Polaris 330 manual

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A car d containing im port ant A TV s afet y inf orm ation s hould be att ached to t he owner ’s manual on the next page. If you cannot locate t his c ard, or if it has been rem oved, please call 1-800- 342-3764 f or ass ist ance. The engine exhaust from this product contains chemicals k nown to the State of Cal ifornia to cause cancer , birth de[...]

1 WELC OME Thank you for purcha sing a Polaris vehic le, and welc ome to our world-w ide family of Polaris owner s. W e proudly produce a n exciting line of utility a nd rec rea tional produc ts. S Snowmobiles S All-te rra in vehicle s (A TVs) S RANGER utility vehicle s S V ict ory m ot orcy cles W e belie ve Polaris sets a standa rd of exce llence[...]

2 Copyri ght 2007 Pol ar is Sal es I nc. All inf orma ti on cont ai ned w ithi n thi s publ ic at ion i s bas ed on t he la te st pr oduct i nfor mat ion at t he ti me of publi ca ti on. Due to cons tant imp ro vem ents in the desig n an d q uality o f pr oduct ion compone nts , some m inor discrep an cies may result betw een th e actual vehicle an[...]

3 TABLE OF CONTENTS KNOW YOUR VEH ICLE 5 ..................... SA FETY 6 ................................... FEA TURES AND CONTROL S 31 ............... OPER A TION 41 .............................. EMISSI ON CONTROL SYST EMS 59 ............ MAINTENANCE 60 ........................... SPECIF ICA TIO NS 104 ........................ POLARIS PRODUCTS 10[...]

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5 KNOW YOUR VEHICLE As the operator of the vehic le, you ar e responsible for your per sonal safe ty , the safety of other s, a nd the protection of our e nvironment. Read a nd understand your owne r ’ s manual, which include s valuable informa tion about all a spects of your vehicle , inc luding safe opera ting proce dures. V ehicle Identificati[...]

6 SAFE TY Operator S afety W ARNING Failur e to f ollow the war nings cont ained in t his manual c an result in serious injury or deat h. A Polar is A T V is not a toy and can be hazardous t o operat e. This vehicle handles differently than ot her vehic les, such as motorcycles and cars. A collision o r rollover can occur quickly , even during r ou[...]

7 SAFE TY Operator S afety The following signa l words and symbols appe ar throughout this manual a nd on your A TV . Y our safe ty is involved when these words and symbols are use d. Be come fa miliar with their mea nings before rea ding the manual. The safety aler t sy mbol , on your vehic le or in t his manual, alert s you to t he pot ential f o[...]

8 SAFE TY Operator S afety W ARNING Serious injury or deat h can res ult if you do not follow thes e instr uct ions and proc edures, which are out lined in f urt her det ail within your owner ’ s manual. S Read this ma nual and a ll labels car efully , and follow the ope rating proce dures desc ribed. S Never ope rate a n A TV without proper inst[...]

9 SAFE TY Operator S afety S Always have th e A TV insp ected b y an aut hori zed P ol aris d ealer if it’ s been i nvolved i n an accident. S Neve r opera te on hills too stee p for the A TV or for your abilities. Pra ctice on sma ller hills befor e attempting la rge r hills. S Always fo llow proper proc edure s for climbing hills. Check the ter[...]

10 SAFE TY Operator S afety S W et bra kes may have reduc ed stopping ability . T est your brake s afte r lea ving water . If nec essar y , apply them lightly seve ral times to a llow frict ion t o dry o ut t he pads . S Always chec k for obstacles or people behind the A TV before oper at- ing i n revers e. Wh en it ’ s safe to p roceed i n rever[...]

11 SAFE TY Operator S afety W ARNING POTENTI AL HAZA RD Oper ating t his A T V wit hout proper inst ruct ion. WHA T CAN HAPPEN The r isk of an accident is great ly incr eased if the operat or does not know how to operat e the A TV pr operly in diff erent situat ions and on different types of t errain. HOW TO A VOID THE HAZA RD Beginning and inexper[...]

12 SAFE TY Operator S afety W ARNING POTENTI AL HAZA RD Carry ing a passenger on an AT V. WHA T CAN HAPPEN Carry ing a passenger great ly reduces t he operat or ’ s ability t o balance and contr ol t he A TV , which could caus e an accident and injury t o the operat or and/or pass enger . HOW TO A VOID THE HAZA RD Never c arry a passenger . The p[...]

13 SAFE TY Operator S afety W ARNING POTENTI AL HAZA RD Oper ating t his A T V on public str eets , roads or highways. WHA T CAN HAPPEN The A T V c ould collide with anot her vehic le. HOW TO A VOID THE HAZA RD Never oper ate t he A T V on any public st reet , r oad or highway , including dirt and gravel r oads. In m any st at es it’s illegal to [...]

14 SAFE TY Operator S afety W ARNING POTENTI AL HAZA RD Oper ating t he A T V af ter consuming alcohol or dr ugs. WHA T CAN HAPPEN Consumpt ion of alc ohol and/or drugs could ser iously aff ect operator 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 whi[...]

15 SAFE TY Operator S afety W ARNING POTENTI AL HAZA RD Att empt ing wheelies, jumps and other stunt s. WHA T CAN HAPPEN Att empt ing st unt s incr eases the c hance of an ac cident , including an over tur n. HOW TO A VOID THE HAZA RD Never att empt wheelies, jumps, or ot her st unt s. Avoid exhibiti on driving. W ARNING POTENTI AL HAZA RD Failur e[...]

16 SAFE TY Operator S afety W ARNING POTENTI AL HAZA RD Removing hands from the handlebars or feet from the f ootr est s during operat ion. WHA T CAN HAPPEN Removing ev en one hand or f oot c an reduce abilit y t o cont rol t he vehicle or could cause loss of balance and ejec tion f rom the A T V . If t he operator ’s foot is not firmly plant ed [...]

