Polaris 330 International manual

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P antone 425 C W ARNING Improper vehicle use can r esult in SEVERE INJUR Y or DEA TH. NEVER operate: S without proper training or instruction. S at speeds too fast for your skills or the conditions. S on public roads - a collision can occur with another vehicle. S with a passenger - passengers affect balance and steering and increase risk of losing[...]

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

1 WELCOME Thank you for purchasin g a Polaris vehicle, and welcome to our world- wide family of Polaris owners. W e proudly produce an exciting line of utility and recreati onal products. • Snowmobiles • All-terrain vehicles (A TVs) • RANGER ® utility vehicles • V ictory Motorcycles ® Always follow the instructions and recommendations in [...]

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

3 T ABLE OF CONTENTS Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 F eatures and Controls . . . . . . . . . . . . . . . . . . . 20 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Emission Control Systems . . . . . . . . . . . .[...]

4 INTRODUCTION The following signal words and symbol s appear throughout th is manual and on your vehicle. Y our safety is involved when these words and sym- bols are used. Become familiar with their meanings before reading the manual. The safety alert symb ol indicates a potential personal inju ry hazard. W ARNING A W ARN ING indicates a hazardous[...]

5 INTRODUCTION Failure to follow the warnings in this manu al can result in serious injury or dea th. This Polaris vehicl e is not a toy and can be hazardo us to operate. A collision or rollover can occur quickly , even during routine maneuvers, if you fail to take proper precautions. Read and understand your owner's manual and all warnings be[...]

6 INTRODUCTION V ehicle Identification Numbers Record your vehicle's identificatio n numbers and key numb er in the spaces provided. Remove the spare key and store it in a safe place. An ignition key can be duplicated only by ordering a Polaris key blank (using your k ey number) and mating it wi th one of your existi ng keys. The ignition swit[...]

7 SAFETY Failure to operate the vehicle properly can result in a collision, loss of control, accident or overturn, which may result i n serious injury or death. Heed all safety warnings outlined in this section of the owner ’ s manual. See the OPERA TION section of the owner ’s manual for proper operating procedures. Equipment Modifications W e[...]

8 SAFETY Safe Riding Gear Always wear appropriate clothing when riding a Polaris vehicle. W ear protective clothing for comfort an d to reduce the chance 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 helmet[...]

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 goggles o r use a shatterproof helmet face shield. Po laris recommends wearing approved Personal Prot ective Equi pment (PPE ) bearing markings such as VESC 8, V -8, Z87.1, or CE. Make [...]

10 SAFETY Operator Safety Read and understand all warnings, cautions and operating procedu res in this man ual and on the safety labels before operatin g the vehicle. Never operate this vehicle without proper instruction. T ake a training course. Beginners should receive training from a certified instructor . Contact an authorized Polaris dealer or[...]

11 SAFETY Operator Safety Always wear an approved helmet that fits properly . Wear eye protection (goggles or face shield), gloves, boots, long sleeve s and long pan ts. Never consume alcohol or drugs before or while operating this vehicle. Never operate at excessive speeds. Travel and turn at speeds appropriate for the terrain, visibility , operat[...]

12 SAFETY Operator Safety Always inspect your Pola ris vehicle befo re each use to verify that it's in safe operating condition. Follow the inspection and mainten ance procedures outlined in this manual. See page 31 . Keep both hands on the handl ebars. Keep your feet on the foot rests. Always travel slowly when operating on unfamiliar terrain[...]

13 SAFETY Operator Safety If the vehicle has been involved in an accide nt, always have an authorized Polaris dealer in spect the entire vehicle for possible damage, i ncluding (but not limited to) brake, thro ttle and steering systems. Never operate on hil ls too steep for the vehicle o r for your abilities. Practice on smaller hills before attemp[...]

14 SAFETY Operator Safety Always follow the procedures outlined in this manual for operating over obstacles. See pa ge 42. Always follow the procedure s outlined in this manu al for operating on slippery or loose surfaces. Use extra caution. Always avoid skidding or sliding . See page 36. Always follow the pro cedures outlined in this manual for dr[...]

