Polaris Offroad Vehicle 330 International User Manual

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The text is printed on 100% recycled

with 40% post-consumer waste (PCW).

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WELCOME

Thank you for purchasing a Polaris vehicle, and welcome to our world-

wide family of Polaris owners. We proudly produce an exciting line of

utility and recreational products.

• 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.

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.

Printed in U.S.A.

2010 Trail Boss 330/Trail Blazer 330 International Owner’s Manual

P/N 9922462

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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

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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.

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INTRODUCTION

WARNING

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 authorized 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 equip-

ment 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.

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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.

VIN

####

Key Number

Vehicle Model Number: ___________________________________________________

Frame VIN: ____________________________________________________________

Engine Serial Number: ___________________________________________________

(right front side of engine crankcase)

Key Number: ___________________________________________________________

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SAFETY

WARNING

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 owner’s manual. See the OPERATION

section of the owner’s manual for proper operating procedures.

Equipment Modifications

We strongly recommend that consumers do not install on a Polaris vehi-

cle any equipment that may increase the speed or power of the vehicle,

or make any other modifications to the vehicle for these purposes.

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.

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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.

Eye Protection

Long

Sleeves

Helmet

Gloves

Long Pants

Boots

Helmet

Wearing a helmet can prevent a severe head injury. Whenever riding a

Polaris vehicle, always wear a helmet that meets or exceeds established

safety standards.

Approved helmets in the USA and Canada bear a U.S. Department of

Transportation (DOT) label.

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.

051039

0006.31

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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.

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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.

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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.

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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.

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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.

+25°

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.

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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.

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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.

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.

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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 Warning

WARNING

Improper ATV use can result in SEVERE INJURY or DEATH

ALWAYS USE AN APPROVED HELMET AND PROTECTIVE GEAR

NEVER USE ON PUBLIC ROADS

NEVER CARRY PASSENGERS

NEVER USE WITH DRUGS OR ALCOHOL

NEVER operate:

• without proper training or instruction

• at speeds too fast for your skills or the conditions

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

• with a passenger - passengers affect balance and steering and increase risk

of losing control

ALWAYS:

• use proper riding techniques to avoid vehicle overturns on hills and rough ter-

rain and in turns

• avoid paved surfaces - pavement may seriously affect handling and control

LOCATE AND READ OWNER’S MANUAL.

FOLLOW ALL INSTRUCTIONS AND WARNINGS.

7175376

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SAFETY

Safety Labels and Locations

Discretionary Warning

General

Warning

WARNING

• Never operate this ATV on

HILLS steeper than 25 degrees

25°. To prevent overturn on

hilly terrain, use throttle and

brakes gradually, and shift

weight uphill.

• REVERSE operation can be

dangerous even at low speeds.

Steering becomes difficult. To

prevent loss of control, avoid

sudden braking or sharp turns.

Discretionary

Warning

7175511

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)

7172666

Rack Warning

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SAFETY

Safety Labels and Locations

“No Passenger”

Warning

Tire Pressure/Load

Warning

Age 16 Warning

Clutch Cover

Warning

“No Passenger” Warning

WARNING

NEVER ride as a passenger.

Passengers can cause a loss of control, resulting in SEVERE INJURY or

DEATH.

7175378

Tire Pressure/Load Warning (Trail Boss)

WARNING

Improper tire pressure or overloading can cause loss of control.

Loss of control can result in severe injury or death.

• Cold tire pressure:

Front: 4.0 psi (27.6 kPa)

Rear: 3.0 psi (20.7 kPa)

• Maximum weight capacity: 415 lbs. (188 kg)

7175444

Tire Pressure/Load Warning (Trail Blazer)

WARNING

Improper tire pressure or overloading can cause loss of control.

Loss of control can result in severe injury or death.

• Cold tire pressure:

Front: 4.0 psi (27.6 kPa)

Rear: 3.0 psi (20.7 kPa)

• Maximum weight capacity: 275 lbs. (125 kg)

7175443

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SAFETY

Safety Labels and Locations

Age 16 Warning

WARNING

Operating this ATV if you are under the age of 16 increases your chance of

severe injury or death.

NEVER operate this ATV if you are under age 16.

7175374

Clutch Cover Warning

WARNING

• Moving parts hazard under belt-clutch guard. To prevent serious injury, do not

operate vehicle with guard removed.

• Do not modify engine or clutch. Doing so can cause part failure, possible

imbalance, and excessive engine RPM, which can result in serious injury or

death.

NO STEP

7172563

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.

7175486

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FEATURES AND CONTROLS

Switches

Engine Stop Switch

The engine will not start

or run when the switch is

in the OFF position.

Headlight

Switch

OFF

Engine

Stop

RUN

Switch

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.

Override

Switch

Hazard

Switch

Horn

Switch

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.

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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

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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.

Reverse

Indicator

Turn Signal/Hazard Indicators

High Beam Indicator

Neutral Indicator

High Temperature Warning

(displays if engine overheats)

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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

Electronic Throttle Control

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.

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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.

Foot Brake

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.

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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.

