Polaris TRAIL BLAZER 330 manual

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

1 WELC O ME Thank you f or pur cha sing a Pola ris ve hicle , and welc ome to our wor ld-wide f amily of Polaris owne rs. W e proudly produc e an exc iting line of utility an d re c re a tional pr oducts. S Snowmobiles S All- ter r ain ve hic les ( A TVs) S RANGER utility vehicle s S V ict ory m ot orcy cles W e belie ve Pola ris sets a standa rd o[...]

2 Copyr i ght 2007 Pol a r i s Sa l e s I nc . A ll i nfor mat ion c onta ine d wi t hi n t hi s publ ic at ion i s ba se d on t he la te st pr oduct i nfor ma ti on at t he ti me of publi c a ti on. Due t o c ons ta nt imp ro v emen ts in t he desig n an d qu ality o f pr oduc ti on com ponent s, s ome mi nor d iscrepan cies may resu lt b etw een [...]

3 TABLE OF CONTENTS KNOW YOUR VE HICLE 5 ..................... SA FE TY 6 ................................... FEA TURES AND CONTROL S 31 ............... OPE RA TION 41 .............................. EMI SSION CONTRO L SYSTEM S 59 ............ MAINT E NANCE 60 ........................... SPECIF ICA TIO NS 104 ........................ POLARIS PRODUCT[...]

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5 KNOW YOUR VEHICLE As the operator of the ve hicle, you are re sponsible for your personal saf ety , the saf ety of others, and the prote ction of our environme nt. Read a nd understand your owner ’ s manual, which include s valuable infor mation about all aspec ts of your vehicle , including saf e oper ating proce dures. V ehicl e Identificati [...]

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

7 SA FETY Operator S afety The f ollowing signal wor ds and symbols appe ar throughout this manua l and on your A TV . Y our saf ety is involved whe n these words and symbols ar e used. Beco me fa miliar with their mea nings bef ore re ading the manual. The safet y alert s ymbol , on your vehic le or in t his manual, alert s you t o the pot ent ial[...]

8 SA FETY Operator S afety W ARNING Serious injury or deat h can r esult if you do not f ollow thes e inst ruct ions and pr ocedures , whic h are out lined in fur ther det ail within y our owner ’s manual. S Rea d this manual and a ll l ab els c aref ully , and follow the opera ting proc edure s descr ibed. S Neve r operate a n A TV without prope[...]

9 SA FETY Operator S afety S Alway s have t he A TV i ns pected b y an aut hor ized P ol aris d ealer i f it ’ s been i nvolved i n an accident. S Ne ver ope rate on hills too steep for the A TV or for your a bilities. Pra ctice o n smalle r hills bef ore atte mpting lar ger hills. S Alwa ys follow prope r proce dures for c limbing hills. Check t[...]

10 SA FETY Operator S afety S W et bra kes may ha ve reduc ed stopping ability . T est your br akes a fter lea ving wate r . If ne cessa ry , apply them lightly seve ral time s to allow frict io n to d ry out t he pad s. S Always che ck for obstacles or people be hind the A TV before ope rat- in g in rev erse. When i t’ s s afe to pro ceed in rev[...]

11 SA FETY Operator S afety W ARNING POTENTI AL HAZ ARD Oper ating t his A T V wit hout pr oper inst ruc tion. WHA T CA N HAPPEN The r isk of an acc ident is great ly inc reased if t he operator does not k now how to oper ate t he A T V proper ly in differ ent s ituat ions and on different t ypes of t err ain. HOW T O A VOID THE HAZ ARD Beginning a[...]

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

13 SA FETY Operator S afety W ARNING POTENTI AL HAZ ARD Oper ating t his A T V on public st reet s, r oads or highways. WHA T CA N HAPPEN The A T V c ould collide with anot her v ehicle. HOW T O A VOID THE HAZ ARD Never oper ate t he A T V on any public st reet , road or highway , including dirt and gr avel roads . I n many s tat es it’s illegal [...]

14 SA FETY Operator S afety W ARNING POTENTI AL HAZ ARD Oper ating t he A T V af ter c onsuming alcohol or dr ugs. WHA T CA N HAPPEN Consumpt ion of alcohol and/ or drugs could ser iously aff ect operat or judgment . Reac tion t ime m ay be slower and operat or balance and per cept ion could be affec ted. Consuming alc ohol and/or drugs bef ore or [...]

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

16 SA FETY Operator S afety W ARNING POTENTI AL HAZ ARD Removing hands f rom t he handlebars or f eet fr om t he foot res ts during operat ion. WHA T CA N HAPPEN Removing ev en one hand or f oot c an reduce abilit y t o cont rol t he vehicle or could c ause loss of balance and ejec tion f rom t he A T V . If t he operator ’ s f oot is not firm ly[...]