15 SAFETY Operator Safety Never exceed the stated load capacity fo r your vehicle. Cargo must be properl y distributed and securely attached. Reduce speed and foll ow the instructions in this manual for carrying cargo or towing. Allow a greate r distance for braking. Never operate this vehicle on a frozen body of water . Always remove the ignition [...]

16 SAFETY Safety Labels and Locations W arning labels have been placed on the vehicle for your p rotection. Read and follow the instructions on each label carefully . If any of the labels shown in this ma nual differ from the labels on your vehicle, always read and follow the instructio ns of the labels on the vehicle. If an informational or graphi[...]

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

18 SAFETY Safety Labels and Locations “No Passenger” W arning W ARNING NEVER ride as a passenger . Passengers can cause a lo ss of control, resulti ng in SEVERE INJURY or DEA TH. 7175378 Tire Pressure/Load W arning (T rail Boss) W ARNING Improper tire pressure or overlo ading can cause lo ss of control. Loss of control can result in severe inju[...]

19 SAFETY Safety Labels and Locations Age 16 W arning W ARNING Operating this A TV if you are under the age of 16 increases your chance of severe injury or death. NEVER operate this A TV if you are under age 16. 7175374 Clutch Cover W arning W ARNING • Moving parts hazard under belt-clutch gu ard. T o prevent serious injury , do not operate vehic[...]

20 FEA TURES AND CONTROLS Switches Engine Stop Switch The engine will not start or run when the switch is in the OFF position. OFF RUN Push the stop switch down to stop the engine quickly . Pull the stop switch up to the RUN position before attempt- ing to start the engine. Both the main switch and the engine stop switch will shut off all electrica[...]

21 FEA TURES AND CONTROLS Switches Headlight Switch The lights do not operate unless the main key switch is on and the engine stop switch is in the RUN position. High Beam Low Beam T urn Signal Switch Push the toggle switch either left or right to activate the corre- sponding turn signal light. The indicator on the pod will al so flash. Return the [...]

22 FEA TURES AND CONTROLS Mirrors Use the mirrors to assist in traffic maneuvers. Always check and adjust the mirrors before driving the vehicle. Indicator Light s W ith the engine running, verify the function of all indicator lights before each use of the vehicle. Tip : The taillight is on wh enever the main swi tch (key) is on. Turn the key off t[...]

23 FEA TURES AND CONTROLS Throttle Lever Press the throttle lever to increase engine s peed and vehicle movement. Release the lever to reduce engine speed and vehicle movem ent. Failure to check or maintain proper opera tion of the throttle system can result in an accident if the throttle lever sticks during operation. Check th e lever for proper o[...]

24 FEA TURES AND CONTROLS Brakes Aggressively applying the brakes when backing down a hill may cause rear tipover . Aggressively applyin g the brakes while moving forward may cause the rear wheels to skid and result in loss of control. Read this owner's manua l and understand the operation of all brake systems on this vehicle. Always use cauti[...]

25 FEA TURES AND CONTROLS Brakes 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 parking brake lock, squeeze and release the brak e [...]

26 FEA TURES AND CONTROLS S teering Lock Lock the steering to prevent unauthor ized use or theft of the vehicle. Tip : Place the steering lock keys in a safe place. The lock must be replaced if the keys are lost. 1. T urn the handlebars to the full left position. 2. Insert the steeri ng lock key and turn it clockwise. 3. Remove the key . 4. Reverse[...]

27 FEA TURES AND CONTROLS Choke The choke assists in starting a cold engine. Refer to the engine start- ing procedure on page 32 for cor- rect choke and throttle settings during starting. Fuel T ank Cap Always refuel with the engine stopped, and outdoors or in a well ventilated area. Refuel on a level surface. Remove the fuel tank cap to add fuel t[...]

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

29 FEA TURES AND CONTROLS Recoil St arter If the battery is too weak to start the engine , use the recoil starter . Follow the starting procedures on page 32, cranking the engine with the recoil starter instead of the main key switch. 1. Grasp the recoil starter rope handle tightly . 2. Pull slowly so you can feel the engine strokes. Tip : The rope[...]

30 OPERA TION Break-In Period The break-in period for your new Polaris vehicle is the first ten hours of operation, or the time it takes to use the first two full ta nk s of gasoline. No single action on your part will in crease the life an d performance of your vehicle more than fo llowing the procedure s for a proper break-in. Careful treatment o[...]

