Polaris Trail Blazer 2004 Owner's Manual
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Polaris Trail Blazer 2004 Owner's Manual

Polaris Trail Blazer 2004 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 4 We’ve created a Web site just for you! Technical tips New product introductions Event schedules Parts and Service Manual information Exciting details about The Way Out Check it out... www.polarisindustries.com/owner...
  • Page 5 Copyright 2003 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: Welcome

    S Personal Task Vehiclest (PTVs) S All-Surface Loaders (ASLs) 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 8: Table Of Contents

    ......POLARIS PRODUCTS .....

  • Page 9: Vehicle Identification Numbers

    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. If both keys are lost, the ignition switch must be replaced.

  • Page 10: Safety

    You should review this information on a regular basis. If you purchased a used Polaris ATV from a party other than a Polaris dealer, you can request this free safety training from any authorized Polaris dealer.

  • Page 11: Operator Safety

    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 ATV or in this manual, alerts you to the potential for personal injury.
  • Page 12 S Never operate an ATV without proper instruction. Take a training course. Beginners should receive training from a certified instructor. Contact an authorized Polaris ATV dealer or call Polaris at 1-800-342-3764 to find out about the training courses nearest you.
  • Page 13 SAFETY 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 14: 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 15 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 16 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 17 SAFETY Operator Safety WARNING POTENTIAL HAZARD Operating an ATV on paved surfaces, including sidewalks, paths, parking lots, and driveways. WHAT CAN HAPPEN ATV tires are designed for off-road use. Operating on paved surfaces may seriously affect the handling and control of the ATV and could result in loss of control, accident, and/or injury.
  • 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 this ATV without wearing an approved helmet, eye protection and protective clothing. WHAT CAN HAPPEN Operating an ATV without an approved helmet increases the risk of a severe head injury or death in the event of an accident.
  • Page 20 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 21 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.
  • Page 22 SAFETY Operator Safety WARNING POTENTIAL HAZARD Failure to inspect the ATV before operating. Failure to properly maintain the ATV. WHAT CAN HAPPEN Poor maintenance increases the possibility of an accident or equipment damage. HOW TO AVOID THE HAZARD Always inspect your ATV before each use to make sure it’s in safe operating condition.
  • Page 23 SAFETY Operator Safety WARNING POTENTIAL HAZARD Failure to use extra caution when operating the ATV on unfamiliar terrain. WHAT CAN HAPPEN Unfamiliar terrain may contain hidden rocks, bumps, or holes that could cause loss of control or overturn. HOW TO AVOID THE HAZARD Travel slowly and use extra caution when operating on unfamiliar terrain.
  • Page 24 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 25 SAFETY Operator Safety WARNING POTENTIAL HAZARD Turning improperly. WHAT CAN HAPPEN Improper turns could cause loss of control and lead to a collision or overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for turning as described in the owner’s manual.
  • Page 26 SAFETY Operator Safety WARNING POTENTIAL HAZARD Climbing hills improperly. WHAT CAN HAPPEN Improper hill climbing could cause loss of control or overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for climbing hills as described in the owner’s manual. Always check the terrain carefully before ascending any hill.
  • Page 27 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 28 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 manual.
  • Page 29 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 30 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 31 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 32 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. See...
  • Page 33 SAFETY Operator Safety WARNING POTENTIAL HAZARD Overloading the ATV or carrying/towing cargo improperly. WHAT CAN HAPPEN Overloading and towing can cause changes in vehicle handling, which could lead to loss of control or an accident. HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this ATV.
  • Page 34 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 35: 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. The part number is printed on the decal.
  • Page 36 SAFETY Safety Decals and Locations WARNING Improper ATV use can result in SEVERE INJURY or DEATH ALWAYS USE NEVER USE NEVER CARRY NEVER USE AN APPROVED ON PUBLIC PASSENGERS WITH DRUGS HELMET AND ROADS OR ALCOHOL PROTECTIVE GEAR NEVER operate: ALWAYS:...

