Free Polaris Trail Blazer 330 Owner's Manual PDF | Manualsnet (2024)

A card containing important ATV safety information should be attached to the owners 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.

The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm.

WARNING

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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.

S Snowmobiles

S All-terrain vehicles (ATVs)

S RANGER utility vehicles

S Victory motorcycles

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 weve ever produced.

For safe and enjoyable operation of your vehicle, be sure to follow the instructions and recommendations in this owners manual. Your manual contains instructions for minor maintenance, but information about major repairs is outlined in the Polaris Service Manual and should be performed only by a Factory Certified Master Service Dealer (MSD) Technician.

Your Polaris dealer knows your vehicle best and is interested in your total satisfaction. Be sure to return to your dealership for all of your service needs during, and after, the warranty period.

We also take great pride in our complete line of apparel, parts and accessories, available through our online store at www.purepolaris.com. Have your accessories and clothing delivered right to your door!

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Copyright 2007 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. Depictions and/or procedures in this publication are intended for reference use only. No liability can be accepted for omissions or inaccuracies. Any reprinting or reuse of the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited.

Printed in U.S.A.

2008 Trail Blazer 330 Owners Manual P/N 9921539

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TABLE OF CONTENTS

KNOW YOUR VEHICLE 5. . . . . . . . . . . . . . . . . . . . .

SAFETY 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FEATURES AND CONTROLS 31. . . . . . . . . . . . . . .

OPERATION 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

EMISSION CONTROL SYSTEMS 59. . . . . . . . . . . .

MAINTENANCE 60. . . . . . . . . . . . . . . . . . . . . . . . . . .

SPECIFICATIONS 104. . . . . . . . . . . . . . . . . . . . . . . .

POLARIS PRODUCTS 107. . . . . . . . . . . . . . . . . . . .

TROUBLESHOOTING 108. . . . . . . . . . . . . . . . . . . . .

WARRANTY 112. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MAINTENANCE LOG 116. . . . . . . . . . . . . . . . . . . . .

INDEX 118. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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KNOW YOUR VEHICLE As the operator of the vehicle, you are responsible for your personal safety, the safety of others, and the protection of our environment. Read and understand your owners manual, which includes valuable information about all aspects of your vehicle, including safe operating procedures.

Vehicle Identification Numbers Record your ATVs 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. The ignition switch must be replaced if all keys are lost.

Vehicle Model Number:

Frame VIN (1):

Engine Serial Number (right front side of engine crankcase):

Key Number (2):

31XX

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SAFETY Operator Safety

WARNING Failure to follow the warnings contained in this manual can result in serious injury or death. A Polaris ATV is not a toy and can be hazardous to operate. This vehicle handles differently than other vehicles, such as motorcycles and cars. A collision or rollover can occur quickly, even during routine maneuvers like turning, or driving on hills or over obstacles, if you fail to take proper precautions. Read and understand your owners manual and all warnings before operating a Polaris ATV.

Age Restrictions This vehicle is an ADULT VEHICLE ONLY. Operation is prohibited for anyone under 16 years of age.

Safety Training ATV safety training is a top priority for Polaris. When you purchased your new ATV, your dealer instructed you on the authorized ATV RiderCoursesm available to you and your eligible family members. This training is included in the purchase price of your ATV. Polaris strongly encourages you and your eligible family members who will be riding the ATV to take the ATV RiderCoursesm. You were also provided with printed materials that explain safe operating procedures. You should review this information on a regular basis.

If you purchased a used Polaris ATV, you can take the ATV RiderCoursesm by calling ATV Enrollment Express at (800) 887-2887 or by visiting www.atvsafety.org. Purchasers of a used Polaris ATV will be charged for this training.

A Polaris ATV is an off-road vehicle. Familiarize yourself with all laws and regulations concerning the operation of the ATV in your area.

We strongly advise you to strictly follow the recommended maintenance program outlined in your owners manual. This preventive maintenance program is designed to ensure that all critical components on your vehicle are thoroughly inspected at specific intervals.

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SAFETY Operator Safety The following signal words and symbols appear throughout this manual and on your ATV. Your safety is involved when these words and symbols are used. Become familiar with their meanings before reading the manual.

The safety alert symbol, on your vehicle or in this manual, alerts you to the potential for personal injury.

WARNING The safety alert warning indicates a potential hazard that may result in serious injury or death.

CAUTION The safety alert caution indicates a potential hazard that may result in minor personal injury or damage to the vehicle.

CAUTION A caution indicates a situation that may result in damage to the vehicle.

NOTE:

A note will alert you to important information or instructions.

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SAFETY Operator Safety

WARNING Serious injury or death can result if you do not follow these instructions and procedures, which are outlined in further detail within your owners manual.

S Read this manual and all labels carefully, and follow the operating procedures described.

S Never operate an ATV without proper instruction. Take a training course. Purchasers of a new Polaris ATV and their eligible family members are entitled to take the ATV RiderCoursesm. Contact ATV Enrollment Express at (800) 887-2887 or visit www.atvsafety.org for information on enrollment in the ATV RiderCoursesm.

S Never allow anyone under 16 years of age to operate this ATV. S Never permit a guest to operate the ATV unless the guest has read this manual and all product labels and has completed a certified safe- ty training course.

S Always avoid operating an ATV on paved surfaces, including side- walks, driveways, parking lots, and streets.

S Never operate an ATV on a public street, road or highway, including a dirt or gravel road.

S Never operate an ATV without wearing an approved helmet that fits properly. Always wear eye protection (goggles or face shield), gloves, boots, a long-sleeved shirt or jacket, and long pants.

S Never consume alcohol or drugs before or while operating an ATV. S Never operate at excessive speeds. Travel at speeds appropriate for the terrain, visibility and operating conditions, and your experience.

S Never attempt wheelies, jumps or other stunts. S Always inspect your ATV before each use to make sure its in safe operating condition. Always follow the inspection and maintenance procedures and schedules outlined in your owners manual.

S Always keep both hands on the handlebars and both feet on the foot- rests of the ATV during operation.

S Always travel slowly and use extra caution when operating on unfa- miliar terrain. Be alert to changing terrain conditions.

S Never operate on excessively rough, slippery, or loose terrain. S Always follow proper turning procedures as described in this manu- al. Practice turning at low speeds before attempting to turn at faster speeds. Do not turn at excessive speeds.

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SAFETY Operator Safety S Always have the ATV inspected by an authorized Polaris dealer if its been involved in an accident.

S Never operate on hills too steep for the ATV or for your abilities. Practice on smaller hills before attempting larger hills.

S Always follow proper procedures for climbing hills. Check the ter- rain carefully before ascend a hill. Never climb hills with excessive- ly slippery or loose surfaces. Shift your weight forward. Never open the throttle suddenly or make sudden gear changes. Never go over the top of a hill at high speed.

S Always follow proper procedures for going downhill and for braking on hills. Check the terrain carefully before you start down a hill. Shift your weight backward. Never go down a hill at high speed. Avoid going down a hill at an angle, which would cause the vehicle to lean sharply to one side. Travel straight down the hill when pos- sible.

S Always follow proper procedures for crossing the side of a hill. Avoid hills with excessively slippery or loose surfaces. Shift your weight to the uphill side of the ATV. Never attempt to turn the ATV around on any hill until youve mastered (on level ground) the turn- ing technique outlined in this manual. Avoid crossing the side of a steep hill when possible.

S Always use proper procedures if you stall or roll backwards while climbing a hill. To avoid stalling, maintain a steady speed when climbing a hill. If you stall or roll backwards, follow the special pro- cedure for braking described in this manual. Always dismount on the uphill side, or to either side if the ATV is pointed straight uphill. Turn the ATV around and remount following the procedure de- scribed in this manual.

S Always check for obstacles before operating in a new area. Never attempt to operate over large obstacles, such as rocks or fallen trees. Always follow proper procedures when operating over obstacles as described in this manual.

S Always be careful of skidding or sliding. On slippery surfaces like ice, travel slowly and use extra caution to reduce the chance of skid- ding or sliding out of control.

S Avoid operating the ATV through deep or fast-flowing water. If its unavoidable, travel slowly, balance your weight carefully, avoid sud- den movements, and maintain a slow and steady forward motion. Do not make sudden turns or stops, and do not make sudden throttle changes.

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SAFETY Operator Safety S Wet brakes may have reduced stopping ability. Test your brakes after leaving water. If necessary, apply them lightly several times to allow friction to dry out the pads.

S Always check for obstacles or people behind the ATV before operat- ing in reverse. When its safe to proceed in reverse, move slowly and avoid turning at sharp angles.

S Always use the size and type of tires specified for your ATV, and always maintain proper tire pressure.

S Never modify an ATV through improper installation or use of acces- sories.

S Never exceed the stated load capacity for your ATV. Cargo must be properly distributed and securely attached. Reduce speed and follow the instructions in this manual for carrying cargo or towing. Allow a greater distance for braking.

S Always remove the ignition key when the vehicle is not in use to prevent unauthorized use or accidental starting.

FORMORE INFORMATIONABOUTATV SAFETY, call theCon- sumer Product Safety Commission at 1-800-638-2772, or visit www.cpsc.gov, visit www.atvsafety.org, or call Polaris at 1-800-342-3764.

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. Any modifications to the original equipment of the vehicle create a substantial safety hazard and increase the risk of bodily injury. The warranty on your Polaris ATV is terminated if any equipment has been added to the vehicle, or if any modifications have been made to the vehicle, that increase its speed or power.

NOTE: The addition of certain accessories, including (but not limited to) mowers, blades, tires, sprayers, or large racks, may change the handling characteristics of the vehicle. Use only Polaris-approved accessories, and familiarize yourself with their function and effect on the vehicle.

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SAFETY Operator Safety

WARNING POTENTIAL HAZARD Operating this ATV without proper instruction. WHAT CAN HAPPEN The risk of an accident is greatly increased if the operator does not know how to operate the ATV properly in different situations and on different types of terrain. HOW TO AVOID THE HAZARD Beginning and inexperienced operators should complete the ATV RiderCoursesm offered by Polaris through the SVIA. They should then regularly practice the skills learned in the course and the operating techniques described in the Owners Manual. For more information about the ATV RiderCoursesm contact ATV Enrollment Express at (800) 887-2887 or visit www.atvsafety.org.

WARNING POTENTIAL HAZARD Failure to follow the age recommendations for this ATV. WHAT CAN HAPPEN Severe injury and/or death could occur if a child under the minimum age recommendation operates an ATV. Even though a child may be within the recommended age group for operating some 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.

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SAFETY Operator Safety

WARNING POTENTIAL HAZARD Carrying a passenger on an ATV. WHAT CAN HAPPEN Carrying a passenger greatly reduces the operators 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. The purpose of the long seat is to allow the operator to shift position as needed during operation. It is not intended for carrying passengers.

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. HOW TO AVOID THE HAZARD Avoid operating the ATV on pavement. If its unavoidable, travel slowly and avoid sudden turns or stops.

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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. In many states its illegal to operate ATVs on public streets, roads and highways.

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. Operating without eye protection could result in an accident and could increase the chance of a severe injury in the event of an accident. HOW TO AVOID THE HAZARD Always wear an approved helmet that fits properly. Always wear eye protection (goggles or face shield), gloves, boots, long-sleeved shirt or jacket, and long pants.

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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. HOW TO AVOID THE HAZARD Never consume alcohol or drugs before or while operating an ATV.

WARNING POTENTIAL HAZARD Operating the ATV at excessive speeds. WHAT CAN HAPPEN Excessive speed increases the operators chance of losing control of the ATV, which can result in an accident. HOW TO AVOID THE HAZARD Always operate the ATV at a speed thats proper for the terrain, visibility and operating conditions, and your experience.

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SAFETY Operator Safety

WARNING POTENTIAL HAZARD Attempting wheelies, jumps and other stunts. WHAT CAN HAPPEN Attempting stunts increases the chance of an accident, including an overturn. HOW TO AVOID THE HAZARD

Never attempt wheelies, jumps, or other stunts. Avoid exhibition driving.

WARNING POTENTIAL HAZARD Failure to inspect the ATV before operating. 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 its in safe operating condition. Always follow the inspection and maintenance procedures and schedules described in the owners manual.

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SAFETY Operator Safety

WARNING POTENTIAL HAZARD Removing hands from the handlebars or feet from the footrests during operation. WHAT CAN HAPPEN Removing even one hand or foot can reduce ability to control the vehicle or could cause loss of balance and ejection from the ATV. If the operators foot is not firmly planted on the footrest, it could come into contact with the rear wheels and lead to accident or injury. HOW TO AVOID THE HAZARD Always keep both hands on the handlebars and both feet on the footrests of the ATV during operation.

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. Always be alert to changing terrain conditions.

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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. HOW TO AVOID THE HAZARD Do not operate on excessively rough, slippery or loose terrain until youve learned and practiced the skills necessary to control the ATV on such terrain. Always use extra caution on rough, slippery or loose terrain.

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 owners manual. Practice turning at slow speeds before attempting to turn at faster speeds. Never turn at excessive speed.