31 OPERA TION Pre-Ride Checklist Failure to inspect and verify that th e vehicle is in safe operating condi- tion before operating increases the risk of an accident. Always inspect the vehicle before each use to make sure it's in safe operating condition. Item Remarks P age Hand brake Ensure proper operation 24 Brake fluid Ensure proper level [...]

32 OPERA TION S t arting the Engine Engine exhaust contains poisonous carbon monoxide and can cause loss of consciousness resulting in severe injury or death. Never run an engine in an enclosed area. 1. Position the vehicle on a level surface. 2. Place the transmission in neutral. 3. Lock the parking brake. Tip : The starter interlock will prevent [...]

33 OPERA TION S t arting the Engine 8. Do not press the throttle while st arting the engine. T urn the ignition key past the ON position to engage the star ter . Activate the starter for a maximum of five seconds, re leasing the key when the engine starts. 9. If the engine does not start, release the starter and wait five seconds. 10. Repeat steps [...]

34 OPERA TION Driving Procedures 1. W ear a helmet and eye protection. See page 8. 2. Sit upright. Kee p your feet on th e footrests. Keep both hands on the handlebars. 3. Star t the engine and allow it to warm up. 4. Shift the transmission into gear . 5. Check your surroun dings and determine your path of travel. 6. Release the parking brake. 7. S[...]

35 OPERA TION T urning the V ehicle 1. Before turning, activate a turn signal to alert oth- ers of your intentions. Activate the left signal before a left turn. Acti- vate the right signal before a right turn. 2. Steer i n the direction of the turn, leaning your upper body to the inside of the turn while sup- porting your weight on the outer footre[...]

36 OPERA TION Driving on Slippery Surfaces Whenever riding on slippery surfaces such as wet trails or loose gravel, or during freezing weather , follow these precau tions: 1. Do not operate on excessively ro ugh, slippery or loose terrain. 2. Slow down when entering slippery areas. 3. Be alert. 4. W atch the trail. 5. A void quick, sharp turns. Tip[...]

37 OPERA TION Driving Uphill Whenever traveling uphill, follow these pre- cautions: 1. A void steep hills (25 ° maximum). 2. Check the terrain carefully . 3. A void hills with excessively slippery or loose surfaces. 4. Shift your weight uphill. 5. Drive straight uphill. 6. Keep your feet on the footrests. 7. Drive at a steady rate of speed to avoi[...]

38 OPERA TION Driving on a Sidehill (Sidehilling) A void crossing the side of a hill (sid ehilling) if possible. If sidehilling is necessary , follow these precautions: 1. Slow down. 2. A void hills with excessively slippery or loose surfaces. 3. A void crossing the sides of steep hills. 4. Shift your weight uphill. 5. Keep your feet on the fo otre[...]

39 OPERA TION Driving Downhill When driving downhill, follow these precautions: 1. Check the terrain carefully . 2. A void hills with excessively slippery or loose surfaces. 3. Never drive downhill at high speed. 4. Slow down. 5. A void driving downhill at an angl e, which can cause the vehicle to pitch sharply to one side. Drive straight downhill.[...]

40 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. Stop the vehicle. Keep your weight uphill. 2. Lock the parking brake. Leave th e transmission in forward gear . T urn the engine off. 3. Dismount on the uphill side of the ve hicle, or on the [...]

41 OPERA TION Driving Through W ater Y our Polaris vehicle can operate through water with a maximum recomm ended depth equal to the bottom of the footrests. Follow these procedures when operating through water: 1. Determine water depths and current before entering water . 2. Choose a crossing where both banks have gradual inclines. 3. A void operat[...]

42 OPERA TION Driving Over Obst acles Follow these precautions whe n operating over obstacles: 1. Always check for obstacles before operating in a new area. 2. Look ahead and learn to read the terrain. Be constantly alert for haz- ards such as logs, rocks and low hanging branches. 3. T ravel slowly and use extra cau tion when operating on unfamilia[...]

