Polaris Trail Boss 330 Quadricycle Owner's Manual
  1. Manuals
  2. Brands
  3. Polaris Manuals
  4. Offroad Vehicle
  5. Trail Boss 330 Quadricycle
  6. Owner's manual
Polaris Trail Boss 330 Quadricycle Owner's Manual

Polaris Trail Boss 330 Quadricycle Owner's Manual

Polaris 2006 atv owner's manual
Hide thumbs Also See for Trail Boss 330 Quadricycle:
Table of Contents

Advertisement

Quick Links

See also: Owner's Manual for Maintenance and Safety , Owner's Manual

Advertisement

Table of Contents
loading

Related Manuals for Polaris Trail Boss 330 Quadricycle

Summary of Contents for Polaris Trail Boss 330 Quadricycle

  • Page 4 Copyright 2004 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 5: Table Of Contents

    ........EMISSION CONTROL SYSTEMS MAINTENANCE AND LUBRICATION POLARIS PRODUCTS TROUBLESHOOTING SPECIFICATIONS WARRANTY .

  • Page 7: 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, so if both keys are lost, the ignition switch must be replaced.

  • Page 8: Safety

    SAFETY Operator Safety The following signal words and symbols appear throughout this manual and on your vehicle. 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. WARNING The safety alert warning indicates a potential hazard that may result in serious injury or death.

  • Page 9: Safety Training

    You were also provided with printed materials that explain safe operating procedures. Review this information on a regular basis. If you purchased a used Polaris Quadricycle from a party other than a Polaris dealer, please request free safety training from any authorized Polaris dealer.

  • Page 10: Equipment Modifications

    This vehicle is approved for OFF-ROAD TOWING ONLY. Operating a Quadricycle/trailer combination on public roads is prohibited. Equipment Modifications The warranty on your Polaris Quadricycle may be terminated if any equipment has been added, or if any modifications have been made, that increase speed or power.

  • Page 11: Operator Safety

    Beginners should receive training from a certified instructor. Contact an authorized Polaris Quadricycle dealer or call Polaris at 1-800-342-3764. Never permit others to operate the Quadricycle unless they have read and understand this manual and all product labels, and have completed a certified safety training course.
  • Page 12 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 a Quadricycle. Never operate at excessive speeds. Travel and turn at speeds appropriate for the terrain, visibility, operating...
  • Page 13 SAFETY Operator Safety Never attempt wheelies, jumps or other stunts. Always inspect your Quadricycle before each use to verify that it’s in safe operating condition. Follow the inspection and maintenance procedures outlined in this manual. See page 56. Keep both hands on the handlebars.
  • Page 14 If a Quadricycle 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.
  • Page 15 SAFETY Operator Safety Never operate on hills too steep for the Quadricycle or for your abilities. Practice on smaller hills before attempting larger hills. Avoid climbing hills steeper than 25_. Always follow the procedures > 25 outlined in this manual for climbing hills.
  • Page 16 SAFETY Operator Safety Always follow the procedures outlined in this manual for braking if you stall or roll backwards while climbing a hill. Never back down a hill. See page 31. Always follow the procedures outlined in this manual for operating over obstacles.
  • Page 17 SAFETY Operator Safety Always follow the procedures outlined in this manual for driving through water. Never drive through deep or fast-flowing water. See page 34. Always follow the procedures outlined in this manual for driving in reverse. See page 36. Always use the size and type of tires specified for your Quadricycle.
  • Page 18 SAFETY Operator Safety Never modify a Quadricycle through improper installation or use of accessories. Never exceed the stated load capacity for your Quadricycle. Cargo must be properly distributed and securely attached. Reduce speed and follow the instructions in this manual for carrying cargo or towing.
  • Page 19 Always keep combustible materials away from the exhaust system. Exposure of combustibles to hot components could result in a fire. FOR MORE INFORMATION ABOUT QUADRICYCLE SAFETY, call Polaris at 1-800-342-3764.