  • Page 37: Override Switch

    To 30 Ft. Lbs. (For models without a hitch). To 40 Ft. Lbs. (For models with a hitch). 7078572 MANUFACTURED BY: POLARIS IND. INC. DATE: OVERRIDE SWITCH VIN: Reverse Speed is THIS VEHICLE IS AN ALL TERRAIN VEHICLE AND IS NOT INTENDED FOR USE ON PUBLIC ROADS.

  • Page 38: Safe Riding Gear

    SAFETY 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 39: 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 40: Throttle Lever

    (1) 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 41: Light Switches

    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 42 Always fill the reservoir as needed whenever the cover is loosened or removed to ensure proper diaphragm operation. We recommend the use of Polaris DOT 3 brake fluid. Do not overfill. 3. If the fluid level is low, add DOT 3 brake fluid only. See page 110 for the part numbers of Polaris products.

  • Page 43: 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 44: 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 45: Auxiliary Brake

    FEATURES AND CONTROLS Auxiliary Brake WARNING Aggressively applying the rear brake when backing down a hill may cause rear tipover, which could result in serious injury or death. Use caution when applying the auxiliary brake. Do not aggressively apply the auxiliary brake when going forward. The rear wheels may skid and slide sideways, causing loss of control and serious injury or death.

  • Page 46: Fuel Valve

    FEATURES AND CONTROLS Choke The choke assists in starting a cold engine. Refer to the engine starting procedure on page 51 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 47: Fuel Safety

    FEATURES AND CONTROLS Fuel Safety WARNING Gasoline is highly flammable and explosive under certain conditions. Always exercise extreme caution whenever handling gaso- line. 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 refueling is performed or where gasoline is stored.

  • Page 48: 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 49 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 50: 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 51: 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 52 OPERATION 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 53 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. Use the following checklist to verify that your vehicle is in proper working condition before each use.

  • Page 54: Starting The Engine

    OPERATION 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 55: 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 56: Driving Safely

    OPERATION 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 57: Making Turns

    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 58: Driving On Slippery Surfaces

    OPERATION 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 59: 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 60 OPERATION 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 61: 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 62: Turning Around On A Hill

    OPERATION 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 63: 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 64 OPERATION 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 65: 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 66: Driving In Reverse

    Use with caution. Avoid backing on inclines, and avoid turning at sharp angles. NOTE: Most Polaris ATVs are 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. Open the throttle just enough to maintain a desired speed.

  • Page 67: 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 68 OPERATION 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 69: 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 70: Emission Control Systems

    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 ATV has a spark arrestor that was tested and approved in accordance with the USDA Forestry Service Standard 5100-1C. Exhaust Emission Control System The emissions from the exhaust of this vehicle are controlled by engine design, including factory-set carburetion and ignition.

  • Page 71: Maintenance And Lubrication

    Auxiliary power outlets provide 12V power for operating accessories such as hand held spot lights. Accessory outlets are available for all models. Contact your Polaris dealer for more information. Polaris has a wide range of additional accessories available for your ATV. See your Polaris dealer. Periodic Maintenance Schedule Careful periodic maintenance will help keep your vehicle in the safest, most reliable condition.

  • Page 72: Periodic Maintenance Schedule

    Perform all services at whichever reading is reached first. WARNING Improperly performing the procedures marked with a could result in component failure and lead to serious injury or death. Have an authorized Polaris dealer perform these services. Item Hours/ Frequency Remarks Miles...
  • Page 73 MAINTENANCE AND LUBRICATION Periodic Maintenance Schedule Item Hours/ Frequency Remarks Miles Taillight/brakelight Pre-Ride Pre-Ride Check operation daily; ap- ply Polaris dielectric grease to socket when replaced Air filter, Weekly Weekly Inspect; replace as needed " main element Transmission oil 20 hrs Monthly Inspect monthly;...
  • Page 74 MAINTENANCE AND LUBRICATION Periodic Maintenance Schedule WARNING Improperly performing the procedures marked with a could result in component failure and lead to serious injury or death. Have an authorized Polaris dealer perform these services. Item Hours/ Frequency Remarks Miles Spark plug 100 hrs.
  • Page 75 MAINTENANCE AND LUBRICATION Periodic Maintenance Record Use the following chart to record periodic maintenance. Maintenance Servicing Servicing Remarks Interval Date Dealer Performed or Person 10 hrs. 20 hrs. 50 hrs. 100 hrs.