43 OPERA TION Driving in Reverse Follow these precautions w hen operating in reverse: 1. Always check for obstacles or people behind the vehicle. 2. Always avoid backing downhill. 3. Back slowly . 4. Apply the bra kes lightly for stopping. 5. A void turning at sharp angles. 6. Never open the throttle suddenly . 7. Do not use the override switch unl[...]

44 OPERA TION Parking on an Incline A void parking on an incline if possible. If it's unavoidable, follow these precautions: 1. S top the engine. 2. Place the transmission in gear . 3. Lock the parking brake. 4. Always block the rear wheels on the do wnhill side. 5. T urn the fuel valve off. 25 ° maximum[...]

45 OPERA TION Hauling Cargo Overloading the vehi cle or carrying or towing cargo i mproperly can al ter vehicle handling and may cause loss of control or brake instability , which can result in serious injury or death. Always follo w these precaution s when hauling cargo: REDUCE SPEED AND ALLOW GREA TER DIST ANCES FOR BRAKING WHEN HAULING CARGO. NE[...]

46 OPERA TION Hauling Cargo Load Distribution Read and understand the load distri bution warnings lis ted on warning labels. Never exceed the specified weights. Never carry car go on the fr ont of the T rail Blazer model. Cargo should be evenly distributed and mounted as low as possible on the rear ra ck. On the T rail Boss model, cargo weight shou[...]

47 OPERA TION Hauling Cargo T owing Loads Some models are equipped with a h itch. Accessory hitch kits are avail- able for other models. T owing is a pproved OFF-ROAD ONL Y . Do not exceed the maximum capacities when towing. Do not tow an y trailer on a grade steeper than 15 ° . Always attach a towed load to the hitch point. Remove the hitch when [...]

48 EMISSION CONTROL SYSTEMS Noise Emission Control System Do not modify the engine, intake or exhaust components, as doing so may affect compliance with gover nmental noise level requi rements. S p ark A rrestor Y our Polaris vehicle has a spa rk arrestor that was designed for on-road and off-road operation. It is required that this spark arrestor [...]

49 MAINTENANCE Periodic Maintenance Chart Careful periodic maintenance will help keep your vehicle in the safest, most reliable condition. Inspection, adjustment and lubrication of important components are explained in the periodic main tenance chart . Inspect, clean, lubricate, adjust and replace parts as necessary . When inspection reveals the ne[...]

50 MAINTENANCE Periodic Maintenance Chart Improperly performing the p rocedures marked with a  could result in component failure and ca use an accident, which may result in seri ous injury or death. Always have an authorized Pola ris dealer perform these services. Maintenance Chart Key X Perform these operations more of ten for vehicles subjecte[...]

51 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) Battery 20 H Monthly 200 (320) Check terminals; clean; test [...]

52 MAINTENANCE Periodic Maintenance Chart Item Maintenance Interval (whichever comes first) Remarks Hours Calendar Miles (Km) X Engine mounts 100 H 12 M 1000 (1600) Inspect Exhaust muffler/ pipe 100 H 12 M 1000 (1600) Inspect Q E Spark plug 100 H 12 M 1000 (1600) Inspect; replace as needed Q E Ignition Timing 100 H 12 M 1000 (1600) Inspect X Wiring[...]

53 MAINTENANCE Lubrication Guide Check and lubricate all components at the intervals outlined in the Peri- odic Maintenance Ch art beginning on page 49. Items not listed in the chart should be lubricated at the General Lubrication interval. The a-arms and lower control arms are lubricated at the factory , and no additional lubrication will be neede[...]

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

55 MAINTENANCE Engine Oil Oil and Filter Change Always change the oil and filter at th e intervals outlined in the Periodic Maintenance Chart beginning on page 49. Always change the oil filter whenever changing oil. 1. Position the vehicle on a level su rface. Place the tr ansmission in neutral. Lock the parking brake. 2. Clean the area around the [...]

56 MAINTENANCE T ransmission Oil Always check and change the transmission oil at the intervals outlined in the Periodic Maintenance Char t beginning on page 49. Polaris recommends the use of Polaris Pr emium AGL Synthetic Gearcase Lube. See page 97 for the part numbers of Polaris products. T ransmission Oil Recommendations Oil Check The dipstick is[...]

57 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 drai n plug and w ipe the magnetic end clean to remove accumulated metallic filings. 6. [...]

