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Polaris Trail Blazer 9922460 Owner's Manual

Polaris industries all-terrain vehicles owner's manual
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Pantone 426C
Trail Boss 330
Trail Blazer 330
Owner's Manual
for Maintenance and Safety
Read this manual carefully. It contains important safety information.
This is an adult vehicle only.
Operation is prohibited for those under 16 years of age.

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Summary of Contents for Polaris Trail Blazer 9922460

  • Page 1 Pantone 426C Trail Boss 330 Trail Blazer 330 Owner's Manual for Maintenance and Safety Read this manual carefully. It contains important safety information. This is an adult vehicle only. Operation is prohibited for those under 16 years of age.
  • Page 2 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 3 The text is printed on 100% recycled with 40% post-consumer waste (PCW).
  • Page 4 Pantone 426c NEVER CARRY NEVER USE PASSENGERS WITH DRUGS OR ALCOHOL 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. 9922460 Rev 02 Printed in USA...
  • Page 5 ® • 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.
  • Page 6 POLARIS, THE WAY OUT, TRAIL BOSS and TRAIL BLAZER are registered trade- marks of Polaris Industries Inc. Copyright 2009 Polaris Sales Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant...

  • Page 7: Table Of Contents

    Maintenance ......57 Polaris Products..... . . 103 Troubleshooting .

  • Page 8: 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.
  • Page 9 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.

  • Page 10: 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.

  • Page 11: Safety

    You should review this information on a regular basis. If you purchased a used Polaris ATV in the United States, you can enroll in the ATV RiderCourse for a fee. Call ATV Enrollment Express at (800) 887-2887 or visit www.atvsafety.org.

  • Page 12: Safety

    Boots 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.

  • Page 13: Eye Protection

    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.

  • Page 14: Safety Warnings

    SAFETY Safety Warnings WARNING 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.

  • Page 15: Handling Gasoline

    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.

  • Page 16: Protective Apparel

    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).

  • Page 17: Operating On Pavement

    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.

  • Page 18: Physical Control Of The Atv

    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.

  • Page 19: Descending Hills Improperly

    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.

  • Page 20: Stalling While Climbing A Hill

    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. •...

  • Page 21: Operating On Slippery Terrain

    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.

  • Page 22: Improper Tire Maintenance

    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.

  • Page 23: Skidding Or Sliding

    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.

  • Page 24: Improper Cargo Loading

    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. •...

  • Page 25: Operating A Damaged Atv

    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.

  • Page 26: General Warning

    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...

  • Page 27: Discretionary Warning

    Safety Labels and Locations Rack Warning Discretionary Warning Discretionary Warning WARNING • Never operate this ATV on HILLS steeper than 25 degrees 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.

  • Page 28: No Passenger" Warning

    Safety Labels and Locations Age 16 Warning “No Passenger” Warning WARNING NEVER ride as a passenger. Passengers can cause a loss of control, resulting in SEVERE INJURY or DEATH. Tire Pressure/Load Warning (TRAIL BOSS) WARNING Improper tire pressure or overloading can cause loss of control. Loss of control can result in severe injury or death.

  • Page 29: Age 16 Warning

    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. Clutch Cover Warning WARNING •...

  • Page 30: Features And Controls

    FEATURES AND CONTROLS Switches Headlight Switch Engine Stop Switch Override Main Key Switch Switch 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.

  • Page 31: Override Switch

    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.
  • Page 32 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...

  • Page 33: Brake Lever

    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. Always contact your dealer for service before operating the vehicle. Squeeze the brake lever toward the handlebar to apply the front and rear brakes.
  • Page 34 FEATURES AND CONTROLS Auxiliary Foot Brake WARNING 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.

  • Page 35: Brake Fluid

    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.

  • Page 36: Hand Brake

    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.