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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.

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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

Gauge

Fuel Tank Cap

Choke

Always refuel with the engine

stopped, and outdoors or in a well

ventilated area. Refuel on a level

surface.

Fuel Tank

Cap

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.

Fuel

Valve

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

OFF

annually. Do not attempt to clean the fuel filter.

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FEATURES AND CONTROLS

Transmission Gear Selector

The transmission gear selector is located

on the right side of the vehicle.

F: Forward Gear

N: Neutral

Gear

Selector

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.

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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.

Recoil Starter

Handle

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.

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OPERATION

Break-In Period

The break-in period for your new Polaris vehicle is the first ten hours of

operation, or the time it takes to use the first two full tanks of gasoline.

No single action on your part will increase the life and performance of

your vehicle more than following the procedures for a proper break-in.

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.

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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

Brake fluid

Foot brake

Ensure proper operation

Ensure proper level

Ensure proper operation

Inspect, lubricate if necessary

Front suspension

Rear suspension

Steering/steering lock

Unlock the steering; ensure free

operation

Tires

Inspect condition and pressure

Wheels/fasteners

Inspect, ensure fastener tightness

Frame nuts, bolts, fasteners Inspect, ensure tightness

Fuel and oil

Ensure proper levels

Throttle

Ensure proper operation

Indicator lights/switches

Engine stop switch

Mirrors

Ensure operation

Ensure proper operation

Adjust for best side/rear vision

Drive chain

Check condition/slack, lubricate as

needed

Air filter, pre-filter

Air box sediment tube

Headlamp

Inspect, clean

Drain deposits whenever visible

Check operation, apply Polaris dielec-

tric grease when lamp is replaced

Brake light/taillight

Riding gear

Check operation, apply Polaris dielec-

tric grease when lamp is replaced

Wear approved helmet, goggles, and

protective clothing

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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

Choke

Knob

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.

Adjusting

Nut

7. Pull the engine stop switch up to RUN.

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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.

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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.

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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.

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OPERATION

Driving on Slippery Surfaces

Turn in

direction of

skid

Sideways

skid

Whenever riding on slippery surfaces such as wet trails or loose gravel,

or during freezing weather, follow these precautions:

1. Do not operate on excessively rough, slippery or loose terrain.

2. 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.

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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.

25° Maximum

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.

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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!

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OPERATION

Driving Downhill

25° Maximum

When driving downhill, follow these precautions:

1. Check the terrain carefully.

2. Avoid hills with excessively slippery or loose surfaces.

3. Never drive downhill at high speed.

4. Slow down.

5. Avoid driving downhill at an angle, which can cause the vehicle to

pitch sharply to one side. Drive straight downhill.

6. Shift your weight rearward.

7. Apply the brakes slightly to aid in slowing.

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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.

8 ft. (2.4 m)

1. Stop the vehicle. Keep your weight uphill.

2. Lock the parking brake. Leave the transmission in forward gear.

Turn the engine off.

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.

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OPERATION

Driving Through Water

Your Polaris vehicle can

operate through water with

a maximum recommended

depth equal to the bottom

of the footrests. Follow

these procedures when

operating through water:

1. Determine water

depths and current

before entering water.

2. Choose a crossing

where both banks have

gradual inclines.

3. Avoid operating

through deep or fast-

flowing water.

Maximum Depth

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 it’s 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.

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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.

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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.

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OPERATION

Parking on an Incline

25° maximum

Avoid parking on an incline if possible. If it's unavoidable, follow these

precautions:

1. Stop the engine.

2. Place the transmission in gear.

3. Lock the parking brake.

4. Always block the rear wheels on the downhill side.

5. Turn the fuel valve off.

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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.

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OPERATION

Hauling Cargo

Load Distribution

Read and understand the load distribution warnings listed on warning

labels. Never exceed the specified weights.

Never carry cargo on the front of the Trail Blazer model. Cargo should

be evenly distributed and mounted as low as possible on the rear rack.

On the Trail Boss model, cargo weight should be evenly distributed (1/3

on the front rack and 2/3 on the rear rack) and mounted as low as possi-

ble. When operating over rough or hilly terrain, reduce speed and cargo

weight to maintain stable driving conditions. Do not obstruct the head-

light beam with cargo.

Trail Boss

Trail Blazer

2/3

1/3

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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.

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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.

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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.

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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.

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

Remarks

(whichever comes first)

Hours Calendar

Miles

(Km)

Steering

Pre-Ride

Daily

Make adjustments as need

ed. See Pre-Ride Checklist

on page 31.