58 MAINTENANCE Brake Fluid Check brake fluid levels for both brake systems before each ride. Always maintain brake fluid at the recommended level. Do not overfill. The brakes should feel firm when they're applied. Spongy or weak brakes may indi cate a fluid leak or low fluid level. A lo w fluid level may also mean that brake pads are wo rn and[...]

59 MAINTENANCE Brake Fluid Hand Brake The master cylinder is located on the left hand le- bar . Maintain the fluid level 6 mm below the top edge of the master cylin- der . Do not overfill. 1. Position the vehicle on a level surf ace. Make sure th e handlebars are straight. 2. V iew the fluid level through the indicator window (eye) on the top of th[...]

60 MAINTENANCE Brakes The front and rear brakes are hydraulic disc brakes. Both brake systems are self-adjusting. Brake Inspections Perform the following checks to keep the brake systems in good op erat- ing condition. Check more often if brakes are used heavily under normal operation. 1. Always keep brake fluid at an adequate level. See page 58. 2[...]

61 MAINTENANCE Side Panel Re moval Tip : Side panel removal may be difficult until the l ocking tabs and receivers have been snapped and unsnap ped a few times. 1. Remove the seat. 2. Remove the push-pin s at the front and rear of the side pan el. 3. Grasp the rear of the side panel near the rea r cab. Pull the panel slightly outward, downward and [...]

62 MAINTENANCE Handlebars The handlebars can be adjusted for rider preference. Improper adjustment of the hand lebars or incorrect torqui ng of the adjuster block tightening bolts can cause li mited steering or l ooseni ng of the ha ndlebars, resulting in loss of control. Follow the adjustment procedures exactly , or see your Polaris dealer for ser[...]

63 MAINTENANCE T oe Alignment Do not attempt to adjust tie rod ali gnment. All tie rod adjustments should be performed by an authorized Polaris dealer . Use the following procedure to check the toe alignment of the vehicle. The recommended toe alignm ent is 3-6 mm toe out. 1. Position the vehicle on a level surface. 2. Set the handlebars in a strai[...]

64 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 sli de it far enough to ex pose the end of the inline cable adjuster . 3. Loosen the adjuster lock nut. 4. Rotate the boot to turn the adjuster until 1/16"[...]

65 MAINTENANCE S teering Assembly The steering assembly o f the A TV should be che cked periodically for loose nuts and bolts. If loose nu ts and bolts are found, see your Polaris dealer for service before operati ng the vehicl e. Camber and Caster The camber and caster are non-adjustable. Rear Spring The rear shock absorber spring is adjusted by r[...]

66 MAINTENANCE Ti r e s Operating your vehicle with worn tires, i mproperly infl ated tires, no n-standard tires or improperly installed tires will affect vehicle handling and could cause an accident. • Maintain proper tire pressure as described on the lab el on your vehicle and in the specifications sectio n of the owner's manu al. • Use [...]

67 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 . Do not service axle nuts that have a cotter pin installed. See your Polaris dealer . 3. Place a suitable stand under the footrest frame to raise the wheel slightly off the g[...]

68 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) F ront 27 ft. lbs. (37 Nm)[...]

69 MAINTENANCE Air Filter 1. Remove the seat. 2. Release the air box cover clips, and remove the air box cover . 3. Loosen the clamp and remove the filter . 4. Remove the fabric type pre-fil- ter from the main filter . W ash the pre-filter in soapy water , then rinse and let dry . 5. Reinstall the pre-filter over the main filter . Install a new mai[...]

70 MAINTENANCE Recoil Housing Always drain the recoil housing after operating the vehicle in wet condi- tions. Drain the housing 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.[...]

71 MAINTENANCE Carburetor Y our Polaris vehicle is calibrated at the factory for optimal performance at altitudes ranging from zero to 1800 meters and at temperatures of 4 degrees C. or higher . Ab ove 1800 me ters the engine air/fuel mixture becomes too rich and the engine lo ses approximately 3% of its power for each 300 meter increase in elevati[...]

