Polaris Trail Blazer Owner's Manual
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Polaris Trail Blazer Owner's Manual

Polaris 2005 atv owner's manual
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  • Page 3 WARNING The engine exhaust from this product contains chemicals known 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 5 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. 2005 Trail Blazer Owner’s Manual P/N 9919472...

  • Page 6: Welcome

    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. Polaris Recreational and Utility Vehicles S Snowmobiles S All-terrain vehicles (ATVs) S Watercraft S Victory motorcycles S RANGER utility vehicles We believe Polaris sets a standard of excellence for all utility and...

  • Page 8: Table Of Contents

    WELCOME ....... . . VEHICLE IDENTIFICATION NUMBERS SAFETY ........FEATURES AND CONTROLS OPERATION .

  • Page 10: Vehicle Identification Numbers

    VEHICLE IDENTIFICATION NUMBERS Record your ATV’s identification numbers and key number in the spaces provided. Remove the spare key and store it in a safe place. Your key can be duplicated only by mating a Polaris key blank with one of your existing keys, so if both keys are lost, the ignition switch must be replaced.

  • Page 11: Safety

    SAFETY Operator Safety WARNING 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.

  • Page 12: 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 13 SAFETY Operator Safety WARNING Serious injury or death can result if you do not follow these instructions and procedures, which are outlined in further detail within your owner’s manual. S Read this manual and all labels carefully, and follow the operating procedures described.
  • Page 14 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. S Always follow proper procedures for climbing hills.

  • Page 15: Equipment Modifications

    SAFETY Operator Safety S Wet brakes may have reduced stopping ability. Test your brakes after leaving water. If necessary, apply them lightly several times to allow friction to dry out the pads. S Always check for obstacles or people behind the ATV before operat- ing in reverse.
  • Page 16 SAFETY Operator Safety WARNING POTENTIAL HAZARD Operating this ATV without proper instruction. WHAT CAN HAPPEN The risk of an accident is greatly increased if the operator does not know how to operate the ATV properly in different situations and on different types of terrain. HOW TO AVOID THE HAZARD Beginning and inexperienced operators should complete the certified training course offered by Polaris.
  • Page 17 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 18 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 19 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 20 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 21 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 22 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 23 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 24 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 25 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 26 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 27 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 28 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 29 SAFETY Operator Safety WARNING POTENTIAL HAZARD Operating the ATV with improper modifications. WHAT CAN HAPPEN Improper installation of accessories or modification of the ATV may cause changes in handling which could lead to an accident. HOW TO AVOID THE HAZARD Never modify the ATV through improper installation or use of accessories.
  • Page 30 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 31: Safety Decals And Locations

    SAFETY Safety Decals and Locations Warning decals have been placed on the ATV for your protection. Read and follow the instructions of the decals and other warnings on the ATV carefully. If any of the decals shown in this manual differ from the decals on your ATV, always read and follow the instructions of the decals on the ATV.
  • Page 32 Safety Decals and Locations Improper ATV use can result in SEVERE INJURY or DEATH ALWAYS USE AN APPROVED HELMET AND PROTECTIVE NEVER operate: ALWAYS: WARNING NEVER USE NEVER CARRY ON PUBLIC PASSENGERS ROADS GEAR SAFETY NEVER USE WITH DRUGS OR ALCOHOL 7172560...

  • Page 33: Override Switch

    SAFETY Safety Decals and Locations Under Seat MANUFACTURED BY: POLARIS IND. INC. DATE: VIN: THIS VEHICLE IS AN ALL TERRAIN VEHICLE AND IS NOT INTENDED FOR USE ON PUBLIC ROADS. CE VÉHICULE EST UN VÉHICULE TOUT TERRAIN QUI NiEST PAS DESTINÉ À ÊTRE UTILISÉ SUR LES CHEMINS PUBLICS. Canadian Certification Decal WARNING Operating this ATV if you are under...

  • Page 34: Safe Riding Gear

    Safe Riding Gear Always wear clothing suited to the type of riding. ATV riding requires special protective clothing for comfort and to reduce the chance of injury. 1. Helmet Your helmet is the most important piece of protective gear for safe riding. A helmet can prevent a severe head injury.

  • Page 35: Features And Controls

    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 36: Throttle Lever

    WARNING Do not start or operate an ATV with sticking or improperly operating throttle controls, which could cause an accident and lead to severe injury or death. Always contact your dealer for service repairs if throttle problems arise. Failure to check or maintain proper operation of the throttle system can result in an accident if the throttle lever sticks during operation.

