slippe r y Surfaces When ever ridi ng o n sl ip pery su rfaces su ch as wet t rail s or lo os e gravel, or du rin g freezing weat her , fol lo w th ese precaut io ns : 1. Slow down when e nter ing slippery a reas. 2. Mai nt ain a hi gh lev el o f alert nes s, read in g t he t rail and avo id in g qu ick, s ha[...]

52 OPERATION Driving Safely Driving Uphill Whe neve r trave ling uphill, follow th ese p recaut io ns: 1. Alwa ys trave l straight uphill. 2. A void stee p hills (25 _ maximum) . 3. Kee p both fe et on the footr ests. 4. T ransfe r your weight forwa rd. 5. P roceed at a s tead y rat e of spee d and throttle ope ning. 6. Rema in ale rt and be prep a[...]

53 OPERATION Driving Safely Sidehilling W ARNING Im properly cros sing hills or t urning on hills c an result in loss of cont rol or v ehicle over tur n, r esult ing in sever e injury or deat h. Avoid cross ing the s ide of a hill when pos sible. F ollow proper procedur es as out lined in t he owner ’s manual. Sidehilling ca n be a dange rous typ[...]

54 OPERATION Driving Safely Driving Downh ill Whe never de scending a hill, follow these pr ecauti on s: 1. P roceed di rect ly d ownh ill. 2. T ransf er your we ight to the re ar of the ve hicle. 3. Sl ow down. 4. Apply the brakes slightly to aid in slowing, using the single br ake leve r . NOT E: F amiliar ize your self with oper ation of t he au[...]

55 OPERATION Driving Safely T urni ng Ar ound on a Hi ll W ARNING Im proper hill c limbing pr ocedures could caus e loss of cont rol or overt urn and r esult in seri ous injury or deat h. Avoid climbing st eep hills ( 25 _ maximu m). Use ext rem e caut ion when operat ing on hills, and follow pr oper operat ing procedur es out lined in the owner ?[...]

56 OPERATION Driving Safely Dr iving Thr ough W ater Y our A TV ca n oper ate through wa ter with a maximum re commende d depth equa l to the bottom of the footr ests (1). Follow these proce dures when ope ra ting through wate r: 1. Dete rmine water de pths an d curre nt be fore c rossing. 2. Choose a crossing wher e both banks have gra dual inclin[...]

57 OPERATION Driving Safely Dr iving Thr ough W ater CAUTION Major engine dam age can res ult if t he vehicl e is not thor oughly inspect ed af ter operat ion in water . P erf orm t he ser vices outlined in the m aintenanc e chart . If your vehic le becomes immer sed or is operat ed in water that exceeds the f oot rest level, t ake it to y our deal[...]

58 OPERATION Driving Safely Dr ivin g Over Obstacles Be al ert! L ook ah ead and l earn to read t he terrai n yo u’re trav eli ng o n. Be con st ant ly al ert fo r hazards s uch as l og s, r ocks an d lo w hang in g bran ches . W ARNING Sever e injury or death c an result if your v ehicle com es in cont act with a hidden obs tac le. Not all obst [...]

59 OPERATION Driving Safely Dr ivin g in Rever se F ol lo w th ese p recaut io ns when op erati ng i n revers e: 1. Always avoid ba cking downhill. 2. Back slowly . 3. When i n reverse, apply the brake s lightly for stopping. 4. A void turning at shar p angle s in rever se. 5. Ne ver ope n the throttle suddenly while ba cking. W ARNING Failur e to [...]

60 OPERATION Hauling Cargo Y our A TV has bee n designed to ca rry or tow a c er tain a m ount of loa d (if e quipped with ra cks). Always r ead a nd under stand the load di st rib ut io n warni ng l abel s on t he vehi cl e, and n ever exceed t he weig ht ca pacitie s outlined in the spec ifica tions sec tion of the ow ner ’ s manua l and o n th[...]

61 OPERATION Hauling Cargo W ARNING Hauling cargo im properly can alt er vehic le handling and may cause los s of cont rol or br ake inst abilit y and res ult in s erious injury or deat h. A lways f ollow these prec autions when hauling cargo: S REDUCE SPEED AN D ALLO W G REA T ER DIST ANCE FO R BRAKING WHEN HAULING C ARGO. S CARG O W EI G HT DI ST[...]

62 OPERATION Driving Safely P a r k i n go na nI n c l i n e A void par king on an inc line if possible. If it’ s unavoidable , follow th ese p recaut io ns: 1. T urn the engine of f. 2. Place the tr ansmission in gear . 3. Set t he par king br ake . 4. Always block the rea r whee ls on t he downhill side. S ee illustra tion. 5. Shut of f the fue[...]

