Polaris TRAILBOSS 330 2009 Trailboss 330 Single-Cylinder User Manual

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. 9921784 Rev 02

Printed in USA

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.

WA RNING

The engine exhaust from this product contains

chemicals known to the State of California to cause

cancer, birth defects or other reproductive harm.

WELCOME

Thank you for purchasing a Polaris vehicle, and welcome to our world-

wide family of Polaris owners. We proudly produce an exciting line of

utility and recreational products.

• Snowmobiles

• All-terrain vehicles (ATVs)

• RANGER utility vehicles

• Victory motorcycles

We believe Polaris sets a standard of excellence for all utility and recre-

ational vehicles manufactured in the world today. Many years of experi-

ence have gone into the engineering, design, and development of your

Polaris vehicle, making it the finest machine we’ve ever produced.

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!

POLARIS and POLARIS THE WAY OUT are registered trademarks of Polaris Indus-

tries Inc.

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.

Printed in U.S.A.

2009 Trail Boss Owner’s Manual

P/N 9921784

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

Maintenance Log . . . . . . . . . . . . . . . . . . . . . . 116

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

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.

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.

Purchasers of a new Polaris ATV and their eligible family members are

entitled to take the ATV RiderCourse

. Contact ATV Enrollment Express at

(800) 887-2887 or visit www.atvsafety.org for information on enrollment in the

ATV RiderCourse

• 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.

WARNING

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

SAFETY

Safety Training

ATV safety training is a top priority for Polaris. When you purchased

your new ATV, your dealer instructed you on the authorized ATV

RiderCourse

available to you and your eligible family members. This

training is included in the purchase price of your ATV. Polaris strongly

encourages you and your eligible family members who will be riding

the ATV to take the ATV RiderCourse

. 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, you can take the ATV

RiderCourse

by calling ATV Enrollment Express at (800) 887-2887 or

by visiting www.atvsafety.org. Purchasers of a used Polaris ATV will be

charged for this 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, 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.

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 established

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

051039

0006.31

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.

Riding 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.

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

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

• 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.

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.

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.

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

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

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

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

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: 4.0 psi (27.6 kPa)

Rear: 3.0 psi (20.7 kPa)

• Maximum weight capacity: 415 lbs. (188 kg)

7175444

“No Passenger”

Warning

Clutch Cover

Warning

Age 16 Warning

Tire Pressure/Load

Warning

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

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.

The override switch also allows activation of All Wheel Drive in

reverse, if the AWD switch is on.

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 electrical 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

FEATURES AND CONTROLS

Switches

Headlight Switch

Use the headlight switch to turn the lights on and off and to change the

lights from high beam to low beam (if equipped). 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)

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 Control (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

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

riding. 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

diagnosis 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

FEATURES AND CONTROLS

Auxiliary Foot Brake

Aggressively applying the auxiliary brake when backing down a hill may cause

rear tipover, which could result in serious injury or death. Never back down a hill.

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, which may result in serious injury or death.

The auxiliary brake system is

intended to be used as a

backup for the main brake sys-

tem. 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

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

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

FEATURES AND CONTROLS

Choke

The choke assists in starting a cold engine. Refer to the engine starting

procedure on page 41 for correct choke and throttle settings during start-

ing.

Fuel Tank Cap

Always refuel with the engine

stopped, and outdoors or in a well

ventilated area. Refuel on a level sur-

face.

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 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.

RES: Turn the valve to the reserve set-

ting if the main fuel supply is

exhausted. Refuel as soon as possible.

Return the valve to the ON position

after refueling.

Reserve fuel range is about 7-10 miles

(11-16 km).

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

Valve

OFF

RES

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

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

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 gasoline.

No single action on your part is as important as following the proce-

dures 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

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.

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.

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.

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.

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

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

Throttle Ensure proper operation 28

Indicator lights/switches Ensure operation 26

Engine stop switch Ensure proper operation 26

Drive chain Check condition/slack, lubricate as

needed

Air filter, pre-filter Inspect, clean 74

Air box sediment tube Drain deposits whenever visible -

Headlamp Check operation, apply Polaris dielec-

tric grease when lamp is replaced

Brake light/tail lamp Check operation, apply Polaris dielec-

tric grease when lamp is replaced

Riding gear Wear approved helmet, goggles, and

protective clothing

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 ten-

sion by rotating the tension

adjusting nut clockwise.

Tip: The variable choke is fully on

when the knob is pulled com-

pletely out. The choke is off when

the knob is pushed completely in.

The choke can be adjusted gradu-

ally, depending on how much

choke is needed for starting. Be

sure the choke is off during opera-

tion, 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

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.