  • Page 20: Safety Decals And Locations

    Warning decals have been placed on the vehicle for your protection. Read and follow the instructions on each decal carefully. If a decal becomes illegible or comes off, contact your Polaris dealer to purchase a replacement. Replacement safety decals are provided by Polaris at no charge.
  • Page 21 SAFETY Safety Decals and Locations NO STEP...
  • Page 22 SAFETY Safety Decals and Locations Decal Text NEVER ride as a passenger. Passengers can cause a loss of control, resulting in SEVERE INJURY or DEATH. MAXIMUM WEIGHT CAPACITY (Gross Vehicle Weight) INCLUDING MACHINE, DRIVER AND CARGO IS 845 LBS. (383 kg) MAXIMUM CARGO CAPACITY 200 LBS.

  • Page 23: Override Switch

    Safety Decals and Locations S Operation of this vehicle without the air filter element will severely damage the engine. S Clean pre-filter element often, more frequent cleaning required in dusty conditions. Do not operate vehicle without pre-filter. Decal Text (H) S Operation of this vehicle without the air filter element will severely damage the engine.
  • Page 24 SAFETY Safety Decals and Locations Hitch Decal TRAILER MAX WEIGHT: 850 LBS. (386 KG) ON LEVEL GROUND HITCH MAX. VERTICAL WEIGHT: 85 LBS. (39 KG) Recoil Decal Recoil handle must be firmly seated to prevent water entry. Drain starter motor if water enters.

  • Page 25: Safe Riding Gear

    Safe Riding Gear Always wear protective clothing to reduce the chance of injury. 1. Helmet Always wear a helmet that meets or exceeds established safety standards. A helmet can prevent a severe head injury. 2. Eye Protection Wear shatterproof goggles or a shatterproof helmet face shield.

  • Page 26: Driving Safely

    SAFETY Driving Safely Driving Procedures 1. Sit upright. Keep your feet on the footrests. Keep 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 27: Making Turns

    Driving Safely Making Turns 1. To make a turn, steer in the direction of the turn, leaning your upper body to the inside of the turn while supporting your weight on the outer footrest. Use the same leaning technique for turning in reverse. 2.

  • Page 28: Driving On Slippery Surfaces

    SAFETY Driving Safely Driving on Slippery Surfaces Whenever driving on slippery or loose surfaces such as wet trails, gravel, snow or ice, follow these precautions: 1. Slow down before driving onto slippery surfaces. 2. Use extra caution. 3. Be alert. Watch the trail. Avoid quick, sharp turns. NOTE: To correct a rear wheel skid, turn the handlebars in the same direction as the skid and shift body weight forward.

  • Page 29: Driving Over Obstacles

    Driving Safely Driving Over Obstacles 1. Always check for obstacles before operating in a new area. Serious injury or death can result if your vehicle comes in contact with a hidden obstacle. 2. Be alert. Watch the terrain. Use extra caution. 3.

  • Page 30: Driving Downhill

    SAFETY Driving Safely Driving Downhill Whenever descending a hill, follow these precautions: 1. Check the terrain carefully. 2. Avoid hills with excessively slippery or loose surfaces. 3. Never go down a hill at high speed. 4. Slow down. 5. Avoid going down a hill at an angle, which can cause the vehicle to pitch sharply to one side.
  • Page 31 Driving Safely 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. Shift your weight uphill. 4. Avoid crossing the sides of steep hills. 5.

  • Page 32: Driving Uphill

    SAFETY Driving Safely Driving Uphill Whenever traveling uphill, follow these precautions: 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.
  • Page 33 Driving Safely Driving Uphill If all forward speed is lost: Keep your weight uphill. If the vehicle begins rolling downhill, never apply engine power. Never apply the hand brake while rolling backwards. Apply the foot brake gradually. When fully stopped, apply the hand brake as well.