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

18 SA FETY Operator S afety W ARNING POTENTI AL HAZ ARD Oper ating on ex cess ively s teep hills . WHA T CA N HAPPEN The v ehicle may over tur n. HOW T O A VOID THE HAZ ARD Never oper ate on hills too s teep f or t he A T V or f or y our abilit ies. Never oper ate t he A T V on hills s teeper t han 25 _ . Prac tic e on smaller hills befor e att emp[...]

19 SA FETY Operator S afety W ARNING POTENTI AL HAZ ARD T rav eling downhill improper ly . WHA T CA N HAPPEN Im properly descending a hill could caus e loss of cont rol or overt urn. HOW T O A VOID THE HAZ ARD Always follow pr oper procedur es for t rav eling down hills as des cribed in the owner ’ s manual. NO TE : A spec ial tec hnique is requi[...]

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

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

22 SA FETY Operator S afety W ARNING POTENTI AL HAZ ARD Im properly operat ing over obs tac les. WHA T CA N HAPPEN Oper ating ov er obst acles could c ause loss of cont rol or ov ert urn. HOW T O A VOID THE HAZ ARD Bef ore operat ing in a new ar ea, chec k f or obst acles . Avoid operating ov er lar ge obst acles s uch as r ocks and f allen tr ees [...]

23 SA FETY Operator S afety W ARNING POTENTI AL HAZ ARD Oper ating t he A T V t hrough deep or f ast -f lowing wat er . WHA T CA N HAPPEN T ires m ay float , c ausing loss of t rac tion and loss of c ontr ol, which could lead t o an accident or ov ert urn. HOW T O A VOID THE HAZ ARD Avoid operating t he A T V t hrough deep or f ast -f lowing wat er[...]

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

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

26 SA FETY Fuel Safety W ARNING Gas oline is highly f lamm able and explosiv e under cer tain condit ions. S Always exerc ise ex tr eme caut ion whenever handling gas oline. S Always ref uel with t he engine st opped, and outdoor s or in a well vent ilated ar ea. S Do not s moke or allow open fl ames or s parks in or near t he area where r efueling[...]

1 2 27 SA FETY Safety D ecals and Locations W arning d ecals have been pl aced on the A TV for your protecti on. Read and fo ll ow t he i ns tru cti on s of t he d ecals o n t he A TV carefu ll y . If any of the decals d epicted in t his m anual differ from t he decals on your A T V , alway s read an d fo ll ow t he i ns tru cti ons of t he d ecals[...]

3 28 SA FETY Safety D ecals and Locations Gene r al W arni ng (3) W ARNING Im proper A TV use can r esult i n SEVERE INJUR Y or DEA TH AL WA YS USE AN APPROVED HELMET AND PROTECTIVE GEAR NEVER USE ON PUBLIC ROADS NEVER CARR Y P ASSENGERS NEVER USE WITH DRUGS OR ALCOHOL NEVER operat e: S wit hout proper t rai ning or inst r ucti on S at speeds too f[...]

4 6 5 29 SA FETY Safety D ecals and Locations No P assen ger W arning (4) W ARNING NEVER r ide as a passenger . Passenger s can cause a los s of c o ntro l, re su ltin g in SEVERE INJUR Y or DEA TH. A g e1 6W a r n i n g( 5 ) W ARNING Oper ating thi s A TV if you are under the age of 16 incr eases your chance of severe inj ury or death. NEVER opera[...]

30 SA FETY Safe Riding G ear Always we ar clothing suited to the t ype of r i ding. A TV riding require s spec i a l protec tive clothing for c omfor t and to reduc e the chanc e of injury . 1. Helm et W eari ng a h elm et can prev ent a s evere h ead injury . Whe never r iding a Polaris vehic le, alway s wear a hel m et t hat m eet s or ex ceeds e[...]

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

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

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

34 FEATURE S AND CO NTROLS Br ake Lever W ARNING Oper ating t he A T V wit h a spongy br ake lever c an res ult in los s of braking, which c ould cause an ac cident . Never oper ate t he A T V with a s pongy-f eeling brak e lever . The fro nt and rear b rakes are app li ed by s queezi ng t he brak e leve r (1) toward the ha ndleba r . The fro nt an[...]

35 FEATURE S AND CO NTROLS Br akes Ch eck th e brake flu id l evel i n t he mas ter cy li nd er befor e each us e of the A TV . The maste r cylinde r (1) is lo cated o n th e left h andl ebar . The f luid leve l can be see n through an indica tor window (2) on the top of the maste r cylinder . This “e ye” will appe ar da rk whe n the f luid lev[...]

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

37 FEATURE S AND CO NTROLS Auxiliary Brake W ARNING Aggres sively applying t he rear br ake when back ing downhill may cause r ear t ipover , which could r esult in ser ious injury or deat h. Use caut ion when applying t he auxiliar y brak e. Do not aggress ively apply t he auxiliary br ake when going f orward. T he rear wheels may s kid and slide [...]

