Polaris Trail Boss 330, Trail Blazer 330 Owner's Manual v5 PDF

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Summary of Content for Polaris Trail Boss 330, Trail Blazer 330 Owner's Manual v5 PDF

PMS 419

Owner's Manual for Maintenance and Safety

Read this manual carefully. It contains important safety information. This is an adult vehicle only.

Operation is prohibited for those under 16 years of age.

International

Trail Boss 330 Trail Blazer 330

The text is printed on 100% recycled with 40% post-consumer waste (PCW).

For your nearest Polaris dealer, call 1-800-POLARIS or visit www.polarisindustries.com Polaris Sales Inc., 2100 Hwy. 55, Medina, MN 55340 Phone 1-888-704-5290 Part No. 9922806 Rev 01 Printed in USA

PMS 419

*9922806 *

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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 excit- ing line of utility and recreational products. Snowmobiles All-terrain vehicles (ATVs) RANGER utility vehicles Victory Motorcycles

Always follow the instructions and recommendations in this manual. The manual contains instructions for minor maintenance, but informa- tion about major repairs is outlined in the POLARIS Service Manual and should be performed only by a factory-certified Master Service Dealer (MSD) technician. Please see your dealer for all of your service needs during (and after) the warranty period. For more information about POLARIS, visit us online at www.polarisindustries.com.

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POLARIS, THE WAY OUT, TRAIL BOSS and TRAIL BLAZER are registered trade- marks of POLARIS Industries Inc. Copyright 2010 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 discrep- ancies may result between the actual vehicle and the information presented in this publi- cation. 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. The original instructions for this vehicle are in English. Other languages are provided as translations of the original instructions. Printed in U.S.A. 2011 TRAIL BOSS 330/TRAIL BLAZER 330 International Owners Manual P/N 9922806

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TABLE OF CONTENTS Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Features and Controls . . . . . . . . . . . . . . . . . . . 20 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Emission Control Systems . . . . . . . . . . . . . . . 48 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 POLARIS Products. . . . . . . . . . . . . . . . . . . . . . 97 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . 98 Specifications. . . . . . . . . . . . . . . . . . . . . . . . . 102 Declaration of Conformity . . . . . . . . . . . . . . . 106 Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 Maintenance Log . . . . . . . . . . . . . . . . . . . . . . 111 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

4

INTRODUCTION The following signal words and symbols appear throughout this manual and on your vehicle. Your safety is involved when these words and sym- bols are used. Become familiar with their meanings before reading the manual.

The safety alert symbol indicates a potential personal injury hazard.

WARNING A WARNING indicates a hazardous situation which, if not avoided, may result in death or serious injury.

CAUTION A CAUTION indicates a hazardous situation which, if not avoided, may result in minor or moderate injury.

NOTICE A NOTICE indicates a situation that may result in property damage.

The Prohibition Safety Sign indicates an action NOT to take in order to avoid a hazard.

The Mandatory Action Sign indicates an action that NEEDS to be taken to avoid a hazard.

5

INTRODUCTION

Failure to follow the warnings in this manual can result in serious injury or death. This POLARIS vehicle is not a toy and can be hazardous to operate. A collision or rollover can occur quickly, even during routine maneuvers, if you fail to take proper precautions. Read and understand your owner's manual and all warnings before operating this POLARIS vehicle.

Safety Training When you purchased your new POLARIS vehicle, your dealer offered a hands-on safety training course. You were also provided with printed materials that explain safe operating procedures. Review this informa- tion on a regular basis. If you purchased a used POLARIS vehicle from a party other than a POLARIS dealer, please request free safety training from any autho- rized POLARIS dealer.

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

Restrictions This vehicle is approved for OFF-ROAD TOWING ONLY. Towing a trailer with this vehicle on public roads is prohibited.

Equipment Modifications The warranty on your POLARIS vehicle may be terminated if any equipment has been added, or if any modifications have been made, that increase speed or power. The addition of certain accessories, including (but not limited to) mowers, blades, tires, sprayers and large racks may change vehicle handling. Use only POLARIS-approved accessories. Know their function and effect on the vehicle.

WARNING

6

INTRODUCTION Vehicle Identification Numbers Record your vehicle's identification numbers and key number in the spaces provided. Remove the spare key and store it in a safe place. An ignition key can be duplicated only by ordering a POLARIS key blank (using your key number) and mating it with one of your existing keys. The ignition switch must be replaced if all keys are lost.

Vehicle Model Number: ___________________________________________________

Frame VIN: ____________________________________________________________

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

Key Number: ___________________________________________________________

####

VIN

Key Number

7

SAFETY

Failure to operate the vehicle properly can result in a collision, loss of control, accident or overturn, which may result in serious injury or death. Heed all safety warnings outlined in this section of the owners manual. See the OPERATION section of the owners manual for proper operating procedures.

Equipment Modifications We strongly recommend that consumers do not install on a POLARIS vehicle any equipment that may increase the speed or power of the vehi- cle, or make any other modifications to the vehicle for these purposes. The warranty on your POLARIS vehicle 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. The addition of certain accessories, including (but not limited to) mow- ers, blades, tires, sprayers, or large racks, may change the handling char- acteristics of the vehicle. Use only POLARIS-approved accessories, and familiarize yourself with their function and effect on the vehicle.

WARNING

8

SAFETY Safe Riding Gear Always wear appropriate clothing when riding a POLARIS vehicle. Wear protective clothing for comfort and to reduce the chance of injury.

Helmet Wearing a helmet can prevent a severe head injury. Whenever riding a POLARIS vehicle, always wear a helmet that meets or exceeds estab- lished 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.

Helmet

Eye Protection

Gloves

Boots

Long Pants

Long Sleeves

E4

051039 0006.31

9

SAFETY Safe Riding Gear Eye Protection Do not depend on eyeglasses or sunglasses for eye protection. When- ever riding a POLARIS vehicle, always wear shatterproof goggles or use a shatterproof helmet face shield. POLARIS recommends wearing approved Personal Protective Equipment (PPE) bearing markings such as VESC 8, V-8, Z87.1, or CE. Make sure protective eye wear is kept clean. Gloves Off-road style gloves with knuckle pads are the best for comfort and protection. Boots The best footwear is a pair of sturdy over-the-calf boots with low heels. 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.

10

SAFETY Operator Safety

Read and understand all warnings, cautions and operating procedures in this manual and on the safety labels before operating the vehicle. Never operate this vehicle without proper instruction. Take a training course. Beginners should receive training from a certified instructor. Contact an authorized POLARIS dealer or visit the POLARIS web site at www.polarisindustries.com. Never permit others to operate the vehicle unless they have read and under- stand this manual and all product labels, and have completed a certified safety training course.

Never allow anyone under 16 years of age to operate this vehicle.

Never carry a passenger.

11

SAFETY Operator Safety

Always wear an approved helmet that fits properly. Wear eye protection (goggles or face shield), gloves, boots, long sleeves and long pants.

Never consume alcohol or drugs before or while operating this vehicle.

Never operate at excessive speeds. Travel and turn at speeds appropriate for the terrain, visibility, operating conditions and your experience.

Never attempt jumps or other stunts.

12

SAFETY Operator Safety

Always inspect your POLARIS vehicle before each use to verify that it's in safe operating condition. Follow the inspection and maintenance procedures outlined in this manual. See page 31.

Keep both hands on the handlebars. Keep your feet on the footrests.

Always travel slowly when operating on unfamiliar terrain. Use extra caution.

Use caution when operating on rough, slippery or loose terrain.

Always follow the procedures outlined in this manual for turning. See page 35. Never turn sharply at excessive speeds, which can lead to vehicle overturn.

13

SAFETY Operator Safety

If the vehicle has been involved in an accident, always have an authorized POLARIS dealer inspect the entire vehicle for possible damage, including (but not limited to) brake, throttle and steering systems.

Never operate on hills too steep for the vehicle or for your abilities. Practice on smaller hills before attempting larger hills. Avoid climbing hills steeper than 25. Always follow the procedures outlined in this manual for climbing hills. See page 37.

Always follow the procedures outlined in this manual for driving downhill and for braking on hills. See page 39.

Always follow the procedures outlined in this manual for crossing the side of a hill. See page 38. Never attempt to turn the vehicle around on any hill until you've mastered (on level ground) the turning technique outlined in this manual.

Always follow the procedures outlined in this manual for braking if you stall or roll backwards while climbing a hill. Never back down a hill. See page 40.

+25

14

SAFETY Operator Safety

Always follow the procedures outlined in this manual for operating over obstacles. See page 42.

Always follow the procedures outlined in this manual for operating on slippery or loose surfaces. Use extra caution. Always avoid skidding or sliding. See page 36.

Always follow the procedures outlined in this manual for driving through water. Never drive through deep or fast-flowing water. See page 41.

Always follow the procedures outlined in this manual for driving in reverse. See page 43.

Always use the size and type of tires specified for your vehicle. Maintain the proper tire pressure.

Never modify this POLARIS vehicle through improper installation or use of accessories.

Operating on paved surfaces may affect the handling and control of the vehicle and could result in loss of control. Avoid sudden turns or swift movement of the handlebars.

15

SAFETY Operator Safety

Never exceed the stated load capacity for your vehicle. 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.

Never operate this vehicle on a frozen body of water unless you have independently verified that the ice is sufficiently thick to support the weight and moving force of the vehicle, you and your cargo, together with any other vehicles in your party. Variances in snow depth and/or water currents may result in uneven ice thickness. Always check with local authorities and residents to confirm ice conditions and thickness over your entire route. Operators assume all risk associated with ice conditions on frozen bodies of water.

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

Always unlock the steering before starting the engine. See page 26.

Handling Gasoline Gasoline is highly flammable and explosive under certain conditions. Always exercise extreme caution whenever handling gasoline. Always refuel with the engine stopped, and outdoors or in a well ventilated

area. Do not smoke or allow open flames or sparks in or near the area where refu-

eling is performed or where gasoline is stored. Do not overfill the tank. Do not fill the tank neck. If gasoline spills on your skin or clothing, immediately wash it off with soap

and water and change clothing. Turn the fuel valve off whenever the vehicle is stored or parked.

Hot components can cause serious burns and fire. Do not touch hot exhaust system components. Always keep combustible materials away from the exhaust system.

For more information about safety, contact an authorized POLARIS dealer or visit the POLARIS web site at

www.polarisindustries.com.

16

SAFETY Safety Labels and Locations Warning labels have been placed on the vehicle for your protection. Read and follow the instructions on each label carefully. If any of the labels shown in this manual differ from the labels on your vehicle, always read and follow the instructions of the labels on the vehicle. If an informational or graphic label becomes illegible or comes off, con- tact your POLARIS dealer to purchase a replacement. Replacement safety labels are provided by POLARIS at no charge. The part number is printed on the label.

General Alert (Multi-Lingual) Before you operate this vehicle, read the owners manual.

Hill Operation Alert Never operate this vehicle on

HILLS steeper than 25 degrees 25.

To prevent flip-over on hilly terrain, when going up or down, use throttle and brakes gradually.

General Alert

Hill Operation Alert

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SAFETY Safety Labels and Locations

Rack Warning, Front and Rear (TRAIL BOSS) WARNING DO NOT TOW FROM RACK

OR BUMPER. Vehicle damage or tipover may result causing severe injury or death. Tow only from tow hooks or hitch.

Max Rack Loads: Front 75 lbs. (34 kg) Rear 125 lbs. (57 kg)

Rack Warning

18

SAFETY Safety Labels and Locations

No Passenger Warning WARNING NEVER ride as a passenger. Passengers can cause a loss of control, resulting in SEVERE INJURY or DEATH.