17 SAFE TY Operator S afety W ARNING POTENTI AL HAZA RD Failu re to use extra caution w hen operat ing on exces sively r ough, slippery or loose ter rain. WHA T CAN HAPPEN Operatin g on excessive ly rough, s lippery or loose terr ain could caus e loss of tr acti on or loss of cont rol, which could r esult in an accident or overt urn. HOW TO A VOID [...]

18 SAFE TY Operator S afety W ARNING POTENTI AL HAZA RD Operat ing on exc essiv ely st eep hills. WHA T CAN HAPPEN The v ehicle may overtur n. HOW TO A VOID THE HAZA RD Never oper ate on hills t oo st eep f or t he A T V or f or your abilities. Never oper ate t he A T V on hills s teeper than 25 _ . Pract ice on s maller hills before at t empt ing [...]

19 SAFE TY Operator S afety W ARNING POTENTI AL HAZA RD T raveling downhill improper ly . WHA T CAN HAPPEN Impr operly descending a hill could caus e loss of contr ol or overt urn. HOW TO A VOID THE HAZA RD Always f ollow proper procedur es for t rav eling down hills as des cribed in the owner ’s manual. NOT E: A special technique is required whe[...]

20 SAFE TY Operator S afety W ARNING POTENTI AL HAZA RD Impr operly c ross ing hills and turning on hills . WHA T CAN HAPPEN Im properly crossing or turning as hills could caus e loss of contr ol or over tur n. HOW TO A VOID THE HAZA RD 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 aster ed the t urning tec hnique [...]

21 SAFE TY Operator S afety W ARNING POTENTI AL HAZA RD Stalling, rolling back wards or improper ly dismount ing while climbing a hill. WHA T CAN HAPPEN The v ehicle could ov ertur n. HOW TO A VOID THE HAZA RD Maint ain steady speed when climbing a hill. If all forwar d speed is lost: Keep your weight uphill. Apply t he single lev er brak e gradual[...]

22 SAFE TY Operator S afety W ARNING POTENTI AL HAZA RD Im properly operating over obstac les. WHA T CAN HAPPEN Oper ating over obstac les could c ause loss of cont rol or overt urn. HOW TO A VOID THE HAZA RD Befor e operat ing in a new area, check f or obs tac les. Avoid operating ov er large obs tac les suc h as roc ks and f allen tr ees when pos[...]

23 SAFE TY Operator S afety W ARNING POTENTI AL HAZA RD Oper ating t he A T V t hrough deep or f ast -f lowing wat er . WHA T CAN HAPPEN T ires m ay float , caus ing loss of t ract ion and loss of cont rol, which could lead t o an accident or over turn. HOW TO A VOID THE HAZA RD Avoid operating t he A T V t hrough deep or f ast -f lowing wat er . I[...]

24 SAFE TY Operator S afety W ARNING POTENTI AL HAZA RD Oper ating t he A T V wit h improper modific ations . WHA T CAN HAPPEN Im proper ins tallat ion of ac cess ories or modific ation of the A T V may c ause changes in handling which could lead to an ac cident . HOW TO A VOID THE HAZA RD Never m odify the A T V t hrough impr oper inst allat ion o[...]

25 SAFE TY Operator S afety W ARNING Leaving the k eys in t he ignit ion can lead t o unauthor ized use of the vehic le result ing in ser ious injury or death. A lways r emove the ignit ion key when the vehicle is not in use. W ARNING Aft er any overt urn or ac cident , hav e a qualified s ervic e dealer inspect the ent ire vehic le for possible da[...]

26 SAFE TY Fuel Safety W ARNING Gasoline is highly flam mable and explos ive under c ert ain conditi ons. S Always exercise ex tr eme caut ion whenever handling gasoline. S Always refuel wit h the engine s topped, and outdoor s or in a well ventilat ed area. S Do not sm oke or allow open flames or sparks in or near t he area where r efueling is per[...]

1 2 27 SAFE TY Safety D ecals and Locations W arning decal s have been placed on t he A TV for your protecti on. R ead and fo ll ow t he i ns tru cti on s of the decal s o n t he A TV carefu ll y . If an y of the decals depi cted in thi s manual differ from t he decals on your A TV , always read and fo ll ow t he i ns tru cti on s of the decal s on[...]

3 28 SAFE TY Safety D ecals and Locations Gener al W ar ning (3) W ARNING Impr oper A TV use can resul t in SEVERE INJUR Y or DEA TH AL W A YS USE AN APPROVED HELMET AND PROTECTIVE GEAR NEVER USE ON PUBLIC ROADS NEVER CARRY P ASSENGERS NEVER USE WITH DRUGS OR ALCOHOL NEVER operat e: S wit hout proper t raini ng or instr uction S at speeds too fast [...]

4 6 5 29 SAFE TY Safety D ecals and Locations No Passenger W arning (4) W ARNING NEVER ri de as a passenger . Passengers can cause a los s o f co n trol, re s ultin g in SEVERE INJUR Y or DEA TH. A g e1 6W a r n i n g( 5 ) W ARNING Operat ing thi s A TV if you are under t he age of 16 incr eases your chance of severe inj ury or death. NEVER operat [...]

30 SAFE TY Safe R iding Gear Always wea r clothing suited to the t ype of riding. A TV riding re quires specia l protective clothing for c omfort and to reduce the c hance of injury . 1. Helmet W earin g a h elm et can prevent a severe h ead injury . Whe never r iding a Polaris vehicle , always wear a helm et t hat meet s or ex ceeds esta blished s[...]