  • Page 37: Indicator Lights

    FEATURES AND CONTROLS 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 38 Brakes Check the brake fluid level in the master cylinder before each use of the ATV. The master cylinder (1) is located on the left handlebar. 1. Position the ATV on level ground with the handlebars straight. 2. View the fluid level through the indicator window (2) on the top of the master cylinder.

  • Page 39: Brake Lever

    FEATURES AND CONTROLS Brake Lever The front and rear brakes are applied by squeezing the brake lever (1) toward the handlebar. The front and rear 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.

  • Page 40: Parking Brake

    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. Squeeze and release the brake lever (1) two or three times, then squeeze and hold.

  • Page 41: Auxiliary Brake

    FEATURES AND CONTROLS 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 42: Fuel Valve

    Choke The choke assists in starting a cold engine. Refer to the engine starting procedure on page 47 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. It has three positions: OFF: For vehicle storage and when transporting.

  • Page 43: Fuel Safety

    FEATURES AND CONTROLS 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 44: Oil Injection Tank

    Oil Injection Tank CAUTION Mixing brands or using a non-recommended oil may cause serious engine damage. We recommend the use of Polaris Premium Synthetic 2-cycle oil for your 2-cycle Polaris ATV. Never substitute or mix oil brands. To avoid serious engine damage, always top off the oil level when refueling.
  • Page 45 FEATURES AND CONTROLS Automatic Transmission Gear Selector The transmission gear selector (1) is located on the right side of the ATV. 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 46: Recoil Starter

    Recoil Starter If the battery has been drained or damaged and cannot start the engine, use of the recoil starter (1) will allow vehicle operation until repairs can be made. The recoil starter is located on the right side of the machine. 1.

  • Page 47: Operation

    OPERATION Break-In Period The break-in period for your new Polaris ATV is defined as the time it takes to use the first tank of fuel. No single action on your part is as important as following the procedures for a proper break-in. Careful treatment of a new engine will result in more efficient performance and longer life for the engine.
  • Page 48 Break-In Period The first tank of fuel must be pre-mixed according to the following instructions. After the break-in period, the oil injection system will provide the necessary engine lubrication without pre-mixing. 1. Premix the recommended oil with gasoline in a suitable gas container.

  • Page 49: Pre-Ride Inspection

    OPERATION Pre-Ride Inspection WARNING If a proper inspection is not done before each use, severe injury or death could result. Always inspect the vehicle before each use to ensure it’s in proper operating condition. Item Brake system / lever travel Brake fluid Auxiliary brake Front suspension...

  • Page 50: Starting The Engine

    Starting the Engine Starting a Cold 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. CAUTION Operating the vehicle immediately after starting could cause engine damage.

  • Page 51: Starting A Warm Engine

    OPERATION Starting the Engine Starting a Warm Engine Warm engines do not normally require the use of the choke. Excessive use of the choke can cause the spark plug to become wet fouled. 1. Position the vehicle on a level surface and place the transmission in neutral.

  • Page 52: 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 53: Making Turns

    OPERATION Driving Safely Making Turns Your Polaris ATV is equipped with a solid rear axle that 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 54: 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 55: Driving Uphill

    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.
  • 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: 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 58: Turning Around On A Hill

    Driving Safely Turning Around on a Hill WARNING Improper hill climbing procedures 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 59: Driving Through Water

    OPERATION 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.
  • Page 60 Driving Safely Driving Through Water CAUTION Major engine damage can result if the vehicle is not thoroughly inspected after operation in water. Perform the services outlined in the maintenance chart. If your vehicle becomes immersed or is operated in water that exceeds the footrest level, take it to your dealer for service before starting the engine.

  • Page 61: 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 62: Driving In Reverse

    Driving Safely Driving in Reverse Follow these precautions when operating in reverse: 1. Always avoid backing downhill. 2. Back slowly. 3. When in reverse, apply the brakes lightly for stopping. 4. Avoid turning at sharp angles in reverse. 5. Never open the throttle suddenly while backing.

  • Page 63: Hauling Cargo

    OPERATION Hauling Cargo Your ATV has been designed to carry or tow a certain amount of load (if equipped with racks). Always read and understand the load distribution warning labels on the vehicle, and never exceed the weight capacities outlined in the specifications section of the owner’s manual and on the safety decals.
  • Page 64 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 65: Parking On An Incline

    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. 2. Place the transmission in gear. 3. Set the parking brake. 4. Always block the rear wheels on the downhill side. See illustration.

