PMS 419
Read this manual carefully. It contains important safety information.
This is an adult vehicle only.
Operation is prohibited for those under 16 years of age.
Owner's Manual
for Maintenance and Safety
Trail Boss 330
Trail Blazer 330
A card containing important ATV safety information should be
attached to the owner's manual on the next page. If you cannot
locate this card, or if it has been removed, please call 1-800-
342-3764 for assistance.
WARNING
The engine exhaust from this product contains chemicals
known to the State of California to cause cancer, birth defects
or other reproductive harm.
The text is printed on 100% recycled
with 40% post-consumer waste (PCW).
For your nearest Polaris dealer,
call 1-800-POLARIS
or visit www.polarisindustries.com
Polaris Sales Inc.,
2100 Hwy. 55, Medina, MN 55340
Phone 1-888-704-5290
Part No. 9923414 Rev 01
Printed in USA
PMS 419
*9923414 *
WARNING
Improper vehicle use can result in SEVERE INJURY or DEATH.
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 control.
ALWAYS:
S use proper riding techniques to avoid vehicle
overturns on hills and rough terrain and in turns.
S avoid paved surfaces - pavement may seriously affect
handling and control.
READ OWNER'S MANUAL.
FOLLOW ALL INSTRUCTIONS AND WARNINGS.
ALWAYS USE
AN APPROVED
HELMET AND
PROTECTIVE
GEAR
NEVER USE
ON PUBLIC
ROADS
NEVER CARRY
PASSENGERS
NEVER USE
WITH DRUGS
OR ALCOHOL
1
WELCOME
Thank you for purchasing a POLARIS vehicle, and welcome to our
world-wide family of POLARIS owners. We proudly produce an excit-
ing line of utility and recreational products.
• Snowmobiles
• All-terrain vehicles (ATVs)
• RANGER
®
utility vehicles
• Victory Motorcycles
®
• Low emission vehicles (LEVs)
We believe POLARIS sets a standard of excellence for all utility and
recreational vehicles manufactured in the world today. Many years of
experience have gone into the engineering, design, and development of
your POLARIS vehicle, making it the finest machine we’ve ever pro-
duced.
For safe and enjoyable operation of your vehicle, be sure to follow the
instructions and recommendations in this owner’s manual. Your manual
contains instructions for minor maintenance, but information about
major repairs is outlined in the POLARIS Service Manual and should be
performed only by a factory certified Master Service Dealer
®
(MSD)
technician.
Your POLARIS dealer knows your vehicle best and is interested in your
total satisfaction. Be sure to return to your dealership for all of your ser-
vice needs during, and after, the warranty period.
We also take great pride in our complete line of apparel, parts and acces-
sories, available through our online store at www.purepolaris.com. Have
your accessories and clothing delivered right to your door!
2
POLARIS, THE WAY OUT, TRAIL BOSS and TRAIL BLAZER are registered trade-
marks of POLARIS Industries Inc.
Copyright 2011 POLARIS Sales Inc. All information contained within this publication
is based on the latest product information at the time of publication. Due to constant
improvements in the design and quality of production components, some minor discrep-
ancies may result between the actual vehicle and the information presented in this publi-
cation. Depictions and/or procedures in this publication are intended for reference use
only. No liability can be accepted for omissions or inaccuracies. Any reprinting or reuse
of the depictions and/or procedures contained within, whether whole or in part, is
expressly prohibited.
The original instructions for this vehicle are in English. Other languages are provided as
translations of the original instructions.
Printed in U.S.A.
2012 TRAIL BOSS 330/TRAIL BLAZER 330 Owner’s Manual
P/N 9923414
3
TABLE OF CONTENTS
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Features and Controls. . . . . . . . . . . . . . . . . . . 26
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Emission Control Systems . . . . . . . . . . . . . . . 56
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
POLARIS Products. . . . . . . . . . . . . . . . . . . . . 103
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . 104
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . 108
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Maintenance Log . . . . . . . . . . . . . . . . . . . . . . 120
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
4
INTRODUCTION
The following signal words and symbols appear throughout this manual
and on your vehicle. Your safety is involved when these words and sym-
bols are used. Become familiar with their meanings before reading the
manual.
The safety alert symbol indicates a potential personal injury hazard.
WARNING
A WARNING indicates a hazardous situation which, if not avoided, may result in
death or serious injury.
CAUTION
A CAUTION indicates a hazardous situation which, if not avoided, may result in
minor or moderate injury.
NOTICE
A NOTICE indicates a situation that may result in property damage.
The Prohibition Safety Sign indicates an action NOT to take in order
to avoid a hazard.
The Mandatory Action Sign indicates an action that NEEDS to be
taken to avoid a hazard.
5
INTRODUCTION
Failure to heed the warnings and safety precautions contained in this manual
can result in severe injury or death. A POLARIS ATV is not a toy and can be
hazardous to operate. This vehicle handles differently than other vehicles, such
as motorcycles and cars. A collision or rollover can occur quickly, even during
routine maneuvers like turning, or driving on hills or over obstacles, if you fail to
take proper precautions.
• Read this owner’s manual. Understand all safety warnings, precautions and
operating procedures before operating a POLARIS ATV. Keep this manual
with the ATV.
• Never operate an ATV without proper instruction. Take a training course.
• This vehicle is an ADULT VEHICLE ONLY. Operation is prohibited for anyone
under 16 years of age.
• Never permit a guest to operate the ATV unless the guest has read this
manual and all product labels and has completed a certified safety training
course.
European Vibration and Noise
The driver-perceived noise and hand/arm and whole body vibration lev-
els of this machinery is measured per prEN 15997.
The operating conditions of the machinery during testing:
The vehicles were in like-new condition. The environment was con-
trolled as indicated by the test procedure(s).
The uncertainty of vibration exposure measurement is dependent on
many factors, including:
• Instrument and calibration uncertainty
• Variations in the machine such as wear of components
• Variation of machine operators such as experience or physique
• Ability of the worker to reproduce typical work during measurements
• Environmental factors such as ambient noise or temperature
WARNING
6
INTRODUCTION
Vehicle Identification Numbers
Record your vehicle's identification 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 your key number) and mating it with one of your existing keys.
The ignition switch must be replaced if all keys are lost.
Vehicle Model Number: ___________________________________________________
Frame VIN: ____________________________________________________________
Engine Serial Number: ___________________________________________________
(right front side of engine crankcase)
Key Number: ___________________________________________________________
####
VIN
Key Number
7
SAFETY
Safety Training
ATV safety training is a top priority for POLARIS. POLARIS strongly
encourages you and any family members who will be riding the ATV to
take a training course.
If you purchased a new POLARIS ATV in the United States, your dealer
provided instruction to you about the authorized ATV RiderCourse
sm
that is available to you and your eligible family members. This training
is included in the purchase price of your ATV. You were also provided
with printed materials that explain safe operating procedures. You
should review this information on a regular basis.
If you purchased a used POLARIS ATV in the United States, you can
enroll in the ATV RiderCourse
sm
for a fee. Call ATV Enrollment
Express at (800) 887-2887 or visit www.atvsafety.org.
If you purchased a POLARIS ATV outside the United States, please
contact your dealer or local law enforcement agencies for information
about safety training.
A POLARIS ATV is an off-road vehicle. Familiarize yourself with all
laws and regulations concerning the operation of this vehicle in your
area.
We strongly advise you to strictly follow the recommended maintenance
program outlined in your owner's manual. This preventive maintenance
program is designed to ensure that all critical components on your vehi-
cle are thoroughly inspected at specific intervals.
FOR MORE INFORMATION ABOUT ATV SAFETY in the United
States, call the Consumer Product Safety Commission at 1-800-
638-2772, or visit www.cpsc.gov, visit www.atvsafety.org, or call
POLARIS at 1-800-342-3764.
8
SAFETY
Safe Riding Gear
Always wear appropriate clothing when riding an ATV. Wear protective
clothing for comfort and to reduce the chance of injury.
Helmet
Wearing a helmet can prevent a severe head injury. Whenever riding a
POLARIS vehicle, always wear a helmet that meets or exceeds estab-
lished safety standards.
Approved helmets in the USA and Canada bear a U.S. Department of
Transportation (DOT) label.
Approved helmets in Europe, Asia and Oceania
bear the ECE 22.05 label. The ECE mark consists
of a circle surrounding the letter E, followed by the
distinguishing number of the country which has
granted approval. The approval number and serial
number will also be displayed on the label.
Helmet
Eye
Protection
Gloves
Boots
Long
Pants
Long
Sleeves
E
4
051039
0006.31
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 or
use a shatterproof helmet face shield. POLARIS recommends wearing
approved Personal Protective Equipment (PPE) bearing markings such
as VESC 8, V-8, Z87.1, or CE. Make sure protective eye wear is kept
clean.
Gloves
Off-road style gloves with knuckle pads are the best for comfort and
protection.
Boots
The best footwear is a pair of sturdy over-the-calf boots with low heels.
Clothing
Always wear long sleeves and long pants to protect arms and legs. Rid-
ing pants with kneepads and a jersey with shoulder pads provide the best
protection.
Equipment Modifications
We strongly recommend that consumers do not install on a POLARIS
ATV any equipment that may increase the speed or power of the vehicle,
or make any other modifications to the vehicle for these purposes.
The warranty on your POLARIS ATV is terminated if any equipment
has been added to the vehicle, or if any modifications have been made to
the vehicle, that increase its speed or power.
The addition of certain accessories, including (but not limited to) mow-
ers, blades, tires, sprayers, or large racks, may change the handling char-
acteristics of the vehicle. Use only POLARIS-approved accessories, and
familiarize yourself with their function and effect on the vehicle.
10
SAFETY
Safety Warnings
Failure to operate the ATV properly can result in a collision, loss of control,
accident or overturn, which may result in serious injury or death. Heed all safety
warnings outlined in this section of the owner’s manual. See the OPERATION
section of the owner’s manual for proper operating procedures.
Operating Without Instruction
Operating this ATV without proper instruction
increases the risk of an accident. The operator
must understand how to operate the ATV properly
in different situations and on different types of
terrain.
Beginning and inexperienced operators should
complete the recommended safety training before
operating this vehicle. See page 7.
Never permit a guest to operate the ATV unless the
guest has read this manual and all product labels
and has completed a certified safety training
course.
Age Restrictions
This vehicle is an ADULT VEHICLE ONLY.
Operation is prohibited for anyone under 16 years
of age.
Even though a child may be within the
recommended age group for operating some ATVs,
he/she may not have the skills, abilities, or
judgment needed to operate an ATV safely and
could be susceptible to accident or injury.
WARNING
11
SAFETY
Safety Warnings
Handling Gasoline
Gasoline is highly flammable and explosive under certain conditions.
• Always exercise extreme caution whenever handling gasoline.
• Always refuel with the engine stopped, and outdoors or in a well ventilated
area.
• Do not smoke or allow open flames or sparks in or near the area where refu-
eling is performed or where gasoline is stored.
• Do not overfill the tank. Do not fill the tank neck.
• If gasoline spills on your skin or clothing, immediately wash it off with soap
and water and change clothing.
• Turn the fuel valve off whenever the vehicle is stored or parked.
Exposure to Exhaust
Engine exhaust fumes are poisonous and can cause loss of consciousness or
death in a short time. Never start the engine or let it run in an enclosed area.
The engine exhaust from this product contains chemicals known to cause
cancer, birth defects or other reproductive harm. Operate this vehicle only
outdoors or in well-ventilated areas.
Failure to Inspect Before Operating
Failure to inspect and verify that the ATV is in safe
operating condition before operating increases the
risk of an accident.
Always inspect the ATV before each use to make
sure it's in safe operating condition.
Always follow all inspection and maintenance
procedures and schedules described in the
owner's manual.
12
SAFETY
Safety Warnings
Protective Apparel
Riding in this vehicle without wearing an
approved helmet and protective eyewear
increases the risk of a serious injuries in the
event of an accident.
Operator and passenger must always wear an
approved helmet that fits properly and eye
protection (goggles or face shield).
Using Alcohol or Drugs
Operating the ATV after consuming
alcohol or drugs could adversely affect
operator judgment, reaction time,
balance and perception.
Never consume alcohol or drugs before
or while operating an ATV.
Carrying a Passenger
Carrying a passenger greatly reduces the
operator's ability to balance and control the
ATV, which may result in an accident or
overturn.
Never carry a passenger on this ATV.
13
SAFETY
Safety Warnings
Operating on Pavement
Operating an ATV on paved surfaces
(including sidewalks, paths, parking lots and
driveways) may adversely affect the
handling of the ATV and could result in loss
of control and accident or overturn.
Avoid operating the ATV on pavement. ATV
tires are designed for off-road use. If it's
unavoidable, travel slowly and avoid sudden
turns or stops.
Operating on Public Roads
Operating this ATV on public streets, roads
or highways could result in a collision with
another vehicle.
Never operate the ATV on any public street,
road or highway, including dirt and gravel
roads. In many states it's unlawful to
operate ATVs on public streets, roads and
highways.
Operating at Excessive
Speeds
Operating the ATV at excessive speeds
increases the operator's risk of losing
control.
Always operate at a speed that's
appropriate for the terrain, the visibility and
operating conditions, and your experience.
14
SAFETY
Safety Warnings
Physical Control of the ATV
Removing a hand from the handlebars or
feet from the footrests during operation can
reduce your ability to control the vehicle or
cause loss of balance and ejection from the
ATV. If the operator's foot is not firmly
planted on the footrest, it could also contact
the rear wheels.
Never remove your hands from the
handlebars while operating, and always
keep both feet on the footrests.
Turning Improperly
Turning improperly could cause loss of
traction, loss of control, accident or overturn.
Always follow proper procedures for turning
as described in the owner's manual.
Never turn abruptly or at sharp angles. Never
turn at high speeds. Practice turning at slow
speeds before attempting to turn at faster
speeds.
Jumps and Stunts
Attempting wheelies, jumps and other
stunts increases the risk of an accident or
overturn.
Never attempt wheelies, jumps, or other
stunts. Avoid exhibition driving.
Improper Hill Climbing
Improper hill climbing could cause loss of
control or overturn. Always follow proper
procedures for climbing hills as described in
the owner's manual. See page 46.
15
SAFETY
Safety Warnings
Descending Hills Improperly
Improperly descending a hill could cause loss
of control or overturn.
• Always follow proper procedures for travel-
ing down hills as described in the owner's
manual. NOTE: A special technique is
required when braking while traveling down-
hill. See page 48.
• Always descend a hill with the transmission
in forward gear. Do not descend a hill with
the transmission in neutral.
• Always check the terrain carefully before
descending a hill.
• Shift your weight rearward.
• Never travel down a hill at high speed.
• Avoid traveling down a hill at an angle, which would cause the vehicle to lean
sharply to one side. Travel straight down the hill when possible.
Crossing Hillsides
Driving on a sidehill is not recommended.
Improper procedure could cause loss of control
or overturn. Avoid crossing the side of any hill
unless absolutely necessary.
If crossing a hillside is unavoidable, always follow
proper procedures as described in the owner's
manual. See page 47.
Never attempt to turn the ATV around on any hill
until you've mastered the turning technique (on
level ground) as described in the owner's
manual. See page 49.
16
SAFETY
Safety Warnings
Stalling While Climbing a Hill
Stalling, rolling backwards or improperly
dismounting while climbing a hill could cause an
overturn.
• Always maintain a steady speed when climbing
a hill.
If all forward speed is lost:
• Keep body weight uphill.
• Apply the single-lever brake gradually.
• Lock the parking brake when fully stopped.
• Dismount on uphill side, or to either side if ATV is pointed straight uphill.
• Turn the ATV around and remount, following the procedure described in the
owner's manual. See page 49.
If the ATV begins rolling downhill:
• Keep body weight uphill.
• Never apply engine power.
• Never apply the auxiliary rear brake while rolling backwards. Apply the single-
lever brake gradually.
• When fully stopped, apply the rear brake as well, and then lock the parking
brake.
• Dismount on uphill side, or to either side if ATV is pointed straight uphill.
• Turn the ATV around and remount, following the procedure described in the
owner's manual. See page 49.
Operating on Steep Hills
Operating on excessively steep hills could cause
an overturn.
Never operate on hills too steep for the ATV or for
your abilities. Never operate the ATV on hills
steeper than 25 degrees.
+25
17
SAFETY
Safety Warnings
Operating on Slippery Terrain
Failure to use extra caution when operating on
excessively rough, slippery or loose terrain could
cause loss of traction, loss of control, accident or
overturn.
