Polaris 9922462 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 pr oper training or instruction. S at speeds too fast for your skills or the conditions. S on public r oads - a collision can occur with another vehicle. S with a passenger - passengers affect balance and steering and incr ease risk of los[...]

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

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 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 T RAIL BLAZER are registered t rade- marks of Polaris Industries Inc. Copyright 2009 Polaris Sales Inc. All inform ation contained within this publication is based on the latest product information at th e time of publication. Due to constant improvements in the design and quality of production compo nents[...]

3 T ABLE OF CONTENTS Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 F eatures and Controls . . . . . . . . . . . . . . . . . . . 20 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 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 haza rd. W ARNING A W ARN ING indicates a hazard[...]

5 INTRODUCTION Failure to follow the warni ngs in this manual can result i n serious injury or death . This Polaris vehi cle is n ot a toy and can be hazardous to op erate. A collision or rollover can occur q uickly , e ven during routine maneuvers, if you fail to take proper precaution s. Read and understand your owner's manual and all warnin[...]

6 INTRODUCTION V ehicle Identification Numbers Record your vehicle's identificatio n numbers and key number in the spaces provided. Remove the spare key and store it in a safe place. An ignition key can be duplicated only by ordering a Polaris key blank (using yo ur key number) and matin g it with one of your existing keys. The ignition switch[...]

7 SAFETY Failure to ope rate the vehicle properly can result 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 the OPERA TION section of the owner ’ s manual for proper operati ng procedures. Equipment Modifications [...]

8 SAFETY Safe Riding Gear Always wear appropriate clothing when riding a Polaris vehicle. W ea r protective clothing fo r comfort and 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 helm[...]

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

10 SAFETY Operator Safety Read and understand all warnings, cautio ns and operating p rocedures in this manual and on the safety labels before operating the vehicle. Never operate this vehicle without proper instruction. T a ke a training cou rse. Beginners should receive training from a certified instructor . Contact an authorized Polaris dealer o[...]

11 SAFETY Operator Safety Always wear an approved helmet that fits properly . W ear eye protection (goggles or face shield), gloves, boots, lo ng sleeves and long pan ts . Never consume alcohol or dr ugs before or while operating this vehicle. Never operate at excessive speeds. T ravel and turn at speeds appropriate for the terrain, visibility , op[...]

12 SAFETY Operator Safety Always inspect your Pola ris vehicle before each use to verify that it's in safe operating condition. Follow the inspection and ma intenance procedures outlined in this manual. See page 31 . Keep both h ands on the handlebars. Keep your feet on th e footrest s. Always travel slowly when ope rating on unfamiliar terra [...]

13 SAFETY Operator Safety If the vehicle has been involved in an accident, always have an au thorized Polaris deale r inspect the enti re vehicle for possible damage, i ncluding (but not limited to) brake, thro ttle and steering systems. Never operate on hills too steep for the vehi cle or for your abilities. Practice on smalle r hills before attem[...]

14 SAFETY Operator Safety Always follow the procedures outl ined in this manual for opera ting over obstacles. See p age 42. Always follow the pro cedures outlined in this manual for o perating on slippery or loose surfaces. Use extra ca ution. Always avoid skid ding or sliding . See page 36. Always follow the procedures ou tlined i n this manual f[...]

15 SAFETY Operator Safety Never exceed the stated load cap acity fo r your vehicle. Carg o must be properly distributed and securely attached. Reduce spee d and follow the instructi ons in this manual for carrying cargo or towing. Allow a greater distance for braking. Never operate this vehicle on a frozen body of wa ter . Always remove the ignitio[...]

16 SAFETY Safety Labels and Locations W arning labe ls have been plac ed 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 dif fer from the la bels on your vehicle , always read and follow the instructio ns of the labels on the vehicle. If an informational or g[...]

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 l ow speeds. 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 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 (T rail Boss) W ARNING Improper tire pressure or overlo ading ca n cause loss of control. Loss of control can result in severe in[...]

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

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 eng ine 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 of f all electri[...]

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 also flash. Return the t[...]

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 wheneve r the main swi tch (key) is on. T urn the key off [...]

23 FEA TURES AND CONTROLS Throttle Lever Press the throttle lever to increase e ngine speed and vehicle movement. Release the lever to reduce engine speed and vehicle movement . Failure to check or ma intain proper operation of the th rottle system can resul t in an accident if the throttle lever sticks during operati on. Check the lever for proper[...]