Tire Pressure/Load Alert (TRAIL BOSS) TIRE PRESSURE IN PSI (KPa): FRONT 4 (27.6) REAR 3 (20.7) MAXIMUM WEIGHT CAPACITY 415 lbs. (188 kg) INCLUDES WEIGHT OF OPERATOR, PASSENGER, CARGO AND ACCESSORIES. Read Owners Manual for more detailed loading information.

Tire Pressure/Load Alert (TRAIL BLAZER) TIRE PRESSURE IN PSI (KPa): FRONT 4 (27.6) REAR 3 (20.7) MAXIMUM WEIGHT CAPACITY 275 lbs. (125 kg) INCLUDES WEIGHT OF OPERATOR, PASSENGER, CARGO AND ACCESSORIES. Read Owners Manual for more detailed loading information.

Clutch Cover Warning

Age 16 Alert

No Passenger Warning Tire Pressure/Load

Alert

19

SAFETY Safety Labels and Locations

Age 16 Alert

Clutch Cover Alert NO STEP

Reverse Override Warning WARNING Improper use of override button can lead to loss of control resulting in severe injury or death. Do not activate override while throttle is engaged. Always apply throttle gradually, while in reverse.

20

FEATURES AND CONTROLS Switches Engine Stop Switch The engine will not start or run when the switch is in the OFF position.

OFF

RUN Push the stop switch down to stop the engine quickly. Pull the stop switch up to the RUN position before attempt- ing to start the engine. Both the main switch and the engine stop switch will shut off all electrical power to the vehicle, including lights.

Override Switch This vehicle is equipped with a reverse speed limiter system. To gain additional wheel speed while backing, release the throttle and press the override switch.

Pressing the override switch while the throttle is open can cause loss of control, which may result in serious injury or death. Always release the throttle before pressing the override switch.

Override Switch

Engine Stop

Switch

Headlight Switch

Horn Switch

Hazard Switch

21

FEATURES AND CONTROLS Switches Headlight Switch The lights do not operate unless the main key switch is on and the engine stop switch is in the RUN position.

High Beam

Low Beam

Turn Signal Switch

Push the toggle switch either left or right to activate the corre- sponding turn signal light. The indicator on the pod will also flash. Return the toggle to the center position and push it inward to end the signal.

Hazard Switch

Push the hazard warning switch to cause all turn signal lights to flash simultaneously. Use this feature to alert others of an emer- gency or other situation requiring caution.

Horn Switch

Press the horn switch to sound the horn. Main Key Switch Use the main key switch to start the engine. See page 32 for starting pro- cedures.

Main Key Switch

22

FEATURES AND CONTROLS Mirrors Use the mirrors to assist in traffic maneuvers. Always check and adjust the mirrors before driving the vehicle.

Indicator Lights With the engine running, verify the function of all indicator lights before each use of the vehicle. Tip: The taillight is on whenever the main switch (key) is on. Turn the key off to

prevent battery drain.

Neutral Indicator

Reverse Indicator

High Temperature Warning (displays if engine overheats)

Turn Signal/Hazard Indicators

High Beam Indicator

23

FEATURES AND CONTROLS Throttle Lever Press the throttle lever to increase engine speed and vehicle movement. Release the lever to reduce engine speed and vehicle movement.

Failure to check or maintain proper operation of the throttle system can result in an accident if the throttle lever sticks during operation. Check the lever for proper operation before starting the engine. Check occasionally during operation. Do not start or operate a vehicle with sticking or improperly operating throttle controls. Contact your dealer for repair if throttle problems arise.

Electronic Throttle Control (ETC) ETC causes the engine to stop if the throttle cable sticks in an open position when the operator releases the throttle lever.

The Electronic Throttle Control (ETC) stops the engine in the event of a throttle system malfunction. Do not modify the ETC system or replace it with other throttle mechanisms.

Electronic Throttle Control

24

FEATURES AND CONTROLS Brakes

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

Foot Brake The all-wheel foot brake is located on the right footrest. The foot brake operates both front and rear brakes. Press the brake pedal down with your foot to apply the all-wheel brakes. If the rear wheels begin to skid or slide while using the foot brake, reduce brake pressure.

Hand Brake Lever The hand brake operates both front and rear brakes. Squeeze the brake lever toward the han- dlebar to apply the all-wheel brakes. If the rear wheels begin to skid or slide while using the hand brake, reduce lever pressure.

Operating the vehicle with a spongy brake lever can result in loss of braking, which could cause an accident. Never operate the vehicle with a spongy-feeling brake lever. Always contact your dealer for service before operating the vehicle.

Foot Brake

25

FEATURES AND CONTROLS Brakes Parking Brake Locking the Parking Brake 1. Place the transmission in gear. 2. Squeeze and release the brake

lever two or three times, then squeeze and hold.

3. Push the parking brake lock forward to engage the lock.

4. Release the brake lever. 5. To release the parking brake

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

Operating the vehicle while the parking brake is engaged could result in an accident and serious injury or death. Always release the parking brake lock before operating.

26

FEATURES AND CONTROLS Steering Lock Lock the steering to prevent unauthorized use or theft of the vehicle. Tip: Place the steering lock

keys in a safe place. The lock must be replaced if the keys are lost.

1. Turn the handlebars to the full left position.

2. Insert the steering lock key and turn it clockwise.

3. Remove the key. 4. Reverse the procedure to unlock

the steering.

The handlebars are locked in the full left position when the steering is locked. Always unlock the steering before starting the engine.

27

FEATURES AND CONTROLS Choke The choke assists in starting a cold engine. Refer to the engine start- ing procedure on page 32 for cor- rect choke and throttle settings during starting.

Fuel Tank Cap Always refuel with the engine stopped, and outdoors or in a well ventilated area. Refuel on a level surface. Remove the fuel tank cap 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 fuel with ethanol content greater than 10 percent, such as E-85 fuel.

Fuel Valve The fuel valve is located on the left side of the vehicle, below the fender. ON: For normal operation. OFF: For vehicle storage and when transporting.

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.

Fuel Tank Cap

Fuel Valve

Fuel Gauge

OFFON

Choke

28

FEATURES AND CONTROLS Transmission Gear Selector The transmission gear selector is located on the right side of the vehicle. F: Forward Gear N: Neutral R: Reverse To shift gears, brake to a complete stop. When the engine is idling, move the lever to the desired gear. NOTICE: Shifting gears with the engine

speed above idle or while the vehicle is moving could cause transmission damage.

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

Gear Selector

29

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

handle tightly. 2. Pull slowly so you can feel

the engine strokes. Tip: The rope will be harder to pull when the engine is on a compression stroke.

When a compression stroke is found, continue pulling the rope just until the engine rolls past the stroke, then stop pulling immediately.

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

4. Repeat all steps until the engine starts. 5. Make sure the handle is fully seated on the housing. NOTICE: 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.

Recoil StarterHandle

30

OPERATION Break-In Period The break-in period for your new POLARIS vehicle is the first ten hours of operation, or the time it takes to use the first two full tanks of gaso- line. No single action on your part will increase the life and performance of your vehicle more than following the procedures for a proper break- in. Careful treatment of a new engine and drive components will result in more efficient performance and longer life for these components. Do not operate at full throttle or high speeds for extended periods during the first three hours of use.

Engine and Drivetrain Break-in 1. Fill the fuel tank with gasoline. See page 27. 2. Check the oil level. Add oil if necessary. 3. Select an open area that allows room to familiarize yourself with

vehicle operation and handling. 4. Drive slowly. Vary the 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 31. 6. Pull only light loads. 7. Change both the oil and the filter at 20 hours or one month.

PVT Break-in (Clutches/Belt) Break in the clutches and belt by operating at slower speeds during the break-in period as recommended. Pull only light loads. Avoid aggres- sive acceleration and high speed operation during the break-in period.

31

OPERATION Pre-Ride Checklist Failure to inspect and verify that the vehicle is in safe operating condi- tion before operating increases the risk of an accident. Always inspect the vehicle before each use to make sure it's in safe operating condition.

Item Remarks Page

Hand brake Ensure proper operation 24

Brake fluid Ensure proper level 58

Foot brake Ensure proper operation 24

Front suspension Inspect, lubricate if necessary 53

Rear suspension Inspect, lubricate if necessary 53

Steering/steering lock Unlock the steering; ensure free operation

26

Tires Inspect condition and pressure 66

Wheels/fasteners Inspect, ensure fastener tightness 66

Frame nuts, bolts, fasteners Inspect, ensure tightness -

Fuel and oil Ensure proper levels 27 54

Throttle Ensure proper operation 23 64

Indicator lights/switches Ensure operation 20

Engine stop switch Ensure proper operation 20

Mirrors Adjust for best side/rear vision 22

Drive chain Check condition/slack, lubricate as needed

72

Air filter, pre-filter Inspect, clean 69

Air box sediment tube Drain deposits whenever visible -

Headlamp Check operation, apply POLARIS dielectric grease when lamp is replaced

21 76

Brake light/taillight Check operation, apply POLARIS dielectric grease when lamp is replaced

77

Riding gear Wear approved helmet, goggles, and protective clothing

8

32

OPERATION Starting the Engine

Engine exhaust contains poisonous carbon monoxide and can cause loss of consciousness resulting in severe injury or death. Never run an engine in an enclosed area.

1. Position the vehicle on a level surface. 2. Place the transmission in neutral. 3. Lock the parking brake. Tip: 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. Tip: 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. If the knob doesn't stay where positioned, increase the ten- sion by rotating the tension adjusting nut clockwise.

Tip: 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, depend- ing 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 compo- nents.

7. Pull the engine stop switch up to RUN.

Choke Knob

Adjusting Nut

33

OPERATION Starting the Engine 8. Do not press the throttle while starting the engine. Turn the ignition

key past the ON position to engage the starter. Activate the starter for a maximum of five seconds, releasing the key when the engine starts.

9. If the engine does not start, release the starter and wait five seconds. 10. Repeat steps 8 and 9 until the engine starts.

Operating the vehicle immediately after starting could cause engine damage. Allow the engine to warm up for several minutes before operating the vehicle. 11. If a warm engine has cooled to a point where it does not readily

start, intermittent use of the choke (knob 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.

12. If the engine slows or stops, 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.

34

OPERATION Driving Procedures

1. Wear a helmet and eye protection. See page 8. 2. Sit upright. Keep your feet on the footrests. Keep both hands on the

handlebars. 3. Start the engine and allow it to warm up. 4. Shift the transmission into gear. 5. Check your surroundings and determine your path of travel. 6. Release the parking brake. 7. Slowly squeeze the throttle lever toward the handlebar to begin

driving. 8. Drive slowly. Practice maneuvering and using the throttle and

brakes on level surfaces.

35

OPERATION Turning the Vehicle 1. Before turning, activate

a turn signal to alert oth- ers of your intentions. Activate the left signal before a left turn. Acti- vate the right signal before a right turn.

2. Steer in the direction of the turn, leaning your upper body to the inside of the turn while sup- porting your weight on the outer footrest. Use the same leaning tech- nique for turning in reverse.

3. Practice turning at slow speeds before attempting to turn at faster speeds.

36

OPERATION Driving on Slippery Surfaces

Whenever riding on slippery surfaces such as wet trails or loose gravel, or during freezing weather, follow these precautions: 1. Do not operate on excessively rough, slippery or loose terrain. 2. Slow down when entering slippery areas. 3. Be alert. 4. Watch the trail. 5. Avoid quick, sharp turns. Tip: To correct a rear wheel skid, turn the handlebars in the same direction as

the skid and shift body weight forward.