Do not operate on excessively rough, slippery or
loose terrain. Always use extra caution on rough,
slippery or loose terrain.
Operating in Unfamiliar Terrain
Failure to use extra caution when operating on
unfamiliar terrain could result in an accident or
overturn.
Unfamiliar terrain may contain hidden rocks,
bumps, or holes that could cause loss of control or
overturn.
Travel slowly and use extra caution when operating
on unfamiliar terrain. Always be alert to changing
terrain conditions.
18
SAFETY
Safety Warnings
Operating Improperly in Reverse
Improperly operating in reverse could result in a collision with an obstacle or
person. Always follow proper operating procedures as outlined in this manual.
See page 52.
Before shifting into reverse gear, always check for obstacles or people behind
the ATV. When it's safe to proceed, back slowly.
Improper Tire Maintenance
Operating this ATV with improper tires
or with improper or uneven tire
pressure could cause loss of control or
accident.
Always use the size and type of tires
specified for your ATV.
Always maintain proper tire pressure as
described in the owner's manual and
on safety labels.
19
SAFETY
Safety Warnings
Operating Over Obstacles
Improperly operating over obstacles could cause loss of control or overturn.
Before operating in a new area, check for obstacles. Avoid operating over large
obstacles such as rocks and fallen trees. If unavoidable, use extreme caution
and always follow proper operating procedures as outlined in this manual. See
page 51.
Skidding or Sliding
Skidding or sliding can cause loss of control or overturn (if tires regain traction
unexpectedly).
On slippery surfaces such as ice or loose gravel, travel slowly and use extra
caution to reduce the chance of skidding or sliding. Do not operate on
excessively slippery surfaces.
Operating Through Deep Water
Operating the ATV through deep or fast-
flowing water could cause the tires to float,
causing loss of control or overturn.
Avoid operating the ATV through deep or
fast-flowing water. If it's unavoidable to
enter water that exceeds the
recommended maximum depth (see page
50):
• Travel slowly.
• Balance your weight carefully.
• Avoid sudden movements.
• Maintain a slow and steady forward motion. Do not make sudden turns or
stops, and do not make sudden throttle changes.
• Wet brakes may have reduced stopping ability. After leaving water, test the
brakes. Apply them lightly several times while driving slowly. The friction will
help dry out the pads.
20
SAFETY
Safety Warnings
Improper Cargo Loading
Overloading the ATV or carrying/towing cargo improperly may cause changes in
handling, which could cause loss of control or an accident.
• Never exceed the stated load capacity for this ATV.
• Cargo should be properly distributed and securely attached.
• Reduce speed when carrying cargo or pulling a trailer. Allow a greater dis-
tance for braking.
• NEVER exceed 50 MPH (80 km/h) when rear cargo loads are above 75 lbs.
(34 kg) and/or front cargo loads are above 37 lbs. (17 kg).
• Always follow the instructions in the owner's manual for carrying cargo or pull-
ing a trailer.
Operating on Frozen Bodies of Water
Operating on frozen bodies of water may result in serious injury or death if the
ATV and/or the operator fall through the ice.
Never operate the ATV on a frozen body of water unless you have
independently verified that the ice is sufficiently thick to support the weight and
moving force of the ATV, you and your cargo, together with any other vehicles in
your party. Variances in snow depth and/or water currents may result in uneven
ice thickness. Always check with local authorities and residents to confirm ice
conditions and thickness over your entire route. ATV operators assume all risk
associated with ice conditions on frozen bodies of water.
Poor Visibility
Operating the ATV in darkness or inclement weather could result in a collision or
accident, especially if operating on a road or street. This ATV is not equipped
with highway-approved lights. Operate this vehicle off-road only. Use caution
and drive at reduced speeds in conditions of reduced visibility such as fog, rain
and darkness. Clean headlights frequently and replace burned out headlamps
promptly.
21
SAFETY
Safety Warnings
Operating a Damaged ATV
Operating a damaged ATV can result in an accident. After any overturn or
accident, have a qualified service dealer inspect the entire machine for possible
damage, including (but not limited to) brakes, throttle and steering systems.
Physical Skills
Safe operation of this rider-active vehicle requires good judgement and physical
skills. Persons with cognitive or physical disabilities who operate this vehicle
have an increased risk of overturn and loss of control.
Hot Exhaust Systems
Exhaust system components are very hot during and after use of the vehicle.
Hot components can cause burns and fire. Do not touch hot exhaust system
components. Always keep combustible materials away from the exhaust
system. Use caution when traveling through tall grass, especially dry grass.
Unauthorized Use of the ATV
Leaving the keys in the ignition can lead to unauthorized use of the vehicle,
which could result in an accident or overturn. Always remove the ignition key
when the vehicle is not in use.
22
SAFETY
Safety Labels and Locations
Warning labels have been placed on the vehicle for your protection.
Read and follow the instructions on each label carefully. If any of the
labels shown in this manual differ from the labels on your vehicle,
always read and follow the instructions of the labels on the vehicle.
If an informational or graphic label becomes illegible or comes off, con-
tact your POLARIS dealer to purchase a replacement. Replacement
safety labels are provided by POLARIS at no charge. The part number is
printed on the label.
General Warning
WARNING
Improper ATV use can result in SEVERE INJURY or DEATH
ALWAYS USE AN APPROVED HELMET AND PROTECTIVE GEAR
NEVER USE ON PUBLIC ROADS
NEVER CARRY PASSENGERS
NEVER USE WITH DRUGS OR ALCOHOL
NEVER operate:
• without proper training or instruction
• at speeds too fast for your skills or the conditions
• on public roads - a collision can occur with another vehicle
• with a passenger - passengers affect balance and steering and increase risk
of losing control
ALWAYS:
• use proper riding techniques to avoid vehicle overturns on hills and rough ter-
rain and in turns
• avoid paved surfaces - pavement may seriously affect handling and control
LOCATE AND READ OWNER’S MANUAL.
FOLLOW ALL INSTRUCTIONS AND WARNINGS.
7175376
23
SAFETY
Safety Labels and Locations
Discretionary Warning
WARNING
• Never operate this ATV on HILLS steeper than 25 degrees 25. To pre-
vent overturn on hilly terrain, use throttle and brakes gradually, and shift
weight uphill.
• REVERSE operation can be dangerous even at low speeds. Steering
becomes difficult. To prevent loss of control, avoid sudden braking or sharp
turns.
7175511
Rack Warning, Front and Rear (TRAIL BOSS)
WARNING
• DO NOT TOW FROM RACK OR BUMPER. Vehicle damage or tipover may
result causing severe injury or death. Tow only from tow hooks or hitch.
• Max Rack Loads: Front 75 lbs. (34 kg) Rear 125 lbs. (57 kg)
7172666
General
Warning
Discretionary
Warning
Rack
Warning
Rack
Warning
24
SAFETY
Safety Labels and Locations
“No Passenger” Warning
WARNING
NEVER ride as a passenger.
Passengers can cause a loss of control, resulting in SEVERE INJURY or
DEATH.
7175378
Tire Pressure/Load Warning (TRAIL BOSS)
WARNING
Improper tire pressure or overloading can cause loss of control.
Loss of control can result in severe injury or death.
• Cold tire pressure:
Front: 5.0 psi (34.5 kPa)
Rear: 5.0 psi (34.5 kPa)
• Maximum weight capacity: 415 lbs. (188 kg)
• NEVER exceed 50 MPH (80 km/h) when rear cargo loads are above 75 lbs.
(34 kg) and/or front cargo loads are above 37 lbs. (17 kg).
7177985
Tire Pressure/Load Warning (TRAIL BLAZER)
WARNING
Improper tire pressure or overloading can cause loss of control.
Loss of control can result in severe injury or death.
• Cold tire pressure:
Front: 5.0 psi (34.5 kPa)
Rear: 5.0 psi (34.5 kPa)
• Maximum weight capacity: 275 lbs. (125 kg)
7177986
“No Passenger”
Warning
Clutch Cover
Warning
Age 16 Warning
Tire Pressure/Load
Warning
25
SAFETY
Safety Labels and Locations
Age 16 Warning
WARNING
Operating this ATV if you are under the age of 16 increases your chance of
severe injury or death.
NEVER operate this ATV if you are under age 16.
7175374
Clutch Cover Warning
WARNING
• Moving parts hazard under belt-clutch guard. To prevent serious injury, do not
operate vehicle with guard removed.
• Do not modify engine or clutch. Doing so can cause part failure, possible
imbalance, and excessive engine RPM, which can result in serious injury or
death.
NO STEP
7172563
Reverse Override Warning
WARNING
Improper use of override button can lead to loss of control resulting in severe
injury or death. Do not activate override while throttle is engaged. Always apply
throttle gradually, while in reverse.
7175486
26
FEATURES AND CONTROLS
Switches
Engine Stop Switch
Move the stop switch either left or right to
the OFF position to stop the engine quickly.
The engine will not start or run when the
switch is off.
Both the main switch and the engine stop switch will shut off all electri-
cal power to the vehicle, including lights.
Main Key Switch
Use the main key switch to start the engine. See page 41 for starting pro-
cedures.
Override
Switch
Main Key Switch
Engine
Stop Switch
Headlight
Switch
OFF OFFRUN
27
FEATURES AND CONTROLS
Switches
Override Switch
This vehicle is equipped with a reverse speed limiter system. To gain
additional wheel speed while backing, release the throttle and press the
override switch.
WARNING! Pressing the override switch while the throttle is open can cause
loss of control, which may result in serious injury or death. Always release the
throttle before pressing the override switch.
Headlight Switch
Use the headlight switch to turn the lights on and off. The key must be in
the ON position and the engine stop switch must be in the RUN position
to operate the headlights.
Indicator Lights
With the engine running, verify the function of all indicator lights before
each use of the vehicle.
Tip: The taillight is on whenever the main switch (key) is on. Turn the key off to
prevent battery drain.
Neutral Indicator
Reverse Indicator
High Temperature Warning
(displays if engine overheats)
28
FEATURES AND CONTROLS
Throttle Lever
Operating an ATV with sticking or improperly operating throttle controls could
cause an accident. Never start or operate an ATV that has a sticking or
improperly operating throttle. Always contact your dealer for service before
operating the vehicle.
Failure to check or maintain proper operation of the throttle system can result in
an accident if the throttle lever sticks during operation. Always check the lever
for free movement and return before starting the engine. Also check
occasionally during operation.
Modifications to the electronic throttle control could result in failure to perform as
designed, which could result in an accident. Do not attempt to modify the throttle
control system or replace it with any after market throttle mechanisms. Always
ensure that the throttle cable is installed and properly routed to the throttle
control.
Engine speed and vehicle move-
ment are controlled by pressing the
throttle lever. The throttle lever is
spring loaded. Engine speed returns
to idle when the lever is released.
This ATV is equipped with
POLARIS Electronic Throttle Con-
trol (ETC), which is designed to
reduce the risk of a frozen or stuck
throttle. If the throttle cable should
stick in an open position when the operator releases the throttle lever,
the engine will stop, and power to the rear wheels will cease.
WARNING
29
FEATURES AND CONTROLS
Brake Lever
Operating the ATV with a spongy brake lever can result in loss of braking, which
could cause an accident. Never operate the ATV with a spongy-feeling brake
lever. Always contact your dealer for service before operating the vehicle.
Squeeze the brake lever toward the handlebar to apply the front and rear
brakes. These brakes are hydraulically activated disc type brakes that
are activated by only one lever.
Always test brake lever travel and master cylinder fluid level before rid-
ing. When squeezed, the lever should feel firm. Any sponginess would
indicate a possible fluid leak or low master cylinder fluid level, which
must be corrected before riding. Contact your dealer for proper diagno-
sis and repairs.
Parking Brake
Locking the Parking 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 for-
ward to engage the lock.
4. Release the brake lever.
5. To release the parking brake lock, squeeze and release the brake
lever. It will return to its unlocked position.
WARNING! Operating the ATV while the parking brake is engaged could result
in an accident or fire. Always check to be sure the parking brake is disengaged
before operating.
The parking brake may relax if left on for a long period of time. Always
block the wheels to prevent rolling. Always block the wheels on the
downhill side of the ATV if leaving it parked on a hill. Another option is
to park the ATV in a sidehill position. Never depend on the parking
brake alone if the ATV is parked on a hill. Always block the wheels to
prevent rolling.
WARNING
30
FEATURES AND CONTROLS
Auxiliary Foot Brake
Never back down a hill. Applying the auxiliary brake when backing down a hill
may cause rear tipover, which could result in serious injury or death.
Use caution when applying the auxiliary brake. Do not aggressively apply the
auxiliary brake when going forward. The rear wheels may skid and slide
sideways, causing loss of control and serious injury or death.
The auxiliary brake system is
intended to be used as a backup
for the main brake system.
Should the main system fail,
use the auxiliary foot brake.
The auxiliary foot brake is
located on the inside of the
right footrest. Operate this
brake with your right foot.
If the rear wheels slide while
using the auxiliary brake,
reduce brake pedal pressure to
brake the rear wheels without
skidding.
WARNING
Auxiliary Foot Brake
31
FEATURES AND CONTROLS
Brake Fluid
An over-full master cylinder may cause brake drag or brake lock-up, which could
result in an accident. Maintain brake fluid at the recommended level. Do not
overfill.
Never store or use a partial bottle of brake fluid. Brake fluid is hygroscopic,
meaning it rapidly absorbs moisture from the air. The moisture causes the
boiling temperature of the brake fluid to drop, which can lead to early brake fade
and the possibility of brake failure, which could result in an accident. After
opening a bottle of brake fluid, always discard any unused portion.
Always maintain brake fluid at the recommended level. Do not overfill.
If the fluid level is low add DOT 4 brake fluid only. See page 103 for the
part numbers of POLARIS products.
Under normal operation, the diaphragm extends into the reservoir as
fluid level drops. If the fluid level is low and the diaphragm is not
extended, a leak is likely and the diaphragm should be replaced. To
ensure proper diaphragm operation, always fill the reservoir as needed
whenever the cover is loosened or removed. Do not overfill.
WARNING
32
FEATURES AND CONTROLS
Brake Fluid
Hand Brake
Check the brake fluid level in the
master cylinder before each use of
the vehicle. The master cylinder is
located on the left handlebar.
Maintain the fluid level 1/4" (6
mm) below the top edge of the
master cylinder. Do not overfill.
1. Position the vehicle on a level
surface. Make sure the han-
dlebars are straight.
2. View the fluid level through
the indicator window (eye) on
the top of the master cylinder. The eye will appear dark when the
fluid level is full. When fluid is low, the eye will be clear.
3. Add the recommended fluid as needed. Do not overfill.
Auxiliary Foot Brake
Check the brake fluid level frequently for the auxiliary brake system.
The brake fluid reservoir is located either under the seat or near the foot
brake. Maintain the fluid level between the minimum and maximum
marks. Do not overfill.
Master Cylinder
Indicator
Window
33
FEATURES AND CONTROLS
Choke
The choke assists in starting a cold
engine. Refer to the engine start-
ing procedure on page 41 for cor-
rect choke and throttle settings
during starting.
Fuel Tank 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 to the fuel tank. Use either
leaded or unleaded gasoline with a
minimum pump octane number of
87=(R+ M/2) octane. Do not use
fuel with ethanol content greater
than 10 percent, such as E-85 fuel.
Fuel Valve
The fuel valve is located on the
left side of the vehicle, below the
fender.
ON: For normal operation.
OFF: For vehicle storage and
when transporting.
Fuel Filter
The in-line fuel filter should be
replaced by your dealer after
every 100 hours of operation or
annually. Do not attempt to clean the fuel filter.
Fuel Tank
Cap
Fuel
Guage
OFFON
Choke
Fuel
Valve
34
FEATURES AND CONTROLS
Automatic Transmission Gear Selector
The transmission gear selector is located
on the right side of the vehicle.
F: Forward Gear
N: Neutral
R: Reverse
To shift gears, brake to a complete stop.
When the engine is idling, move the lever
to the desired gear.
NOTICE: Shifting gears with the engine
speed above idle or while the
vehicle is moving could cause
transmission damage.
Whenever the ATV is left unattended,
always place the transmission in gear and
lock the parking brake.
Gear
Selector
35
FEATURES AND CONTROLS
Recoil Starter
If the battery is too weak to start
the engine, use the recoil starter.
Follow the starting procedures on
page 41, 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 will be harder to pull when the engine is on a compression stroke.
When a compression stroke is found, continue pulling the rope just until the
engine rolls past the stroke, then stop pulling immediately.