  • Page 34: Turning Around On A Hill

    SAFETY Driving Safely Turning Around on a Hill If the vehicle stalls while climbing a hill, never back down the hill! Use the K-turn to turn around. 2.4 m 1. Stop the vehicle. Keep your weight uphill. 2. Lock the hydraulic parking brake. 3.
  • Page 35 Driving Safely Turning Around on a Hill 8. Lock the hydraulic parking brake. Remount from the uphill side. Keep your weight uphill. 9. Apply the foot brake. 10. With the transmission still in forward, start the engine. 11. Squeeze and release the brake lever to release the parking brake. 12.

  • Page 36: Driving Through Water

    SAFETY Driving Safely Driving Through Water Follow these procedures when operating through water: 1. Check water depth and current before crossing. 2. Avoid operating in water deeper than the bottom of the footrests (1). If it’s unavoidable, travel slowly, balance your weight carefully and avoid sudden movements.
  • Page 37 Driving Safely Driving Through Water CAUTION If the vehicle stops while fully submerged, major engine damage can result if the machine is not thoroughly inspected. Take the vehicle to your dealer before starting the engine. If your vehicle becomes fully immersed, and it’s impossible to take it to a dealer before starting it, follow the steps described on page 92.

  • Page 38: Driving In Reverse

    SAFETY Driving Safely Driving in Reverse Follow these precautions when operating in reverse: 1. Avoid backing downhill. 2. Always check for obstacles or people behind the vehicle before backing. 3. Drive slowly. 4. Apply the foot brake lightly for stopping. 5.

  • Page 39: Parking On An Incline

    SAFETY Driving Safely Parking on an Incline Avoid parking on an incline. If it’s unavoidable, follow these precautions: 1. Turn the engine off. 2. Place the transmission in gear. 3. Lock the mechanical parking brake. 4. Always block the rear wheels on the downhill side. 5.
  • Page 40 SAFETY Driving Safely Hauling Cargo and Towing WARNING Overloading the vehicle or carrying or towing cargo improperly can alter vehicle handling and may cause loss of control or brake instability. Always follow these precautions when hauling cargo. S Read and understand the load distribution warnings listed on the vehicle warning labels.
  • Page 41 Driving Safely Hauling Cargo and Towing Towing Towing is approved OFF-ROAD ONLY. Operating a Quadricycle/trailer combination on public roads is prohibited. Do not exceed the maximum capacities when towing. Do not tow any trailer on a grade steeper than 15°. Trail Boss 330 Maximum Towed Load QUADRICYCLE...

  • Page 42: Features And Controls

    FEATURES AND CONTROLS Controls/Instruments (1) Main Key Switch Turn the main key switch off to stop the engine and end all electrical power to the vehicle. Turn the switch on to engage the starter. After starting the engine, release the key to the RUNNING LIGHTS position.
  • Page 43 Controls/Instruments (3) Engine Stop Switch Move the stop switch to the OFF position to stop the engine. All electrical power to the vehicle will end. The engine will not start or run when the switch is in the OFF position. Move the stop switch to the ON (RUN) position before attempting to start the engine.
  • Page 44 FEATURES AND CONTROLS Controls/Instruments (10) (13) (12) (6) Electronic Throttle Control (ETC) ETC causes the engine to stop if the throttle cable sticks in an open position when the operator releases the throttle lever. WARNING The Electronic Throttle Control (ETC) stops the engine in the event of a throttle system malfunction.
  • Page 45 Controls/Instruments (9) Hazard Warning Switch Push the hazard warning switch to cause all turn indicators to flash simultaneously. Use this feature to alert others of an emergency or other situation requiring caution. (10) Rear Brake Lever The left brake lever operates the hydraulic rear brakes only. See page (11) Parking Brake Lever The right brake lever is used as a mechanical parking brake only.

  • Page 46: Rear Brake Lever

    FEATURES AND CONTROLS Brakes Foot Brake The all-wheel foot brake (1) is located on the right footrest. The foot brake operates both front and rear brakes. Press the brake pedal forward with your foot to engage the all-wheel brakes. The master cylinder (2) is located near the foot brake.
  • Page 47 Brakes WARNING Operating the Quadricycle 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. Locking the Parking Brake (Mechanical) The right brake lever is used as a mechanical parking brake only. It is not intended to be used as a brake lever.