63 EMISSION C ON TR OL SYSTEMS Noise E mi ssion Contr ol System Do not modif y the engine, intake o r exhaust compone nts, as doing so may af fec t c omplianc e with state and loca l noise le vel re quireme nts. Spar k Ar r estor Y our Polar is vehic le ha s a spa rk arr estor tha t was teste d and a pproved in accordance with the US DA F or est Se[...]

64 MAINTENANCE AND LUBRICATION Accessor ies Auxilia ry powe r outlets provide 12V powe r for oper ating access ories such a s ha nd held spot lights. See your Polaris de aler . Per iodic Maintenance C hart Care ful periodic mainte nance will help kee p your ve hicle in the safe st, most relia ble condition. Inspe ction, adjustment a nd lubrica tion[...]

65 MAINTENANCE AND LUBRICATION Per iodic Maintenance C hart P erform all s ervi ces at whi chever mai nt enance in terv al is reached fi rst . Item Maint enance Inter val (w hichev er c omes f irs t) Remarks Hours C alendar Miles (Km) J Steer ing -- Pre- Ride -- Mak e adjustments as need- e d S e e P r e R i d e C h e c k l i s t " Front s us [...]

66 MAINTENANCE AND LUBRICATION Per iodic Maintenance C hart Item Maint enance Inter val (w hichev er c omes f irs t) Remarks Hours C alendar Miles (Km) Car buretor float bowl 50 H 6M 500 ( 800) Drain bowl per iodic ally and prior t o st orage J E Thrott le Cable/ ETC Switc h 50 H 6M 500 ( 800) Inspec t; adjus t; lubric ate; replac e if nec es s ary[...]

67 MAINTENANCE AND LUBRICATION Per iodic Maintenance C hart Item Maint enance Inter val (w hichev er c omes f irs t) Remarks Hours C alendar Miles (Km) J Brak e fluid 200 H 24 M 2000 (3200) Change ev ery two y ears Spark arres tor 300 H 36 M 3000 (4800) Clean out E Idle s peed -- Adjus t as needed J T oe adjus tment -- Ins pec t periodic ally; adju[...]

68 MAINTENANCE AND LUBRICATION Per iod ic Maintenan ce Recor d Use t he fol l owin g chart t o record peri odi c mai nt enance. Maintenance In terval Perfo rmed Se rv icing Date Ser vic ing Dealer or Pe rs on Remarks 10 hrs. 20 hrs. 50 hrs. 100 hrs.[...]

69 MAINTENANCE AND LUBRICATION Lubr ication R ecomm endati ons Chec k and lubric ate all c omponents a t the inte rvals outline d in the Periodic Mainte nance Char t beginning on page 65. Lubr ication C hart K ey " More often unde r seve re use, such a s wet or dusty conditions L Polar is Pre mium All Se ason Gre ase or gre ase c onforming to [...]

70 MAINTENANCE AND LUBRICATION Lubr ication Recom m endations P olar is 2 - Cycl e Lubric ants Polar i s Premium 2-c ycle lubr icants ar e the most advanc ed for mulation of oils, specific ally designe d for today’ s 2-cyc le engines. These lubric ants provide additives for 2- cycle e ngines t hat ar e lacking in today’ s fuel. These ne cessa r[...]

71 MAINTENANCE AND LUBRICATION Lubr ication Recom m endations E ngine Oi l Check The oi l t ank cap (1) i s lo cated forward of the hea dlight. Check the oil befor e each u se of th e vehi cle. R efil l t he o il when refuel in g. 1. Position the A TV on a level su rface. 2. Remove the oil tank ca p a nd inspec t the oil leve l in the tank. 3. Add [...]

72 MAINTENANCE AND LUBRICATION Lubr ication Recom m endations T ransm issio n Oil Check The tra nsmission oil dipstick ( 1) is loca ted on the right side of the vehicle . Check and cha nge the transmission oil at the interva ls outlined in the Periodic Ma intenanc e Chart beginning on pa ge 65. Mainta in the tra nsmission oil l e vel in the SAFE op[...]

73 MAINTENANCE AND LUBRICATION Adju stmen ts Oil Pump Bleeding CAUTION If t he oil supply line has been disconnec ted f rom the pum p, or if the oil r eserv oir and supply line have been com pletely run out of oil, t he oil pump m ust be bled. I f the pum p is not bled, air in t he lines may prevent oil deliv ery t o the engine, r esulting in s eve[...]

