Polaris TRAIL BLAZER 330 Owner's Manual
Polaris TRAIL BLAZER 330 Owner's Manual

Polaris TRAIL BLAZER 330 Owner's Manual

Polaris atv user manual
Table of Contents

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Summary of Contents for Polaris TRAIL BLAZER 330

  • Page 3 WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm. 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.
  • Page 4 S All-terrain vehicles (ATVs) S RANGER utility vehicles S Victory motorcycles We believe Polaris sets a standard of excellence for all utility and recreational vehicles manufactured in the world today. Many years of experience have gone into the engineering, design, and development of your Polaris vehicle, making it the finest machine we’ve ever...
  • Page 5 Copyright 2007 Polaris Sales Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this publication.
  • Page 6: Table Of Contents

    ......EMISSION CONTROL SYSTEMS MAINTENANCE SPECIFICATIONS POLARIS PRODUCTS TROUBLESHOOTING WARRANTY ......
  • Page 8: Know Your Vehicle

    Record your ATV’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.
  • Page 9: Safety

    Failure to follow the warnings contained in this manual can result in serious 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.
  • Page 10: Operator Safety

    Operator Safety The following signal words and symbols appear throughout this manual and on your ATV. Your safety is involved when these words and symbols are used. Become familiar with their meanings before reading the manual. The safety alert symbol, on your vehicle or in this manual, alerts you to the potential for personal injury.
  • Page 11 S 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 Enrollment Express at (800) 887-2887 or visit www.atvsafety.org for information on enrollment in the ATV RiderCourse S Never allow anyone under 16 years of age to operate this ATV.
  • Page 12 Operator Safety S Always have the ATV inspected by an authorized Polaris dealer if it’s been involved in an accident. S Never operate on hills too steep for the ATV or for your abilities. Practice on smaller hills before attempting larger hills.
  • Page 13: Equipment Modifications

