Polaris Trail Blazer 9921773 manual

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For your nearest Polaris dealer , call 1-800-POLARIS or visit www .polarisindustries.com Polaris Sales Inc., 2100 Hwy 55 Medina, MN 55340 Phone 1-888-704-5290 Part No. 9921773 Rev 01 Printed in USA[...]

A card containi ng important A TV safety informa tion should be attached to the owner's man ual on the next page. If you canno t locate th is card, or if it has been removed, plea se 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 [...]

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 a ll [...]

2 POLARIS and POLARIS THE W A Y OUT are regist ered tradem arks of Polari s Indus- tries Inc. Copyright 2008 Polaris Sales Inc. All inform ation contained within this publication is based on the latest product information at th e time of pub lication. Due to constant improvements in the design and quality of production compo nents, some minor discr[...]

3 T ABLE OF CONTENTS Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 F eatures and Controls . . . . . . . . . . . . . . . . . . . 26 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 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 potentia l personal injury ha zard. W ARN ING A W ARNING indi cates a hazar[...]

5 INTRODUCTION Failure to hee d the w arnings and safety pre cautions 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 ha ndles differently than other vehicles, such as motorcycles and cars. A collision or rollover can occur quickly , even during routine maneuv[...]

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 mating it wi th one of your ex isting keys. The ignition switc[...]

7 SAFETY Safety T raining A TV safety training is a top priority for Polaris. Wh en you purchase d your new A TV , yo ur dealer instructed you on the authorized A TV RiderCourse sm availa ble to you and y our e ligible family members. This training is included in the purchase price of your A TV . Polaris strongly encourages you and y our eligible f[...]

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 ch ance 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 Equi pment (PPE) bearing markings such as VESC 8, V -8, Z87.1, or CE. Make su[...]

10 SAFETY Safety W arnings Failure to operate the A TV pro perly can re sult in a collision , loss of control, accident or overturn, which may result in serious inju ry or death. Heed all safety warnings outlined in this section of the owne r ’s manual. See th e OPERA TION section of the owner ’ s manual for proper operati ng procedures. Operat[...]

11 SAFETY Safety W arnings Handling Gasoline Gasoline is h ighly flammable and explosive u nder certain conditions. • Always exercise extreme cautio n whenever h andling gasoli ne. • Always refuel with the engine stopped, and outdoors or i n a well ventil ated area. • Do not smoke or allow open flames or sparks in or near the area where refu-[...]

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 inj uries 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 Op[...]

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 co uld result in loss of control and accident or overturn. Avoid operating the A TV on pavement. 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 co ntrol the ve hicle or 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 descri bed in th e owner's manual. NOTE: A special techn ique is required when braking while traveling down- hill. See page 49. • Always descend a [...]

16 SAFETY Safety W arnings S t alling While Climbing a Hill S talling, rolling backwards or improperl y 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 terrain 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 cautio n 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 54. Before shifting into reverse gear , always check for obstacles or people behind the A TV . When i t'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 c aution and always follow proper ope rating proce dures as outlined [...]

20 SAFETY Safety W arnings Improper Cargo Loading Overloading the A TV or carryin g/towing cargo improperly may cau se changes in handling, which could cause loss of contro l or an accident. • Never exceed the stated load capa city for this A TV . • Cargo should b e properl y distributed and securely attached. • Reduce speed when carrying car[...]

21 SAFETY Safety W arnings Operating a Damaged A TV Operating a da maged A T V can result in a n accident. After any overturn or accident, have a qual ified service dealer in spect 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 ic[...]

22 SAFETY Safety Labels and Locations W arning labels have b een placed on the ve hicle for your protec tion. Read and follow the instructions on each label carefully . If any of the labels shown in this ma nual dif fer from the labe ls on your vehicle, always read and follow the instructio ns of the labels on the vehicle. If an informational or gr[...]

23 SAFETY Safety Labels and Locations Discretionary W arning W ARNING • Never operate this A TV on HILLS steeper tha n 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 t eering becomes difficult. T o prevent loss of[...]

24 SAFETY Safety Labels and Locations “No Passenger” W arning W ARNIN G 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 arning W ARNIN G Improper tire pressure or overlo ading ca n cause loss of control. Loss of control can result in severe injury or deat[...]

25 SAFETY Safety Labels and Locations Age 16 W arning W ARNING Operating this A TV if you are unde r 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 under belt-clutch gu ard. T o prevent seriou s injury , do not operate v[...]