  • Page 66: Emission Control Systems

    EMISSION CONTROL SYSTEMS Noise Emission Control System Do not modify the engine, intake or exhaust components, as doing so may affect compliance with state and local noise level requirements. Spark Arrestor Your Polaris vehicle has a spark arrestor that was tested and approved in accordance with the USDA Forest Service Standard 5100-1C.

  • Page 67: Maintenance And Lubrication

    MAINTENANCE AND LUBRICATION Accessories Auxiliary power outlets provide 12V power for operating accessories such as hand held spot lights. See your Polaris dealer. 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.

  • Page 68: Periodic Maintenance Chart

    MAINTENANCE AND LUBRICATION 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 "...
  • Page 69 MAINTENANCE AND LUBRICATION Periodic Maintenance Chart Item Hours Calendar Carburetor float bowl Throttle Cable/ ETC Switch Choke cable Carburetor air intake ducts/ flange Drive belt Engine oil change 100 H " Oil filter change 100 H " Valve clearance 100 H Fuel system 100 H Fuel filter...
  • Page 70 MAINTENANCE AND LUBRICATION Periodic Maintenance Chart Item Hours Calendar Brake fluid 200 H Spark arrestor 300 H Idle speed Toe adjustment Headlight aim Perform these procedures more often for vehicles subjected to severe use. " E Emission Control System Service (California) Have an authorized Polaris dealer perform these services.
  • Page 71 MAINTENANCE AND LUBRICATION Periodic Maintenance Record Use the following chart to record periodic maintenance. Maintenance Servicing Interval Performed 10 hrs. 20 hrs. 50 hrs. 100 hrs. Servicing Date Dealer or Person Remarks...

  • Page 72: Lubrication Recommendations

    MAINTENANCE AND LUBRICATION Lubrication Recommendations Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart beginning on page 65. Lubrication Chart Key More often under severe use, such as wet or dusty conditions " Polaris Premium All Season Grease or grease conforming to NLG No.
  • Page 73 MAINTENANCE AND LUBRICATION Lubrication Recommendations Polaris 2-Cycle Lubricants Polaris Premium 2-cycle lubricants are the most advanced formulation of oils, specifically designed for today’s 2-cycle engines. These lubricants provide additives for 2-cycle engines that are lacking in today’s fuel. These necessary additives keep ring grooves cleaner for less ring sticking and improved overall engine cleanliness.

  • Page 74: Engine Oil Check

    MAINTENANCE AND LUBRICATION Lubrication Recommendations Engine Oil Check The oil tank cap (1) is located forward of the headlight. Check the oil before each use of the vehicle. Refill the oil when refueling. 1. Position the ATV on a level surface.

  • Page 75: Transmission Oil Change

    MAINTENANCE AND LUBRICATION Lubrication Recommendations Transmission Oil Check The transmission oil dipstick (1) is located on the right side of the vehicle. Check and change the transmission oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 65. Maintain the transmission oil level in the SAFE operating range (2).

  • Page 76: Oil Pump Bleeding

    MAINTENANCE AND LUBRICATION Adjustments Oil Pump Bleeding CAUTION If the oil supply line has been disconnected from the pump, or if the oil reservoir and supply line have been completely run out of oil, the oil pump must be bled. If the pump is not bled, air in the lines may prevent oil delivery to the engine, resulting in severe engine damage.

  • Page 77: Oil Pump

    MAINTENANCE AND LUBRICATION Adjustments Oil Pump If it becomes necessary to increase oil flow into the fuel system, the oil pump can be adjusted. 1. Before adjusting the oil pump, check the engine idle RPM and carburetor settings in the specifications section beginning on page 103.
  • Page 78 MAINTENANCE AND LUBRICATION Adjustments Brakes The front and rear brakes are hydraulic disc brakes, activated by moving the single brake lever toward the handlebar. These brakes are self-adjusting. 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, such as operation in hilly country or in muddy terrain.

  • Page 79: Toe Alignment

    MAINTENANCE AND LUBRICATION Adjustments 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. Toe Alignment Use the following procedure to check the toe alignment of the vehicle. The recommended toe alignment is 1/8″...

