Polaris Offroad Vehicle Trail Boss 330 Quadricycle User Manual

Download from Www.Somanuals.com. All Manuals Search And Download.

based on the latest product information at the time of publication. Due to constant

improvements in the design and quality of production components, some minor

discrepancies may result between the actual vehicle and the information presented in this

publication. Depictions and/or procedures in this publication are intended for reference

use only. Manufacturer accepts no liability 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.

2005 Trail Boss 330 Quadricycle Owner’s Manual P/N 9919822

Download from Www.Somanuals.com. All Manuals Search And Download.

TABLE OF CONTENTS

VEHICLE IDENTIFICATION NUMBERS . . . . . . . . . . . . . . . 5

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

FEATURES AND CONTROLS . . . . . . . . . . . . . . . . . . . . . . 40

OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

EMISSION CONTROL SYSTEMS . . . . . . . . . . . . . . . . . . . 60

MAINTENANCE AND LUBRICATION . . . . . . . . . . . . . . . . 61

POLARIS PRODUCTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

MAINTENANCE RECORD . . . . . . . . . . . . . . . . . . . . . . . . 113

INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

Download from Www.Somanuals.com. All Manuals Search And Download.

VEHICLE IDENTIFICATION NUMBERS

Record your vehicle’s identification numbers and key number.

Remove the spare key and store it in a safe place. Your key can be

duplicated only by mating a Polaris key blank with one of your

existing keys, so if both keys are lost, the ignition switch must be

replaced.

31XX

Vehicle Model Number:

Frame VIN (1):

Engine Serial Number (2):

(right front side of engine crankcase)

Key Number (3):

Download from Www.Somanuals.com. All Manuals Search And Download.

SAFETY

Operator Safety

The following signal words and symbols appear throughout this

manual and on your vehicle. Become familiar with their meanings

before reading the manual.

The safety alert symbol, on your vehicle or in this manual, alerts

you to the potential for personal injury.

WARNING

The safety alert warning indicates a potential hazard that may

result in serious injury or death.

CAUTION

The safety alert caution indicates a potential hazard that may

result in minor personal injury or damage to the vehicle.

CAUTION

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

vehicle.

NOTE:

A note will alert you to important information or instructions.

Download from Www.Somanuals.com. All Manuals Search And Download.

SAFETY

Operator Safety

WARNING

Failure to follow the warnings in this manual can result in serious

injury or death.

A Polaris Quadricycle 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 a Polaris Quadricycle.

Safety Training

When you purchased your new Quadricycle, your dealer offered a

hands-on safety training course. You were also provided with printed

materials that explain safe operating procedures. Review this

information on a regular basis.

If you purchased a used Polaris Quadricycle from a party other than a

Polaris dealer, please request free safety training from any authorized

Polaris dealer.

Age Restriction

This vehicle is an ADULT VEHICLE ONLY. Operation is prohibited

for anyone under 16 years of age.

Download from Www.Somanuals.com. All Manuals Search And Download.

SAFETY

Operator Safety

Know Your Vehicle and Riding Area

You are responsible for your personal safety, the safety of others and

the protection of the environment. Read and understand your owner’s

manual. It includes important information about Quadricycle safety.

Ride responsibly. Know all laws and regulations concerning the

operation of this vehicle in your area.

Restrictions

This vehicle is approved for OFF-ROAD TOWING ONLY. Operating

a Quadricycle/trailer combination on public roads is prohibited.

Equipment Modifications

The warranty on your Polaris Quadricycle may be terminated if any

equipment has been added, or if any modifications have been made,

that increase speed or power.

NOTE: 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.

Download from Www.Somanuals.com. All Manuals Search And Download.

SAFETY

Operator Safety

WARNING

Serious injury or death can result if you do not follow the

instructions and procedures listed here and throughout this

manual.

Read and understand all warnings,

cautions and operating procedures

in this manual and on the safety

labels before operating the Quadricycle.

Never operate a Quadricycle without

proper instruction. Take a training

course. Beginners should receive

training from a certified instructor.

Contact an authorized Polaris Quadricycle

dealer or call Polaris at 1-800-342-3764.

Never permit others to operate the Quadricycle unless they have

read and understand this manual and all product labels, and have

completed a certified safety training course.

Never allow anyone under 16 years

of age to operate this vehicle.

Never carry a passenger. The

purpose of the long seat is to allow

the operator to shift position.

Download from Www.Somanuals.com. All Manuals Search And Download.

SAFETY

Operator Safety

Always wear an approved

helmet that fits properly.

Wear eye protection

(goggles or face shield),

gloves, boots, long

sleeves and long pants.

Never consume alcohol or

drugs before or while

operating a Quadricycle.

Never operate at

excessive speeds. Travel

and turn at speeds

appropriate for the terrain,

visibility, operating

conditions and your

experience.

Download from Www.Somanuals.com. All Manuals Search And Download.

SAFETY

Operator Safety

Never attempt wheelies, jumps or

other stunts.

Always inspect your

Quadricycle before each

use to verify that it’s in

safe operating condition.

Follow the inspection and

maintenance procedures

outlined in this manual. See

page 56.

Keep both hands on

the handlebars. Keep

your feet on the

footrests.

Always travel slowly when

operating on unfamiliar

terrain. Use extra caution.

Download from Www.Somanuals.com. All Manuals Search And Download.

SAFETY

Operator Safety

Use caution when operating

on rough, slippery or loose

terrain.

Always follow the procedures

outlined in this manual for

turning. See page 25.

Never turn sharply at

excessive speeds, which can

lead to vehicle overturn.

If a Quadricycle has been

involved in an accident, always

have an authorized Polaris

dealer inspect the entire vehicle

for possible damage, including

(but not limited to) brake,

throttle and steering systems.

Download from Www.Somanuals.com. All Manuals Search And Download.

SAFETY

Operator Safety

Never operate on hills too

steep for the Quadricycle or for

your abilities. Practice on

smaller hills before attempting

larger hills. Avoid climbing hills

steeper than 25_.

Always follow the procedures

outlined in this manual for

climbing hills. See page 30.

> 25_

Always follow the procedures

outlined in this manual for driving

downhill and for braking on

hills. See page 28.

Always follow the procedures

outlined in this manual for crossing

the side of a hill. See page 29.

Never attempt to turn the Quadricycle

around on any hill until you’ve

mastered (on level ground) the

turning technique outlined in this

manual.

Download from Www.Somanuals.com. All Manuals Search And Download.

SAFETY

Operator Safety

Always follow the procedures

outlined in this manual for braking if

you stall or roll backwards while

climbing a hill. Never back down a

hill. See page 31.

Always follow the procedures

outlined in this manual for

operating over obstacles.

See page 27.

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 26.