3. Allow the recoil rope to rewind into the recoil assembly, then pull
the rope abruptly and forcefully to start the engine.
4. Repeat all steps until the engine starts.
5. Make sure the handle is fully seated on the housing.
NOTICE: Extending the recoil starter rope until it stops can cause damage to
the recoil assembly. Do not extend the starter rope so far that it stops.
If the starter rope handle is not seated properly, water may enter the
recoil housing and damage components. Make sure the handle is
fully seated on the recoil housing, especially when traveling in wet
areas.
Recoil Starter
Handle
36
OPERATION
Failure to operate the ATV properly can result in a collision, loss of control,
accident or overturn, which may result in serious injury or death. Read and
understand all safety warnings outlined in the safety section of this owner’s
manual.
Break-In Period
The break-in period for your new POLARIS ATV is the first ten hours
of operation, or the time it takes to use the first two full tanks of gaso-
line. No single action on your part is as important as following the pro-
cedures for a proper break-in. Careful treatment of a new engine and
drive components will result in more efficient performance and longer
life for these components.
NOTICE: Excessive heat build-up during the first three hours of operation will
damage close-fitted engine parts and drive components. Do not
operate at full throttle or high speeds during the first three hours of
use.
WARNING
37
OPERATION
Break-In Period
Engine and Drivetrain Break-in
1. Fill the fuel tank with gasoline. See page 33. Always exercise
extreme caution whenever handling gasoline.
2. Check the oil level on the dipstick. See page 62. Add oil if neces-
sary to maintain the level in the safe operating range.
3. Drive slowly at first. Select an open area that allows room to famil-
iarize yourself with vehicle operation and handling.
4. Vary the throttle positions. Do not operate at sustained idle.
5. Perform regular checks on fluid levels, controls and areas outlined
on the daily pre-ride inspection checklist. See page 40.
6. Pull only light loads.
7. Change both the oil and the filter at 20 hours or one month, which-
ever comes first.
PVT Break-in (Clutches/Belt)
A proper break-in of the clutches and drive belt will ensure a longer life
and better performance. Break in the clutches and belt by operating at
slower speeds during the break-in period as recommended. Pull only
light loads. Avoid aggressive acceleration and high speed operation dur-
ing the break-in period.
If a belt fails, always clean away all debris when replacing the belt.
38
OPERATION
Safe Operation Practices
1. Complete the recommended safety training before operating this
vehicle. See page 7.
2. Do not allow anyone under 16 years of age to operate this vehicle.
Do not allow anyone with cognitive or physical disabilities to oper-
ate this vehicle.
3. Never carry a passenger on this ATV.
4. Engine exhaust fumes are poisonous. Never start the engine or let it
run in an enclosed area.
5. Before operating, learn how to use the auxiliary brake for emer-
gency situations (if service brakes become inoperable).
6. Operate this vehicle off-road only. Never operate the vehicle on
pavement or on any public street, road or highway, including dirt
and gravel roads.
7. Use caution and drive at reduced speeds in conditions of reduced
visibility such as fog, rain and darkness. Clean headlights fre-
quently and replace burned out headlamps promptly.
8. Drive in a manner appropriate for your skills and operating condi-
tions. Never operate at excessive speeds. Never attempt wheelies,
jumps, or other stunts. Never remove your hands from the handle-
bars while operating, and always keep both feet on the footrests.
9. Never consume alcohol or drugs before or while operating an ATV.
10. Always use the size and type of tires specified for your vehicle.
Always maintain proper tire pressure.
11. Never operate a damaged ATV. After any overturn or accident, have
a qualified service dealer inspect the entire machine for possible
damage.
12. Never operate the ATV on a frozen body of water unless you have
independently verified that the ice is sufficiently thick to support the
weight and moving force of the ATV, you and your cargo, together
with any other vehicles in your party.
13. Do not touch hot exhaust system components. Always keep com-
bustible materials away from the exhaust system.
14. Always remove the ignition key when the vehicle is not in use to
prevent unauthorized use.
39
OPERATION
Know Your Riding Area/Tread Lightly
Familiarize yourself with all laws and regulations concerning the opera-
tion of this off-road vehicle in your area. Respect the environment in
which you ride. Find out where the designated riding areas are by con-
tacting your POLARIS dealer, a local riding club or local officials.
Help keep our trails open for recreational vehicle use. As an off-road
enthusiast, you represent the sport and can set a good example (or a poor
example) for others to follow. Tread lightly. Operate with respect for the
terrain, avoid littering, and always stay on the designated trails.
Trail Etiquette
Always practice good etiquette when riding. Allow a safe distance
between your vehicle and other vehicles operating in the same area.
Communicate to oncoming operators by signaling the number of vehi-
cles in your group. When stopping, move your vehicle to the edge of the
trail as far as possible to allow others to pass safely.
40
OPERATION
Pre-Ride Checklist
Failure to inspect and verify that the ATV is in safe operating condition
before operating increases the risk of an accident. Always inspect the
ATV before each use to make sure it's in safe operating condition.
Item Remarks Page
Brake system/lever travel Ensure proper operation 29
66
Brake fluid Ensure proper level 31
Auxiliary brake Ensure proper operation 30
Front suspension Inspect, lubricate if necessary 61
Rear suspension Inspect, lubricate if necessary 61
Steering Ensure free operation -
Tires Inspect condition and pressure 71
Wheels/fasteners Inspect, ensure fastener tightness 71
Frame nuts, bolts, fasteners Inspect, ensure tightness -
Fuel and oil Ensure proper levels 33
62
Throttle Ensure proper operation 28
69
Indicator lights/switches Ensure operation 26
Engine stop switch Ensure proper operation 26
Drive chain Check condition/slack, lubricate as
needed
77
Air filter, pre-filter Inspect, clean 74
Air box sediment tube Drain deposits whenever visible -
Headlamp Check operation, apply POLARIS
dielectric grease when lamp is
replaced
27
81
Brake light/tail lamp Check operation, apply POLARIS
dielectric grease when lamp is
replaced
82
Riding gear Wear approved helmet, goggles, and
protective clothing
8
41
OPERATION
Starting the Engine
1. Position the vehicle on a level surface outdoors or in a well-venti-
lated area.
2. Place the transmission in neutral.
3. Lock the parking brake.
Tip: The starter interlock will prevent the engine from starting if the transmission
is in gear and the brake is not engaged.
4. Turn the fuel valve on.
5. Sit on the vehicle.
Tip: Do not use the choke if starting a warm engine. Excessive use of the choke
can cause the spark plug to become wet fouled.
6. If the engine is cold, pull the choke
knob out until it stops. If the knob
doesn't stay where positioned,
increase the tension by rotating the
tension adjusting nut clockwise.
Tip: The variable choke is fully on when the
knob is pulled completely out. The choke
is off when the knob is pushed completely
in. The choke can be adjusted gradually,
depending on how much choke is needed
for starting. Be sure the choke is off dur-
ing operation, as excess fuel washing into
the engine oil will increase wear on
engine components.
7. Move the engine stop switch to RUN.
8. Do not press the throttle while starting the engine.
Choke
Knob
Adjusting
Nut
42
OPERATION
Starting the Engine
9. Turn the ignition key past the ON position to engage the starter.
Activate the starter for a maximum of five seconds, releasing the
key when the engine starts.
NOTICE: Operating the vehicle immediately after starting could cause engine
damage. Allow the engine to warm up for several minutes before
operating the vehicle.
10. If the engine does not start, return the key to the OFF position and
wait five seconds before attempting to start again. Activate the
starter for another five seconds if necessary. Repeat this procedure
until the engine starts.
Tip: If a warm engine has cooled to a point where it does not readily start, inter-
mittent use of the choke (knob pulled half way out) may be necessary. If the
engine is over-choked when warm, depress the throttle lever fully while
cranking to aid in starting. Release the throttle lever immediately after the
engine starts. If the engine does not start and all conditions are favorable,
change the spark plug and try again.
11. If the engine slows or stops, position the choke knob half way in to
allow proper engine warm up. Vary the engine RPM slightly with
the throttle to aid in warm-up. When the engine idles smoothly,
push the choke completely in.
43
OPERATION
Driving Procedures
1. Wear a helmet and eye protection. See page 8.
2. Sit upright with both feet on the footrests and both hands on the
handlebars.
3. Start the engine and allow it to warm up.
4. Shift the transmission into gear.
5. Check your surroundings and determine your path of travel.
6. Release the parking brake.
7. Slowly depress the throttle with your right thumb and begin driving.
8. Drive slowly. Practice maneuvering and using the throttle and
brakes on level surfaces.
44
OPERATION
Turning the Vehicle
Your ATV is equipped with
a solid rear axle, which
drives both rear wheels
equally at all times. This
means that the wheel on the
outside of the turn must
travel a greater distance than
the inside wheel when turn-
ing and the inside tire must
slip traction slightly.
To turn, steer in the direction
of the turn, leaning your
upper body to the inside of
the turn while supporting
your weight on the outer
footrest. This technique
alters the balance of traction
between the rear wheels, allowing the turn to be made smoothly. The
same leaning technique should be used for turning in reverse.
Practice making turns at slow speeds before attempting to turn at faster
speeds.
WARNING! Turning improperly can result in vehicle overturn. Never turn
abruptly or at sharp angles. Never turn at high speeds.
45
OPERATION
Driving on Slippery Surfaces
Whenever riding on slippery surfaces such as wet trails or loose gravel,
or during freezing weather, follow these precautions:
1. Do not operate on excessively rough, slippery or loose terrain.
2. Slow down when entering slippery areas.
3. Maintain a high level of alertness, reading the trail and avoiding
quick, sharp turns, which can cause skids.
4. Never apply the brakes during a skid. Correct a skid by turning the
handlebars in the direction of the skid and shifting your body
weight forward.
Sideways
skid
Turn in
direction of
skid
46
OPERATION
Driving Uphill
Braking and handling are greatly affected when operating in hilly ter-
rain. Improper procedure could cause loss of control or overturn. When-
ever traveling uphill, follow these precautions:
1. Drive straight uphill.
2. Avoid steep hills (25 maximum).
3. Always check the terrain carefully before ascending any hill.
4. Never climb hills with excessively slippery or loose surfaces.
5. Keep both feet on the footrests.
6. Shift body weight uphill.
7. Proceed at a steady rate of speed and throttle opening. Opening the
throttle suddenly could cause the ATV to flip over backwards.
8. Remain alert and be prepared to take emergency action. This may
include quick dismounting of the vehicle.
25 Maximum
47
OPERATION
Driving on a Sidehill (Sidehilling)
Driving on a sidehill is not recommended. Improper procedure could
cause loss of control or overturn. Avoid crossing the side of any hill
unless absolutely necessary.
If crossing a sidehill is unavoidable, follow these precautions:
1. Slow down.
2. Avoid crossing the side of a steep hill.
3. Shift body weight uphill.
4. Keep your feet on the footrests.
5. If the vehicle begins to tip, quickly turn the front wheel downhill, if
possible, or dismount on the uphill side immediately!
48
OPERATION
Driving Downhill
When driving downhill, follow these precautions:
1. Avoid steep hills (25 maximum).
2. Shift body weight uphill.
3. Drive straight downhill.
4. Slow down. Excessive speed when traveling downhill can cause
loss of control.
5. Squeeze the brake lever gradually. Applying the brakes too firmly
may cause the rear wheels to lock, which could result in loss of con-
trol.
25 Maximum
49
OPERATION
Turning Around on a Hill (K-Turn)
If the vehicle stalls while climbing a hill, never back it down the hill!
Use the K-turn to turn around.
1. Stop and lock the parking brake while keeping body weight uphill.
2. Leave the transmission in forward and shut off the engine.
3. Dismount on the uphill side of the vehicle, or on the left if the vehi-
cle is pointing straight uphill.
4. Staying uphill of the vehicle, turn the handlebars full left.
5. While holding the brake lever, release the parking brake lock and
slowly allow the vehicle to roll around to your right until it's point-
ing across the hill or slightly downward.
6. Lock the parking brake. Remount the vehicle from the uphill side,
keeping body weight uphill.
7. Start the engine with the transmission still in forward.
8. Release the parking brake and proceed slowly, controlling speed
with the brake lever, until the vehicle is on more level ground.
8 ft. (2.4 m)
50
OPERATION
Driving Through Water
Your ATV can operate
through water with a maxi-
mum recommended depth
equal to the bottom of the
footrests. Follow these pro-
cedures when operating
through water:
1. Determine water
depths and current
before entering water.
2. Choose a crossing
where both banks have
gradual inclines.
3. Avoid operating
through deep or fast-
flowing water.
NOTICE: Major engine damage can result if the vehicle is not thoroughly
inspected after operation in water. Perform the services outlined in
the maintenance chart. See page 57. The following areas need
special attention: engine oil, transmission oil, front and rear
gearcases (if equipped) and all grease fittings
.
If the vehicle tips or overturns in water, or if the engine stops during or
after operating in water, restarting can result in serious engine
damage. Transport the vehicle to your dealer for service before
restarting the engine. If this is not possible, follow the vehicle
immersion inspection and drying procedures outlined on page 85,
then see your dealer for service at the first opportunity.
4. After leaving water, test the brakes. Apply them lightly several
times while driving slowly. The friction will help dry out the pads.
If it’s unavoidable to enter water deeper than the footrest level:
• Proceed slowly. Avoid rocks and obstacles.
• Balance your weight carefully. Avoid sudden movements.
• Maintain a steady rate of speed. Do not make sudden turns or stops.
Do not make sudden throttle changes.
Maximum Depth
51
OPERATION
Driving Over Obstacles
Follow these precautions when 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. Travel slowly and use extra caution when operating on unfamiliar
terrain. Not all obstacles are immediately visible.
4. Never attempt to operate over large obstacles, such as rocks or
fallen trees.
52
OPERATION
Driving in Reverse
Follow these precautions when operating in reverse:
1. Always check for obstacles or people behind the vehicle.
2. Always avoid backing downhill.
3. Back slowly.
4. Apply the brakes lightly for stopping.
5. Avoid turning at sharp angles.
6. Never open the throttle suddenly.
7. Do not use the override switch unless additional wheel speed is
required for vehicle movement. Use the override with caution as
rearward vehicle speed is greatly increased. Do not operate at wide
open throttle. Operate the throttle just enough to maintain a desired
speed.
NOTICE: Excessive throttle operation while in the speed limit mode may cause
fuel to build in the exhaust, resulting in engine popping and/or engine
damage.
53
OPERATION
Parking on an Incline
Avoid parking on an incline if possible. If it's unavoidable, follow these
precautions:
1. Stop the engine.
2. Place the transmission in gear.
3. Lock the parking brake.
4. Always block the rear wheels on the downhill side.
5. Turn the fuel valve off.
25 maximum
54
OPERATION
Hauling Cargo
Overloading the vehicle or carrying or towing cargo improperly can alter vehicle
handling and may cause loss of control or brake instability, which can result in
serious injury or death. Always follow these precautions when hauling cargo:
REDUCE SPEED AND ALLOW GREATER DISTANCES FOR BRAKING
WHEN HAULING CARGO.
NEVER EXCEED THE MAXIMUM WEIGHT CAPACITY of the vehicle. When
determining the weight you are adding to the vehicle, include the weight of the
operator, accessories, loads in the rack or box and the load on the trailer tongue.
The combined weight of these items must not exceed the maximum weight
capacity.
CARRY LOADS AS LOW ON THE RACKS AS POSSIBLE. Carrying loads high
on the racks raises the center of gravity of the vehicle and creates a less stable
operating condition.
SECURE ALL LOADS BEFORE OPERATING. Unsecured loads can create
unstable operating conditions, which could result in loss of control of the vehicle.
OPERATE ONLY WITH STABLE AND SAFELY ARRANGED LOADS. When
handling off-centered loads that cannot be centered, securely fasten the load
and operate with extra caution. Always attach the tow load to the hitch point
designated for your vehicle.
HEAVY LOADS CAN CAUSE BRAKING AND CONTROL PROBLEMS. Use
extreme caution when applying brakes with a loaded vehicle. Avoid terrain or
situations that may require backing downhill.
USE EXTREME CAUTION when operating with loads that extend over the rack
sides. Stability and maneuverability may be adversely affected, causing the
vehicle to overturn.
DO NOT BLOCK THE FRONT HEADLIGHT BEAM when carrying loads on the
front rack.
DO NOT TRAVEL FASTER THAN THE RECOMMENDED SPEEDS.