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

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 lo ck key an d turn it clockwise. 3. Remove the key . 4. Rever[...]

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 outdoo rs or in a well ventilated area. Refuel on a level surface. Remove the fuel tank cap to add fuel [...]

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 th e vehi[...]

29 FEA TURES AND CONTROLS Recoil St arter If the battery is too weak to start the engin e, use the rec oil starter . Follow the starting procedures on page 32, cran king the en gine with the recoil starter instead of the main key switc h. 1. Grasp the recoil starte r rope handle tightly . 2. Pull slowly so you can feel the engine strokes. Tip : The[...]

30 OPERA TION Break-In Period The break-in p eriod for your new Polaris vehicle is the first ten hou rs of operation, or the time it takes to use the first two full ta nks of gasoline. No single action on your part will in crease the life an d per formance of your vehicle mo re than following the procedures fo r a proper break-in. Careful treatment[...]

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 br ake. Tip : The starter interlock will preven [...]

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 t he starter . Acti vate the starter for a maximum of five seconds, re le asing the key when the engine starts. 9. If the engine does not start, release the starter and wait five seconds. 10. Repeat step[...]

34 OPERA TION Driving Procedures 1. W ear a helmet and eye protection. See page 8. 2. Sit upright. Keep your fe et on th e footrests. K eep 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 determine your path of travel. 6. Release the parking brake. 7. [...]

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. S teer in the direction of the turn, leaning your upper body to the in side of the turn while sup- porting your weight o n the outer foot[...]

36 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. Be alert. 4. W atch the trail. 5. A void quick, sharp turns. Ti[...]

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 th e footrests. 7. Drive at a steady rate of speed t o av[...]

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 footres[...]

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. S top the vehicle. Keep your weight uphill. 2. Lock the parking brake. Leave th e transmission in forward gear . T urn the engine of f. 3. Dismount on the uphill side of the ve hi cle, or on t[...]

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

42 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 and use extra cau tion when operating on unfamilia[...]

43 OPERA TION Driving in Reverse Follow these precautions when operating in reve rse: 1. Always check for obstacles or people behind the vehicle. 2. Always avoid ba cking downhill. 3. Back slowly . 4. Apply the brakes lightly for stopping. 5. A void turning at 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 br ake. 4. Always block the rear wh eels on the downhill side. 5. T urn the fuel valve off. 25 ° maximum[...]

45 OPERA TION Hauling Cargo Overloading the vehicle or ca rrying or tow ing 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 p recautions when hauling ca rgo: REDUCE SPEED AND ALLOW GREA TER DIST ANCES FOR BRAKING WHEN HAULING CARGO. [...]

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 a s low as possible on the rear rack. On the T rail Boss model, carg o weight sho[...]

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 approved O FF-ROAD ONL Y . Do not exceed the maximum capacities when tow ing. 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 requirements. S p ark Arrestor Y our Polaris vehicle has a spark arrestor that was de signed for on-road and of f-road operation. It is required that this spark ar restor [...]

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

50 MAINTENANCE Periodic Maintenance Chart Improperly performing the procedures marked with a  could result in component failure an d cause an accident, which ma y result in seri ous 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 subjec[...]

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 Chart 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 needed[...]

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 thi s 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 [...]

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 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[...]

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

57 MAINTENANCE T r ansmission 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. [...]

58 MAINTENANCE Brake Fluid Check brake fluid levels for both brake systems before each ride. Always maintain brake fluid at th e recommended lev el. Do not overfil l. The brakes should feel firm when they're applied. Spongy or weak brakes may i ndicate a fluid leak or low fluid level. A low fluid level may also mean that brake pads are wo rn a[...]

59 MAINTENANCE Brake Fluid Hand Brake The master cylinder is located on the l eft handle- 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 operat- 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 Removal Tip : Side panel removal may b e difficult until the locking tabs and rece ivers have been snapped and unsnapped a few times. 1. Remove the seat. 2. Remove the push-pins at the front and rear of the side panel. 3. Grasp the rear of the side panel near the rear cab. Pull the panel slightly outward, downward and rear[...]