74 MAINTENANCE AND LUBRICATION Adju stmen ts Oil Pump If it bec omes ne ce ssary to incre ase oil flow into the fuel system, the oil pu mp can b e adju st ed. 1. Befor e adjusting the oil pump, chec k the engine idle RPM and car bure tor settings in the spe cifica tions section be ginning on page 103. 2. Loose n the throttle ca ble jam nut and turn[...]

75 MAINTENANCE AND LUBRICATION Adju stmen ts Br akes The front and re ar brake s are hydra ulic disc brakes, activa ted by moving the single brake le ver towar d t he handle bar . These bra kes ar e self -adjusting. The fo ll owi ng checks are recom men ded t o k eep t he brak e sys tem i n good oper ating condition. Chec k more of ten if bra kes a[...]

76 MAINTENANCE AND LUBRICATION Adju stmen ts W ARNING Sever e injury or death c an result f rom improper toe alignm ent and adjust ment . Do not at tem pt t o adjust t ie rod alignment . All t ie rod adjust ment s should be per for med by an aut horiz ed Polaris dealer . T oe Ali gnm ent Use the following proce dure to chec k the toe alignment of t[...]

77 MAINTENANCE AND LUBRICATION Adju stmen ts Steer in g Assem b ly The ste er ing assembly of the A TV should be che cked pe riodica lly for loose nuts and bolts. If loose nuts and bolts are found, see your Polaris dea l er f or servic e befo re ope ra ting the vehicle. Cam b er and Caster The ca m ber a nd caste r are non- adjustable . Rear S prin[...]

78 MAINTENANCE AND LUBRICATION Adju stmen ts W ARNING Im proper adjust ment of t he handlebars or inc orrec t tor quing of the adjus ter block t ight ening bolts can caus e limit ed st eering or loosening of the handlebar s, result ing in los s of c ontr ol and possible s erious per sonal injur y or deat h. Follow t he adjust ment procedur es exact[...]

79 MAINTENANCE AND LUBRICATION Adju stmen ts Ca r buretor IMPOR T ANT : Y our Polar i s A TV is calibr ated a t the f actory f or optimal pe rf orma nce at a ltitudes ra nging from ze ro to 6,000 fee t (1800 m) and temper atures of +40 degre es F . (4 degr ees C. ) or higher . Above 6000 fe et (1800 m) the e ngine air/f uel mixture bec omes over l [...]

80 MAINTENANCE AND LUBRICATION Adju stmen ts W ARNING Oper ating y our A T V wit h worn t ires, impr operly inf lat ed tir es, non-st andard t ires or impr operly inst alled tir es will affect v ehicle handling and could caus e an accident res ulting in s erious injur y or death. Maint ain proper t ire pr essur e as desc ribed on t he decal on your[...]

81 MAINTENANCE AND LUBRICATION Adju stment s Wheel Installation 1. Place the tra nsmission in gear and loc k t he pa rking bra ke. W ARNING Im properly ins talled wheels can adver sely affec t t ire wear and vehicle handling, which c an result in ser ious injury or deat h. Always ensure t hat all nuts are t orqued t o specif icat ion. Do not serv i[...]

82 MAINTENANCE AND LUBRICATION Adju stmen ts Fr ont Wheel H ub Ti ghtening Front whee l bea ring tightne ss and spindle nut rete ntion are cr itica l compone nt operations. All se rvice must be pe rf ormed by your aut ho rized P ol aris deal er . Ti re T read Depth Alway s repl ace t i res when tread depth is wor n t o 1/8 ″ ( .3 cm) or less. See[...]

83 MAINTENANCE AND LUBRICATION Adju stmen ts Drive Chain Polaris A TV drive cha ins are equippe d with o-ring-se aled, perma nently greas ed pi ns and rol lers . Ho wever , th e out er s urfaces o f th e rol ler mu st be lubric ate d. 1. Always inspec t the drive chain prior to opera ting the vehicle. Chec k for dama ged or missing o-rings or dama [...]

84 MAINTENANCE AND LUBRICATION Adju stmen ts Rear Dr ive Chain Slack CAUTION Adjust ing or oper ating t he A T V wit h improper rear dr ive chain slack can r esult in sever e damage t o the t ransm iss ion and drive component s. Alway s mak e sure t he slac k is wit hin t he st ated specif icat ions. Chec k the a mount of c hain slac k in thre e di[...]