  • Page 37: Fuel Valve

    FEATURES AND CONTROLS Choke The choke assists in starting a cold engine. Refer to the engine start- ing procedure on page 41 for cor- rect choke and throttle settings during starting. Fuel Fuel Tank Cap Choke Guage Always refuel with the engine stopped, and outdoors or in a well ventilated area.
  • Page 38 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.

  • Page 39: Recoil Starter

    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.

  • Page 40: 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 proce- dures for a proper break-in.

  • Page 41: 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.

  • Page 42: Safe Operation Practices

    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.

  • Page 43: Trail Etiquette

    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.

  • Page 44: Pre-Ride Checklist

    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 approved helmet, goggles, and...

  • Page 45: Starting The Engine

    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.
  • Page 46 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.

  • Page 47: Driving Procedures

    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.

  • Page 48: Turning The Vehicle

    OPERATION Turning the Vehicle Your ATV is equipped with a solid rear axle, which drives both rear wheels equally at all times. This means that the wheel on the outside of the turn must travel a greater distance than the inside wheel when turn- ing and the inside tire must slip traction slightly.

  • Page 49: Driving On Slippery Surfaces

    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.
  • Page 50 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.
  • Page 51 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.
  • Page 52 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.
  • Page 53 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. 8 ft. (2.4 m) 1. Stop and lock the parking brake while keeping body weight uphill. 2.

  • Page 54: Driving Through Water

    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.

  • Page 55: Driving Over Obstacles

    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.

  • Page 56: Driving In Reverse

    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.

  • Page 57: Parking On An Incline

    OPERATION Parking on an Incline 25° maximum 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.

  • Page 58: Hauling Cargo

    OPERATION Hauling Cargo WARNING 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.

  • Page 59: Towing Loads

    NOTICE: Using an improper hitch or exceeding the maximum hitch weight capacity can result in serious damage to the vehicle and will void your ATV warranty. Always install Polaris-approved (or equivalent) accessories designed for ATV use. Always attach a towed load to the hitch point. If towing a load, reduce rear rack cargo weight by the amount of tongue weight.

  • Page 60: 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 USFS standard 5100-1c. Federal law requires that this spark arrestor be installed and functional when the vehicle is operated on public lands.

  • Page 61: 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 121.

  • Page 62: Maintenance

    Improperly performing the procedures marked with a component failure and cause an accident, which may result in serious injury or death. Always have an authorized Polaris dealer perform these services. Maintenance Chart Key Perform these operations more often for vehicles subjected to severe use.
  • Page 63 Periodic Maintenance Chart Perform all services at whichever maintenance interval is reached first. Item Hours Calendar Steering Front suspension Rear suspension Tires Brake fluid level Brake lever travel Brake system Wheels/fasteners Frame fasteners Engine oil level Air filter, pre-filter Air box sediment tube Headlamp/tail lamp...
  • Page 64 Spark arrestor 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) Hours Calendar Miles (Km) 50 H...

  • Page 65: Lubrication Guide

    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.

  • Page 66: Engine Oil

    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.

  • Page 67: Oil And Filter Change

    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.

  • Page 68: Transmission Oil

    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.

  • Page 69: Oil Change

    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.

  • Page 70: Brake Inspections

    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.

  • Page 71: Side Panel Removal

    Side Panel Removal Tip: Side panel removal may be difficult until the locking tabs and receivers have been snapped and unsnapped a few times. 1. Remove the seat. 2. Remove the push-pins at the front and rear of the side panel. 3.

  • Page 72: Toe Alignment

    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.

  • Page 73: Throttle Cable Freeplay

    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. MAINTENANCE Boot...

  • Page 74: Camber And Caster

    Follow the adjustment procedures exactly, or see your Polaris dealer for service. 1. Remove the handlebar cover to access the handlebar bolts.

  • Page 75: Tire Tread Depth

    1/8" (3 mm) 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.

  • Page 76: Wheel Removal

    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.