38 FEATURE S AND CO NTROLS Choke The choke a ssists in star ting a cold engine . Refe r to the engine star ting proc edure on page 43 for co rr ec t choke and throttle settings during star ting. Fuel V alve The f uel v alv e (1) i s l ocat ed o n t he left s ide o f the vehic le, below the fe nder . It has three positions: OFF: For vehicle stor age[...]

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

40 FEATURE S AND CO NTROLS Recoil S tarter If the batter y has bee n dra i ne d or dama ged and ca nnot start the engine , use of the reco il starte r (1) will allow ve hicle ope ration until re pairs ca n be made. The re coil star ter is locate d on the right side of th e mach in e. Polaris 4- cycle engines a re equippe d with automa tic deco mpre[...]

41 OPERATION Br eak - In P er iod The br ea k-in period for your new Polar is A TV is the first ten hour s of oper ation, or the time it take s to use the first two full tanks of gasoline. No single a ction on your par t is as important a s following the proc edur es for a prope r break- in. Caref ul treatme nt of a new engine and dr ive compone nt[...]

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. A lways ins pect t he vehic le befor e each use to ens ure it ’ s i n proper oper ating c ondition. Pre - Ri de Chec kl is t Item Remarks See Page Br ake system / lever t ravel Ensure proper oper ati on 34, 7[...]

43 OPERATION Star ti ng the Engi ne W ARNING Engine exhaus t c ontains pois onous car bon monox ide and can cause los s of consc iousnes s res ulting in s evere injur y or deat h. Never r un an engine in an enclosed ar ea. 1. Position the vehicle on a leve l su rface. 2. Place the tr ansmission in neutr al. 3. Lock the par king bra ke. NOT E: T he [...]

44 OPERATION Star ti ng the Engi ne 7. Move the engine stop switch to R UN. NOT E: Do not pres s t he thr ott le while st art ing t he engine. 8. T urn the ignition ke y past the ON position to e ngage the sta rter . Activa t e the star ter for a maximum of five sec onds, relea sing the key whe n the engine star ts. 9. If the engine doe s not start[...]

45 OPERATION Driving Safely Driving Pr oced ures 1. Sit upright with both feet on the footrests a nd both hands on the handle bars. 2. Start the e ngine a nd allow it to warm up, then shif t the tra nsmission into gear . 3. Check your surroundings and de termine your path of tra vel. 4. Relea se t he pa rking bra ke. 5. Slowly depre ss the throttle[...]

46 OPERATION Driving Safely Hauling Cargo Acc essory r ac ks and hitche s are availa ble from your Polaris de aler . Always re ad and unde rstand the loa d distribution war nings on all warni ng l abel s, and n ever exceed t he sp ecifi ed weig ht cap ac itie s for the vehic l e. Maxim um T owing C apacities Refe r to the specific ations at the re [...]

47 OPERATION Driving Safely Hauling Cargo W ARNING Hauling cargo im properly can alt er vehic le handling and may cause los s of cont rol or br ake inst abilit y and res ult in s erious injury or deat h. Always f ollow thes e precaut ions when hauling cargo: S REDUCE SPEED AN D ALLO W G REA T ER DIST ANCE FO R BRAKING WHEN HAULING C ARGO . S CARG O[...]

48 OPERATION Driving Safely Making T urns Y our Polar is A TV is equipped w ith a solid rea r axle , which drive s both re ar w hee ls equally at a l l time s. This mea ns that the w heel on the outside of the turn must trave l a greate r distance tha n the inside wheel whe n turning and the inside tire must slip tr ac tion slightly . T o make a tu[...]

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

50 OPERATION Driving Safely Driving Uphill W ARNING Brak ing and handling are great ly aff ect ed when operat ing in hilly ter rain. I mproper procedur e could c ause loss of cont rol or overt urn and r esult in seri ous injury or deat h. Avoid climbing st eep hills ( 25 _ maximu m). Use ext rem e caut ion when operat ing on hills, and f ollow prop[...]

51 OPERATION Driving Safely Driving Uphill Whe neve r tra veling uphill, follow these pr ecauti on s: 1. Alwa ys trave l straight uphill. 2. A void stee p hills (25 _ maximum) . 3. Kee p both feet on the footre sts. 4. T ransfe r your weight forw ar d. 5. P roceed at a st eady rat e of sp eed and t hro ttle opening. 6. Rema in ale rt and be pr epa [...]

52 OPERATION Driving Safely Driving Downh ill Whe never de scending a hill, follow these pr ecaut io ns: 1. P roceed di rect ly d ownh ill. 2. T ransf er your we ight to the re ar of the ve hicle. 3. Sl ow down. 4. Apply the brakes slightly to aid in slowing, using the single bra ke leve r . NOT E: F amiliar ize your self wit h operat ion of t he a[...]

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

8’ (2. 4 m) 54 OPERATION Driving Safely T urni ng Ar ound on a Hi ll If the ve hicle stalls while c limbing a hill, neve r back it down the hill! Use the K- turn to turn ar ound. 1. Stop and lock the pa rking bra ke while ke eping body weight uphill. 2. Lea ve the tra nsmission in forwa rd and shut of f the e ngine. 3. Dismount on the uphill side[...]