  • Page 48: Steering Lock

    FEATURES AND CONTROLS Steering Lock Lock the steering to prevent unauthorized use or theft of the vehicle. 1. Turn the handlebars to the full left position. 2. Insert the steering lock key and turn it clockwise. 3. Remove the key. 4.

  • Page 49: Fuel Tank

    Fuel Tank The fuel tank filler cap (1) is located directly below the handlebar. Refuel with either leaded or unleaded gasoline with a minimum of 87 octane. WARNING S Gasoline is highly flammable and explosive under certain conditions. S Use extreme caution whenever handling gasoline. S Refuel with the engine stopped.

  • Page 50: Transmission Gear Selector

    FEATURES AND CONTROLS Transmission Gear Selector The transmission gear selector (1) is located on the right side of the vehicle. Whenever the vehicle is left unattended, place the transmission in gear and lock the mechanical parking brake. F: Forward Gear N: Neutral R: Reverse CAUTION...

  • Page 51: Recoil Starter

    Recoil Starter If the battery is too weak to start the engine, use the recoil starter (1). Follow the starting procedures on page 57, cranking the engine with the recoil starter instead of the main key switch. 1. Grasp the recoil starter rope handle tightly.

  • Page 52: Instrument Cluster

    FEATURES AND CONTROLS Instrument Cluster The instrument cluster senses vehicle speed from the right front wheel. It measures distance as well as hours of operation. It also includes a reverse speed limiter function that limits reverse speed to about 11-14 km/h.

  • Page 53: Rider Information Center

    If the instrument cluster fails to illuminate, a battery over-voltage condition may have caused it to shut down to protect the electrical system. If this occurs, take the Quadricycle to your Polaris dealer. 1. Gear Indicator - As the shift lever is...
  • Page 54 FEATURES AND CONTROLS Instrument Cluster Rider Information Center The reverse override button on the left handlebar is also the mode button. Use the mode button to toggle through the four (4) standard modes of the rider information center. NOTE: The transmission cannot be in reverse. Mode 1 - Odometer The odometer records the total distance traveled by the vehicle since manufacture.

  • Page 55: Diagnostic Mode

    FEATURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode The diagnostic mode is for informational purposes only. Please return your Quadricycle to your dealer for all major repairs. The wrench icon will display when the gauge is in the diagnostic mode.
  • Page 56 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode Screen 5: Programmable service interval The programmable service interval provides a convenient reminder when routine maintenance is due. This feature is pre-set at 50 hours. You must enable the programmable service interval before it can be used.

  • Page 57: Operation

    Break-In Period The break-in period for your new Polaris Quadricycle 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 Quadricycle more than following the procedures for a proper break-in.
  • Page 58 Ensure proper operation Ensure operation Ensure proper operation Inspect, clean Drain deposits whenever visible Check operation, apply Polaris dielec- tric grease when lamp is replaced Check operation, apply Polaris dielec- tric grease when lamp is replaced Wear helmet, goggles, protective...

  • Page 59: Starting The Engine

    Starting the Engine WARNING Engine exhaust contains poisonous carbon monoxide and can cause loss of consciousness resulting in serious injury or death. Never run an engine in an enclosed area or indoors. CAUTION Operating the vehicle immediately after starting could cause engine damage.
  • Page 60 OPERATION Starting the Engine 7. Turn the ignition key to the ON position to engage the starter. Activate the starter for a maximum of five seconds, releasing the key when the engine starts. NOTE: Do not press the throttle while starting the engine.

  • Page 61: Pvt Drying

    S Always follow all recommended maintenance procedures. See your dealer as outlined in the owner’s manual. S This PVT system is intended for use on Polaris products only. Do not install it in any other product. S Always make sure the PVT housing is securely in place during operation.

  • Page 62: 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 63: Maintenance And Lubrication

    Perform these procedures more frequently for vehicles subjected to " severe use. Emission Control System Service Have an authorized Polaris dealer perform these services. WARNING Improperly performing the procedures marked with a result in component failure and lead to serious injury or death.