Download from Www.Somanuals.com. All Manuals Search And Download.

SAFETY

Operator Safety

Always follow the

procedures outlined in

this manual for driving

through water. Never

drive through deep or

fast-flowing water. See

page 34.

Always follow the procedures

outlined in this manual for

driving in reverse. See page 36.

Always use the size

and type of tires specified

for your Quadricycle.

Maintain the proper

tire pressure.

Download from Www.Somanuals.com. All Manuals Search And Download.

SAFETY

Operator Safety

Never modify a

Quadricycle through

improper installation

or use of accessories.

Never exceed the stated

load capacity for your

Quadricycle. Cargo

must be properly

2/3

1/3

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 the Quadricycle on

a frozen body of water.

Operating on paved surfaces may

seriously affect the handling and

control of the Quadricycle and

could result in loss of control,

accident, and/or injury.

Avoid sudden turns or swift

movement of the

handlebars.

Download from Www.Somanuals.com. All Manuals Search And Download.

SAFETY

Operator Safety

Always remove the ignition

key when the vehicle is not

in use to prevent

unauthorized use or

accidental starting.

Always keep combustible materials away from the exhaust

system. Exposure of combustibles to hot components could

result in a fire.

FOR MORE INFORMATION ABOUT QUADRICYCLE SAFETY,

call Polaris at 1-800-342-3764.

Download from Www.Somanuals.com. All Manuals Search And Download.

SAFETY

Safety Decals and Locations

Warning decals have been placed on the vehicle for your protection.

Read and follow the instructions on each decal carefully. If a decal

becomes illegible or comes off, contact your Polaris dealer to purchase

a replacement. Replacement safety decals are provided by Polaris at no

charge. The part number is printed on the decal.

Decal Text

Never operate this vehicle on

hills steeper than 25 degrees.

To prevent flipover on hilly

terrain, when going up or

down, use throttle and brakes

gradually.

Download from Www.Somanuals.com. All Manuals Search And Download.

SAFETY

Safety Decals and Locations

NO STEP

Download from Www.Somanuals.com. All Manuals Search And Download.

SAFETY

Safety Decals and Locations

Decal Text

NEVER ride as a passenger.

WARNING

Passengers can cause

a loss of control, resulting

in SEVERE INJURY or DEATH.

7172566

TIRE PRESSURE IN PSI (KPa):

FRONT 5 (34.5) REAR 5 (34.5)

MAXIMUM WEIGHT CAPACITY (Gross Vehicle Weight)

INCLUDING MACHINE, DRIVER AND CARGO IS 845 LBS. (383 kg)

MAXIMUM CARGO CAPACITY 200 LBS. (91 kg)

Read Owner’s Manual for more detailed loading information.

7173301

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

Download from Www.Somanuals.com. All Manuals Search And Download.

SAFETY

Safety Decals and Locations

ATTENTION

Operation of this vehicle

without the air filter

Specific

carburetor jetting

element will severely damage the

engine.

and adjustments are required

depending on temperature

and altitude. See your Owner’s

Manual.

Clean pre-filter element often,

more frequent cleaning

required in dusty conditions.

Do not operate vehicle without

pre-filter.

Factory setting:

40_ to 80_ F. at 0-3000 feet

(5_ to 27_ C. at 0-900 meters).

7170007

Decal Text (H)

S Operation of this vehicle without the air filter element will severely

damage the engine.

S Clean pre-filter element often, more frequent cleaning required in

dusty conditions. Do not operate vehicle without pre-filter.

S Specific carburetor jetting and adjustments are required depending

on temperature and altitude. See your Owner’s Manual.

Factory setting:

40_ to 80_ F. at 0-3000 feet (5_ to 27_ C. at 0-900 meters).

OVERRIDE

SWITCH

Reverse speed is

limited.

Reverse override

is controlled by the

override switch.

See your Owner’s

Manual.

7079906

Download from Www.Somanuals.com. All Manuals Search And Download.

SAFETY

Safety Decals and Locations

Hitch Decal

TRAILER MAX WEIGHT:

850 LBS. (386 KG) ON LEVEL GROUND

HITCH MAX. VERTICAL WEIGHT: 85 LBS. (39 KG)

7170915

Recoil Decal

Recoil handle must be firmly

seated to prevent water entry.

Drain starter motor if water

enters. See owner’s manual

7172562

Download from Www.Somanuals.com. All Manuals Search And Download.

SAFETY

Safe Riding Gear

Always wear protective clothing to reduce the chance of injury.

1. Helmet

Always wear a helmet that meets or

exceeds established safety standards. A

helmet can prevent a severe head injury.

2. Eye Protection

Wear shatterproof goggles or a

shatterproof helmet face shield. Use a

lens anti-fogging product to keep them

clean.

3. Gloves

Wear off-road style gloves with knuckle

pads.

4. Boots

Wear strong over-the-calf boots with

heels, like moto-cross boots.

5. Clothing

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. Do not wear loose clothing

that can get entangled in the vehicle, tree

branches or shrubs.

Download from Www.Somanuals.com. All Manuals Search And Download.

SAFETY

Driving Safely

Driving Procedures

1. Sit upright. Keep your feet on the footrests. Keep both hands on the

handlebars.

2. Start the engine and allow it to warm up, then shift the transmission

into gear.

3. Check your surroundings and determine your path of travel.

4. Release the parking brake.

5. Slowly squeeze the throttle lever toward the handlebar to begin

driving. Squeeze the throttle lever further to increase speed.

6. Drive slowly. Practice maneuvering and using the throttle and brakes

on level surfaces.

Download from Www.Somanuals.com. All Manuals Search And Download.

SAFETY

Driving Safely

Making Turns

1. To make a turn, steer in the

direction of the turn, leaning

your upper body to the inside of

the turn while supporting your

weight on the outer footrest.

Use the same leaning technique

for turning in reverse.

2. Practice turning at slow speeds

before attempting to turn at

faster speeds.

Never operate at

excessive speeds. Travel

and turn at speeds

appropriate for the terrain,

visibility, operating

conditions and your

experience.

Always follow the procedures

outlined in this manual for

turning. Never turn sharply at

excessive speeds, which can

lead to vehicle overturn.

Download from Www.Somanuals.com. All Manuals Search And Download.

SAFETY

Driving Safely

Driving on Slippery Surfaces

Whenever driving on slippery or loose surfaces such as wet trails,

gravel, snow or ice, follow these precautions:

1. Slow down before driving onto slippery surfaces.

2. Use extra caution.

3. Be alert. Watch the trail. Avoid quick, sharp turns.

NOTE: To correct a rear wheel skid, turn the handlebars in the same

direction as the skid and shift body weight forward.

Always follow the procedures

outlined in this manual for

operating on slippery or loose

surfaces. Use extra caution.