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SAFETY Operator Safety

WARNING POTENTIAL HAZARD Operating on excessively steep hills. WHAT CAN HAPPEN The vehicle may overturn. HOW TO AVOID THE HAZARD Never operate on hills too steep for the ATV or for your abilities. Never operate the ATV on hills steeper than 25_. Practice on smaller hills before attempting large hills.

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 owners manual. Always check the terrain carefully before ascending any hill. Never operate the ATV on hills steeper than 25_. Never climb hills with excessively slippery or loose surfaces. Shift your weight forward. Never open the throttle suddenly while traveling uphill. The ATV could flip over backwards. Never go over the top of any hill at high speed. An obstacle, a sharp drop, or another vehicle or person could be on the other side of the hill.

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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 owners manual. NOTE: A special technique is required when braking while traveling downhill. See page 52. Always check the terrain carefully before descending a hill. Shift your weight backward. Never travel down a hill at high speed. Avoid traveling down a hill at an angle, which would cause the vehicle to lean sharply to one side. Travel straight down the hill when possible.

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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 youve mastered the turning technique (on level ground) as described in the owners manual. See page 54. Use extra caution when turning on any hill. Avoid crossing the side of a steep hill. When crossing the side of a hill: Always follow proper procedures as described in the owners manual. Avoid hills with excessively slippery or loose surfaces. Shift your weight to the uphill side of the ATV.

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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. Apply the single lever brake gradually. When fully stopped, apply the auxiliary rear brake as well, then lock the parking brake. If the ATV begins rolling backwards: Keep weight uphill. Never apply engine power. Never apply the auxiliary rear brake while rolling backwards. Apply the single-lever brake gradually. When fully stopped, apply the auxiliary rear brake as well, and then lock the parking brake. Dismount on uphill side, or to either side if ATV is pointed straight uphill. Turn the ATV around and remount, following the procedure described in the owners manual. See page 54.

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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. If unavoidable, use extreme caution and always follow proper procedures as outlined in the owners manual.

WARNING POTENTIAL HAZARD Skidding or sliding. WHAT CAN HAPPEN Skidding or sliding can cause loss of control. If the tires regain traction unexpectedly, the ATV could overturn. HOW TO AVOID THE HAZARD On slippery surfaces such as ice, travel slowly and use extra caution to reduce the chance of skidding or sliding out of control.

WARNING POTENTIAL HAZARD Improperly operating in reverse. WHAT CAN HAPPEN The ATV could collide with an obstacle or person, resulting in severe injury. HOW TO AVOID THE HAZARD Before shifting into reverse gear, always check for obstacles or people behind the ATV. When its safe to proceed, back slowly.

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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. If its unavoidable to enter water that exceeds the recommended maximum depth (see page 55), travel slowly, balance your weight carefully, avoid sudden movements, and maintain a slow and steady forward motion. Do not make sudden turns or stops, and do not make sudden throttle changes. Wet brakes may have reduced stopping ability. Always test the brakes after leaving water. If necessary, apply them several times to let friction dry out the pads.

WARNING POTENTIAL HAZARD Operating this ATV with improper tires, or with improper or uneven tire pressure. WHAT CAN HAPPEN Use of improper tires, or operation of the ATV with improper or uneven tire pressure, could cause loss of control or accident. HOW TO AVOID THE HAZARD Always use the size and type of tires specified for the ATV. Always maintain proper tire pressure as specified.

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SAFETY Operator Safety

WARNING POTENTIAL HAZARD Operating the ATV with improper modifications. WHAT CAN HAPPEN Improper installation of accessories or modification of the ATV may cause changes in handling which could lead to an accident. HOW TO AVOID THE HAZARD Never modify the ATV through improper installation or use of accessories. 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 your authorized Polaris ATV dealer for more information.

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. Cargo should be properly distributed and securely attached. Reduce speed when carrying cargo or pulling a trailer. Allow a greater distance for braking. Always follow the instructions in the owners manual for carrying cargo or pulling a trailer. See page 46.

WARNING POTENTIAL HAZARD Operating on frozen bodies of water. WHAT CAN HAPPEN Severe injury or death can result if the ATV and/or the operator fall through the ice. HOW TO AVOID THE HAZARD Never operate the ATV on a frozen body of water.

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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.

WARNING Safe operation of this rider-active vehicle requires good judgement and physical skills. Persons with cognitive or physical disabilities who operate this vehicle have an increased risk of overturn and loss of control, which could result in severe injury or death.

CAUTION Exhaust system components are very hot during and after use of the vehicle. Hot components can cause serious burns and fire. Do not touch hot exhaust system components. Always keep combustible materials away from the exhaust system. Use caution when traveling through tall grass, especially dry grass.

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SAFETY Fuel Safety

WARNING Gasoline is highly flammable and explosive under certain conditions. S Always exercise extreme caution whenever handling gasoline. S Always refuel with the engine stopped, and outdoors or in a well ventilated area. S Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored. S Do not overfill the tank. Do not fill the tank neck. S If gasoline spills on your skin or clothing, immediately wash it off with soap and water and change clothing. S Never start the engine or let it run in an enclosed area. Engine exhaust fumes are poisonous and can cause loss of consciousness or death in a short time. S Turn the fuel valve off whenever the ATV is stored or parked.

WARNING The engine exhaust from this product contains chemicals known to cause cancer, birth defects or other reproductive harm. Operate this vehicle only outdoors or in well-ventilated areas.

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SAFETY Safety Decals and Locations Warning decals have been placed on the ATV for your protection. Read and follow the instructions of the decals on the ATV carefully. If any of the decals depicted in this manual differ from the decals on your 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.

Discretionary Warning (1) WARNING S Never operate this vehicle on HILLS steeper than 25 degrees

25. To prevent flipover on hilly terrain, when going up or down, use throttle and brakes gradually.

S REVERSE operation can be dangerous, even at low speeds. Steering becomes difficult. To prevent flipover, avoid sudden braking or sharp turns.

S Use OVERRIDE for reverse speed limiter with caution. To prevent loss of control, never activate override button with open throttle.

S PARKING BRAKE may relax when used for more than 5 minutes. When parking on grades, leave shift in forward.

Clutch Cover Warning (2) WARNING NO STEP S Moving parts hazard under belt-clutch guard. To prevent serious injury, do not operate vehicle with guard removed.

S Do not modify engine or clutch. Doing so can cause part failure, possible im- balance, and excessive engine RPM, which can result in serious injury or death.

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SAFETY Safety Decals and Locations General Warning (3) WARNING Improper ATV use can result in SEVERE INJURY or DEATH ALWAYS USE AN APPROVED HELMET AND PROTECTIVE GEAR NEVER USE ON PUBLIC ROADS NEVER CARRY PASSENGERS NEVER USE WITH DRUGS OR ALCOHOL NEVER operate: S without proper training or instruction S at speeds too fast for your skills or the conditions

S on public roads -- a collision can occur with another vehicle

S with a passenger -- passengers affect balance and steering and increase risk of losing control

ALWAYS: S use proper riding techniques to avoid vehicle overturns on hills and rough terrain and in turns

S avoid paved surfaces -- pavement may seriously affect handling and control LOCATE AND READ OWNERS MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS. IF OWNERS MANUAL IS MISSING, CONTACT A POLARIS DEALER FOR A REPLACEMENT.

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SAFETY Safety Decals and Locations No Passenger Warning (4) WARNING NEVER ride as a passenger. Passengers can cause a loss of control, resulting in SEVERE INJURY or DEATH.

Age 16 Warning (5) 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.

Tire Pressure/Load Warning (6) WARNING IMPROPER TIRE PRESSURE OR OVERLOADING can cause loss of control resulting in SEVERE INJURY OR DEATH. TIRE PRESSURE IN PSI (KPa): FRONT 4 (27.6) REAR 3 (20.7) MAXIMUM WEIGHT CAPACITY 305 LBS. (138 KG). Reduce speed and allow greater distance for braking when carrying cargo. Overloading or carrying tall, off-center, or unsecured loads will increase your risk of losing control. Loads should be centered, carried as low as possible, and firmly secured to the racks. With dual racks, load distribution 1/3 front 2/3 rear is best. For stability on rough or hilly terrain, reduce speed and cargo. Do not block headlight. Be careful if load extends over the side of the rack. Read Owners Manual for more detailed loading information.

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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 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. Approved helmets in Europe, Asia and Oceania bear the ECE 22.05 label. The ECE mark consists of a circle surrounding the letter E, followed by the distinguishing number of the country which has granted approval. The approval number and serial number will also be displayed on the label. 2. Eye Protection Do not depend on eyeglasses or sunglasses for eye protection. Whenever 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. Make sure protective eye wear is kept clean. 3. Gloves Off-road style gloves with knuckle pads are the best for comfort and protection. 4. Boots The best footwear is a pair of sturdy over-the-calf boots with low heels. 5. Clothing Always wear long sleeves and long pants to protect arms and legs. Riding pants with kneepads and a jersey with shoulder pads provide the best protection.

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051039 0006.031

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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. To gain additional power while backing, depress the override switch.

Main Switch (2) - To start the engine, slide the stop switch to the center RUN position and turn the main key switch clockwise past the ON position. Release the key when the engine starts.

NOTE: Turn off the main switch to end all electrical power to the vehicle, including the lights.

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.

Engine Stop Switch (3) - The engine will not start or run when the switch is in its OFF position. Its purpose is to provide the operator with a quick means of engine shutdown in case of an emergency. To stop the engine, slide the stop switch either right or left to the OFF position.

NOTE: Turning off the engine stop switch will shut off all electrical power to the vehicle, including the lights.

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RUN OFFOFF

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FEATURES AND CONTROLS Light Switches

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. Its 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.

Use the light switch (1) to turn the lights on and off.

NOTE: The lights wont work unless the key is in the ON position and the shut-off switch is in the RUN position.

Indicator Lights With the engine running, verify the function of all indicator lights each time the ATV is used.

NOTE: The taillight is on whenever the main switch (key) is on. Turn the key off to prevent battery drain.

1. Transmission Neutral Indicator 2. Transmission Reverse Indicator 3. High Temp Warning (displays if engine overheats)

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FEATURES AND CONTROLS Throttle Lever

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

Engine speed and vehicle movement are controlled by pressing the throttle lever. The 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 throttle cable should stick in an open position when the operator releases the throttle lever, the engine will stop, and power to the rear wheels will cease.

WARNING The Electronic Throttle Control (ETC) stops the engine in the event of a throttle system malfunction and is provided for your safety. Do not attempt to modify the ETC system or replace it with any after market throttle mechanisms.

1

34

FEATURES AND CONTROLS Brake Lever

WARNING Operating the ATV with a spongy brake lever can result in loss of braking, which could cause an accident. Never operate the ATV with a spongy-feeling brake lever.

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. When squeezed, the lever should feel firm. Any sponginess would indicate a possible fluid leak or low master cylinder fluid level, which must be corrected before riding. Contact your dealer for proper diagnosis and repairs.

1

35

FEATURES AND CONTROLS Brakes Check the brake fluid level in the master cylinder before each use of the ATV. The master cylinder (1) is located on the left handlebar.

The fluid level can be seen through an indicator window (2) on the top of the master cylinder. This eye will appear dark when the fluid level is full. When fluid needs to be added, the eye will be clear.

WARNING An over-full master cylinder may cause brake drag or brake lock-up, which could result in serious injury or death. Maintain brake fluid at the recommended level. Do not overfill.

NOTE: When checking the fluid level, the ATV must be on level ground with the handlebars straight. If the fluid level is low add DOT 4 brake fluid only. DO NOT OVERFILL. See page 107 for the part numbers of Polaris products.

WARNING Never store or use a partial bottle of brake fluid. Brake fluid is hygroscopic, meaning it rapidly absorbs moisture from the air. The moisture causes the boiling temperature of the brake fluid to drop, which can lead to early brake fade and the possibility of accident or severe injury. After opening a bottle of brake fluid, always discard any unused portion.

1 2

36

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. Squeeze and release the brake lever two or

three times, then squeeze and hold. 2. Push the park brake lock (1)

forward to engage the brake. Release the brake lever.

3. To release the parking brake lock, squeeze and release the brake lever. It will return to its unlocked position.

Important Safeguards S The parking brake may relax if left on for a long period of time. Al- ways block the wheels to prevent rolling.

S Always block the wheels on the downhill side of the ATV if leaving it parked on a hill. Another option is to park the ATV in a sidehill position.

S Never depend on the parking brake alone if the ATV is parked on a hill. Always block the wheels to prevent rolling.

1

37

FEATURES AND CONTROLS Auxiliary Brake

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

The auxiliary foot brake (1), is located on the inside of the right floorboard and is operated by the right foot. The auxiliary brake serves as a backup to the main brake system if the main system becomes inoperative.

If the rear wheels slide while using the auxiliary brake, reduce brake pedal pressure to brake the rear wheels without skidding.

Check the brake fluid level frequently for the auxiliary brake system. The reservoir is located under the seat or near the foot brake. Maintain the fluid level between the maximum and minimum marks.

1

38

FEATURES AND CONTROLS Choke The choke assists in starting a cold engine. Refer to the engine starting procedure on page 43 for correct choke and throttle settings during starting.