X Front suspension

X Rear suspension

Tires

X Brake fluid level

X Brake lever travel

Brake system

Wheels/fasteners

Frame fasteners

X Engine oil level

X Air filter, pre-filter

Inspect; clean often; replace

as needed

X Air box sediment

Daily

Drain deposits when visible

tube

Headlamp/tail

lamp

Check operation; apply

dielectric grease if replacing

X Air filter,

E main element

Weekly

Inspect; replace as needed

Recoil housing

(if applicable)

Drain water as needed,

check often if operating in wet

conditions

X Brake pad wear

10 H

Monthly

100 (160) Inspect periodically

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MAINTENANCE

Periodic Maintenance Chart

Item

Maintenance Interval

Remarks

(whichever comes first)

Hours Calendar

Miles

(Km)

Battery

20 H

25 H

Monthly

200 (320) Check terminals; clean; test

250 (400) Inspect level; change yearly

250 (400) Inspect; clean if needed

X Transmission oil

X Engine breather

E filter (if equipped)

X General

50 H

3 M

6 M

500 (800) Lubricate all fittings, pivots,

cables, etc.

lubrication

Carburetor float

bowl

500 (800) Drain bowl periodically and

prior to storage

Throttle Cable/

ETC Switch

Choke cable

500 (800) Inspect; adjust; lubricate;

replace if necessary

500 (800) Inspect; adjust; lubricate;

replace if necessary

E Carburetor air

500 (800 Inspect duct for proper seal-

ing/air leaks

intake ducts/flange

Drive belt

500 (800) Inspect; adjust; replace as

needed

X Engine oil change 100 H

1000 (1600) Perform a break-in oil change

at 20 hours

X Oil filter change

100 H

6 M

1000 (1600) Replace with oil change

1000 (1600) Inspect; adjust

Valve clearance

12 M

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

X Perform these procedures more often for vehicles subjected to severe use.

E Emission-Related Service

Q Have an authorized Polaris dealer perform these services.

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MAINTENANCE

Periodic Maintenance Chart

Item

Maintenance Interval

Remarks

(whichever comes first)

Hours Calendar

Miles

(Km)

X Engine mounts

100 H

12 M

1000 (1600) Inspect

Exhaust muffler/

pipe

Spark plug

100 H

12 M

1000 (1600) Inspect; replace as needed

1000 (1600) Inspect

Ignition Timing

X Wiring

1000 (1600) Inspect for wear, routing,

security; apply dielectric

grease to connectors

subjected to water, mud, etc.

Clutches (drive

100 H

12 M

1000 (1600) Inspect; clean; replace worn

parts

and driven)

Front wheel

bearings

1000 (1600) Inspect; replace as needed

Brake fluid

200 H

300 H

24 M

36 M

2000 (3200) Change every two years

3000 (4800) Clean out

Spark arrestor

Idle speed

Adjust as needed

Toe adjustment

Inspect periodically; adjust

when parts are replaced

Headlight aim

Adjust as needed

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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 See page 54.

Synthetic 2W-50

Brake Fluid

DOT 4 Only

See page 58.

Drive Chain(s)

O-ring chain lube or SAE Lubricate.

80/90

Transmission Oil

AGL Synthetic Gearcase See page 56.

Lube

Swing Arm

Bushings

XPremium All Season

Grease

Locate fittings on swing arm and

grease with grease gun

Axle Housing

Tie Rod Ends

XPremium 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.

Tie Rod Ends

Axle

Housing

Swing Arm

Bushings

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MAINTENANCE

Engine Oil

Oil Recommendations

Always change the oil filter whenever changing oil.

Polaris recommends the use of Polaris PS-4 PLUS Performance Syn-

thetic 2W-50 4-cycle oil or a similar oil for this engine. Oil may need to

be changed more frequently if Polaris oil is not used. Always use 2W-50

oil. Follow the manufacturer's recommendations for ambient tempera-

ture operation. 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

Lubricant

Capacity

Drain Plug Torque

PS-4 PLUS Performance

1.9 qts. (1.8 l) (with oil cooler)

14 ft. lbs. (19 Nm)

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

Oil Level

The oil dipstick is located on the left side of the vehicle.

1. Position the vehicle on a

Safe Range

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.

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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.

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MAINTENANCE

Transmission Oil

Always check and change the transmission oil at the intervals outlined

in the Periodic Maintenance Chart beginning on page 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

Gearcase

Lubricant

Capacity

Drain Plug

Torque

Transmission

Premium AGL Synthetic

Gearcase Lubricant

11.3 oz.

(335 ml)

14 ft. lbs.

(19 Nm)

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.

Dipstick

5. Reinstall the dipstick.

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MAINTENANCE

Transmission Oil

Oil Change

1. Position the vehicle on a level

surface.

Adjuster

Bolt

Jam

Nut

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.

Drain Plug

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.

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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.

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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.

Indicator

Window

Master

Cylinder

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.

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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

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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.

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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.

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.

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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 ser-

vice.

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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.

Boot

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

1.6-3 mm

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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

Adjuster

clockwise or counterclockwise to

increase or decrease spring tension.

Accessory springs are available through

your Polaris dealer.

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MAINTENANCE

Tires

WARNING

Operating your vehicle with worn tires, improperly inflated tires, non-standard

tires or improperly installed tires will affect vehicle handling and could cause an

accident.

• 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.

3 mm

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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.

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MAINTENANCE

Tires

Wheel Nut Torque Specifications

Rear

50 ft. lbs.

(68 Nm)

Front

27 ft. lbs.