  • Page 76: 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 When suspension action becomes stiff, or after washing ∆...
  • Page 77 With new generation lubricity technology, Polaris oils excel in meeting the lubrication demands of today’s high performance 2-cycle engines. We recommend the use of these optimum oils for Polaris liquid cooled or air cooled 2-cycle engines. Polaris premium 2-cycle oils will mix with each other, but consistent performance will be enhanced by selecting only one of the premium oils and maintaining regular use of that oil through the life of the unit.

  • Page 78: 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 79: Transmission Oil Check

    We recommend the use of AGL Synthetic Gearcase Lubricant. See page 110 for the part numbers of Polaris products. 1. Position the ATV on a level surface. 2. Remove the transmission oil dipstick and wipe it clean.

  • Page 80: Oil Pump Bleeding

    1. Fill the oil tank with the recommended oil. See page 110 for the part numbers of Polaris products. 2. Loosen the bleeder screw one full turn. Allow oil to flow from the bleed screw for five to ten seconds, then tighten the bleed screw.

  • Page 81: 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 107.
  • Page 82 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 83: Toe Alignment

    (3). Rear measurement should be 1/16″ - 1/8″ (.2 to .3 cm) more than the front measurement. NOTE: If you discover improper alignment, see your Polaris dealer for service.

  • Page 84: Steering Assembly

    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 85: Throttle Cable Freeplay

    Follow the adjustment procedures exactly, or see your Polaris dealer for service. Handlebars The handlebars can be adjusted for rider preference.
  • Page 86 NOTE: Continuous operation of the engine without proper jetting when required can cause poor performance, overheating or engine damage. See your Polaris dealer for more information about jetting the ATV for conditions in your area. If the engine idle speed is not satisfactory, and all other conditions are favorable, the carburetor can be adjusted.

  • Page 87: 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 88: Wheel Installation

    5. Torque the wheel nuts according to the wheel nut torque specifications chart. NOTE: All nuts that have a cotter pin installed must be serviced by an authorized Polaris dealer. Wheel Nut Torque Specifications Check the wheel nut torques occasionally and when they’ve been loosened for maintenance service.

  • Page 89: Front Wheel Hub Tightening

    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 1/8I (.3 cm) Always replace tires when tread depth is worn to 1/8″ (.3 cm) or less.

  • Page 90: Drive Chain

    2. Check for correct slack adjustment. 3. Maintain the stone guard to rear sprocket clearance at 1/8″ (.3 cm). 4. Regularly lubricate the drive chain with Polaris chain lube or SAE 80-90 lube. See page 110 for the part numbers of Polaris products.

  • Page 91: 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 92 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 93: 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 94: 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 95: 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 96: 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) and replace it with a new lamp.

  • Page 97: Spark Plugs

    CAUTION Using non-recommended spark plugs can result in serious engine damage. Always use Polaris-recommended spark plugs. Spark plug condition is indicative of engine operation. The spark plug firing end condition should be read after the engine has been warmed up and the vehicle has been driven at higher speeds.

  • Page 98: 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 99: 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 100: 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 101: 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 102: 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 103: 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 104: Battery Storage

    Check battery voltage each month during storage and recharge as needed to maintain a full charge. NOTE: Battery charge can be maintained by using a Polaris Battery Tendert charger (PN 2871076) or by charging about once a month to make up for normal self-discharge.
  • Page 105 MAINTENANCE AND LUBRICATION Battery Battery Charging NOTE: Always verify battery condition before and 1-2 hours after the end of charging. State of Voltage Action Charge Time* Charge (Using constant current charger @ standard amps specified on top of battery) 100% 12.8-13.0 volts None, check at None required...