31 FEATURES AND CONTROLS Electr ical Switches W ARNING Act ivat ing the ov erride s witc h while the t hrot t le is open can c ause loss of contr ol, r esult ing in sever e injury or death. Do not activat e the over ride swit ch while t he t hrot tle is open. Overri d e S witch (1) (Reve rse Spee d Limiter) - This vehicle is equipped with a re vers[...]

32 FEATURES AND CONTROLS Light Sw itches W ARNING Oper ating t he A T V on st reet s or roads, es pecially in dar kness , could res ult in an ac cident and serious injury or death. Y our A TV is not equipped with highway -approv ed lights . It ’s designed f or and mus t be us ed for off -road us e only . Use cau tion and drive at reduced speeds i[...]

33 FEATURES AND CONTROLS Throttle Lever W ARNING Do not st art or operat e an A T V wit h st icking or improperly operat ing throt t le cont rols, which could c ause an acc ident and lead to sev ere injur y or deat h. Always cont act your dealer f or serv ice repairs if thr ott le problems arise. Failur e to chec k or maintain proper operation of t[...]

34 FEATURES AND CONTROLS Br ake Lever W ARNING Oper ating t he A T V wit h a spongy br ake lever can result in loss of braking, which could caus e an accident . Never operate t he A T V with a spongy -f eeling brake lev er . The fro nt and rear brak es are appl ied b y sq ueezi ng t he brake lever ( 1) toward the handle bar . The fro nt and rear br[...]

35 FEATURES AND CONTROLS Br akes Ch eck the brak e flui d l evel i n th e mas ter cy li nd er befor e each us e of the A TV . The ma ster cylinde r (1) is locat ed on t he l eft han dl ebar . The fluid le vel can be seen thr ough an indica tor window (2) on the top of the maste r cylinder . This “eye ” will appe ar dar k when the fluid leve l i[...]

36 FEATURES AND CONTROLS Park ing B rake W ARNING Oper ating t he A T V while t he parking br ake is engaged c ould result in an acci dent and serious injur y or death. Alway s check t o be sure t he park ing brake is disengaged before oper ating. Setting the Par king Brake 1. Sq ueeze and releas e th e brak e lev er two or three time s, then squ e[...]

37 FEATURES AND CONTROLS Auxiliary Brake W ARNING Aggres sively applying the rear brake when back ing downhill may cause r ear t ipover , which could result in serious injury or deat h. Use caut ion when applying t he auxiliary brake. Do not aggress ively apply the auxiliary brake when going f orward. T he rear wheels may ski d and slide sideway s,[...]

38 FEATURES AND CONTROLS Choke The choke assists in starting a co ld engine. R efe r to the engine starting proce dure on page 43 for cor rect choke a nd throttle settings during starting. Fuel V alve The fu el v alve (1 ) i s l ocat ed on the l eft s id e of the vehic le, below the fender . It has three positions: OFF: For vehicle stora ge and whe[...]

39 FEATURES AND CONTROLS Automatic T r ansm ission Gear Selector The transmission gea r selec tor (1) is located on the right side of the vehicle . F: For war d N: Neutral R: Rev erse CAUTION Shift ing gears with t he engine speed above idle or while the vehicle is moving could caus e tr ansmi ssion dam age. T o change gears , s top t he vehicl e, [...]

40 FEATURES AND CONTROLS Recoil Star ter If the batter y has bee n drained or damage d and ca nnot start the engine, use of the re coil starter ( 1) will allow vehic le opera tion until repa irs can be made . The r ecoil starte r is l ocate d on the r ight side of th e mach in e. Polaris 4- cycle e ngines ar e equippe d with automa tic decom pres s[...]

41 OPERATION Br eak-In Per iod The bre ak-in per iod for your new Polaris A TV is the first ten hours of opera tion, or the time it take s t o use the first two full tanks of gasoline. No single ac tion on your part is a s important as following the proce dures for a proper br eak-in. Carefu l tre atment of a new engine and drive c omponents will r[...]

42 OPERATION Pr e -Ride Inspection W ARNING If a proper inspec tion is not done bef ore each us e, s evere injur y or deat h could res ult. Alway s inspec t t he vehic le befor e each use to ens ure it ’s in proper operat ing condit ion. Pre - Ride Che ck lis t Item Remarks See Page Brake system / lever t ravel Ensure proper oper ati on 34, 71 Br[...]

43 OPERATION Star ting the E ngine W ARNING Engine exhaus t cont ains pois onous car bon monoxide and c an cause los s of consciousnes s res ulting in s evere injur y or deat h. Never r un an engine in an enclosed ar ea. 1. Position the vehic le on a level surface. 2. Plac e the transmission in neutra l. 3. Loc k the parking br ake. NOT E: T he st [...]

44 OPERATION Star ting the E ngine 7. Move the e ngine stop switch to RUN. NOT E: Do not press t he t hrot tle while s tar ting t he engine. 8. T urn the ignition key past the ON position to enga ge the star ter . Activate the sta rter for a maximum of five se conds, releasing the key when the engine sta rts. 9. I f the engine does not start, relea[...]

45 OPERATION Driving Safely Driving Pr oced ures 1. Sit upright with both fe et on the footre sts and both hands on the handleba rs. 2. Star t the engine and allow it to warm up, then shift the tran smission into gear . 3. Che ck your surr oundings and deter mine your path of tr avel. 4. Re lease the parking bra ke. 5. Slowly de press the thro ttle[...]

46 OPERATION Driving Safely Hauling Cargo Acce ssory ra cks and hitc hes ar e ava ilable fr om your Polaris de aler . Always re ad and unde rstand the load distr ibution warnings on a ll warnin g lab els , an d never exceed t he s pecifi ed wei ght capac ities for the vehicle . Maximu m T owing C apaciti es Refe r to the spe cifications at the re a[...]