Sideways skid

Turn in direction of

skid

37

OPERATION Driving Uphill Whenever traveling uphill, follow these pre- cautions: 1. Avoid steep hills (25

maximum). 2. Check the terrain

carefully. 3. Avoid hills with

excessively slippery or loose surfaces.

4. Shift your weight uphill.

5. Drive straight uphill. 6. Keep your feet on the

footrests. 7. Drive at a steady rate of speed to avoid stalling. 8. Be alert. Be prepared to take emergency action. This may include

dismounting quickly. 9. Never open the throttle suddenly or make sudden gear changes. 10. Never go over the top of a hill at high speed. If all forward speed is lost: Keep your weight uphill. If the vehicle begins rolling downhill, never apply engine power. Never apply the brakes aggressively while rolling backwards. Apply the brakes gradually. When fully stopped, lock the parking brake. See page 25. Dismount on the uphill side, or to either side if the vehicle is pointed straight uphill. Turn the vehicle around using the K-Turn. See page 40.

25 Maximum

38

OPERATION Driving on a Sidehill (Sidehilling)

Avoid crossing the side of a hill (sidehilling) if possible. If sidehilling is necessary, follow these precautions: 1. Slow down. 2. Avoid hills with excessively slippery or loose surfaces. 3. Avoid crossing the sides of steep hills. 4. Shift your weight uphill. 5. Keep your feet on the footrests. 6. If the vehicle begins to tip, quickly turn the front wheels downhill

(if possible) or dismount on the uphill side immediately!

39

OPERATION Driving Downhill

When driving downhill, follow these precautions: 1. Check the terrain carefully. 2. Avoid hills with excessively slippery or loose surfaces. 3. Never drive downhill at high speed. 4. Slow down. 5. Avoid driving downhill at an angle, which can cause the vehicle to

pitch sharply to one side. Drive straight downhill. 6. Shift your weight rearward. 7. Apply the brakes slightly to aid in slowing.

25 Maximum

40

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

1. Stop the vehicle. Keep your weight uphill. 2. Lock the parking brake. Leave the transmission in forward gear.

Turn the engine off. 3. Dismount on the uphill side of the vehicle, or on the left if the vehi-

cle is pointing straight uphill. 4. Staying uphill of the vehicle, turn the handlebars full left. Squeeze

the brake lever to release the parking brake. 5. Slowly release the brake lever and allow the vehicle to roll around

to your right until it's pointing across the hill or slightly downward. 6. Lock the parking brake. Remount from the uphill side. Keep your

weight uphill. 7. Apply the foot brake. Squeeze and release the brake lever to release

the parking brake. 8. Release the foot brake and drive slowly downhill. Control speed

with either the hand or foot brake until the vehicle is on level ground.

8 ft. (2.4 m)

41

OPERATION Driving Through Water Your POLARIS vehicle can operate through water with a maximum recom- mended depth equal to the bottom of the footrests. Follow these procedures when operating through water: 1. Determine water

depths and current before entering water.

2. Choose a crossing where both banks have gradual inclines.

3. Avoid operating through deep or fast- flowing water.

NOTICE: Major engine damage can result if the vehicle is not thoroughly inspected after operation in water. Perform the services outlined in the maintenance chart. See page 49. The following areas need special attention: engine oil, transmission oil, front and rear gearcases (if equipped) and all grease fittings. If the vehicle tips or overturns in water, or if the engine stops during or after operating in water, restarting can result in serious engine damage. Transport the vehicle to your dealer for service before restarting the engine. If this is not possible, follow the vehicle immersion inspection and drying procedures outlined on page 80, then see your dealer for service at the first opportunity.

4. After leaving water, test the brakes. Apply them lightly several times while driving slowly. The friction will help dry out the pads.

If its unavoidable to enter water deeper than the footrest level: Proceed slowly. Avoid rocks and obstacles. Balance your weight carefully. Avoid sudden movements. Maintain a steady rate of speed. Do not make sudden turns or stops.

Do not make sudden throttle changes.

Maximum Depth

42

OPERATION Driving Over Obstacles

Follow these precautions when operating over obstacles: 1. Always check for obstacles before operating in a new area. 2. Look ahead and learn to read the terrain. Be constantly alert for haz-

ards such as logs, rocks and low hanging branches. 3. Travel slowly and use extra caution when operating on unfamiliar

terrain. Not all obstacles are immediately visible. 4. Never attempt to operate over large obstacles, such as rocks or

fallen trees.

43

OPERATION Driving in Reverse

Follow these precautions when operating in reverse: 1. Always check for obstacles or people behind the vehicle. 2. Always avoid backing downhill. 3. Back slowly. 4. Apply the brakes lightly for stopping. 5. Avoid turning at sharp angles. 6. Never open the throttle suddenly. 7. Do not use the override switch unless additional wheel speed is

required for vehicle movement. Use the override with caution as rearward vehicle speed is greatly increased. Do not operate at wide open throttle. Operate the throttle just enough to maintain a desired speed.

NOTICE: 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.

44

OPERATION Parking on an Incline

Avoid parking on an incline if possible. If it's unavoidable, follow these precautions: 1. Stop the engine. 2. Place the transmission in gear. 3. Lock the parking brake. 4. Always block the rear wheels on the downhill side. 5. Turn the fuel valve off.

25 maximum

45

OPERATION Hauling Cargo

Overloading the vehicle or carrying or towing cargo improperly can alter vehicle handling and may cause loss of control or brake instability, which can result in serious injury or death. Always follow these precautions when hauling cargo: REDUCE SPEED AND ALLOW GREATER DISTANCES FOR BRAKING WHEN HAULING CARGO. NEVER EXCEED THE MAXIMUM WEIGHT CAPACITY of the vehicle. When determining the weight you are adding to the vehicle, include the weight of the operator, accessories, loads in the rack or box and the load on the trailer tongue. The combined weight of these items must not exceed the maximum weight capacity. When operating over rough or hilly terrain, reduce speed and cargo to maintain stable driving conditions. CARRY LOADS AS LOW ON THE RACK AS POSSIBLE. Carrying a load high on the rack raises the center of gravity of the vehicle and creates a less stable operating condition. SECURE ALL LOADS BEFORE OPERATING. Unsecured loads can create unstable operating conditions, which could result in loss of control of the vehicle. OPERATE ONLY WITH STABLE AND SAFELY ARRANGED LOADS. When handling off-centered loads that cannot be centered, securely fasten the load and operate with extra caution. Always attach the tow load to the hitch point designated for your vehicle. 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. USE EXTREME CAUTION when operating with loads that extend over the rack sides. Stability and maneuverability may be adversely affected, causing the vehicle to overturn. DO NOT TRAVEL FASTER THAN THE RECOMMENDED SPEEDS. Vehicle should never exceed 10 mph (16 kph) while towing a load on a level 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.

46

OPERATION Hauling Cargo Load Distribution Read and understand the load distribution warnings listed on warning labels. Never exceed the specified weights. Never carry cargo on the front of the TRAIL BLAZER model. Cargo should be evenly distributed and mounted as low as possible on the rear rack. On the TRAIL BOSS model, cargo weight should be evenly distributed (1/3 on the front rack and 2/3 on the rear rack) and mounted as low as possible. When operating over rough or hilly terrain, reduce speed and cargo weight to maintain stable driving conditions. Do not obstruct the headlight beam with cargo.

1/3 2/3

TRAIL BOSS

TRAIL BLAZER

47

OPERATION Hauling Cargo Towing Loads Some models are equipped with a hitch. Accessory hitch kits are avail- able for other models. Towing is approved OFF-ROAD ONLY. Do not exceed the maximum capacities when towing. Do not tow any trailer on a grade steeper than 15. Always attach a towed load to the hitch point. Remove the hitch when not towing a trailer. If towing a load, reduce rear rack cargo weight by the amount of tongue weight. The combination of rear rack cargo weight and tongue weight must

not exceed the rear rack capacity. The total load (operator, accessories, cargo and weight on hitch) must

not exceed the maximum weight capacity of the vehicle.

48

EMISSION CONTROL SYSTEMS Noise Emission Control System Do not modify the engine, intake or exhaust components, as doing so may affect compliance with governmental noise level requirements.

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

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.

Electromagnetic Interference This spark ignition system complies with Canadian ICES-002. This vehicle complies with the EMC requirements of European direc- tives 97/24/EC and 2004/108/EC. Non-ionizing Radiation: This vehicle emits some electromagnetic energy. People with active or non-active implantable medical devices (such as heart monitoring or controlling devices) should review the lim- itations of their device and the applicable electromagnetic standards and directives that apply to this vehicle.

49

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 111. Service and adjustments are important for proper vehicle operation. If you're 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 (16 km/h). Vehicles subjected to severe use must be inspected and serviced more frequently. Severe Use Definition Frequent immersion in mud, water or sand Racing or race-style high RPM use Prolonged low speed, heavy load operation Extended idle 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 crank- case. 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.

50

MAINTENANCE Periodic Maintenance Chart

Improperly performing the procedures marked with a could result in component failure and cause an accident, which may result in serious injury or death. Always have an authorized POLARIS dealer perform these services.

Maintenance Chart Key Perform these operations more often for vehicles subjected to severe use.

E Emission-related service (Failure to conduct this maintenance will not void the emissions warranty but may affect emissions.) 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)

Steering - Pre-Ride - Make adjustments as need ed. See Pre-Ride Checklist on page 31.Front suspension - Pre-Ride -

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

Headlamp/tail lamp

- Daily - Check operation; apply dielectric grease if replacing

E Air filter, main element

- Weekly - Inspect; replace as needed

Recoil housing (if applicable)

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

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

51

MAINTENANCE Periodic Maintenance Chart

Perform these procedures more often for vehicles subjected to severe use. E Emission-Related Service

Have an authorized POLARIS dealer perform these services.

Item Maintenance Interval (whichever comes first)

Remarks

Hours Calendar Miles (Km)

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

E Throttle Cable/ ETC Switch

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

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 duct for proper seal- ing/air leaks

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

Engine oil change 100 H 6 M 1000 (1600) Perform a break-in oil change at 20 hours

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

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

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

52

MAINTENANCE Periodic Maintenance Chart

Item Maintenance Interval (whichever comes first)

Remarks

Hours Calendar Miles (Km)

Engine mounts 100 H 12 M 1000 (1600) Inspect

Exhaust muffler/ pipe

100 H 12 M 1000 (1600) Inspect

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

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.

Clutches (drive and driven)

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

Front wheel bearings

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

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

Toe adjustment - Inspect periodically; adjust when parts are replaced

Headlight aim - Adjust as needed

53

MAINTENANCE Lubrication Guide Check and lubricate all components at the intervals outlined in the Peri- odic Maintenance Chart beginning on page 49. Items not listed in the chart should be lubricated at the General Lubrication interval. The a-arms and lower control arms are lubricated at the factory, and no additional lubrication will be needed. However, if these components are subjected to severe use, grease zerks have been provided for additional lubrication at the user's discretion.

Item Lube Method Engine Oil PS-4 PLUS Performance

Synthetic 2W-50 See page 54.

Brake Fluid DOT 4 Only See page 58.

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

Lubricate.

Transmission Oil AGL PLUS Transmission Fluid

See page 56.

Swing Arm Bushings

Premium All Season Grease

Locate fittings on swing arm and grease with grease gun

Axle Housing

Tie Rod Ends Premium All Season Grease

Lift boot, clean away dirt and grease, apply fresh grease by hand and reas- semble. Perform when suspension action becomes stiff, or after washing.