(37 Nm)

Check the wheel nut torques occasionally and when they've been loos-

ened for service.

Item

Torque Specification

Front Wheel Nuts

Rear Wheel Nuts

27 ft. lbs. (37 Nm)

50 ft. lbs. (68 Nm)

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MAINTENANCE

Air Filter

1. Remove the seat.

Pre-Filter

2. Release the air box cover clips,

and remove the air box cover.

Main Filter

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.

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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.

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MAINTENANCE

Carburetor

Your Polaris vehicle is calibrated at the factory for optimal performance

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 condi-

tions 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

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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.

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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.

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

Use the following procedure if adjustment is required.

1. Remove the chain guard.

Pin Punch

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.

Locking Bolts

5. Insert a pin punch through

the sprocket hub and into the

eccentric housing.

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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.

Clip

Position

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).

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MAINTENANCE

Lights

Headlight Beam Adjustment

The headlight beam can be adjusted slightly upward or downward. Use

the following procedure to make the adjustment.

25 ft.

(7.6 m)

2" (5 cm)

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.

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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.

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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

Screw

cover mounting screws.

Remove the lens cover

and gasket and set aside

for reassembly.

Cover

Lamp

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.

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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.

Plug Condition

Torque Specification

New Spark Plug

12-15 Nm

23-27 Nm

Previously Installed Spark Plug

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.

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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.

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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-

Drain Screw

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.

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MAINTENANCE

Spark Arrestor

WARNING

Failure to heed the following warnings while servicing the spark arrestor could

result in serious injury or death. Never run the engine in an enclosed area.

Remove any combustible materials from the area. Wear eye protection and

leather work gloves. 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.

Exhaust

Outlet

2. Place the transmission in

neutral.

3. Lock the parking brake.

4. Remove the arrestor clean-

out plug from the bottom

of the muffler.

Clean-Out Plug

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.

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MAINTENANCE

PVT System

WARNING

Failure to comply with the instructions in this warning can result in severe injury

or death.

Do not modify any component of the PVT system. Doing so may reduce its

strength so that a failure may occur at a high speed. The PVT system has been

precision balanced. Any modification will cause the system to be out of balance,

creating vibration and additional loads on components.

The PVT system rotates at high speeds, creating large amounts of force on

clutch components. Extensive engineering and testing has been conducted to

ensure the safety of this product. However, as the owner, you have the following

responsibilities to make sure this system remains safe:

• Always follow all recommended maintenance procedures. See your dealer as

outlined in the 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.

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MAINTENANCE

PVT System

The basic operation of the Polaris PVT system is dependent on engine

speed and vehicle torque requirements. As engine speed increases, the

force exerted on the movable drive sheave by the flyweights also

increases. This, in turn, increases the amount of pinch applied to the

drive belt. Similarly, if the engine speed decreases, the amount of cen-

trifugal 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.

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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.

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MAINTENANCE

Battery

WARNING

Improperly connecting or disconnecting battery cables can result in an explosion

and cause serious injury or death. When removing the battery, always

disconnect the negative (black) cable first. When reinstalling the battery, always

connect the negative (black) cable last.

WARNING

Battery electrolyte is poisonous. It contains sulfuric acid. Serious burns can

result from contact with skin, eyes or clothing.

Antidote:

External: Flush with water.

Internal: Drink large quantities of water or milk. Follow with milk of magnesia,

beaten egg, or vegetable oil. Call physician immediately.

Eyes: Flush with water for 15 minutes and get prompt medical attention.

Batteries produce explosive gases. Keep sparks, flame, cigarettes, etc. away.

Ventilate when charging or using in an enclosed space. Always shield eyes

when working near batteries. KEEP OUT OF REACH OF CHILDREN.

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.

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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.

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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 don’t interfere with safe seat installation.

10. Reinstall the seat.

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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 Bat-

tery 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

Upper

Mark

Lower

Mark

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.

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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

battery’s 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.

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MAINTENANCE

Battery

Battery Charging (Sealed Battery)

Always verify battery condition before and 1-2 hours after the end of

charging.

Charge Time

State of

Charge

(Using constant current

Voltage

Action

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

3-6 hours

charge given,

check in 3 months

50%-75%

25%-50%

12.0-12.5 volts

11.5-12.0 volts

Needs charge

5-11 hours

At least 13 hours,

verify state of charge

0%-25%

11.5 volts or less Needs charge with

desulfating charger

At least 20 hours

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MAINTENANCE

Cleaning and Storage

Washing the Vehicle

Keeping your Polaris vehicle clean will not only improve its appearance

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 garden

hose and a pail of mild soap and water.

1. Use a professional-type washing cloth, cleaning the upper body first

and the lower parts last.

2. Rinse with clean water frequently.

3. Dry surfaces with a chamois to prevent water spots.

Washing Tips

• 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.

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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:

• Wheel bearings

• Radiator (if equipped)

• Transmission seals

• Brakes

• Electrical components/wiring

• Switches and controls

• Cab and body panels

• Labels and decals

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.

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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.

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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 recommended

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.

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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.