55 OPERATION Driving Safely Dr iving Thr ough W ater Y our A TV can ope rate thr ough water with a maximum re commende d depth e qual to t he bottom of the footr ests (1) . Follow th ese pro cedu res when oper ating through wa ter: 1. De termine wa ter depths a nd cur re nt bef ore c rossing. 2. Choose a crossing where both banks have gra dual inc [...]

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

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

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

59 EMISSION C ON TR OL SYSTEMS Noise E mi ssion Contr ol System Do not modify the engine, intake o r exhaust compone nts, as doing so may af fect complia nce with U.S .A. EP A noise control requir ements (40 CFR 205) and loc al noise le vel re quirements. Operation on Public Lan ds in the U.S.A. Y our Pola ris vehic le ha s a spark a rre stor that [...]

60 MAINTENANCE Per iodic Maintenance C hart Care ful periodic mainte nance will help kee p your vehicle in the safe st, most relia ble condition. Inspe ction, adjustment a nd lubrica tion of importa nt components ar e expla ined in the periodic mainte nance c hart. Ins pect , clean , lub ricat e, adj us t and repl ace p arts as necess ary . When in[...]

61 MAINTENANCE Per iodic Maintenance C hart Maintena nce Char t Key " P erform t hes e proced ures m ore freq uent ly for v ehicl es s ub ject ed t o seve re use. E Emission-r elate d servic e (Failure to conduc t this mainte nan ce will not void the emissions warra nt y but may a f fe ct e missions.) J Have an au th ori zed P ol aris d ealer [...]

62 MAINTENANCE Per iodic Maintenance C hart Item Maint enance Int er val (w hichev er c omes f irs t) Remarks Hours C alendar Miles (Km) " J Brak e pad w ear 10 H Monthly 100 (160) Ins pec t periodic ally Battery 20 H Monthly 200 (320) Check ter minals; c lean; tes t " T rans mis s ion oil 25 H Monthly 250 (400) Inspec t lev el; c hange y[...]

63 MAINTENANCE Per iodic Maintenance C hart Item Maint enance Int er val (w hichev er c omes f irs t) Remarks Hours C alendar Miles (Km) " Cooling hos es (if applic able) 100 H 12 M 1000 (1600) Ins pec t for leak s " Engine mounts 100 H 12 M 1000 ( 1600) Ins pect Ex haus t muf f ler/ pipe 100 H 12 M 1000 (1600) Ins pec t J E Spark plug 10[...]

64 MAINTENANCE Lubr ication Recom m endations Chec k and lubric ate all c omponents at the inte rvals outline d in the Periodic Ma intena nce Chart beginning on page 60. Items not listed in the cha rt should be lubrica ted at the Gene ral Lubrica tion interva l. NOT E: T he a-ar ms and lower c ontr ol arms are lubr icat ed at t he fac tor y , and n[...]

65 MAINTENANCE Lubr ication Recom m endations (1) (2) (3) (4)[...]

66 MAINTENANCE Engi ne Oil Alwa ys chec k and cha nge the engine oil at the interv als outlined in the P eriod ic M ain ten ance C hart beg i nning on page 60. Always change the oil filter whe never c hanging oil. Oil R ecom mendati ons Polar is rec ommends the use of Polaris PS- 4 P LU S P er for manc e Synthetic 2W -50 4-c ycle oil or a similar o[...]

67 MAINTENANCE Engi ne Oil Oil an d Filter Change 1. Position the vehicle on a leve l surf ace. 2. Clean the ar ea around the dr ain plug. 3. Run the engine for two to three minutes until warm. S top the engine . CAUTION Contac t with hot oil may result in serious burns. Do not allow hot oil to c ome int o cont act with s kin. 4. Place a dr ain pan[...]

68 MAINTENANCE T r ansmission Oil Alwa ys chec k and cha nge the transmission oil at the interva ls outlined in the Periodic Mainte nance Cha rt beginning on page 60. Mainta in the oil level at the bottom of the fill hole threa ds. W e rec ommend the use of Premium AGL S ynthetic Ge arca se Lubrica nt. See page 107 for the par t numbers of Pola ris[...]

69 MAINTENANCE T r ansmission Oil Oil Chan ge 1. P lace a drain p an beneat h t he tra nsmission oil drain plug area. 2. Loosen the j am nut ( A). 3. T urn the adjuste r bolt (B) in to allow the re moval of the drain plug (C). 4. Remove the dra in plug and wipe the magne tic end cle an to remo ve accu mu lat ed m eta llic filings. 5. After the oil [...]

A B 70 MAINTENANCE T oe A lignm ent W ARNING Sever e injury or death c an result f rom im proper t oe alignment and adjust ment . Do not at t empt t o adjust t ie rod alignment . All t ie rod adjust ment s should be per for med by an aut horiz ed Polaris dealer . Use the following proce dure to che ck the t oe alignme nt of the vehicle. The re comm[...]