Always avoid skidding or

sliding.

Download from Www.Somanuals.com. All Manuals Search And Download.

SAFETY

Driving Safely

Driving Over Obstacles

1. Always check for obstacles before operating in a new area. Serious

injury or death can result if your vehicle comes in contact with a

hidden obstacle.

2. Be alert. Watch the terrain. Use extra caution.

3. Never operate over large obstacles.

4. Avoid hazards such as logs, rocks and low branches.

Always follow the procedures

outlined in this manual for

operating over obstacles.

Download from Www.Somanuals.com. All Manuals Search And Download.

SAFETY

Driving Safely

Driving Downhill

Whenever descending a hill,

follow these precautions:

1. Check the terrain carefully.

2. Avoid hills with excessively

slippery or loose surfaces.

3. Never go down a hill at high

speed.

4. Slow down.

5. Avoid going down a hill at an

angle, which can cause the

vehicle to pitch sharply to one side.

6. Drive straight downhill.

7. Shift your weight rearward.

8. Apply the foot brake slightly to aid in slowing.

9. Know how to use the hand brake.

Always follow the procedures

outlined in this manual for driving

downhill and for braking on

hills.

Never operate at

excessive speeds. Travel

and turn at speeds

appropriate for the terrain,

visibility, operating

conditions and your

experience.

Download from Www.Somanuals.com. All Manuals Search And Download.

SAFETY

Driving Safely

Sidehilling

Avoid crossing the side of a hill (sidehilling) if possible. If sidehilling

is necessary, follow these precautions:

1. Slow down.

2. Avoid hills with excessively slippery or loose surfaces.

3. Shift your weight uphill.

4. Avoid crossing the sides of steep hills.

5. Keep your feet on the footrests.

6. Steer slightly into the hill.

NOTE: If the vehicle begins to tip, quickly turn the front wheels

downhill (if possible) or dismount on the uphill side

immediately!

Always follow the procedures

outlined in this manual for crossing

the side of a hill.

Never attempt to turn the

Quadricycle around on any hill until

you’ve mastered (on level ground)

the turning technique outlined in this

manual.

Download from Www.Somanuals.com. All Manuals Search And Download.

SAFETY

Driving Safely

Driving Uphill

Whenever traveling uphill, follow these precautions:

1. Avoid steep hills (25_ maximum).

2. Check the terrain carefully.

3. Avoid hills with excessively slippery or loose surfaces.

4. Shift your weight uphill.

5. Drive straight uphill.

6. 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.

< 25_

Download from Www.Somanuals.com. All Manuals Search And Download.

SAFETY

Driving Safely

Driving Uphill

If all forward speed is lost:

Keep your weight uphill.

If the vehicle begins rolling downhill, never apply engine power. Never

apply the hand brake while rolling backwards.

Apply the foot brake gradually. When fully stopped, apply the hand

brake as well. Lock the hydraulic parking brake.

Dismount on the uphill side, or to either side if the vehicle is pointed

straight uphill. Turn the vehicle around and remount, following the

procedure described on page 32.

Always follow the procedures

outlined in this manual for

climbing hills. Avoid climbing

hills steeper than 25_.

> 25_

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.

Download from Www.Somanuals.com. All Manuals Search And Download.

SAFETY

Driving Safely

Turning Around on a Hill

If the vehicle stalls while climbing a hill, never back down the hill!

Use the K-turn to turn around.

2.4 m

1. Stop the vehicle. Keep your weight uphill.

2. Lock the hydraulic parking brake.

3. Leave the transmission in forward gear. Turn the engine off.

4. Dismount on the uphill side of the vehicle, or on the left if the

vehicle is pointing straight uphill.

5. Stay uphill of the vehicle and turn the handlebars full left.

6. Squeeze the brake lever to release the parking brake.

7. 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.

Download from Www.Somanuals.com. All Manuals Search And Download.

SAFETY

Driving Safely

Turning Around on a Hill

8. Lock the hydraulic parking brake. Remount from the uphill side.

Keep your weight uphill.

9. Apply the foot brake.

10. With the transmission still in forward, start the engine.

11. Squeeze and release the brake lever to release the parking brake.

12. Release the foot brake and drive slowly downhill. Control speed

with the foot brake until the vehicle is on level ground.

Always follow the procedures

outlined in this manual for

climbing hills. See page 30.

> 25_

Always follow the procedures

outlined in this manual for crossing

the side of a hill. See page 29.

Download from Www.Somanuals.com. All Manuals Search And Download.

SAFETY

Driving Safely

Driving Through Water

Follow these procedures when operating through water:

1. Check water depth and current before crossing.

2. Avoid operating in

water deeper than the

bottom of the footrests (1).

If it’s unavoidable,

travel slowly, balance

your weight carefully

and avoid sudden

movements. Maintain a

slow and steady forward

motion. Do not make

sudden turns, stops or

throttle changes.

3. Choose a crossing where

both banks have gradual inclines.

4. Drive slowly.

5. Avoid rocks and obstacles.

6. Wet brakes may have reduced stopping ability. Always test your

brakes after leaving water. If necessary, apply them lightly several

times to allow friction to dry out the pads.

Always follow the

procedures outlined in

this manual for driving

through water. Never

drive through deep or

fast-flowing water.

Download from Www.Somanuals.com. All Manuals Search And Download.

SAFETY

Driving Safely

Driving Through Water

CAUTION

If the vehicle stops while fully submerged, major engine damage

can result if the machine is not thoroughly inspected. Take the

vehicle to your dealer before starting the engine.

If your vehicle becomes fully immersed, and it’s impossible to take it

to a dealer before starting it, follow the steps described on page 92.

Have the vehicle serviced by your dealer promptly.

NOTE: If water has been ingested into the transmission (PVT),

follow the procedure on page 59.

Download from Www.Somanuals.com. All Manuals Search And Download.

SAFETY

Driving Safely

Driving in Reverse

Follow these precautions when operating in reverse:

1. Avoid backing downhill.

2. Always check for obstacles or

people behind the vehicle

before backing.

3. Drive slowly.

4. Apply the foot brake

lightly for stopping.

5. Avoid turning at

sharp angles.

6. Never apply the throttle

suddenly.

7. Do not use the override switch unless additional power is required

for vehicle movement. Use with caution.

NOTE: Reverse speed is greatly increased when the override switch

is used. Do not operate at full throttle. Apply just enough

throttle to maintain the desired speed.

CAUTION

Excessive throttle operation while in the speed limit mode may

cause fuel to build in the exhaust, resulting in engine popping

and/or engine damage.

Always follow the procedures

outlined in this manual for

driving in reverse.

Download from Www.Somanuals.com. All Manuals Search And Download.