47 OPERATION Driving Safely Hauling Cargo W ARNING Hauling cargo im properly can alter v ehicle handling and may cause los s of c ontr ol or brak e inst ability and result in serious injury or deat h. Always f ollow these prec autions when hauling cargo: S REDUCE SPEED AN D ALLOW GREA TER DI ST ANCE FOR BRAKING WHEN H AULING CARGO. S CARGO WE IG HT[...]

48 OPERATION Driving Safely Making T u rns Y our Polaris A TV is equipped with a solid r ear axle, whic h drives both rea r whe els equa lly at all time s. This mea ns that the whee l on the outside of the turn must tr avel a grea ter distance tha n the inside wheel whe n turning and the inside tire must slip tr action slightly . T o make a turn, s[...]

49 OPERATION Driving Safely Driving on Slippery S urfaces Whenev er ridi ng o n sl ipp ery su rfaces such as wet trai ls or loo se grav el, or duri ng freezi ng weat her , fo ll ow t hese precau ti on s: 1. Slow down whe n entering slippe ry are as. 2. Mai nt ain a h ig h level of al ert ness , read in g the t rai l and av oi di ng qui ck, sharp t [...]

50 OPERATION Driving Safely Driving Uphill W ARNING Brak ing and handling are great ly affec ted when oper ating in hilly ter rain. I mproper procedure c ould cause los s of control or overt urn and r esult in s erious injury or deat h. Avoid climbing st eep hills ( 25 _ maximum). Use ext reme c aution when oper ating on hills , and f ollow proper [...]

51 OPERATION Driving Safely Driving Uphill Whe never tr aveling uphill, follow these pr ecautio ns : 1. A lways tra vel stra ight uphill. 2. A void stee p hills (25 _ maximum) . 3. Ke ep both fee t on the footre sts. 4. T ransf er your weight forwa rd. 5. Pro ceed at a st eady rat e of speed an d th ro ttle opening. 6. Re main aler t and be pre par[...]

52 OPERATION Driving Safely Driving Downhill Whe never de scending a hill, follow these pr ecauti on s: 1. Pro ceed di rectl y do wnh ill. 2. T ra nsfer your weight to the rea r of the vehic le. 3. Slow down. 4. Apply the brake s slightly to aid in slowing, using the single brake leve r . NOT E: F amiliariz e yours elf wit h operat ion of the auxil[...]

53 OPERATION Driving Safely Sidehilling W ARNING Impr operly crossing hills or tur ning on hills can r esult in loss of contr ol or v ehicle over tur n, r esult ing in sever e injury or death. Avoid cross ing the s ide of a hill when pos sible. Follow proper procedur es as out lined in the owner ’s manual. Sidehilling can be a dange rous type of [...]

8’ (2. 4 m) 54 OPERATION Driving Safely T urning A round on a H ill If the ve hicle stalls while c limbing a hill, neve r back it down the hill! Use the K-tur n to turn around. 1. Stop and loc k the parking br ake while keeping body w eight uphill. 2. Le ave the tr ansmission in for ward a nd shut off the engine. 3. Dismount on the uphill side of[...]

55 OPERATION Driving Safely Dr iving Thr ough W ater Y our A TV c an opera te through wate r with a maximum rec ommende d depth equa l to the bottom of the footre sts (1). F ollow thes e pro cedures when opera ting through water: 1. D eter mine water depths and c urrent befor e crossing. 2. Choose a c rossing where both banks have gradua l inclines[...]

56 OPERATION Driving Safely Driving Over Obstacles Be alert ! Look 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 for h azards su ch as l ogs , ro cks an d low h angi ng branch es. W ARNING Severe injur y or death can res ult if your v ehicle com es in cont act with a hidden obst acle. Not all obst acles [...]

57 OPERATION Driving Safely Driving in Rever se Fo ll ow t hes e precau ti on s when op erati ng in rev erse: 1. Alwa ys avoid backing downhill. 2. Ba ck slowly . 3. When in rev erse, apply the brake s lightly for stopping. 4. A void turning at sharp angles in r ever se. 5. N ever open the throttle suddenly while bac king. W ARNING Failur e to use [...]

58 OPERATION Driving Safely P a r k i n go na nI n c l i n e A void parking on an incline if possible. If it’ s unavoidable, follow thes e precau ti on s: 1. T urn the engine of f. 1. Plac e the transmission in gear . 2. Set the parking bra ke. 3. Alwa ys block t he rea r wheels on t he downhill side. See illustration. 4. Shut of f the fuel suppl[...]

59 EMISSION C ONT RO L SYST EMS Noise Em ission C ontrol System Do not modify the engine, intake o r exhaust components, as doing so may af fect complianc e with U.S .A. EP A noise control requir ements (40 CFR 205) and loca l noise leve l requir ements. Operation on Public Land s in the U.S .A. Y our Polaris vehic le has a spark a rre stor that wa[...]

60 MAINTENANCE Per iodic Maintenance Char t Care ful periodic mainten ance will help keep your vehic le in t he safe st, most relia ble condition. Inspec tion, adjustment and lubric ation of important compone nts are expla ined in the periodic maintenan ce char t. Insp ect, cl ean, l ub ricat e, adj us t and replace parts as necess ary . Wh en ins [...]

61 MAINTENANCE Per iodic Maintenance Char t Maintenanc e Char t Key " Perfo rm t hese p roced ures m ore freq uent ly for vehi cl es su bj ected to sever e use. E Emission-re lated ser vice (Failur e to conduct this maintenanc e will not void the emissions warrant y but may af fect e missions.) J Have an au th ori zed P ol aris dealer p erform[...]