85 MAINTENANCE AND LUBRICATION Adju stmen ts Rear Dr ive Chain Slack 1. R ol l t he A TV forward or back ward to adjust the cha in slack to the prope r tension. See the illustra tion for pr oper splice link clip ope ning position (1) . 2. T ig ht en t he eccen tri c lo cki ng bol t s to 30 ft. lbs. (41 Nm) for ma chines without the hitch a nd 45 ft[...]

86 MAINTENANCE AND LUBRICATION Filter System s Air Filter Rem o val and Ser vice 1. Remove the A TV sea t. 2. Rele ase the c lips secur i ng the cove r assembly to the air box. 3. Loose n the clamp sec uring the filter , a nd remove the f ilter . 4. Remove the f oam pre- filter fr om the main filter . 5. W ash the pre -filte r in soapy wa ter , the[...]

87 MAINTENANCE AND LUBRICATION Lights Whe n servic ing a ha logen lamp, don’ t touch the la mp with bar e finger s. Oil fr om your skin le aves a re sidue, causing a hot spot tha t will shorten the life of the la mp. W ARNING Poor light ing while driv ing can res ult in s evere injur y or deat h. Headlight and t aillight lenses bec ome dirt y dur[...]

88 MAINTENANCE AND LUBRICATION Lights Headlight Adju stm ent 1. Position the vehicle on a lev el s urface wi th th e hea dlight approxima tely 25 ft . (7. 6 m ) from a fla t wall. 2. Mea sure the distance fr om t he floor to the cent er of t he head li gh t and m ake a mark on t he wall at th e sam e hei ght . 3. Start the engine and turn on the he[...]

89 MAINTENANCE AND LUBRICATION Lights T aillight/Brakelight Lamp Replacement If the taillight/br akelight does not wor k the lamp may ne ed to be repl aced. 1. Remove the ta illight lens cove r mounting scre ws. Remove the lens c over and gaske t and set aside f or rea ssembly . 2. Remove the lamp (1). Apply di elect ri c grease t o t he s ock et a[...]

90 MAINTENANCE AND LUBRICATION Spar k P lugs Always use the spar k plugs rec ommended for your A TV . Refer to the spec i fic ations se ction beginning on page 103 for the r ec ommended spar k plug type a nd gap. CAUTION Using non-r ecomm ended spark plugs c an result in ser ious engine damage. Alway s use P olaris- recom mended spar k plugs. Spar [...]

91 MAINTENANCE AND LUBRICATION V eh ic le I mmersi on CAUTION If your vehic le becomes immer sed, major engine dam age can result if the m achine is not t horoughly ins pect ed. T ake t he vehicle t o your dealer bef ore s tart ing t he engine. If it’ s impossible to take your A TV to a deale r bef ore sta rting it, follow the steps outlined belo[...]

92 MAINTENANCE AND LUBRICATION Spar k Ar r estor W ARNING Failur e to heed t he f ollowing warnings while s ervic ing the s park arres tor could res ult in s erious injur y or deat h. Do no t pe rform service on the sp ark arrestor whi le the system is hot. Exhaust system t em peratures ca n reach 1000 ° F . A llow component s t o cool s ufficient[...]

93 MAINTENANCE AND LUBRICATION Recoil Hou sing T o preven t possible engine damage , always dr ain the rec oil housing (1) a f t e ro p e r a t i n gt h eA T Vi nv e r yw e t conditions. This should also be done bef ore storing the A TV . W ater will en ter the r ecoil housing if the star ter ha ndle is disengage d from the rope guide when under wa[...]

94 MAINTENANCE AND LUBRICATION PV T System The basic ope ration of the P olar is PVT system is de pende nt on engine sp eed and veh icl e to rque req ui rement s . As eng in e speed in creases , t he forc e exer ted on the m ovable d rive shea ve by t he flywe ights also incr ease s. This, in turn, incr ease s the a mount of “pinc h” applie d t[...]

95 MAINTENANCE AND LUBRICATION PV T System W ARNING Failur e to c omply wit h t he inst ruct ions in t his warning c an result in sever e injury or deat h. Do not modify any component of th e PVT system. Doing so may reduce it s s tr ength s o that a f ailure may occur at a high s peed. The PVT system has been precisio n balanced. Any modif icat io[...]

96 MAINTENANCE AND LUBRICATION Batter y W ARNING Im properly connec ting or disconnec ting bat t ery c ables can r esult in an explosion and c ause ser ious injury or deat h. When remov ing the bat t ery , always dis connect t he negativ e (black ) cable f irst . W hen reinst alling t he batt ery , always connect t he negativ e (black ) cable las t[...]