SAFETY

Driving Safely

Parking on an Incline

Avoid parking on an incline. If it’s unavoidable, follow these

precautions:

1. Turn the engine off.

2. Place the transmission in gear.

3. Lock the mechanical parking brake.

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

5. Turn the fuel valve off.

Download from Www.Somanuals.com. All Manuals Search And Download.

SAFETY

Driving Safely

Hauling Cargo and Towing

WARNING

Overloading the vehicle or carrying or towing cargo improperly

can alter vehicle handling and may cause loss of control or brake

instability. Always follow these precautions when hauling cargo.

S Read and understand the load distribution warnings listed on the

vehicle warning labels.

S Never exceed the stated load capacity for this vehicle.

S REDUCE SPEED AND ALLOW GREATER DISTANCES FOR

BRAKING WHEN HAULING CARGO OR TOWING. Use ex-

treme caution when applying brakes. Avoid situations that re-

quire backing downhill.

S When operating over rough or hilly terrain, reduce speed, cargo

and towed load to maintain stable driving conditions.

S Do not obstruct the headlight when loading the front rack.

S CARRY LOADS AS LOW ON THE RACK AS POSSIBLE. Car-

rying a load high on the rack raises the center of gravity of the

vehicle and creates a less stable operating condition. Reduce

load weight when cargo is high. Secure off-centered loads that

cannot be centered and operate with extra caution.

S CARRYING A LOAD on only one rack may cause the vehicle to

overturn. Split the load between the front rack and rear rack,

with 1/3 in the front and 2/3 in the back. Do not exceed load ca-

pacities. See specifications beginning on page 108.

S SECURE ALL LOADS BEFORE OPERATING. Unsecured

loads can create unstable operating conditions, which could

result in loss of control of the vehicle.

S OPERATE ONLY WITH STABLE AND SAFELY ARRANGED

LOADS. When handling off-centered loads that cannot be

centered, securely fasten the load and operate with extra

caution. Always attach the tow load to the hitch point

designated for your vehicle.

S WHEN LOAD EXTENDS BEYOND RACK SIDES, stability and

maneuverability may be adversely affected, causing the ma-

chine to overturn. Use extreme caution.

S TOWING is approved OFF-ROAD ONLY. Operating a Quadri-

cycle/trailer combination on public roads is prohibited.

S TOWING SPEED should never exceed 16 km/h. Never exceed

8 km/h when towing loads in rough terrain, while cornering, or

while ascending or descending hills.

Download from Www.Somanuals.com. All Manuals Search And Download.

SAFETY

Driving Safely

Hauling Cargo and Towing

2/3

1/3

Towing

Towing is approved OFF-ROAD ONLY. Operating a

Quadricycle/trailer combination on public roads is prohibited. Do not

exceed the maximum capacities when towing. Do not tow any trailer

on a grade steeper than 15°.

Trail Boss 330

QUADRICYCLE

Maximum Towed Load

(Level Ground)

Maximum Vertical Hitch

Weight

386 kg

38.6 kg

Download from Www.Somanuals.com. All Manuals Search And Download.

FEATURES AND CONTROLS

Controls/Instruments

(2)

(4)

(5)

(3)

(1)

(1) Main Key Switch

Turn the main key switch off to stop the engine and end all

electrical power to the vehicle.

Turn the switch on to engage the starter.

After starting the engine, release the key to the RUNNING

LIGHTS position.

Turn the switch to LIGHTS ON to switch the headlights on.

WARNING

Do not attach a large key fob or key ring to the main switch. It

may contact the gas tank cap when turning, causing an

interruption to the electrical system and an unexpected engine

shut-down during operation. This could result in serious injury or

death.

(2) Speedometer Mode/Override Switch (Reverse Speed Limiter)

To gain additional power while operating in reverse, cancel the reverse

speed limit function by pressing the override switch before opening the

throttle.

WARNING

Activating the override switch with the throttle open and while

operating in reverse can cause loss of control. Do not activate

the override switch while the throttle is open.

Download from Www.Somanuals.com. All Manuals Search And Download.

FEATURES AND CONTROLS

Controls/Instruments

(3) Engine Stop Switch

(3)

Move the stop switch to the

OFF position to stop the

engine. All electrical power to

the vehicle will end. The

engine will not start or run

when the switch is in the OFF

position.

OFF

Move the stop switch to the

ON (RUN) position before

attempting to start the engine.

(4) Light Switch

(4)

Toggle the lights from high beam to

low beam.

NOTE: The lights do not operate

unless the main key

OFF

switch is on and the

engine stop switch is in

the RUN position.

(5) Throttle lever

Press the throttle lever to

increase engine speed and

vehicle movement. Release

the lever to reduce engine

speed and vehicle movement.

(5)

WARNING

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 Quadricycle with sticking or improperly

operating throttle controls.

Contact your dealer for repair if throttle problems arise.

Download from Www.Somanuals.com. All Manuals Search And Download.

FEATURES AND CONTROLS

Controls/Instruments

(6)

(11)

(10)

(13)

(12)

(8) (9)

(7)

(14)

(6) Electronic Throttle Control (ETC)

(6)

ETC causes the engine to stop

if the throttle cable sticks in

an open position when the

operator releases the throttle

lever.

WARNING

The Electronic Throttle Control (ETC) stops the engine in the

event of a throttle system malfunction. Do not modify the ETC

system or replace it with other throttle mechanisms.

(7) Choke Knob

The choke assists in starting a cold engine. See page 57.

(8) Horn

Press the horn button to

alert others of your

presence.

OFF

(8)

Download from Www.Somanuals.com. All Manuals Search And Download.

FEATURES AND CONTROLS

Controls/Instruments

(9) Hazard Warning Switch

Push the hazard warning switch

to cause all turn indicators to

flash simultaneously. Use this

feature to alert others of an

emergency or other situation

requiring caution.

(9)

(10) Rear Brake Lever

The left brake lever operates the hydraulic rear brakes only. See page

44.

(11) Parking Brake Lever

The right brake lever is used as a mechanical parking brake only. See

page 45.

(12) Turn Indicator

Push the toggle switch either left or right

to activate the corresponding turn signal.

Return the toggle to the center position to

end the signal.

OFF

(13) Mirrors

Use the mirrors to assist in traffic

maneuvers. Always check and adjust the

mirrors before driving the Quadricycle.

(12)

(14) Instrument Panel

View certain vehicle functions on the instrument panel. The

corresponding lights illuminate when the feature is activated.

HOT

Left Turn Engine Hot

Neutral

High Beam Right Turn

Download from Www.Somanuals.com. All Manuals Search And Download.

FEATURES AND CONTROLS

Brakes

Foot Brake

The all-wheel foot brake (1) is located on

the right footrest. The foot brake operates

both front and rear brakes. Press the brake

pedal forward with your foot to engage

the all-wheel brakes.