Fuel Valve The fuel valve (1) is located on the left side of the vehicle, below the fender. It has three positions:

OFF: For vehicle storage and when transporting.

ON: For normal operation.

RES: For reserve supply if main supply is exhausted.

NOTE: Theres about a 7 to 10 mile (11.2 to 16 km) range on reserve gas. Always refill the gas tank as soon as possible after using the reserve supply.

Always return the valve to the ON position after refueling.

Fuel Tank Remove the fuel tank cap (2) to add fuel to the fuel tank. Use either leaded or unleaded gasoline with a minimum pump octane number of 87=(R+ M/2) octane. Do not use E- 85 fuel.

Refer to the specifications section at the rear of this manual for tank capacity.

Fuel Filter The in-line fuel filter should be replaced by your dealer after every 100 hours of operation, or annually. Do not attempt to clean the fuel filter.

RES

ON

OFF

2

1

39

FEATURES AND CONTROLS Automatic Transmission Gear Selector The transmission gear selector (1) is located on the right side of the vehicle.

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.

Whenever the ATV is left unattended, always place the transmission in gear and lock the parking brake.

1 F

N

R

40

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

Polaris 4-cycle engines are equipped with automatic decompressors. This makes recoil starting possible by reducing the amount of compression during starting. The decompressor senses when the engine is spinning fast enough to start and restores compression when running.

1. Position the vehicle on a level surface and lock the parking brake (see page 36).

2. Shift the transmission into neutral. 3. Make sure the engine stop switch is set to RUN and the main key

switch is in the ON position.

NOTE: If the engine is cold, use the choke as outlined on page 43.

4. Grasp the recoil starter rope handle (2) firmly and pull slowly so you can feel the engine strokes.

NOTE: Every other stroke will be a compression stroke and will make the rope harder to pull. When a compression stroke is found, continue pulling the rope just until the engine rolls past the stroke, then stop pulling immediately.

5. Allow the recoil rope to rewind into the recoil assembly, then pull the rope abruptly and forcefully to start the engine.

6. Repeat steps 4-5 if necessary.

CAUTION Extending the recoil starter rope until it stops can cause damage to the recoil assembly. Do not extend the starter rope so far that it stops. If the starter rope handle is not seated properly, water may enter the recoil housing and damage components. Make sure the handle is fully seated on the recoil housing, especially when traveling in wet areas.

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41

OPERATION Break-In Period The break-in period for your new Polaris ATV is the first ten hours of operation, or the time it takes to use the first two full tanks of gasoline. No single action on your part is as important as following the procedures for a proper break-in. Careful treatment of a new engine and drive components will result in more efficient performance and longer life for these components.

CAUTION Excessive heat build-up during the first three hours of operation will damage close-fitted engine parts and drive components. Do not operate at full throttle or high speeds during the first three hours of use.

Engine and Drivetrain Break-in 1. Fill the fuel tank with gasoline (see page 38). 2. Check the oil level (see page 66). Add the recommended oil as

needed. 3. Drive slowly at first. Select an open area that allows room to

familiarize yourself with vehicle operation and handling. 4. Vary throttle positions. Do not operate at sustained idle. 5. Perform regular checks on fluid levels, controls and areas outlined

on the daily pre-ride inspection checklist. See page 42. 6. Pull only light loads. 7. During the break-in period, change both the oil and the filter at 20

hours or one month, whichever comes first.

PVT Break-in (Clutches/Belt) A proper break-in of the clutches and drive belt will ensure a longer life and better performance. Break in the clutches and belt by operating at slower speeds during the break-in period as recommended. Pull only light loads. Avoid aggressive acceleration and high speed operation during the break-in period.

42

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 its in proper operating condition.

Pre-Ride Checklist Item Remarks See

Page

Brake system / lever travel Ensure proper operation 34, 71

Brake fluid Ensure proper level 35

Auxiliary brake Ensure proper operation 72

Front suspension Inspect, lubricate if necessary 64

Rear suspension Inspect, lubricate if necessary 64

Steering Ensure free operation --

Tires Inspect condition and pressure 78

Wheels / fasteners Inspect, ensure fastener tightness 77

Frame nuts, bolts, fasteners Inspect, ensure tightness --

Fuel and oil Ensure proper levels 66

Coolant level (if applicable) Ensure proper level --

Coolant hoses (if applicable) Inspect for leaks --

Throttle Ensure proper operation 33, 73

Indicator lights / switches Ensure operation 31, 32

Engine stop switch Ensure proper operation 31

Drive chain Check condition / slack, lubricate as needed

79, 80

Air filter, pre-filter Inspect, clean 84

Air box sediment tube Drain deposits whenever visible --

Headlamp Check operation, apply Polaris dielec- tric grease when lamp is replaced

82

Brake light / tail lamp Check operation, apply Polaris dielec- tric grease when lamp is replaced

83

Riding gear Wear helmet, goggles, protective clothing

30

43

OPERATION Starting the 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.

1. Position the vehicle on a level surface.

2. Place the transmission in neutral.

3. Lock the parking brake.

NOTE: The starter interlock will prevent the engine from starting if the transmission is in gear and the brake is not engaged.

4. Turn the fuel valve on. 5. Sit on the vehicle.

NOTE: Do not use the choke if starting a warm engine. Excessive use of the choke can cause the spark plug to become wet fouled.

6. If the engine is cold, pull the choke knob out until it stops (1).

NOTE: The variable choke is fully on when the knob is pulled completely out. The choke is off when the knob is pushed completely in. The choke can be adjusted gradually, depending on how much choke is needed for starting. Be sure the choke is off during operation, as excess fuel washing into the engine oil will increase wear on engine components.

NOTE: If the knob doesnt stay where positioned, increase the tension by rotating the tension adjusting nut (2) clockwise.

1

2

44

OPERATION Starting the Engine 7. Move the engine stop switch to RUN.

NOTE: Do not press the throttle while starting the engine.

8. 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.

9. If the engine does not start, release the key and wait five seconds. Activate the starter for another five seconds. Repeat this procedure until the engine starts.

NOTE: If a warm engine has cooled to a point where it does not readily start, intermittent use of the choke button (pulled half way out) may be necessary. If the engine is over-choked when warm, depress the throttle lever fully while cranking to aid in starting. Release the throttle lever immediately after the engine starts. If the engine does not start and all conditions are favorable, change the spark plug and try again.

10. If the engine slows, position the choke knob half way in to allow proper engine warm up. Vary the engine RPM slightly with the throttle to aid in warm-up. When the engine idles smoothly, push the choke completely in.

CAUTION Operating the vehicle immediately after starting could cause engine damage. Allow the engine to warm up for several minutes before operating the vehicle.

45

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. Release the parking brake. 5. Slowly depress the throttle with your right thumb and begin

driving. Vehicle speed is controlled by the amount of throttle opening.

6. Drive slowly. Practice maneuvering and using the throttle and brakes on level surfaces.

46

OPERATION Driving Safely Hauling Cargo

Accessory racks and hitches are available from your Polaris dealer. Always read and understand the load distribution warnings on all warning labels, and never exceed the specified weight capacities for the vehicle.

Maximum Towing Capacities Refer to the specifications at the rear of this manual for towing capacities. When towing, reduce the rear rack cargo load capacity by the amount of trailer tongue weight.

Never tow any trailer on a grade steeper than 15.

2/3 1/3

47

OPERATION Driving Safely 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. S CARGO WEIGHT DISTRIBUTION should be 1/3 on the front rack and 2/3 on the rear rack. When operating over rough or hilly terrain, reduce speed and cargo to maintain stable driving conditions. Carrying loads on one rack only increases the pos- sibility of vehicle overturn. S LOADS MUST BE CARRIED AS LOW ON THE RACKS AS POSSIBLE. Carrying loads high on the racks raises the center of gravity of the vehicle and creates a less stable operating condition. When cargo loads are carried high on the racks, the weight of the loads must be reduced to maintain stable operat- ing conditions. S ALL LOADS MUST BE SECURED BEFORE OPERATING. Unsecured loads can create unstable operating conditions, which could result in loss of control of the vehicle. S OPERATE ONLY WITH STABLE AND SAFELY ARRANGED LOADS. When handling off-centered loads that cannot be cen- tered, securely fasten load and operate with extra caution. Al- ways attach the tow load to the hitch point designated for your vehicle. S HEAVY LOADS CAN CAUSE BRAKING AND CONTROL PROBLEMS. Use extreme caution when applying brakes with a loaded vehicle. Avoid terrain or situations that may require backing downhill. S EXTREME CAUTION MUST BE USED when operating with loads extending over the rack sides. Stability and maneuver- ability may be adversely affected, causing the machine to over- turn. S DO NOT BLOCK THE FRONT HEADLIGHT BEAM when carry- ing loads on the front rack. S DO NOT TRAVEL FASTER THAN THE RECOMMENDED SPEEDS. Vehicle should never exceed 10 mph (16 kph) while towing a load on a level grass surface. Vehicle speed should never exceed 5 mph (8 kph) when towing loads in rough terrain, while cornering, or while ascending or descending a hill.

48

OPERATION Driving Safely Making Turns

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

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. This technique alters the balance of traction between the rear wheels, allowing the turn to be made smoothly. The same leaning technique should be used for turning in reverse.

NOTE: Practice making turns at slow speeds before attempting to turn at faster speeds.

WARNING Turning at sharp angles or at excessive speeds can result in vehicle overturn and lead to serious injury. Avoid turning at sharp angles. Never turn at high speeds.

49

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. 3. Correct a skid by turning the handlebars in the direction of the skid

and shifting your body weight forward.

WARNING Failure to exercise care when operating on slippery surfaces can result in loss of tire traction and cause loss of control, accident, and serious injury or death. Never apply the brakes during a skid. Do not operate on excessively slippery surfaces. Always reduce speed and use additional caution.

50

OPERATION Driving Safely Driving Uphill

WARNING Braking and handling are greatly affected when operating in hilly terrain. Improper procedure 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 owners manual.

25_ Maximum

51

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. 6. Remain alert and be prepared to take emergency action.

This may include quick dismounting of the vehicle. If all forward speed is lost: Keep your weight uphill. Apply the single lever brake, gradually. When fully stopped, apply the auxiliary brake as well, then lock the park brake.

If the ATV begins rolling backwards: Keep your weight uphill. Never apply engine power. Never apply the auxiliary rear brake while rolling backwards. Apply the single-lever brake, gradually. When fully stopped, apply the auxiliary rear brake as well, and then lock the parking brake. Dismount on uphill side, or to either side if ATV is pointed straight uphill. Turn the ATV around and remount, following the procedure described on page 54.

52

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.

NOTE: Familiarize yourself with operation of the auxiliary rear brake pedal for additional braking in the event of normal service brake loss.

WARNING Excessive speed can cause loss of control and lead to serious injury or death. Always operate slowly when traveling downhill.

53

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 owners manual.

Sidehilling can be a dangerous type of driving and should be avoided if at all possible. If you do enter into a situation where sidehilling is necessary, follow these precautions:

1. Slow down. 2. Lean into the hill, transferring your upper bodyweight toward the hill

while keeping your feet on the footrests. 3. Steer slightly into the hill to maintain vehicle directions.

NOTE: If the vehicle begins to tip, quickly turn the front wheel downhill, if possible, or dismount on the uphill side immediately!

8 (2.4 m)

54

OPERATION Driving Safely Turning Around on a Hill If the vehicle stalls while climbing a hill, never back it down the hill! Use the K-turn to turn around.

1. Stop and lock the parking brake while keeping body weight uphill. 2. Leave the transmission in forward and shut off the engine. 3. Dismount on the uphill side of the vehicle, or on the left if the

vehicle is pointing straight uphill. 4. Staying uphill of the vehicle, turn the handlebars full left. 5. While holding the brake lever, release the parking brake lock and

slowly allow the vehicle to roll around to your right until its pointing across the hill or slightly downward.

6. Lock the parking brake and remount the vehicle from the uphill side, keeping body weight uphill.

7. Restart the engine with the transmission still in forward. 8. Release the parking brake and proceed slowly, controlling speed

with the brake, until the vehicle is on more level ground.

55

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. Choose a crossing where both banks have gradual inclines.

3. Proceed slowly, avoiding rocks and obstacles if possible. 4. After crossing, dry the brakes by applying light pressure to the

lever until braking action is normal. After running the vehicle in water, its critical to have it serviced as outlined in the maintenance chart. See page 60. The following areas need special attention: engine oil, transmission oil, front and rear gearcases (if equipped), and all grease fittings.

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.

NOTE: Avoid operating the vehicle through deep or fast-flowing water. If you cannot avoid water that exceeds the recommended maximum depth, go slowly, balance your weight carefully, avoid sudden movements, and maintain a slow and steady forward motion. Do not make sudden turns or stops, and do not make sudden throttle changes.

If your vehicle becomes immersed, and its impossible to take it to a dealer before starting it, follow the steps described on page 87. Have the vehicle serviced by your dealer at the first opportunity.

1

56

OPERATION Driving Safely Driving Over Obstacles

Be alert! Look ahead and learn to read the terrain youre 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. Not all obstacles are immediately visible. Travel with caution in unfamiliar terrain.