NEVER exceed 50 MPH (80 km/h) when rear cargo loads are above 75 lbs. (34
kg) and/or front cargo loads are above 37 lbs. (17 kg).
Vehicle should never exceed 10 mph (16 kph) while towing a load on a level
surface. Vehicle speed should never exceed 5 mph (8 kph) when towing loads in
rough terrain, while cornering, or while ascending or descending a hill.
WARNING
55
OPERATION
Hauling Cargo
Never exceed the weight capacities specified for your ATV on warning
labels and in the specifications section of this manual.
Always read and understand the load distribution warnings on the rack
and hitch warning labels.
Never carry cargo on the front of the TRAIL BLAZER. Cargo should be
evenly distributed and mounted as low as possible on the rear rack.
NEVER exceed 50 MPH (80
km/h) when rear cargo loads
are above 75 lbs. (34 kg) and/or
front cargo loads are above 37
lbs. (17 kg).
On the TRAIL BOSS, cargo
weight should be evenly dis-
tributed (1/3 on the front rack
and 2/3 on the rear rack) and
mounted as low as possible.
When operating over rough or
hilly terrain, reduce speed and
cargo weight to maintain sta-
ble driving conditions. Do not
obstruct the headlight beam
with cargo.
Towing Loads
Some models are equipped with a hitch. Accessory hitch kits are avail-
able for other models.
NOTICE: Using an improper hitch or exceeding the maximum hitch weight
capacity can result in serious damage to the vehicle and will void
your ATV warranty. Always install POLARIS-approved (or equivalent)
accessories designed for ATV use.
Always attach a towed load to the hitch point. If towing a load, reduce
rear rack cargo weight by the amount of tongue weight.
• The combination of rear rack cargo weight and tongue weight must
not exceed the rear rack capacity.
• The total load (operator, accessories, cargo and weight on hitch) must
not exceed the maximum weight capacity of the vehicle.
1/3
2/3
TRAIL BOSS
only
56
EMISSION CONTROL SYSTEMS
Noise Emission Control System
Do not modify the engine, intake or exhaust components, as doing so
may affect compliance with U.S.A. EPA noise control requirements (40
CFR 205) and local noise level requirements.
Operation on Public Lands in the U.S.A.
Your POLARIS vehicle has a spark arrester that was tested and qualified
to be in accordance with the USFS standard 5100-1c. Federal law
requires that this spark arrester be installed and functional when the
vehicle is operated on public lands.
Operation of off-road vehicles on public lands in the U.S.A. is regulated
by 43 CFR 420. Violations are subject to monetary penalties. Federal
regulations can be viewed online at www.gpoaccess.gov/ecfr/.
Crankcase Emission Control System
This engine is equipped with a closed crankcase system. Blow-by gases
are forced back to the combustion chamber by the intake system. All
exhaust gases exit through the exhaust system.
Exhaust Emission Control System
The emissions from the exhaust of this vehicle are controlled by engine
design, including factory-set fuel delivery and ignition. The engine and
related components must be maintained at POLARIS specifications to
achieve optimal performance.
Engine idle speed is the only adjustment POLARIS recommends that
the operator perform. Any other adjustments should be performed by an
authorized POLARIS dealer.
The vehicle compliance labels are located on the steering post.
Electromagnetic Interference
This spark ignition system complies with Canadian ICES-002.
This vehicle complies with the EMC requirements of European direc-
tives 97/24/EC and 2004/108/EC.
Non-ionizing Radiation: This vehicle emits some electromagnetic
energy. People with active or non-active implantable medical devices
(such as heart monitoring or controlling devices) should review the lim-
itations of their device and the applicable electromagnetic standards and
directives that apply to this vehicle.
57
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 maintenance chart.
Inspect, clean, lubricate, adjust and replace parts as necessary. When
inspection reveals the need for replacement parts, use genuine
POLARIS parts available from your POLARIS dealer.
Record maintenance and service in the Maintenance Log beginning on
page 120.
Service and adjustments are important for proper vehicle operation. If
you're not familiar with safe service and adjustment procedures, have a
qualified dealer perform these operations.
Maintenance intervals in the following chart are based upon average rid-
ing conditions and an average vehicle speed of approximately 10 miles
per hour (16 km/h). Vehicles subjected to severe use must be inspected
and serviced more frequently.
Severe Use Definition
• Frequent immersion in mud, water or sand
• Racing or race-style high RPM use
• Prolonged low speed, heavy load operation
• Extended idle
• Short trip cold weather operation
Pay special attention to the oil level. A rise in oil level during cold
weather can indicate contaminants collecting in the oil sump or crank-
case. Change oil immediately if the oil level begins to rise. Monitor the
oil level, and if it continues to rise, discontinue use and determine the
cause or see your dealer.
58
MAINTENANCE
Periodic Maintenance Chart
Improperly performing the procedures marked with a could result in
component failure and cause an accident, which may result in serious injury or
death. Always have an authorized POLARIS dealer perform these services.
Maintenance Chart Key
Perform these operations more often for vehicles subjected to
severe use.
E Emission-related service (Failure to conduct this maintenance will
not void the emissions warranty but may affect emissions.)
Have an authorized POLARIS dealer perform these services.
WARNING
59
MAINTENANCE
Periodic Maintenance Chart
Perform all services at whichever maintenance interval is reached first.
Item Maintenance Interval
(whichever comes first)
Remarks
Hours Calendar Miles
(Km)
Steering - Pre-Ride - Make adjustments as need
ed. See Pre-Ride Checklist
on page 40.
Front suspension - Pre-Ride -
Rear suspension - Pre-Ride -
Tires - Pre-Ride -
Brake fluid level - Pre-Ride -
Brake lever travel - Pre-Ride -
Brake system - Pre-Ride -
Drive chain - Pre-Ride -
Wheels/fasteners - Pre-Ride -
Frame fasteners - Pre-Ride -
Engine oil level - Pre-Ride -
E
Air filter, pre-filter - Daily - Inspect; clean often; replace
as needed
Air box sediment
tube
- Daily - Drain deposits when visible
Headlamp/tail
lamp
- Daily - Check operation; apply
dielectric grease if replacing
E
Air filter,
main element
- Weekly - Inspect; replace as needed
Recoil housing
(if applicable)
- Weekly - Drain water as needed,
check often if operating in wet
conditions
Brake pad wear 10 H Monthly 100 (160) Inspect periodically
Battery 20 H Monthly 200 (320) Check terminals; clean; test
Transmission oil 25 H Monthly 250 (400) Inspect level; change yearly
E
Engine breather
filter (if equipped)
25 H Monthly 250 (400) Inspect; clean if needed
General
lubrication
50 H 3 M 500 (800) Lubricate all fittings, pivots,
cables, etc.
Carburetor float
bowl
50 H 6 M 500 (800) Drain bowl periodically and
prior to storage
E
Throttle Cable/
ETC Switch
50 H 6 M 500 (800) Inspect; adjust; lubricate;
replace if necessary
E
Choke cable 50 H 6 M 500 (800) Inspect; adjust; lubricate;
replace if necessary
60
MAINTENANCE
Periodic Maintenance Chart
Perform these procedures more often for vehicles subjected to severe use.
E Emission-Related Service
Have an authorized POLARIS dealer perform these services.
Item Maintenance Interval
(whichever comes first)
Remarks
Hours Calendar Miles
(Km)
E Carburetor air
intake ducts/flange
50 H 6 M 500 (800 Inspect duct for proper seal-
ing/air leaks
Drive belt 50 H 6 M 500 (800) Inspect; adjust; replace as
needed
Engine oil change 100 H 6 M 1000 (1600) Perform a break-in oil change
at 20 hours
Oil filter change 100 H 6 M 1000 (1600) Replace with oil change
E
Valve clearance 100 H 12 M 1000 (1600) Inspect; adjust
E
Fuel system/filter 100 H 12 M 1000 (1600) Check for leaks at tank cap,
lines, fuel valve, filter, pump,
carburetor; replace lines
every two years
Engine mounts 100 H 12 M 1000 (1600) Inspect
Exhaust muffler/
pipe
100 H 12 M 1000 (1600) Inspect
E
Spark plug 100 H 12 M 1000 (1600) Inspect; replace as needed
E
Ignition Timing 100 H 12 M 1000 (1600) Inspect
Wiring 100 H 12 M 1000 (1600) Inspect for wear, routing,
security; apply dielectric
grease to connectors
subjected to water, mud, etc.
Clutches (drive
and driven)
100 H 12 M 1000 (1600) Inspect; clean; replace worn
parts
Front wheel
bearings
100 H 12 M 1000 (1600) Inspect; replace as needed
Brake fluid 200 H 24 M 2000 (3200) Change every two years
Spark arrester 300 H 36 M 3000 (4800) Clean out
Idle speed - Adjust as needed
Toe adjustment - Inspect periodically; adjust
when parts are replaced
Headlight aim - Adjust as needed
61
MAINTENANCE
Lubrication Guide
Check and lubricate all components at the intervals outlined in the Peri-
odic Maintenance Chart beginning on page 57. Items not listed in the
chart should be lubricated at the General Lubrication interval. See page
103 for the part numbers of POLARIS products.
The a-arms and lower control arms are lubricated at the factory, and no
additional lubrication will be needed. However, if these components are
subjected to severe use, grease zerks have been provided for additional
lubrication at the user's discretion.
Item Lube Method
Engine Oil PS-4 PLUS Performance
Synthetic 2W-50
See page 62.
Brake Fluid DOT 4 Only See page 31.
Drive Chain(s) O-ring chain lube or SAE
80/90
Lubricate.
Transmission Oil AGL PLUS Transmission
Fluid
See page 64.
Swing Arm
Bushings
Premium All Season
Grease
Locate fittings on swing arm and
grease with grease gun
Axle Housing
Tie Rod Ends Premium All Season
Grease
Lift boot, clean away dirt and grease,
apply fresh grease by hand and reas-
semble. Perform when suspension
action becomes stiff, or after washing.
Swing Arm
Bushings
Axle
Housing
Tie Rod Ends
62
MAINTENANCE
Engine Oil
Oil Recommendations
Always change the oil filter whenever changing oil.
POLARIS recommends the use of POLARIS PS-4 PLUS Performance
Synthetic 2W-50 4-cycle oil or a similar oil for this engine. Oil may
need to be changed more frequently if POLARIS oil is not used. Always
use 2W-50 oil. Follow the manufacturer's recommendations for ambient
temperature operation.
NOTICE: Mixing brands or using a non-recommended oil may cause serious
engine damage. Always use the recommended oil. Never substitute
or mix oil brands.
Oil Specifications
Oil Level
The oil dipstick is located on the left side of the vehicle.
1. Position the vehicle on a
level surface. Place the
transmission in neutral.
Lock the parking brake.
2. Start the engine. Allow it to
idle for 30 seconds. Stop
the engine.
3. Remove the dipstick. Wipe it dry with a clean cloth.
4. Reinstall the dipstick completely.
5. Remove the dipstick and check the oil level. Add oil as needed.
Maintain the oil level in the safe range. Do not overfill.
6. Reinstall the dipstick.
Lubricant Capacity Drain Plug Torque
PS-4 PLUS Performance
Synthetic 2W-50 4-Cycle Oil
1.9 qts. (1.8 l) (with oil cooler)
1.7 qts. (1.6 l) (oil change only)
14 ft. lbs. (19 Nm)
{
Safe Range
63
MAINTENANCE
Oil and Filter Change
Always change the oil and filter at the intervals outlined in the Periodic
Maintenance Chart beginning on page 57. Always change the oil filter
whenever changing oil.
1. Position the vehicle on a level surface. Place the transmission in
neutral. Lock the parking brake.
2. Clean the area around the drain plug.
3. Start the engine. Allow it to idle for two to three minutes. Stop the
engine.
4. Place a drain pan under the engine crankcase. Remove the drain
plug. Allow the oil to drain completely.
CAUTION! Hot oil can cause burns to skin. Do not allow hot oil to contact skin.
5. Reinstall the drain plug with a new sealing washer. Torque to speci-
fication. See page 62.
Tip: The sealing surfaces on the drain plug and crankcase should be clean and
free of burrs, nicks or scratches.
6. Place towels under the oil filter. Using an oil filter wrench, turn the
filter counterclockwise to remove it.
7. Using a clean, dry cloth, clean the filter sealing surface on the
crankcase.
8. Lubricate the gasket on the new filter with a film of new engine oil.
Check to make sure the gasket is in good condition.
9. Install the new filter and turn by hand until the filter gasket contacts
the sealing surface, then turn an additional 1/2 turn.
10. Remove the dipstick and fill the sump with 1.7 quarts (1.6 l) of the
recommended oil (see page 62). Reinstall the dipstick.
11. Start the engine and allow it to idle for one to two minutes. Stop the
engine and inspect for leaks.
12. Recheck the oil level and add oil as necessary to bring the level to
the upper mark on the dipstick.
13. Discard used oil and filter properly.
64
MAINTENANCE
Transmission Oil
Always check and change the transmission oil at the intervals outlined
in the Periodic Maintenance Chart beginning on page 57. POLARIS
recommends the use of POLARIS AGL PLUS Transmission Fluid. See
page 103 for the part numbers of POLARIS products.
Transmission Oil Recommendations
Oil Check
The dipstick is located on the right side of the vehicle near the recoil
handle.
1. Position the vehicle on a
level surface.
2. Remove the dipstick.
Wipe it dry with a clean
cloth.
3. Reinstall the dipstick
completely.
4. Remove the dipstick and
check the fluid level. Add
fluid as needed. Maintain
the fluid level in the safe
range. Do not overfill.
5. Reinstall the dipstick.
Gearcase Lubricant Capacity Drain Plug
To r qu e
Transmission AGL PLUS Transmission
Fluid
11.3 oz.
(335 ml)
14 ft. lbs.
(19 Nm)
Dipstick
65
MAINTENANCE
Transmission 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. Turn the adjuster bolt in to allow
the removal of the drain plug.
5. Remove the drain plug and wipe
the magnetic end clean to
remove accumulated metallic
filings.
6. Allow the oil to drain com-
pletely.
7. Reinstall the drain plug with a
new sealing washer. Torque to
specification.
8. Turn the adjuster bolt out until it
touches the frame, and then turn
an additional 1/2 turn.
9. Tighten the jam nut securely while holding the adjuster bolt.
10. Add the recommended lubricant through the dipstick hole until the
oil level is between the upper and lower limits. Do not overfill.
11. Reinstall the dipstick.
12. Check for leaks.
Jam
Nut
Drain Plug
Adjuster
Bolt
66
MAINTENANCE
Brakes
The front and rear brakes are hydraulic disc brakes, activated by moving
the single brake lever toward the handlebar. The auxiliary foot brake is
also hydraulic. Both brake systems are self-adjusting.
Brake Inspections
The following checks are recommended to keep the brake system in
good operating condition. Check more often if brakes are used heavily
under normal operation.
1. Always keep brake fluid at an
adequate level. See page 31.
2. Check the brake system for fluid
leaks.
3. Check the brakes for excessive
travel or spongy feel.
4. Check the friction pads for wear,
damage and looseness. Replace
the pads when the friction mate-
rial is worn to 1 mm.
5. Check the security and surface
condition of the disc.
1 mm
67
MAINTENANCE
Side Panel Removal
Tip: Side panel removal may be difficult until the locking tabs and receivers 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 rearward to disengage the upper
front section.
4. To reinstall the side panel, align the upper and lower front section
with the mating front cab tabs. Push the panel upward and forward
until the panel is fully seated at the front. Lock the rear of the panel
into the rear front cab tabs. Reinstall the push-pins at the front and
rear of the side panel.
68
MAINTENANCE
Toe Alignment
Use the following procedure to check the toe alignment of the vehicle.
The recommended toe alignment is 1/8" to 1/4" (3-6 mm) toe out.
WARNING! Severe injury or death can result from improper toe alignment and
adjustment. Do not attempt to adjust tie rod alignment. All tie rod adjustments
should be performed by an authorized POLARIS dealer.
1. Position the vehicle on a level surface.
2. Set the handlebars in a straight-ahead position and secure them in
this position.
3. Place a chalk mark on the
center line of the front tires
approximately 10" (25.4 cm)
from the floor, or as close to
the hub/axle center line as
possible. Make sure both
marks are the same distance
from the floor.
4. Measure the distance
between the marks and
record the measurement (1).
5. Move the vehicle until the
chalk marks are at the rear of
the tires, even with the hub/
axle center line.
6. Measure the distance between the marks and record the
measurement (2).
7. Subtract measurement 2 from measurement 1. The difference is the
vehicle toe-out alignment.