  • Page 64: Periodic Maintenance Chart

    " (break-in) General " lubrication Perform these procedures more often for vehicles subjected to severe use. " E Emission Control System Service Have an authorized Polaris dealer perform these services. Maintenance Interval (whichever comes first) Kilometers Pre-Ride Pre-Ride Pre-Ride Pre-Ride...
  • Page 65 Spark plug Ignition Timing Wiring " Perform these procedures more often for vehicles subjected to severe use. " E Emission Control System Service Have an authorized Polaris dealer perform these services. Maintenance Interval (whichever comes first) Kilometers 1000 1000 12 M...
  • Page 66 " parking brake Headlight aim Perform these procedures more often for vehicles subjected to severe use. " E Emission Control System Service Have an authorized Polaris dealer perform these services. Maintenance Interval (whichever comes first) Kilometers 12 M 1000 12 M...

  • Page 67: Lubrication Recommendations

    Engine Brakes Transmission Drive chain(s) (1) Ball Joint (2) Swing Arm Bushings (3) Axle Housing Lube Polaris Premium 4 See page 66. Synthetic 0W40 DOT 3 fluid only See page 74. Premium AGL See Page 72. Synthetic Gearcase Lube O-ring chain lube...

  • Page 68: Engine Oil

    Use of another API certified “SH” oil is acceptable as long as it’s 0W-40. Oil may need to be changed more frequently if Polaris Premium 4 is not used. See page 103 for the part numbers of Polaris products.

  • Page 69: Oil Check

    MAINTENANCE AND LUBRICATION Oil Check 1. Position the vehicle on a level surface. 2. Place the transmission in neutral. 3. Lock the mechanical parking brake. 4. Start the engine. Allow it to idle for 30 seconds. 5. Turn the engine off. 6.

  • Page 70: Oil And Filter Change

    Always replace the oil and filter within a few hours of draining the oil. Do not allow the vehicle to be without oil overnight. 1. Use Polaris-recommended products. Oil filter 0W/40 oil 1.
  • Page 71 MAINTENANCE AND LUBRICATION Oil and Filter Change 6. Place a drain pan under the vehicle. 7. Remove the drain plug. 8. Drain the oil. CAUTION Hot oil may result in serious burns. Do not allow hot oil to contact skin. 9.
  • Page 72 MAINTENANCE AND LUBRICATION Oil and Filter Change 13. Lubricate the filter o-ring. 14. Install the new oil filter. After the filter contacts the engine surface, turn it 1/2 turn by hand. 15. Remove the dipstick. 16. Add two .95 liter bottles of 0W/40 oil.
  • Page 73 MAINTENANCE AND LUBRICATION Engine Oil Cooler Maintenance The oil cooling system requires little maintenance other than keeping the cooler (1) free of mud and debris. CAUTION Do not use a high pressure washer to remove debris from the cooler. The pressure may damage the cooling fins.

  • Page 74: Transmission Oil Check

    MAINTENANCE AND LUBRICATION Transmission Oil Check See page 65 for recommended lubricants. See page 103 for the part numbers of Polaris products. 1. Position the vehicle on a level surface. 2. Place the transmission in gear. 3. Lock the mechanical parking brake.

  • Page 75: Transmission Oil Change

    MAINTENANCE AND LUBRICATION Transmission Oil Change 1. Position the vehicle on a level surface. 2. Place the transmission in gear. 3. Lock the mechanical parking brake. 4. Loosen the jam nut (1). 5. Turn the adjuster bolt (2) inward. 6. Remove the drain plug (3). Wipe it clean.

  • Page 76: Brake Check

    The brake system should be inspected by your dealer. Fill the reservoir as needed whenever the cover is loosened or removed to ensure proper diaphragm operation. Use Polaris DOT 3 brake fluid. Do not overfill. NOTE: Reservoir levels will decrease as brake pads become worn.
  • Page 77 MAINTENANCE AND LUBRICATION Brakes Brake Fluid Check Check brake fluid levels before each use of the vehicle. The brakes should feel firm when they’re applied. Spongy or weak brakes may indicate a fluid leak or low fluid level. A low fluid level may also mean that brake pads are worn and need to be replaced.