  • Page 80: Steering Assembly

    MAINTENANCE AND LUBRICATION Adjustments 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 81: Throttle Cable Freeplay

    MAINTENANCE AND LUBRICATION Adjustments 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 possible serious personal injury or death. Follow the adjustment procedures exactly, or see your Polaris dealer for service.
  • Page 82 MAINTENANCE AND LUBRICATION Adjustments 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 83: Wheel Removal

    MAINTENANCE AND LUBRICATION Adjustments 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 84: Wheel Installation

    MAINTENANCE AND LUBRICATION Adjustments Wheel Installation 1. Place the transmission in gear and lock the parking brake. WARNING Improperly installed wheels can adversely affect tire wear and vehicle handling, which can result in serious injury or death. Always ensure that all nuts are torqued to specification. Do not service axle nuts that have a cotter pin installed.

  • Page 85: Front Wheel Hub Tightening

    MAINTENANCE AND LUBRICATION Adjustments 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. See illustration.

  • Page 86: Drive Chain

    MAINTENANCE AND LUBRICATION Adjustments Drive Chain 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. 1. Always inspect the drive chain prior to operating the vehicle. Check for damaged or missing o-rings or damaged rollers.

  • Page 87: Rear Drive Chain Slack

    MAINTENANCE AND LUBRICATION Adjustments 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.
  • Page 88 MAINTENANCE AND LUBRICATION Adjustments Rear Drive Chain Slack 1. 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). 2. Tighten the eccentric locking bolts to 30 ft.

  • Page 89: Filter Systems

    MAINTENANCE AND LUBRICATION Filter Systems Air Filter Removal and Service 1. Remove the ATV seat. 2. Release the clips securing the cover assembly to the air box. 3. Loosen the clamp securing the filter, and remove the filter. 4. Remove the foam pre-filter from the main filter. 5.

  • Page 90: Headlight Lamp Replacement

    MAINTENANCE AND LUBRICATION 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 91: Headlight Adjustment

    MAINTENANCE AND LUBRICATION Lights Headlight Adjustment 1. Position the vehicle on a level surface with the headlight approximately 25 ft. (7.6 m) from a flat wall. 2. Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height.

  • Page 92: Indicator Lamp Replacement

    MAINTENANCE AND LUBRICATION 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). Apply dielectric grease to the socket and install the new lamp.

  • Page 93: Spark Plugs

    MAINTENANCE AND LUBRICATION Spark Plugs Always use the spark plugs recommended for your ATV. Refer to the specifications section beginning on page 103 for the recommended spark plug type and gap. CAUTION Using non-recommended spark plugs can result in serious engine damage.

  • Page 94: Vehicle Immersion

    MAINTENANCE AND LUBRICATION 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 95: Spark Arrestor

    MAINTENANCE AND LUBRICATION 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 96: Recoil Housing

    MAINTENANCE AND LUBRICATION Recoil Housing To prevent possible engine damage, always drain the recoil housing (1) after operating the ATV in very wet conditions. This should also be done before storing the ATV. Water will enter the recoil housing if the starter handle is disengaged from the rope guide when under water.

  • Page 97: Pvt System

    MAINTENANCE AND LUBRICATION 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 98: Pvt Drying

    MAINTENANCE AND LUBRICATION PVT System WARNING 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.

  • Page 99: Battery Removal

    MAINTENANCE AND LUBRICATION 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.

  • Page 100: Battery Charging

    MAINTENANCE AND LUBRICATION 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.
  • Page 101 MAINTENANCE AND LUBRICATION Battery Battery Charging 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 Action charger @ standard amps specified on top of battery)

  • Page 102: Cleaning And Storage

    MAINTENANCE AND LUBRICATION Cleaning and Storage See page 106 for the part numbers of Polaris products. Cleaning the ATV Keeping your ATV clean will not only improve its appearance but it can also extend the life of various components. With a few precautions, your ATV can be cleaned much like an automobile.

  • Page 103: Fluid Levels

    MAINTENANCE AND LUBRICATION Cleaning and Storage Storage Tips See page 106 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. Exterior Make necessary repairs and then clean the ATV thoroughly with mild soap and warm water to remove all dirt and grime.

  • Page 104: Storage Tips

    MAINTENANCE AND LUBRICATION Cleaning and Storage Storage Tips See page 106 for the part numbers of Polaris products. Engine Use Polaris Fogging Oil and follow the directions on the can. If you choose not to use Polaris Fogging Oil, perform the following procedure.

  • Page 105: Transporting An Atv

    MAINTENANCE AND LUBRICATION 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. 1. Wash chrome rims frequently. Use a mild detergent to remove any salt, dirt, mud or grime.