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.

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

turning 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 tech-

nique alters the balance of trac-

tion 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.

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. Engage AWD before wheels begin to lose traction.

NOTICE: Severe damage to drive train may occur if AWD is engaged while the

wheels are spinning. Allow the rear wheels to stop spinning before

engaging AWD, or engage AWD before wheels begin to lose traction.

4. Maintain a high level of alertness, reading the trail and avoiding

quick, sharp turns, which can cause skids.

5. 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

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

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!

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.

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)

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

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.

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.

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.

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.

CARGO WEIGHT DISTRIBUTION should be 1/3 on the front rack and 2/3 on

the rear rack. When operating over rough or hilly terrain, reduce speed and

cargo to maintain stable driving conditions. Carrying loads on only one rack

increases the possibility of vehicle overturn.

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. 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

OPERATION

Hauling Cargo

Never exceed the weight

capacities specified for your

ATV on warning labels and in

the specifications section of

this manual.

Cargo weight should be

evenly distributed (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 stable

driving conditions. Do not

obstruct the headlight beam

with cargo.

Towing Loads

Always attach a towed load to the hitch point. Remove the hitch from

the ATV when not towing a trailer. 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.

NOTICE: Using an improper hitch or

exceeding the maximum tongue

weight capacity can result in

serious damage to the vehicle and

will void your ATV warranty. Never

install a hitch longer than 4" (10

cm). Never install automotive

accessories on your Polaris ATV.

Always install Polaris-approved (or

equivalent) accessories designed

for ATV use.

1/3

2/3

Maximum

4" (10 cm)

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 arrestor that was tested and qualified to

be in accordance with the USDA Forest Service Standard 5100-1C. Fed-

eral law requires that this spark arrestor 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 8343.1(c). Violations are subject to monetary penalties. Fed-

eral 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 can be found on the frame tubing of the

vehicle.

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.

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 116.

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

riding 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.

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

X 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.)

Q Have an authorized Polaris dealer perform these services.

WARNING

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.

X Front suspension - Pre-Ride -

X Rear suspension - Pre-Ride -

Tires - Pre-Ride -

X Brake fluid level - Pre-Ride -

X Brake lever travel - Pre-Ride -

Brake system - Pre-Ride -

Wheels/fasteners - Pre-Ride -

Frame fasteners - Pre-Ride -

X Engine oil level - Pre-Ride -

Air filter, pre-filter - Daily - Inspect; clean often; replace

as needed

X Air box sediment

tube

- Daily - Drain deposits when visible

Headlamp/tail

lamp

- Daily - Check operation; apply

dielectric grease if replacing

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

X Transmission oil 25 H Monthly 250 (400) Inspect level; change yearly

Engine breather

filter (if equipped)

25 H Monthly 250 (400) Inspect; clean if needed

X 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

Throttle Cable/

ETC Switch

50 H 6 M 500 (800) Inspect; adjust; lubricate;

replace if necessary

Choke cable 50 H 6 M 500 (800) Inspect; adjust; lubricate;

replace if necessary

MAINTENANCE

Periodic Maintenance Chart

X Perform these procedures more often for vehicles subjected to severe use.

E Emission-Related Service

Q Have an authorized Polaris dealer perform these services.

Item Maintenance Interval

(whichever comes first)

Remarks

Hours Calendar Miles

(Km)

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

X Engine oil change 100 H 6 M 1000 (1600) Perform a break-in oil change

at 20 hours

X Oil filter change 100 H 6 M 1000 (1600) Replace with oil change

Valve clearance 100 H 12 M 1000 (1600) Inspect; adjust

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

X Engine mounts 100 H 12 M 1000 (1600) Inspect

Exhaust muffler/

pipe

100 H 12 M 1000 (1600) Inspect

Spark plug 100 H 12 M 1000 (1600) Inspect; replace as needed

Ignition Timing 100 H 12 M 1000 (1600) Inspect

X 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 arrestor 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

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 Synthetic Gearcase

Lube

See page 64.

Ball Joint XPremium All Season

Grease

Locate fitting on back side of struts and

grease with grease gun.

Swing Arm

Bushings

XPremium All Season

Grease

Locate fittings on swing arm and

grease with grease gun

Axle Housing

Swing Arm

Bushings

Ball Joint

Axle

Housing

MAINTENANCE

Engine Oil

Oil Recommendations

Polaris recommends the use of Polaris PS-4 PLUS Performance Syn-

thetic 2W-50 4-cycle oil or a similar oil for this engine. Oil may need to

be changed more frequently if Polaris oil is not used. Always use 2W-50

oil. Follow the manufacturer's recommendations for ambient tempera-

ture 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

Dipstick

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.