57

OPERATION Driving Safely Driving in Reverse Follow these precautions when operating in reverse:

1. Always avoid backing downhill.

2. Back slowly. 3. When in reverse,

apply the brakes lightly for stopping.

4. Avoid turning at sharp angles in reverse.

5. Never open the throttle suddenly while backing.

WARNING Failure to use caution when operating in reverse can result in serious injury or death. Before shifting into reverse, always check for obstacles or people behind the vehicle. When its safe to proceed, back slowly. Do not use the override switch unless additional power is required for vehicle movement. Use with caution. Avoid backing on inclines, and avoid turning at sharp angles.

NOTE: This Polaris ATV is 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.

CAUTION Excessive throttle operation while in the speed limit mode may cause fuel to build in the exhaust, resulting in engine popping and/or engine damage.

58

OPERATION Driving Safely Parking on an Incline

Avoid parking on an incline if possible. If its unavoidable, follow these precautions:

1. Turn the engine off. 1. Place the transmission in gear. 2. Set the parking brake. 3. Always block the rear wheels on the downhill side. See

illustration. 4. Shut off the fuel supply.

59

EMISSION CONTROL SYSTEMS Noise Emission Control System Do not modify the engine, intake or exhaust components, as doing so may affect compliance with U.S.A. EPA noise control requirements (40 CFR 205) and local noise level requirements.

Operation on Public Lands in the U.S.A. Your Polaris vehicle has a spark arrestor that was tested and qualified to be in accordance with the USDA Forest Service Standard 5100-1C. Federal law requires that this spark arrestor be installed and functional when the vehicle is operated on public lands.

Operation of off-road vehicles on public lands in the U.S.A. is regulated by 43 CFR 8343.1(c). Violations are subject to monetary penalties. Federal regulations can be viewed online at www.gpoaccess.gov/ecfr/.

Crankcase Emission Control System This engine is equipped with a closed crankcase system. Blow-by gases are forced back to the combustion chamber by the intake system. All exhaust gases exit through the exhaust system.

Exhaust Emission Control System The emissions from the exhaust of this vehicle are controlled by engine design, including factory-set fuel delivery and ignition. The engine and related components must be maintained at Polaris specifications to achieve optimal performance.

Engine idle speed is the only adjustment Polaris recommends that the operator perform. Any other adjustments should be performed by an authorized Polaris dealer.

The emissions label is located on the left front portion of the frame or under the seat.

Electromagnetic Interference This spark ignition system complies with Canadian ICES-002.

This vehicle complies with the EMC requirements of European directives 97/24/EC and 89/336/EEC.

60

MAINTENANCE Periodic Maintenance Chart Careful periodic maintenance will help keep your vehicle in the safest, most reliable condition. Inspection, adjustment and lubrication of important components are explained in the periodic maintenance chart.

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 116.

NOTE: Service and adjustments are important for proper vehicle operation. If youre not familiar with safe service and adjustment procedures, have a qualified dealer perform these operations.

Maintenance intervals in the following chart are based upon average riding conditions and an average vehicle speed of approximately 10 miles per hour. Vehicles subjected to severe use must be inspected and serviced more frequently.

Severe Use Definition S Frequent immersion in mud, water or sand S Racing or race-style high RPM use S Prolonged low speed, heavy load operation S Extended idle S Short trip cold weather operation Pay special attention to the oil level. A rise in oil level during cold weather can indicate contaminants collecting in the oil sump or crankcase. Change oil immediately if the oil level begins to rise. Monitor the oil level, and if it continues to rise, discontinue use and determine the cause or see your dealer.

61

MAINTENANCE Periodic Maintenance Chart Maintenance Chart Key " Perform these procedures more frequently for vehicles subjected to

severe use. E Emission-related service (Failure to conduct this maintenance will

not void the emissions warranty but may affect emissions.) J Have an authorized Polaris dealer perform these services.

WARNING Improperly performing the procedures marked with a J could result in component failure and lead to serious injury or death. Have an authorized Polaris dealer perform these services.

Perform all services at whichever maintenance interval is reached first.

Item Maintenance Interval (whichever comes first)

Remarks

Hours Calendar Miles (Km)

J Steering -- Pre-Ride -- Make adjustments as need- ed See Pre Ride Checklist

" Front suspension -- Pre-Ride -- . -

on page 42. " Rear suspension -- Pre-Ride --

Tires -- Pre-Ride --

" Brake fluid level -- Pre-Ride --

" Brake lever travel -- Pre-Ride --

Brake system -- Pre-Ride --

Wheels/fasteners -- Pre-Ride --

Frame fasteners -- Pre-Ride --

" Engine oil level -- Pre-Ride --

"

E Air filter, pre-filter -- Daily -- Inspect; clean often; replace

as needed

" Air box sediment tube

-- Daily -- Drain deposits when visible

Coolant (if applicable)

-- Daily -- Check level daily, change coolant every 2 years

Headlamp/tail lamp

-- Daily -- Check operation; apply dielectric grease if replacing

"

E Air filter, main element

-- Weekly -- Inspect; replace as needed

Recoil housing -- Weekly -- Drain water as needed, check often if operating in wet conditions

62

MAINTENANCE Periodic Maintenance Chart

Item Maintenance Interval (whichever comes first)

Remarks

Hours Calendar Miles (Km)

"

J

Brake pad wear 10 H Monthly 100 (160) Inspect periodically

Battery 20 H Monthly 200 (320) Check terminals; clean; test

" Transmission oil 25 H Monthly 250 (400) Inspect level; change yearly

"

E Engine breather filter (if equipped)

25 H Monthly 250 (400) Inspect; clean if needed

" General lubrication

50 H 3 M 500 (800) Lubricate all fittings, pivots, cables, etc.

Carburetor float bowl

50 H 6 M 500 (800) Drain bowl periodically and prior to storage

J

E Throttle Cable/ ETC Switch

50 H 6 M 500 (800) Inspect; adjust; lubricate; replace if necessary

J

E Choke cable 50 H 6 M 500 (800) Inspect; adjust; lubricate;

replace if necessary

E Carburetor air intake ducts/ flange

50 H 6 M 500 (800) Inspect ducts for proper sealing/air leaks

Drive belt 50 H 6 M 500 (800) Inspect; adjust; replace as needed

Cooling system (if applicable)

50 H 6 M 1000 (1600) Inspect coolant strength seasonally; pressure test system yearly

" Engine oil change 100 H 6 M 1000 (1600) Perform a break-in oil change at one month

" Oil filter change 100 H 6 M 1000 (1600) Replace with oil change

" Oil tank vent hose 100 H 12 M 1000 (1600) Inspect routing, condition

J

E Valve clearance 100 H 12 M 1000 (1600) Inspect; adjust

J

E Fuel system/filter 100 H 12 M 1000 (1600) Check for leaks at tank cap,

lines, fuel valve, filter, pump, carburetor; replace lines every two years

" Radiator (if applicable)

100 H 12 M 1000 (1600) Inspect; clean external surfaces

63

MAINTENANCE Periodic Maintenance Chart

Item Maintenance Interval (whichever comes first)

Remarks

Hours Calendar Miles (Km)

" Cooling hoses (if applicable)

100 H 12 M 1000 (1600) Inspect for leaks

" Engine mounts 100 H 12 M 1000 (1600) Inspect

Exhaust muffler/ pipe

100 H 12 M 1000 (1600) Inspect

J

E Spark plug 100 H 12 M 1000 (1600) Inspect; replace as needed

J

E Ignition Timing 100 H 12 M 1000 (1600) Inspect

" Wiring 100 H 12 M 1000 (1600) Inspect for wear, routing, security; apply dielectric grease to connectors subjected to water, mud, etc.

J Clutches (drive and driven)

100 H 12 M 1000 (1600) Inspect; clean; replace worn parts

J Front wheel bearings

100 H 12 M 1000 (1600) Inspect; replace as needed

J Brake fluid 200 H 24 M 2000 (3200) Change every two years

Spark arrestor 300 H 36 M 3000 (4800) Clean out

Idle speed -- Adjust as needed

J Toe adjustment -- Inspect periodically; adjust when parts are replaced

Headlight aim -- Adjust as needed

" Perform these procedures more often for vehicles subjected to severe use. E Emission-Related Service J Have an authorized Polaris dealer perform these services.

64

MAINTENANCE Lubrication Recommendations Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart beginning on page 60. Items not listed in the chart should be lubricated at the General Lubrication interval.

NOTE: The a-arms and lower control arms are lubricated at the factory, and no additional lubrication will be needed. However, if these components are subjected to severe use, grease zerks have been provided for additional lubrication at the users discretion.

Lubrication Chart Key " More often under severe use, such as wet or dusty conditions L Polaris Premium All Season Grease or grease conforming to NLG

No. 2, such as Conoco Superlube M or Mobilegrease Special F Use Polaris Premium U-Joint Lube every 500 miles, before long

periods of storage, or after pressure washing or submerging When suspension action becomes stiff, or after washing

Item Lube Method

Engine Oil PS-4 PLUS Performance Synthetic 2W-50

Add to proper level on dipstick.

Brake Fluid DOT 4 fluid only Maintain level between fill lines. See page 35.

Drive chain(s) O-ring chain lube or SAE 80/90

Lubricate.

(1) Transmission AGL Synthetic Gearcase Lube

Maintain as recommended on page 68.

(2) Swing Arm Bushings

"LGrease Locate fittings on swing arm and grease with grease gun.

(3) Tie Rod Ends "LGrease Lift boot, clean away dirt and grease, apply fresh grease by hand and reassemble.

(4) Axle Housing "L Grease Locate fittings on swing arm and grease with grease gun.

65

MAINTENANCE Lubrication Recommendations

(1)

(2)

(3)

(4)

66

MAINTENANCE Engine Oil Always check and change the engine oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 60. Always change the oil filter whenever changing oil. Oil Recommendations Polaris recommends the use of Polaris PS-4 PLUS Performance Synthetic 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 manufacturers recommendations for ambient temperature operation.

See page 107 for the part numbers of Polaris products.

CAUTION Mixing brands or using a non-recommended oil may cause serious engine damage. Always use the recommended oil. Never substitute or mix oil brands.

Oil Check The oil fill is located on the left side of the vehicle (1).

1. Position the machine on a level surface. 2. Start the engine and let it idle for 20-30 seconds. Stop the engine. 3. Remove the dipstick and wipe it dry with a clean cloth. 4. Screw the dipstick completely in. 5. Remove the dipstick and read the oil level. Maintain the oil level in

the safe operating range (2). Do not overfill.

1

2

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MAINTENANCE Engine Oil Oil and Filter Change 1. Position the vehicle on a level surface. 2. Clean the area around the drain plug. 3. Run the engine for two to three minutes until warm. Stop the

engine.

CAUTION Contact with hot oil may result in serious burns. Do not allow hot oil to come into contact with skin.

4. Place a drain pan beneath the engine crankcase and remove the drain plug.

5. Allow the oil to drain completely. 6. Install a new sealing washer on the drain plug.

NOTE: The sealing surfaces on the drain plug and crankcase should be clean and free of burrs, nicks or scratches.

7. Reinstall the drain plug and torque to 14 ft. lbs. (19 Nm). 8. Place shop towels beneath the oil filter. Using an oil filter wrench,

turn the filter counterclockwise to remove. 9. Using a clean, dry cloth, clean the filter sealing surface on the

crankcase. 10. Lubricate the gasket on the new filter with a film of engine oil.

Check to make sure the gasket is in good condition. 11. Install the new filter and turn by hand until the filter gasket

contacts the sealing surface, then turn and additional 1/2 turn. 12. Remove the dipstick and fill the sump with 1.7 quarts (1.6 l) of the

recommended oil. 13. Place the gear selector in neutral and set the parking brake. 14. Start the engine and let it idle for one to two minutes. Stop the

engine and inspect for leaks. 15. Recheck the oil level and add oil as necessary to bring the level to

the upper mark on the dipstick. 16. Dispose of used filter and oil properly.

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MAINTENANCE Transmission Oil Always check and change the transmission oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 60. Maintain the oil level at the bottom of the fill hole threads. We recommend the use of Premium AGL Synthetic Gearcase Lubricant. See page 107 for the part numbers of Polaris products. Oil Check The transmission dipstick (1) is located on the right side of the machine near the recoil handle.

NOTE: We recommend the use of Polaris Premium AGL Synthetic Gearcase Lube. See page 107 for the part numbers of Polaris products.

1. Position the ATV on a level surface. Remove the dipstick and wipe it clean.

2. Reinstall the dipstick completely, then remove it and check the level. Add the recommended lubricant to bring the level into the safe operating range. See Specifications beginning on page 104 for capacity.

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MAINTENANCE Transmission Oil Oil Change 1. Place a drain pan beneath the

transmission oil drain plug area.

2. Loosen the jam nut (A). 3. Turn the adjuster bolt (B) in to

allow the removal of the drain plug (C).

4. Remove the drain plug and wipe the magnetic end clean to remove accumulated metallic filings.

5. After the oil has drained completely, install a new sealing washer and reinstall the drain plug. Torque to 14 ft. lbs. (19 Nm).