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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 mate-

rials. They do not allow enough ventilation to prevent condensation, 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.

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POLARIS PRODUCTS

Part

Number

Description

Engine Lubricant

2870791

2876244

2876245

Fogging Oil (12 oz. Aerosol)

PS-4 PLUS Performance Synthetic 2W-50 4-Cycle Oil (qt./.95 l)

PS-4 PLUS Performance Synthetic 2W-50 4-Cycle Oil (gal./3.8 l)

Gearcase / Transmission Lubricants

2873602

2873603

2871653

2872276

2870465

Premium AGL Synthetic Gearcase Lubricant (qt./.95 l)

Premium AGL Synthetic Gearcase Lube (gal./3.8 l)

Premium ATV Angle Drive Fluid (8 oz./237 ml)

Premium ATV Angle Drive Fluid (2.5 gal./9.5 l)

Pump for Gallon (3.8 l) Jug

Grease / Specialized Lubricants

2871312

2871322

2871423

2871460

2871515

2871551

2871329

2872073

2872348

Grease Gun Kit, Premium All Season

Premium All Season Grease (3 oz./89 ml cartridge)

Premium All Season Grease (14 oz./414 ml cartridge)

Starter Drive Grease

Premium U-Joint Lube (3 oz./89 ml cartridge)

Premium U-Joint Lube (14 oz./414 ml cartridge)

Dielectric Grease (Nyogel^TM

)

Chain Lube, Aerosol (6.25 oz./185 ml)

Chain Lube, Aerosol (16 oz./473 ml)

Additives / Miscellaneous

Carbon Clean Plus

2871326

2870652

2872189

2871956

2859044

Fuel Stabilizer

DOT 4 Brake Fluid

Loctite^TM565 Thread Sealant

Polaris Battery Tender^TMCharger

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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

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

ground speed (3-7 MPH) 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- Use the throttle quickly and effectively.

ment

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 Dry out the PVT. See page 84. Inspect clutch seals for

or snow ingestion into the damage if repeated leaking occurs.

PVT system

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

Improper break-in

Install the recommended belt.

Always break in a new belt and/or clutch. See page 30.

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TROUBLESHOOTING

Engine Doesn't Turn Over

Possible Cause

Solution

Low battery voltage

Recharge the battery to 12.8 VDC

Check all connections and tighten

Loose battery connections

Loose solenoid connections

Engine Turns Over, Fails to Start

Possible Cause

Solution

Out of fuel

Turn fuel valve to reserve, refuel

Inspect and clean or replace

Clogged fuel valve or filter

Water is present in fuel

Fuel valve is turned off

Old or non-recommended fuel

Fouled or defective spark plug(s)