    We are concerned for the safety of our customers and for the general public. Therefore, 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.
  • Page 14 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. HOW TO AVOID THE HAZARD No one under the age of 16 should operate a Polaris ATV.
  • Page 15 SAFETY Operator Safety WARNING POTENTIAL HAZARD Carrying a passenger on an ATV. WHAT CAN HAPPEN Carrying a passenger greatly reduces the operator’s ability to balance and control the ATV, which could cause an accident and injury to the operator and/or passenger. HOW TO AVOID THE HAZARD Never carry a passenger.
  • Page 16 SAFETY Operator Safety WARNING POTENTIAL HAZARD Operating this ATV on public streets, roads or highways. WHAT CAN HAPPEN The ATV could collide with another vehicle. HOW TO AVOID THE HAZARD Never operate the ATV on any public street, road or highway, including dirt and gravel roads.
  • Page 17 SAFETY Operator Safety WARNING POTENTIAL HAZARD Operating the ATV after consuming alcohol or drugs. WHAT CAN HAPPEN Consumption of alcohol and/or drugs could seriously affect operator judgment. Reaction time may be slower and operator balance and perception could be affected. Consuming alcohol and/or drugs before or while operating an ATV could result in an accident causing severe injury or death.
  • Page 18 SAFETY Operator Safety WARNING POTENTIAL HAZARD Attempting wheelies, jumps and other stunts. WHAT CAN HAPPEN Attempting stunts increases the chance of an accident, including an overturn. HOW TO AVOID THE HAZARD Never attempt wheelies, jumps, or other stunts. Avoid exhibition driving. WARNING POTENTIAL HAZARD Failure to inspect the ATV before operating.
  • Page 19 SAFETY Operator Safety WARNING POTENTIAL HAZARD Removing hands from the handlebars or feet from the footrests during operation. WHAT CAN HAPPEN Removing even one hand or foot can reduce ability to control the vehicle or could cause loss of balance and ejection from the ATV. If the operator’s foot is not firmly planted on the footrest, it could come into contact with the rear wheels and lead to accident or injury.
  • Page 20 SAFETY Operator Safety WARNING POTENTIAL HAZARD Failure to use extra caution when operating on excessively rough, slippery or loose terrain. WHAT CAN HAPPEN Operating on excessively rough, slippery or loose terrain could cause loss of traction or loss of control, which could result in an accident or overturn.
  • Page 21 SAFETY Operator Safety WARNING POTENTIAL HAZARD Operating on excessively steep hills. WHAT CAN HAPPEN The vehicle may overturn. HOW TO AVOID THE HAZARD Never operate on hills too steep for the ATV or for your abilities. Never operate the ATV on hills steeper than 25_. Practice on smaller hills before attempting large hills.
  • Page 22 SAFETY Operator Safety WARNING POTENTIAL HAZARD Traveling downhill improperly. WHAT CAN HAPPEN Improperly descending a hill could cause loss of control or overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for traveling down hills as described in the owner’s manual. NOTE: A special technique is required when braking while traveling downhill.
  • Page 23 SAFETY Operator Safety WARNING POTENTIAL HAZARD Improperly crossing hills and turning on hills. WHAT CAN HAPPEN Improperly crossing or turning as hills could cause loss of control or overturn. HOW TO AVOID THE HAZARD 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...
  • Page 24 SAFETY Operator Safety WARNING POTENTIAL HAZARD Stalling, rolling backwards or improperly dismounting while climbing a hill. WHAT CAN HAPPEN The vehicle could overturn. HOW TO AVOID THE HAZARD Maintain steady speed when climbing a hill. If all forward speed is lost: Keep your weight uphill.
  • Page 25 SAFETY Operator Safety WARNING POTENTIAL HAZARD Improperly operating over obstacles. WHAT CAN HAPPEN Operating over obstacles could cause loss of control or overturn. HOW TO AVOID THE HAZARD Before operating in a new area, check for obstacles. Avoid operating over large obstacles such as rocks and fallen trees when possible.
  • Page 26 SAFETY Operator Safety WARNING POTENTIAL HAZARD Operating the ATV through deep or fast-flowing water. WHAT CAN HAPPEN Tires may float, causing loss of traction and loss of control, which could lead to an accident or overturn. HOW TO AVOID THE HAZARD Avoid operating the ATV through deep or fast-flowing water.
  • Page 27 Never modify the ATV through improper installation or use of accessories. All parts and accessories added to the vehicle must be genuine Polaris Industries Inc. or equivalent components designed for use on this ATV and should be installed and used according to approved instructions.
  • Page 28 SAFETY Operator Safety WARNING Leaving the keys in the ignition can lead to unauthorized use of the vehicle resulting in serious injury or death. Always remove the ignition key when the vehicle is not in use. WARNING After any overturn or accident, have a qualified service dealer inspect the entire vehicle for possible damage, including (but not limited to) brakes, throttle and steering systems.
  • Page 29: Fuel Safety

    SAFETY Fuel Safety WARNING Gasoline is highly flammable and explosive under certain conditions. S Always exercise extreme caution whenever handling gasoline. S Always refuel with the engine stopped, and outdoors or in a well ventilated area. S Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored.
  • Page 30: Safety Decals And Locations

    ATV, always read and follow the instructions of the decals on the ATV. If any decal becomes illegible or comes off, contact your Polaris dealer to purchase a replacement. Replacement safety decals are provided by Polaris at no charge.
  • Page 31 S use proper riding techniques to avoid vehicle overturns on hills and rough terrain and in turns S avoid paved surfaces -- pavement may seriously affect handling and control LOCATE AND READ OWNER’S MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS. IF OWNER’S MANUAL IS MISSING, CONTACT A POLARIS DEALER FOR A REPLACEMENT.
  • Page 32 SAFETY Safety Decals and Locations No Passenger Warning (4) WARNING NEVER ride as a passenger. Passengers can cause a loss of control, resulting in SEVERE INJURY or DEATH. Age 16 Warning (5) WARNING Operating this ATV if you are under the age of 16 increases your chance of severe injury or death.
  • Page 33: Safe Riding Gear

    2. Eye Protection Do not depend on eyeglasses or sunglasses for eye protection. Whenever 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.
  • Page 34: Features And Controls