6. Turn the adjuster bolt (B) out until it touches the frame, and then turn an additional 1/2 turn.

7. Tighten the jam nut securely while holding the adjuster bolt. 8. Add the recommended lubricant through the dipstick hole until the

oil level is between the upper and lower limits. Do not overfill. 9. Check for leaks.

A

B

C

A

B

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MAINTENANCE Toe Alignment

WARNING Severe injury or death can result from improper toe alignment and adjustment. Do not attempt to adjust tie rod alignment. All tie rod adjustments should be performed by an authorized Polaris dealer.

Use the following procedure to check the toe alignment of the vehicle. The recommended toe alignment is 1/8 to 1/4 toe out.

1. Position the vehicle on a level surface.

2. Set the handlebars in a straight-ahead position and secure them in this position.

3. Place a chalk mark on the center line of the front tires approximately 10 (25.4 cm) from the floor, or as close to the hub/axle center line as possible. Make sure both marks are the same distance from the floor.

4. Measure the distance between the marks and record the measurement (A).

5. Move the vehicle until the chalk marks are at the rear of the tires, even with the hub/axle centerline.

6. Measure the distance between the marks and record the measurement (B).

7. Subtract measurement B from measurement A. The difference is the vehicle toe-out alignment.

NOTE: If you discover improper alignment, see your Polaris dealer for service.

71

MAINTENANCE 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 in hilly country or in muddy terrain.

WARNING Never store or use a partial bottle of brake fluid. Brake fluid is hygroscopic, meaning it rapidly absorbs moisture from the air. The moisture causes the boiling temperature of the brake fluid to drop, which can lead to early brake fade and the possibility of accident or severe injury. After opening a bottle of brake fluid, always discard any unused portion.

1. Always maintain brake fluid at an adequate level (see page 35).

WARNING An over-full master cylinder may cause brake drag or brake lock-up, which could result in serious injury or death. Maintain brake fluid at the recommended level. Do not overfill.

NOTE: Under normal operation, the diaphragm extends into the reservoir as fluid level drops. If the fluid level is low and the diaphragm is not extended, a leak is likely and the diaphragm should be replaced. Always fill the reservoir as needed whenever the cover is loosened or removed to ensure proper diaphragm operation. Use Polaris DOT 4 brake fluid. Do not overfill.

72

MAINTENANCE Brakes 1. Check the brake system for fluid leaks. 2. Check the brakes for excessive travel or

spongy feel. 3. Check the friction pads for wear,

damage and looseness. 4. Check the security and surface

condition of the disc.

NOTE: Pads should be changed when worn to 3/64 (.1 cm).

Auxiliary Brake The auxiliary brake system is intended to be used as a backup for the main brake system. Should the main system fail, the rear brake can be activated by depressing the foot pedal on the inside of the right footrest. The hydraulic auxiliary brake system requires no adjustment.

NOTE: Since this is a rear brake only, it will not be as effective as the all-wheel single lever system.

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.

Rear Spring The rear shock absorber spring is adjusted by rotating the adjuster (1) either clockwise or counterclockwise to increase or decrease spring tension.

NOTE: Accessory springs are available through your Polaris dealer.

3/64 (.1 cm)

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23

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MAINTENANCE Throttle Cable Freeplay Throttle cable freeplay is adjusted at the handlebar. 1. Locate the throttle cable

adjuster on the handlebar.

2. Squeeze the end of the rubber boot (1) and slide it far enough to expose the end of the inline cable adjuster (2).

3. Loosen the locknut (3). 4. Rotate the boot to turn

the adjuster until 1/16 to 1/8 (2-3 mm) freeplay is achieved at the thumb lever.

NOTE: While adjusting freeplay, be sure to flip the throttle lever back and forth.

5. Tighten the locknut. 6. Squeeze the end of the

rubber boot and slide it over the cable adjuster to its original position.

74

MAINTENANCE Handlebars

WARNING Improper adjustment of the handlebars or incorrect torquing of the adjuster block tightening bolts can cause limited steering or loosening of the handlebars, resulting in loss of control and possible serious personal injury or death. Follow the adjustment procedures exactly, or see your Polaris dealer for service.

The handlebars can be adjusted for rider preference.

1. Remove the handlebar cover to access the handlebar bolts (1).

2. Loosen the four bolts. 3. Adjust the handlebar to the

desired height. Be sure the handlebars do not contact the gas tank or any other part of the machine when turned fully to the left or right.

4. Torque the two front bolts to 10-12 ft. lbs. (14-17 Nm), then torque the two rear bolts. A gap of up to 1/8 will remain at the rear bolts.

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MAINTENANCE Carburetor IMPORTANT: Your Polaris ATV is calibrated at the factory for optimal performance at altitudes ranging from zero to 6,000 feet (1800 m) and temperatures of +40 degrees F. (4 degrees C.) or higher. Above 6000 feet (1800 m) the engine air/fuel mixture becomes overly rich and the engine loses approximately 3% of its power for each 1000-foot (304.8 m) increase in elevation. Although this power cannot be regained, adjustments to the carburetor and drive system can be made to allow more efficient operation. Optional jets, available from your Polaris dealer, are required for operation above 6,000 feet and temperatures below +40 degrees F. (4 degrees C.)

NOTE: Continuous operation of the engine without proper jetting when required can cause poor performance, overheating and engine or PVT 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.

1. Warm up the engine by running the vehicle for approximately five minutes.

2. Place the transmission in gear and engage the parking brake.

3. Adjust the carburetor idle screw (1) either in or out until the desired idle RPM is reached. Refer to the specifications section beginning on page 104 for the proper setting.

NOTE: Turn the screw in (clockwise) to raise RPM. Turn the screw out (counterclockwise) to lower RPM.

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76

MAINTENANCE Wheels

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 owners manual. Always use original equipment size and type when replacing tires. Make sure the wheels are installed properly. Always replace tires when the tread depth measures 1/8 (.3 cm) or less.

Wheel Removal 1. Stop the engine, place the transmission in gear and lock the

parking brake. 2. Loosen the wheel nuts slightly. 3. Elevate the side of the vehicle by placing a suitable stand under the

footrest frame. 4. Remove the wheel nuts and remove the wheel.

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MAINTENANCE Wheels Wheel Installation 1. Place the transmission in gear and lock the parking brake.

WARNING Improperly installed wheels can adversely affect tire wear and vehicle handling, which can result in serious injury or death. Always ensure that all nuts are torqued to specification. Do not service axle nuts that have a cotter pin installed. See your Polaris dealer.

2. Place the wheel on the wheel hub with the valve stem toward the outside and rotation arrows on the tire pointing toward forward rotation.

3. Install the wheel nuts and finger tighten. On vehicles with tapered rear wheel nuts, make sure the tapered ends of the nuts fit into the tapers on the wheels.

4. Lower the vehicle to the ground. 5. Torque the nuts to specification.

Wheel Nut Torque Specifications Check the wheel nut torques occasionally and when theyve been loosened for maintenance.

Item Specification

Front Wheel Nuts 27 ft. lbs. (37 Nm)

Rear Wheel Nuts 50 ft. lbs. (68 Nm)

27 ft. lbs. (37 Nm)

Rear

50 ft. lbs. (68 Nm)

Front

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MAINTENANCE Wheels Front Wheel Hub Tightening Front wheel bearing tightness and spindle nut retention are critical component operations. All service must be performed by your authorized Polaris dealer.

Tire Tread Depth Always replace tires when tread depth is worn to 1/8 (.3 cm) or less. See illustration.

WARNING Operating the vehicle with worn tires will increase the possibility of skidding, which could lead to loss of control and serious injury or death. Always replace tires when the tread depth measures 1/8 (.3 cm) or less.

WARNING Use of non-standard size or type of tires or improper tire inflation may adversely affect vehicle maneuverability and cause loss of control resulting in serious injury or death. Maintain proper tire pressure as outlined in this owners manual. When replacing a tire always use original equipment size and type.

1/8I (.3 cm)

79

MAINTENANCE Drive Chain Polaris ATV drive chains are equipped with o-ring-sealed, permanently greased pins and rollers. However, the outer surfaces of the roller must be lubricated.

Always inspect the drive chain prior to operating the vehicle. Check for damaged or missing o-rings or damaged rollers. Also check for correct slack adjustment. Maintain the stone guard to rear sprocket clearance at 1/8 (.3 cm).

Regularly lubricate the drive chain with Polaris Chain Lube, an SAE 80-90 lube or an approved o-ring chain spray lube. See page 107 for the part numbers of Polaris products.

CAUTION Washing the drive chain with a high pressure washer or gasoline can cause damage to the o-rings, causing premature wear and drive chain failure. Do not use a high pressure washer or gasoline to clean the drive chain.

80

MAINTENANCE Drive Chain 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.

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 (.48 cm - .95 cm) deflection. Use the following procedure if adjustment is required.

1. Remove the chain guard. 2. Loosen the chain guide. 3. Loosen the two eccentric

locking bolts (1). 4. Loosen the caliper mounting

bolt located on the left side of the swing arm.

5. Insert a pin punch (2) through the sprocket hub and into the eccentric housing.

3/16-3/8 (.48 cm - .95 cm)

1

2

1

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MAINTENANCE Drive Chain Rear Drive Chain Slack 6. Roll the ATV forward or backward

to adjust the chain slack to the proper tension. See the illustration for proper splice link clip opening position (1).

7. Tighten the eccentric locking bolts to 30 ft. lbs. (41 Nm) for machines without the hitch and 45 ft. lbs. (61 Nm) for machines with a hitch.

8. Tighten the caliper mount bolt to 15 ft. lbs. (20 Nm). 9. Remove the pin punch. 10. Roll the ATV forward, checking chain tension in several places

around the chain.

NOTE: The chain is adjusted correctly when the tightest portion of the chain has approximately 3/8 (10mm) deflection.

11. Position the chain guide to allow 1/8 (3mm) clearance and tighten the retaining bolt to 5 ft. lbs. (7 Nm).

12. Reinstall the chain guard.

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MAINTENANCE Lights When servicing a halogen lamp, dont 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. Wash the headlights frequently to maintain lighting quality. Hot components can cause serious burns to skin. Do not service the headlamps until theyve cooled sufficiently.

Headlight Lamp Replacement 1. Remove the front cover and unplug the light harness. 2. Remove the rubber cap from the back of the headlight to reveal the

retention screw. 3. Remove the small phillips head screw, and carefully remove the

bulb from the housing. 4. Insert the new bulb into the housing and reinstall the retention

screw. Reinstall the rubber cap. 5. Reconnect the light harness and reinstall the cover. 6. Adjust the headlight aim if necessary.

83

MAINTENANCE 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). 3. Apply dielectric grease to the

socket and install the new lamp.

4. Test the taillight/brakelight for proper operation.

5. Reinstall the gasket and lens cover.

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 plier or similar tool, pull the lamp out of the

indicator panel housing. 4. Insert the new bulb and seat it by turning it 1/4 turn clockwise. 5. Reinstall the instrument panel if removed.

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84

MAINTENANCE Air Filter 1. Remove the seat, release the

clips, and remove the air box cover.

2. Loosen the clamp and remove the filter.

3. If equipped, remove the fabric type pre-filter (1) from the main filter (2). Wash the pre-filter in soapy water, then rinse and let dry. Reinstall the pre-filter over the main filter.

4. Replace the main filter with a new filter if needed.

5. Reinstall the filter into the air box and tighten the clamp. Do not over tighten the clamp, as filter damage could occur.

2

1

85

MAINTENANCE Spark Plugs Spark Plug Recommendations

CAUTION Using non-recommended spark plugs can result in serious engine damage. Always use Polaris-recommended spark plugs. Refer to the specifications section beginning on page 104.

Refer to the specifications section beginning on page 104 for the recommended spark plug type and gap for your vehicle. Torque spark plugs to specification.

Plug Condition Torque Specification

New Spark Plug 9-11 ft. lbs. (12-15 Nm)

Previously Installed Spark Plug 17-20 ft. lbs. (23-27 Nm)

Spark Plug Inspection Spark plug condition is indicative of engine operation. Check the spark plug firing end condition after the engine has been warmed up and the vehicle has been driven at higher speeds. Immediately check the spark plug for correct color. See page 86.

WARNING A hot exhaust system and engine can cause serious burns. Wear protective gloves when removing a spark plug for inspection.

1. Remove the spark plug cap. 2. Using the special wrench provided in the tool pouch, rotate the

spark plug counterclockwise to remove it. 3. Reverse the procedure for spark plug installation. Torque to

specification.

86

MAINTENANCE Spark Plugs Spark Plug Inspection Normal 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 indicates the proper type and heat range for the engine and the service.

NOTE: The tip should not be white. A white insulator tip indicates overheating, caused by use of an improper spark plug or incorrect carburetion adjustments.

Wet Fouled Plug The wet fouled insulator tip is black. A damp oil film covers the firing end. There may be a carbon layer over the entire nose. Generally, the electrodes are not worn. General causes of fouling are excessive oil, use of non-recommended injection oil, improper use of the choke, or incorrect carburetion adjustments.

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.

The drain screw is located at the bottom of the recoil housing. Use a wrench to remove the screw. Be sure to reinstall the screw after draining the housing.

NOTE: Do not open the crankcase drain unless the engine has ingested water. On 4-cycle engines, some engine oil will be lost if the crankcase drain is opened.