Swing Arm Bushings

Axle Housing

Tie Rod Ends

54

MAINTENANCE Engine Oil Oil Recommendations Always change the oil filter whenever changing oil. 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 manufacturer's recommendations for ambient temperature operation. See page 97 for the part numbers of POLARIS products.

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 Specifications

Oil Level The oil dipstick is located on the left side of the vehicle. 1. Position the vehicle on a

level surface. Place the transmission in neutral. Lock the parking brake.

2. Start the engine. Allow it to idle for 30 seconds. Stop the engine.

3. Remove the dipstick. Wipe it dry with a clean cloth. 4. Reinstall the dipstick completely. 5. Remove the dipstick and check the oil level. Add oil as needed.

Maintain the oil level in the safe range. Do not overfill. 6. Reinstall the dipstick.

Lubricant Capacity Drain Plug Torque PS-4 PLUS Performance

Synthetic 2W-50 4-Cycle Oil 1.9 qts. (1.8 l) (with oil cooler) 1.7 qts. (1.6 l) (oil change only)

14 ft. lbs. (19 Nm)

{Safe Range

55

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

neutral. Lock the parking brake. 2. Clean the area around the drain plug. 3. Start the engine. Allow it to idle for two to three minutes. Stop the

engine. 4. Place a drain pan under the engine crankcase. Remove the drain

plug. Allow the oil to drain completely. CAUTION! Hot oil can cause burns to skin. Do not allow hot oil to contact skin. 5. Reinstall the drain plug with a new sealing washer. Torque to speci-

fication. See page 54. Tip: The sealing surfaces on the drain plug and crankcase should be clean and

free of burrs, nicks or scratches. 6. Place towels under the oil filter. Using an oil filter wrench, turn the

filter counterclockwise to remove it. 7. Using a clean, dry cloth, clean the filter sealing surface on the

crankcase. 8. Lubricate the gasket on the new filter with a film of new engine oil.

Check to make sure the gasket is in good condition. 9. Install the new filter and turn by hand until the filter gasket contacts

the sealing surface, then turn an additional 1/2 turn. 10. Remove the dipstick and fill the sump with 1.7 quarts (1.6 l) of the

recommended oil (see page 54). Reinstall the dipstick. 11. Start the engine and allow it to idle for one to two minutes. Stop the

engine and inspect for leaks. 12. Recheck the oil level and add oil as necessary to bring the level to

the upper mark on the dipstick. 13. Discard used oil and filter properly.

56

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

Transmission Oil Recommendations

Oil Check The dipstick is located on the right side of the vehicle near the recoil handle. 1. Position the vehicle on a

level surface. 2. Remove the dipstick.

Wipe it dry with a clean cloth.

3. Reinstall the dipstick completely.

4. Remove the dipstick and check the fluid level. Add fluid as needed. Maintain the fluid level in the safe range. Do not overfill.

5. Reinstall the dipstick.

Gearcase Lubricant Capacity Drain Plug Torque

Transmission AGL PLUS Transmission Fluid

11.3 oz. (335 ml)

14 ft. lbs. (19 Nm)

Dipstick

57

MAINTENANCE Transmission Oil Oil Change 1. Position the vehicle on a level

surface. 2. Place a drain pan beneath the

transmission oil drain plug area. 3. Loosen the jam nut. 4. Turn the adjuster bolt in to allow

the removal of the drain plug. 5. Remove the drain plug and wipe

the magnetic end clean to remove accumulated metallic filings.

6. Allow the oil to drain com- pletely.

7. Reinstall the drain plug with a new sealing washer. Torque to specification.

8. Turn the adjuster bolt out until it touches the frame, and then turn an additional 1/2 turn.

9. Tighten the jam nut securely while holding the adjuster bolt. 10. Add the recommended lubricant through the dipstick hole until the

oil level is between the upper and lower limits. Do not overfill. 11. Reinstall the dipstick. 12. Check for leaks.

Jam Nut

Drain Plug

Adjuster Bolt

58

MAINTENANCE Brake Fluid Check brake fluid levels for both brake systems before each ride. Always maintain brake fluid at the recommended level. Do not overfill. The brakes should feel firm when they're applied. Spongy or weak brakes may indicate a fluid leak or low fluid level. A low fluid level may also mean that brake pads are worn and need to be replaced. Do not operate the vehicle with spongy or weak brakes. See your dealer for ser- vice.

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

If the fluid level is low add DOT 4 brake fluid only. See page 97 for the part numbers of POLARIS products.

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

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. To ensure proper diaphragm operation, always fill the reservoir as needed whenever the cover is loosened or removed. Do not overfill.

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.

59

MAINTENANCE Brake Fluid Hand Brake The master cylinder is located on the left handle- bar. Maintain the fluid level 6 mm below the top edge of the master cylin- der. Do not overfill.

1. Position the vehicle on a level surface. Make sure the handlebars are straight.

2. View the fluid level through the indicator window (eye) on the top of the master cylinder. The eye will appear dark when the fluid level is full. When fluid is low, the eye will be clear.

3. Add the recommended fluid as needed. Do not overfill.

Foot Brake 1. Position the vehicle on a level surface. 2. The brake fluid reservoir is located either under the seat or near the

foot brake. View the fluid level in the master cylinder. 3. Maintain the fluid level between the minimum and maximum

marks. Do not overfill.

Master Cylinder

Indicator Window

60

MAINTENANCE Brakes The front and rear brakes are hydraulic disc brakes. Both brake systems are self-adjusting.

Brake Inspections Perform the following checks to keep the brake systems in good operat- ing condition. Check more often if brakes are used heavily under normal operation. 1. Always keep brake fluid at an

adequate level. See page 58. 2. Check the brake systems regularly

for fluid leaks. 3. Check the brakes for excessive

travel or spongy feel. 4. Check the friction pads for wear,

damage and looseness. Replace the pads when the friction mate- rial is worn to 1 mm.

5. Check the security and surface condition of the disc.

1 mm

61

MAINTENANCE Side Panel Removal Tip: Side panel removal may be difficult until the locking tabs and receivers have

been snapped and unsnapped a few times. 1. Remove the seat. 2. Remove the push-pins at the front and rear of the side panel. 3. Grasp the rear of the side panel near the rear cab. Pull the panel

slightly outward, downward and rearward to disengage the upper front section.

4. To reinstall the side panel, align the upper and lower front section with the mating front cab tabs. Push the panel upward and forward until the panel is fully seated at the front. Lock the rear of the panel into the rear front cab tabs. Reinstall the push-pins at the front and rear of the side panel.

62

MAINTENANCE Handlebars The handlebars can be adjusted for rider preference.

Improper adjustment of the handlebars or incorrect torquing of the adjuster block tightening bolts can cause limited steering or loosening of the handlebars, resulting in loss of control. Follow the adjustment procedures exactly, or see your POLARIS dealer for service.

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

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

desired height. 4. 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.

5. Torque the front two bolts to 14-17 Nm, then torque the rear two bolts. A gap of up to 3 mm will remain at the rear bolts.

Handlebar Bolts

63

MAINTENANCE Toe Alignment

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 3-6 mm 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 (1).

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

6. Measure the distance between the marks and record the measurement (2).

7. Subtract measurement 2 from measurement 1. The difference is the vehicle toe-out alignment.

8. If you discover improper alignment, see your POLARIS dealer for service.

1

2

64

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

adjuster at the handlebar. 2. Squeeze the end of the rub-

ber boot and slide it far enough to expose the end of the inline cable adjuster.

3. Loosen the adjuster lock nut. 4. Rotate the boot to turn the

adjuster until 1/16" to 1/8" (1.5-3 mm) of freeplay is achieved at the thumb lever. While adjusting freeplay, be sure to flip the throttle lever back and forth.

5. Tighten the lock nut. 6. Squeeze the end of the rub-

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

Lock Nut Adjuster

Boot

1.6-3 mm

65

MAINTENANCE Steering Assembly The steering assembly of the ATV should be checked periodically for loose nuts and bolts. If loose nuts and bolts are found, see your POLARIS dealer for service before operating the vehicle.

Camber and Caster The camber and caster are non-adjustable.

Rear Spring The rear shock absorber spring is adjusted by rotating the adjuster either clockwise or counterclockwise to increase or decrease spring tension. Accessory springs are available through your POLARIS dealer.

Adjuster

66

MAINTENANCE Tires

Operating your vehicle with worn tires, improperly inflated tires, non-standard tires or improperly installed tires will affect vehicle handling and could cause an accident. Maintain proper tire pressure as described on the label on your vehicle and in

the specifications section of the owner's manual. Use only original equipment size and type when replacing tires. Make sure the wheels are installed properly. Replace tires when the tread depth measures 3 mm or less.

Refer to the specifications section beginning on page 102 for recom- mended tire type, size and pressure.

Front Wheel Hub Tightening Front wheel bearing tightness and spindle nut retention are critical com- ponent operations. All service must be performed by your authorized POLARIS dealer.

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

WARNING

3 mm

67

MAINTENANCE Tires Wheel Removal 1. Position the vehicle on a level surface. Place the transmission in

gear. Lock the parking brake. 2. Loosen the wheel nuts slightly.

Do not service axle nuts that have a cotter pin installed. See your POLARIS dealer. 3. Place a suitable stand under the

footrest frame to raise the wheel slightly off the ground.

4. Remove the wheel nuts. 5. Remove the wheel.

Wheel Installation 1. Place the wheel on the wheel hub

with the valve stem toward the outside and the rotation arrows on the tire pointing toward forward rotation.

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

3. Lower the vehicle to the ground. 4. Torque the wheel nuts to

specification (page 68).

Loose nuts could cause a tire to come off during operation, which could result in an accident or overturn. Always ensure that all nuts are torqued to specification.

68

MAINTENANCE Tires Wheel Nut Torque Specifications

Check the wheel nut torques occasionally and when they've been loos- ened for service.

Item Torque Specification

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

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

Rear 50 ft. lbs. (68 Nm)

Front 27 ft. lbs. (37 Nm)

69

MAINTENANCE Air Filter 1. Remove the seat. 2. Release the air box cover clips,

and remove the air box cover. 3. Loosen the clamp and remove

the filter. 4. Remove the fabric type pre-fil-

ter from the main filter. Wash the pre-filter in soapy water, then rinse and let dry.

5. Reinstall the pre-filter over the main filter. Install a new main filter if needed.

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

7. Reinstall the air box cover and the seat.

Pre-Filter

Main Filter

70

MAINTENANCE Recoil Housing Always drain the recoil housing after operating the vehicle in wet condi- tions. Drain the housing before storing the vehicle. Make sure the hous- ing is completely dry before reinstalling the drain plug. Water will enter the recoil housing if the starter handle is disengaged from the rope guide when under water. 1. Place the transmission in gear. 2. Lock the parking brake. 3. Stop the engine. 4. Remove the drain screw on the

bottom of the recoil housing. 5. Reinstall the drain screw. Tip: 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.

71

MAINTENANCE Carburetor Your POLARIS vehicle is calibrated at the factory for optimal perfor- mance at altitudes ranging from zero to 1800 meters and at temperatures of 4 degrees C. or higher. Above 1800 meters the engine air/fuel mixture becomes too rich and the engine loses approximately 3% of its power for each 300 meter 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 and clutch components, available from your POLARIS dealer, are required for operation above 1800 meters and at temperatures below 4 degrees C. Tip: Continuous operation of the engine without proper jetting when required

can cause poor performance, overheating or PVT or engine damage. See your POLARIS dealer for more information about jetting the vehicle for con- ditions in your area.