  • Page 78: Toe Alignment

    Polaris dealer for service. WARNING Do not attempt to adjust alignment. All steering adjustments should be performed by an authorized Polaris dealer. Rear Springs The rear shock absorber springs are adjustable. Use the spanner wrench (1) in the tool kit.

  • Page 79: Handlebar Adjustment

    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. 14-17 N-m...

  • Page 80: Carburetor Idle Adjustment

    Optional jets and clutch components, available from your Polaris dealer, are required for operation above 1800 meters. Jetting is required only when operating below 4 degrees C. at 1800 meters and lower.

  • Page 81: Throttle Cable Freeplay Adjustment

    MAINTENANCE AND LUBRICATION Throttle Cable Freeplay Adjustment 1. Locate the throttle cable adjuster (1) on the handlebar. 2. Slide the boots (2) off the cable adjuster sleeve (3). Loosen the adjuster (4). 3. Turn the adjuster until 1.6-3.2 mm of freeplay exists at the lever. NOTE: Move the throttle lever back and forth while...

  • Page 82: Side Panel Removal

    MAINTENANCE AND LUBRICATION Side Panel Removal NOTE: 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. Grasp the rear of the side panel near the rear cab. Pull the panel forward and outward quickly and firmly to disengage the rear tabs.
  • Page 83 MAINTENANCE AND LUBRICATION Wheel Removal / Installation CAUTION Operating with improperly installed wheels will affect vehicle handling and could cause an accident resulting in serious injury or death. Always use original equipment size and type when replacing tires. Install wheels properly. 1.

  • Page 84: Tire Tread Depth

    MAINTENANCE AND LUBRICATION Tires Tire Tread Depth Always replace tires when tread depth is worn to 3 mm or less. WARNING Operating your vehicle with worn tires, improperly inflated tires, non-standard tires or improperly installed tires will affect vehicle handling and could cause an accident.

  • Page 85: Drive Chain

    MAINTENANCE AND LUBRICATION Drive Chain Always inspect the drive chain before operating the vehicle. Check for damaged or missing o-rings or damaged rollers. Check for correct slack adjustment. Maintain the stone guard-to-rear sprocket clearance at 3 mm. Lubricate the outer surfaces of the roller regularly. Lubricate the drive chain as outlined in the Lubrication Chart on page High pressure water may damage components.

  • Page 86: Fuel Filter

    MAINTENANCE AND LUBRICATION Drive Chain Rear Drive Chain Slack 5. Roll the vehicle forward or backward to adjust the chain slack to the proper tension. See the illustration for proper splice link clip opening position (1). 6. Tighten the eccentric locking bolts to 61 N-m.

  • Page 87: Air Filter

    MAINTENANCE AND LUBRICATION Air Filter 1. Position the vehicle on a level surface. 2. Place the transmission in gear. 3. Lock the mechanical parking brake. 4. Remove the seat. 5. Unlatch the air box clips (1). Remove the air box cover. 6.
  • Page 88 MAINTENANCE AND LUBRICATION Lights WARNING Poor lighting can result in loss of control or an accident. Lights become dirty during normal operation. Wash the headlights and tail lights frequently. Hot components can cause serious burns to skin. Do not service the headlamps until they’ve cooled.

  • Page 89: High Beam Adjustment

    MAINTENANCE AND LUBRICATION Lights High Beam Adjustment 1. Position the vehicle on a level surface. The headlight should be approximately 7.6 meters from a wall. 2. Place the transmission in neutral. 3. Lock the mechanical parking brake. 4. Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height.

