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Polaris 9922462 Owner's Manual For Maintenance And Safety

Polaris industries all-terrain vehicles owner's manual
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Summary of Contents for Polaris 9922462

  • Page 2 FOLLOW ALL INSTRUCTIONS AND WARNINGS. Pantone 425 C NEVER CARRY NEVER USE PASSENGERS WITH DRUGS OR ALCOHOL For your nearest Polaris dealer, visit www.polarisindustries.com Polaris Sales Inc., 2100 Hwy. 55, Medina, MN 55340 U.S.A. Part No. 9922462 Rev 01 Printed in U.S.A.
  • Page 3 The text is printed on 100% recycled with 40% post-consumer waste (PCW).
  • Page 4 WELCOME Thank you for purchasing a Polaris vehicle, and welcome to our world- wide family of Polaris owners. We proudly produce an exciting line of utility and recreational products. • Snowmobiles • All-terrain vehicles (ATVs) • RANGER utility vehicles ®...
  • Page 5 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 6: Table Of Contents

    Maintenance ......49 Polaris Products......97 Troubleshooting .

  • Page 7: 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 8: Safety Training

    Failure to follow the warnings in this manual can result in serious injury or death. This Polaris vehicle is not a toy and can be hazardous to operate. A collision or rollover can occur quickly, even during routine maneuvers, if you fail to take proper precautions.

  • Page 9: 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 10: Safety

    Equipment Modifications We strongly recommend that consumers do not install on a Polaris vehi- cle any equipment that may increase the speed or power of the vehicle, or make any other modifications to the vehicle for these purposes.

  • Page 11: 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 12: 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 13: Operator Safety

    Take a training course. Beginners should receive training from a certified instructor. Contact an authorized Polaris dealer or visit the Polaris web site at www.polarisindustries.com. Never permit others to operate the vehicle unless they have read and under- stand this manual and all product labels, and have completed a certified safety training course.
  • Page 14 SAFETY Operator Safety Always wear an approved helmet that fits properly. Wear eye protection (goggles or face shield), gloves, boots, long sleeves and long pants. Never consume alcohol or drugs before or while operating this vehicle. Never operate at excessive speeds. Travel and turn at speeds appropriate for the terrain, visibility, operating conditions and your experience.
  • Page 15 SAFETY Operator Safety Always inspect your Polaris vehicle before each use to verify that it's in safe operating condition. Follow the inspection and maintenance procedures outlined in this manual. See page 31. Keep both hands on the handlebars. Keep your feet on the footrests.
  • Page 16 Operator Safety If the vehicle has been involved in an accident, always have an authorized Polaris dealer inspect the entire vehicle for possible damage, including (but not limited to) brake, throttle and steering systems. Never operate on hills too steep for the vehicle or for your abilities.
  • Page 17 43. Always use the size and type of tires specified for your vehicle. Maintain the proper tire pressure. Never modify this Polaris vehicle through improper installation or use of accessories. Operating on paved surfaces may affect the handling and control of the vehicle and could result in loss of control.
  • Page 18 Hot components can cause serious burns and fire. Do not touch hot exhaust system components. Always keep combustible materials away from the exhaust system. For more information about safety, contact an authorized Polaris dealer or visit the Polaris web site at www.polarisindustries.com. SAFETY...

  • Page 19: 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 20 Safety Labels and Locations Discretionary Warning WARNING • Never operate this ATV on HILLS steeper than 25 degrees 25°. To prevent 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 21: No Passenger" Warning

    SAFETY 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 22: 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 23: Features And Controls

    Switches Engine Stop Switch The engine will not start or run when the switch is in the OFF position. Push the stop switch down to stop the engine quickly. Pull the stop switch up to the RUN position before attempt- ing to start the engine.

  • Page 24: Headlight Switch

    Switches Headlight Switch The lights do not operate unless the main key switch is on and the engine stop switch is in the RUN position. High Beam Low Beam Turn Signal Switch Push the toggle switch either left or right to activate the corre- sponding turn signal light.

  • Page 25: Indicator Lights

    FEATURES AND CONTROLS Mirrors Use the mirrors to assist in traffic maneuvers. Always check and adjust the mirrors before driving the vehicle. Indicator Lights With the engine running, verify the function of all indicator lights before each use of the vehicle. Tip: The taillight is on whenever the main switch (key) is on.

  • Page 26: Throttle Lever

    FEATURES AND CONTROLS Throttle Lever Press the throttle lever to increase engine speed and vehicle movement. Release the lever to reduce engine speed and vehicle movement. Failure to check or maintain proper operation of the throttle system can result in an accident if the throttle lever sticks during operation.