71 MAINTENANCE Br akes The front and re ar brake s are hydr aulic disc bra kes, activa ted by moving the single brake le ver toward the handleba r . These bra kes are self -adjusting. The fo ll owi ng ch ecks are reco mm ended t o k eep t he brak e sy st em i n good oper ating condition. Check mor e ofte n i f br akes a re used he avily under norma[...]

72 MAINTENANCE Br akes 1. Ch eck t he b rake sy st em fo r flu id leak s. 2. Ch eck t he b rakes f or exces si ve t ravel or spongy fe el. 3. Ch eck th e fricti on p ads fo r wear , dama ge and looseness. 4. Ch eck th e securi ty an d su rface condition of the disc. NOT E: P ads should be c hanged when worn t o 3/64 ″ (. 1 cm). Auxiliary Brake Th[...]

1 2 3 73 MAINTENANCE Thr ottle Cable Fr eepla y Thr ottle ca ble fre epla y is adjuste d at the handleba r . 1. Loc ate the throttle c able adj us ter o n t he handle bar . 2. S queeze t he en d o f th e rubbe r boot (1) and slide it far enough to expose the end of the inline cabl e adj ust er (2). 3. Loosen the locknut (3). 4. Rotate the boot to t[...]

74 MAINTENANCE Handlebar s W ARNING Im proper adjust ment of t he handlebars or inc orrec t tor quing of the adjus ter bloc k t ightening bolt s c an cause lim ited s teer ing or loosening of the handlebar s, result ing in los s of c ontr ol and possible s erious per sonal injur y or deat h. F ollow t he adjust ment procedur es exact ly , or s ee y[...]

75 MAINTENANCE Car bur etor IMPOR T ANT : Y our Polar is A TV is ca librate d at the f actor y for optimal pe rforma nce a t altitude s ra nging fr om ze ro to 6, 000 fe et (1800 m) and temper atures of +40 degre es F . (4 degree s C. ) or higher . Above 6000 fe et (1800 m) the e ngine air /fue l mixture be comes ove rly rich a nd the engine loses [...]

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

77 MAINTENANCE Wheels Wheel Installation 1. Place the tra nsmission in gear and loc k t he pa rking bra ke. W ARNING Im properly inst alled wheels c an advers ely affec t t ire wear and vehicle handling, which c an result in ser ious injury or deat h. Always ensure t hat all nuts are t orqued t o specif icat ion. Do not serv ice axle nut s t hat ha[...]

78 MAINTENANCE Wheels Fr ont W heel Hub T ightening Front whee l bear ing tightness a nd spindle nut rete ntion are c ritica l compone nt opera tions. All servic e must be p er formed by your aut ho rized P ol aris deal er . Ti re T read Depth Alway s repl ace t ires wh en tread depth is wor n t o 1/8 ″ ( . 3 cm) or le ss. See illustr ation. W AR[...]

79 MAINTENANCE Drive Chain Polaris A TV drive cha ins are e quipped with o-ring-se aled, perma nently greas ed pi ns and r ol lers . Howev er , t he o ut er su rfaces of t he ro ll er m ust be lubric ated. Always inspe ct the dr ive chain pr i or to ope rating the ve hicle. Check for dama ged or missing o-r ings or damage d roller s. Also che ck f [...]

80 MAINTENANCE Drive Chain Rear Dr ive Chain Slack CAUTION Adjust ing or oper ating t he A T V wit h improper r ear driv e chain slack can r esult in s evere dam age to t he t ransm ission and dr ive component s. Alway s mak e sure t he slac k is wit hin t he st ated specif icat ions. Chec k the amount of c hain sla ck in thre e dif fere nt locatio[...]

81 MAINTENANCE Drive Chain Rear Dr ive Chain Slack 6. R ol l t he A TV forward o r backward to adjust the chain sla ck to the prope r t en sion. See the illustra tion for pr oper splice link c lip opening position (1) . 7. T ig ht en t he eccent ri c lo cki ng b ol ts to 30 ft. lbs. (41 Nm) for mac hines without the hitch a nd 45 ft. l bs. (61 Nm) [...]

82 MAINTENANCE Lights Whe n servic ing a halogen la mp, don’ t touch the lamp with ba re finger s. Oil fr om your skin lea ves a residue, c ausing a hot spot tha t will shorten the life of the la mp. W ARNING Poor light ing while driv ing can res ult in s evere injur y or deat h. Headlight and t aillight lens es becom e dirt y during nor mal oper[...]

83 MAINTENANCE Lights T aillight/Brakelight L am p Replacement If the taillight/bra kelight doe s not work the l amp ma y need to be repl aced. 1. Remove the ta illight lens cover mounting scre ws. Remove the lens c over and ga sket and set aside f or reasse mbly . 2. Remove the lamp (1). 3. Apply dielec tric grea se t o the so cket and i ns tal l [...]