  • Page 90: Indicator Lamp Replacement

    MAINTENANCE AND LUBRICATION Lights Taillight/Signal Light Replacement 1. Place the transmission in gear. 2. Lock the mechanical parking brake. 3. Rotate the taillight socket counterclockwise to remove it. 4. Remove the lamp. 5. Apply dielectric grease to the socket. 6. Install the new lamp. 7.
  • Page 91 MAINTENANCE AND LUBRICATION Recoil Housing Drain Always drain the recoil housing (1) after operating the vehicle in wet conditions. Always remove the drain plug before storing the vehicle. NOTE: Water will enter the recoil housing if the starter handle (2) is disengaged from the rope guide when under water.

  • Page 92: Spark Plugs

    MAINTENANCE AND LUBRICATION Spark Plugs 1. Remove the left side panel. See page 80. 2. Remove the spark plug wire (1). Use the spark plug wrench (2) to remove the spark plug (3). Turn the plug counterclockwise to remove it. 3.

  • Page 93: Spark Plug Condition

    MAINTENANCE AND LUBRICATION Spark Plugs Spark Plug Condition Normal The insulator tip is tan or brown. There are few combustion deposits. The electrodes are not burned or eroded. This indicates the proper type and heat range for the engine and the service. NOTE: The tip should not be white.

  • Page 94: Vehicle Immersion

    MAINTENANCE AND LUBRICATION Vehicle Immersion CAUTION If the vehicle stops while fully submerged, major engine damage can result if the machine is not thoroughly inspected. Take the vehicle to your dealer before starting the engine. If your vehicle has been totally submerged in water and it’s impossible to have it serviced before further operation, perform the following procedure.
  • Page 95 MAINTENANCE AND LUBRICATION Vehicle Immersion 5. Loosen the carburetor drain screw (1) and drain the carburetor. 6. Turn the ignition key to the ON position to engage the starter. Engage the starter for only 2-3 seconds. 7. Tighten the carburetor drain screw. 8.

  • Page 96: Spark Arrestor

    MAINTENANCE AND LUBRICATION Spark Arrestor Occasionally, the spark arrestor may accumulate carbon, which can restrict the exhaust if left unattended. Purge the spark arrestor. WARNING Allow components to cool sufficiently before servicing. The exhaust system can get extremely hot. Never run the engine in an enclosed area or indoors.
  • Page 97 MAINTENANCE AND LUBRICATION Spark Arrestor 5. Quickly squeeze and release the throttle lever several times to purge carbon from the system. 6. If carbon comes out of the exhaust, cover or plug the exhaust outlet (1). Wear leather gloves for protection.

  • Page 98: Battery Removal

    MAINTENANCE AND LUBRICATION Battery WARNING Improperly connecting or disconnecting battery cables can cause sparks which could result in an explosion, causing 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 99: Battery Charging

    NOTE: Battery charge can be maintained by using a Polaris Battery Tendert charger (P/N 2871076) or by charging about once a month to make up for normal self-discharge. Battery...
  • Page 100 MAINTENANCE AND LUBRICATION Battery Battery Charging Chart (Constant Current Charger) 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 NOTE: Always verify battery condition before and one to two hours after charging.

  • Page 101: Cleaning The Vehicle

    NOTE: If warning and safety labels are damaged, contact your Polaris dealer for free replacements. Waxing the Vehicle Wax the vehicle with any non-abrasive automotive paste wax. Avoid harsh cleaners since they can scratch the finish.

  • Page 102: Storing The Vehicle

    MAINTENANCE AND LUBRICATION Storing the Vehicle See page 103 for the part numbers of Polaris products. Clean the Vehicle See page 99. Stabilize the Fuel 1. Fill the fuel tank. 2. Add Polaris Carbon Clean Fuel Treatment or Polaris Fuel Stabilizer.

  • Page 103: Engine Fogging

    Accessories Auxiliary power outlets provide 12V power for operating accessories such as hand held spot lights. See your Polaris dealer for more information about accessories.

  • Page 104: Transporting The Vehicle

    MAINTENANCE AND LUBRICATION Transporting the Vehicle Follow these procedures when transporting the vehicle. 1. Turn the engine off. Remove the key to prevent loss during transporting. 2. Place the transmission in gear. 3. Lock the mechanical parking brake. 4. Turn the fuel valve off. 5.