62 MAINTENANCE Per iodic Maintenance Char t Item Maintenance I nter val (whic hev er c omes fir s t) Remarks Hours Calendar Miles (Km) " J Brak e pad wear 10 H Monthly 100 (160) Inspec t per iodically Battery 20 H Monthly 200 (320) Check terminals ; c lean; tes t " Transmis s ion oil 25 H Monthly 250 (400) Inspec t lev el; c hange year ly[...]

63 MAINTENANCE Per iodic Maintenance Char t Item Maintenance I nter val (whic hev er c omes fir s t) Remarks Hours Calendar Miles (Km) " Cooling hos es (if applic able) 100 H 12 M 1000 (1600) Inspec t for leak s " Engine mounts 100 H 12 M 1000 (1600) Ins pec t Ex haust muffler/ pipe 100 H 12 M 1000 (1600) Inspec t J E Spark plug 100 H 12 [...]

64 MAINTENANCE Lubricati on Recom m endations Chec k and lubrica te all compone nts at the inter vals outlined in the Periodic Mainte nance Char t beginning on page 60. Items not listed in the char t should be lubricated at the Gen eral Lubric ation interval. NOT E: T he a-arm s and lower c ontr ol arms are lubricat ed at the fact ory , and no addi[...]

65 MAINTENANCE Lubricati on Recom m endations (1) (2) (3) (4)[...]

66 MAINTENANCE Engi ne Oil Always che ck and cha nge the engine oil at the intervals outlined in the Peri od ic M ain ten ance C hart begi nning on page 60. Always change the oil filter whe never c hanging oil. Oil R ecomm endations Polar is rec ommends the use of Pola ris PS-4 PLUS Per forma nce Synthetic 2W -50 4-c ycle oil or a similar oil for t[...]

67 MAINTENANCE Engi ne Oil Oil and Filter Chang e 1. Position the vehic le on a level surf ace. 2. Clea n the area a round the drain plug. 3. Run the e ngine for two to thr ee minutes until war m. Stop the engine. CAUTION Contact wit h hot oil may result in serious burns. Do not allow hot oil to c ome int o cont act wit h sk in. 4. Plac e a drain p[...]

68 MAINTENANCE T ransmission Oil Always che ck and cha nge the transmission oil at t he interva ls outlined in the Periodic Mainte nance Char t beginning on page 60. Maintain the oil level at the bottom of t he fill hole threa ds. W e rec ommend the use of Premium AGL Synthetic Gearc ase Lubrica nt. See page 107 for the part numbe rs of Polaris pr [...]

69 MAINTENANCE T ransmission Oil Oil Chang e 1. Pl ace a drain pan b eneat h th e tran smission oil drain plug area. 2. Loose n the jam nut ( A). 3. T urn the a djuster bolt (B) in to allow the remova l of t he drain plug (C). 4. Re move the drain plug and wipe the magne tic end clea n to remov e accum ul ated met a llic filings. 5. Af ter the oil [...]

A B 70 MAINTENANCE T oe Al ignm ent W ARNING Sever e injury or death can res ult f rom improper t oe alignment and adjustm ent. Do not att empt to adjus t t ie rod alignment . All t ie rod adjustm ents should be perf ormed by an authoriz ed Polaris dealer . Use the following proce dure to check the toe alignment of the vehicle . The rec ommended to[...]

71 MAINTENANCE Br akes The front and re ar brake s are hydraulic disc br akes, activate d by moving the single brake leve r toward the handleba r . These brakes ar e self- adjusting. The fo ll owi ng ch ecks are recomm ended to keep the b rake sy st em i n good opera ting condition. Check more often if br akes a re used he avily under nor mal opera[...]

72 MAINTENANCE Br akes 1. Ch eck th e brak e sys tem for fl ui d l eaks . 2. Ch eck t he brak es fo r exces si ve t ravel or spongy fee l. 3. Check t he fri cti on pad s for wear , damage a nd looseness. 4. Ch eck the s ecurit y and s urface condition of the disc. NOT E: Pads should be changed when worn t o 3/64 ″ (.1 cm). Auxiliary Brake The a u[...]

1 2 3 73 MAINTENANCE Throttl e Cable Fr eeplay Throttle c able fr eepla y is adjusted at the handleba r . 1. L ocate the thro ttle cable adj ust er on the handleba r . 2. Sq ueeze t he end of t he rubber boot (1) a nd slide it far e nough to expose the end of the inline cable ad ju st er (2). 3. Loose n the locknut (3). 4. Rota te the boot to turn [...]

74 MAINTENANCE Handlebar s W ARNING Im proper adjust ment of t he handlebars or incorrect t orquing of the adjust er bloc k t ightening bolt s c an cause lim ited s teer ing or loosening of t he handlebars , r esult ing in loss of cont rol and possible s erious per sonal injury or death. Follow t he adjust ment procedur es exact ly , or s ee your P[...]

75 MAINTENANCE Car bur etor IMPOR T ANT : Y our Pola ris A TV is calibr ated a t the fac tory for optimal per formanc e at altitude s ranging fr om zero to 6,000 fe et (1800 m) and tempera tures of +40 degre es F . (4 degree s C .) or higher . Above 6000 fee t (1800 m) the e ngine air/fue l mixture bec omes over ly rich and the engine loses approxi[...]

76 MAINTENANCE Wheels W ARNING Operat ing your A TV with worn t ires, improper ly inf lated t ires , non-st andard tir es or impr operly inst alled tires will affec t vehic le handling and could caus e an accident result ing in serious injury or death. Maint ain proper t ire pr essur e as desc ribed on t he decal on your A TV and in your owner ’s[...]