Carburetor/Engine Idle RPM Adjustment If the engine idle speed is not satisfac- tory, and all other conditions are favor- able, the carburetor can be adjusted. 1. Place the transmission in gear. Lock

the parking brake. 2. Start the engine and allow it to warm

up for approximately five minutes. 3. Turn the screw in (clockwise) to

raise RPM. Turn the screw out (counterclockwise) to lower RPM.

Idle Adjuster

72

MAINTENANCE Drive Chain Drive Chain Lubrication The drive chains are equipped with o-ring-sealed, permanently greased pins and rollers. However, the outer surfaces of the roller must be lubri- cated. 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 mm). Regularly lubricate the drive chain with POLARIS Chain Lube, an SAE 80-90 lube or an approved o-ring chain spray lube. See page 97 for the part numbers of POLARIS products.

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.

73

MAINTENANCE Drive Chain Rear Drive Chain Slack Check the amount of chain slack in three different locations by moving the vehicle slightly forward to gain slack at the top side of the rear chain. Measure the chain slack at the tightest of the three positions. At this point the chain should have 3/16"-3/8" (5 mm - 10 mm) deflection.

Adjusting or operating the vehicle 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.

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. 4. Loosen the caliper mounting

bolt located on the left side of the swing arm.

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

1

3/16"-3/8" (5 mm - 10 mm)

Locking Bolts

Pin Punch

74

MAINTENANCE Drive Chain Rear Drive Chain Slack 6. Roll the vehicle forward or back-

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

7. Tighten the eccentric locking bolts to 30 ft. lbs. (41 Nm) for machines without the hitch and 45 ft. 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 vehicle forward, checking chain tension in several places

around the chain. Tip: 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" (3 mm) clearance and tighten

the retaining bolt to 5 ft. lbs. (7 Nm). 12. Reinstall the chain guard (if equipped).

Clip Position

75

MAINTENANCE Lights Headlight Beam Adjustment The headlight beam can be adjusted slightly upward or downward. Use the following procedure to make the adjustment.

1. Position the vehicle on a level surface with the headlight approxi- mately 25 ft. (7.6 m) from a wall.

2. Place the transmission in neutral. 3. Lock the parking brake. 4. Measure the distance from the floor to the center of the headlight

and make a mark on the wall at the same height. Include rider weight on the seat when measuring.

5. Start the engine. Turn the headlight on. 6. Observe the headlight aim on the wall. The most intense part of the

headlight beam should be two inches (5 cm) below the mark on the wall.

7. Tighten or loosen the lower headlight screws to adjust the beam upward or downward or to the left or right.

25 ft. (7.6 m)

2" (5 cm) X X

76

MAINTENANCE Lights

Poor lighting can result in loss of control or an accident. Lights become dirty during normal operation. Wash the headlights and taillights frequently.

Hot components can cause burns to skin. Allow lamps to cool before servicing.

Headlamp Replacement When servicing a halogen lamp, do not touch the lamp with bare fingers. Oil from your skin leaves a residue, causing a hot spot that will shorten the life of the lamp. Hold the plastic part of the lamp. 1. Remove the wire harness connector from the back of the headlight. 2. Grasp the bulb housing and turn it counterclockwise to remove the

bulb. 3. Apply dielectric grease to the light bulb socket before installing the

new bulb. Install the replacement bulb into the headlight housing and rotate clockwise firmly.

Tip: The bulb must be positioned so the harness installs into the lamp at the bot- tom.

4. Reinstall the connector to the back of the headlight.

77

MAINTENANCE Lights Indicator Lamp Replacement 1. Remove the instrument panel, if necessary, to access the back of the

indicator panel. 2. Using a small, straight-blade screwdriver, turn the base of the bulb

1/4 turn counterclockwise. 3. Using a needle-nose pliers or similar tool, pull the lamp out of the

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

Taillight/Brakelight Lamp Replacement 1. Remove the taillight lens

cover mounting screws. Remove the lens cover and gasket and set aside for reassembly.

2. Remove the lamp. 3. Apply dielectric grease

to the socket and install the new lamp.

4. Test the taillight/brake light for proper opera- tion.

5. Reinstall the gasket and lens cover.

Screw

Lamp

Cover

78

MAINTENANCE Spark Plugs Spark Plug Recommendations Refer to the specifications section beginning on page 102 for the recom- mended spark plug type and gap for your vehicle. NOTICE: Using non-recommended spark plugs can result in serious engine

damage. Always use POLARIS-recommended spark plugs.

Spark Plug Inspection Check the spark plug firing end condition after the engine has been warmed up and the vehicle has been driven at higher speeds. Immedi- ately check the spark plug for correct color. See page 79.

A hot exhaust system and engine can cause burns. Wear protective gloves when removing a spark plug for inspection. 1. Rotate the spark plug cap. 2. Using the special wrench provided in the tool pouch, rotate the

spark plug counterclockwise to remove it. 3. Inspect the electrodes for wear

and carbon buildup. Replace worn or fouled plugs. Verify that the gap is at specification before installation.

4. Reverse the procedure for spark plug installation. Torque to specification.

Plug Condition Torque Specification

New Spark Plug 12-15 Nm

Previously Installed Spark Plug 23-27 Nm

79

MAINTENANCE Spark Plugs Spark Plug Condition Normal Spark Plug The normal insulator tip is gray, tan or light brown. There will be few combustion deposits. The electrodes are not burned or eroded. This indi- cates the proper type and heat range for the engine and the service. The tip should not be flaky and white. A white insulator tip indicates overheating, caused by use of an improper spark plug or incorrect carbu- retion adjustments. Wet Fouled Spark 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 oil, improper use of the choke, or incorrect throt- tle body/carburetor adjustments.

80

MAINTENANCE Vehicle Immersion If your vehicle becomes immersed, major engine damage can result if the machine is not thoroughly inspected. Take the vehicle to your dealer before starting the engine. If it's impossible to take your vehicle to a dealer before starting it, fol- low the steps outlined below. 1. Move the vehicle out of the

water. 2. Turn the fuel valve off. 3. Check the air box. If water is

present, dry the air box and replace the filter with a new filter.

4. Remove the spark plug. 5. Loosen the carburetor drain screw

and drain the carburetor. 6. Turn the engine over several times

using the electric start. 7. Dry the spark plug. Reinstall the plug

or install a new plug. 8. Tighten the carburetor drain screw. 9. Turn the fuel valve on. 10. Attempt to start the engine. If neces-

sary, repeat the drying procedure. 11. Have the vehicle serviced by your

dealer promptly, whether you succeed in starting it or not. 12. If water has been ingested into the transmission, follow the proce-

dure on page 84 for drying.

Drain Screw

81

MAINTENANCE Spark Arrestor

Failure to heed the following warnings while servicing the spark arrestor could result in serious injury or death. Never run the engine in an enclosed area. Remove any combustible materials from the area. Wear eye protection and leather work gloves. Do not stand behind or in front of the vehicle while purging. Never go under the vehicle while it's inclined. The exhaust system can get extremely hot. Do not perform service on the spark arrestor while the system is hot. Allow components to cool sufficiently before proceeding.

Use the following procedure to periodically purge accumulated carbon from the exhaust pipe/muffler. 1. Position the vehicle on a

level surface. 2. Place the transmission in

neutral. 3. Lock the parking brake. 4. Remove the arrestor clean-

out plug from the bottom of the muffler.

5. Start the engine. 6. Quickly squeeze and release the throttle lever several times to purge

carbon from the system. 7. If carbon comes out of the exhaust, cover or plug the exhaust outlet.

Wear protective gloves. 8. Lightly tap on the exhaust pipe with a rubber mallet while repeating

step 6. 9. If particles are still suspected to be in the muffler, elevate the rear of

the vehicle one foot (30 cm) higher than the front. Block the wheels. 10. Repeat steps 6 to 8 until no more particles are expelled. 11. Stop the engine. Allow the arrestor to cool. 12. Reinstall the arrestor plug and remove the exhaust outlet cover or

plug.

WARNING

Exhaust Outlet

Clean-Out Plug

82

MAINTENANCE PVT System

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 owner's manual. This PVT system is intended for use on POLARIS products only. Do not

install it in any other product. Always make sure the PVT housing is securely in place during operation.

WARNING

83

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 fly- weights 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 (8 km/h), due to the system's dependence on engine speed. For example, when operating at a ground speed of 3 MPH (5 km/h), the engine would be running at only about 1500 RPM, with an engagement speed of about 1400 RPM. Whenever operating this close to the engage- ment speed, the engine may be running at a speed too low to provide the pinch needed to prevent belt slip. Belt slip is responsible for creating the excessive heat that destroys belts, wears clutch components and causes outer clutch covers to fail. If the vehicle will be operated for extended periods below 5 MPH (8 km/h), 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 greatly extends the life of the PVT components (belt, cover, etc.). Tip: Avoid heavy pulling and extended low-speed operation.

84

MAINTENANCE PVT System PVT Drying There may be some instances when water is accidently ingested into the PVT system. Use the following instructions to dry it out before operat- ing. 1. Move the vehicle out of the water. 2. Remove the PVT drain plug. Allow the water to drain completely.

Reinstall the drain plug. 3. Start the engine. Place the transmission in neutral. 4. 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.

5. Allow the engine RPM to settle to idle speed, then shift the trans- mission into forward gear.

6. Test for belt slippage. If the belt slips, repeat the process. 7. Take the vehicle to your dealer for service as soon as possible.

85

MAINTENANCE Battery

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 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.

Your vehicle may have either a sealed battery, which requires little maintenance, or a conventional battery. A sealed battery can be identi- fied 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 termi- nals with dielectric grease or petroleum jelly. Be careful not to allow cleaning solution or tap water into a conventional battery.

WARNING

WARNING

86

MAINTENANCE Battery Battery Removal 1. Place the transmission in gear. 2. Lock the parking brake. 3. Remove the seat. 4. Disconnect the battery hold-down strap. 5. Remove the battery cover (if equipped). 6. On conventional batteries, remove the battery vent tube. 7. Disconnect the black (negative) battery cable first. 8. Disconnect the red (positive) battery cable last. 9. Lift the battery out of the vehicle. Be careful not to tip a conven-

tional battery sideways, which could spill electrolyte. NOTICE: 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.

87

MAINTENANCE Battery Battery Installation Using a new battery that has not been fully charged can damage the bat- tery and result in a shorter life. It can also hinder vehicle performance. Follow the battery charging instructions on page 89 before installing the battery. 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 bat-

teries do not have a vent tube). 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.

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 (if equipped). 8. Secure the battery hold-down strap. 9. Verify that cables are properly routed. Cables should be routed low

so they dont interfere with safe seat installation. 10. Reinstall the seat.

88

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 it's fully charged, and store it out of the sun in a cool, dry place. Check battery voltage each month during storage and recharge as needed to maintain a full charge. Tip: Power plug leads may need to be bent down so that the battery cover can

be installed. POLARIS recommends maintaining battery charge by using a POLARIS 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 97 for the part numbers of POLARIS products.

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. Add only distilled water. Tap water contains minerals that are harmful to a battery.

Lower Mark

Upper Mark

89

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

ing or spilled electrolyte during charging. See page 86. 2. Charge the battery with a charging output no larger than 1/10 of the

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

3. Reinstall the battery. See page 87. Make sure the positive terminal is toward the front of the vehicle.

Battery Charging (Sealed Battery) The following battery charging instructions apply only to the installa- tion 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.