    Electrical Switches WARNING Activating the override switch while the throttle is open can cause loss of control, resulting in severe injury or death. Do not activate the override switch while the throttle is open. Override Switch (1) (Reverse Speed Limiter) - This vehicle is equipped with a reverse speed limiter system.
  • Page 35: Indicator Lights

    FEATURES AND CONTROLS Light Switches WARNING Operating the ATV on streets or roads, especially in darkness, could result in an accident and serious injury or death. Your ATV is not equipped with highway-approved lights. It’s designed for and must be used for off-road use only. Use caution and drive at reduced speeds in conditions of reduced visibility such as fog, rain and darkness.
  • Page 36: Throttle Lever

    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.
  • Page 37: Brake Lever

    FEATURES AND CONTROLS Brake Lever WARNING 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. The front and rear brakes are applied by squeezing the brake lever (1) toward the handlebar.
  • Page 38 If the fluid level is low add DOT 4 brake fluid only. DO NOT OVERFILL. See page 107 for the part numbers of Polaris products. WARNING Never store or use a partial bottle of brake fluid. Brake fluid is hygroscopic, meaning it rapidly absorbs moisture from the air.
  • Page 39: Parking Brake

    FEATURES AND CONTROLS Parking Brake WARNING Operating the ATV while the parking brake is engaged could result in an accident and serious injury or death. Always check to be sure the parking brake is disengaged before operating. Setting the Parking Brake 1.
  • Page 40: Auxiliary Brake

    Auxiliary Brake WARNING Aggressively applying the rear brake when backing downhill may cause rear tipover, which could result in serious injury or death. Use caution when applying the auxiliary brake. Do not aggressively apply the auxiliary brake when going forward. The rear wheels may skid and slide sideways, causing loss of control and serious injury or death.
  • Page 41: Fuel Valve

    FEATURES AND CONTROLS Choke The choke assists in starting a cold engine. Refer to the engine starting procedure on page 43 for correct choke and throttle settings during starting. Fuel Valve The fuel valve (1) is located on the left side of the vehicle, below the fender.
  • Page 42 Automatic Transmission Gear Selector The transmission gear selector (1) is located on the right side of the vehicle. F: Forward N: Neutral R: Reverse CAUTION Shifting gears with the engine speed above idle or while the vehicle is moving could cause transmission damage. To change gears, stop the vehicle, and with the engine idling, move the lever to the desired gear.
  • Page 43: Recoil Starter

    The recoil starter is located on the right side of the machine. Polaris 4-cycle engines are equipped with automatic decompressors. This makes recoil starting possible by reducing the amount of compression during starting.
  • Page 44: Operation

    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 procedures for a proper break-in.
  • Page 45 Ensure proper operation Check condition / slack, lubricate as needed Inspect, clean Drain deposits whenever visible Check operation, apply Polaris dielec- tric grease when lamp is replaced Check operation, apply Polaris dielec- tric grease when lamp is replaced Wear helmet, goggles, protective...
  • Page 46: Starting The Engine

    Starting the Engine WARNING Engine exhaust contains poisonous carbon monoxide and can cause loss of consciousness resulting in severe injury or death. Never run an engine in an enclosed area. 1. Position the vehicle on a level surface. 2. Place the transmission in neutral.
  • Page 47 OPERATION Starting the Engine 7. Move the engine stop switch to RUN. NOTE: Do not press the throttle while starting the engine. 8. 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.
  • Page 48: Driving Safely

    Driving Safely Driving Procedures 1. Sit upright with both feet on the footrests and both hands on the handlebars. 2. Start the engine and allow it to warm up, then shift the transmission into gear. 3. Check your surroundings and determine your path of travel. 4.
  • Page 49: Hauling Cargo

    OPERATION Driving Safely Hauling Cargo Accessory racks and hitches are available from your Polaris dealer. Always read and understand the load distribution warnings on all warning labels, and never exceed the specified weight capacities for the vehicle. Maximum Towing Capacities Refer to the specifications at the rear of this manual for towing capacities.
  • Page 50 Driving Safely Hauling Cargo WARNING Hauling cargo improperly can alter vehicle handling and may cause loss of control or brake instability and result in serious injury or death. Always follow these precautions when hauling cargo: S REDUCE SPEED AND ALLOW GREATER DISTANCE FOR BRAKING WHEN HAULING CARGO.
  • Page 51: Making Turns