77 MAINTENANCE Wheels Wheel Installation 1. Plac e the tra nsmission in gear a nd lock the par king brake . W ARNING Im properly installed wheels c an advers ely affec t t ire wear and vehicle handling, which can res ult in s erious injur y or deat h. Always ens ure t hat all nut s ar e tor qued to s pecif icat ion. Do not serv ice axle nut s t hat[...]

78 MAINTENANCE Wheels Front W heel Hub T ightening Front wheel be aring tightness a nd spindle nut rete ntion are c ritica l component ope rations. All servic e must be pe rforme d by your auth ori zed P ol aris d ealer . Tir e T read Depth Always rep lace ti res when t read depth is worn to 1/8 ″ ( .3 cm) or less. See illustr ation. W ARNING Ope[...]

79 MAINTENANCE Drive Chain Polaris A TV drive chains are e quipped with o-ring-se aled, perma nently greased pin s an d rol l ers. Ho wever, the o ut er su rfaces o f th e rol ler m us t be lubrica ted. Always inspec t the drive cha in prior to opera ting the vehicle . C heck f or damage d or missing o-r ings or damaged r ollers. Also che ck for co[...]

80 MAINTENANCE Drive Chain Rear Dr ive Cha in Slack CAUTION Adjust ing or operat ing t he A T V wit h improper rear drive c hain slack can result in severe dam age to t he t ransm ission and dr ive component s. Always m ake sur e the s lack is within t he stat ed specif icat ions. Check the amount of c hain slack in thr ee dif fere nt locations by [...]

81 MAINTENANCE Drive Chain Rear Dr ive Cha in Slack 6. Rol l t he A TV forward o r backward to adjust the c hain slac k to the proper te nsion. See the illustration for prope r splice link clip opening position (1). 7. T igh ten the eccen tr ic l ock in g bo lt s to 30 ft. lbs. (41 Nm) for mac hines without the hitch a nd 45 ft. lbs. (61 Nm) for ma[...]

82 MAINTENANCE Lights Whe n servicing a halogen la mp, don’t touch the la mp with bare finger s. Oil from your skin leav es a re sidue, cau sing a hot spot that will shorten the life of the la mp. W ARNING Poor light ing while driv ing can result in sever e injury or death. Headlight and t aillight lens es becom e dirt y during nor mal operation.[...]

83 MAINTENANCE Lights T ailligh t/Brakelight Lamp Replacement If the taillight/bra kelight does not work the lamp may ne ed to be replaced . 1. Re move the taillight lens cover mounting scre ws. Remove the lens cove r and gaske t and set aside for r easse mbly . 2. Re move the lamp (1). 3. Apply diele ctric gre ase to the sock et and i nst al l th [...]

84 MAINTENANCE Air Filter 1. Rem ov e th e seat , release t he clips, and remove the a ir box cover . 2. Loose n the cla mp and remove the filte r . 3. I f equipped, remove the fa bric type pre- filter (1) f rom the main filter ( 2). W ash the pre- filter in soap y wat er , t hen ri nse and l et dry . Reinsta ll t he pre- filter over the main filte[...]

85 MAINTENANCE Spar k Pl ugs Spar k Plug Recom mendations CAUTION Using non-r ecomm ended spark plugs can result in serious engine damage. Alway s use P olaris- recom mended spar k plugs. Ref er to t he specif icat ions s ect ion beginning on page 104 . Refer to the spec ifications sec tion beginning on page 104 for the rec ommended spa rk plug typ[...]

86 MAINTENANCE Spar k Pl ugs Spark P lug In spection Normal Plug The normal insulator tip is gray , tan or light brown. There will be fe w combustion deposits. The electr odes are not burned or erode d. This indicate s the proper type and heat range f or the engine and the servic e. NOT E: T he tip s hould not be whit e. A whit e insulat or t ip in[...]

87 MAINTENANCE V eh icle I mmers ion CAUTION If your vehic le becomes immers ed, m ajor engine damage c an result if t he machine is not t horoughly ins pect ed. T ake t he vehicle t o your dealer before s tar ting t he engine. If it’ s impossible to take your A TV to a dea ler befor e starting it, follow the steps outlined below . 1. Move the A [...]

88 MAINTENANCE PV T System The basic oper ation of the Polaris PVT system is dependent on engine speed and veh icl e to rqu e requi remen ts . As engi ne s peed increas es, the forc e exerte d on the movable dr ive sheave by the flyweights also incre ases. This, in turn, incre ases the a mount of “pinch ” applied to the drive belt. Similarly , [...]

89 MAINTENANCE PV T System W ARNING Failure t o com ply wit h the ins tr uct ions in t his warning can r esult in sever e injury or death. Do not modify any component of th e PVT syst em. Doing so may reduce it s s tr ength so t hat a failure m ay occ ur at a high speed. The PVT system has been precisio n balanced. Any modificat ion will cause the [...]

90 MAINTENANCE Spar k Ar restor W ARNING Failur e to heed t he following war nings while ser vicing t he spar k arres tor could r esult in s erious injur y or deat h. Do no t pe rform service on the spa rk arrestor while the system is hot. Exhaust syst em tem perat ures ca n reach 1000 ° F . Allow component s t o cool s ufficient ly bef ore proc e[...]

91 MAINTENANCE Batter y Y our A TV ma y have e ither a se aled ba ttery , whic h require s little maintena nce, or a conventiona l batter y . A sea led batter y can be identifie d by its flat cove rs on the top of the batte ry . A conventional batte ry has six fille r ca ps on the top of the ba ttery . Always kee p battery te rminals and c onnectio[...]