  • Page 77: Wheel Nut Torque Specifications

    Tires Wheel Nut Torque Specifications Front 27 ft. lbs. (37 Nm) Check the wheel nut torques occasionally and when they've been loos- ened for service. Item Front Wheel Nuts Rear Wheel Nuts MAINTENANCE Rear 50 ft. lbs. (68 Nm) Torque Specification 27 ft.

  • Page 78: Air Filter

    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.

  • Page 79: Recoil Housing

    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.
  • Page 80 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...

  • Page 81: Drive Chain

    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.

  • Page 82: Rear Drive Chain Slack

    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"...
  • Page 83 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.

  • Page 84: Headlight Beam Adjustment

    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.

  • Page 85: Headlamp Replacement

    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.

  • Page 86: Indicator Lamp Replacement

    Lights Indicator Lamp Replacement 1. Remove the instrument panel or front cover, if necessary, to access the back of the indicator panel. 2. Using a small, straight-blade screwdriver, turn the base of the bulb 1/4 turn counterclockwise. 3. Using a needle-nose pliers or similar tool, pull the lamp out of the indicator panel housing.

  • Page 87: Spark Plugs

    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. Plug Condition New Spark Plug Previously Installed Spark Plug Spark Plug Inspection Spark plug condition is indicative of engine operation.

  • Page 88: Spark Plug Condition

    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.

  • Page 89: Vehicle Immersion

    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.

  • Page 90: Spark Arrestor

    MAINTENANCE Spark Arrestor WARNING 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.

  • Page 91: Pvt System

    • 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 92 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 93: Pvt Drying

    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.
  • Page 94 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. WARNING Battery electrolyte is poisonous.

  • Page 95: Battery Removal

    Battery Battery Removal 1. Place the transmission in gear. 2. Lock the parking brake. 3. Remove the seat. 4. Disconnect the battery hold-down strap. 5. On conventional batteries, remove the battery vent tube. 6. Disconnect the black (negative) battery cable first. 7.

  • Page 96: Battery Installation

    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.

  • Page 97: Battery Storage

    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.
  • Page 98 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.
  • Page 99 Battery Battery Charging (Sealed Battery) 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 charger @ standard amps specified on top of battery)

  • Page 100: Cleaning And Storage

    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.

  • Page 101: Polishing 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 • Avoid the use of automotive products, some of which can scratch the finish of your vehicle.
  • Page 102 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.

  • Page 103: Storage Tips

    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.
  • Page 104 7. If Polaris fuel system additive is not used, the fuel tank, fuel lines, and carburetor should be completely drained of gasoline.
  • Page 105 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...

  • Page 106: Transporting The Vehicle

    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.

  • Page 107: Polaris Products

    2872348 Chain Lube, Aerosol (16 oz.) 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 POLARIS PRODUCTS Engine Lubricant Additives / Miscellaneous Charger...

  • Page 108: Troubleshooting

    Dry out the PVT. See page 89. Inspect clutch seals for damage if repeated leaking occurs. See your Polaris dealer. Check for fouled plugs or foreign material in gas tank, fuel lines or carburetor. See your dealer.
  • Page 109 Inspect plugs and replace if necessary Inspect plugs, verify stop switch is on Inspect, clean and/or replace spark plugs Replace the filter Immediately see your Polaris dealer Recharge the battery to 12.8 VDC See your dealer Solution Inspect, clean and/or replace spark plugs...
  • Page 110 TROUBLESHOOTING Engine Pings or Knocks Possible Cause Poor quality or low octane fuel Incorrect ignition timing Incorrect spark plug gap or heat range Idle set too low Engine Runs Irregularly, Stalls or Misfires Possible Cause Fouled or defective spark plugs Worn or defective spark plug wires Incorrect spark plug gap or heat range Loose ignition connections...
  • Page 111 Set gap to specs or replace plug Check all connections and tighten Recharge the battery to 12.8 VDC Replace with fresh recommended fuel Inspect and clean or replace See your dealer See your dealer See your dealer Clean engine exterior See your Polaris dealer...