    Driving Safely Making Turns Your Polaris 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.
  • Page 52: Driving On Slippery Surfaces

    Driving Safely Driving on Slippery Surfaces Whenever riding on slippery surfaces such as wet trails or loose gravel, or during freezing weather, follow these precautions: 1. Slow down when entering slippery areas. 2. Maintain a high level of alertness, reading the trail and avoiding quick, sharp turns which can cause skids.
  • Page 53: Driving Uphill

    OPERATION Driving Safely Driving Uphill WARNING Braking and handling are greatly affected when operating in hilly terrain. Improper procedure could cause loss of control or overturn and result in serious injury or death. Avoid climbing steep hills (25_ maximum). Use extreme caution when operating on hills, and follow proper operating procedures outlined in the owner’s manual.
  • Page 54 OPERATION Driving Safely Driving Uphill Whenever traveling uphill, follow these precautions: 1. Always travel straight uphill. 2. Avoid steep hills (25_ maximum). 3. Keep both feet on the footrests. 4. Transfer your weight forward. 5. Proceed at a steady rate of speed and throttle opening. 6.
  • Page 55: Driving Downhill

    OPERATION Driving Safely Driving Downhill Whenever descending a hill, follow these precautions: 1. Proceed directly downhill. 2. Transfer your weight to the rear of the vehicle. 3. Slow down. 4. Apply the brakes slightly to aid in slowing, using the single brake lever.
  • Page 56 Driving Safely Sidehilling WARNING Improperly crossing hills or turning on hills can result in loss of control or vehicle overturn, resulting in severe injury or death. Avoid crossing the side of a hill when possible. Follow proper procedures as outlined in the owner’s manual. Sidehilling can be a dangerous type of driving and should be avoided if at all possible.
  • Page 57: Turning Around On A Hill

    OPERATION Driving Safely Turning Around on a Hill If the vehicle stalls while climbing a hill, never back it down the hill! Use the K-turn to turn around. 8’ (2.4 m) 1. Stop and lock the parking brake while keeping body weight uphill. 2.
  • Page 58: Driving Through Water

    Driving Safely Driving Through Water Your ATV can operate through water with a maximum recommended depth equal to the bottom of the footrests (1). Follow these procedures when operating through water: 1. Determine water depths and current before crossing. 2. Choose a crossing where both banks have gradual inclines.
  • Page 59: Driving Over Obstacles

    OPERATION Driving Safely Driving Over Obstacles Be alert! Look ahead and learn to read the terrain you’re traveling on. Be constantly alert for hazards such as logs, rocks and low hanging branches. WARNING Severe injury or death can result if your vehicle comes in contact with a hidden obstacle.
  • Page 60: Driving In Reverse

    Avoid backing on inclines, and avoid turning at sharp angles. NOTE: This Polaris ATV is equipped with a reverse speed limiter. The override button should be used with caution as rearward vehicle speed is greatly increased. Do not operate at wide open throttle.
  • Page 61 OPERATION Driving Safely Parking on an Incline Avoid parking on an incline if possible. If it’s unavoidable, follow these precautions: 1. Turn the engine off. 1. Place the transmission in gear. 2. Set the parking brake. 3. Always block the rear wheels on the downhill side. See illustration.
  • Page 62: Emission Control Systems

    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. Federal law requires that this spark arrestor be installed and functional when the vehicle is operated on public lands.
  • Page 63: Maintenance

    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.
  • Page 64: Periodic Maintenance Chart