8. If you discover improper alignment, see your POLARIS dealer for
service.
1
2
69
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" to 1/8"
(1.5-3 mm) of freeplay is
achieved at the thumb lever.
While adjusting freeplay, be
sure to flip the throttle lever
back and forth.
5. Tighten the lock nut.
6. Squeeze the end of the rub-
ber boot and slide it over the
cable adjuster to its original
position.
Steering Assembly
The steering assembly of the ATV should be checked periodically for
loose nuts and bolts. If loose nuts and bolts are found, see your
POLARIS dealer for service before operating the vehicle.
Lock Nut
Adjuster
Boot
70
MAINTENANCE
Camber and Caster
The camber and caster are non-adjustable.
Rear Spring
The rear shock absorber spring is
adjusted by rotating the adjuster either
clockwise or counterclockwise to
increase or decrease spring tension.
Accessory springs are available through
your POLARIS dealer.
Handlebars
The handlebars can be adjusted for rider preference.
WARNING! Improper adjustment of the handlebars or incorrect torquing of the
adjuster block tightening bolts can cause limited steering or loosening of the
handlebars, resulting in loss of control and serious injury or death. Follow the
adjustment procedures exactly, or see your POLARIS dealer for service.
1. Remove the handlebar cover to
access the handlebar bolts.
2. Loosen the four handlebar bolts.
3. Adjust the handlebar to the
desired height.
4. Be sure the handlebars do not
contact the gas tank or any other
part of the machine when turned
fully to the left or right.
5. Torque the front two bolts to 10-12 ft. lbs. (14-17 Nm), then torque
the rear two bolts. A gap of up to 1/8" (3 mm) will remain at the rear
bolts.
Adjuster
Handlebar Bolts
71
MAINTENANCE
Tires
Operating your ATV with worn tires, improperly inflated tires, non-standard tires
or improperly installed tires will affect vehicle handling and could cause an
accident resulting in serious injury or death. Always follow all tire maintenance
procedures as outlined in this manual and on the labels on the vehicle. Always
use original equipment size and type when replacing tires.
Refer to the specifications section beginning on page 108 for recom-
mended tire type, size and pressure.
Tire Tread Depth
Always replace tires
when tread depth is
worn to 1/8" (3 mm) or
less.
Front Wheel Hub Tightening
Front wheel bearing tightness and spindle nut retention are critical com-
ponent operations. All service must be performed by your authorized
POLARIS dealer.
WARNING
1/8" (3 mm)
72
MAINTENANCE
Tires
Wheel Removal
1. Position the vehicle on a level surface. Place the transmission in
gear. Lock the parking brake.
2. Loosen the wheel nuts slightly.
WARNING! 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 ground.
4. Remove the wheel nuts.
5. Remove the wheel.
Wheel Installation
1. Place the wheel on the wheel hub
with the valve stem toward the
outside and the rotation arrows on
the tire pointing toward forward
rotation.
2. Install the wheel nuts finger tight.
On vehicles with tapered rear
wheel nuts, make sure the tapered
ends of the nuts fit into the tapers
on the wheels.
3. Lower the vehicle to the ground.
4. Torque the wheel nuts to
specification (page 73).
WARNING! Loose nuts could cause a tire to come off during operation, which
could result in an accident or overturn. Always ensure that all nuts are torqued to
specification.
73
MAINTENANCE
Tires
Wheel Nut Torque Specifications
Check the wheel nut torques occasionally and when they've been loos-
ened for service.
Item Torque Specification
Front Wheel Nuts 27 ft. lbs. (37 Nm)
Rear Wheel Nuts 50 ft. lbs. (68 Nm)
Rear
50 ft. lbs.
(68 Nm)
Front
27 ft. lbs.
(37 Nm)
74
MAINTENANCE
Air Filter
1. Position the vehicle on a level surface. Place the transmission in
gear. Lock the parking brake.
2. Remove the seat.
3. Release the air box cover clips,
and remove the air box cover.
4. Loosen the clamp and remove
the filter.
5. Remove the pre-filter from the
main filter.
6. Wash the pre-filter in soapy
water, then rinse and let dry.
7. Reinstall the pre-filter over the
main filter. Replace the main
filter if needed.
8. Reinstall the air filter into the
air box. Tighten the clamp, but
do not over-tighten as filter
damage could occur.
9. Reinstall the air box cover and the seat.
Pre-Filter
Main Filter
75
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.
Water will enter the recoil housing if the starter handle is disengaged
from the rope guide when under water.
1. Place the transmission in gear.
2. Lock the parking brake.
3. Stop the engine.
4. Remove the drain screw on the
bottom of the recoil housing.
5. Reinstall the drain screw.
Tip: Do not open the crankcase drain
unless the engine has ingested water.
On 4-cycle engines, some engine oil
will be lost if the crankcase drain is
opened.
76
MAINTENANCE
Carburetor
Your POLARIS ATV is calibrated at the factory for optimal perfor-
mance at altitudes ranging from zero to 6,000 feet (1800 m) and temper-
atures of +40 degrees F. (4 degrees C.) or higher. Above 6000 feet (1800
m) the engine air/fuel mixture becomes overly rich and the engine loses
approximately 3% of its power for each 1000-foot (304.8 m) increase in
elevation. Although this power cannot be regained, adjustments to the
carburetor and drive system can be made to allow more efficient opera-
tion. Optional jets, available from your POLARIS dealer, are required
for operation above 6,000 feet and temperatures below +40 degrees F. (4
degrees C.)
Tip: Continuous operation of the engine without proper jetting when required
can cause poor performance, overheating or PVT or engine damage. See
your POLARIS dealer for more information about jetting the ATV for condi-
tions in your area.
Carburetor/Engine Idle RPM Adjustment
If the engine idle speed is not satisfac-
tory, and all other conditions are favor-
able, the carburetor can be adjusted.
1. Place the transmission in gear. Lock
the parking brake.
2. Start the engine and allow it to warm
up for approximately five minutes.
3. Turn the screw in (clockwise) to
raise RPM. Turn the screw out
(counterclockwise) to lower RPM.
Idle
Adjuster
77
MAINTENANCE
Drive Chain
Drive Chain Lubrication
POLARIS ATV drive chains are equipped with o-ring-sealed, perma-
nently greased pins and rollers. However, the outer surfaces of the roller
must be lubricated.
Always inspect the drive chain prior to operating the vehicle. Check for
damaged or missing o-rings or damaged rollers. Also check for correct
slack adjustment. Maintain the stone guard to rear sprocket clearance at
1/8” (3 mm).
Regularly lubricate the drive chain with POLARIS Chain Lube, an SAE
80-90 lube or an approved o-ring chain spray lube. See page 103 for the
part numbers of POLARIS products.
NOTICE: Washing the drive chain with a high pressure washer or gasoline can
cause damage to the o-rings, causing premature wear and drive
chain failure. Do not use a high pressure washer or gasoline to clean
the drive chain.
78
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 the tightest of the three positions. At
this point the chain should have 3/16"-3/8" (5 mm - 10 mm) deflection.
NOTICE: Adjusting or operating the ATV with improper rear drive chain slack
can result in severe damage to the transmission and drive
components. Always make sure the slack is within the stated
specifications.
Use the following procedure if
adjustment is required.
1. Remove the chain guard (if
equipped).
2. Loosen the chain guide.
3. Loosen the two eccentric
locking bolts.
4. Loosen the caliper mounting
bolt located on the left side of
the swing arm.
5. Insert a pin punch through the
sprocket hub and into the
eccentric housing.
1
3/16"-3/8" (5 mm - 10 mm)
Locking Bolts
Pin Punch
Caliper Mounting Bolts
79
MAINTENANCE
Drive Chain
Rear Drive Chain Slack
6. Roll the ATV forward or backward
to adjust the chain slack to the
proper tension. See the illustration
for proper splice link clip opening
position.
7. Tighten the eccentric locking bolts
to 30 ft. lbs. (41 Nm) for machines
without the hitch and 45 ft. lbs. (61
Nm) for machines with a hitch.
8. Tighten the caliper mount bolt to 15
ft. lbs. (20 Nm)
9. Remove the pin punch.
10. Roll the ATV forward, checking chain tension in several places
around the chain.
Tip: The chain is adjusted correctly when the tightest portion of the chain has
approximately 3/8" (10mm) deflection.
11. Position the chain guide to allow 1/8" (3 mm) clearance and tighten
the retaining bolt to 5 ft. lbs. (7 Nm).
12. Reinstall the chain guard (if equipped).
Clip
Position
80
MAINTENANCE
Lights
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 surface 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 the distance from the floor to the center of the headlight
and make a mark on the wall at the same height. Include rider
weight on the seat when measuring.
5. Start the engine. Turn the headlight on.
6. Observe the headlight aim on the wall. The most intense part of the
headlight beam should be two inches (5 cm) below the mark on the
wall.
7. Loosen the pivot bolt and adjust the beam to the desired position.
8. Tighten the bolt and torque to 60 in. lbs. (7 Nm).
25 ft.
(7.6 m)
2" (5 cm)
X
X
81
MAINTENANCE
Lights
Poor lighting can result in reduced visibility when driving. Headlight
and taillight lenses become dirty during normal operation. Clean lights
frequently and replace burned out lamps promptly. Always make sure
lights are adjusted properly for best visibility.
Headlamp Replacement
When servicing a halogen lamp, don't touch the lamp with bare fingers.
Oil from your skin leaves a residue, causing a hot spot that will shorten
the life of the lamp.
1. Remove the wire harness connector from the back of the headlight.
CAUTION! Hot components can cause burns to skin. Allow lamps to cool
before servicing.
2. Grasp the bulb housing and turn it counterclockwise to remove the
bulb.
3. Apply dielectric grease to the light bulb socket before installing the
new bulb. Install the replacement bulb into the headlight housing
and rotate clockwise firmly.
Tip: The bulb must be positioned so the harness installs into the lamp at the bot-
tom.
4. Reinstall the connector to the back of the headlight.
82
MAINTENANCE
Lights
Indicator Lamp Replacement
1. Remove the instrument panel or front cover, if necessary, to access
the back of the indicator panel.
2. Using a small, straight-blade screwdriver, turn the base of the bulb
1/4 turn counterclockwise.
3. Using a needle-nose pliers or similar tool, pull the lamp out of the
indicator panel housing.
4. Insert the new bulb and seat it by turning it 1/4 turn clockwise.
5. Reinstall the instrument panel or front cover.
Taillight/Brakelight Lamp Replacement
1. From the rear of the brake-
light, remove the two
screws holding the lens
cover in place. Remove the
lens cover.
2. Remove the lamp and
replace it with a new lamp.
3. Test the light for proper
operation.
4. Reinstall the lens cover.
Screw
Lamp
Cover
83
MAINTENANCE
Spark Plugs
Spark Plug Recommendations
Refer to the specifications section beginning on page 108 for the recom-
mended spark plug type and gap for your vehicle. Torque spark plugs to
specification.
NOTICE: Using non-recommended spark plugs can result in serious engine
damage. Always use POLARIS-recommended spark plugs.
Spark Plug Inspection
Spark plug condition is indicative of engine operation. Check the spark
plug firing end condition after the engine has been warmed up and the
vehicle has been driven at higher speeds. Immediately check the spark
plug for correct color. See page 84.
CAUTION! A hot exhaust system and engine can cause burns. Wear
protective gloves when removing a spark plug for inspection.
1. Rotate the spark plug cap.
2. Using the special wrench provided in the tool pouch, rotate the
spark plug counterclockwise to remove it.
3. Inspect the electrodes for wear
and carbon buildup. Replace
worn or fouled plugs. Verify that
the gap is at specification before
installation.
4. Reverse the procedure for spark
plug installation. Torque to
specification.
Plug Condition Torque Specification
New Spark Plug 9-11 ft. lbs. (12-15 Nm)
Previously Installed Spark Plug 17-20 ft. lbs. (23-27 Nm)
84
MAINTENANCE
Spark Plugs
Spark Plug Condition
Normal Spark Plug
The normal insulator tip is gray, tan 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 white. A white insulator tip indicates
overheating, caused by use of an improper spark plug or incorrect carbu-
retion adjustments.
Wet Fouled Spark Plug
The wet fouled insulator tip is black. A damp oil film covers the firing
end. There may be a carbon layer over the entire nose. Generally, the
electrodes are not worn. General causes of fouling are excessive oil, use
of non-recommended oil, improper use of the choke, or incorrect throt-
tle body/carburetor adjustments.
85
MAINTENANCE
Vehicle Immersion
If your vehicle becomes immersed, major engine damage can result if
the machine is not thoroughly inspected. Take the vehicle to your dealer
before starting the engine.
If it's impossible to take your ATV to a dealer before starting it, follow
the steps outlined below.
1. Move the vehicle out of the
water.
2. Turn the fuel valve off.
3. Check the air box. If water is
present, dry the air box and
replace the filter with a new filter.
4. Remove the spark plug.
5. Loosen the carburetor drain screw
and drain the carburetor.
6. Turn the engine over several times
using the electric start.
7. Dry the spark plug. Reinstall the plug
or install a new plug.
8. Tighten the carburetor drain screw.
9. Turn the fuel valve on.
10. Attempt to start the engine. If neces-
sary, repeat the drying procedure.
11. Take the ATV to your dealer for ser-
vice as soon as possible, whether you succeed in starting it or not.
12. If water has been ingested into the PVT, follow the procedure on
page 89 for drying out the PVT.
Drain Screw
86
MAINTENANCE
Spark Arrester
Failure to heed the following warnings while servicing the spark arrester could
result in serious injury or death. Never run the engine in an enclosed area.
Remove any combustible materials from the area. Wear eye protection and
leather work gloves. Do not stand behind or in front of the vehicle while purging.
Never go under the vehicle while it's inclined.
The exhaust system can get extremely hot. Do not perform service on the spark
arrester while the system is hot. Allow components to cool sufficiently before
proceeding.
Use the following procedure to periodically purge accumulated carbon
from the exhaust pipe/muffler.
1. Position the vehicle on a
level surface.
2. Place the transmission in
neutral.
3. Lock the parking brake.
4. Remove the arrester
clean-out plug from the
bottom of the muffler.
5. Start the engine.
6. Quickly squeeze and release the throttle lever several times to purge
carbon from the system.
7. If carbon comes out of the exhaust, cover or plug the exhaust outlet.
Wear protective gloves.
8. Lightly tap on the exhaust pipe with a rubber mallet while repeating
step 6.
9. If particles are still suspected to be in the muffler, elevate the rear of
the vehicle one foot (30 cm) higher than the front. Block the wheels.
10. Repeat steps 6 to 8 until no more particles are expelled.
11. Stop the engine. Allow the arrester to cool.
12. Reinstall the arrester plug and remove the exhaust outlet cover or
plug.
WARNING
Exhaust
Outlet
Clean-Out Plug
87
MAINTENANCE
PVT 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 high speed. The PVT system has been
precision balanced. Any modification will cause the system to be out of balance,
creating vibration and additional loads on components.
The PVT system rotates at high speeds, creating large amounts of force on
clutch components. Extensive engineering and testing has been conducted to
ensure the safety of this product. However, as the owner, you have the following
responsibilities to make sure this system remains safe:
• Always follow all recommended maintenance procedures. Always look for
and remove debris inside and around the clutch and vent system when
replacing the belt.
• See your dealer as outlined in the owner's manual.
• This PVT system is intended for use on POLARIS products only. Do not
install it in any other product.
• Always make sure the PVT housing is securely in place during operation.
WARNING
88
MAINTENANCE
PVT System
The basic operation of the POLARIS PVT system is dependent on
engine speed and vehicle torque requirements. As engine speed
increases, the force exerted on the movable drive sheave by the fly-
weights also increases. This, in turn, increases the amount of pinch
applied to the drive belt. Similarly, if the engine speed decreases, the
amount of centrifugal force decreases, reducing the amount of belt
pinch. This begins to occur at speeds of less than 5 MPH (8 km/h), due
to the system's dependence on engine speed.
For example, when operating at a ground speed of 3 MPH (5 km/h), the
engine would be running at only about 1500 RPM, with an engagement
speed of about 1400 RPM. Whenever operating this close to the engage-
ment speed, the engine may be running at a speed too low to provide the
pinch needed to prevent belt slip. Belt slip is responsible for creating the
excessive heat that destroys belts, wears clutch components and causes
outer clutch covers to fail.