  • Page 27: Foot Brake

    FEATURES AND CONTROLS Brakes Aggressively applying the brakes when backing down a hill may cause rear tipover. Aggressively applying the brakes while moving forward may cause the rear wheels to skid and result in loss of control. Read this owner's manual and understand the operation of all brake systems on this vehicle.

  • Page 28: Parking Brake

    Brakes Parking Brake Locking the Parking Brake 1. Place the transmission in gear. 2. Squeeze and release the brake lever two or three times, then squeeze and hold. 3. Push the parking brake lock forward to engage the lock. 4. Release the brake lever. 5.
  • Page 29 FEATURES AND CONTROLS Steering Lock Lock the steering to prevent unauthorized use or theft of the vehicle. Tip: Place the steering lock keys in a safe place. The lock must be replaced if the keys are lost. 1. Turn the handlebars to the full left position.

  • Page 30: Fuel Valve

    FEATURES AND CONTROLS Choke The choke assists in starting a cold engine. Refer to the engine start- ing procedure on page 32 for cor- rect choke and throttle settings during starting. Fuel Fuel Tank Cap Gauge Choke Always refuel with the engine stopped, and outdoors or in a well ventilated area.

  • Page 31: Transmission Gear Selector

    FEATURES AND CONTROLS 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 32: Recoil Starter

    Recoil Starter If the battery is too weak to start the engine, use the recoil starter. Follow the starting procedures on page 32, cranking the engine with the recoil starter instead of the main key switch. 1. Grasp the recoil starter rope handle tightly.

  • Page 33: Operation

    OPERATION Break-In Period The break-in period for your new Polaris vehicle 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 will increase the life and performance of your vehicle more than following the procedures for a proper break-in.

  • Page 34: Pre-Ride Checklist

    Adjust for best side/rear vision 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 35: Starting The Engine

    OPERATION Starting the Engine Engine exhaust contains poisonous carbon monoxide and can cause loss of consciousness resulting in severe injury or death. Never run an engine in an enclosed area. 1. Position the vehicle on a level surface. 2. Place the transmission in neutral. 3.
  • Page 36 Starting the Engine 8. Do not press the throttle while starting the engine. Turn the ignition key past the ON position to engage the starter. Activate the starter for a maximum of five seconds, releasing the key when the engine starts.
  • Page 37 OPERATION Driving Procedures 1. Wear a helmet and eye protection. See page 8. 2. Sit upright. Keep your feet on the footrests. Keep both hands on the handlebars. 3. Start the engine and allow it to warm up. 4. Shift the transmission into gear. 5.

  • Page 38: Turning The Vehicle

    Turning the Vehicle 1. Before turning, activate a turn signal to alert oth- ers of your intentions. Activate the left signal before a left turn. Acti- vate the right signal before a right turn. 2. Steer in the direction of the turn, leaning your upper body to the inside of the turn while sup-...

  • Page 39: Driving On Slippery Surfaces

    OPERATION Driving on Slippery Surfaces Turn in Sideways direction of skid skid 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.

  • Page 40: Driving Uphill

    Driving Uphill Whenever traveling uphill, follow these pre- cautions: 1. Avoid steep hills (25° maximum). 2. Check the terrain carefully. 3. Avoid hills with excessively slippery or loose surfaces. 4. Shift your weight uphill. 5. Drive straight uphill. 6. Keep your feet on the footrests.
  • Page 41 OPERATION Driving on a Sidehill (Sidehilling) Avoid crossing the side of a hill (sidehilling) if possible. If sidehilling is necessary, follow these precautions: 1. Slow down. 2. Avoid hills with excessively slippery or loose surfaces. 3. Avoid crossing the sides of steep hills. 4.

  • Page 42: Driving Downhill

    OPERATION Driving Downhill 25° Maximum When driving downhill, follow these precautions: 1. Check the terrain carefully. 2. Avoid hills with excessively slippery or loose surfaces. 3. Never drive downhill at high speed. 4. Slow down. 5. Avoid driving downhill at an angle, which can cause the vehicle to pitch sharply to one side.
  • Page 43 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 the vehicle. Keep your weight uphill. 2. Lock the parking brake. Leave the transmission in forward gear. Turn the engine off.

  • Page 44: Driving Through Water

    Driving Through Water Your Polaris vehicle can operate through water with a maximum recommended depth equal to the bottom of the footrests. Follow these procedures when operating through water: 1. Determine water depths and current before entering water. 2. Choose a crossing where both banks have gradual inclines.

  • Page 45: 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 46: Driving In Reverse

    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 47: 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 48: Hauling Cargo

    OPERATION Hauling Cargo Overloading the vehicle or carrying or towing cargo improperly can alter vehicle handling and may cause loss of control or brake instability, which can result in serious injury or death. Always follow these precautions when hauling cargo: REDUCE SPEED AND ALLOW GREATER DISTANCES FOR BRAKING WHEN HAULING CARGO.