26 FEA TURES AND CONTROLS Switches Override Switch This vehicle is equipped with a re verse sp eed limit er 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 cause loss of control, wh ich may resu lt in seri ous injury o r[...]

27 FEA TURES AND CONTROLS Switches Headlight Switch Use the headlight switch to turn the lig h ts on and of f. The key must be in the ON position and the engine stop switch must be in the RUN position to operate the headlights. Indicator Light s W ith the engine runni ng, verify the function of all indicator ligh ts before each use of the vehicle. [...]

28 FEA TURES AND CONTROLS Throttle Lever Operating an A TV with sticking o r impr operly operating throttle 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 deal er for service before operating the vehicle. Failure to check or ma intain proper operati on o[...]

29 FEA TURES AND CONTROLS Brake Lever Operating the A TV with a spongy brake leve r can result in loss of braking, whi ch could cause an accident. Neve r operat e th e A TV with a spongy-fee ling brake lever . Always contact your dealer for service before operating the vehicl e. Squeeze the brake lever toward the handleb ar to apply the front and r[...]

30 FEA TURES AND CONTROLS Parking Brake Locking the P arking 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. T o release the pa rking brake lock, squeeze and release the brake lever .[...]

31 FEA TURES AND CONTROLS Auxiliary Foot Brake Aggressively applying the auxi liary brake when backing down a hill may cause rear tipover , which could result in seri ous in jury or death. Never back down a hill. Use caution when applying the a uxiliary bra ke. Do not aggressivel y apply the auxiliary brake when going forward. The rear wheels may s[...]

32 FEA TURES AND CONTROLS Brake Fluid An over-full master cylinder may cause brake drag or b rake lock-up, which could 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 hygrosco pic, meaning it rapidly absorbs moisture from the air . The moistur[...]

33 FEA TURES AND CONTROLS Brake Fluid Hand Brake Check the brake fluid level in the master cylinder before eac h use of the vehi cle. The mas ter cylind er 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 th[...]

34 FEA TURES AND CONTROLS Choke The choke assists in starting a cold engine. Refer to the engine starting procedure on page 42 for correct ch oke and throttle settings during start- ing. 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 t[...]

35 FEA TURES AND CONTROLS Recoil St arter If the battery is too weak to start the engin e, use th e recoil s tarter . Follow the starting procedures on page 42, cranking the engine with the recoil starter instead of the main key switc h. 1. Grasp the recoil star ter rope handle tightly . 2. Pull slowly so you can feel the engine strokes. Tip : The [...]

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

37 OPERA TION Failure to operate the A TV properly can resul 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 for your new Polaris A TV is the first ten hours of[...]

38 OPERA TION Break-In Period Engine and Drivetrain Break-in 1. Fill the fuel tank with gasoline. See page 34. Always exercise extreme caution whenever handling gasoline. 2. Check the oil level on the dipstick. See page 64. 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[...]

39 OPERA TION Safe Operation Practices 1. Complete the recommen ded safety training before op erating this vehicle. See page 7. 2. Do not allow any one under 16 year s of age to operate this ve hicle. 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 haus[...]

40 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 r ide. Find out where the de signated riding areas are by con- tacting your Polaris dealer , a local rid ing club or local officials. Help keep[...]

41 OPERA TION Pre-Ride Checklist Failure to inspect and verify that th e A T V is in safe operating condition before operating increases the risk of an accident. Always inspect the A TV before ea ch use to make sure it's in safe operating condition. Item Remarks P age Brake system/lever travel Ensure proper operation 29 69 Brake fluid Ensure p[...]

42 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 th e parking b rake. Tip : The starter interlock will preven t the eng ine from starting if the transmi ssion is in gear and the brake is not engaged. 4. T urn the fuel valve on. 5. S[...]

43 OPERA TION S t arting the Engine 9. T urn 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 after st a rting could cause engi ne damage. Allow the engine to warm up for several minutes before oper[...]

44 OPERA TION Driving Procedures 1. W ear a helmet and eye protection. See page 8. 2. Sit upright with both feet on th e foo trests and both hands 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 determi ne your path of travel. 6. Release the parking brake. 7. Slo[...]

45 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 distan ce than th e inside w heel when turn- ing and the inside tire must slip traction slightly . T o turn, steer in the direction of the t[...]