84 MAINTENANCE Air Filter 1. Rem ov e th e seat , rel ease t he clips, and remove the a ir box cove r . 2. Loosen the clamp a nd re m ove the filte r . 3. If equippe d, remove the fa bric type pre -filter ( 1) from the main filte r (2). W ash the pre -filte r i n so apy wat er , t hen ri ns e and let dry . Reinsta l l the pre- filter over the main [...]

85 MAINTENANCE Spar k P lugs S par k Plug R ecomm endations CAUTION Using non-r ecomm ended spark plugs c an result in ser ious engine damage. Alway s use P olaris- recom mended spar k plugs. Ref er to t he spec ific ations s ect ion beginning on page 104 . Refe r to the spec ifica tions section beg inning on page 104 for the re comme nded spark pl[...]

86 MAINTENANCE Spar k P lugs Spar k Plug Inspectio n Normal Plug The norma l i nsulator tip is gray , tan or light brown. There will be fe w combustion deposits. The ele ctrodes ar e not burned or erode d. This indica t es the prope r t ype and he at range f or the engine and the servic e. NOT E: T he t ip should not be whit e. A whit e insulat or [...]

87 MAINTENANCE V eh icl e Imme rsio n CAUTION If your vehic le becomes im mers ed, m ajor engine damage c an result if the m achine is not t horoughly ins pect ed. T ake t he vehicle t o your dealer bef ore s tart ing t he engine. If it’ s impossible to take your A TV to a deale r befor e starting it, follow the steps outlined below . 1. Move the[...]

88 MAINTENANCE PV T System The basic ope ration of the P ola ris PVT system is depende nt on engine sp eed and v ehi cle t orq ue requ irem ent s. As en gi ne sp eed i ncreas es, t he forc e exer t ed on the movable drive shea ve by the flyweights also incr ease s. This, in turn, incre ase s the amount of “ pinch” a pplied to the drive be lt. S[...]

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

90 MAINTENANCE Spar k Ar r estor W ARNING Failur e to heed t he f ollowing warnings while s ervic ing the s park arres tor could res ult in s erious injur y or deat h. Do no t perform service o n the spa rk arrestor whi le the system is hot. Exhaust syst em tem perat ures ca n reach 1000 ° F . A llow component s t o cool s ufficient ly bef ore pr [...]

91 MAINTENANCE Batter y Y our A TV may ha ve e ither a se aled ba ttery , which re quires little mainte nance , or a c onventional ba ttery . A seale d batter y ca n be identif ied by its flat c overs on the top of the batte ry . A conventiona l batte ry has six f iller caps on the top of the batte ry . Always ke ep batter y termina ls and conne ct[...]

92 MAINTENANCE Batter y W ARNING Im properly connec ting or dis connect ing bat ter y cables c an result in an explosion and c ause ser ious injury or deat h. W hen remov ing the bat t ery , always dis connect t he negativ e (black ) cable f irst . W hen reins talling t he bat ter y , alway s connec t t he negativ e (black ) cable las t. Bat tery R[...]

93 MAINTENANCE Batter y Battery Installation Using a ne w batter y that has not bee n fully cha r ged c an da mage the bat tery an d resu lt i n a sho rter l ife. It can al so h in der veh icl e per formanc e. F ollow the ba ttery c har ging instructions on page s 95-97 bef ore installing the batte ry . 1. Ensur e that the batte ry is fully cha r g[...]

94 MAINTENANCE Batter y Batter y Stor age Whe never the ve hicle is not used for a per iod of three months or more, remo ve t he bat t ery from th e veh icl e, en sure t hat i t’ s fu ll y ch ar g ed, and st ore it ou t of t he sun i n a cool , d ry pl ace. C heck b att ery vol t age each mo nt h du rin g st orage and r echarge as needed t o mai [...]

95 MAINTENANCE Batter y Batte ry Fluid (C onventional B atter y) A poorly ma intained ba ttery will dete riora te ra pidly . C he ck the ba tter y fluid le vel of ten. Maintain the fluid leve l between the upper a nd lower leve l mar ks (1). Add only distille d wate r . T ap wa ter conta i ns miner als that ar e ha rmful to a batte ry . Batter y Ch[...]

96 MAINTENANCE Batter y Batter y Char ging (Sealed B attery) The f ollowing batte ry cha rging instr uctions apply only to the in st all ati on o f a sealed bat t ery . R ead al l in st ruct io ns b efore proceed in g with the i nsta llation of this ba ttery . The seale d batter y is alre ady fille d with ele ctro lyte a nd has be en sea led and f [...]

97 MAINTENANCE Batter y Batter y Char ging (Sealed B attery) NOT E: A lways v erif y bat ter y condit ion bef ore and 1-2 hour s af ter t he end of c harging. Stat e of Char ge Vo l t a g e Acti on Charge T ime* (Us ing cons tant cur rent char ger @ s tandard amps spec ified on top of battery) 100% 12.8- 13.0 volt s None, check at 3 mos. f rom dat [...]