  • Page 106: Cleaning And Storage

    Polaris dealer for free replacement. Polaris does not recommend the use of a high pressure type car wash system for washing the ATV. If a high pressure system is used, exercise extreme care to avoid water damage to the wheel bearings, transmission seals, body panels, brakes, warning labels and decals.

  • Page 107: Storage Tips

    It also prevents bacterial growth and promotes better starting after the storage period. 1. Fill the fuel tank with fuel and add Polaris Carbon Clean or Fuel Stabilizer. Follow the instructions on the container for the recommended amounts.

  • Page 108: Fluid Levels

    This will ensure coverage of the piston rings, cylinder walls and crankshaft bearings. 5. Treat the fuel system with Polaris Carbon Clean. 6. If Polaris fuel system additive is not used, fuel tank, fuel lines, and carburetor should be completely drained of gasoline. Lubricate Inspect all cables and lubricate with Polaris Cable Lubricant.

  • Page 109: Transporting An Atv

    Set the tire pressure and safely support the ATV with the tires 1-2” off the ground. Be sure the storage area is well ventilated, and cover the machine with a genuine Polaris ATV 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 110: Specifications

    SPECIFICATIONS 2004 Trail Blazer Capacities Body Style Gen III Gross Vehicle Weight 765 lbs. (347 kg) Fuel Capacity 3.5 U.S. gal. (13.2 l) Engine Oil 2 qts. (1.89 l) Transmission Oil 32 oz. (.95 l) Front Rack (Accessory) 30 lbs. (13.6 kg) (Maximum Capacity) Rear Rack (Accessory) 60 lbs.
  • Page 111 SPECIFICATIONS 2004 Trail Blazer Drive System Drive System Type Shift Type Side Lever (F-N-R) Gear Reduction - Low Not Applicable Gear Reduction - Reverse 3.05/1 Gear Reduction - Forward 2.68/1 Front Drive (ratio) Not Applicable Final Drive (ratio) 11/36 76P Center Drive (ratio) Not Applicable Drive Chain...

  • Page 112: Jetting Chart

    SPECIFICATIONS 2004 Trail Blazer Jetting Chart Altitude Ambient Below 0°F 0° to 40°F +40° to +80°F +80°F & Above Temperature (Below --18°C) (--18°C to (+5°C to (+26°C & Above) +5°C) +26°C) 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.

  • Page 113: Polaris Products

    POLARIS PRODUCTS Part No. Description Engine Lubricant 2870791 Fogging Oil (12 oz. Aerosol) 2871098 Premium 2-Cycle Engine Oil (qt.) 2871097 Premium 2-Cycle Engine 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.)

  • Page 114: Troubleshooting

    PVT system. Clutch malfunction. Contact your Polaris dealer for inspection of clutch com- ponents. Poor engine performance. Check for fouled plugs or foreign material in gas tank, fuel lines, or carburetor. Contact your dealer for service.
  • Page 115 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 Solution Low battery voltage Recharge battery to 12.8 VDC Loose battery connections Check all connections and tighten...
  • Page 116 Incorrect spark plug gap or heat range Set gap to specs or replace plugs Old or non-recommended fuel Replace with new fuel Incorrectly installed spark plug wires See your Polaris dealer Incorrect ignition timing See your Polaris dealer Mechanical failure See your Polaris dealer...
  • Page 117 Inspect, clean and/or replace spark plugs Fouled or defective spark plugs Inspect, clean and/or replace spark plugs Worn or defective spark plug wires See your Polaris dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs Loose ignition connections...

  • Page 118: 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 119: Engine Oil

    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 120 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 121: Index

    INDEX Accessories ....FEATURES ....36-47 Adjustments .
  • Page 122 ... Tire Tread Depth ....POLARIS PRODUCTS ..Toe Alignment .

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