46 OPERA TION Driving on Slippery Surfaces Whenever riding on slippery surfaces such as wet trails 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 avoi[...]

47 OPERA TION Driving Uphill Braking and handling are greatly af fe cted when operating in hilly ter- rain. Imprope r procedure cou ld cause loss of c ontrol 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 a[...]

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

49 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 brakes too firmly may cause the rear w[...]

50 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 b ody weight uphill. 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[...]

51 OPERA TION Driving Over Obst acles Follow these precautions when operating over obstacle s: 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 slowly an d use ex tra cau tion when operating on unfamil[...]

52 OPERA TION Driving Through W ater Y our A TV can op erate through wa ter with a maximum recommended depth equal to the bottom of the footrests. Follow these procedures when operating t hrough water: 1. Determine water depths and current before entering water . 2. Choose a crossing where both banks have gradual in clines. Maximum Depth[...]

53 OPERA TION Driving Through W ater 3. A void operatin g through deep o r fast-flowing water . NOTICE: Major engine damage can result if th e vehicle is not thorou ghly inspected after operation in water . Perform the services outlined in the maintenance chart. See page 59. The fo llowing areas need special attention: engi ne oil, tran smission oi[...]

54 OPERA TION Driving in Reverse Follow these precautions when operating in reve rse: 1. Always check for obstacles or peop le behind the vehi cle. 2. Always avoid ba cking downhi ll. 3. Back slowly . 4. Apply the brakes lightly for stopping. 5. A void turnin g at sharp angles. 6. Never open the throttle suddenly . 7. Do not use the override switch[...]

55 OPERA TION Parking on an Incline A void parking on an in cline if poss ible. If it's unavoidable, follow these precautions: 1. S top the engine. 2. Place the transmission in gear . 3. Lock th e parking b rake. 4. Always block the rear wh eels on the downhill side. 5. T urn the fuel valve off.[...]

56 OPERA TION Hauling Cargo Overloading the vehi cle or carryi ng or to w ing cargo i mproperly ca n alter vehicl e handling and may cause loss of control or brake instability , which can result in serious injury or death. Always follo w these p recautions when hauling ca rgo: REDUCE SPEED AND ALLOW GREA TER DIST ANCES FOR BRAKING WHEN HAULING CARG[...]

57 OPERA TION Hauling Cargo Never exceed the weight capacities specified for your A TV on warning labels and in the specifications section of this manual. Carg o weight should b e evenly distributed (1/3 on the front rack and 2/3 on the rear rack) and mounted as low as possible. When operating over rough or hilly terrain, reduce s peed an d car go [...]

58 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[...]

59 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 intenanc e chart. Inspect, clean, lubricate, adjust and replace parts as nece ssary . When inspection reveals the [...]

60 MAINTENANCE Periodic Maintenance Chart Improperly performing the procedures marked with a  could result i n component failure an d cause an accident, which ma y result in se rious 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[...]

61 MAINTENANCE Periodic Maintenance Chart Perform all services at whiche ver main tenance inter val 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 41. X F ront suspension - Pre- Ride - X Rear su spens ion - Pr[...]

62 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[...]

63 MAINTENANCE Lubrication Guide Check and lubricate all components at the intervals outlined in the Peri- odic Maintenance Chart beginni ng on page 59. 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 [...]

64 MAINTENANCE Engine Oil Oil Recommendations 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 re commendatio ns for ambient tempera- ture operation[...]

65 MAINTENANCE Oil and Filter Change Always change the oil and filter at th e intervals outlined in the Periodic Maintenance Chart beginning on page 59. 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[...]

66 MAINTENANCE T ransmission Oil Always check and change the transmission oil at the intervals outlined in the Periodic Maintenance Chart beg inning on pag e 59. Polaris recommends the use of Pola ris Pr emium AGL Synthetic Gearcase Lube. See page 103 for the p art numbers of Po laris products. T ransmission Oil Recommendations Oil Check The dipsti[...]

67 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 urn the adjuster bolt in to allow the removal of the drain plug. 5. Remove the d rain plug and wipe the magnetic end clean to remove accumulated metallic filings. 6. A[...]

68 MAINTENANCE Recoil Housing Always drain the recoil housing after operating the vehicle in wet condi- tions. Drain the h ousing before storing the vehicle. Make sure the hous- 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 . 1[...]

69 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[...]