  • Page 49: Load Distribution

    OPERATION Hauling Cargo Load Distribution Read and understand the load distribution warnings listed on warning labels. Never exceed the specified weights. Never carry cargo on the front of the Trail Blazer model. Cargo should be evenly distributed and mounted as low as possible on the rear rack. On the Trail Boss model, cargo weight should be evenly distributed (1/3 on the front rack and 2/3 on the rear rack) and mounted as low as possi- ble.

  • Page 50: Towing Loads

    Hauling Cargo Towing Loads Some models are equipped with a hitch. Accessory hitch kits are avail- able for other models. Towing is approved OFF-ROAD ONLY. Do not exceed the maximum capacities when towing. Do not tow any trailer on a grade steeper than 15°.

  • Page 51: Emission Control Systems

    Spark Arrestor Your Polaris vehicle has a spark arrestor that was designed for on-road and off-road operation. It is required that this spark arrestor remain installed and functional when the vehicle is operated.

  • Page 52: 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 111.

  • Page 53: 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 54 Engine oil change Oil filter change Valve clearance Fuel system/filter Perform these procedures more often for vehicles subjected to severe use. E Emission-Related Service Have an authorized Polaris dealer perform these services. Maintenance Interval (whichever comes first) Miles (Km) 20 H...
  • Page 55 MAINTENANCE Periodic Maintenance Chart Item Hours Calendar Engine mounts Exhaust muffler/ pipe Spark plug Ignition Timing Wiring Clutches (drive and driven) Front wheel bearings Brake fluid Spark arrestor Idle speed Toe adjustment Headlight aim Maintenance Interval (whichever comes first) Miles (Km) 100 H 12 M...

  • Page 56: Lubrication Guide

    Lubrication Guide Check and lubricate all components at the intervals outlined in the Peri- odic Maintenance Chart beginning on page 49. Items not listed in the chart should be lubricated at the General Lubrication interval. The a-arms and lower control arms are lubricated at the factory, and no additional lubrication will be needed.

  • Page 57: 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 58: Oil And Filter Change

    Engine Oil Oil and Filter Change Always change the oil and filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 49. Always change the oil filter whenever changing oil. 1. Position the vehicle on a level surface. Place the transmission in neutral.

  • Page 59: Transmission Oil

    Transmission Oil Always check and change the transmission oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 49. Polaris recommends the use of Polaris Premium AGL Synthetic Gearcase Lube. See page 97 for the part numbers of Polaris products.

  • Page 60: 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 61: Brake Fluid

    Never operate the vehicle with spongy-feeling brakes. If the fluid level is low add DOT 4 brake fluid only. See page 97 for the part numbers of Polaris products. An over-full master cylinder may cause brake drag or brake lock-up, which could result in serious injury or death.

  • Page 62: Hand Brake

    Brake Fluid Hand Brake The master cylinder is located on the left handle- bar. Maintain the fluid level 6 mm below the top edge of the master cylin- der. Do not overfill. 1. Position the vehicle on a level surface. Make sure the handlebars are straight.

  • Page 63: Brake Inspections

    Brakes The front and rear brakes are hydraulic disc brakes. Both brake systems are self-adjusting. Brake Inspections Perform the following checks to keep the brake systems in good operat- ing condition. Check more often if brakes are used heavily under normal operation.

  • Page 64: 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 65 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. Follow the adjustment procedures exactly, or see your Polaris dealer for service. 1. Remove the handlebar cover to access the handlebar bolts.

  • Page 66: 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. MAINTENANCE...

  • Page 67: Throttle Cable Freeplay

    Throttle Cable Freeplay Adjust throttle cable freeplay at the handlebar. 1. Locate the throttle cable adjuster at the handlebar. 2. Squeeze the end of the rub- ber boot and slide it far enough to expose the end of the inline cable adjuster. 3.

  • Page 68: Steering Assembly

    MAINTENANCE 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 69: Front Wheel Hub Tightening

    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. Tire Tread Depth Always replace tires 3 mm when tread depth is worn to 3 mm or less.

  • Page 70: Wheel Removal

    1. Position the vehicle on a level surface. Place the transmission in gear. Lock the parking brake. 2. Loosen the wheel nuts slightly. 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 71: Wheel Nut Torque Specifications

    MAINTENANCE 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 Rear 50 ft. lbs. (68 Nm) Torque Specification 27 ft.

  • Page 72: Air Filter

    Air Filter 1. Remove the seat. 2. Release the air box cover clips, and remove the air box cover. 3. Loosen the clamp and remove the filter. 4. Remove the fabric type pre-fil- ter from the main filter. Wash the pre-filter in soapy water, then rinse and let dry.