No spark to spark plug

Overuse of choke

Drain the fuel system and refuel

Turn the fuel valve on

Replace with fresh recommended fuel

Inspect plugs and replace if necessary

Inspect plugs, verify stop switch is on

Inspect, clean and/or replace spark plugs

Replace the filter

Clogged fuel filter

Water or fuel in crankcase

Low battery voltage

Immediately see your Polaris dealer

Recharge the battery to 12.8 VDC

See your dealer

Mechanical failure

Engine Backfires

Possible Cause

Solution

Weak spark from spark plug

Incorrect spark plug gap or heat range

Old or non-recommended fuel

Incorrectly installed spark plug wires

Incorrect ignition timing

Inspect, clean and/or replace spark plugs

Set gap to specs or replace plugs

Replace with fresh recommended fuel

See your dealer

Mechanical failure

See your dealer

Exhaust leaks

Replace exhaust seals

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TROUBLESHOOTING

Engine Pings or Knocks

Possible Cause

Solution

Poor quality or low octane fuel

Incorrect ignition timing

Replace with recommended fuel

See your dealer

Incorrect spark plug gap or heat range

Idle set too low

Set gap to specs or replace plugs

Adjust idle speed

Engine Runs Irregularly, Stalls or Misfires

Possible Cause

Solution

Fouled or defective spark plugs

Worn or defective spark plug wires

Incorrect spark plug gap or heat range

Loose ignition connections

Water present in fuel

Inspect, clean and/or replace spark plugs

See your dealer

Set gap to specs or replace plugs

Check all connections and tighten

Replace with new fuel

Low battery voltage

Recharge battery to 12.8 VDC

Inspect and replace

Kinked or plugged fuel tank vent line

Incorrect fuel

Replace with recommended fuel

Inspect and clean or replace

See your dealer

Clogged air filter

Reverse speed limiter malfunction

Electronic throttle control malfunction

Other mechanical failure

See your dealer

Possible Lean Fuel Cause

Solution

Low or contaminated fuel

Low octane fuel

Add or change fuel, clean the fuel system

Replace with recommended fuel

Replace filter

Clogged fuel filter

Incorrect jetting

See your dealer

Possible Rich Fuel Cause

Solution

Overuse of choke

Fuel is very high octane

Incorrect jetting

Inspect, clean and/or replace spark plugs

Replace with lower octane fuel

See your dealer

100

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TROUBLESHOOTING

Engine Stops or Loses Power

Possible Cause

Solution

Out of fuel

Turn fuel valve to reserve, refuel

Inspect and replace

Kinked or plugged fuel vent line

Water is present in fuel

Replace with new fuel

Overuse of choke

Inspect, clean and/or replace spark plugs

See your dealer

Fouled or defective spark plugs

Worn or defective spark plug wires

Incorrect spark plug gap or heat range

Loose ignition connections

Low battery voltage

Set gap to specs or replace plug

Check all connections and tighten

Recharge the battery to 12.8 VDC

Replace with fresh recommended fuel

Inspect and clean or replace

See your dealer

Incorrect fuel

Clogged air filter

Reverse speed limiter malfunction

Electronic throttle control malfunction

Other mechanical failure

Overheated engine

See your dealer

Clean radiator screen and core if

equipped

Clean engine exterior

See your Polaris dealer

101

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SPECIFICATIONS

Trail Boss 330

Maximum Weight Capacity

415 lbs. (188 kg) (includes weight of operator,

cargo and accessories)

Dry Weight

Fuel Capacity

Engine Oil Capacity

535 lbs. (243 kg)

4 gal. (15.1 l)

1.9 qts. (1.8 l) (with oil cooler)

1.7 qts. (1.6 l) (oil change only)

Transmission Oil

Front Rack Capacity

Rear Rack Capacity

11.3 oz. (335 ml)

75 lbs. (34 kg)

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

Unbraked Trailer Towing

Capacity*

850 lbs. (385.6 kg)

1263 lbs. (573 kg)

Overall Length

Overall Width

Overall Height

Wheelbase

75 in. (190.5 cm)

45 in. (114 cm)

49 in. (124.5 cm)

48.5 in. (124 cm)

Ground Clearance

Minimum Turning Radius

Engine Model Number/Type

Lubrication

4.75 in. (12 cm)

65 in. (165 cm) unloaded

ES-32PFE-108 / 4 Cycle, Single Cylinder

Wet Sump

Engine Cooling

Displacement

Bore x Stroke

Alternator Output

Compression Ratio

Carburetor

Air with fan assisted oil cooler

329 cc

78.5 x 68

200w @5000 RPM

9.2:1

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

Ignition Timing

Idle RPM

DC CDI

30° +/- 2° @ 5000 RPM

1500

Spark Plug / Gap

BKR6E / .036 in. (.9 mm)

* Based on EU Directive 76/432/EC

102

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SPECIFICATIONS

Trail Boss 330

Driving System Type

Shift Type

Automatic PVT (Polaris Variable Transmission)

Side Lever (F/N/R)

Gear Reduction, Reverse

Gear Reduction, Forward

Drive Ratio, Final

Drive Chain

3.05:1

2.68:1

3.64:1

520 O-Ring

Tires/Pressure, Front

Tires/Pressure, Rear

Front Suspension

Rear Suspension

Shock Adjustment

Brakes, Front and Rear

Brake, Auxiliary

Brake, Parking

Headlight

23 x 7-10 (4 psi/27.6 kPa)

22 x 11-10 (3 psi/20.7 kPa)

MacPherson strut with 8.2" (21 cm) travel

Progressive rate with 10.5" (26.7 cm) travel

CAM

Single-Control Hydraulic Disc

Foot-Activated Hydraulic Disc, Rear Wheel

Hydraulic lock, all wheel

2 Dual Beam 30w/30w

12V 8.26W

Taillights

Brake Light

12V 26.9W

Battery

12V 14AH

Indicators

High Beam/Turn Signals/High Temp/Neutral/

Reverse

Jetting Chart

ALTITUDE

AMBIENT TEMPERATURE

Meters (Feet)

Below 40° F

40°F and above

(5°C and above)

(Below 5° C)

0-1800 (0-6000)

127.5

120

122.5

115

1800-3700 (6000-12000)

Clutching Chart

Altitude

Shift

Drive Clutch

Spring

Driven Clutch

Helix/Spring/

Meters (Feet)

Weight

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

103

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SPECIFICATIONS

Trail Blazer 330

Maximum Weight Capacity

275 lbs. (125 kg) (includes weight of opera-

tor, cargo and accessories)

Dry Weight

Fuel Capacity

Engine Oil Capacity

496 lbs. (225 kg)

4 gal. (15.1 l)

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)

Rear Rack Capacity (Accessory)

Hitch Tongue Weight Capacity

30 lbs. (13.6 kg) (Maximum)

60 lbs. (27.2 kg) (Maximum)

85 lbs. (38.6 kg) (Rear rack capacity and

tongue weight not to exceed 60 lbs./27.2 kg)

Hitch Towing Rating

Unbraked Trailer Towing Capacity*

Overall Length

Overall Width

Overall Height

Wheelbase

Ground Clearance

Minimum Turning Radius

Engine Model Number/Type

Lubrication

850 lbs.(386 kg)

1263 lbs. (573 kg)

75 in. (190.5 cm)

45 in. (114 cm)

49 in. (124.5 cm)

48.5 in. (124 cm)