70 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 from improper toe alignment and adjustment. Do not attemp t to adjust ti e rod alignment. All tie rod adjustments should be perfo[...]

71 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 avail- able through your Polaris dealer . Handlebars The handlebars can be adjusted for rider p[...]

72 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 th e end of the inline cable adjuster . 3. Loosen the adjuster lock nut. 4. Rotate the boot to turn the adjuster until 1/16" [...]

73 MAINTENANCE Ti r e s Operating your A TV with worn tires, impr ope rly inflated 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[...]

74 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 nut s that have a cotter pin installed. See your Polaris deale r . 3. Place a suitable stand under the footrest frame to raise the wheel slight[...]

75 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 Specification 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)[...]

76 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[...]

77 MAINTENANCE Carburetor Y our Polaris A TV is cali brated at the facto ry for optimal 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 fo r ea c[...]

78 MAINTENANCE Drive Chain Drive Chain Lubrication Polaris A TV drive chains are equipped with o-ring-sea led, permanently greased pins and rollers. Howeve r , 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 [...]

79 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 - 1 0 mm) deflection.[...]

80 MAINTENANCE Drive Chain Rear Drive Chain Slack 1. 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. 2. T ighten 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. 3.[...]

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 an d replace burned ou t lamps promptly . Always make sure lights are adjusted properly for best visibility . Headlamp Replacement When servicing a halo gen lamp, don'[...]

82 MAINTENANCE Light s T aillight/Brakelight Lamp Replacement 1. Remove the taillight lens cover mounting screws. Remove the lens cover and gasket and set aside for reassembly . 2. Remove the lamp. 3. Apply dielectric grease to the socket and install the new lamp. 4. T est the taillight/brake light for proper operation. 5. Reinstall the gasket and [...]

83 MAINTENANCE Spar k P l ug s S p ark Plug Recommendations Refer to the sp ecifications section beg inning on p age 108 for the recom- mended spark plug type and gap fo r your vehicle. 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 ug s S p ark Plug Condition Normal S park Plug 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 tip[...]

85 MAINTENANCE V ehicle Immersion If your vehicle bec omes immersed, ma jor engine da mage can result if the machine is not thorou ghly inspected. T ake the vehicle to your dealer 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 wat[...]

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 materi als from the area . We ar eye protect ion and leather work gloves. Do not stand behind or in front of the vehicle wh ile purging[...]

87 MAINTENANCE P V T 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 i ts strength so that a failure ma y occur at a high speed. The PVT system ha s been precision balanced. Any modification will cause the system to be out of bal[...]

88 MAINTENANCE P V T 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 [...]

89 MAINTENANCE P V T 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. Al lo w the water to drain completely . Reinstall the dra in plug. 3. S tart the engine. Pl[...]

90 MAINTENANCE Battery Improperly connecting or discon necting battery cables can resul t 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 s[...]

91 MAINTENANCE Battery Battery Removal 1. Place the transmission in gear . 2. Lock th e parking b rake. 3. Disconnect the battery hold-down strap. 4. Remove the battery cover . 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. [...]

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 ba ttery in t[...]

93 MAINTENANCE Battery Batter y S tor age 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 ge d, and store it out of the sun in a cool, dry place. Check battery voltage each month during s torage and recha rge as needed to maintain a full char ge. Tip : Powe[...]

94 MAINTENANCE Battery Battery Charging (Conventional Battery) 1. Remove the battery from the vehi cle to preven t damage from leak- ing or spilled ele ctrolyte during cha r ging. See pa ge 91. 2. Char ge the battery with a char ging output no larger than 1/10 of the battery’ s amp/hr rating. Charge as needed to raise the specific grav- ity to 1.[...]

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 o f batter y) 100% 12.8-13.0 volts None, check at 3 mos. from date of manufacture None required 75%-1[...]

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

97 MAINTENANCE Cleaning and S torage W ashing the V ehicle If a high pressure water system is u sed for clea ning (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 Tips NOTICE: S tarting the engine during the storage period will di sturb 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 recommended. See page 96. Stabilize the[...]

100 MAINTENANCE Cleaning and S torage Sto r a g e Tips Fluid Levels Inspect the fluid levels. Chan ge fluids as recommended in th e Periodic Maintenance Chart beg inning on page 5 9. • T ransmission • Brake fluid (change every two years and any time the fluid looks dark or contaminated) F og the Engine 1. T reat the fuel system with Po laris Ca[...]