If the ATV will be operated for extended periods below 5 MPH (8 km/
h), or for towing loads, we recommend that you install a one tooth
smaller counter shaft sprocket to raise the operating RPM far enough
above the engagement RPM to reduce heat caused by incomplete
engagement. Reducing the temperature inside the clutch cover greatly
extends the life of the PVT components (belt, cover, etc.).
Tip: Avoid heavy pulling and extended low-speed operation.
89
MAINTENANCE
PVT System
PVT Drying
There may be some instances when water 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. Allow the water to drain completely.
Reinstall the drain plug.
3. Start the engine. Place the transmission in neutral.
4. Apply varying throttle for 10-15 seconds to expel the moisture and
air-dry the belt and clutches. Do not hold the throttle wide open for
more than 10 seconds.
5. Allow the engine RPM to settle to idle speed, then shift the trans-
mission into forward gear.
6. Test for belt slippage. If the belt slips, repeat the process.
7. Take the vehicle to your dealer for service as soon as possible.
90
MAINTENANCE
Battery
Improperly connecting or disconnecting battery cables can result in an explosion
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 sulfuric acid. Serious burns can
result from contact with skin, eyes or clothing.
Antidote:
External: Flush with water.
Internal: Drink large quantities of water or milk. Follow with milk of magnesia,
beaten egg, or vegetable oil. Call physician immediately.
Eyes: Flush with water for 15 minutes and get prompt medical attention.
Batteries produce explosive gases. Keep sparks, flame, cigarettes, etc. away.
Ventilate when charging or using in an enclosed space. Always shield eyes
when working near batteries. KEEP OUT OF REACH OF CHILDREN.
Your ATV may have either a sealed battery, which requires little mainte-
nance, or a conventional battery. A sealed battery can be identified by its
flat covers on the top of the battery. A conventional battery has six filler
caps on the top of the battery.
Always keep battery terminals and connections free of corrosion. If
cleaning is necessary, remove corrosion with a stiff wire brush. Wash
with a solution of one tablespoon baking soda and one cup water. Rinse
well with tap water and dry off with clean shop towels. Coat the termi-
nals with dielectric grease or petroleum jelly. Be careful not to allow
cleaning solution or tap water into a conventional battery.
WARNING
WARNING
91
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. On conventional batteries, remove the battery vent tube.
6. Disconnect the black (negative) battery cable first.
7. Disconnect the red (positive) battery cable last.
8. Lift the battery out of the ATV. Be careful not to tip a conventional
battery sideways, which could spill electrolyte.
NOTICE: If electrolyte spills, immediately wash it off with a solution of one
tablespoon baking soda and one cup water to prevent damage to the
vehicle.
92
MAINTENANCE
Battery
Battery Installation
Using a new battery that has not been fully charged can damage the bat-
tery and result in a shorter life. It can also hinder vehicle performance.
Follow the battery charging instructions on page 94 before installing the
battery.
1. Ensure that the battery is fully charged.
2. Place the battery in the battery holder in the rear cab.
3. With conventional batteries, install the battery vent tube (sealed bat-
teries do not have a vent tube). The vent tube must be free of
obstructions and securely installed. Route the tube away from the
frame and vehicle body to prevent contact with electrolyte.
WARNING! Battery gases could accumulate in an improperly installed vent tube
and cause an explosion, resulting in serious injury or death. Always ensure that
the vent tube is free of obstructions and is securely installed as recommended.
4. On conventional batteries, coat the terminals with dielectric grease
or petroleum jelly.
5. Connect and tighten the red (positive) cable first.
6. Connect and tighten the black (negative) cable last.
7. Secure the battery hold-down strap.
8. Verify that cables are properly routed. Cables should be routed low
so they don’t interfere with safe seat installation.
9. Reinstall the seat.
93
MAINTENANCE
Battery
Battery Storage
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 charged, and
store it out of the sun in a cool, dry place. Check battery voltage each
month during storage and recharge as needed to maintain a full charge.
Tip: Power plug leads may need to be bent down so that the battery cover can
be installed.
POLARIS recommends maintaining battery charge by using a
POLARIS Battery Tender charger or by charging about once a month to
make up for normal self-discharge. Battery Tender can be left connected
during the storage period, and will automatically charge the battery if
the voltage drops below a pre-determined point. See page 103 for the
part numbers of POLARIS products.
Battery Fluid (Conventional Battery)
A poorly maintained battery will
deteriorate rapidly. Check the battery
fluid level often. Maintain the fluid
level between the upper and lower
level marks.
Add only distilled water. Tap water
contains minerals that are harmful to
a battery.
Lower
Mark
Upper
Mark
94
MAINTENANCE
Battery
Battery Charging (Conventional Battery)
1. Remove the battery from the vehicle to prevent damage from leak-
ing or spilled electrolyte during charging. See page 91.
2. Charge the battery with a charging 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 or greater.
3. Reinstall the battery. See page 92. Make sure the positive terminal is
toward the front of the vehicle.
Battery Charging (Sealed Battery)
The following battery charging instructions apply only to the installa-
tion of a sealed battery. Read all instructions before proceeding with the
installation of this battery.
The sealed battery is already filled with electrolyte and has been sealed
and fully charged at the factory. Never pry the sealing strip off or add
any other fluid to this battery.
The single most important thing about maintaining a sealed battery is to
keep it fully charged. Since the battery is sealed and the sealing strip
cannot be removed, you must use a voltmeter or multimeter to measure
DC voltage.
WARNING! An overheated battery may explode, causing severe injury or
death. Always watch charging times carefully. Stop charging if the battery
becomes very warm to the touch. Allow it to cool before resuming charging.
For a refresh charge, follow all instructions carefully.
1. Check the battery voltage with a voltmeter or multimeter. A fully
charged battery will register 12.8 V or higher.
2. If the voltage is less than 12.8 volts, recharge the battery at 1.2 amps
or less until battery voltage is 12.8 or greater.
3. When using an automatic charger, refer to the charger manufac-
turer's instructions for recharging. When using a constant current
charger, use the following guidelines for recharging.
95
MAINTENANCE
Battery
Battery Charging (Sealed Battery)
Always verify battery condition before and 1-2 hours after the end of
charging.
State of
Charge
Voltage Action
Charge Time
(Using constant current
charger @ standard amps
specified on top of battery)
100% 12.8-13.0 volts None, check at 3
mos. from date of
manufacture
None required
75%-100% 12.5-12.8 volts May need slight
charge, if no
charge given,
check in 3 months
3-6 hours
50%-75% 12.0-12.5 volts Needs charge 5-11 hours
25%-50% 11.5-12.0 volts Needs charge At least 13 hours,
verify state of charge
0%-25% 11.5 volts or less Needs charge with
desulfating charger
At least 20 hours
96
MAINTENANCE
Cleaning and Storage
Washing the Vehicle
Keeping your POLARIS vehicle clean will not only improve its appear-
ance 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 garden hose,
using mild soap.
Certain products, including insect repellents and chemicals, will
damage plastic surfaces. Do not allow these types of products to
contact the vehicle.
The best and safest way to clean your POLARIS vehicle is with a gar-
den hose and a pail of mild soap and water.
1. Use a professional-type washing cloth, cleaning the upper body first
and the lower parts last.
2. Rinse with clean water frequently.
3. Dry surfaces with a chamois to prevent water spots.
Washing Tips
• Avoid the use of harsh cleaners, which can scratch the finish.
• Do not use a power washer to clean the vehicle.
• Do not use medium to heavy duty compounds on the finish.
• Always use clean cloths and pads for cleaning and polishing. Old or
reused cloths and pads may contain dirt particles that will scratch the
finish.
97
MAINTENANCE
Cleaning and Storage
Washing the Vehicle
If a high pressure water system is used for cleaning (not recommended),
exercise extreme caution. The water may damage components and could
remove paint and decals. Avoid directing the water stream at the follow-
ing items:
If an informational or graphic label becomes illegible or comes off, con-
tact your POLARIS dealer to purchase a replacement. Replacement
safety labels are provided by POLARIS at no charge.
Grease all zerk fittings immediately after washing. Allow the engine to
run for a while to evaporate any water that may have entered the engine
or exhaust system.
Polishing the Vehicle
POLARIS recommends the use of common household aerosol furniture
polish for polishing the finish on your POLARIS vehicle. Follow the
instructions on the container.
Polishing Tips
• Avoid the use of automotive products, some of which can scratch the
finish of your vehicle.
• Always use clean cloths and pads for cleaning and polishing. Old or
reused cloths and pads may contain dirt particles that will scratch the
finish.
• Wheel bearings • Electrical components/wiring
• Radiator (if equipped) • Switches and controls
• Transmission seals • Cab and body panels
• Brakes • Labels and decals
98
MAINTENANCE
Cleaning and Storage
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 chrome
wheels more often if they're exposed to salt or other corrosive elements.
1. Wash chrome wheels frequently. Use a mild detergent. Never use
abrasive cleaners on plated or painted surfaces.
2. Rinse well with clear water. Soap, detergents, salt, dirt, mud and
other elements can cause corrosion.
3. Polish the clean chrome wheels periodically. Use an automotive
grade chrome polish.
4. Routinely and liberally apply a weather resistant wax to each pol-
ished chrome wheel. Choose a product suitable for chrome finishes.
Read and follow the product labels and instructions.
Removing Corrosion
If light rust is found on the chrome finish, use steel wool (#0000-OTT
grade) to remove it. Gently rub the affected areas with the steel wool
until the corrosion has been removed. Clean and polish the wheel as out-
lined above.
99
MAINTENANCE
Cleaning and Storage
Storage Tips
NOTICE: Starting the engine during the storage period will disturb the
protective film created by fogging and damage could occur. Never
start the engine during the storage period.
Clean the Exterior
Make any necessary repairs and clean the vehicle as recommended. See
page 96.
Stabilize the Fuel
1. Fill the fuel tank.
2. Add POLARIS Carbon Clean Fuel Treatment or POLARIS Fuel
Stabilizer. Follow the instructions on the container for the recom-
mended amount. Carbon Clean removes water from fuel systems,
stabilizes fuel and removes carbon deposits from pistons, rings,
valves and exhaust systems.
3. Allow the engine to run for 15-20 minutes to allow the stabilizer to
disperse through the fuel in the tank and carburetor.
4. Turn the fuel valve off.
5. Drain the carburetor bowl.
Oil and Filter
Change the oil and filter. See page 63.
Air Filter / Air Box
1. Inspect and clean (or replace) the pre-cleaner and air filter.
2. Clean the air box.
3. Drain the sediment tube.
Recoil Housing
1. Drain the recoil housing. See page 75.
100
MAINTENANCE
Cleaning and Storage
Storage Tips
Fluid Levels
Inspect the fluid levels. Change fluids as recommended in the Periodic
Maintenance Chart beginning on page 57.
• Demand drive unit (if equipped)
• Transmission
• Brake fluid (change every two years and any time the fluid looks dark
or contaminated)
Fog the Engine
1. Treat the fuel system with POLARIS Carbon Clean. See page 99.
2. Support the front end of the machine so the engine is level or tilted
slightly rearward.
3. Remove the spark plug. Pour 2-3 tablespoons (30-40 ml) of engine
oil into the hole.
Tip: Use a section of small hose and a small plastic squeeze bottle filled with the
pre-measured amount of oil.
4. Reinstall the spark plug. Torque to specification.
5. Apply dielectric grease to the inside of the spark plug cap. Reinstall
the cap.
6. Turn the engine over several times using the recoil starter. Oil will
be forced in and around the piston rings and ring lands, coating the
cylinder with a protective film of fresh oil.
7. If POLARIS fuel system additive is not used, the fuel tank, fuel
lines, and carburetor should be completely drained of gasoline.
8. To eliminate any fuel remaining in the carburetor, run the engine
until it stops.
101
MAINTENANCE
Cleaning and Storage
Storage Tips
Inspect and Lubricate
Inspect all cables and lubricate all areas of the vehicle as recommended
in the Periodic Maintenance Chart beginning on page 57.
Battery Storage
See pages 93-94 for storage and charging procedures.
Storage Area/Covers
Set the tire pressure and safely support the ATV with the tires slightly
off the ground. Be sure the storage area is well ventilated. Cover the
vehicle with a genuine POLARIS cover. Do not use plastic or coated
materials. They do not allow enough ventilation to prevent condensa-
tion, and may promote corrosion and oxidation.
102
MAINTENANCE
Transporting the Vehicle
Follow these procedures when
transporting the vehicle.
1. Stop the engine.
2. Place the transmission in gear.
3. Lock the parking brake.
4. Turn the fuel valve off.
5. Secure the fuel cap, oil cap and
seat.
6. Remove the key to prevent loss
during transporting.
7. Always tie the frame of the
ATV to the transporting unit
securely with suitable straps or
rope. Do not attach tie straps to
the front A-arm bolt pockets,
racks or handlebars.
103
POLARIS PRODUCTS
Part
Number
Description
Engine Lubricant
2870791 Fogging Oil (12 oz./355 ml Aerosol)
2876244 PS-4 PLUS Performance Synthetic 2W-50 4-Cycle Oil (qt./.95 l)
2876245 PS-4 PLUS Performance Synthetic 2W-50 4-Cycle Oil (gal./3.8 l)
Gearcase / Transmission Lubricants
2878068 AGL PLUS Transmission Fluid (qt./.95 l)
2878069 AGL PLUS Transmission Fluid (gal./3.8 l)
2871653 Premium ATV Angle Drive Fluid (8 oz./237 ml)
2872276 Premium ATV Angle Drive Fluid (2.5 gal./9.5 l)
2870465 Pump for Gallon (3.8 l) Jug
Grease / Specialized Lubricants
2871312 Grease Gun Kit, Premium All Season
2871322 Premium All Season Grease (3 oz./89 ml cartridge)
2871423 Premium All Season Grease (14 oz./414 ml cartridge)
2871460 Starter Drive Grease
2871515 Premium U-Joint Lube (3 oz./89 ml cartridge)
2871551 Premium U-Joint Lube (14 oz./414 ml cartridge)
2871329
Dielectric Grease (Nyogel
TM
)
Additives / Miscellaneous
2871326 Carbon Clean Plus
2870652 Fuel Stabilizer
2872189 DOT 4 Brake Fluid
2871956
Loctite
TM
565 Thread Sealant
2859044
POLARIS Battery Tender
TM
Charger
104
TROUBLESHOOTING
Drive Belt Wear/Burn
Possible Cause Solution
Starting out going up a
steep incline
Use low range (if equipped) or turn around using the K-
turn (see page 49).
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 tempera-
tures
Warm the engine at least 5 minutes. With the transmission
in neutral, advance the throttle to about 1/8 throttle in
short bursts, 5 to 7 times. The belt will become more flex-
ible and prevent belt burning.
Slow/easy clutch engage-
ment
Use the throttle quickly and effectively.
Towing/pushing at low
RPM/low ground speed
Use low range only (if equipped).
Utility use/plowing Use low range only (if equipped).
Stuck in mud or snow Shift the transmission to low range (if equipped). Care-
fully use fast, aggressive throttle application to engage
clutch. WARNING! Excessive throttle may cause loss of
control and vehicle overturn.
Climbing over large
objects from a stopped
position
Belt slippage from water
or snow ingestion into the
PVT system
Dry out the PVT. See page 89. Inspect clutch seals for
damage if repeated leaking occurs.
Clutch malfunction See your POLARIS dealer.
Poor engine performance Check for fouled plugs or foreign material in gas tank,
fuel lines or carburetor. See your dealer.
Slippage from failure to
warm up belt
Always warm up the belt by operating below 30 mph (48
km/h) for one mile (1.6 km). Operate 5 miles (8 km) or
more when temperature is below freezing.
Wrong or missing belt Install the recommended belt.
Improper break-in Always break in a new belt and/or clutch. See page 37.