The master cylinder (2) is located near the

foot brake. Inspect and maintain the brake

fluid level as outlined in this manual. See

pages 56 and 75.

Rear Brake Lever

The left brake lever (1) operates the

hydraulic rear brakes only. Squeeze the

brake lever toward the handlebar to

apply the rear brakes.

If the rear wheels begin to skid or slide

while using this brake, reduce lever

pressure.

Inspect and maintain the brake fluid level in the master cylinder (2) as

recommended. See pages 56 and 75.

WARNING

Aggressively applying the rear brake when backing down a hill

may cause rear tipover.

Aggressively applying the rear brake 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 only the rear brakes.

Download from Www.Somanuals.com. All Manuals Search And Download.

FEATURES AND CONTROLS

Brakes

WARNING

Operating the Quadricycle while the parking brake is engaged

could result in an accident and serious injury or death. Always

check to be sure the parking brake is disengaged before

operating.

Locking the Parking Brake (Mechanical)

The right brake lever is used as a mechanical parking brake only. It is

not intended to be used as a brake lever.

1. Squeeze the right brake

lever (1) toward the

handlebar.

2. Move the park brake

lock (2) toward the

handlebar until the peg (3)

fits into the slot on the

lever. Release the lock lever.

3. To release the parking brake lock, squeeze and release the brake

lever. The parking brake will release automatically.

NOTE: The parking brake may relax if left on for a long period of

time. Always block the wheels to prevent rolling. Never

depend on the parking brake alone if the vehicle is parked on

a hill. Always block the wheels to prevent rolling.

Locking the Parking Brake (Hydraulic)

The hydraulic parking brake lock is a temporary lock. Do not rely on

the hydraulic parking brake when leaving the vehicle unattended.

Always lock the mechanical parking brake.

1. Squeeze the left brake lever (1).

2. Move the park brake lock (2) to

the locked position. This will

prevent the lever from returning

to the released position.

3. To release the parking brake

lock, squeeze and release the

brake lever. The parking brake

will release automatically.

Download from Www.Somanuals.com. All Manuals Search And Download.

FEATURES AND CONTROLS

Steering Lock

Lock the steering to prevent unauthorized use or theft of the vehicle.

1. Turn the handlebars to the full left position.

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

3. Remove the key.

4. Reverse the procedure to unlock the steering.

NOTE: Place the steering lock keys in a safe place. The lock must

be replaced if the keys are lost.

Download from Www.Somanuals.com. All Manuals Search And Download.

FEATURES AND CONTROLS

Fuel Tank

The fuel tank filler cap (1) is located directly below the handlebar.

Refuel with either leaded or unleaded gasoline with a minimum of 87

octane.

WARNING

S Gasoline is highly flammable and explosive under certain

conditions.

S Use extreme caution whenever handling gasoline.

S Refuel with the engine stopped. Refuel outdoors or in a well

ventilated area.

S Never fill a fuel container while it’s in the cargo box. Static

electricity between the box and container could cause a spark.

S Do not smoke or allow open flames or sparks in or near the

area where refueling is performed or where gasoline is stored.

S Do not overfill the tank. Do not fill the tank neck.

S If gasoline spills on your skin or clothing, immediately wash it off

with soap and water and change clothing.

S Turn the fuel valve off whenever the vehicle is stored or parked.

Fuel Valve

The fuel valve (2) is located on the left side panel.

RES

OFF

Turn the valve off before storage and when

transporting.

Turn the valve on for normal

operation.

RES

Turn the valve to the reserve setting if

the main fuel supply is exhausted.

Refuel as soon as possible. Reserve

fuel range is about 11-16 km.

NOTE: Return the valve to the ON

position after refueling.

Download from Www.Somanuals.com. All Manuals Search And Download.

FEATURES AND CONTROLS

Transmission Gear Selector

The transmission gear selector (1)

is located on the right side of the

vehicle.

Whenever the vehicle is left

unattended, place the transmission

in gear and lock the mechanical

parking brake.

R N F

F: Forward Gear

N: Neutral

R: Reverse

CAUTION

Shifting gears with the engine speed above idle or while the

vehicle is moving can cause transmission damage. Stop the

vehicle, release the throttle and move the lever to the desired

gear. See your dealer if you experience any shifting problems.

Download from Www.Somanuals.com. All Manuals Search And Download.

FEATURES AND CONTROLS

Recoil Starter

If the battery is too weak to start

the engine, use the recoil starter (1).

Follow the starting procedures on

page 57, cranking the engine with

the recoil starter instead of the

main key switch.

1. Grasp the recoil starter rope

handle tightly. Pull slightly

until the starter mechanism

engages.

2. Pull the rope abruptly to start the engine.

CAUTION

Extending the starter rope too far will 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.

Download from Www.Somanuals.com. All Manuals Search And Download.

FEATURES AND CONTROLS

Instrument Cluster

The instrument cluster senses vehicle speed from the right front wheel.

It measures distance as well as hours of operation. It also includes a

reverse speed limiter function that limits reverse speed to about 11-14

km/h. See page 40 for additional information.

1. Rider Information Center

2. Speedometer needle (In addition to showing vehicle speed, the

needle flashes when a warning condition exists.)

3. Speedometer

CAUTION

To prevent damage to the instrument cluster, wash the

Quadricycle by hand or with a garden hose using mild soap.

Do not use alcohol to clean the instrument cluster.

Immediately wash off any gasoline that splashes on the

instrument cluster.

Download from Www.Somanuals.com. All Manuals Search And Download.

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

The rider information center is located in the instrument cluster. All

segments will light up for 2.5 seconds at start-up.

NOTE: If the instrument cluster fails to illuminate, a battery

over-voltage condition may have caused it to shut down to

protect the electrical system. If this occurs, take the

Quadricycle to your Polaris dealer.

1. Gear Indicator - As

the shift lever is

moved, this indicator

shows the gear the

transmission is in.

H = High Range

(Forward)

N = Neutral

R = Reverse

2. Engine Hour Display Indicator

3. Service Interval/Diagnostic Mode Indicator

4. Odometer/Tachometer/Tripmeter/ Hour Meter

5. Check Engine Warning Indicator - “HOT” will display when the

engine is overheating. Turn off the engine or serious damage could

result.

6. Mode Indicator

Download from Www.Somanuals.com. All Manuals Search And Download.

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

The reverse override button on the left handlebar is also the mode

button. Use the mode button to toggle through the four (4) standard

modes of the rider information center.

NOTE: The transmission cannot be in reverse.

Mode 1 - Odometer

The odometer records the total distance traveled by the vehicle since

manufacture.

Mode 2 -Trip Meter

The trip meter records the distance traveled on each trip if it’s reset

before each trip. To reset the trip meter, select the trip meter mode.