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 Premium AGL Synthetic Gearcase Lube.

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 com-

pletely.

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 q u e

Transmission Premium AGL Synthetic

Gearcase Lubricant

11.3 oz.

(335 ml)

14 ft. lbs.

(19 Nm)

Dipstick

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

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

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. Grasp the rear of the side

panel near the rear cab. With

a quick and firm motion,

pull the panel forward and

outward to disengage the

two rear tabs.

3. Place your hand on top of

the side panel behind the

fuel tank. With a quick and

firm motion, push down on

the side panel to disengage

the top rear two tabs. Then

pull up on the side panel to

disengage the front upper

and lower tabs.

4. To reinstall the side panel,

align the panel tabs with the

slots on the front cab. Push

the panel upward and for-

ward until the tabs lock.

Bend the rear of the side

panel and insert the two tabs

into the rear cab.

Step 3

Step 2

Step 4

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 ser-

vice.

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

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

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)

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.

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)

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

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.

MAINTENANCE

Carburetor

Your Polaris ATV is calibrated at the factory for optimal performance at

altitudes ranging from zero to 6,000 feet (1800 m) and temperatures 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 conditions

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

MAINTENANCE

Drive Chain

Drive Chain Lubrication

Polaris ATV drive chains are equipped with o-ring-sealed, permanently

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.

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.

3/16"-3/8" (5 mm - 10 mm)

Locking Bolts

Pin Punch

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

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 switch to high beam.

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)

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.

MAINTENANCE

Lights

Taillight/Brakelight Lamp Replacement

1. Remove the taillight lens cover

mounting screws. Remove the

lens cover and gasket and set

aside for reassembly.

2. Remove the lamp.

3. Apply dielectric grease to the

socket and install the new lamp.

4. Test the taillight/brake light for

proper operation.

5. Reinstall the gasket and lens cover.

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.

Lamp

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)

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.

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

MAINTENANCE

Spark Arrestor

Failure to heed the following warnings while servicing the spark arrestor 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

arrestor 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 arrestor

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. Place the transmission in neutral. Lock the parking brake. Repeat

steps 6 to 8 until no more particles are expelled.

11. Stop the engine. Allow the arrestor to cool.

12. Reinstall the arrestor plug and remove the exhaust outlet cover or

plug.

WARNING

Exhaust

Outlet

Clean-Out Plug

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. 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

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 flyweights also

increases. This, in turn, increases the amount of pinch applied to the

drive belt. Similarly, if the engine speed decreases, the amount of cen-

trifugal 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.

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.

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

MAINTENANCE

Battery

Battery Removal

1. Place the transmission in gear.

2. Lock the parking brake.

3. Disconnect the battery hold-down strap.

4. Remove the battery cover.

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.

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.

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. Install the battery cover.

8. Secure the battery hold-down strap.

9. Verify that cables are properly routed. Cables should be safely

tucked away at the front and rear of the battery.

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 Bat-

tery 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

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.

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

MAINTENANCE

Cleaning and Storage

Washing the Vehicle

Keeping your Polaris vehicle clean will not only improve its appearance

but it can also extend the life of various components.

NOTICE: High water pressure may damage components. Polaris recommends

washing the vehicle by hand or with a 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 garden

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.

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

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.

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 recommended

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 (front gearcase)

• 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 mate-

rials. They do not allow enough ventilation to prevent condensation, 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 # Description

Engine Lubricant

2870791 Fogging Oil (12 oz. 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

2873602 Premium AGL Synthetic Gearcase Lubricant (qt./.95 l)

2873603 Premium AGL Synthetic Gearcase Lube (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 Jug

Grease / Specialized Lubricants

2871312 Grease Gun Kit, Premium All Season (3 oz.)

2871322 Premium All Season Grease (3 oz. cartridge)

2871423 Premium All Season Grease (14 oz. cartridge)

2871460 Starter Drive Grease (2 oz.)

2871515 Premium U-Joint Lube (3 oz.)

2871551 Premium U-Joint Lube (14 oz.)

2871329

Dielectric Grease (Nyogel

)

2872073 Chain Lube, Aerosol (6.25 oz.)

2872348 Chain Lube, Aerosol (16 oz.)

Additives / Miscellaneous

2871326 Carbon Clean Plus (12 oz.)

2870652 Fuel Stabilizer (16 oz.)

2872189 DOT4 Brake Fluid (12 oz.)

2871956

Loctite

565 Thread Sealant

2859044

Polaris Battery Tender

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

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 opera-

tor, cargo and accessories)

Dry Weight 505 lbs. (229 kg)