72 MAINTENANCE Drive Chain Drive Chain Lubrication The drive chai ns are equipped wit h o-ring-sealed, permanently greased pins and rollers. Howeve r , the outer surfaces of the roller must be lubri- cated. Always inspect the drive chain prior to operating the vehicle. Check for damaged or missing o-rings or dama ged rollers. Also check for correct[...]

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

74 MAINTENANCE Drive Chain Rear Drive Chain Slack 6. Roll the vehicle forward or back- ward to adjust the chain slack to the proper tension. See the illustration for proper splice link clip opening position. 7. 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 hitc[...]

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

76 MAINTENANCE Light s Poor lighting can result in loss of control or an accident. Lights become dirty during normal operation. Wash the headlights and t aillights frequently . Hot components can caus e burns to skin. Allow lamps to cool before servicing. Headlamp Replacement When servicing a halogen lamp, do not touch the lamp with bare fingers. O[...]

77 MAINTENANCE Light s Indicator Lamp Replacement 1. Remove the instrument panel, if necessary , to access the back of the indicator panel. 2. Using a small, straight-blade scre wdriver , turn the base of the bulb 1/4 turn counterclockwise. 3. Using a needle-nose pliers or sim ilar tool, pull the lamp out of the indicator panel housing . 4. Insert [...]

78 MAINTENANCE Spar k P l ug s Sp ark Plug Recommendations Refer to the specifications sect ion beginning on page 1 02 for the recom- mended spark plug ty pe and gap for your vehicle. NOTICE: Using non-recommended spark plugs can result in serious engine damage. Always use Polaris-recommended spark plugs. Sp ark Plug Inspection Check the spark plug[...]

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

80 MAINTENANCE V ehicle Immersion If your vehicle becomes imm ersed, major engine da mage can result if the machine is not thoroughly inspecte d. T ake the vehicle to your dealer before starting the engine. If it's impossible to take your vehicle to a dealer before starting it, fol- low the steps outlined below . 1. Move the vehicle o ut of th[...]

81 MAINTENANCE S p ark A rrestor Failure to heed the following warnings whil e servicing the spark arrestor could result in serious injury or death. Ne ver run the engine in an enclosed area. Remove any combustible materials from the area. Wear eye protec tion and leather work gloves. Do not stand behind or in fro nt of the vehicle while purging. N[...]

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

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

84 MAINTENANCE P VT System PVT Drying There may be some instances when wate r is accidently ingested into the PVT system. Use the following instructions to dry it out before operat- ing. 1. Move the vehicle out of the water . 2. Remove the PVT drain plug. Allo w the water to drain completely . Reinstall the drain plug. 3. Start the engine. Place th[...]

85 MAINTENANCE Battery Improperly connecting or disconnecting battery ca bles can result in an explosio n and cause serious injury or death. When removing the battery , always disconnect the negative (black) cable first. When reinstalling the battery , always connect the negative (black) cable last. Battery electrolyte is poisonous. It contains sul[...]

86 MAINTENANCE Battery Battery Removal 1. Place the transmission in gear . 2. Lock the parking brake. 3. Remove the seat. 4. Disconnect the battery hold-down strap. 5. Remove the battery cover (if equipped). 6. On conventional batteries, re move the battery vent tube. 7. Disconnect the black (negative) battery cable first. 8. Disconnect the red (po[...]

87 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 can also hinder vehicle performance. Follow the battery charging instructio ns on page 89 before installing the battery . 1. Ensure that the battery is fully char ged. 2. Place the battery in th[...]

88 MAINTENANCE Battery Battery S torage Whenever the vehicle is not used for a period of three mo nths or more, remove the battery from the vehicle, ensure that it's fully char ged, and store it out of the sun in a cool, dry place. Check battery voltage each month during storag e and recharge as needed to mainta in a full charge. Tip : Power p[...]

89 MAINTENANCE Battery Battery Charging (Conventional Battery) 1. Remove the battery from the vehi cle to prevent damage from leak- ing or spilled electroly te during charging. See page 86. 2. Charge 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 1.270 o[...]

90 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 Time (Using constant cu rrent charger @ standard amps specifie d on top of batt ery) 100% 12.8-13.0 volts None, check at 3 mos. from date of manufacture None required 75%-10[...]