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MAINTENANCE 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 its impossible to take your ATV to a dealer before starting it, follow the steps outlined below.

1. Move the ATV to dry land or at the very least, to water below the footrests.

2. Check the airbox for any water. Drain and dry it if water is present.

3. Turn the fuel valve off. 4. Remove the spark plug. 5. Turn the engine over several times

using the electric start. 6. Loosen the carburetor drain screw (1). 7. Dry the spark plug and reinstall, or replace it with a new plug. 8. Tighten the carburetor drain screw. 9. Turn the fuel valve on. 10. Attempt to start the engine. If necessary, repeat the drying

procedure. 11. Take the ATV to your dealer for service as soon as possible,

whether you succeed in starting it or not.

NOTE: If water has been ingested into the PVT, follow the procedure on page 89 for drying out the PVT.

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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. Similarly, if the engine speed decreases, the amount of centrifugal force decreases, reducing the amount of belt pinch. This begins to occur at speeds of less than 5 MPH, due to the systems dependence on engine speed.

For example, when operating at a ground speed of 3 MPH, the engine would be running at only about 1500 RPM, with an engagement speed of about 1400 RPM. Whenever operating this close to the engagement point, the engine may be running at a speed too low to provide the adequate pinch needed to prevent incomplete engagement. Incomplete engagement creates excessive heat that can destroy belts and clutch covers. In some cases, excessive clutch wear and damage may result.

If the ATV will be operated for extended periods below 5 MPH, or for towing loads, we recommend that you install a one tooth smaller counter shaft sprocket to raise the operating RPM far enough above the engagement RPM to reduce heat caused by incomplete engagement. Reducing the temperature inside the clutch cover extends the life of the PVT components (belt, cover, etc.).

NOTE: Avoid heavy pulling and extended low-speed operation.

89

MAINTENANCE PVT System

WARNING Failure to comply with the instructions in this warning can result in severe injury or death. Do not modify any component of the PVT system. Doing so may reduce its strength so that a failure may occur at a high speed. The PVT system has been precision balanced. Any modification will cause the system to be out of balance, creating vibration and additional loads on components. The PVT system rotates at high speeds, creating large amounts of force on clutch components. Extensive engineering and testing has been conducted to ensure the safety of this product. However, as the owner, you have the following responsibilities to make sure this system remains safe: Always follow all recommended maintenance procedures. See your dealer as outlined in the owners 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.

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 operating:

1. Remove the drain plug and allow the water to drain. Reinstall the drain plug.

2. Start the engine and shift the transmission into neutral. Apply varying throttle for 10-15 seconds to expel the moisture and air-dry the belt and clutches. Do not hold the throttle wide open for more than 10 seconds.

3. Allow the engine RPM to settle to idle speed, then shift the transmission to the lowest available range.

4. Test for belt slippage. If the belt slips, repeat the process. 5. Take the vehicle to your dealer for service as soon as possible.

90

MAINTENANCE 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. Remove any combustible materials from the area. Wear eye protection and leather work gloves. Do not stand behind or in front of the vehicle while purging. Never run the engine in an enclosed area. Exhaust contains poisonous carbon monoxide gas. Never go under the vehicle while its inclined.

1. Remove the arrestor clean-out plug (1) from the bottom of the muffler.

2. Place the transmission in neutral and start the engine.

3. Purge carbon from the system by momentarily revving the engine several times.

4. If carbon is expelled, cover or plug the exhaust outlet (2) and rap on the pipe around the cleanout plug while revving the engine several more times.

5. If particles are still suspected to be in the muffler, elevate the rear of the vehicle one foot higher than the front. Set the parking brake and block the wheels. Make sure the vehicle is in neutral and repeat steps 3 and 4 until no more particles are expelled when the engine is revved.

6. Stop the engine and allow the arrestor to cool. Reinstall the arrestor plug and remove the outlet cover or plug.

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91

MAINTENANCE Battery Your ATV may have either a sealed battery, which requires little maintenance, or a conventional battery. A sealed battery can be identified by its flat covers on the top of the battery. A conventional battery has six filler caps on the top of the battery. Always keep battery terminals and connections free of corrosion. If cleaning is necessary, remove corrosion with a stiff wire brush. Wash with a solution of one tablespoon baking soda and one cup water. Rinse well with tap water and dry off with clean shop towels. Coat the terminals with dielectric grease or petroleum jelly. Be careful not to allow cleaning solution or tap water into a conventional battery.

Conventional Battery

WARNING Battery electrolyte is poisonous. It contains sulfuric acid. Serious burns can result from contact with skin, eyes or clothing. Antidote: External: Flush with water. Internal: Drink large quantities of water or milk. Follow with milk of magnesia, beaten egg, or vegetable oil. Call physician immediately. Eyes: Flush with water for 15 minutes and get prompt medical attention. Batteries produce explosive gases. Keep sparks, flame, cigarettes, etc. away. Ventilate when charging or using in an enclosed space. Always shield eyes when working near batteries. KEEP OUT OF REACH OF CHILDREN.

92

MAINTENANCE Battery

WARNING Improperly connecting or disconnecting battery cables can result in an explosion and cause serious injury or death. When removing the battery, always disconnect the negative (black) cable first. When reinstalling the battery, always connect the negative (black) cable last.

Battery Removal 1. Disconnect the hold-down strap holding the battery in position, and

remove battery cover. 2. On conventional batteries, remove the battery vent tube. 3. Disconnect the black (negative) battery cable first. 4. Disconnect the red (positive) battery cable next. 5. Lift the battery out of the ATV. Be careful not to tip a conventional

battery sideways, which could spill electrolyte.

CAUTION If electrolyte spills, immediately wash it off with a solution of one tablespoon baking soda and one cup water to prevent damage to the vehicle.

93

MAINTENANCE Battery Battery Installation Using a new battery that has not been fully charged can damage the battery and result in a shorter life. It can also hinder vehicle performance. Follow the battery charging instructions on pages 95-97 before installing the battery.

1. Ensure that the battery is fully charged.

2. Place the battery in the battery holder.

3. With conventional batteries, install the battery vent tube (sealed batteries do not have a vent tube).

NOTE: The vent tube must be free of obstructions and securely installed. Route the tube away from the frame and vehicle body to prevent contact with electrolyte.

WARNING Battery gases could accumulate in an improperly installed vent tube and cause an explosion, resulting in serious injury or death. Always ensure that the vent tube is free of obstructions and is securely installed as recommended.

4. On conventional batteries, coat the terminals with dielectric grease or petroleum jelly.

5. Connect and tighten the red (positive) cable first.

6. Connect and tighten the black (negative) cable last.

7. Install the battery cover.

8. Secure the battery hold-down strap.

9. Verify that cables are properly routed.

NOTE: Cables should be safely tucked away at the front and rear of the battery.

94

MAINTENANCE Battery Battery Storage Whenever the vehicle is not used for a period of three months or more, remove the battery from the vehicle, ensure that its fully charged, and store it out of the sun in a cool, dry place. Check battery voltage each month during storage and recharge as needed to maintain a full charge.

NOTE: Power plug leads may need to be bent down so that the battery cover can be installed.

NOTE: Battery charge can be maintained by using a Polaris Battery Tender charger or by charging about once a month to make up for normal self-discharge. Battery Tender can be left connected during the storage period, and will automatically charge the battery if the voltage drops below a pre-determined point. See page 107 for the part numbers of Polaris products.

95

MAINTENANCE Battery Battery Fluid (Conventional Battery) A poorly maintained battery will deteriorate rapidly. Check the battery fluid level often. Maintain the fluid level between the upper and lower level marks (1). Add only distilled water. Tap water contains minerals that are harmful to a battery.

Battery Charging (Conventional Battery) 1. Remove the battery from the vehicle to prevent damage from

leaking or spilled electrolyte during charging. See page 92. 2. Charge the battery with a charging output no larger than 1/10 of the

batterys amp/hr rating. Charge as needed to raise the specific gravity to 1.270 or greater.

3. Reinstall the battery. See page 93. Make sure the positive terminal is toward the front of the vehicle.

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MAINTENANCE Battery Battery Charging (Sealed Battery) The following battery charging instructions apply only to the installation of a sealed battery. Read all instructions before proceeding with the installation of this battery.

The sealed battery is already filled with electrolyte and has been sealed and fully charged at the factory. Never pry the sealing strip off or add any other fluid to this battery.

The single most important thing about maintaining a sealed battery is to keep it fully charged. Since the battery is sealed and the sealing strip cannot be removed, you must use a voltmeter or multimeter to measure DC voltage.

WARNING An overheated battery could explode, causing severe injury or death. Always watch charging times carefully. Stop charging if the battery becomes very warm to the touch. Allow it to cool before resuming charging.

For a refresh charge, follow all instructions carefully.

1. Check the battery voltage with a voltmeter or multimeter. A fully charged battery will register 12.8 V or higher.

2. If the voltage is less than 12.8 volts, recharge the battery.

NOTE: When using an automatic charger, refer to the charger manufacturers instructions for recharging. When using a constant current charger, use the following guidelines for recharging.

97

MAINTENANCE Battery Battery Charging (Sealed Battery) NOTE: Always verify battery condition before and 1-2 hours after the

end of charging.

State of Charge

Voltage Action Charge Time* (Using constant current

charger @ standard amps specified on top of battery)

100% 12.8-13.0 volts None, check at 3 mos. from date of

manufacture

None required

75%-100% 12.5-12.8 volts May need slight charge, if no charge given,

check in 3 months

3-6 hours

50%-75% 12.0-12.5 volts Needs Charge 5-11 hours

25%-50% 11.5-12.0 volts Needs Charge At least 13 hours, verify state of charge

0%-25% 11.5 volts or less Needs Charge At least 20 hours

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MAINTENANCE Cleaning and Storage See page 107 for the part numbers of Polaris products.

Washing the Vehicle Keeping your ATV clean will not only improve its appearance but it can also extend the life of various components.

CAUTION High water pressure may damage ATV components. Polaris recommends washing the vehicle by hand or with a garden hose, using mild soap. Certain products, including insect repellants and chemicals, will damage plastic surfaces. Do not allow these types of products to come into contact with 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.

2. Rinse with clean water frequently. 3. Dry surfaces with a chamois to prevent water spots.

Washing Tips S Avoid the use of harsh cleaners, which can scratch the finish. S Do not use a power washer to clean the vehicle. S Do not use medium to heavy duty compounds on the finish. S Always use clean cloths and pads for cleaning and polishing. Old or reused cloths and pads may contain dirt particles that will scratch the finish.

99

MAINTENANCE Cleaning and Storage Washing the Vehicle If a high pressure water system is used for cleaning (not recommended), exercise extreme caution. The water may damage components and could remove paint and decals. Avoid directing the water stream at the following items: S Wheel bearings S Radiator (if equipped) S Transmission seals S Brakes S Cab and body panels S Labels and decals S Electrical components and wiring

NOTE: If warning and safety labels are damaged, contact your Polaris dealer for free replacement.

Grease all zerk fittings immediately after washing. Allow the engine to run for a while to evaporate any water that may have entered the engine or exhaust system. 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 S Avoid the use of automotive products, some of which can scratch the finish of your vehicle.

S Always use clean cloths and pads for cleaning and polishing. Old or reused cloths and pads may contain dirt particles that will scratch the finish.

100

MAINTENANCE Cleaning and Storage Chrome Wheel Care (if equipped) Proper maintenance will protect chrome wheels from corrosion, preserve wheel life and ensure a like new appearance for many years.

NOTE: Chrome wheels exposed to road salt (or salt in the air in coastal areas) are more susceptible to corrosion if not properly cleaned. Clean chrome wheels more often if theyre exposed to salt or other corrosive elements.

1. Wash chrome wheels frequently. Use a mild detergent. Never use abrasive cleaners on plated or painted surfaces.

2. Rinse well with clear water. Soap, detergents, salt, dirt, mud and other elements can cause corrosion.

3. Polish the clean chrome wheels periodically. Use an automotive grade chrome polish.

4. Routinely and liberally apply a weather resistant wax to each polished chrome wheel. Choose a product suitable for chrome finishes. Read and follow the product labels and instructions.

Removing Corrosion If light rust is found on the chrome finish, use steel wool (#0000-OTT grade) to remove it. Gently rub the affected areas with the steel wool until the corrosion has been removed. Clean and polish the wheel as outlined above.

101

MAINTENANCE Cleaning and Storage Storage Tips See page 107 for the part numbers of Polaris products.

CAUTION Starting the engine during the storage period will disturb the protective film created by fogging and damage could occur. Never start the engine during the storage period.

Clean the Exterior Make any necessary repairs and clean the vehicle as recommended. See page 98.

Fuel Stabilizer 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.

NOTE: Carbon Clean removes water from fuel systems, stabilizes fuel and removes carbon deposits from pistons, rings, valves and exhaust systems.

3. Allow the engine to run for 15-20 minutes to allow the stabilizer to disperse through the fuel in the tank and carburetor.

4. Turn the fuel valve off. 5. Drain the carburetor bowl.

Oil and Filter Change the oil and filter. See page 67.