Press and hold the mode button (override button) until the total

changes to 0.

NOTE: The trip meter displays a decimal point, but the odometer

does not.

Mode 3 - Hour Meter

The hour meter logs the total hours the engine has been in operation.

Mode 4 - Tachometer

The tachometer displays engine RPM. Small fluctuations in the RPM

are normal due to changes in humidity, temperature and elevation.

Download from Www.Somanuals.com. All Manuals Search And Download.

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

Diagnostic Mode

The diagnostic mode is for informational purposes only. Please return

your Quadricycle to your dealer for all major repairs.

The wrench icon will display when the gauge is in the diagnostic

mode.

Steps to enter the diagnostic mode:

1. Turn the main key switch off and wait 10 seconds.

2. Shift the transmission into neutral or park.

3. Hold the mode button and turn the main key switch on.

4. Release the switch as soon as the display is activated.

5. Use the mode button to toggle through the six (6) diagnostic

screens.

Three (3) ways to leave the diagnostic mode:

S Shift the transmission out of neutral.

S Turn the main key switch off and on.

S Move the tires.

Screen 1: Battery voltage

Screen 2: Tachometer

Screen 3: AWD diagnostic

This screen indicates whether or not current is flowing through the

AWD system.

Screen 4: Gear circuit diagnostic

This screen displays the resistance value (in ohms) being read at the

gear switch input.

Download from Www.Somanuals.com. All Manuals Search And Download.

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

Diagnostic Mode

Screen 5: Programmable service interval

The programmable service interval provides a convenient reminder

when routine maintenance is due. This feature is pre-set at 50 hours.

You must enable the programmable service interval before it can be

used.

When set, the hours of operation are subtracted from the set hours until

0 is reached. The wrench icon will flash quickly for five seconds each

time the engine is started as a reminder that service is due.

Setting the Service Interval

1. Press and hold the mode/override button until the wrench icon

flashes. Release the button.

2. Press the button once to advance the setting by one hour. Press and

hold the button to advance the hours at a faster pace.

3. When the desired time increment is displayed, release the button.

When the wrench stops flashing, service hours are set.

NOTE: If you scroll past the intended number, hold the button down

until the count turns over to 0. You can then reset the

number.

Disabling the Service Interval

1. Toggle to the service interval mode.

2. Press and hold the mode button for approximately seven (7)

seconds. The service interval is disabled when the word OFF

displays.

Screen 6: Miles/Kilometers toggle

The display in the tripmeter and odometer can be changed to display

either kilometers or miles. The current display mode will be shown as

either KM or MP.

1. Press and hold the mode button until the letters flash.

2. Press and release the mode button once. When the display stops

flashing, the mode has been set.

Download from Www.Somanuals.com. All Manuals Search And Download.

OPERATION

Break-In Period

The break-in period for your new Polaris Quadricycle is the first ten

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

gasoline. No single action on your part will increase the life and

performance of your Quadricycle more than following the procedures

for a proper break-in. Careful treatment of a new engine will result in

more efficient performance and a longer life.

Do not operate at full throttle or high speeds for extended periods

during the first three hours of use.

Perform the following procedures carefully.

1. Fill the fuel tank with gasoline.

2. Check the oil level on the dipstick. Add oil if necessary.

See page 67.

3. Select an open area that allows room to familiarize yourself with

vehicle operation and handling.

4. Drive slowly. Vary throttle positions. Do not operate at sustained

idle.

5. Perform regular checks on fluid levels, controls and areas outlined

on the daily pre-ride inspection checklist. See page 56.

6. Pull only light loads.

7. Perform the break-in oil change at one month.

Download from Www.Somanuals.com. All Manuals Search And Download.

OPERATION

Pre-Ride Inspection

Pre-Ride Checklist

Item

Brake system

Remarks

See

Page

Ensure proper operation

Brake fluid

Ensure proper level

Foot brake

Ensure proper operation

Front suspension

Rear suspension

Steering

Inspect, lubricate if necessary

Ensure free operation

Tires

Inspect condition and pressure

Inspect, ensure fastener tightness

Inspect condition, lubricate frequently

Wheels / fasteners

Drive chain

Frame nuts, bolts, fasteners Inspect, ensure tightness

Fuel and oil

Ensure proper levels

Ensure proper operation

Ensure operation

47, 67

41, 79

Throttle

Indicator lights / switches

Engine stop switch

Air filter, pre-filter

Air box sediment tube

Headlamp

Ensure proper operation

Inspect, clean

Drain deposits whenever visible

Check operation, apply Polaris dielec-

tric grease when lamp is replaced

Brake light / tail lamp

Riding gear

Check operation, apply Polaris dielec-

tric grease when lamp is replaced

Wear helmet, goggles, protective

clothing

Download from Www.Somanuals.com. All Manuals Search And Download.

OPERATION

Starting the Engine

WARNING

Engine exhaust contains poisonous carbon monoxide and can

cause loss of consciousness resulting in serious injury or death.

Never run an engine in an enclosed area or indoors.

CAUTION

Operating the vehicle immediately after starting could cause

engine damage. Allow the engine to warm up for several minutes

before operating.

1. Position the vehicle on a

level surface.

2. Sit on the vehicle.

3. Lock the mechanical

parking brake.

RES

4. Turn the fuel valve on.

5. Move the engine stop switch to RUN.

OFF

6. If the engine is cold, pull

the choke knob (1) out until it

stops. A warm engine will not

require the use of the choke.

FULL ON

HALF ON

OFF

NOTE: Make sure the choke is off during operation. Excess fuel

washing into the engine oil will increase wear on engine

components.

Download from Www.Somanuals.com. All Manuals Search And Download.

OPERATION

Starting the Engine

7. Turn the ignition key to the ON

position to engage the starter. Activate

the starter for a maximum of five

seconds, releasing the key when the

engine starts.

NOTE: Do not press the throttle while

starting the engine.

8. If the engine does not start, release the

starter and wait five seconds.

9. Repeat steps 7 and 8 until the engine starts.

10. If the engine slows or stops, position the choke knob half way in.

11. Vary engine RPM slightly with the throttle. When the engine idles

smoothly, push the choke all the way in.

Download from Www.Somanuals.com. All Manuals Search And Download.

OPERATION

Polaris Variable Transmission

Preventing Belt Slip / Failure

Belt slip creates heat that destroys belts and causes outer clutch covers

to fail. Avoid heavy pulling and extended low speed operation.

WARNING

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:

S Always follow all recommended maintenance procedures. See

your dealer as outlined in the owner’s manual.

S This PVT system is intended for use on Polaris products only.

Do not install it in any other product.

S Always make sure the PVT housing is securely in place during

operation.