91 MAINTENANCE Cleaning and St orage W ashing th e V ehicle Keeping your Polaris vehicle clean will not only improve its appearance but it can also extend the life of various comp onents. NOTICE: High water pressure may damage comp onents. Polaris recommends washing the vehicle by hand or with a garden hose, using mild soap. Certain products, inclu[...]

92 MAINTENANCE Cleaning and St orage W ashing the V ehicle If a high pressure water system is u sed for cleaning (not recommended), exercise extreme caution. The wate 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 comes[...]

93 MAINTENANCE Cleaning and St orage 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 years. Chrome wheels exposed to road salt (or salt in the air in coastal areas) are more susceptible to corrosion if not properly cleaned. Clean chro[...]

94 MAINTENANCE Cleaning and St orage Sto r ag e Ti ps NOTICE: S tarting the engine during the storage perio d will disturb the protective film created by fogging and damage could occur . Never start the engine during the storage peri od. Clean the Exterior Make any necessary repairs and clean the vehicle as recommended. Se e page 91. Stabilize the [...]

95 MAINTENANCE Cleaning and St orage Sto r ag e Ti ps Fluid Levels Inspect the fluid levels. Change fluids as recommende d in the Periodic Maintenance Chart beginn ing on page 49. • Demand drive unit (if equipped) • T ransmission • Brake fluid (change every two years and any time the fluid loo ks dark or contaminated) Fog the Engine 1. T reat[...]

96 MAINTENANCE Cleaning and St orage Sto r ag e Ti ps Inspect and Lubricate Inspect all cables and lu bricate all areas of the vehicle as recommended in the Periodic Maintenance Chart beginning on page 49. Battery Storage See pages 88-89 for storage and charging procedures. Storage Area/Covers Set the tire pressure and safely support the vehicle wi[...]

97 POLARIS PRODUCTS Part Number Description Engine Lubr icant 2870791 Fogging Oil (12 oz. Aerosol) 2876244 PS-4 PLUS Performance Synthe tic 2W-50 4-Cycle Oil (qt./.95 l) 2876245 PS-4 PLUS Performa nce Synthetic 2W -50 4-Cycle Oil (gal./3.8 l ) Gearcase / T r ansmission Lubricants 2873602 Premium AGL Synthetic Ge arcase Lubricant (qt./.95 l) 2873603[...]

98 TROUBLESHOOTING Drive Belt Wear/Burn Possible Cause Solution Starting out going up a steep incl ine Use low range (if equipped) or turn around using the K- turn (see page 40). Driving at low RPM or ground speed (3-7 MPH) Drive at a higher speed or use low range (if equipped) more frequently . Insufficient warm-up at low ambient te mpera- tures W[...]

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

100 TROUBLESHOOTING Engine Pings or Knocks Engine Runs Irregularl y , St alls or Misfires Possible Cause Solution Poor quality or low octane fu el Replace with recommended 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 Solution[...]

101 TROUBLESHOOTING Engine Stop 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, clea n a nd/or replace spark plugs Fouled or defective spark plugs Inspec t, clean and/or replace spa[...]

102 SPECIFICA TIONS * Based on EU Directive 76/ 432/EC T rail Boss 330 Maximum W eight Capacity 415 lbs. (188 kg) (includes weight of operator , cargo and accessories) Dry W eight 535 lbs. (243 kg) Fuel Capacity 4 gal. (15.1 l) Engine Oil Capacity 1.9 qts. (1.8 l) (with oil cooler) 1.7 qts. (1.6 l) (oil change only) T ransmission Oil 1 1.3 oz. (335[...]

103 SPECIFICA TIONS Jetting Chart Clutching Chart T rail Boss 330 Driving System T ype Aut omatic PVT (Pola ris V ariable T ransmission) Shift T ype Side Lever (F/N/R) Gear Reduction, Reverse 3.05:1 Gear Reduction, Forward 2.68:1 Drive Ratio, Final 3.64:1 Drive Chain 520 O-Ring T ires/Pressure, Front 23 x 7-10 (4 psi/27.6 kPa) T ires/Pressure, Rear[...]