105
TROUBLESHOOTING
Engine Doesn't Turn Over
Engine Turns Over, Fails to Start
Engine Backfires
Possible Cause Solution
Low battery voltage Recharge the battery to 12.8 VDC
Loose battery connections Check all connections and tighten
Loose solenoid connections Check all connections and tighten
Possible Cause Solution
Out of fuel Turn fuel valve to reserve, refuel
Clogged fuel valve or filter Inspect and clean or replace
Water is present in fuel Drain the fuel system and refuel
Fuel valve is turned off Turn the fuel valve on
Old or non-recommended fuel Replace with fresh recommended fuel
Fouled or defective spark plug(s) Inspect plugs and replace if necessary
No spark to spark plug Inspect plugs, verify stop switch is on
Overuse of choke Inspect, clean and/or replace spark plugs
Clogged fuel filter Replace the filter
Water or fuel in crankcase Immediately see your POLARIS dealer
Low battery voltage Recharge the battery to 12.8 VDC
Mechanical failure See your dealer
Possible Cause Solution
Weak spark from spark plug Inspect, clean and/or replace spark plugs
Incorrect spark plug gap or heat range Set gap to specs or replace plugs
Old or non-recommended fuel Replace with fresh recommended fuel
Incorrectly installed spark plug wires See your dealer
Incorrect ignition timing See your dealer
Mechanical failure See your dealer
Exhaust leaks Replace exhaust seals
106
TROUBLESHOOTING
Engine Pings or Knocks
Engine Runs Irregularly, Stalls or Misfires
Possible Cause Solution
Poor quality or low octane fuel 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
Fouled or defective spark plugs Inspect, clean and/or replace spark plugs
Worn or defective spark plug wires See your dealer
Incorrect spark plug gap or heat range Set gap to specs or replace plugs
Loose ignition connections Check all connections and tighten
Water present in fuel Replace with new fuel
Low battery voltage Recharge battery to 12.8 VDC
Kinked or plugged fuel tank vent line Inspect and replace
Incorrect fuel Replace with recommended fuel
Clogged air filter Inspect and clean or replace
Reverse speed limiter malfunction See your dealer
Electronic throttle control malfunction See your dealer
Other mechanical failure See your dealer
Possible Lean Fuel Cause Solution
Low or contaminated fuel Add or change fuel, clean the fuel system
Low octane fuel Replace with recommended fuel
Clogged fuel filter Replace filter
Incorrect jetting See your dealer
Possible Rich Fuel Cause Solution
Overuse of choke Inspect, clean and/or replace spark plugs
Fuel is very high octane Replace with lower octane fuel
Incorrect jetting See your dealer
107
TROUBLESHOOTING
Engine Stops or Loses Power
Possible Cause Solution
Out of fuel Turn fuel valve to reserve, refuel
Kinked or plugged fuel vent line Inspect and replace
Water is present in fuel Replace with new fuel
Overuse of choke Inspect, clean and/or replace spark plugs
Fouled or defective spark plugs Inspect, clean and/or replace spark plugs
Worn or defective spark plug wires See your dealer
Incorrect spark plug gap or heat range Set gap to specs or replace plug
Loose ignition connections Check all connections and tighten
Low battery voltage Recharge the battery to 12.8 VDC
Incorrect fuel Replace with fresh recommended fuel
Clogged air filter Inspect and clean or replace
Reverse speed limiter malfunction See your dealer
Electronic throttle control malfunction See your dealer
Other mechanical failure See your dealer
Overheated engine Clean engine exterior
See your POLARIS dealer
108
SPECIFICATIONS
* Based on EU Directive 76/432/EC
TRAIL BOSS 330
Maximum Weight Capacity 415 lbs. (188 kg) (includes weight of operator,
cargo and accessories)
Dry Weight 531 lbs. (241 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)
Transmission Oil 11.3 oz. (335 ml)
Front Rack Capacity 75 lbs. (34 kg)
Rear Rack Capacity 125 lbs. (57 kg)
Hitch Tongue Weight Capacity 85 lbs. (38.6 kg) (Rear rack capacity and tongue
weight not to exceed 125 lbs./57 kg)
Hitch Towing Rating 850 lbs. (385.6 kg)
Unbraked Trailer Towing
Capacity*
1263 lbs. (573 kg)
Overall Length 75 in. (190.5 cm)
Overall Width 45 in. (114 cm)
Overall Height 49 in. (124.5 cm)
Wheelbase 48.8 in. (124 cm)
Ground Clearance 4.75 in. (12 cm)
Minimum Turning Radius 65 in. (165 cm) unloaded
Engine Model Number/Type ES-32PFE-10A / 4 Cycle, Single Cylinder
Lubrication Wet Sump
Engine Cooling Air with fan assisted oil cooler
Displacement 329 cc
Bore x Stroke 78.5 x 68
Alternator Output 200w @5000 RPM
Compression Ratio 9.2:1
Carburetor BST 34
Pilot Jet 42.5
Main Jet 122.5
Needle Jet P-4 (829)
Jet Needle 4HB48-3
Pilot Air Jet 160
Pilot Screw 2.0+ turns
Ignition System DC CDI
Ignition Timing 30 +/- 2 @ 5000 RPM
Idle RPM 1500
Spark Plug / Gap BKR6E / .036 in. (.9 mm)
109
SPECIFICATIONS
Jetting Chart
Clutching Chart
TRAIL BOSS 330
Driving System Type Automatic PVT (POLARIS Variable Transmis-
sion)
Shift Type 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
Tires/Pressure, Front 23 x 8-12 (5 psi/34.5 kPa)
Tires/Pressure, Rear 22 x 11-10 (5 psi/34.5 kPa)
Front Suspension MacPherson strut with 8.2" (21 cm) travel
Rear Suspension Progressive rate with 10.5" (26.7 cm) travel
Shock Adjustment CAM
Brakes, Front and Rear Single-Control Hydraulic Disc
Brake, Auxiliary Foot-Activated Hydraulic Disc, Rear Wheel
Brake, Parking Hydraulic lock, all wheel
Headlight 2 Dual Beam 30w/30w
Taillights 12V 5W
Brake Light 12V 26.9W
Battery 12V 14AH
Indicators High Temp/Neutral/Reverse
ALTITUDE
Meters (Feet)
AMBIENT TEMPERATURE
Below 40 F
(Below 5 C)
40F and above
(5C and above)
0-1800 (0-6000) 127.5 122.5
1800-3700 (6000-12000) 120 115
Altitude
Meters (Feet)
Shift
Weight
Drive Clutch
Spring
Driven Clutch
Spring
Helix/Spring/
Setting
0-1800
(0-6000)
10RHF
5632282
Blue/Gray
7042202
Black
7041782
40
5131446
2+2
1800-3700
(6000-12000)
20-40
5631356
Blue/Gray
7042202
Black
7041782
40
5131446
2+2
110
SPECIFICATIONS
* Based on EU Directive 76/432/EC
TRAIL BLAZER 330
Maximum Weight Capacity 275 lbs. (125 kg) (includes weight of opera-
tor, cargo and accessories)
Dry Weight 492 lbs. (223 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)
Transmission Oil 11.3 oz. (33 ml)
Front Rack Capacity (Accessory) 30 lbs. (13.6 kg) (Maximum)
Rear Rack Capacity (Accessory) 60 lbs. (27.2 kg) (Maximum)
Hitch Tongue Weight Capacity 85 lbs. (38.6 kg) (Rear rack capacity and
tongue weight not to exceed 60 lbs./27.2 kg)
Hitch Towing Rating 850 lbs.(386 kg)
Unbraked Trailer Towing Capacity* 1263 lbs. (573 kg)
Overall Length 75 in. (190.5 cm)
Overall Width 45 in. (114 cm)
Overall Height 49 in. (124.5 cm)
Wheelbase 48.8 in. (124 cm)
Ground Clearance 4.75 in. (12 cm)
Minimum Turning Radius 83 in. (211 cm) unloaded
Engine Model Number/Type ES-32PFE-10A / 4 Cycle, Single Cylinder
Lubrication Wet Sump
Engine Cooling Air with fan assisted oil cooler
Displacement 329cc
Bore x Stroke 78.5 x 68
Alternator Output 200w @5000 RPM
Compression Ratio 9.2:1
Carburetor BST 34
Pilot Jet 42.5
Main Jet 122.5
Needle Jet P-4 (829)
Jet Needle 4HB48-3
Pilot Air Jet 160
Pilot Screw 2.0 turns
Ignition System DC CDI
Ignition Timing 30 +/- 2 @ 5000 RPM
Idle RPM 1500
Spark Plug / Gap BKR6E / .036 in. (.9 mm)
111
SPECIFICATIONS
Jetting Chart
Clutching Chart
TRAIL BLAZER 330
Driving System Type Automatic PVT (POLARIS Variable Transmis-
sion)
Shift Type 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
Tires/Pressure, Front 23 x 8-12 (5 psi/34.5 kPa)
Tires/Pressure, Rear 22 x 11-10 (5 psi/34.5 kPa)
Front Suspension MacPherson strut with 8.2" (21 cm) travel
Rear Suspension Progressive rate with 10.5" (26.7 cm) travel
Shock Adjustment CAM
Brakes, Front and Rear Single-Control Hydraulic Disc
Brake, Auxiliary Foot-Activated Hydraulic Disc, Rear Wheel
Brake, Parking Hydraulic lock, all wheel
Headlight 1 Single Beam, 50w
Taillights 12V 5W
Brake Light 12V 26.9W
Battery 12V 14AH
Indicators High Temp/Neutral/Reverse
ALTITUDE
Meters (Feet)
AMBIENT TEMPERATURE
Below 40 F
(Below 5 C)
40F and above
(5C and above)
0-1800 (0-6000) 127.5 122.5
1800-3700 (6000-12000) 120 115
Altitude
Meters (Feet)
Shift
Weight
Drive Clutch
Spring
Driven Clutch
Spring
Helix/Spring/
Setting
0-1800
(0-6000)
10RHF
5632282
Blue/Gray
7042202
Black
7041782
45
5131446
2-2
1800 & above
(6000 & above)
20-40
5631356
Blue/Gray
7042202
Black
7041782
45
5131446
2-2
112
WARRANTY
LIMITED WARRANTY
POLARIS Sales Inc., 2100 Highway 55, Medina, MN 55340, gives a SIX MONTH
LIMITED WARRANTY on all components of the POLARIS All Terrain Vehicle (ATV)
against defects in material or workmanship. POLARIS also gives a one year limited
warranty on the final drive chain (if equipped) for failure due to defects. This warranty
covers the parts and labor charges for repair or replacement of defective parts which are
covered by this warranty. This warranty begins on the date of purchase. This warranty is
transferable to another consumer during the warranty period through a POLARIS dealer.
REGISTRATION
At the time of sale, the Warranty Registration Form must be completed by your dealer
and submitted to POLARIS within ten days. Upon receipt of this registration, POLARIS
will record the registration for warranty. No verification of registration will be sent to
the purchaser as the copy of the Warranty Registration Form will be the warranty entitle-
ment. If you have not signed the original registration and received the customer copy,
please contact your dealer immediately. NO WARRANTY COVERAGE WILL BE
ALLOWED UNLESS YOUR ATV IS REGISTERED WITH POLARIS.
Initial dealer preparation and set-up of your ATV is very important in ensuring trouble-
free operation. Purchasing a machine in the crate or without proper dealer set-up will
void your warranty coverage.
113
WARRANTY
WARRANTY COVERAGE AND EXCLUSIONS:
LIMITATIONS OF WARRANTIES AND REMEDIES
The POLARIS limited warranty excludes any failures that are not caused by a defect in
material or workmanship. This warranty does not cover accidental damage, normal wear
and tear, abuse or improper handling. This warranty also does not cover any ATV that
has been altered structurally, modified, neglected, improperly maintained, used for rac-
ing, or used for purposes other than for which it was manufactured, or for any damages
which occur during trailer transit or as a result of unauthorized service or the use of
unauthorized parts. In addition, this warranty does not cover physical damage to paint or
finish, stress cracks, tearing or puncturing of upholstery material, corrosion, or defects in
parts, components or the ATV due to fire, explosions or any other cause beyond
POLARIS' control.
Warranty does not apply to parts exposed to friction surfaces, stresses, environmental
conditions and/or contamination for which they were not designed or not intended,
including but not limited to the following items:
Warranty applies to the product only and does not allow for coverage of personal loss.
Some items are considered "consumable," meaning they are considered part of normal
maintenance or part of completing an effective repair. The following items are excluded
from warranty coverage in the event of a warranty claim:
• Wheels and tires • Finished and unfinished surfaces
• Suspension components • Carburetor/Throttle body components
• Brake components • Engine components
• Seat components • Drive belts
• Clutches and components • Hydraulic components
• Steering components • Circuit breakers/Fuses
• Batteries • Electronic components
• Light bulbs/Sealed beam lamps
• Spark Plugs • Lubricants such as oil, grease, etc.
• Filters • Batteries (unless defective)
• Fuel • Cosmetic damage/repair
• Sealants • Coolants
• Hotel fees • Meals
• Towing charges • Shipping/ handling fees
• Mileage • Product pick-up/delivery
• Rentals/Loss of product use • Loss of vacation/personal time
114
WARRANTY
LIMITATIONS OF WARRANTIES AND REMEDIES
This warranty also excludes failures resulting from improper lubrication; improper
engine timing; improper fuel; surface imperfections caused by external stress, heat, cold
or contamination; operator error or abuse; improper component alignment, tension,
adjustment or altitude compensation; failure due to snow, water, dirt or other foreign
substance ingestion/contamination; improper maintenance; modified components; use
of aftermarket components resulting in failure; unauthorized repairs; repairs made after
the warranty period expires or by an unauthorized repair center; use of the product in
competition or for commercial purposes. Warranty will not apply to any product which
has been damaged by abuse, accident, fire or any other casualty not determined a defect
of materials or workmanship.
This warranty does not cover the use of unauthorized lubricants, chemicals, or fuels that
are not compatible with the ATV. The exclusive remedy for breach of this warranty shall
be, at POLARIS' exclusive option, repair or replacement of any defective materials, or
components or products. THE REMEDIES SET FORTH IN THIS WARRANTY ARE
THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS
WARRANTY. POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR
INCIDENTAL, CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIP-
TION, WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR
ANY OTHER CONTRACT, NEGLIGENCE, OR OTHER TORT OR OTHERWISE.
THIS EXCLUSION OF CONSEQUENTIAL, INCIDENTAL, AND SPECIAL DAM-
AGES IS INDEPENDENT FROM AND SHALL SURVIVE ANY FINDING THAT
THE EXCLUSIVE REMEDY FAILED OF ITS ESSENTIAL PURPOSE. Some states
do not permit the exclusion or limitation of incidental or consequential damages or
implied warranties, so the above limitations or exclusions may not apply to you if incon-
sistent with controlling state law.
115
WARRANTY
ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE
IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PAR-
TICULAR PURPOSE) ARE LIMITED IN DURATION TO THE ABOVE SIX
MONTH WARRANTY PERIOD. POLARIS FURTHER DISCLAIMS ALL EXPRESS
WARRANTIES NOT STATED IN THIS WARRANTY. Some states do not allow limi-
tations on how long an implied warranty lasts, so the above limitation may not apply to
you if inconsistent with controlling state law.
HOW TO OBTAIN WARRANTY SERVICE
If your ATV requires warranty service, you must take it to a POLARIS dealer authorized
to repair POLARIS ATVs. When requesting warranty service you must present your
copy of the Warranty Registration form to the dealer. (THE COST OF TRANSPORTA-
TION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY). POLARIS sug-
gests that you use your original selling dealer; however, you may use any POLARIS
Servicing Dealer to perform warranty service.
Please work with your dealer to resolve any warranty issues. Should your dealer require
any additional assistance they will contact the appropriate person at POLARIS.
This warranty gives you specific legal rights, and you may also have other rights which
vary from state to state.
If any of the above terms are void because of state or federal law, all other warranty
terms will remain in effect.
Engine Oil
1. Mixing oil brands or using non-recommended oil may cause engine damage. We rec-
ommend the use of POLARIS engine oil for your ATV.
2. Damage resulting from the use of non-recommended lubricants may not be covered
by warranty.
SPARK ARRESTER
POLARIS warrants that the spark arrester in this vehicle will meet the efficiency
requirements of USFS standard 5100-1c for at least 1000 hours when subjected to nor-
mal use and when maintenance and installation are in accordance with POLARIS rec-
ommendations.
116
WARRANTY
Exported Vehicles
EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE IS NO WAR-
RANTY OR SERVICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD
OUTSIDE THE COUNTRY OF THE SELLING DEALER'S AUTHORIZED LOCA-
TION.
This policy does not apply to vehicles that have received authorization for export from
POLARIS Industries. Dealers may not give authorization for export. You should consult
an authorized dealer to determine this vehicle's warranty or service bulletin coverage if
you have any questions.
This policy does not apply to vehicles registered to government officials or military per-
sonnel on assignment outside the country of the selling dealer's authorized location.
This policy does not apply to Safety Bulletins.
How to Get Service
In the Country where your vehicle was purchased:
Warranty or Service Bulletin repairs must be done by an authorized POLARIS dealer. If
you move or are traveling within the country where your vehicle was purchased, War-
ranty or Service Bulletin repairs may be requested from any authorized POLARIS dealer
who sells the same line as your vehicle.