62 MAINTENANCE Handlebars The handlebars can be adjusted for rider preference. Improper adjustment of th e handlebars or inco rrect torquing of the adjuster block tightening b olts can cause limite d steering or loosen i ng of the ha ndlebars, resulting in loss of control. Follow the adjustment procedures exactly , or see your Polaris dealer for se[...]

63 MAINTENANCE T oe Alignment Do not attempt to adjust ti e rod alignment. All tie rod adjustments should be performed by an authorized Polaris deal er . 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 stra[...]

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 slide it far enough to expose the end of the inline cable adjuster . 3. Loosen the adjuster lock nut. 4. Rotate the boot to turn the adjuster until 1/16" t[...]

65 MAINTENANCE S teering Assembly The steering assemb ly of the A TV should be checked period ically for loose nuts and bo lts. If loose nuts and bolts are found, see your Polaris dealer for service before ope rating the v ehicle. Camber and Caster The camber and caster are non-adjustable. Rear S pring The rear shock absorber spring is adjusted by [...]

66 MAINTENANCE Ti r e s Operating your veh icle with worn tires, impr operly infl ated tires, non-standard tires or improperly installed tires will affect vehicle handling and could cause an accident. • Maintain proper tire pressure as described on th e label on your vehicle an d in the specifications sectio n of the owner's manual. • 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 Spe cification F ront Wheel Nuts 27 ft. lbs. (37 Nm) Rear Wheel Nuts 50 ft. lbs. (68 Nm) Rear 50 ft. lbs. (68 Nm) 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 a sh the pre-filter in soapy water , then rinse and let dry . 5. Reinstall the pre-filter over the main filter . Install a new ma[...]

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

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 highe r . Above 1800 me ters the engine air/fuel mixture becomes too rich and the engine lo ses approximately 3% of its powe r for each 300 meter incr ease in eleva[...]

72 MAINTENANCE Drive Chain Drive Chain Lubrication The drive ch ains are equipp ed with o-ring-sealed, permanently greased pins and rollers. Howe ver , 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 dif ferent locations by moving the vehicle slightly forward to gain slack at the top side of the rear chain. Measure the chain slack at th e tightest of the three positions. At this point the chain should have 3/16" -3/8" (5 mm - 10 mm) deflection. [...]

74 MAINTENANCE Drive Chain Rear Drive Chain Slack 6. Roll the vehicle forward or back- ward to adjust the chain slac k 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 hi[...]

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 br ake. 4. Measure t[...]

76 MAINTENANCE Light s Poor lighting can result in loss of control or an accident. Lights become dirty during normal operation. W ash the headlights and taillights frequently . Hot component s can cause burns to skin. Allow lamp s to cool b efore servicing. Headlamp Replacement When servicing a halogen lamp, do not touch the lamp with bare fingers.[...]

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 l amp out of the indicator panel hou sing. 4. Insert[...]

78 MAINTENANCE Spar k P l ug s S p ark Plug Recommendations Refer to the specifi cations section beginning on page 102 for the recom- mended spark pl ug type and gap for you r vehicle. NOTICE: Using non-recommended spark plugs can result in serious engine damage. Always use Po laris-recommended spark plugs. S p ark Plug Inspection Check the spark p[...]

79 MAINTENANCE Spar k P l ug s S p ark Plug Condition Normal Spar k 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[...]

80 MAINTENANCE V ehicle Immersion If your vehicle bec omes immersed, majo r engine damag e 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 out of th[...]

81 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 combusti ble materials from the area. Wear eye protection and leather work gloves. Do not stand behind or in front of the vehicle wh ile purging. Ne[...]

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

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 P VT Drying There may be some instances w hen 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. S tart the engine. Place[...]

85 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 , a lways connect the negative (black) cable last. Battery electrolyte is poisono us. It contains [...]

86 MAINTENANCE Battery Battery Removal 1. Place the transmission in gear . 2. Lock the parking br ake. 3. Remove the seat. 4. Disconnect the battery hold-down strap. 5. 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 (p[...]

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 ca n also hinder vehicle performance. Follow the battery char ging instructio ns on page 89 before installing the battery . 1. Ensure that the battery is fully char ged. 2. Place the battery in [...]

88 MAINTENANCE Battery Batter y S torage Whenever the vehicle is not used for a period of three months or more, remove the battery from the vehicle, ensure that it's fully char ged, and store it out of the sun in a cool, dry place. Check battery voltage each month during s torage and recha r ge as needed to mainta in a full char ge. Tip : Powe[...]