  • Page 106: Specifications

    2005 Trail Blazer Body Style Gross Vehicle Weight Fuel Capacity Engine Oil Transmission Oil Front Rack (Accessory) (Maximum Capacity) Rear Rack (Accessory) Tongue Weight Tow Hitch Tow Capacity Turn Radius Ground Clearance Height Length Seat Height Dry Weight Wheel Base...
  • Page 107 SPECIFICATIONS 2005 Trail Blazer Drive System Type Shift Type Gear Reduction - Low Gear Reduction - Reverse Gear Reduction - Forward Front Drive (ratio) Final Drive (ratio) Center Drive (ratio) Drive Chain Front Tire Rear Tire Front Suspension Rear Suspension...

  • Page 108: Jetting Chart

    2005 Trail Blazer Jetting Chart Altitude Ambient Temperature 0-900 Meters (0-3000) (Feet) (Feet) 900-1800 (3000-6000) 1800-2700 (6000-9000) 2700-3700 (9000-12000) Turn air screw out 1/2 turn CCW from seat. Raise needle clip 1 position to lower jet needle. Clutching Chart Altitude...

  • Page 109: Polaris Products

    POLARIS PRODUCTS Part No. Description Engine Lubricant 2870791 Fogging Oil (12 oz. Aerosol) 2871098 Premium Blue 2-Cycle Mineral Oil (qt.) 2871097 Premium Blue 2-Cycle Mineral Oil (gal.) 2871721 Premium Gold Synthetic 2-Cycle Oil (qt.) 2871722 Premium Gold Synthetic 2-Cycle Oil (gal.) 2874438 VES II Synthetic 2-Cycle Oil (qt.) 2874439...

  • Page 110: Troubleshooting

    Drive Belt and Cover Problems Possible Cause Driving the ATV onto a pickup or tall trailer in high range. Starting out going up a steep incline. Driving at low RPM or low ground speed (at approximately 3-7 MPH). Insufficient warm-up of ATVs exposed to low am- bient temperatures.
  • Page 111 TROUBLESHOOTING Contact your Polaris dealer for service if you’re unable to identify solutions using the following charts. Engine Doesn’t Turn Over Possible Cause Low battery voltage Loose battery connections Loose solenoid connections Engine Turns Over, Fails to Start Possible Cause Out of fuel Clogged fuel valve or filter Water is present in fuel...
  • Page 112 Engine Backfires Possible Cause Weak spark from spark plugs Incorrect spark plug gap or heat range Old or non-recommended fuel Incorrectly installed spark plug wires Incorrect ignition timing Mechanical failure Engine Runs Irregularly, Stalls or Misfires Possible Weak Spark Cause Fouled or defective spark plugs Worn or defective spark plug wires Incorrect spark plug gap or heat range...
  • Page 113 TROUBLESHOOTING Engine Stops or Loses Power Possible Cause Out of fuel Kinked or plugged fuel vent line Water present in fuel Overuse of choke Fouled or defective spark plugs Worn or defective spark plug wires Incorrect spark plug gap or heat range Loose ignition connections Low battery voltage Incorrect fuel...

  • Page 114: Warranty

    WARRANTY LIMITED WARRANTY Polaris Sales Inc., 2100 Highway 55, Medina, MN 55340, gives a SIX MONTH LIMITED WARRANTY on all components of the Polaris All Terrain Vehicle (ATV) against defects in material or workmanship. Polaris also gives a one year limited warranty on the final drive chain for failure due to defects.

  • Page 115: Engine Oil

    WARRANTY WARRANTY COVERAGE AND EXCLUSIONS: LIMITATIONS OF WARRANTIES AND REMEDIES ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE) ARE LIMITED IN DURATION TO THE ABOVE SIX MONTH WARRAN- TY PERIOD. POLARIS FURTHER DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY.
  • Page 116 WARRANTY Exported Vehicles EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE IS NO WAR- RANTY OR SERVICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD OUTSIDE THE COUNTRY OF THE SELLING DEALER’S AUTHORIZED LOCA- TION. This policy does not apply to vehicles that have received authorization for export from Polaris Industries.

  • Page 117: Index

    INDEX Accessories ....Adjustments ....Age Restrictions .
  • Page 118 ......Oil Injection Tank ....Oil Pump Adjustment .

This manual is also suitable for:

2005 trail blazer

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