    Emission-related service (Failure to conduct this maintenance will not void the emissions warranty but may affect emissions.) Have an authorized Polaris dealer perform these services. WARNING Improperly performing the procedures marked with a result in component failure and lead to serious injury or death.
  • Page 65 MAINTENANCE Periodic Maintenance Chart Item Hours Calendar Brake pad wear " Battery Transmission oil " Engine breather " filter (if equipped) General " lubrication Carburetor float bowl Throttle Cable/ ETC Switch Choke cable Carburetor air intake ducts/ flange Drive belt Cooling system (if applicable) Engine oil change...
  • Page 66 Idle speed Toe adjustment Headlight aim Perform these procedures more often for vehicles subjected to severe use. " E Emission-Related Service Have an authorized Polaris dealer perform these services. Maintenance Interval (whichever comes first) Miles (Km) 12 M 1000 (1600) Inspect for leaks...
  • Page 67: Lubrication Recommendations

    More often under severe use, such as wet or dusty conditions " Polaris Premium All Season Grease or grease conforming to NLG No. 2, such as Conoco Superlube M or Mobilegrease Special Use Polaris Premium U-Joint Lube every 500 miles, before long...
  • Page 68 MAINTENANCE Lubrication Recommendations...
  • Page 69: Engine Oil

    Polaris recommends the use of Polaris PS-4 PLUS Performance Synthetic 2W-50 4-cycle oil or a similar oil for this engine. Oil may need to be changed more frequently if Polaris oil is not used. Always use 2W-50 oil. Follow the manufacturer’s recommendations for ambient temperature operation.
  • Page 70: Oil And Filter Change

    Engine Oil Oil and Filter Change 1. Position the vehicle on a level surface. 2. Clean the area around the drain plug. 3. Run the engine for two to three minutes until warm. Stop the engine. CAUTION Contact with hot oil may result in serious burns. Do not allow hot oil to come into contact with skin.
  • Page 71: Transmission Oil

    Periodic Maintenance Chart beginning on page 60. Maintain the oil level at the bottom of the fill hole threads. We recommend the use of Premium AGL Synthetic Gearcase Lubricant. See page 107 for the part numbers of Polaris products. Oil Check The transmission dipstick (1) is located on the right side of the machine near the recoil handle.
  • Page 72: Oil Change

    Transmission Oil Oil Change 1. Place a drain pan beneath the transmission oil drain plug area. 2. Loosen the jam nut (A). 3. Turn the adjuster bolt (B) in to allow the removal of the drain plug (C). 4. Remove the drain plug and wipe the magnetic end clean to remove accumulated metallic filings.
  • Page 73: Toe Alignment

    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. Use the following procedure to check the toe alignment of the vehicle.
  • Page 74 Always fill the reservoir as needed whenever the cover is loosened or removed to ensure proper diaphragm operation. Use Polaris DOT 4 brake fluid. Do not overfill. MAINTENANCE...
  • Page 75: Steering Assembly

    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. Camber and Caster The camber and caster are non-adjustable.
  • Page 76: Throttle Cable Freeplay

    Throttle Cable Freeplay Throttle cable freeplay is adjusted at the handlebar. 1. Locate the throttle cable adjuster on the handlebar. 2. Squeeze the end of the rubber boot (1) and slide it far enough to expose the end of the inline cable adjuster (2).
  • Page 77 Follow the adjustment procedures exactly, or see your Polaris dealer for service. The handlebars can be adjusted for rider preference.
  • Page 78 Carburetor IMPORTANT: 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.
  • Page 79: Wheel Removal

    MAINTENANCE Wheels WARNING 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. Maintain proper tire pressure as described on the decal on your ATV and in your owner’s manual.
  • Page 80: Wheel Installation

    Always ensure that all nuts are torqued to specification. Do not service axle nuts that have a cotter pin installed. See your Polaris dealer. 2. Place the wheel on the wheel hub with the valve stem toward the outside and rotation arrows on the tire pointing toward forward rotation.
  • Page 81: Front Wheel Hub Tightening

    Front Wheel Hub Tightening Front wheel bearing tightness and spindle nut retention are critical component operations. All service must be performed by your authorized Polaris dealer. Tire Tread Depth Always replace tires when tread depth is worn to 1/8″ (.3 cm) or less.
  • Page 82: Drive Chain

    Maintain the stone guard to rear sprocket clearance at 1/8″ (.3 cm). Regularly lubricate the drive chain with Polaris Chain Lube, an SAE 80-90 lube or an approved o-ring chain spray lube. See page 107 for the part numbers of Polaris products.
  • Page 83: Rear Drive Chain Slack