92 MAINTENANCE Batter y W ARNING Im properly connecting or disconnect ing bat ter y cables can result in an explosion and c ause ser ious injury or death. When remov ing the bat ter y , always disc onnect the negativ e (black ) cable fir st . W hen reins talling t he bat ter y , alway s connec t t he negative ( black) cable last . Batt ery Remova l[...]

93 MAINTENANCE Batter y Battery Installation Using a new batter y that has not bee n fully char ged ca n damage the batt ery and res ul t i n a shor ter li fe. It can als o hi nder veh icl e perf ormance . F ollow the batte ry cha rging instr uctions on page s 95-97 befo re installing the batter y . 1. E nsure that the batte ry is fully char ged. 2[...]

94 MAINTENANCE Batter y Batter y Stor age Whe never the ve hicle is not used for a period of three months or more, remov e th e bat tery from t he veh icl e, ensu re that it ’ s fu ll y ch arged, an d st ore it o ut o f the su n in a coo l, dry pl ace. C heck b att ery vo lt age each mo nth d uri ng s to rage and rech arge as needed to m ain tai [...]

95 MAINTENANCE Batter y Batter y Flui d (Conventional B attery) A poorly ma intained ba ttery will dete riorate r apidly . Check the batte ry fluid leve l often. Maintain the fluid level be tween the upper and lower level mark s (1). Add only distille d wate r . T ap w ater contains mine rals that ar e harmf ul to a batte ry . Batter y Charging (Co[...]

96 MAINTENANCE Batter y Batter y Charging (S ealed Battery) The following ba ttery ch ar ging instructions a pply only to the ins tal l ati on o f a sealed bat tery . R ead all i ns tru cti on s before pro ceedi ng with the insta llation of this ba ttery . The se aled ba ttery is a lrea dy fille d with elec trolyte a nd has be en sea led and fully [...]

97 MAINTENANCE Batter y Batter y Charging (S ealed Battery) NOT E: Alway s ver ify batt ery c ondition bef ore and 1- 2 hours af t er t he end of c harging. Stat e of Charge Vo l t a g e Action Char ge Ti me* (Us ing cons tant cur rent char ger @ s tandard amps spec ified on top of battery) 100% 12.8- 13.0 volt s None, check at 3 mos. f rom date of[...]

98 MAINTENANCE Cleaning and S tor age See page 107 for the par t numbers of Polaris products. W ashin g the V ehicle Keep ing your A TV clea n will not only improve its appea ranc e but it can a lso extend the life of var ious components. CAUTION High water pressure m ay damage A TV components . Polaris recom mends was hing the v ehicle by hand or [...]

99 MAINTENANCE Cleaning and S tor age W ashin g the V ehicle If a high pressur e wate r system is used f or clea ning (not recomm end ed), exerci se ex trem e caut io n. The wat er m ay dam age components and could remove pain t and decal s. A void d irecting t he wate r stre am at the following items: S Wheel beari ng s S Radiator (if e quipped) S[...]

100 MAINTENANCE Cleaning and S tor age Chr ome W heel Car e (if equipped) Pro per mai nten ance wil l prot ect chro me wheel s from corros io n, preserv e wheel life an d ens ure a ”l ik e new” app earance for many y ears. NOT E: Chrom e wheels expos ed to r oad salt (or salt in the air in coast al areas ) are m ore sus cept ible to c orros ion[...]

101 MAINTENANCE Cleaning and S tor age Sto rag e Tip s See page 107 for the par t numbers of Polaris products. CAUTION Star ting t he engine during t he st orage per iod will dist urb t he prot ecti ve film c reat ed by f ogging and damage could oc cur . Never star t t he engine during t he st orage per iod. Clean t he Exterio r Make any n ecess ar[...]

102 MAINTENANCE Cleaning and S tor age Sto rag e Tip s Flu id Levels Inspec t the fluid leve ls. Add or change fluids as r ecommende d in the Periodic Maintena nce Chart beginning on page 60. S T ransmission fluid S Brak e fluid (c hange e very two ye ars a nd any time the f luid looks dark or conta minated) Fog the Engi ne 1. S upport the front en[...]

103 MAINTENANCE Cleaning and S tor age Sto rag e Tip s Inspe ct and Lubric ate Insp ect al l cables and l ubri cat e all areas of t he v ehi cle as recomm end ed in the Periodic Maintena nce Char t beginning on page 60. Batte ry S torage See page s 94-97 for stora ge and c har ging procedur es. Sto rage Ar ea/Covers Set the tire pressur e and safe [...]

104 SPECIFICA TIO NS 2008 T rail Blazer 330 Capac ities & Dimen sio ns Body Styl e Gen III Dry W e ight 488 lbs . ( 221 kg) Ma ximum W eight Ca pac it y 305 lbs . ( 138 kg) Fro n t Rack C apacity (A ccesso ry ) 30 lbs . ( 14 kg) Rear Rack C ap acity (Accesso ry ) 60 lbs . ( 27 kg) Hitch T ow in g Ratin g (A ccesso ry) 850 lbs .( 386 kg) Un b ra[...]

105 SPECIFICA TIO NS 2008 T rail Blazer 330 Drive S ystem Dri ve Syste m T ype Au to matic P o laris V ariable Transm issio n (P V T) Shif t T ype Side Le ver ( H-N- R) Gea r Reduct ion - Reve rs e 3.05: 1 Gear R edu ctio n - Fo rward 2. 68:1 Fin al D rive (ratio ) 1 1/40 78P Driv e Ch ain 520 O-Ri ng Front T ire s / Pre ss ure 2 3x7 - 1 0/4p s i( [...]