101 MAINTENANCE Cleaning and S torage Sto r a g e Tips Inspect and Lubricate Inspect all cable s and lubricate al l areas of the vehicle as recommende d in the Periodic Maintenance Chart beginn ing on page 59. 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 th e parking b rake. 4. T urn the fuel valve off. 5. Secure the fuel cap, oil cap and seat. 6. Remove the key to prev ent loss during transporting. 7. Always tie the frame of the A TV to [...]

103 POL ARIS PRODUCTS P art # Description 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 Synth etic Gearcase Lubricant (qt./.95 l) 2873603 Premi[...]

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 50). 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 St art Engine Backfires Possible Cause Solution T ripped circuit breake r Reset the breaker 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 [...]

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 recomme nded 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 with 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 sp[...]

108 SPECIFICA TIONS * Based on EU Directiv e 76/432/EC T rail Blazer 330 Maximum W eight Capacity 275 lbs. (125 kg) (includes weight of opera- tor , cargo and accessories) Dry W eight 488 lbs. (221 kg) Fuel Capacity 3.25 gal. (12.3 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 o[...]

109 SPECIFICA TIONS Jetting Chart Clutching Ch art T rail Blazer 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/Pres sure, Front 23 x 7-10 (4 psi/27.6 kPa) T ires/Pressure, R[...]

110 W ARRANTY LIMITED W ARRANTY Polaris Sales Inc., 2100 Highway 55, Medina, 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 co[...]

111 W ARRANTY W ARRANTY COVERAGE AND E XCLUSIONS: LIMIT A TIONS OF W ARRANT IES AND REMEDIE S The Polaris l imited warrant y excludes 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 or improper handling. This warranty also does not cover any A [...]

112 W ARRANTY ALL IMPLIED W ARRANTIES (INCLU DING BUT NOT LIMITED TO THE IMPLIED W A RRANTIES OF MERCHANT ABILITY AN D FITNESS FOR A P A R- TICULAR PURPOSE) ARE LIMITED IN DURA TION TO THE ABOVE SIX MONTH W ARRANTY PERIOD. POLARIS FUR THER D ISCLAIMS ALL EXPRESS W ARRANTIES NOT ST A TED IN THIS W ARR ANTY . Some states do not al low limi- tations o[...]

113 W ARRANTY Exported V ehicles EXCEP T WHERE SPECIFICALL Y REQUIRED BY LA W , THERE IS NO W AR- RANTY OR SER V ICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD OUTSIDE THE COUNTR Y OF THE SELLING DEALER'S AUTHORIZED LO CA- TION. This policy does not apply to vehicles that have received authorization for expo rt from Polaris Industries. De[...]

114 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 citizen outside of the country in which the vehicle was originally pur chased, a ll warranty coverage will be denied. Notice If your vehicle is registered outside of the country where it was purchased, and you hav[...]

115 W ARRANTY U.S.A. EP A Emission s Limited W arranty This All T errain V ehicle (A TV) or Off Road Utility V ehicle (ORUV) emissions lim ited warranty is in addition to the Polaris st andard limited warrant y for this vehicle. Polaris warrants that this vehi cle is; (1) designed, built, and equipped to conform at the time of initial sale with the[...]

116 MAINTENANCE LOG Present this section of your manual 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[...]

117 MAINTENANCE L OG DA TE MILES (KM) OR HOURS TECHNICIAN SERVICE PERFORMED / COMMEN TS[...]

11 8 INDEX A Air Filt er . . . . . . . . . . . . . . . . . . . . . 76 B Battery . . . . . . . . . . . . . . . . . . . . 90-95 Charging (Conventional) . . . . . 94 Charging (Sealed) . . . . . . . . 94-95 Fluid (Conventional) . . . . . . . . 93 Installati on . . . . . . . . . . . . . . . . 92 Removal . . . . . . . . . . . . . . . . . . 91 Storage . .[...]

11 9 INDEX L Lights . . . . . . . . . . . . . . . . . . . . . 81-82 Headlamp Replacemen t . . . . . . 81 Indicator Lam p Replacement . . 82 Taillight/ Brakelight . . . . . . . . . . 82 Lubrication G uide . . . . . . . . . . . . . . . 63 M Maintenan ce Chart . . . . . . . . . . . 59-62 Modificati ons . . . . . . . . . . . . . . . . . . . 9 N Noise E[...]