    MAINTENANCE Drive Chain Rear Drive Chain Slack CAUTION 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. 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.
  • Page 84 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 (1). 7. Tighten the eccentric locking bolts to 30 ft. lbs. (41 Nm) for machines without the hitch and 45 ft.
  • Page 85: Headlight Lamp Replacement

    MAINTENANCE Lights 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. WARNING Poor lighting while driving can result in severe injury or death. Headlight and taillight lenses become dirty during normal operation.
  • Page 86: Indicator Lamp Replacement

    Lights Taillight/Brakelight Lamp Replacement If the taillight/brakelight does not work the lamp may need to be replaced. 1. Remove the taillight lens cover mounting screws. Remove the lens cover and gasket and set aside for reassembly. 2. Remove the lamp (1). 3.
  • Page 87: Air Filter

    MAINTENANCE Air Filter 1. Remove the seat, release the clips, and remove the air box cover. 2. Loosen the clamp and remove the filter. 3. If equipped, remove the fabric type pre-filter (1) from the main filter (2). Wash the pre-filter in soapy water, then rinse and let dry.
  • Page 88: Spark Plugs

    Spark Plug Recommendations CAUTION Using non-recommended spark plugs can result in serious engine damage. Always use Polaris-recommended spark plugs. Refer to the specifications section beginning on page 104 Refer to the specifications section beginning on page 104 for the recommended spark plug type and gap for your vehicle. Torque spark plugs to specification.
  • Page 89: Recoil Housing

    MAINTENANCE Spark Plugs Spark Plug Inspection Normal 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 indicates the proper type and heat range for the engine and the service. NOTE: The tip should not be white.
  • Page 90: Vehicle Immersion

    Vehicle Immersion CAUTION 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.
  • Page 91: Pvt System

    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.
  • Page 92: Pvt Drying

    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.
  • Page 93: Spark Arrestor

    MAINTENANCE Spark Arrestor WARNING Failure to heed the following warnings while servicing the spark arrestor could result in serious injury or death. Do not perform service on the spark arrestor while the system is hot. Exhaust system temperatures can reach 1000° F. Allow components to cool sufficiently before proceeding.
  • Page 94: Conventional Battery

    Battery Your ATV may have either a sealed battery, which requires little maintenance, 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.
  • Page 95: Battery Removal

    MAINTENANCE Battery WARNING 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 Removal 1.
  • Page 96: Battery Installation

    Battery Battery Installation Using a new battery that has not been fully charged can damage the battery and result in a shorter life. It can also hinder vehicle performance. Follow the battery charging instructions on pages 95-97 before installing the battery. 1.
  • Page 97: Battery Storage

    Power plug leads may need to be bent down so that the battery cover can be installed. NOTE: Battery charge can be maintained by using a Polaris Battery Tender charger or by charging about once a month to make up for normal self-discharge. Battery Tender can be left...
  • Page 98 Battery 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 (1). Add only distilled water. Tap water contains minerals that are harmful to a battery.
  • Page 99 MAINTENANCE Battery Battery Charging (Sealed Battery) The following battery charging instructions apply only to the installation 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.
  • Page 100 Battery Battery Charging (Sealed Battery) NOTE: Always verify battery condition before and 1-2 hours after the end of charging. State of Voltage Charge 100% 12.8-13.0 volts 75%-100% 12.5-12.8 volts 50%-75% 12.0-12.5 volts 25%-50% 11.5-12.0 volts 0%-25% 11.5 volts or less MAINTENANCE Action (Using constant current...
  • Page 101: Cleaning And Storage

    Do not allow these types of products to come into contact with 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.
  • Page 102: Washing The Vehicle

    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 S Avoid the use of automotive products, some of which can scratch the finish of your vehicle.
  • Page 103 MAINTENANCE Cleaning and Storage Chrome Wheel Care (if equipped) Proper maintenance will protect chrome wheels from corrosion, preserve wheel life and ensure a ”like new” appearance for many years. NOTE: Chrome wheels exposed to road salt (or salt in the air in coastal areas) are more susceptible to corrosion if not properly cleaned.
  • Page 104: Storage Tips