106 SPECIFICA TIO NS 2008 T rail Blazer 330 Jetting Chart Altitu de AMBIENT TEMPERA TURE Below 40 ° F (Bel ow 5 ° C) +40 ° F and above (+5 ° C and above) Meters (Feet ) 0-1800 (0- 6000) 127.5 122. 5 1800-3700 (6000- 12000) 120 11 5 Clutc hing Char t Altitude Shif t Weight Driv e Clutc h Spring Driven Clu tch Spring Helix /Spring Setting Meters [...]

107 POLARIS PRODUCTS Part No. Descri pti on Engine Lubr icant 2870791 Fogging Oi l ( 12 oz. Aer osol) 2876244 PS-4 PLUS Per for mance Synthet ic 2W -50 4-Cycl e Oil ( qt.) 2876245 PS-4 PLUS Per for mance Synthet ic 2W -50 4-Cycl e Oil ( gal.) Gearcase / T ransmi ssion Lubri cants 2873602 Premi um AGL Synt hetic G earcase Lube (qt .) 2873603 Premi u[...]

108 TROUBLE SH OOTING Contact your Polaris dea ler for servic e if you’re una ble to identify solutions using the following c harts. Drive Belt and Cover Pr oblems Possibl e Cause Solut ion Dri ving onto a pic kup or tall trailer in h ig h ran ge Shif t t ra nsm is si on to low ra nge dur ing l oadi ng of t he A TV to pre vent be lt burni ng. Sta[...]

109 TROUBLE SH OOTING Engine Doesn’t T urn Over Possi bl e Cause Sol uti on Tripp ed circuit b reak er Reset th e b reaker Lo w b attery v o ltage Re cha r ge ba tte ry t o 12.8 VDC Loose ba tte ry conne ct ions Ch eck all con n ectio ns and tig h ten Loose s olenoi d conne cti ons Ch eck all con n ectio ns and tig h ten Engine T urns Over , Fail[...]

11 0 TROUBLE SH OOTING Engine Backfires Possi bl e Cause Sol uti on W eak s park f rom s park pl ugs In sp ect, clean and /o r replace spark p lu g s Inco rrect spark p lu g g ap o r heat rang e Set ga p to s pec s or re plac e pl ugs Old or non- re comme nded fue l Repl ac e wit h new fuel Inco rrectly in stalled sp ark plu g w ires Se e your Pola[...]

111 TROUBLE SH OOTING Engi ne Stops or Loses Powe r Possi bl e Cause Sol uti on Out of fuel Turn fu el valv e to reserve, refuel Kinke d or plugge d fue l vent l ine Insp ect an d replace W ater p resent in fuel Repl ac e wit h new fuel Ove rus e of choke Insp ect, clean and /o r replace spark p lu g s Foule d or de fec ti ve s par k plugs Insp ect[...]

11 2 WARRANTY LIM ITED W ARRANT Y Pola ri s Sal es I nc. , 2100 Highwa y 55, Medi na, MN 55340, give s a SI X MONTH LI MI TED W ARRANTY on all c omponents of the Pol ar is Al l T er ra in V e hic le ( A TV) aga ins t def ec ts in m at er ia l or workma nshi p. Polar is al so gi ves a one yea r l imi te d war ra nty on t he f ina l dri ve cha in for[...]

11 3 WARRANTY W ARRANTY COVERAGE AND EXCL USIONS: LIMIT A TI ONS OF W ARRANTIES AND REME DIE S ALL IMPLI ED W ARRANTI ES (INCLUDI NG BUT NOT LIMITED TO THE IMPLIED W ARRANTIES OF MERCHANT ABILI TY AND FITNESS FOR A P AR TICULAR PURPOSE) ARE LI MITED IN DURA TI ON T O THE ABOVE SIX MONTH W ARRAN- TY PERIOD. POLARIS FUR THER DISCLAIMS ALL EXPRESS W A[...]

11 4 WARRANTY Exported V ehicles EXCEPT WHERE SPECIFI CALL 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 AUTHORI ZED LOCA- TION. Th is po licy d oes no t app ly to v eh icles that hav e received auth o rizatio n fo r e xpor t fr om Pola ri s[...]

11 5 WARRANTY U.S. A. EP A Emiss io n s L i mit e d W a rran t y Th is Al l T errain V eh icle (A TV ) or O ff Road Utility V eh icle (OR U V) em ission s lim ited warran ty is in add ition to th e Po laris standard lim ited warran ty fo r this veh icle. Po laris w arrants t hat th is v eh icle is; (1 ) d esign ed , b u ilt, an d eq u ip p ed to co[...]

11 6 MAINTENANCE LOG Use th e fol lo wing chart t o reco rd peri od ic m ain tenan ce. DA TE MIL ES ( KM) TECHNI CIAN SERVICE PERFORMED / COMMENTS[...]

11 7 MAINTENANCE LOG DA TE MIL ES ( KM) TECHNI CIAN SERVICE PERFORMED / COMMENTS[...]

11 8 INDEX A Ag e R estriction s 6 ................ Air F ilter 84 ..................... Au x iliary B rak e 37, 7 2 ............ B Bat te ry 91- 97 .................... Bat te ry Cha r ging (Conve nti onal ) 95 .. Bat te ry Cha r ging ( Sea le d) 96-97 ...... Bat te ry Fl uid ( Convent iona l) 95 ..... Battery In stallatio n 93 ............. Bat t[...]

11 9 INDEX N Nois e Emiss ion Contr ol Syst em 59 ... O Oil C hange 67 ................... Oil C h eck 66 .................... Oil R ec omme ndat ions 66 ........... Oil , Engine 66-67 ................. Oil , Tra nsmis sion 68-69 ............ Ope ra tor Sa fe ty 6-25 ............... Ov errid e Sw itch 31 ............... P Park in g Brak e 36 ......[...]