  • Page 105: Polaris Products

    Chain Lube (185 ml aerosol) 2872348 Chain Lube (473 ml aerosol) Additives / Miscellaneous Brake and Clutch Cleaner 2872889 2871326 Carbon Clean Plus (355 ml) 2870652 Fuel Stabilizer (473 ml) 2870990 DOT3 Brake Fluid 2872893 Engine Degreaser 2871956 LOCTITE 565 Thread Sealant POLARIS PRODUCTS...

  • Page 106: Troubleshooting

    Dry out the PVT as outlined on page 59. Inspect clutch seals for damage if repeated leaking occurs. Contact your Polaris dealer for inspection of clutch com- ponents. fuel lines, or carburetor. Contact your dealer for service.
  • Page 107 Contact your Polaris dealer for service if you’re unable to identify solutions using the following charts. Engine Does Not Rotate Possible Cause Blown fuse Low battery voltage Loose battery connections Loose solenoid / starter connections Engine Rotates, Fails to Start...

  • Page 108: Engine Backfires

    Engine Backfires Inspect, clean and/or replace spark plugs Set gap to specs or replace plugs Replace with new fuel See your Polaris dealer See your Polaris dealer See your Polaris dealer Inspect, clean and/or replace spark plugs See your Polaris dealer...
  • Page 109 Inspect and replace Replace with new fuel Inspect, clean and/or replace spark plugs Inspect, clean and/or replace spark plugs See your Polaris dealer Set gap to specs or replace plugs Check all connections and tighten Recharge battery / Check charging system...

  • Page 110: Specifications

    SPECIFICATIONS 2005 Trail Boss 330 Quadricycle Body Style Gross Vehicle Weight Fuel Capacity Transmission Oil Engine Oil Capacity Front Rack Rear Rack Tongue Weight Towing Rating Unbraked Trailer Towing Capacity* 573 kg Turn Radius Ground Clearance Height Length Width Seat Height...
  • Page 111 2005 Trail Boss 330 Quadricycle Drive System Type Shift Type Gear Reduction - Reverse Gear Reduction - Forward Final Drive (ratio) Drive Chain Front Tires Rear Tires Front Suspension: Mac Strut Rear Suspension: Progressive Rate Swing Arm Shock Adjustment Brake System...

  • Page 112: Jetting Chart

    SPECIFICATIONS 2005 Trail Boss 330 Quadricycle Jetting Chart Altitude AMBIENT TEMPERATURE Meters 0-1800 1800-3700 Clutching Chart Altitude Meters 0-1800 1800-3700 Below 5° C 127.5 Shift Drive Clutch Weight Spring 10RH Blue/Green 5630709 7041157 20-40 Blue/Green 5631356 7041157 +5°C and above 122.5...

  • Page 113: Warranty

    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 Quadricycle that has...
  • Page 114 HOW TO OBTAIN WARRANTY SERVICE If your Quadricycle requires warranty service, you must take it to a Polaris dealer authorized to repair Polaris Quadricycles. When requesting warranty service you must present your copy of the Warranty Registration form to the dealer. (THE COST OF TRANSPORTA- TION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY).

  • Page 115: Maintenance Record

    MAINTENANCE RECORD DATE MILES/KM TECHNICIAN SERVICE PERFORMED / COMMENTS...
  • Page 116 MAINTENANCE RECORD DATE MILES/KM TECHNICIAN SERVICE PERFORMED / COMMENTS...
  • Page 117 MAINTENANCE RECORD DATE MILES/KM TECHNICIAN SERVICE PERFORMED / COMMENTS...

  • Page 118: Index

    INDEX Accessories ....Age Restriction ....Air Filter .
  • Page 119 Parking on an Incline ... . Periodic Maintenance Chart POLARIS PRODUCTS ..Pre Ride Inspection ....

This manual is also suitable for:

2005 trail boss 330

Table of Contents