    Cleaning and Storage Storage Tips See page 107 for the part numbers of Polaris products. CAUTION 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.
  • Page 105 7. Treat the fuel system with Polaris Carbon Clean. See page 101. 8. If Polaris fuel system additive is not used, the fuel tank, fuel lines, and carburetor should be completely drained of gasoline.
  • Page 106: Transporting The Atv

    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. NOTE: Do not use plastic or coated materials. They do not allow enough ventilation to prevent condensation, and may promote corrosion and oxidation.
  • Page 107: Specifications

    SPECIFICATIONS 2008 Trail Blazer 330 Body Style Dry Weight Maximum Weight Capacity Front Rack Capacity (Accessory) Rear Rack Capacity (Accessory) Hitch Towing Rating (Accessory) Unbraked Trailer Towing Capacity* 1263 lbs. (573 kg) Tongue Weight Fuel Capacity Transmission Oil Capacity Engine Oil Capacity...
  • Page 108 2008 Trail Blazer 330 Drive System Type Shift Type Gear Reduction - Reverse Gear Reduction - Forward Final Drive (ratio) Drive Chain Front Tires / Pressure Rear Tires / Pressure Front Suspension Rear Suspension Shock Adjustment Front/Rear Brakes Auxiliary Foot Brake...
  • Page 109: Jetting Chart

    SPECIFICATIONS 2008 Trail Blazer 330 Jetting Chart Altitude AMBIENT TEMPERATURE Meters 0-1800 (Feet) (0-6000) 1800-3700 (6000-12000) Clutching Chart Altitude Meters 0-1800 (Feet) (0-6000) 1800-3700 (6000-12000) Below 40° F (Below 5° C) 127.5 Shift Drive Clutch Weight Spring 10RH Blue/Green 5630709...
  • Page 110: Polaris Products

    Chain Lube (6.25 oz. aerosol) 2872348 Chain Lube (16 oz. aerosol) Additives / Miscellaneous Carbon Clean Plus (12 oz.) 2871326 2870652 Fuel Stabilizer (16 oz.) 2872189 DOT 4 Brake Fluid 2871956 LOCTITE 565 Thread Sealant 2859044 Polaris Battery Tendert Charger POLARIS PRODUCTS...
  • Page 111: Troubleshooting

    TROUBLESHOOTING Contact your Polaris dealer for service if you’re unable to identify solutions using the following charts. Drive Belt and Cover Problems Possible Cause Driving onto a pickup or tall trailer in high range Starting out going up a steep incline...
  • Page 112 Turn the fuel valve on Replace with new fuel Inspect plug(s), replace if necessary Inspect plug(s), verify stop switch is on Immediately see your Polaris dealer Inspect, clean and/or replace spark plugs Replace the filter Recharge battery to 12.8 VDC...
  • Page 113 Incorrect jetting Solution Inspect, clean and/or replace spark plugs Set gap to specs or replace plugs Replace with new fuel See your Polaris dealer See your Polaris dealer See your Polaris dealer Solution Inspect, clean and/or replace spark plugs See your Polaris dealer...
  • Page 114 Inspect and replace Replace with new fuel Inspect, clean and/or replace spark plugs Inspect, clean and/or replace spark plugs See your Polaris dealer Set gap to specs or replace plugs Check all connections and tighten Recharge battery to 12.8 VDC...
  • Page 115: Warranty

    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.
  • Page 116 HOW TO OBTAIN WARRANTY SERVICE If your ATV requires warranty service, you must take it to a Polaris dealer authorized to re- pair 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).
  • Page 117 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...
  • Page 118 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.
  • Page 119: Maintenance Log

    MAINTENANCE LOG Use the following chart to record periodic maintenance. DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS...
  • Page 120 MAINTENANCE LOG DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS...
  • Page 121: Index

    INDEX Age Restrictions ....Air Filter ..... Auxiliary Brake .
  • Page 122 Parking on an Incline ... Periodic Maintenance Chart Polaris Products ....Pre Ride Inspection ... . .

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2008 trail blazer 330

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