An overheated battery may 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 at 1.2 amps

or less until battery voltage is 12.8 or greater. 3. When using an automatic charger, refer to the charger manufac-

turer's instructions for recharging. When using a constant current charger, use the following guidelines for recharging.

90

MAINTENANCE Battery Battery Charging (Sealed Battery) 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 with desulfating charger

At least 20 hours

91

MAINTENANCE Cleaning and Storage Washing the Vehicle Keeping your POLARIS vehicle clean will not only improve its appear- ance but it can also extend the life of various components. NOTICE: High water pressure may damage components. POLARIS

recommends washing the vehicle by hand or with a garden hose, using mild soap. Certain products, including insect repellents and chemicals, will damage plastic surfaces. Do not allow these types of products to contact the vehicle.

The best and safest way to clean your POLARIS vehicle is with a gar- den 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 Avoid the use of harsh cleaners, which can scratch the finish. Do not use a power washer to clean the vehicle. Do not use medium to heavy duty compounds on the finish. 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.

92

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 follow- ing items:

If an informational or graphic label becomes illegible or comes off, con- tact your POLARIS dealer to purchase a replacement. Replacement safety labels are provided by POLARIS at no charge. 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 Avoid the use of automotive products, some of which can scratch the

finish of your vehicle. 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.

Wheel bearings Electrical components/wiring Radiator (if equipped) Switches and controls Transmission seals Cab and body panels Brakes Labels and decals

93

MAINTENANCE Cleaning and Storage Chrome Wheel Care (if equipped) Proper maintenance will protect chrome wheels from corrosion, pre- serve wheel life and ensure a like new appearance for many years. Chrome wheels exposed to road salt (or salt in the air in coastal areas) are more susceptible to corrosion if not properly cleaned. Clean chrome wheels more often if they're 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 pol-

ished 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 out- lined above.

94

MAINTENANCE Cleaning and Storage Storage Tips NOTICE: 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 91. Stabilize the Fuel 1. Fill the fuel tank. 2. Add POLARIS Carbon Clean Fuel Treatment or POLARIS Fuel

Stabilizer. Follow the instructions on the container for the recom- mended amount. 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 54. 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 1. Drain the recoil housing. See page 70.

95

MAINTENANCE Cleaning and Storage Storage Tips Fluid Levels Inspect the fluid levels. Change fluids as recommended in the Periodic Maintenance Chart beginning on page 49. Demand drive unit (if equipped) Transmission Brake fluid (change every two years and any time the fluid looks dark

or contaminated)

Fog the Engine 1. Treat the fuel system with POLARIS Carbon Clean. See page 94. 2. Support the front end of the machine so the engine is level or tilted

slightly rearward. 3. Remove the spark plug. Pour 2-3 tablespoons (30-40 ml) of engine

oil into the hole. Tip: 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 electric start. Oil will

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

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

8. To eliminate any fuel remaining in the carburetor, run the engine until it stops.

96

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 49. Battery Storage See pages 88-89 for storage and charging procedures. Storage Area/Covers Set the tire pressure and safely support the vehicle with the tires slightly off the ground. Be sure the storage area is well ventilated. Cover the vehicle with a genuine POLARIS cover. Do not use plastic or coated materials. They do not allow enough ventilation to prevent condensa- tion, and may promote corrosion and oxidation.

Transporting the Vehicle Follow these procedures when trans- porting the vehicle. 1. Stop the engine. 2. Place the transmission in gear. 3. Lock the parking brake. 4. Turn the fuel valve off. 5. Secure the fuel cap, oil cap and

seat. 6. Remove the key to prevent loss

during transporting. 7. Always tie the frame of the vehicle

to the transporting unit securely with suitable straps or rope. Do not attach tie straps to the front A-arm bolt pockets, racks or handlebars.

97

POLARIS PRODUCTS Part Number Description

Engine Lubricant 2870791 Fogging Oil (12 oz. Aerosol) 2876244 PS-4 PLUS Performance Synthetic 2W-50 4-Cycle Oil (qt./.95 l) 2876245 PS-4 PLUS Performance Synthetic 2W-50 4-Cycle Oil (gal./3.8 l)

Gearcase / Transmission Lubricants 2878068 AGL PLUS Transmission Fluid (qt./.95 l) 2878069 AGL PLUS Transmission Fluid (gal./3.8 l) 2871653 Premium ATV Angle Drive Fluid (8 oz./237 ml) 2872276 Premium ATV Angle Drive Fluid (2.5 gal./9.5 l) 2870465 Pump for Gallon (3.8 l) Jug

Grease / Specialized Lubricants 2871312 Grease Gun Kit, Premium All Season 2871322 Premium All Season Grease (3 oz./89 ml cartridge) 2871423 Premium All Season Grease (14 oz./414 ml cartridge) 2871460 Starter Drive Grease 2871515 Premium U-Joint Lube (3 oz./89 ml cartridge) 2871551 Premium U-Joint Lube (14 oz./414 ml cartridge) 2871329 Dielectric Grease (NyogelTM) 2872073 Chain Lube, Aerosol (6.25 oz./185 ml) 2872348 Chain Lube, Aerosol (16 oz./473 ml)

Additives / Miscellaneous 2871326 Carbon Clean Plus 2870652 Fuel Stabilizer 2872189 DOT 4 Brake Fluid 2871956 LoctiteTM 565 Thread Sealant 2859044 POLARIS Battery TenderTM Charger

98

TROUBLESHOOTING Drive Belt Wear/Burn

Possible Cause Solution

Starting out going up a steep incline

Use low range (if equipped) or turn around using the K- turn (see page 40).

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

Drive at a higher speed or use low range (if equipped) more frequently.

Insufficient warm-up at low ambient tempera- tures

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 (if equipped).

Utility use/plowing Use low range only (if equipped). Stuck in mud or snow Shift the transmission to low range (if equipped). Care-

fully 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 Belt slippage from water or snow ingestion into the PVT system

Dry out the PVT. See page 84. Inspect clutch seals 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 (48 km/h) for one mile (1.6 km). Operate 5 miles (8 km) or more when temperature is below freezing.

Wrong or missing belt Install the recommended belt. Improper break-in Always break in a new belt and/or clutch. See page 30.

99

TROUBLESHOOTING Engine Doesn't Turn Over

Engine Turns Over, Fails to Start

Engine Backfires

Possible Cause Solution

Low battery voltage Recharge the battery to 12.8 VDC Loose battery connections Check all connections and tighten Loose solenoid connections Check all connections and tighten

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 fresh recommended fuel Fouled or defective spark plug(s) Inspect plugs and replace if necessary No spark to spark plug Inspect plugs, verify stop switch is on Overuse of choke Inspect, clean and/or replace spark plugs Clogged fuel filter Replace the filter Water or fuel in crankcase Immediately see your POLARIS dealer Low battery voltage Recharge the battery to 12.8 VDC Mechanical failure See your dealer

Possible Cause Solution

Weak spark from spark plug 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 fresh recommended fuel Incorrectly installed spark plug wires See your dealer Incorrect ignition timing See your dealer Mechanical failure See your dealer Exhaust leaks Replace exhaust seals

100

TROUBLESHOOTING Engine Pings or Knocks

Engine Runs Irregularly, Stalls or Misfires

Possible Cause Solution

Poor quality or low octane fuel Replace with recommended fuel Incorrect ignition timing See your dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs Idle set too low Adjust idle speed

Possible Cause Solution

Fouled or defective spark plugs Inspect, clean and/or replace spark plugs Worn or defective spark plug wires See your 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 tank 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 dealer Electronic throttle control malfunction See your dealer Other mechanical failure See your dealer

Possible Lean Fuel 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 dealer

Possible Rich Fuel 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 dealer

101

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 is 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 dealer Incorrect spark plug gap or heat range Set gap to specs or replace plug Loose ignition connections Check all connections and tighten Low battery voltage Recharge the battery to 12.8 VDC Incorrect fuel Replace with fresh recommended fuel Clogged air filter Inspect and clean or replace Reverse speed limiter malfunction See your dealer Electronic throttle control malfunction See your dealer Other mechanical failure See your dealer Overheated engine Clean radiator screen and core if

equipped Clean engine exterior See your POLARIS dealer

102

SPECIFICATIONS

* Based on EU Directive 76/432/EC

TRAIL BOSS 330 Maximum Weight Capacity 415 lbs. (188 kg) (includes weight of opera-

tor, cargo and accessories) Dry Weight 535 lbs. (243 kg) Fuel Capacity 4 gal. (15.1 l) Engine Oil Capacity 1.9 qts. (1.8 l) (with oil cooler)

1.7 qts. (1.6 l) (oil change only) Transmission Oil 11.3 oz. (335 ml) Front Rack Capacity 75 lbs. (34 kg) Rear Rack Capacity 125 lbs. (57 kg) Hitch Tongue Weight Capacity 85 lbs. (38.6 kg) (Rear rack capacity and

tongue weight not to exceed 125 lbs./57 kg) Hitch Towing Rating 850 lbs. (385.6 kg) Unbraked Trailer Towing Capacity* 1263 lbs. (573 kg) Overall Length 75 in. (190.5 cm) Overall Width 45 in. (114 cm) Overall Height 49 in. (124.5 cm) Wheelbase 48.5 in. (124 cm) Ground Clearance 4.75 in. (12 cm) Minimum Turning Radius 65 in. (165 cm) unloaded Engine Model Number/Type ES-32PFE-109 / 4 Cycle, Single Cylinder Lubrication Wet Sump Engine Cooling Air with fan assisted oil cooler Displacement 329 cc Bore x Stroke 78.5 x 68 Alternator Output 200w @5000 RPM Compression Ratio 9.2:1 Carburetor BST 34 Pilot Jet 42.5 Main Jet 122.5 Needle Jet P-4 (829) Jet Needle 4HB48-3 Pilot Air Jet 160 Pilot Screw 2.0+ turns Ignition System DC CDI Ignition Timing 30 +/- 2 @ 5000 RPM Idle RPM 1500 Spark Plug / Gap BKR6E / .036 in. (.9 mm)

103

SPECIFICATIONS

Jetting Chart

Clutching Chart

TRAIL BOSS 330 Driving System Type Automatic PVT (POLARIS Variable Transmis-

sion) Shift Type Side Lever (F/N/R) Gear Reduction, Reverse 3.05:1 Gear Reduction, Forward 2.68:1 Drive Ratio, Final 3.64:1 Drive Chain 520 O-Ring Tires/Pressure, Front 23 x 7-10 (4 psi/27.6 kPa) Tires/Pressure, Rear 22 x 11-10 (3 psi/20.7 kPa) Front Suspension MacPherson strut with 8.2" (21 cm) travel Rear Suspension Progressive rate with 10.5" (26.7 cm) travel Shock Adjustment CAM Brakes, Front and Rear Single-Control Hydraulic Disc Brake, Auxiliary Foot-Activated Hydraulic Disc, Rear Wheel Brake, Parking Hydraulic lock, all wheel Headlight 2 Dual Beam 30w/30w Taillights 12V 8.26W Brake Light 12V 26.9W Battery 12V 14AH Indicators High Beam/Turn Signals/High Temp/Neutral/

Reverse

ALTITUDE Meters (Feet)

AMBIENT TEMPERATURE Below 40 F (Below 5 C)

40F and above (5C and above)

0-1800 (0-6000) 127.5 122.5

1800-3700 (6000-12000) 120 115

Altitude Meters (Feet)

Shift Weight

Drive Clutch Spring

Driven Clutch Spring

Helix/Spring/ Setting

0-1800 (0-6000)