104 SPECIFICA TIONS * Based on EU Directive 76/ 432/EC T rail Blazer 330 Maximum W eight Capacity 2 75 lbs. (125 kg) (includes weight of opera- tor , cargo and accessories) Dry W eight 496 lbs. (225 kg) Fuel Capacity 4 gal. (15.1 l) Engine Oil Capacity 1.9 qts. (1.8 l) (with oil cooler) 1.7 qts. (1.6 l) (oil change only) T ransmission Oil 1 1.3 oz.[...]

105 SPECIFICA TIONS Jetting Chart Clutching Chart T rail Blazer 330 Driving System T ype Aut omatic PVT (Pola ris V ariable T ransmission) Shift T ype Side Lever (F/N/R) Gear Reduction, Reverse 3.05:1 Gear Reduction, Forward 2.68:1 Drive Ratio, Final 3.64:1 Drive Chain 520 O-Ring T ires/Pressure, Front 23 x 7-10 (4 psi/27.6 kPa) T ires/Pressure, Re[...]

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

107 W ARRANTY LIMITED W ARRANTY Polaris Industries Inc., 2100 Highway 55, Medina, MN 55340, gives a TWO YEAR LIMITED W ARRANTY on all components of th e Polaris vehicle against defects in material or workmanshi p. This warranty covers the parts and labor charges for repair or replacement of defective parts which are cove red by this warranty . This[...]

108 W ARRANTY W ARRANTY COVERAGE AND EXCLUSIONS: LIMIT A TIONS OF W ARRANTIES AND REMEDIE S The Polaris limi ted warranty excludes any failu res that are not caused by a defect in material or workmanship. Th is warranty does not cover acci dental damage, normal wear and tear , abuse or improper handling. This wa rranty also does not c over any vehi[...]

109 W ARRANTY LIMIT A TIONS OF W ARRANTIES AND REMEDIE S This warranty also excludes failures resu lting from improper lubrication; improper engine timing; improper fuel; su r face imperfections caused by external stress, heat, cold or contamination; operator error or abuse; improper component alignment, tension, adjustment or alti tude compensatio[...]

110 W ARRANTY ALL IMPLIED W ARRANTIES (INCLUDING BUT NOT LIMITED TO THE IMPLIED W A RRANTIES OF MERCHANT ABILITY AND FITNESS FOR A P AR- TICULAR PURPOSE) ARE LIMITED IN DURA TION TO THE ABOVE TWO YEAR W ARRANTY PERIOD. POLARIS FUR THER DISCLAIM S ALL EXPRESS W ARRANTIES NOT ST A TED IN THIS W A RR ANTY . Some states do not al low limi- tations on h[...]

111 MAINTENANCE LOG Present this section of your ma nual to your dealer each ti me you r 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 / COMMENTS[...]

112 MAINTENANCE LOG DA TE MILES (KM) OR HOURS TECHNICIAN SERVICE PERFORMED / COMMENTS[...]

11 3 INDEX A Age Restricti ons . . . . . . . . . . . . . . . . . 5 Air Filte r . . . . . . . . . . . . . . . . . . . . . . 69 B Battery . . . . . . . . . . . . . . . . . . . . 85-90 Charging (Conventiona l) . . . . . . . 89 Charging (Sealed) . . . . . . . . . 89-90 Fluid (Conventional) . . . . . . . . . . 88 Installation . . . . . . . . . . . . . .[...]

11 4 INDEX I Idle RPM Adjust ment . . . . . . . . . . . 71 Immersion . . . . . . . . . . . . . . . . . . . . 80 Indicator Lights . . . . . . . . . . . . . . . . 22 J Jetting Chart, Tr ail Boss . . . . . . . . 103 Jetting Chart, Trail Blaz er . . . . . . . 105 K Key Switch. . . . . . . . . . . . . . . . . . . . 21 K-Turn . . . . . . . . . . . . . . [...]

11 5 INDEX S Stop Switch . . . . . . . . . . . . . . . . . . . . 20 Storage . . . . . . . . . . . . . . . . . . . . 91-96 Switches . . . . . . . . . . . . . . . . . . . 20-21 Engine Stop Switc h . . . . . . . . . . . 20 Hazard Swit ch . . . . . . . . . . . . . . . 21 Headlight Switc h . . . . . . . . . . . . . 21 Horn Switch . . . . . . . . . . . .[...]