98 MAINTENANCE Cleaning a nd Stor age See page 107 for the pa rt numbers of Polaris products. W ashin g the V eh icle Kee ping your A TV cle an will not only improve its a ppea ranc e but it ca n also exte nd the life of various c omponents. CAUTION High water pres sure m ay damage A T V c omponent s. Polaris recom mends was hing the v ehicle by ha[...]

99 MAINTENANCE Cleaning a nd Stor age W ashin g the V eh icle If a high pressur e wate r system is used f or clea ning (not recom men ded) , ex ercis e ext reme cau ti on . T he wat er may dam age components and could rem ove pain t and decals. A voi d directin g the wa ter str eam a t the follow i ng ite ms: S Wheel b earin gs S Radiator ( if equi[...]

100 MAINTENANCE Cleaning a nd Stor age Chr ome W heel C ar e (if equipped) P roper mai nt enance wil l pro tect ch rome wheel s from corro si on, pres erve wheel l ife and ens ure a ”l ike n ew” appearan ce for m any y ears. NOT E: Chr ome wheels ex posed t o road salt (or s alt in t he air in coast al areas ) are m ore sus cept ible to c orros[...]

101 MAINTENANCE Cleaning a nd Stor age Sto ra ge Ti ps See page 107 for the pa rt numbers of Polaris products. CAUTION St art ing the engine dur ing the s tor age period will dist urb t he prot ect ive f ilm cr eated by fogging and dam age could occ ur . Never st art the engine dur ing the s tor age period. Clean t he Exter ior Mak e any necess ary[...]

102 MAINTENANCE Cleaning a nd Stor age Sto ra ge Ti ps Flu id Levels Inspe ct the fluid le vels. Add or cha nge fluids as r ec ommended in the Periodic Mainte nance Char t beginning on page 60. S T ransmission f luid S Bra ke fluid ( cha nge eve ry two yea rs and a ny time the f luid looks dar k or contamina ted) Fog the E ngine 1 . Support the fro[...]

103 MAINTENANCE Cleaning a nd Stor age Sto ra ge Ti ps Inspe ct a nd Lubric ate Ins pect al l cab les and l ub ricat e al l areas o f th e veh icl e as reco mm end ed in the P e riodic Ma i ntena nce Char t beginning on page 60. Batte ry S tora ge See pa ges 94-97 for storage and char ging procedur es. Sto rage A rea/Cover s Set the tire pre ssure [...]

104 SPECIFIC ATIO NS 2008 T r ail Blazer 330 Capac ities & D im ensio n s Body Styl e Gen III Dr y W ei ght 488 l bs . ( 221 kg) Ma ximum W e ight Ca pa ci ty 305 l bs . ( 138 kg) F ron t Rack C ap acity (Accesso ry ) 30 l bs . ( 14 kg) Rear Rack C ap acity (Accesso ry ) 60 l bs . ( 27 kg) Hitch T o win g R ating (A ccesso ry ) 850 lbs .( 386 k[...]

105 SPECIFIC ATIO NS 2008 T r ail Blazer 330 Drive S ystem Dr ive Sys te m T ype Au to matic P o laris V ariab le Transm issio n (P VT ) Shi f t T ype Side Le ve r (H - N- R) Ge ar Re duct ion - Re ver se 3.05: 1 Gear R ed u ction - F orw ard 2.68: 1 Fi nal D riv e (ratio) 1 1/40 78P Driv e C hain 520 O- Ring Fr ont T ir es / Pr es sur e 2 3x7 - 1 [...]

106 SPECIFIC ATIO NS 2008 T r ail Blazer 330 Jetting Chart Altitu d e AMBIENT TEMPERA TURE Below 40 ° F (B elow 5 ° C) +40 ° F and above (+5 ° C and above) Meters (F eet) 0-1800 (0- 6000) 127.5 122. 5 1800-3700 (6000- 12000) 120 11 5 Cl utching Char t Altitude Shi ft W eight Driv e C lutch Sprin g Driven Cl utch Sprin g Helix /Spring Setting Me[...]

107 POLARIS PRODUCTS Part No. Descr ipt ion Engine Lubr icant 2870791 Fogging O il ( 12 oz. Aer osol) 2876244 PS-4 P LUS Per for mance Synt heti c 2W -50 4- Cycle Oi l ( qt. ) 2876245 PS-4 P LUS Per for mance Synt heti c 2W -50 4- Cycle Oi l ( gal.) Gear case / T r ansmissi on Lubri cants 2873602 Prem ium AGL Synt heti c Gearcase Lube ( qt. ) 28736[...]