Fuel Capacity 3.25 gal. (12.3 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 46 in. (117 cm)

Overall Height 46 in. (117 cm)

Wheelbase 49.5 in. (125.7 cm)

Ground Clearance 5.5 in. (14 cm)

Minimum Turning Radius 75 in. (190.5 cm) unloaded

Engine Model Number/Type ES-32PFE-106 / 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

Spark Plug / Gap BKR6E / .036 in. (.9 mm)

109

SPECIFICATIONS

Jetting Chart

Clutching Chart

Trail Boss 330

Driving System Type Automatic PVT (Polaris Variable Transmission)

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 7-10 (4 psi/27.6 kPa)

Tires/Pressure, Rear 22 x 11-10 (3 psi/20.7 kPa)

Front Suspension MacPherson strut with 6.7" (17 cm) travel

Rear Suspension Progressive rate with 9" (23 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 8.26W

Brake Light 12V 26.9W

Battery 12V 14AH

Indicators High Beam/High Temp/Neutral/Reverse

ALTITUDE

Meters (Feet)

AMBIENT TEMPERATURE

Below 40° F

(Below 5° C)

40°F and above

(5°C 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)

10RH

5630709

Blue/Green

7041157

Black

7041782

40°

5131446

2+2

1800-3700

(6000-12000)

20-40

5631356

Blue/Green

7041157

Black

7041782

40°

5131446

2+2

110

WARRANTY

LIMITED WARRANTY

Polaris Sales Inc., 2100 Highway 55, Medina, MN 55340, gives a SIX MONTH LIM-

ITED 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 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.

111

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.

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 com-

ponents or products. THE REMEDIES SET FORTH IN THIS 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 WARRANTY OR ANY

OTHER CONTRACT, NEGLIGENCE, OR OTHER TORT OR OTHERWISE. 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

inconsistent with controlling state law.

112

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 TRANSPORTATION TO

AND FROM THE DEALER IS YOUR RESPONSIBILITY). Polaris suggests 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 ARRESTOR

Polaris warrants that the spark arrestor in this vehicle will meet the efficiency require-

ments of 43 CFR 8340.1(c) for at least 1000 hours when subjected to normal use and

when maintenance and installation are in accordance with Polaris recommendations.

113

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 Recalls.

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, Warranty 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 per-

form 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 importation

rules vary considerably from country to country. You may be required to present docu-

mentation of your move to Polaris Industries in order to continue your warranty cover-

age. You may also be required to obtain documentation from Polaris Industries in order

to register your vehicle in your new country.

114

WARRANTY

Exported Vehicles

How to Get Service

If Purchased From A Private Party:

If you purchase a Polaris product from a private citizen outside of the country in which

the vehicle was originally purchased, all warranty coverage will be denied.

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. (Vehicles registered to Government offi-

cials or military personnel on assignment outside of the country where the vehicle was

purchased will continue to be covered by the basic warranty.)

For questions call Polaris Customer Assistance:

United States: 1-888-704-5290

Canada: 1-204-925-7100

115

WARRANTY

U.S.A. EPA Emissions Limited Warranty

This All Terrain Vehicle (ATV) or Off Road Utility Vehicle (ORUV) emissions limited

warranty is in addition to the Polaris standard limited warranty for this vehicle.

Polaris warrants that this vehicle is; (1) designed, built, and equipped to conform at the

time of initial sale with the requirements of 40 CFR 1051 and, (2) free from defects in

materials and workmanship that may keep it from meeting these requirements.

The emissions warranty period for this vehicle begins on the date the vehicle is deliv-

ered to the original retail purchaser and ends 30 months (2.5 years) after that date, after

5000 km (3100 miles), or after 500 hours of operation, whichever comes first.

This emission-related warranty covers components whose failure would increase an

engine's emissions, including electronic controls, fuel injection, exhaust-gas recircula-

tion, aftertreatment, or any other system utilized in this vehicle to control emissions.

Replacing or repairing other components not covered by this emissions warranty or the

standard warranty is the responsibility of the owner; including the parts, labor and other

costs associated with recommended maintenance.

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 prod-

ucts. 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.

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 any engine that 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.

If you have any questions regarding your warranty rights and responsibilities, you

should contact the Polaris Warranty Department at 1-888-704-5290.

116

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

117

MAINTENANCE LOG

DATE MILES (KM)

OR HOURS

TECHNICIAN SERVICE PERFORMED / COMMENTS

Polaris TRAILBOSS 330 2009 Trailboss 330 Single-Cylinder Vehicle

Product's Documents

Owner’s Manual

Specifications

Polaris TRAILBOSS 330 Questions and Answers

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