4.75 in. (12 cm)

83 in. (211 cm) unloaded

ES-32PFE-108 / 4 Cycle, Single Cylinder

Wet Sump

Engine Cooling

Displacement

Air with fan assisted oil cooler

329cc

Bore x Stroke

78.5 x 68

Alternator Output

Compression Ratio

Carburetor

200w @5000 RPM

9.2:1

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

Ignition Timing

Idle RPM

DC CDI

30° +/- 2° @ 5000 RPM

1500

Spark Plug / Gap

BKR6E / .036 in. (.9 mm)

* Based on EU Directive 76/432/EC

104

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SPECIFICATIONS

Trail Blazer 330

Driving System Type

Shift Type

Automatic PVT (Polaris Variable Transmission)

Side Lever (F/N/R)

Gear Reduction, Reverse

Gear Reduction, Forward

Drive Ratio, Final

Drive Chain

3.05:1

2.68:1

3.64:1

520 O-Ring

Tires/Pressure, Front

Tires/Pressure, Rear

Front Suspension

Rear Suspension

Shock Adjustment

Brakes, Front and Rear

Brake, Auxiliary

Brake, Parking

Headlight

23 x 7-10 (4 psi/27.6 kPa)

22 x 11-10 (3 psi/20.7 kPa)

MacPherson strut with 8.2" (21 cm) travel

Progressive rate with 10.5" (26.7 cm) travel

CAM

Single-Control Hydraulic Disc

Foot-Activated Hydraulic Disc, Rear Wheel

Hydraulic lock, all wheel

1 Single Beam, 55w

12V 8.26W

Taillights

Brake Light

12V 26.9W

Battery

12V 14AH

Indicators

High Beam/Turn Signals/High Temp/Neutral/

Reverse

Jetting Chart

ALTITUDE

AMBIENT TEMPERATURE

Meters (Feet)

Below 40° F

40°F and above

(5°C and above)

(Below 5° C)

0-1800 (0-6000)

127.5

120

122.5

115

1800-3700 (6000-12000)

Clutching Chart

Altitude

Shift

Drive Clutch

Spring

Driven Clutch

Helix/Spring/

Meters (Feet)

Weight

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

105

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DECLARATION OF CONFORMITY

Polaris Industries Inc.,

2100 Hwy 55, Medina, MN 55340 U.S.A.

Telephone 763-542-0500

We, Polaris Industries Inc., declare that the vehicles listed below conform to the

essential health and safety requirements applicable to off-road all-terrain vehicles.

APPLICABLE EUROPEAN DIRECTIVES

TEST / EVALUATION METHODS

98/37/EC as amended (Machinery Directive)

EN 1050 hazard analysis

CD 77/311/EEC driver-perceived noise level

2004/108/EC as amended (EMC Directive)

CISPR 12:2001

CAN/CSA-C108.4-M92

EN 55012:2002

EN 61000-6-2:2001

PRODUCT IDENTIFICATION

VEHICLE SERIES

TRADE NAME

MODEL

YEARS

SOUND

PRESSURE

dB (A)

___KA05__

___KA09__

___FA09__

___VA17__

___PB20__

___BA32__

___CA32__

___BA50__

___GJ45__

___GJ52__, ___GP52__

___LH27__

___LH46__

___MN50__

OUTLAW 50

OUTLAW 90

SPORTSMAN 90

RZR 170

PHOENIX 200

TRAIL BLAZER 330

TRAIL BOSS 330

SCRAMBLER 500

OUTLAW 450

2008, 2009, 2010

2009, 2010

76.8

81.3

76.8

79.6

80.7

81.1

80.2

80.4

80.8

77.2

83.6

77.2

80.1

80.4

76.5

85.8

2008, 2009, 2010

2009, 2010

OUTLAW 525

SPORTSMAN 300

SPORTSMAN 400

SPORTSMAN 500 EFI

SPORTSMAN 550 EFI

___ZN55__ ___ZX55__

___TN55__, ___DN55__ SPORTSMAN X2/TOURING 550 2010

___MN76__ SPORTSMAN 800 2008, 2009, 2010

___TN85__, ___DN85__ SPORTSMAN X2/TOURING 850 2010

___CL76__

___ZN85__, ___ZX85__

SPORTSMAN 800 6X6

SPORTSMAN 850 EFI

2009, 2010

2010

___RH50__, ___HH50__ RANGER 500 EFI 4X4

___HH76__

___WH76__

___HR__

___HY__

___VH76__

RANGER 800 EFI 4X4

RANGER 800 EFI CREW

RANGER 800 6X6

RANGER HD 800 4X4

RANGER RZR

2010

2008, 2009, 2010

Authorized Signatory:

__________________________________

Alexander A. Kennedy, Product Compliance

Polaris Industries Inc., Engineering Operations

301 5th Avenue SW, Roseau, MN 56751

106

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WARRANTY

LIMITED WARRANTY

Polaris Industries Inc., 2100 Highway 55, Medina, MN 55340, gives a TWO YEAR

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.