10RHF 5632282

Blue/Gray 7042202

Black 7041782

40 5131446

2+2

1800-3700 (6000-12000)

20-40 5631356

Blue/Gray 7042202

Black 7041782

40 5131446

2+2

104

SPECIFICATIONS

* Based on EU Directive 76/432/EC

TRAIL BLAZER 330 Maximum Weight Capacity 275 lbs. (125 kg) (includes weight of opera-

tor, cargo and accessories) Dry Weight 496 lbs. (225 kg) Fuel Capacity 4 gal. (15.1 l) Engine Oil Capacity 1.9 qts. (1.8 l) (with oil cooler)

1.7 qts. (1.6 l) (oil change only) Transmission Oil 11.3 oz. (33 ml) Front Rack Capacity (Accessory) 30 lbs. (13.6 kg) (Maximum) Rear Rack Capacity (Accessory) 60 lbs. (27.2 kg) (Maximum) Hitch Tongue Weight Capacity 85 lbs. (38.6 kg) (Rear rack capacity and

tongue weight not to exceed 60 lbs./27.2 kg) Hitch Towing Rating 850 lbs.(386 kg) Unbraked Trailer Towing Capacity* 1263 lbs. (573 kg) Overall Length 75 in. (190.5 cm) Overall Width 45 in. (114 cm) Overall Height 49 in. (124.5 cm) Wheelbase 48.5 in. (124 cm) Ground Clearance 4.75 in. (12 cm) Minimum Turning Radius 83 in. (211 cm) unloaded Engine Model Number/Type ES-32PFE-109 / 4 Cycle, Single Cylinder Lubrication Wet Sump Engine Cooling Air with fan assisted oil cooler Displacement 329cc Bore x Stroke 78.5 x 68 Alternator Output 200w @5000 RPM Compression Ratio 9.2:1 Carburetor BST 34 Pilot Jet 42.5 Main Jet 122.5 Needle Jet P-4 (829) Jet Needle 4HB48-3 Pilot Air Jet 160 Pilot Screw 2.0 turns Ignition System DC CDI Ignition Timing 30 +/- 2 @ 5000 RPM Idle RPM 1500 Spark Plug / Gap BKR6E / .036 in. (.9 mm)

105

SPECIFICATIONS

Jetting Chart

Clutching Chart

TRAIL BLAZER 330 Driving System Type Automatic PVT (POLARIS Variable Transmis-

sion) Shift Type Side Lever (F/N/R) Gear Reduction, Reverse 3.05:1 Gear Reduction, Forward 2.68:1 Drive Ratio, Final 3.64:1 Drive Chain 520 O-Ring Tires/Pressure, Front 23 x 7-10 (4 psi/27.6 kPa) Tires/Pressure, Rear 22 x 11-10 (3 psi/20.7 kPa) Front Suspension MacPherson strut with 8.2" (21 cm) travel Rear Suspension Progressive rate with 10.5" (26.7 cm) travel Shock Adjustment CAM Brakes, Front and Rear Single-Control Hydraulic Disc Brake, Auxiliary Foot-Activated Hydraulic Disc, Rear Wheel Brake, Parking Hydraulic lock, all wheel Headlight 1 Single Beam, 55w Taillights 12V 8.26W Brake Light 12V 26.9W Battery 12V 14AH Indicators High Beam/Turn Signals/High Temp/Neutral/

Reverse

ALTITUDE Meters (Feet)

AMBIENT TEMPERATURE Below 40 F (Below 5 C)

40F and above (5C and above)

0-1800 (0-6000) 127.5 122.5

1800-3700 (6000-12000) 120 115

Altitude Meters (Feet)

Shift Weight

Drive Clutch Spring

Driven Clutch Spring

Helix/Spring/ Setting

0-1800 (0-6000)

10RHF 5632282

Blue/Gray 7042202

Black 7041782

45 5131446

2-2

1800 & above (6000 & above)

20-40 5631356

Blue/Gray 7042202

Black 7041782

45 5131446

2-2

106

DECLARATION OF CONFORMITY POLARIS Industries Inc., 2100 Hwy 55, Medina, MN 55340 U.S.A. Telephone 763-542-0500 April 22, 2010

We, POLARIS Industries Inc., declare that the vehicles listed below conform to the essential health and safety requirements applicable to off-road all-terrain vehicles.

PRODUCT IDENTIFICATION

APPLICABLE EUROPEAN DIRECTIVES TEST / EVALUATION METHODS 2006/42/EC as amended (Machinery Directive) EN 1050 hazard analysis

prEN 15997 driver-perceived noise level prEN 15997 vibration

2004/108/EC as amended (EMC Directive) CISPR 12:2009 CAN/CSA-C108.4-M92

EN 55012:2007 EN 61000-6-2:2005

VEHICLE SERIES TRADE NAME MODEL YEARS

___KA05__ / ___KA09__ OUTLAW 50 / 90 2008, 2009, 2010, 2011 ___FA09__ SPORTSMAN 90 2008, 2009, 2010, 2011 ___VA17__ RZR 170 2009, 2010, 2011 ___PB20__ PHOENIX 200 2008, 2009, 2010, 2011 ___BA32__, ___NA32__ TRAIL BLAZER 330 2008, 2009, 2010, 2011 ___CA32__, ___EA32__ TRAIL BOSS 330 2008, 2009, 2010, 2011 ___BA50__, ___BG50__ SCRAMBLER 500 2008, 2009, 2010, 2011 ___GJ45__ OUTLAW 450 2008, 2009, 2010, 2011 ___GJ52__, ___GP52__ OUTLAW 525 / 525 S 2008, 2009, 2010, 2011 ___LH46__ SPORTSMAN 400 2008, 2009, 2010, 2011 ___MH50__ SPORTSMAN 500 HO 2008, 2009, 2010, 2011 ___DH50__ SPORTSMAN 500 HO TOURING 2010, 2011 ___ZN55__ ___ZX55__ SPORTSMAN 550 EFI 2009, 2010, 2011 ___TN55__, ___TX55__ SPORTSMAN 550 X2 2010, 2011 ___DN55__, ___DX55__ SPORTSMAN 550 TOURING 2010, 2011 ___MN76__ SPORTSMAN 800 2008, 2009, 2010, 2011 ___CL76__, ___CF76__ SPORTSMAN 800 6X6 2009, 2010, 2011 ___ZN85__, ___ZX85__ SPORTSMAN 850 EFI 2009, 2010, 2011 ___TN85__, ___TX85__ SPORTSMAN 850 X2 2010, 2011 ___DN85__, ___DX85__ SPORTSMAN 850 TOURING 2010, 2011 ___RH45__ RANGER 400 / 450 2010, 2011 ___RH50__ RANGER 500 4X4 2010, 2011 ___TH76__ RANGER 800 EFI 4X4 2010, 2011 ___WH50__ RANGER 500 CREW 2011 ___WH76__ RANGER 800 EFI CREW 2010, 2011 ___HR76__ RANGER 800 6X6 2010, 2011 ___HY76__, ___TY76__ RANGER HD 800 4X4 2010, 2011 ___TH90__ RANGER DIESEL 2011 ___WH90__ RANGER DIESEL CREW 2011 ___VH76__, ___VY76__ RANGER RZR / RZR S 2008, 2009, 2010, 2011 ___XH76__ RANGER RZR 4 2011

European Community Person Authorized to Compile the Technical File:

Ross Clifford, General Manager POLARIS Britain Ltd Forge Mills Park, Station Road Coleshill, Warwickshire B46 1HT

Authorized Manufacturer Signatory Empowered to Draw up the EC Declaration of Conformity:

Lawrence E. Keller, Product Compliance Manager 7290 East Viking Blvd. Wyoming, MN 55092

107

WARRANTY LIMITED WARRANTY POLARIS Industries Inc., 2100 Highway 55, Medina, MN 55340, gives a SIX MONTH LIMITED WARRANTY on all components of the POLARIS vehicle against defects in material or workmanship. 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 transferable to another consumer during the warranty period through a POLARIS dealer.

REGISTRATION At the time of sale, the Warranty Registration Form must be completed by your dealer and submitted to POLARIS within ten days. Upon receipt of this registration, POLARIS will record the registration for warranty. No verification of registration will be sent to the purchaser as the copy of the Warranty Registration Form will be the warranty entitle- ment. 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 VEHICLE IS REGISTERED WITH POLARIS. Initial dealer preparation and set-up of your vehcile is very important in ensuring trou- ble-free operation. Purchasing a machine in the crate or without proper dealer set-up will void your warranty coverage.

108

WARRANTY WARRANTY COVERAGE AND EXCLUSIONS: LIMITATIONS OF WARRANTIES AND REMEDIES The POLARIS limited warranty excludes any failures that are not caused by a defect in material or workmanship. This warranty does not cover accidental damage, normal wear and tear, abuse or improper handling. This warranty also does not cover any vehicle that has been altered structurally, modified, neglected, improperly maintained, used for rac- ing, or used for purposes other than for which it was manufactured, or for any damages which occur during trailer transit or as a result of unauthorized service or the use of unauthorized parts. In addition, 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 the vehicle due to fire, explosions or any other cause beyond POLARIS' control.

Warranty does not apply to parts exposed to friction surfaces, stresses, environmental conditions and/or contamination for which they were not designed or not intended, including but not limited to the following items:

Warranty applies to the product only and does not allow for coverage of personal loss. Some items are considered "consumable," meaning they are considered part of normal maintenance or part of completing an effective repair. The following items are excluded from warranty coverage in the event of a warranty claim:

Wheels and tires Finished and unfinished surfaces Suspension components Carburetor/Throttle body components Brake components Engine components Seat components Drive belts Clutches and components Hydraulic components Steering components Circuit breakers/Fuses Batteries Electronic components Light bulbs/Sealed beam lamps

Spark Plugs Lubricants such as oil, grease, etc. Filters Batteries (unless defective) Fuel Cosmetic damage/repair Sealants Coolants Hotel fees Meals Towing charges Shipping/ handling fees Mileage Product pick-up/delivery Rentals/Loss of product use Loss of vacation/personal time

109

WARRANTY LIMITATIONS OF WARRANTIES AND REMEDIES This warranty also excludes failures resulting from improper lubrication; improper engine timing; improper fuel; surface imperfections caused by external stress, heat, cold or contamination; operator error or abuse; improper component alignment, tension, adjustment or altitude compensation; failure due to snow, water, dirt or other foreign substance ingestion/contamination; improper maintenance; modified components; use of aftermarket components resulting in failure; unauthorized repairs; repairs made after the warranty period expires or by an unauthorized repair center; use of the product in competition or for commercial purposes. Warranty will not apply to any product which has been damaged by abuse, accident, fire or any other casualty not determined a defect of materials or workmanship.

This warranty does not cover the use of unauthorized lubricants, chemicals, or fuels that are not compatible with the vehicle. The exclusive remedy for breach of this warranty shall be, at POLARIS' exclusive option, repair or replacement of any defective materi- als, 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 WAR- RANTY OR ANY OTHER CONTRACT, NEGLIGENCE, OR OTHER TORT OR OTHERWISE. THIS EXCLUSION OF CONSEQUENTIAL, INCIDENTAL, AND SPECIAL DAMAGES IS INDEPENDENT FROM AND SHALL SURVIVE ANY FINDING THAT THE EXCLUSIVE REMEDY FAILED OF ITS ESSENTIAL PUR- POSE. Some states do not permit the exclusion or limitation of incidental or consequen- tial damages or implied warranties, so the above limitations or exclusions may not apply to you if inconsistent with controlling state law.