Air Filter / Air Box 1. Inspect and clean (or replace) the pre-cleaner and air filter. 2. Clean the air box. 3. Drain the sediment tube.

Recoil Housing Drain the recoil housing. See page 86.

102

MAINTENANCE Cleaning and Storage Storage Tips Fluid Levels Inspect the fluid levels. Add or change fluids as recommended in the Periodic Maintenance Chart beginning on page 60. S Transmission fluid S Brake fluid (change every two years and any time the fluid looks dark or contaminated)

Fog the Engine 1. Support the front end of the machine so the engine is level or tilted

slightly rearward. 2. Remove the spark plug. 3. Pour 2-3 tablespoons (29-44 ml) of engine oil into the hole.

NOTE: Use a section of small hose and a small plastic squeeze bottle filled with the pre-measured amount of oil.

4. Reinstall the spark plug. Torque to specification. 5. Apply dielectric grease to the inside of the spark plug cap.

Reinstall the cap. 6. Turn the engine over several times using the recoil starter. Oil will

be forced in and around the piston rings and ring lands, coating the cylinder with a protective film of fresh oil.

7. Treat the fuel system with Polaris Carbon Clean. See page 101. 8. If Polaris fuel system additive is not used, the fuel tank, fuel lines,

and carburetor should be completely drained of gasoline. 9. To eliminate any fuel remaining in the carburetor, run the engine

until it stops.

103

MAINTENANCE Cleaning and Storage Storage Tips Inspect and Lubricate Inspect all cables and lubricate all areas of the vehicle as recommended in the Periodic Maintenance Chart beginning on page 60.

Battery Storage See pages 94-97 for storage and charging procedures.

Storage Area/Covers Set the tire pressure and safely support the ATV with the tires slightly off the ground. Be sure the storage area is well ventilated. Cover the vehicle with a genuine Polaris cover.

NOTE: Do not use plastic or coated materials. They do not allow enough ventilation to prevent condensation, and may promote corrosion and oxidation.

Transporting the ATV Follow these procedures when transporting the vehicle.

1. Turn off the engine and remove the key to prevent loss during transporting.

2. Turn the fuel valve off. 3. Be sure the fuel cap, oil cap

and seat are installed correctly. 4. Always tie the frame of the

ATV to the transporting unit securely using suitable straps or rope.

5. Always place the transmission in gear and lock the parking brake.

104

SPECIFICATIONS 2008 Trail Blazer 330

Capacities & Dimensions Body Style Gen III Dry Weight 488 lbs. (221 kg) Maximum Weight Capacity 305 lbs. (138 kg) Front Rack Capacity (Accessory) 30 lbs. (14 kg) Rear Rack Capacity (Accessory) 60 lbs. (27 kg) Hitch Towing Rating (Accessory) 850 lbs.(386 kg) Unbraked Trailer Towing Capacity* 1263 lbs. (573 kg) Tongue Weight 85 lbs. (38.6 kg) Fuel Capacity 3.25 gal. (12.3 l) Transmission Oil Capacity 11.3 oz. (33 ml) Engine Oil Capacity 1.9 qts. (1.8 l) (including oil cooler)

1.7 qts. (1.6 l) (at oil change) Turn Radius 83 in. (211 cm) Ground Clearance 5.5 in. (14 cm) Length 75 in. (190.5 cm) Width 46 in. (117 cm) Height 46 in. (117 cm) Wheel Base 48 in. (122 cm)

Engine & Cooling Engine Model Number / Type ES-32PFE-103 / 4 Cycle, Single Cylinder Lubrication Wet Sump Bore x Stroke 78.5 x 68 Displacement 329cc Compression Ratio 9.2:1 Engine Cooling Air with fan assisted oil cooler Alternator Output (watts) 200w @5000 rpm Carburetion BST 34 Main Jet 122.5 Pilot Jet 42.5 Needle Jet P-4 (829) Pilot Air Jet 160 Pilot Screw 2.0 turns Jet Needle 4HB48-3 Ignition DC CDI Timing 30 2@ 5000 RPM Spark Plug Type / Gap BKR6E / .036 in. (.9 mm)

* Based on EU Directive 76/432/EC

105

SPECIFICATIONS 2008 Trail Blazer 330

Drive System

Drive System Type Automatic Polaris Variable Transmission (PVT)

Shift Type Side Lever (H-N-R)

Gear Reduction - Reverse 3.05:1

Gear Reduction - Forward 2.68:1

Final Drive (ratio) 11/40 78P

Drive Chain 520 O-Ring

Front Tires / Pressure 23 x 7-10 / 4 psi (27.6 KPa)

Rear Tires / Pressure 22 x 11-10 / 3 psi (20.7 KPa)

Suspension and Brakes

Front Suspension MacPherson strut with 8.2 in. (21 cm) travel

Rear Suspension Progressive Rate Swing Arm with 10.5 in. (27 cm) travel

Shock Adjustment CAM

Front/Rear Brakes Hydraulic disc

Auxiliary Foot Brake Hydraulic disc

Parking Brake Hydraulic lock, all wheel

Features

Headlight 1 Single Beam, 55w

Taillight 8.26w

Brake Light 26.9w

Battery 12V 14 AH

DC Plug-In (Rear) Accessory

DC Socket (Forward) Accessory

Electric Start Standard

High Temp Indicator Standard

Windshield Accessory

Neutral Indicator Standard

Reverse Indicator Standard

Speedometer Accessory

Fuel Gauge Standard

Tool Kit Standard

106

SPECIFICATIONS 2008 Trail Blazer 330 Jetting Chart Altitude AMBIENT

TEMPERATURE Below 40 F (Below 5 C)

+40F and above (+5C and above)

Meters (Feet)

0-1800 (0-6000)

127.5 122.5

1800-3700 (6000-12000)

120 115

Clutching Chart Altitude Shift

Weight Drive Clutch

Spring Driven Clutch

Spring Helix/Spring Setting

Meters (Feet)

0-1800 (0-6000)

10RH 5630709

Blue/Green 7041157

Black 7041782

45 5131446 2--2

1800-3700 (6000-12000)

20-40 5631356

Blue/Green 7041157

Black 7041782

45 5131446 2--2

107

POLARIS PRODUCTS Part No. Description

Engine Lubricant 2870791 Fogging Oil (12 oz. Aerosol)

2876244 PS-4 PLUS Performance Synthetic 2W-50 4-Cycle Oil (qt.)

2876245 PS-4 PLUS Performance Synthetic 2W-50 4-Cycle Oil (gal.)

Gearcase / Transmission Lubricants 2873602 Premium AGL Synthetic Gearcase Lube (qt.)

2873603 Premium AGL Synthetic Gearcase Lube (gal.)

2871653 Premium ATV Angle Drive Fluid (8 oz.)

2872276 Premium ATV Angle Drive Fluid (2.5 gal.)

2870465 Pump for Gallon Jug

2871654 Premium Demand Drive Hub Fluid (8 oz.)

2872277 Premium Demand Drive Hub Fluid (2.5 gal.)

Grease / Specialized Lubricants 2871322 Premium All Season Grease (3 oz. cartridge)

2871423 Premium All Season Grease (14 oz. cartridge)

2871460 Starter Drive Grease

2871515 Premium U-Joint Lube (3 oz.)

2871551 Premium U-Joint Lube (14 oz.)

2871312 Grease Gun Kit

2871329 Dielectric Grease (Nyogelt)

2872073 Chain Lube (6.25 oz. aerosol)

2872348 Chain Lube (16 oz. aerosol)

Additives / Miscellaneous 2871326 Carbon Clean Plus (12 oz.)

2870652 Fuel Stabilizer (16 oz.)

2872189 DOT 4 Brake Fluid

2871956 LOCTITE 565 Thread Sealant

2859044 Polaris Battery Tendert Charger

108

TROUBLESHOOTING Contact your Polaris dealer for service if youre unable to identify solutions using the following charts.

Drive Belt and Cover Problems Possible Cause Solution

Driving onto a pickup or tall trailer in high range

Shift transmission to low range during loading of the ATV to prevent belt burning.

Starting out going up a steep incline

When starting out on an incline, use low range or dis- mount the ATV (after first applying the park brake) and perform the K-turn as described on page 54.

Driving at low RPM or low ground speed (at approximately 3-7 MPH)

Drive at a higher speed or use low range more frequently. The use of low range is highly recommended for cooler PVT operating temperatures and longer component life.

Insufficient warm-up of ATVs exposed to low am- bient temperatures

Warm the engine at least 5 minutes. With the transmission in neutral, advance the throttle to about 1/8 throttle in short bursts, 5 to 7 times. The belt will become more flex- ible and prevent belt burning.

Slow/easy clutch engage- ment

Use the throttle quickly and effectively.

Towing/pushing at low RPM/low ground speed

Use low range only.

Utility use/plowing Use low range only.

Stuck in mud or snow Shift the transmission to low range, and carefully use fast, aggressive throttle application to engage clutch. WARNING: Excessive throttle may cause loss of control and vehicle overturn.

Climbing over large objects from a stopped position

Shift the transmission to low range and carefully use fast, brief, aggressive throttle application to engage clutch. WARNING: Excessive throttle may cause loss of control and vehicle overturn.

Belt slippage from water or snow ingestion into the PVT system

Shift the transmission to neutral. Using the throttle, vary the engine RPM from idle to full throttle. Repeat several times as required. During this procedure, the throttle should not be held at the full position for more than 10 seconds. Clutch seals should be inspected for damage if repeated leaking occurs.

Clutch malfunction See your Polaris dealer.

Poor engine performance Check for fouled plugs or foreign material in gas tank, fuel lines, or carburetor. See your dealer.

Slippage from failure to warm up belt

Always warm up the belt by operating below 30 mph for one mile (5 miles or more when temperature is below freezing).

Wrong or missing belt Always use the recommended belt.

Improper break-in Always break in a new belt and/or clutch by avoiding aggressive or high speed operation during the first two full tanks of fuel.

109

TROUBLESHOOTING Engine Doesnt Turn Over

Possible Cause Solution

Tripped circuit breaker Reset the breaker

Low battery voltage Recharge battery to 12.8 VDC

Loose battery connections Check all connections and tighten

Loose solenoid connections Check all connections and tighten

Engine Turns Over, Fails to Start

Possible Cause Solution

Out of fuel Turn fuel valve to reserve, refuel

Clogged fuel valve or filter Inspect and clean or replace

Water is present in fuel Drain the fuel system and refuel

Fuel valve is turned off Turn the fuel valve on

Old or non-recommended fuel Replace with new fuel

Fouled or defective spark plug(s) Inspect plug(s), replace if necessary

No spark to spark plug Inspect plug(s), verify stop switch is on

Crankcase filled with water or fuel Immediately see your Polaris dealer

Overuse of choke Inspect, clean and/or replace spark plugs

Clogged fuel filter Replace the filter

Low battery voltage Recharge battery to 12.8 VDC

Mechanical failure See your Polaris dealer

Engine Pings or Knocks

Possible Cause Solution

Poor quality or low octane fuel Replace with recommended fuel

Incorrect ignition timing See your Polaris dealer

Incorrect spark plug gap or heat range Set gap to specs or replace plugs

110

TROUBLESHOOTING Engine Backfires

Possible Cause Solution

Weak spark from spark plugs Inspect, clean and/or replace spark plugs

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

Engine Runs Irregularly, Stalls or Misfires

Possible Weak Spark Cause Solution

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 Check all connections and tighten

Water present in fuel Replace with new fuel

Low battery voltage Recharge battery to 12.8 VDC

Kinked or plugged fuel vent line Inspect and replace

Incorrect fuel Replace with recommended fuel

Clogged air filter Inspect and clean or replace

Reverse speed limiter malfunction See your Polaris dealer

Electronic throttle control malfunction See your Polaris dealer

Other mechanical failure See your Polaris dealer

Possible Lean Fuel Mixture Cause Solution

Low or contaminated fuel Add or change fuel, clean the fuel system

Low octane fuel Replace with recommended fuel

Clogged fuel filter Replace filter

Incorrect jetting See your Polaris dealer

Possible Rich Fuel Mixture Cause Solution

Overuse of choke Inspect, clean and/or replace spark plugs

Fuel is very high octane Replace with lower octane fuel

Incorrect jetting See your Polaris dealer

111

TROUBLESHOOTING Engine Stops or Loses Power

Possible Cause Solution

Out of fuel Turn fuel valve to reserve, refuel

Kinked or plugged fuel vent line Inspect and replace

Water present in fuel Replace with new fuel

Overuse of choke 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 Check all connections and tighten

Low battery voltage Recharge battery to 12.8 VDC

Incorrect fuel Replace with recommended fuel

Clogged air filter Inspect and clean or replace

Reverse speed limiter malfunction See your Polaris dealer

Electronic throttle control malfunction See your Polaris dealer

Other mechanical failure See your Polaris dealer

112

WARRANTY LIMITED WARRANTY Polaris Sales Inc., 2100 Highway 55,Medina,MN 55340, gives a SIXMONTHLIMITED WARRANTY on all components of the Polaris All Terrain Vehicle (ATV) against defects inmaterial orworkmanship. 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. This warranty begins on the date of purchase. This warranty is transferrable to another consumer during the war- ranty period through a Polaris dealer.