97 MAINTENANCE AND LUBRICATION Batter y Batter y Stor age Whe never the ve hicle is not use d for a per iod of three months or more, remo ve t he bat t ery from th e veh icl e, ensu re th at i t’ s ful ly charged, and st ore it ou t of t he sun i n a cool , d ry pl ace. Ch eck bat tery v ol tag e each mo nt h du rin g st orage and r echarge as ne[...]

98 MAINTENANCE AND LUBRICATION Batter y Bat tery Cha rgin g NOT E: A lways v erif y bat ter y condit ion bef ore and 1-2 hour s af ter the end of c harging. Stat e of Char ge Vo l t a g e Acti on Charge T ime* (Us ing cons tant cur rent char ger @ standar d amps spec ified on top of battery) 100% 12.8- 13.0 volt s None, check at 3 mos. fr om date o[...]

99 MAINTENANCE AND LUBRICATION Cleaning a nd Stor age See page 106 for the pa rt numbers of Polaris products. Cleaning th e A TV Kee ping your A TV cle an will not only improve its appe ara nce but it ca n also exte nd the life of va rious c omponents. W ith a f ew precauti ons, your A TV can be cleaned mu ch lik e a n automobi le. W ashin g the A [...]

100 MAINTENANCE AND LUBRICATION Cleaning a nd Stor age Sto ra ge Ti ps See page 106 for the pa rt numbers of Polaris products. CAUTION St art ing the engine dur ing the s tor age period will dist urb t he prot ect ive f ilm cr eated by fogging and dam age could occ ur . Nev er st art the engine dur ing the s tor age period. Exterio r Make nec essar[...]

101 MAINTENANCE AND LUBRICATION Cleaning a nd Stor age Sto ra ge Ti ps See page 106 for the pa rt numbers of Polaris products. Engine Use Polaris Fogging Oil a nd follow the direc tions on the ca n. If you choose not to use P olar is F ogging Oil, pe rf orm the following proce dure. 1. Support the front end of the machine so the engine is leve l or[...]

102 MAINTENANCE AND LUBRICATION Cleaning a nd Stor age Chr ome W heel Ca re (if equi pped) P roper mai nt enance wil l pro tect ch rome wheel s from corro si on, pres erve wheel l ife and ens ure a “l ike n ew” appearan ce for m any years. 1. W ash chrome r ims freque ntly . Use a mild deter gent to remove an y salt, dirt, mud or grime . Neve r[...]

103 SPECIFIC ATIO NS 2005 T r ail Blazer Capac ities Body Styl e Gen III Gro ss V eh icle W eig h t 765 l bs . ( 347 kg) F uel C ap acity 3.5 U. S. gal . (13. 2 l) Engi ne Oi l 2 qt s . ( 1.89 l ) Transm issio n Oi l 1 1 .3 oz. (.33 l) F ron t R ack (A ccesso ry ) (Max im um C ap acity) 30 l bs . ( 13.6 kg) Rear R ack (A ccesso ry ) 60 l bs . ( 27.[...]

104 SPECIFIC ATIO NS 2005 T r ail Blazer Drive S ystem Dr ive Sys te m T ype PVT Shi ft T ype Side Le ver ( F-N- R) Gear R ed u ction - Lo w No t A p plicab le Ge ar Re duct ion - Reve rs e 3.05/ 1 Gear R ed u ction - Fo rward 2. 68/1 Fro n t D rive (ratio ) No t A p plicab le Fi nal D riv e (ratio) 1 1/36 76P Cen ter D riv e (ratio) No t A p plica[...]

105 SPECIFIC ATIO NS 2005 T r ail Blazer Jetting Chart Alti tude Ambient T emperatur e Below 0 ° F (Below - - 18 ° C) 0 ° to 40 ° F (- -1 8 ° Ct o + 5 ° C) + 40 ° to + 80 ° F ( + 5 ° Ct o + 26 ° C) + 80 ° F & Abov e ( + 26 ° C& Above) Meters ( Feet ) 0-900 (0- 3000) 150 140 130 120 ( F e e t ) 900-1800 (3000- 6000) 140 130 120 1[...]