  • Page 112: Specifications

    SPECIFICATIONS Maximum Weight Capacity Dry Weight Fuel Capacity Engine Oil Capacity Transmission Oil Front Rack Capacity Rear Rack Capacity Hitch Tongue Weight Capacity Hitch Towing Rating Unbraked Trailer Towing Capacity* Overall Length Overall Width Overall Height Wheelbase Ground Clearance Minimum Turning Radius Engine Model Number/Type Lubrication Engine Cooling...

  • Page 113: Jetting Chart

    Meters (Feet) 0-1800 (0-6000) 5632282 1800-3700 (6000-12000) 5631356 TRAIL BOSS 330 Automatic PVT (Polaris Variable Transmission) Side Lever (F/N/R) 3.05:1 2.68:1 3.64:1 520 O-Ring 23 x 7-10 (4 psi/27.6 kPa) 22 x 11-10 (3 psi/20.7 kPa) MacPherson strut with 8.2" (21 cm) travel Progressive rate with 10.5"...
  • Page 114 Maximum Weight Capacity Dry Weight Fuel Capacity Engine Oil Capacity Transmission Oil Front Rack Capacity (Accessory) Rear Rack Capacity (Accessory) Hitch Tongue Weight Capacity Hitch Towing Rating Unbraked Trailer Towing Capacity* Overall Length Overall Width Overall Height Wheelbase Ground Clearance Minimum Turning Radius Engine Model Number/Type Lubrication...
  • Page 115 Meters (Feet) 0-1800 (0-6000) 5632282 1800 & above (6000 & above) 5631356 TRAIL BLAZER 330 Automatic PVT (Polaris Variable Transmission) Side Lever (F/N/R) 3.05:1 2.68:1 3.64:1 520 O-Ring 23 x 7-10 (4 psi/27.6 kPa) 22 x 11-10 (3 psi/20.7 kPa) MacPherson strut with 8.2"...

  • Page 116: Declaration Of Conformity

    Polaris Industries Inc., 2100 Hwy 55, Medina, MN 55340 U.S.A. Telephone 763-542-0500 We, Polaris Industries Inc., declare that the vehicles listed below conform to the essential health and safety requirements applicable to off-road all-terrain vehicles. APPLICABLE EUROPEAN DIRECTIVES 98/37/EC as amended (Machinery Directive)

  • Page 117: Warranty

    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.
  • Page 118 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...
  • Page 119 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.
  • Page 120 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.
  • Page 121 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.
  • Page 122 How to Get Service If Purchased From A Private Party: If you purchase a Polaris product from a private citizen, to be kept and used outside of the country in which the vehicle was originally purchased, all warranty coverage will be denied.
  • Page 123 This emissions limited warranty is in addition to the Polaris standard limited warranty for your vehicle. Polaris Industries Inc. warrants that at the time it is first purchased, this emissions-certified vehicle is designed, built and equipped so it conforms with applica- ble U.S.
  • Page 124 Polaris dealer to perform any service that may be necessary for your vehicle. Polaris also recommends that you use only Pure Polaris parts. It is a potential violation of the Clean Air Act if a part supplied by an aftermarket parts manufacturer reduces the effectiveness of the vehicle's emission controls.

  • Page 125: Maintenance Log

    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) TECHNICIAN SERVICE PERFORMED / COMMENTS OR HOURS...

  • Page 126: Maintenance Log

    MAINTENANCE LOG DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS OR HOURS...

  • Page 127: Index

    Air Filter ..... . 74 Apparel, Protective ... . . 12 Battery .
  • Page 128 Parking on an Incline ... . 53 Periodic Maintenance Chart ..57-60 Polaris Product List ... . 103 Polishing the Vehicle... . 97 Pre-Ride Checklist .
  • Page 129 Training......7 Transmission Oil... . . 64-65 Transporting the Vehicle .

This manual is also suitable for:

2010 trail blazer 3302010 trail boss 330

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