PVT Drying

If water is ingested into the PVT system, dry it before operating the

vehicle.

1. Remove the drain plug. Drain the water. Reinstall the drain plug.

2. Place the transmission in neutral. Lock the mechanical parking

brake. Start the engine.

3. 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.

4. Allow the engine RPM to return to idle speed, then shift the

transmission to the lowest available range.

5. Test for belt slippage. If the belt slips, repeat the process.

6. Take the vehicle to your dealer for service promptly.

Download from Www.Somanuals.com. All Manuals Search And Download.

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.

Crankcase Emission Control System

This engine is equipped with a closed crankcase system. Blow-by

gases are forced back to the combustion chamber by the intake system.

The system does not allow the blow-by gases to enter the atmosphere.

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.

The emissions label (1) is located

on the recoil cover.

Adjustment to engine idle is the only adjustment recommended that the

operator perform. Any other adjustments should be performed by an

authorized Polaris dealer.

Electromagnetic Interference

This spark ignition system complies with USA requirements, Canadian

ICES--002 and European directives 89/336/EEC and 97/24/EC.

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE AND LUBRICATION

Periodic Maintenance Chart

Maintenance intervals in the following chart are based upon average

riding conditions. Vehicles subjected to severe use must be inspected

and serviced more frequently.

Severe Use Definition

S Frequent immersion in mud, water or sand

S Racing or race-style high RPM use

S Prolonged low speed, heavy load operation

S Extended idle

S Short trip cold weather operation

NOTE: Service and adjustments are critical. If you are not familiar

with safe service and adjustment procedures, have a

qualified Polaris dealer perform these operations.

The programmable service interval mode on the instrument cluster will

help determine when maintenance service is due. See page 54.

Maintenance Chart Key

Perform these procedures more frequently for vehicles subjected to

severe use.

Emission Control System Service

Have an authorized Polaris dealer perform these services.

WARNING

Improperly performing the procedures marked with a J could

result in component failure and lead to serious injury or death.

Have an authorized Polaris dealer perform these services.

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE AND LUBRICATION

Periodic Maintenance Chart

Perform all services at whichever maintenance interval is reached first.

Item

Maintenance Interval

(whichever comes first)

Remarks

Hours Calendar Kilometers

Steering

Pre-Ride

Make adjustments as need-

ed. See Pre-Ride Checklist

on page 56.

Front suspension

Rear suspension

Tires

Brake fluid level

Brake lever travel

Brake systems

Wheels/fasteners

Drive chain

Frame fasteners

Engine oil level

Air filter, pre-filter

Daily

Inspect; clean often

Air box sediment

tube

Drain deposits when visible

Headlamp/tail

lamp

Daily

Check operation; apply

dielectric grease if replacing

Air filter,

main element

Weekly

Inspect; replace as needed

Recoil housing

Drain water as needed,

check often if operating in

wet conditions

Brake pad wear

Monthly

100

Inspect periodically

Battery

Monthly

200

250

Check terminals; clean; test

Inspect level; change yearly

Inspect; replace if necessary

Transmission oil

Engine breather

filter

Engine oil change

(break-in)

1 M

3 M

250

500

Perform a break-in oil

change at one month

General

lubrication

Lubricate all fittings, pivots,

cables, etc.

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

Emission Control System Service

Have an authorized Polaris dealer perform these services.

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE AND LUBRICATION

Periodic Maintenance Chart

Item

Maintenance Interval

(whichever comes first)

Remarks

Hours Calendar Kilometers

Carburetor float

bowl

6 M

500

Drain bowl periodically and

prior to storage

Throttle Cable/

ETC Switch

Inspect; adjust; lubricate;

replace if necessary

Choke cable

Inspect; adjust; lubricate;

replace if necessary

Carburetor air

intake ducts/

flange

Inspect ducts for proper

sealing/air leaks

Drive belt

6 M

500

1000

1000)

Inspect; adjust; replace as

needed

Engine oil change

Oil filter change

Valve clearance

Fuel system

100

Perform a break-in oil

change at one month

6 M

Replace with oil change

12 M

Inspect; adjust

Check for leaks at tank cap,

lines, fuel valve, filter, pump,

carburetor; replace lines

every two years

Fuel filter

100

12 M

1000

Replace yearly

Engine mounts

100

12 M

1000

Inspect

Exhaust muffler/

pipe

Spark plug

Ignition Timing

Wiring

100

12 M

1000

Inspect; replace as needed

Inspect

Inspect for wear, routing,

security; apply dielectric

grease to connectors

subjected to water, mud, etc.

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

Emission Control System Service

Have an authorized Polaris dealer perform these services.

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE AND LUBRICATION

Periodic Maintenance Chart

Item

Maintenance Interval

(whichever comes first)

Remarks

Hours Calendar Kilometers

Clutches (drive

and driven)

100

12 M

1000

Inspect; clean; replace worn

parts

Front wheel

bearings

100

12 M

1600

Inspect; replace as needed

Brake fluid

200

300

24 M

36 M

2000

3000

Change every two years

Clean out

Spark arrestor

Idle speed

Adjust as needed

Toe adjustment

Inspect periodically; adjust

when parts are replaced

Foot brake and

rear brake

Inspect daily; adjust as

needed

Mechanical

parking brake

Inspect daily; adjust cable as

needed

Headlight aim

Adjust as needed

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

Emission Control System Service

Have an authorized Polaris dealer perform these services.

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE AND LUBRICATION

Torque Symbol

=Torque the item as specified.

Lubrication Recommendations

Check and lubricate all components at the intervals outlined in the

Periodic Maintenance Chart beginning on page 61. Items not listed in

the chart should be lubricated at the General Lubrication interval.

Item

Lube

Method

Engine

Polaris Premium 4 See page 66.

Synthetic 0W40

Brakes

DOT 3 fluid only

See page 74.

See Page 72.

Transmission

Premium AGL

Synthetic

Gearcase Lube

Drive chain(s)

(1) Ball Joint

O-ring chain lube

or SAE 80/90

Lubricate as often as required and

before each ride in wet conditions

Premium U-Joint

Grease

Locate fittings and grease.

(2) Swing Arm

Bushings

(3) Axle Housing

(2)

(3)

(1)

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE AND LUBRICATION

Engine Oil

Polaris Premium 4 Synthetic Oil is the only oil recommended for use

in this engine. Use of another API certified “SH” oil is acceptable as

long as it’s 0W-40. Oil may need to be changed more frequently if

Polaris Premium 4 is not used. See page 103 for the part numbers of

Polaris products.

Always check and change the engine oil at the intervals outlined in the

Periodic Maintenance Chart beginning on page 61.

CAUTION

Using a non-recommended oil may cause serious engine damage.