  • Page 73: 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 74 Tip: Continuous operation of the engine without proper jetting when required can cause poor performance, overheating or PVT or engine damage. See your Polaris dealer for more information about jetting the vehicle for condi- tions in your area. Carburetor/Engine Idle RPM Adjustment...

  • Page 75: 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 97 for the part numbers of Polaris products.

  • Page 76: Rear Drive Chain Slack

    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 77 Drive Chain Rear Drive Chain Slack 6. Roll the vehicle forward or back- ward 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 78: 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 79: Headlamp Replacement

    MAINTENANCE Lights Poor lighting can result in loss of control or an accident. Lights become dirty during normal operation. Wash the headlights and taillights frequently. Hot components can cause burns to skin. Allow lamps to cool before servicing. Headlamp Replacement When servicing a halogen lamp, do not touch the lamp with bare fingers.

  • Page 80: Indicator Lamp Replacement

    Lights Indicator Lamp Replacement 1. Remove the instrument panel, 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 81: Spark Plugs

    Refer to the specifications section beginning on page 102 for the recom- mended spark plug type and gap for your vehicle. NOTICE: Using non-recommended spark plugs can result in serious engine damage. Always use Polaris-recommended spark plugs. Plug Condition New Spark Plug...

  • Page 82: 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 83: 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 vehicle to a dealer before starting it, fol- low the steps outlined below.

  • Page 84: Spark Arrestor

    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 85: 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 86 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 87: 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 88 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 89: Battery Removal

    MAINTENANCE 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. Remove the battery cover (if equipped). 6. On conventional batteries, remove the battery vent tube. 7.

  • Page 90: Battery Installation

    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 89 before installing the battery.

  • Page 91: 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 92 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 86. 2. Charge the battery with a charging output no larger than 1/10 of the battery’s amp/hr rating.
  • Page 93 MAINTENANCE 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 Action charger @ standard amps specified on top of battery)

  • Page 94: 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 95: 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 96 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 97: Storage Tips

    91. 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 98: Fluid Levels

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

  • Page 99: Transporting The Vehicle

    Set the tire pressure and safely support the vehicle with the tires slightly off the ground. Be sure the storage area is well ventilated. Cover the vehicle with a genuine Polaris cover. Do not use plastic or coated mate- rials. They do not allow enough ventilation to prevent condensation, and may promote corrosion and oxidation.

  • Page 100: Polaris Products

    Chain Lube, Aerosol (6.25 oz./185 ml) 2872348 Chain Lube, Aerosol (16 oz./473 ml) 2871326 Carbon Clean Plus 2870652 Fuel Stabilizer 2872189 DOT 4 Brake Fluid 2871956 Loctite 565 Thread Sealant 2859044 Polaris Battery Tender POLARIS PRODUCTS Engine Lubricant Additives / Miscellaneous Charger...

  • Page 101: Troubleshooting

    Dry out the PVT. See page 84. 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 102: Troubleshooting

    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 103 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 Water present in fuel...
  • Page 104 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 radiator screen and core if equipped Clean engine exterior See your Polaris dealer...

  • Page 105: 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 106 0-1800 10RHF (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 107 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 108: Jetting Chart

    0-1800 10RHF (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" (21 cm) travel Progressive rate with 10.5"...

  • Page 109: 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 110: Warranty

    At the time of sale, the Warranty Registration Form must be completed by your dealer and submitted to Polaris within ten days. Upon receipt of this registration, Polaris will record the registration for warranty. No verification of registration will be sent to the purchaser as the copy of the Warranty Registration Form will be the warranty entitle- ment.
  • Page 111 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 vehicle that...
  • Page 112 This warranty does not cover the use of unauthorized lubricants, chemicals, or fuels that are not compatible with the vehicle. The exclusive remedy for breach of this warranty shall be, at Polaris' exclusive option, repair or replacement of any defective materials, or components or products. THE REMEDIES SET FORTH IN THIS WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY.
  • Page 113 HOW TO OBTAIN WARRANTY SERVICE If your vehicle requires warranty service, you must take it to a Polaris dealer authorized to repair Polaris vehicles. When requesting warranty service you must present your copy of the Warranty Registration form to the dealer.

  • Page 114: 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 115 MAINTENANCE LOG DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS OR HOURS...

  • Page 116: Index

    Age Restrictions ....5 Air Filter ..... . 69 Battery .
  • Page 117 Periodic Maintenance Chart ..49-52 Polaris Product List ....97 Polishing the Vehicle... . . 92 Pre-Ride Checklist.
  • Page 118 Stop Switch ....20 Storage ....91-96 Switches .

This manual is also suitable for:

Trail boss 330 international2010 trail boss 330 international2010 trail blazer 330 international

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