Outside the Country where your vehicle was purchased:
If you are traveling temporarily outside the country where your vehicle was purchased,
you should take your vehicle to an authorized POLARIS dealer. You must show the
dealer photo identification from the country of the selling dealer's authorized location as
proof of residence. Upon residence verification, the servicing dealer will be authorized
to perform the warranty repair.
If You Move:
If you move to another country, be sure to contact POLARIS Customer Assistance and
the customs department of the destination country before you move. Vehicles importa-
tion rules vary considerably from country to country. You may be required to present
documentation of your move to POLARIS Industries in order to continue your warranty
coverage. You may also be required to obtain documentation from POLARIS Industries
in order to register your vehicle in your new country. You should warranty register your
vehicle at a local POLARIS dealer in your new country immediately after you move to
continue your warranty coverage and to ensure that you receive safety information and
notices regarding your vehicle.
117
WARRANTY
Exported Vehicles
How to Get Service
If Purchased From A Private Party:
If you purchase a POLARIS product from a private citizen, to be kept and used outside
of the country in which the vehicle was originally purchased, all warranty coverage will
be denied. You must nonetheless warranty register your vehicle under your name and
address with a local POLARIS dealer in your country to ensure that you receive safety
information and notices regarding your vehicle.
Notice
If your vehicle is registered outside of the country where it was purchased, and you have
not followed the procedure set out above, your vehicle will no longer be eligible for war-
ranty or service bulletin coverage of any kind, other than safety bulletins. (Vehicles reg-
istered to Government officials or military personnel on assignment outside of the
country where the vehicle was purchased will continue to be covered by the basic war-
ranty.)
For questions call POLARIS Customer Assistance:
United States: 1-888-704-5290
Canada: 1-204-925-7100
118
WARRANTY
U.S.A. EPA Emissions Limited Warranty
This emissions limited warranty is in addition to the POLARIS standard limited war-
ranty for your vehicle. POLARIS Industries Inc. warrants that at the time it is first pur-
chased, this emissions-certified vehicle is designed, built and equipped so it conforms
with applicable U.S. Environmental Protection Agency emission regulations. POLARIS
warrants that the vehicle is free from defects in materials and workmanship that would
cause it to fail to meet these regulations.
The warranty period for this emissions-certified vehicle starts on the date the vehicle is
first purchased and continues for a period of 500 hours of engine operation, 5000 kilo-
meters (3100 miles) of vehicle travel, or 30 calendar months from the date of purchase,
whichever comes first.
This emissions limited warranty covers components whose failure increases the vehi-
cle’s regulated emissions, and it covers components of systems whose only purpose is to
control emissions. Repairing or replacing other components not covered by this war-
ranty is the responsibility of the vehicle owner. This emissions limited warranty does not
cover components whose failure does not increase the vehicle’s regulated emissions.
For exhaust emissions, emission-related components include any engine parts related to
the following systems:
The following parts are also considered emission-related components for exhaust emis-
sions:
The following parts are considered emission-related components for evaporative emis-
sions:
*As related to the evaporative emission control system.
• Air-induction system • Ignition system
• Fuel system • Exhaust gas recirculation systems
• Aftertreatment devices • Sensors
• Crankcase ventilation valves • Electronic control units
• Fuel Tank • Vacuum Control Diaphragms*
• Fuel Cap • Control Cables*
• Fuel Line • Control Linkages*
• Fuel Line Fittings • Purge Valves
• Clamps* • Vapor Hoses
• Pressure Relief Valves* • Liquid/Vapor Separator
• Control Valves* • Carbon Canister
• Control Solenoids* • Canister Mounting Brackets
• Electronic Controls* • Carburetor Purge Port Connector
119
WARRANTY
U.S.A. EPA Emissions Limited Warranty
The exclusive remedy for breach of this limited warranty shall be, at the exclusive
option of POLARIS, repair or replacement of any defective materials, components or
products. THE REMEDIES SET FORTH IN THIS LIMITED WARRANTY ARE THE
ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WAR-
RANTY. POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCI-
DENTAL, CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY
DESCRIPTION,WHETHER ARISING OUT OF EXPRESS OR IMPLIED WAR-
RANTY OR ANY OTHER CONTRACT, NEGLIGENCE OR OTHER TORT OR
OTHERWISE. THIS EXCLUSION OF CONSEQUENTIAL, INCIDENTAL, AND
SPECIAL DAMAGES IS INDEPENDENT FROM AND SHALL SURVIVE ANY
FINDING THAT THE EXCLUSIVE REMEDY FAILED OF ITS ESSENTIAL PUR-
POSE.
ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO ANY
IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PAR-
TICULAR PURPOSE) ARE LIMITED IN DURATION TO THE WARRANTY
PERIOD DESCRIBED HEREIN. POLARIS DISCLAIMS ALL EXPRESS WARRAN-
TIES NOT STATED IN THIS WARRANTY. Some states do not allow limitations on
how long an implied warranty lasts, so the above limitation may not apply if it is incon-
sistent with the controlling state law.
This limited warranty excludes failures not caused by a defect in material or workman-
ship.This limited warranty does not cover damage due to accidents, abuse or improper
handling, maintenance or use. This limited warranty also does not cover any engine that
has been structurally altered, or when the vehicle has been used in racing competition.
This limited warranty also does not cover physical damage, corrosion or defects caused
by fire, explosions or other similar causes beyond the control of POLARIS.
Owners are responsible for performing the scheduled maintenance identified in the
owner's manual. POLARIS may deny warranty claims for failures that have been caused
by the owner’s or operator’s improper maintenance or use, by accidents for which
POLARIS has no responsibility, or by acts of God.
Any qualified repair shop or person may maintain, replace, or repair the emission con-
trol devices or systems on your vehicle. POLARIS recommends that you contact an
authorized POLARIS dealer to perform any service that may be necessary for your vehi-
cle. POLARIS also recommends that you use only Pure POLARIS parts. It is a potential
violation of the Clean Air Act if a part supplied by an aftermarket parts manufacturer
reduces the effectiveness of the vehicle's emission controls. Tampering with emission
controls is prohibited by federal law.
If you have any questions regarding your warranty rights and responsibilities, please
contact the POLARIS Warranty Department at 1-888-704-5290.
120
MAINTENANCE LOG
Present this section of your manual to your dealer each time your vehicle is serviced.
This will provide you and future owners with an accurate log of maintenance and ser-
vices performed.
DATE MILES (KM)
OR HOURS
TECHNICIAN SERVICE PERFORMED / COMMENTS
121
MAINTENANCE LOG
DATE MILES (KM)
OR HOURS
TECHNICIAN SERVICE PERFORMED / COMMENTS
122
MAINTENANCE LOG
DATE MILES (KM)
OR HOURS
TECHNICIAN SERVICE PERFORMED / COMMENTS
123
INDEX
A
Air Filter . . . . . . . . . . . . . . . . . . . . . . 74
Apparel, Protective . . . . . . . . . . . . . 12
B
Battery . . . . . . . . . . . . . . . . . . . . 90-95
Charging (Conventional) . . . . . . . 94
Charging (Sealed) . . . . . . . . . 94-95
Fluid (Conventional) . . . . . . . . . . 93
Installation . . . . . . . . . . . . . . . . . . 92
Removal . . . . . . . . . . . . . . . . . . . . 91
Storage . . . . . . . . . . . . . . . . . . . . . 93
Boots . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Brake Fluid . . . . . . . . . . . . . . . . . 31-32
Brake Inspections . . . . . . . . . . . . . . . 66
Brake Lever. . . . . . . . . . . . . . . . . . . . 29
Brake, Foot . . . . . . . . . . . . . . . . . . . . 30
Brake, Parking . . . . . . . . . . . . . . . . . 29
Brakes . . . . . . . . . . . . . . . . . . . . . . . . 66
Break-In Period. . . . . . . . . . . . . . 36-37
C
Camber Adjustment . . . . . . . . . . . . . 70
Carburetor . . . . . . . . . . . . . . . . . . . . . 76
Carburetor Adjustment . . . . . . . . . . . 76
Cargo. . . . . . . . . . . . . . . . . . . . . . 54-55
Caster Adjustment. . . . . . . . . . . . . . . 70
Choke . . . . . . . . . . . . . . . . . . . . . . . . 33
Chrome Wheel Care . . . . . . . . . . . . . 98
Cleaning and Storage . . . . . . . . 96-101
Clothing . . . . . . . . . . . . . . . . . . . . . . . 9
Clutching Chart, TRAIL BOSS . . . 109
Clutching Chart, TRAIL BLAZER 111
Consumer Product Safety . . . . . . . . . . 7
Corrosion Removal, Chrome . . . . . . 98
Crankcase Emission Control System 56
D
Drive Belt Wear/Burn. . . . . . . . . . . 104
Drive Chain. . . . . . . . . . . . . . . . . 77-79
Drive Chain Lubrication . . . . . . . . . . 77
Drive Chain Slack. . . . . . . . . . . . 78-79
Drivetrain Break-In. . . . . . . . . . . . . . 37
D
Driving Downhill . . . . . . . . . . . . . . . 48
Driving in Reverse . . . . . . . . . . . . . . 52
Driving on a Sidehill. . . . . . . . . . . . . 47
Driving on Slippery Surfaces . . . . . . 45
Driving Over Obstacles . . . . . . . . . . 51
Driving Procedures . . . . . . . . . . . . . . 43
Driving Through Water . . . . . . . . . . 50
Driving Uphill. . . . . . . . . . . . . . . . . . 46
E
Electromagnetic Interference . . . . . . 56
Emissions Limited Warranty . 118-119
Engine Break-In . . . . . . . . . . . . . . . . 37
Engine Fogging. . . . . . . . . . . . . . . . 100
Engine Idle RPM Adjustment. . . . . . 76
Engine Oil . . . . . . . . . . . . . . . . . . . . . 62
Equipment Modifications . . . . . . . . . . 9
Etiquette, Trail Riding . . . . . . . . . . . 39
Exhaust Emission Control System . . 56
Eye Protection. . . . . . . . . . . . . . . . . . . 9
F
Fluid, Brake . . . . . . . . . . . . . . . . 31-32
Foot Brake, Auxiliary . . . . . . . . . . . . 30
Fuel Filter . . . . . . . . . . . . . . . . . . . . . 33
Fuel Safety . . . . . . . . . . . . . . . . . . . . 11
Fuel Tank Cap. . . . . . . . . . . . . . . . . . 33
Fuel Valve. . . . . . . . . . . . . . . . . . . . . 33
G
Gasoline Handling . . . . . . . . . . . . . . 11
Gear Selector . . . . . . . . . . . . . . . . . . 34
Gloves . . . . . . . . . . . . . . . . . . . . . . . . . 9
H
Handlebar Adjustment . . . . . . . . . . . 70
Hauling Cargo. . . . . . . . . . . . . . . 54-55
Headlamp Replacement . . . . . . . . . . 81
Headlight Beam Adjustment. . . . . . . 80
Headlight Switch . . . . . . . . . . . . . . . 27
Helmet. . . . . . . . . . . . . . . . . . . . . . . . . 8
124
INDEX
I
Idle RPM Adjustment . . . . . . . . . . . 76
Immersion . . . . . . . . . . . . . . . . . . . . 85
Indicator Lights . . . . . . . . . . . . . . . . 27
J
Jetting Chart, TRAIL BOSS . . . . . 109
Jetting Chart, TRAIL BLAZER . . 111
K
Key Switch. . . . . . . . . . . . . . . . . . . . 26
K-Turn . . . . . . . . . . . . . . . . . . . . . . . 49
L
Lights . . . . . . . . . . . . . . . . . . . . . 80-82
Headlamp Replacement . . . . . . . 81
Headlight Beam Adjustment. . . . 80
Indicator Lamp Replacement . . . 82
Taillight/Brakelight Replacement 82
Lubrication Guide . . . . . . . . . . . . . . 61
M
Maintenance Chart. . . . . . . . . . . . 57-60
Modifications. . . . . . . . . . . . . . . . . . . 9
N
Noise Emission Control System . . . 56
O
Oil, Engine. . . . . . . . . . . . . . . . . . . . 62
Oil, Transmission. . . . . . . . . . . . . 64-65
Oil and Filter Change. . . . . . . . . . . . 63
Oil Level, Engine. . . . . . . . . . . . . . . 62
Oil Recommendations . . . . . . . . . . . 62
Operation on Public Lands . . . . . . . 56
Override Switch . . . . . . . . . . . . . . . . 27
P
Parking Brake . . . . . . . . . . . . . . . . . 29
Parking on an Incline. . . . . . . . . . . . 53
Periodic Maintenance Chart . . . . 57-60
Polaris Product List . . . . . . . . . . . . 103
Polishing the Vehicle. . . . . . . . . . . . 97
Pre-Ride Checklist. . . . . . . . . . . . . . 40
PVT Break-In. . . . . . . . . . . . . . . . . . 37
PVT Drying . . . . . . . . . . . . . . . . . . . 89
PVT System . . . . . . . . . . . . . . . . . 87-89
R
Recoil Housing . . . . . . . . . . . . . . . . . 75
Recoil Starter . . . . . . . . . . . . . . . . . . . 35
Reverse Operation . . . . . . . . . . . . . . . 52
Riding Area . . . . . . . . . . . . . . . . . . . . 39
Riding Gear . . . . . . . . . . . . . . . . . . . 8-9
S
Safe Operation Practices . . . . . . . . . . 38
Safety Labels . . . . . . . . . . . . . . . 22-25
"No Passenger" Warning . . . . . . . 24
Age 16 Warning . . . . . . . . . . . . . . 25
Clutch Cover Warning . . . . . . . . . 25
Discretionary Warning . . . . . . . . . 23
General Warning. . . . . . . . . . . . . . 22
Rack Warning, Front and Rear . . . 23
Reverse Override Warning . . . . . . 25
Tire Pressure/Load Warning. . . . . 24
Safety Training . . . . . . . . . . . . . . . . . . 7
Safety Warnings . . . . . . . . . . . . . 10-21
Severe Use . . . . . . . . . . . . . . . . . . . . . 57
Side Panel Removal. . . . . . . . . . . . . . 67
Sidehilling . . . . . . . . . . . . . . . . . . . . . 47
Signal Words . . . . . . . . . . . . . . . . . . . . 4
Spark Arrestor . . . . . . . . . . . . . . . . . . 86
Spark Plugs . . . . . . . . . . . . . . . . . 83-84
Spring Adjustments, Rear . . . . . . . . . 70
Starting the Engine . . . . . . . . . . . 41-42
Steering Assembly. . . . . . . . . . . . . . . 69
Storage. . . . . . . . . . . . . . . . . . . . 96-101
Switches . . . . . . . . . . . . . . . . . . . 26-27
Engine Stop Switch. . . . . . . . . . . . 26
Headlight Switch . . . . . . . . . . . . . 27
Main Key Switch . . . . . . . . . . . . . 26
T
Throttle Cable Freeplay . . . . . . . . . . . 69
Throttle Lever . . . . . . . . . . . . . . . . . . 28
Tire Tread Depth . . . . . . . . . . . . . . . . 71
Tires . . . . . . . . . . . . . . . . . . . . . . 71-73
Front Wheel Hub Tightening . . . . 71
Tread Depth . . . . . . . . . . . . . . . . . 71
Wheel Installation . . . . . . . . . . . . . 72
Wheel Nut Torque . . . . . . . . . . . . 73
Wheel Removal . . . . . . . . . . . . . . 72
Toe Alignment. . . . . . . . . . . . . . . . . . 68
Towing Loads . . . . . . . . . . . . . . . . . . 55
Trail Etiquette . . . . . . . . . . . . . . . . . . 39
125
INDEX
T
Training. . . . . . . . . . . . . . . . . . . . . . . . 7
Transmission Oil. . . . . . . . . . . . . 64-65
Transporting the Vehicle . . . . . . . . 102
Tread Lightly . . . . . . . . . . . . . . . . . . 39
Turning Around on a Hill . . . . . . . . . 49
Turning the Vehicle . . . . . . . . . . . . . 44
V
Vehicle Identification Numbers . . . . . 6
Vehicle Immersion . . . . . . . . . . . . . . 85
W
Warning Symbols . . . . . . . . . . . . . . . . 4
Washing the Vehicle. . . . . . . . . . 96-97
Wheel Hub Tightening . . . . . . . . . . . 71
Wheel Installation. . . . . . . . . . . . . . . 72
Wheel Nut Torque Specifications. . . 73
Wheel Removal . . . . . . . . . . . . . . . . 72