REGISTRATION At the time of sale, theWarranty 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 entitlement. If you have not signed the original registration and received the customer copy, please contact your dealer immediately. NO WARRANTY COVERAGE WILL BE ALLOWED UNLESS YOUR ATV IS REGISTERED WITH POLARIS. Initial dealer preparation and set-up of your ATV is very important in ensuring trouble-free operation. Purchasing amachine in the crate or without proper dealer set-up will void your warranty coverage.

WARRANTY COVERAGE AND EXCLUSIONS: LIMITATIONS OF WARRANTIES AND REMEDIES ThePolaris limited warranty excludes any failures that are not caused by a defect inmaterial or workmanship. This warranty does not cover accidental damage, normal wear and tear, abuse or improper handling. This warranty also does not cover any ATV that has been al- tered structurally, modified, neglected, improperly maintained, used for racing, or used for purposes other than for which it wasmanufactured, or for any damages which occur during trailer transit or as a result of unauthorized service or the use of unauthorized parts. In addi- tion, this warranty does not cover physical damage to paint or finish, stress cracks, tearing or puncturing of upholstery material, corrosion, or defects in parts, components or theATV due to fire, explosions or any other cause beyond Polaris control. This warranty does not cover the use of unauthorized lubricants, chemicals, or fuels that are not compatible with the ATV. 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. POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL, CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION,WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CON- TRACT, NEGLIGENCE, OR OTHER TORT OR OTHERWISE. Some states do not per- mit theexclusion or limitation of incidental or consequential damagesor impliedwarranties, so the above limitations or exclusionsmay not apply to you if inconsistent with controlling state law.

113

WARRANTY WARRANTY COVERAGE AND EXCLUSIONS: LIMITATIONS OF WARRANTIES AND REMEDIES ALL IMPLIEDWARRANTIES (INCLUDINGBUTNOT LIMITEDTO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE)ARELIMITED INDURATION TOTHEABOVESIXMONTHWARRAN- TYPERIOD. POLARIS FURTHERDISCLAIMSALLEXPRESSWARRANTIESNOT STATED IN THISWARRANTY. Some states do not allow limitations on how long an im- plied warranty lasts, so the above limitation may not apply to you if inconsistent with con- trolling state law.

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 COSTOF TRANSPORTATION TOAND FROMTHEDEALER IS YOURRESPONSIBILITY). Polaris suggests that you use your original selling dealer; however, you may use any Polaris Servicing Dealer to performwar- ranty service.

Pleaseworkwith your dealer to resolve anywarranty issues. Should your dealer require any additional assistance they will contact the appropriate personnel at Polaris.

Thiswarranty gives you specific legal rights, and youmay also have other rightswhich vary from state to state. If any of the above terms are void because of state or federal law, all other warranty terms will remain in effect.

Engine Oil 1. Mixing oil brands or using non-recommended oilmay cause engine damage. We recom- mend the use of Polaris engine oil. 2. Damage resulting from the use of non-recommended lubricants may not be covered by warranty.

SPARK ARRESTOR Polaris warrants that the spark arrestor in this vehicle will meet the efficiency requirements of 43 CFR 8343.1(c) for at least 1000 hourswhen subjected to normal useandwhenmainte- nance and installation are in accordance with Polaris recommendations.

114

WARRANTY Exported Vehicles EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE IS NO WAR- RANTY OR SERVICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD OUTSIDE THE COUNTRY OF THE SELLING DEALERS AUTHORIZED LOCA- TION. This policy does not apply to vehicles that have received authorization for export from Polaris Industries. Dealers may not give authorization for export. You should consult an authorized dealer to determine this vehicles warranty or service bulletin coverage if you have any questions. This policy does not apply to vehicles registered to government officials or military per- sonnel on assignment outside the country of the selling dealers authorized location. This policy does not apply to Safety Recalls.

How to Get Service In the Country where your vehicle was purchased: Warranty or Service Bulletin repairs must be done by an authorized Polaris dealer. If you move or are traveling within the country where your vehicle was purchased, Warranty or Service Bulletin repairs may be requested from any authorized Polaris dealer who sells the same line as your vehicle.

Outside the Country where your vehicle was purchased: If you are traveling temporarily outside the country where your vehicle was purchased, you should take your vehicle to an authorized Polaris dealer. You must show the dealer photo identification from the country of the selling dealers authorized location as proof of residence. Upon residence verification, the servicing dealer will be authorized to per- form the warranty repair.

If You Move: If you move to another country, be sure to contact Polaris Customer Assistance and the customs department of the destination country before you move. Vehicles importation rules vary considerably from country to country. You may be required to present docu- mentation of your move to Polaris Industries in order to continue your warranty cover- age. You may also be required to obtain documentation from Polaris Industries in order to register your vehicle in your new country.

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 If your vehicle is registered outside of the country where it was purchased, and you have not followed the procedure set out above, your vehicle will no longer be eligible for war- ranty or service bulletin coverage of any kind. (Vehicles registered to Government offi- cials or military personnel on assignment outside of the country where the vehicle was purchased will continue to be covered by the basic warranty.)

For questions call Polaris Customer Assistance:

United States: 1-888-704-5290

Canada: 1-204-925-7100

115

WARRANTY U.S.A. EPA Emissions Limited Warranty This All Terrain Vehicle (ATV) or Off Road Utility Vehicle (ORUV) emissions limited warranty is in addition to the Polaris standard limited warranty for this vehicle. Polaris warrants that this vehicle is; (1) designed, built, and equipped to conform at the time of initial sale with the requirements of 40 CFR 1051 and, (2) free from defects in materials and workmanship that may keep it from meeting these requirements. The emissions warranty period for this vehicle begins on the date the vehicle is delivered to the original retail purchaser and ends 30 months (2.5 years) after that date, after 5000 km (3100 miles), or after 500 hours of operation, whichever comes first. This emission-related warranty covers components whose failure would increase an en- gines emissions, including electronic controls, fuel injection, exhaust-gas recirculation, aftertreatment, or any other system utilized in this vehicle to control emissions. Replac- ing or repairing other components not covered by this emissions warranty or the standard warranty is the responsibility of the owner; including the parts, labor and other costs associated with recommended maintenance. The exclusive remedy for breach of this limited warranty shall be, at the exclusive option of Polaris, repair or replacement of any defective materials, components or products. THE REMEDIES SET FORTH IN THIS LIMITED WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY. POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL, CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION,WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CON- TRACT, NEGLIGENCE OR OTHER TORT OR OTHERWISE. ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO ANY IM- PLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICU- LAR PURPOSE) ARE LIMITED IN DURATION TO THE WARRANTY PERIOD DESCRIBED HEREIN. POLARIS DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY. Some states do not allow limitations on how long an implied warranty lasts, so the above limitation may not apply if it is inconsistent with the controlling state law. This limited warranty excludes failures not caused by a defect in material or workman- ship. This limited warranty does not cover damage due to accidents, abuse or improper handling, maintenance or use. This limited warranty also does not cover any engine that has been structurally altered, or any engine that has been used in racing competition. This limited warranty also does not cover physical damage, corrosion or defects caused by fire, explosions or other similar causes beyond the control of Polaris. If you have any questions regarding your warranty rights and responsibilities, you should contact the Polaris Warranty Department at 1-888-704-5290.

116

MAINTENANCE LOG Use the following chart to record periodic maintenance.

DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS

117

MAINTENANCE LOG

DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS

118

INDEX A

Age Restrictions 6. . . . . . . . . . . . . . . . Air Filter 84. . . . . . . . . . . . . . . . . . . . . Auxiliary Brake 37, 72. . . . . . . . . . . .

B Battery 91-97. . . . . . . . . . . . . . . . . . . . Battery Charging (Conventional) 95. . Battery Charging (Sealed) 96-97. . . . . . Battery Fluid (Conventional) 95. . . . . Battery Installation 93. . . . . . . . . . . . . Battery Removal 92. . . . . . . . . . . . . . . Battery Storage 94. . . . . . . . . . . . . . . . Belt Break-in 41. . . . . . . . . . . . . . . . . . Brake Lever 34. . . . . . . . . . . . . . . . . . Brake, Auxiliary 72. . . . . . . . . . . . . . . Brakes 35, 71-72. . . . . . . . . . . . . . . . . . Break-In Period 41. . . . . . . . . . . . . . . .

C Camber and Caster 72. . . . . . . . . . . . . Carburetor 75. . . . . . . . . . . . . . . . . . . . Choke 38. . . . . . . . . . . . . . . . . . . . . . . Chrome Wheel Care 100. . . . . . . . . . . Cleaning and Storage 98-103. . . . . . . . Clutch Break-in 41. . . . . . . . . . . . . . . . Crankcase Emission Control System 59

D Drive Chain 79-81. . . . . . . . . . . . . . . . Drivetrain Break-in 41. . . . . . . . . . . . . Driving Downhill 52. . . . . . . . . . . . . . Driving in Reverse 57. . . . . . . . . . . . . Driving on Slippery Surfaces 49. . . . . Driving Over Obstacles 56. . . . . . . . . . Driving Procedures 45. . . . . . . . . . . . . Driving Safely 45-58. . . . . . . . . . . . . . . Driving Through Water 55. . . . . . . . . . Driving Uphill 50-51. . . . . . . . . . . . . .

E Electrical Switches 31. . . . . . . . . . . . . Emissions Warranty 115. . . . . . . . . . . Engine Break-in 41. . . . . . . . . . . . . . . Engine Fogging 102. . . . . . . . . . . . . . Equipment Modifications 10. . . . . . . . Exhaust Emission Control System 59.

F Front Wheel Hub Tightening 78. . . . . Fuel Filter 38. . . . . . . . . . . . . . . . . . . . Fuel Safety 26. . . . . . . . . . . . . . . . . . . Fuel Stabilizer 101. . . . . . . . . . . . . . . . Fuel Tank 38. . . . . . . . . . . . . . . . . . . . Fuel Valve 38. . . . . . . . . . . . . . . . . . . .

G Gear Selector 39. . . . . . . . . . . . . . . . . .

H Handlebars 74. . . . . . . . . . . . . . . . . . . Hauling Cargo 46-47. . . . . . . . . . . . . . . Headlight Lamp Replacement 82. . . . .

I Indicator Lamp Replacement 83. . . . . Indicator Lights 32. . . . . . . . . . . . . . . .

K K-turn 54. . . . . . . . . . . . . . . . . . . . . . .

L Light Switches 32. . . . . . . . . . . . . . . . Lights 82-83. . . . . . . . . . . . . . . . . . . . . Lubrication Recommendations 64-65. .

M Main Switch 31. . . . . . . . . . . . . . . . . . Making Turns 48. . . . . . . . . . . . . . . . .

119

INDEX N

Noise Emission Control System 59. . .

O Oil Change 67. . . . . . . . . . . . . . . . . . . Oil Check 66. . . . . . . . . . . . . . . . . . . . Oil Recommendations 66. . . . . . . . . . . Oil, Engine 66-67. . . . . . . . . . . . . . . . . Oil, Transmission 68-69. . . . . . . . . . . . Operator Safety 6-25. . . . . . . . . . . . . . . Override Switch 31. . . . . . . . . . . . . . .

P Parking Brake 36. . . . . . . . . . . . . . . . . Parking on an Incline 58. . . . . . . . . . . Periodic Maintenance Chart 60-63. . . . Polaris Products 107. . . . . . . . . . . . . . Pre Ride Inspection 42. . . . . . . . . . . . . PVT Break-in 41. . . . . . . . . . . . . . . . . PVT Drying 89. . . . . . . . . . . . . . . . . . PVT System 88-89. . . . . . . . . . . . . . . .

R Rear Drive Chain Slack 80-81. . . . . . . . Rear Spring 72. . . . . . . . . . . . . . . . . . . Recoil Housing 86. . . . . . . . . . . . . . . . Recoil Starter 40. . . . . . . . . . . . . . . . .

S Safe Riding Gear 30. . . . . . . . . . . . . . . Safety Decals and Locations 27-29. . . . Safety Training 6. . . . . . . . . . . . . . . . . Sidehilling 53. . . . . . . . . . . . . . . . . . . Spark Arrestor 90. . . . . . . . . . . . . . . . . Spark Plugs 85-86. . . . . . . . . . . . . . . . . Specifications 104-106. . . . . . . . . . . . . Starting the Engine 43-44. . . . . . . . . . . Steering Assembly 72. . . . . . . . . . . . . Stop Switch 31. . . . . . . . . . . . . . . . . . . Storage Tips 101-103. . . . . . . . . . . . . .

T Taillight/Brakelight Lamp

Replacement 83. . . . . . . . . . . . . . Throttle Cable Freeplay 73. . . . . . . . . . Throttle Lever 33. . . . . . . . . . . . . . . . . Tire Tread Depth 78. . . . . . . . . . . . . . . Toe Alignment 70. . . . . . . . . . . . . . . . Towing Capacities 46. . . . . . . . . . . . . . Transmission Gear Selector 39. . . . . . . Transmission Oil 68. . . . . . . . . . . . . . . Transmission Oil Change 69. . . . . . . . Tran