89 MAINTENANCE Battery Battery Charging (Conventional Battery) 1. Remove the battery from the vehi cle to prevent d amage from leak- ing or spilled ele ctrolyte during cha r ging . See page 86. 2. Char ge the battery with a charging output no lar ger than 1/10 of the battery’ s amp/hr rating. Char ge as needed to ra ise the specific grav- ity to [...]

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 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[...]

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

92 MAINTENANCE Cleaning and S torage W ashing the V ehicle If a high pressure water system is u sed for clea ning (not 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 com[...]

93 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[...]

94 MAINTENANCE Cleaning and S torage Sto r a g e Tips NOTICE: S tarting the engine during the storag e period will disturb the protective film created by fogging and damage could 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 91. Stabilize the [...]

95 MAINTENANCE Cleaning and S torage Sto r a g e Tips Fluid Levels Inspect the fluid levels. Chan ge fluids as reco mmended in th e Periodic Maintenance Chart beg inning on page 49. • Demand drive unit (if equipped) • T ransmission • Brake fluid (change every two years and any time the fluid looks dark or contaminated) F og the Engine 1. T re[...]

96 MAINTENANCE Cleaning and S torage Sto r a g e Tips Inspect and Lubricate Inspect all cables a nd lubricate all areas of the vehicle as recommended in the Periodic Maintenance Chart beginn ing 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 w[...]

97 POLARIS PRODUCTS Part Number Description Engine L ubricant 2870791 Fogging Oil (12 oz. Aerosol) 2876244 PS-4 PLUS Performance Synth e tic 2 W-50 4-Cycle Oil (q t./.95 l ) 2876245 PS-4 PLUS Per formance Synthet ic 2W-5 0 4-Cycle Oil (gal ./3.8 l) Gearcase / T r ansmission Lubrica nt s 2873602 Premium AGL Synthetic Ge arcase Lubricant (qt./.95 l) [...]

98 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 40). 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- tures[...]

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

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 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 Soluti[...]

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

102 SPECIFICA TIONS * Based on EU Directiv e 76/432/EC T rail Boss 330 Maximum W eight Capacity 415 lbs. (188 kg) (includes weight of operator , cargo and accessories) Dry W e ight 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. (33[...]

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

104 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 , car go and accessories) Dry W e ight 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 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/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 e lephone 763-542- 0500 W e, Polar is 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 workma nshi p. This warranty covers the parts and labor char ges for repair or replacement of defective parts which are cove r ed by this warranty . T[...]

108 W A RRANTY W ARRANTY COVERAGE AND EXCLUSIONS: LIMIT A T IONS OF W ARRANTIES AND REMEDIES The Polaris l imited warranty exc ludes any failu res that are not caused by a def ect in material or workmanship. Th is warranty does not cover acci dental damage, normal wear and tear , abuse or improper handling. This wa rranty also does not c over any v[...]

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

110 W A RRANTY ALL IMPLIED W ARRANTIES (INCLUDING BUT NOT LIMITED TO THE IMPLIED W ARRANTIES 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 DISCLAIMS ALL EXPRES S W ARRANTIES NOT ST A TED IN THIS W ARR ANTY . Some states do not allow limi- tations on how[...]

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

112 MAINTENANCE LOG DA TE MILES (K M) OR HOURS TECHNICIAN SERVICE PERFORMED / COMMEN TS[...]

11 3 INDEX A Age Restric tions . . . . . . . . . . . . . . . . . 5 Air Filt er . . . . . . . . . . . . . . . . . . . . . . 69 B Battery . . . . . . . . . . . . . . . . . . . . 85-90 Charging (Convent ional) . . . . . . . 89 Charging (Sealed) . . . . . . . . . 89-90 Fluid (Conventional) . . . . . . . . . . 88 Installat ion . . . . . . . . . . . . . [...]

11 4 INDEX I Idle RPM Adjus tment . . . . . . . . . . . 71 Immersion . . . . . . . . . . . . . . . . . . . . 80 Indicator L ights . . . . . . . . . . . . . . . . 22 J Jetting Chart , Trail Boss . . . . . . . . 103 Jetting Chart, Trai l Blazer . . . . . . . 105 K Key Switch. . . . . . . . . . . . . . . . . . . . 21 K-Turn . . . . . . . . . . . . . .[...]

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