107

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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:

•

Wheels and tires

•

Finished and unfinished surfaces

Carburetor/Throttle body components

Engine components

Suspension components

Brake components

Seat components

Clutches and components

Steering components

Batteries

Drive belts

Hydraulic components

Circuit breakers/Fuses

Electronic components

Light bulbs/Sealed beam lamps

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:

•

Spark Plugs

Filters

Fuel

Sealants

Hotel fees

Towing charges

Mileage

Rentals/Loss of product use

•

Lubricants such as oil, grease, etc.

Batteries (unless defective)

Cosmetic damage/repair

Coolants

Meals

Shipping/ handling fees

Product pick-up/delivery

Loss of vacation/personal time

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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 materials, or

components or products. THE REMEDIES SET FORTH IN THIS WARRANTY ARE

THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS

WARRANTY. POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR

INCIDENTAL, CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIP-

TION, WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR

ANY OTHER CONTRACT, NEGLIGENCE, OR OTHER TORT OR OTHERWISE.

Some states do not permit the exclusion or limitation of incidental or consequential

damages or implied warranties, so the above limitations or exclusions may not apply to

you if inconsistent with controlling state law.

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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 TWO

YEAR 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 authorized

to repair Polaris vehicles. When requesting warranty service you must present your copy

of the Warranty Registration form to the dealer. (THE COST OF TRANSPORTATION

TO AND FROM THE DEALER IS YOUR RESPONSIBILITY). 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.

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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

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MAINTENANCE LOG

DATE

MILES (KM)

OR HOURS

TECHNICIAN

SERVICE PERFORMED / COMMENTS

112

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INDEX

Age Restrictions . . . . . . . . . . . . . . . . . 5

Air Filter . . . . . . . . . . . . . . . . . . . . . . 69

Driving on a Sidehill. . . . . . . . . . . . . 38

Driving on Slippery Surfaces . . . . . . 36

Driving Over Obstacles . . . . . . . . . . 42

Driving Procedures . . . . . . . . . . . . . . 34

Driving Through Water . . . . . . . . . . 41

Driving Uphill. . . . . . . . . . . . . . . . . . 37

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

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

Fluid, Brake . . . . . . . . . . . . . . . . 58-59

Foot Brake . . . . . . . . . . . . . . . . . . . . 24

Fuel Filter . . . . . . . . . . . . . . . . . . . . . 27

Fuel Safety . . . . . . . . . . . . . . . . . . . . 15

Fuel Tank Cap. . . . . . . . . . . . . . . . . . 27

Fuel Valve. . . . . . . . . . . . . . . . . . . . . 27

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

Gasoline Handling . . . . . . . . . . . . . . 15

Gear Selector . . . . . . . . . . . . . . . . . . 28

Gloves. . . . . . . . . . . . . . . . . . . . . . . . . 9

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

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

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INDEX

Idle RPM Adjustment . . . . . . . . . . . 71

Immersion . . . . . . . . . . . . . . . . . . . . 80

Indicator Lights . . . . . . . . . . . . . . . . 22

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

Jetting Chart, Trail Boss . . . . . . . . 103

Jetting Chart, Trail Blazer . . . . . . . 105

Key Switch. . . . . . . . . . . . . . . . . . . . 21

K-Turn . . . . . . . . . . . . . . . . . . . . . . . 40

Recoil Housing . . . . . . . . . . . . . . . . . 70

Recoil Starter. . . . . . . . . . . . . . . . . . . 29

Reverse Operation . . . . . . . . . . . . . . . 43

Riding Gear . . . . . . . . . . . . . . . . . . . 8-9

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

Headlamp Replacement . . . . . . . 76

Headlight Beam Adjustment. . . . 75

Indicator Lamp Replacement . . . 77

Taillight/Brakelight Replacement 77

Load Distribution. . . . . . . . . . . . . . . 46

Lubrication Guide . . . . . . . . . . . . . . 53

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

"No Passenger" Warning . . . . . . . 18

Age 16 Warning . . . . . . . . . . . . . . 19

Clutch Cover Warning . . . . . . . . . 19

Discretionary Warning . . . . . . . . . 17

General Warning. . . . . . . . . . . . . . 16

Rack Warning, Front and Rear . . . 17

Reverse Override Warning . . . . . . 19

Tire Pressure/Load Warning. . . . . 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

Maintenance Chart. . . . . . . . . . . . 49-52

Mirrors. . . . . . . . . . . . . . . . . . . . . . . 22

Modifications. . . . . . . . . . . . . . . . . 5, 7

Noise Emission Control System . . . 48

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

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INDEX

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

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

Vehicle Identification Numbers . . . . . 6

Vehicle Immersion . . . . . . . . . . . . . . 80

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

Warning Symbols . . . . . . . . . . . . . . . . 4

Washing the Vehicle. . . . . . . . . . 91-92

Wheel Hub Tightening . . . . . . . . . . . 66

Wheel Installation. . . . . . . . . . . . . . . 67

Wheel Nut Torque Specifications. . . 68

Wheel Removal . . . . . . . . . . . . . . . . 67

115

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