110

WARRANTY ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PAR- TICULAR PURPOSE) ARE LIMITED IN DURATION TO THE ABOVE SIX MONTH WARRANTY PERIOD. POLARIS FURTHER DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY. Some states do not allow limi- tations on how long an implied warranty lasts, so the above limitation may not apply to you if inconsistent with controlling state law.

HOW TO OBTAIN WARRANTY SERVICE If your vehicle requires warranty service, you must take it to a POLARIS dealer autho- rized to repair POLARIS vehicles. When requesting warranty service you must present your copy of the Warranty Registration form to the dealer. (THE COST OF TRANS- PORTATION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY). POLARIS suggests that you use your original selling dealer; however, you may use any POLARIS Servicing Dealer to perform warranty service. Please work with your dealer to resolve any warranty issues. Should your dealer require any additional assistance they will contact the appropriate person at POLARIS. This warranty gives you specific legal rights, and you may also have other rights which 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.

111

MAINTENANCE LOG Present this section of your manual to your dealer each time your vehicle is serviced. This will provide you and future owners with an accurate log of maintenance and ser- vices performed.

DATE MILES (KM) OR HOURS

TECHNICIAN SERVICE PERFORMED / COMMENTS

112

MAINTENANCE LOG

DATE MILES (KM) OR HOURS

TECHNICIAN SERVICE PERFORMED / COMMENTS

113

INDEX A

Age Restrictions . . . . . . . . . . . . . . . . . 5 Air Filter . . . . . . . . . . . . . . . . . . . . . . 69

B Battery . . . . . . . . . . . . . . . . . . . . 85-90

Charging (Conventional) . . . . . . . 89 Charging (Sealed) . . . . . . . . . 89-90 Fluid (Conventional) . . . . . . . . . . 88 Installation . . . . . . . . . . . . . . . . . . 87 Removal . . . . . . . . . . . . . . . . . . . . 86 Storage . . . . . . . . . . . . . . . . . . . . . 88

Boots . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Brake Fluid . . . . . . . . . . . . . . . . . 58-59 Brake Inspections . . . . . . . . . . . . . . . 60 Brake, Foot . . . . . . . . . . . . . . . . . . . . 24 Brake, Hand . . . . . . . . . . . . . . . . . . . 24 Brake, Parking . . . . . . . . . . . . . . . . . 25 Brakes . . . . . . . . . . . . . . . . . . 24-25, 60 Break-In Period. . . . . . . . . . . . . . . . . 30

C Camber Adjustment . . . . . . . . . . . . . 65 Carburetor . . . . . . . . . . . . . . . . . . . . . 71 Carburetor Adjustment . . . . . . . . . . . 71 Cargo. . . . . . . . . . . . . . . . . . . . . . 45-47 Caster Adjustment. . . . . . . . . . . . . . . 65 Choke . . . . . . . . . . . . . . . . . . . . . . . . 27 Chrome Wheel Care . . . . . . . . . . . . . 93 Cleaning and Storage . . . . . . . . . 91-96 Clothing . . . . . . . . . . . . . . . . . . . . . . . 9 Clutching Chart, TRAIL BOSS . . . 103 Clutching Chart, TRAIL BLAZER 105 Corrosion Removal, Chrome . . . . . . 93

D Drive Belt Wear/Burn . . . . . . . . . . . . 98 Drive Chain. . . . . . . . . . . . . . . . . 72-74 Drive Chain Lubrication . . . . . . . . . . 72 Drive Chain Slack. . . . . . . . . . . . 73-74 Drivetrain Break-In. . . . . . . . . . . . . . 30 Driving Downhill . . . . . . . . . . . . . . . 39 Driving in Reverse . . . . . . . . . . . . . . 43

D Driving on a Sidehill. . . . . . . . . . . . . 38 Driving on Slippery Surfaces . . . . . . 36 Driving Over Obstacles . . . . . . . . . . 42 Driving Procedures . . . . . . . . . . . . . . 34 Driving Through Water . . . . . . . . . . 41 Driving Uphill. . . . . . . . . . . . . . . . . . 37

E Electromagnetic Interference . . . . . . 48 Engine Break-In . . . . . . . . . . . . . . . . 30 Engine Fogging. . . . . . . . . . . . . . . . . 95 Engine Idle RPM Adjustment. . . . . . 71 Engine Oil . . . . . . . . . . . . . . . . . . 54-55 Engine Stop Switch. . . . . . . . . . . . . . 20 Equipment Modifications . . . . . . . . 5, 7 Exhaust Emission Control System . . 48 Eye Protection. . . . . . . . . . . . . . . . . . . 9

F Fluid, Brake . . . . . . . . . . . . . . . . 58-59 Foot Brake . . . . . . . . . . . . . . . . . . . . 24 Fuel Filter . . . . . . . . . . . . . . . . . . . . . 27 Fuel Safety . . . . . . . . . . . . . . . . . . . . 15 Fuel Tank Cap. . . . . . . . . . . . . . . . . . 27 Fuel Valve. . . . . . . . . . . . . . . . . . . . . 27

G Gasoline Handling . . . . . . . . . . . . . . 15 Gear Selector . . . . . . . . . . . . . . . . . . 28 Gloves . . . . . . . . . . . . . . . . . . . . . . . . . 9

H Handlebar Adjustment . . . . . . . . . . . 62 Hauling Cargo. . . . . . . . . . . . . . . 45-47 Hazard Switch. . . . . . . . . . . . . . . . . . 21 Headlamp Replacement . . . . . . . . . . 76 Headlight Beam Adjustment. . . . . . . 75 Headlight Switch . . . . . . . . . . . . . . . 21 Helmet. . . . . . . . . . . . . . . . . . . . . . . . . 8 Horn Switch . . . . . . . . . . . . . . . . . . . 21

114

INDEX I

Idle RPM Adjustment . . . . . . . . . . . 71 Immersion . . . . . . . . . . . . . . . . . . . . 80 Indicator Lights . . . . . . . . . . . . . . . . 22

J Jetting Chart, TRAIL BOSS . . . . . 103 Jetting Chart, TRAIL BLAZER . . 105

K Key Switch. . . . . . . . . . . . . . . . . . . . 21 K-Turn . . . . . . . . . . . . . . . . . . . . . . . 40

L Lights . . . . . . . . . . . . . . . . . . . . . 75-77

Headlamp Replacement . . . . . . . 76 Headlight Beam Adjustment. . . . 75 Indicator Lamp Replacement . . . 77 Taillight/Brakelight Replacement 77

Load Distribution. . . . . . . . . . . . . . . 46 Lubrication Guide . . . . . . . . . . . . . . 53

M Maintenance Chart. . . . . . . . . . . . 49-52 Mirrors . . . . . . . . . . . . . . . . . . . . . . . 22 Modifications. . . . . . . . . . . . . . . . . 5, 7

N Noise Emission Control System . . . 48

O Oil, Engine. . . . . . . . . . . . . . . . . . 54-55 Oil, Transmission. . . . . . . . . . . . . 56-57 Oil Change, Engine . . . . . . . . . . . . . 55 Oil Level, Engine. . . . . . . . . . . . . . . 54 Oil Recommendations . . . . . . . . . . . 54 Operator Safety . . . . . . . . . . . . . . 10-15 Override Switch . . . . . . . . . . . . . . . . 20

P Parking Brake . . . . . . . . . . . . . . . . . . 25 Parking on an Incline. . . . . . . . . . . . . 44 Periodic Maintenance Chart . . . . 49-52 Polaris Product List . . . . . . . . . . . . . . 97 Polishing the Vehicle. . . . . . . . . . . . . 92 Pre-Ride Checklist . . . . . . . . . . . . . . . 31 PVT Break-In . . . . . . . . . . . . . . . . . . 30 PVT Drying . . . . . . . . . . . . . . . . . . . . 84 PVT System. . . . . . . . . . . . . . . . . 82-84

R Recoil Housing . . . . . . . . . . . . . . . . . 70 Recoil Starter . . . . . . . . . . . . . . . . . . . 29 Reverse Operation . . . . . . . . . . . . . . . 43 Riding Gear . . . . . . . . . . . . . . . . . . . 8-9

S Safety Labels . . . . . . . . . . . . . . . 16-19

"No Passenger" Warning . . . . . . . 18 Age 16 Alert . . . . . . . . . . . . . . . . . 19 Clutch Cover Alert . . . . . . . . . . . . 19 Hill Operation Alert . . . . . . . . . . . 16 General Alert . . . . . . . . . . . . . . . . 16 Rack Warning, Front and Rear . . . 17 Reverse Override Warning . . . . . . 19 Tire Pressure/Load Alert. . . . . . . . 18

Safety Training . . . . . . . . . . . . . . . . . . 5 Severe Use . . . . . . . . . . . . . . . . . . . . . 49 Side Panel Removal. . . . . . . . . . . . . . 61 Sidehilling . . . . . . . . . . . . . . . . . . . . . 38 Signal Words . . . . . . . . . . . . . . . . . . . . 4 Spark Arrestor . . . . . . . . . . . . . . . . . . 81 Spark Arrestor Requirements . . . . . . 48 Spark Plugs . . . . . . . . . . . . . . . . . 78-79 Spring Adjustments, Rear . . . . . . . . . 65 Starting the Engine . . . . . . . . . . . 32-33 Steering Assembly. . . . . . . . . . . . . . . 65 Steering Lock. . . . . . . . . . . . . . . . . . . 26

115

INDEX S

Stop Switch . . . . . . . . . . . . . . . . . . . . 20 Storage . . . . . . . . . . . . . . . . . . . . 91-96 Switches . . . . . . . . . . . . . . . . . . . 20-21

Engine Stop Switch . . . . . . . . . . . 20 Hazard Switch . . . . . . . . . . . . . . . 21 Headlight Switch . . . . . . . . . . . . . 21 Horn Switch . . . . . . . . . . . . . . . . . 21 Main Key Switch . . . . . . . . . . . . . 21 Override Switch . . . . . . . . . . . . . . 20 Turn Signal Switch. . . . . . . . . . . . 21

T Throttle Cable Freeplay . . . . . . . . . . 64 Throttle Lever . . . . . . . . . . . . . . . . . . 23 Tire Tread Depth. . . . . . . . . . . . . . . . 66 Tires . . . . . . . . . . . . . . . . . . . . . . 66-68

Front Wheel Hub Tightening . . . . 66 Tread Depth . . . . . . . . . . . . . . . . . 66 Wheel Installation . . . . . . . . . . . . 67 Wheel Nut Torque . . . . . . . . . . . . 68 Wheel Removal . . . . . . . . . . . . . . 67

Toe Alignment . . . . . . . . . . . . . . . . . 63

T Towing Loads . . . . . . . . . . . . . . . . . . 47 Training, Safety . . . . . . . . . . . . . . . . . 5 Transmission Oil. . . . . . . . . . . . . 56-57 Transporting the Vehicle . . . . . . . . . 96 Turn Signal Switch . . . . . . . . . . . . . . 21 Turning Around on a Hill . . . . . . . . . 40 Turning the Vehicle . . . . . . . . . . . . . 35

V Vehicle Identification Numbers . . . . . 6 Vehicle Immersion . . . . . . . . . . . . . . 80

W Warning Symbols . . . . . . . . . . . . . . . . 4 Washing the Vehicle. . . . . . . . . . 91-92 Wheel Hub Tightening . . . . . . . . . . . 66 Wheel Installation . . . . . . . . . . . . . . . 67 Wheel Nut Torque Specifications. . . 68 Wheel Removal . . . .

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