108 TROUB LES HOOTING Contac t your P olar i s dea l er f or servic e if you’re una ble to identify solutions using the follow i ng c har ts. Dr ive Belt an d Cover Problems Possibl e Cause Solut ion Dr ivi ng onto a pi ckup or tall trailer in h ig h ran ge Shi f t t r a nsmi ss ion t o low r a nge dur ing l oadi ng of t he A TV t o pr eve nt be [...]

109 TROUB LES HOOTING Engine Doesn’t T u r n Over Po ssibl e Cause Solut io n Trip ped circu it b reak er Reset th e b reak er Lo w b attery v o ltag e Re cha r ge ba tt er y to 12. 8 VDC Loos e bat te ry conne ct ions Ch eck all con n ectio n s an d tig h ten Loos e sol enoi d c onne ct ions Ch eck all con n ectio n s an d tig h ten Engine T urn[...]

11 0 TROUB LES HOOTING Engine Backfir es Po ssibl e Cause Solut io n W e a k spa rk f rom s pa rk pl ugs In sp ect, clean and /o r replace spark p lu g s In correct sp ark plu g g ap o r heat rang e Se t ga p to s pec s or re pla ce plugs Ol d or non- re com me nded f uel Re pla ce wi th new fue l In correctly in stalled sp ark p lug w ires Se e yo[...]

111 TROUB LES HOOTING E ngine S tops or Lose s Power Po ssibl e Cause Solut io n Out of fuel Tu rn fuel v alve to reserve, refu el Ki nked or plugge d f uel ve nt li ne Insp ect an d rep lace W ater p resent in fu el Re pla ce wi th new fue l Ove rus e of choke In spect, clean an d/o r replace spark p lu g s Foul e d or de fe ct ive spa rk pl ugs I[...]

11 2 WARRANTY LI MIT ED W ARRANTY Pol a ri s Sal es I nc. , 2100 Highwa y 55, Me dina , M N 55340, gi ves a SI X MONTH LI MI TED W ARRANTY on a ll c ompone nts of t he Pola ri s All T e rr ai n V ehi cl e (A TV) aga ins t def ec ts i n ma te ri al or wor kma nshi p. Pola ri s a ls o give s a one yea r l imi te d wa rr ant y on the f ina l dr ive c [...]

11 3 WARRANTY W ARRANT Y COVERAGE AND EXCL USIONS: LIMI T A TIO NS OF W ARRANTIE S AND REMEDI ES ALL IM P LI ED W ARRANTIES (I NCLUDING BUT NOT LIMI TED TO THE IMPLI ED W ARRANTIES OF MERCHANT ABILI TY AND FITNESS FOR A P AR TICULAR PURPOSE) ARE LI MITED I N DURA TION TO THE ABOVE SIX MONTH W ARRAN- TY PERI OD. POLARI S FUR THER DI SCLAIMS ALL EXPR[...]

11 4 WARRANTY Exported V ehicles EXCEPT WHERE SPECI FICALL Y REQUIRED BY LA W , THERE I S NO W AR- RANTY OR SER VICE BULLETI N COVERAGE ON THIS VEHI CLE IF I T IS SOLD OUTSIDE THE COUNTR Y OF THE SELLING DEALER’ S AUTHORIZED LOCA- TION. T his po licy d o es n o t app ly to v eh icles th at hav e received au th orizatio n fo r e xpor t f rom Pol a[...]

11 5 WARRANTY U. S.A. EP A Emis si o n s L imi te d W arra n t y Th is A ll T errain V eh icle (A TV ) o r Off Ro ad U tility V eh icle (O RU V) em issio ns lim ited warran ty is in add itio n to the Po laris stand ard limited w arran ty for this veh icle. P olaris w arran ts th at thi s veh icle is; (1 ) d esig ned , b u ilt, an d eq u ip ped to c[...]

11 6 MAINTENANCE LOG Use t he fol l owin g chart t o record p erio di c mai nt enance. DA TE MIL ES ( KM) TECHNICIAN SER VICE PER FORMED / CO MM EN TS[...]

11 7 MAINTENANCE LOG DA TE MIL ES ( KM) TECHNICIAN SER VICE PER FORMED / CO MM EN TS[...]

11 8 INDEX A Ag e R estrictio ns 6 ................ Air F ilter 8 4 ..................... Au x iliary B rak e 37 , 7 2 ............ B Ba tte r y 91- 97 .................... Ba tt e ry Cha r ging ( Convent iona l) 95 .. Ba tt e ry Cha r ging ( Sea le d) 96- 97 ...... Ba tt e ry Fl uid ( Conve nt iona l) 95 ..... Battery In stallatio n 9 3 ..........[...]

11 9 INDEX N Noi se Emi ss ion Contr ol Syst em 59 ... O Oi l Change 67 ................... Oi l Ch eck 6 6 .................... Oi l Rec omme ndat ions 66 ........... Oi l, Engi ne 66- 67 ................. Oi l, T ra nsm is si on 68- 69 ............ Ope ra tor Sa fe ty 6-25 ............... Ov errid e S witch 3 1 ............... P Park in g B rake [...]