106 POLARIS PRODUCTS Part No. Descr ipti on Engine Lubr icant 2870791 Fogging O il ( 12 oz. A erosol ) 2871098 Prem ium Blue 2-Cycl e M iner al Oil ( qt. ) 2871097 Prem ium Blue 2-Cycl e M iner al Oil ( gal. ) 2871721 Prem ium Gol d Synthet ic 2-Cycl e Oil (qt .) 2871722 Prem ium Gol d Synthet ic 2-Cycl e Oil (gal .) 2874438 VES II Synt heti c 2- C[...]

107 TROUB LES HOOTIN G Dr ive Belt and Cover Problems Po ssib l e Cause Solu tion Dr ivi ng the A TV onto a p icku p o r tall trailer in hi gh ra nge . A void s toppi ng on the ra mp or cr ee ping s low l y up the ramp . T h ese p ractices may slip th e clu tch and b elt. St a r ti ng out goi ng up a steep in cline. Whe n st ar ti ng out on a n inc[...]

108 TROUB LES HOOTIN G Contac t your P ola ris dea ler for se rvice if you’r e unable to i dentif y solutions using the follow i ng ch ar ts. Engine Doesn’t T urn Over Po ssibl e Cause Sol uti on Lo w b attery v o ltag e Re c har ge ba tt er y to 12. 8 VDC Loos e ba tt e r y conne c ti ons Ch eck all con n ectio n s an d tigh ten Loos e s ole n[...]

109 TROUB LES HOOTIN G Engine Backfir es Po ssibl e Cause Sol uti on W e a k spa rk f rom s par k plugs In spect, clean an d/o r replace spark p lu g s In correct sp ark plu g g ap o r heat rang e Se t ga p to s pec s or re pla ce pl ugs Ol d or non- re comm e nded f uel Re pl a c e wi t h new fue l In correctly in stalled sp ark p lug w ires Se e [...]

11 0 TROUB LES HOOTIN G E ngine S tops or Lose s Pow er Po ssibl e Cause Sol uti on Out of fuel Tu rn fuel v alve to reserve, refu el Ki nked or plugge d fue l vent l ine In sp ect an d rep lace W ater p resent in fuel Repl ac e wit h ne w fue l Ove rus e of choke In sp ect, clean and /o r rep lace spark p lu gs Foul e d or def ec ti ve s par k plu[...]

111 WARRANTY LI MIT ED W ARRANTY Pol a r is Sa le s I nc ., 2100 Highw a y 55, Me dina , M N 55340, gi ves a SI X MO NTH LI MI TED W ARRANTY on al l com pone nts of t he Pol ar is Al l T e rr a in V e hic le ( A TV) aga ins t def ec ts i n ma te ri al or wor kma nshi p. Pol a r i s a ls o give s a one ye a r l i mi te d war ra nty on t he f ina l d[...]

11 2 WARRANTY W ARRANT Y COVERAGE AND EXCL USIONS: LIMI T A TIO NS OF W ARRANTIE S AND REMEDI ES ALL IM P LI ED W ARRANTIES ( INCLUDING BUT NOT LI MITED T O THE I MPLI ED W ARRANTIES OF MERCHANT ABILI TY AND FI TNESS FOR A P AR TICULAR PURPOSE) ARE LI MITED I N DURA TION TO THE ABOVE SIX MONTH W ARRAN- TY PERI OD. POLARI S FUR THER DISCLAI MS ALL E[...]

11 3 WARRANTY Exported V ehicles EXCEPT WHERE SPECI FICALL Y REQUIRED BY LA W , THERE IS NO W AR- RANTY OR SER VICE BULLETI N COVERAGE ON THIS VEHI CLE IF I T IS SOLD OUTSIDE THE COUNTR Y OF THE SELLING DEALER’ S AUTHORIZED LOCA- TION. T his po licy d o es n ot ap ply to v eh icles that hav e receiv ed au tho rizatio n fo r e xpor t f r om Pol a [...]

11 4 INDEX A Accesso ries 6 4 ................... Adj ust ment s 73-85 ................ Ag e R estrictio ns 8 ................ Air F ilter 8 6 ..................... Au x iliary B rak e 38 , 7 5 ............ B Ba tt er y 96-98 .................... Ba t te ry Cha r gi ng 97- 98 ............. Battery In stallatio n 96 ............. Ba tt er y Remova l[...]

11 5 INDEX O Oil 70 .......................... Oil I njectio n T an k 41 .............. Oi l Pump Adjus tm e nt 74 ........... Oil P u m p B leed ing 7 3 ............. OPERA TI ON 44- 62 ............... Ope ra tor Sa fe ty 8- 27 ............... Ov errid e S witch 3 2 ............... P Park in g B rake 3 7 ................. P a r k i n go na nI n c [...]