Use only Polaris Premium 4 All Season Synthetic Oil or an API

certified 0W-40 “SH” oil. Never substitute or mix oil brands.

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE AND LUBRICATION

Oil Check

1. Position the vehicle on a

level surface.

2. Place the transmission in

neutral.

3. Lock the mechanical

parking brake.

4. Start the engine. Allow it to

idle for 30 seconds.

5. Turn the engine off.

6. Remove the dipstick.

Wipe it clean.

7. Reinstall the dipstick completely.

8. Remove the dipstick. Check the oil

level.

9. Add oil as needed to bring the level

between the minimum and maximum

marks.

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE AND LUBRICATION

Oil and Filter Change

Always change the engine oil at the intervals outlined in the Periodic

Maintenance Chart beginning on page 61. Always change the oil filter

when changing oil. Change the oil more often if the vehicle is routinely

subjected to:

S operation in dusty or wet conditions.

S operation when air temperature is below -12° C.

S short trips at -12° to -1° C. (engine fails to reach operating tempera-

ture).

CAUTION

If the Quadricycle is left without oil in the system for extended

periods, the oil pump may lose its prime, which could result in

engine damage. Always replace the oil and filter within a few

hours of draining the oil. Do not allow the vehicle to be without oil

overnight.

1. Use Polaris-recommended

products.

Oil filter

0W/40 oil

1. Position the vehicle on a

level surface.

2. Place the transmission in

neutral.

3. Lock the mechanical

parking brake.

4. Start the engine. Allow it

to idle for two minutes.

5. Turn the engine off.

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE AND LUBRICATION

Oil and Filter Change

6. Place a drain pan under the

vehicle.

7. Remove the drain plug.

8. Drain the oil.

CAUTION

Hot oil may result in serious burns. Do not allow hot oil to contact

skin.

9. Reinstall the drain plug with a new

sealing washer.

=19 N-m

10. Place towels under the oil

filter.

11. Using an oil filter wrench (4),

turn the filter counterclockwise to

remove it.

12. Clean the filter sealing area on

the engine.

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE AND LUBRICATION

Oil and Filter Change

13. Lubricate the filter o-ring.

14. Install the new oil filter.

After the filter contacts the

engine surface, turn it 1/2

turn by hand.

15. Remove the dipstick.

16. Add two .95 liter bottles of

0W/40 oil.

17. Reinstall the dipstick.

18. Start the engine. Allow it to idle for

two minutes.

19. Turn the engine off.

20. Check for oil leaks.

21. Check the oil level. Add oil as needed

to bring the level between the minimum

(MIN) and maximum (MAX) marks.

22. Discard used oil and filter properly.

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE AND LUBRICATION

Engine Oil Cooler Maintenance

The oil cooling system

requires little maintenance

other than keeping the

cooler (1) free of mud and

debris.

CAUTION

Do not use a high

pressure washer to

remove debris from the

cooler. The pressure

may damage the

cooling fins. Use only

low pressure water.

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE AND LUBRICATION

Transmission Oil Check

See page 65 for recommended lubricants. See page 103 for the part

numbers of Polaris products.

1. Position the vehicle on a

level surface.

2. Place the transmission in

gear.

3. Lock the mechanical

parking brake.

4. Remove the dipstick.

Wipe it clean.

5. Reinstall the dipstick

completely.

6. Remove the dipstick.

Check the oil level.

7. Maintain the level

between the minimum

(MIN) and maximum

(MAX) marks.

8. Add fluid as needed.

Do not overfill.

9. Reinstall the dipstick.

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE AND LUBRICATION

Transmission Oil Change

1. Position the vehicle on a

level surface.

2. Place the transmission in

gear.

3. Lock the mechanical

parking brake.

4. Loosen the jam nut (1).

5. Turn the adjuster bolt (2)

inward.

6. Remove the drain plug (3).

Wipe it clean.

7. Drain the fluid into a drain pan.

8. Install a new sealing washer.

Reinstall the drain plug.

=19 N-m

9. Turn the adjuster bolt outward

until it touches the frame, and

then turn an additional 1/2 turn.

10. Tighten the jam nut securely

while holding the adjuster bolt.

11. Remove the dipstick.

12. Add 335 ml of the recommended fluid.

13. Reinstall the dipstick.

14. Check for oil leaks.

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE AND LUBRICATION

Brakes

Under normal operation, a 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. The brake system should be inspected by your dealer.

Fill the reservoir as needed whenever the cover is loosened or removed

to ensure proper diaphragm operation. Use Polaris DOT 3 brake fluid.

Do not overfill.

NOTE: Reservoir levels will decrease as brake pads become worn.

When checking the fluid level, the vehicle must be on level

ground with the handlebars straight. If the fluid level is low,

check brake pad thickness before adding brake fluid. DO

NOT OVERFILL.

Brake Check

Perform the following checks to keep the brake systems in good

operating condition. Check more often if brakes are used heavily

during normal operation.

WARNING

Do not overfill the reservoirs. An over-full master cylinder may

cause brake drag or brake lock-up, which could cause brake loss

or loss of control. Maintain brake fluid at the recommended level.

1. Check the brake systems regularly for

fluid leaks.

2. Check the brakes for excessive travel

or spongy feel.

3. Check the brake pads for wear,

damage or looseness. Replace pads

when they are worn to 1 mm.

4. Check the security and surface

condition of the brake discs.

1 mm

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE AND LUBRICATION

Brakes

Brake Fluid Check

Check brake fluid levels before each use of the vehicle.

The brakes should feel firm when they’re applied. Spongy or weak

brakes may indicate a fluid leak or low fluid level. A low fluid level

may also mean that brake pads are worn and need to be replaced. Do

not operate the vehicle with spongy or weak brakes. See your dealer for

service.

Master Cylinder (Handlebar)

The master cylinder (1) is

located on the left

handlebar. View the fluid

level through the indicator

window (eye) on the top of

the master cylinder.

A dark eye (2) indicates a

full fluid level.

A clear eye (3) indicates a

low fluid level.

Master Cylinder (Foot Brake)

The foot brake master

Max

Min

cylinder (4) is located under

the right rear fender. View the

fluid level through the reservoir

body. Fluid level is full at the

MAX mark. Add brake fluid if the

level reaches the MIN mark.

WARNING

Once open, a bottle of brake fluid absorbs moisture from the air,

which causes the boiling temperature of the brake fluid to drop.

This can lead to early brake fade and the possibility of accident.

Do not store opened brake fluid. Properly discard any unused

portion.

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE AND LUBRICATION

Steering / Suspension

Toe Alignment

Use the following procedure to check the toe alignment of the vehicle.

The recommended toe alignment is 3-6 mm toe out.

1. Set the handlebars in a

straight-ahead position.

2. Place stands (1) in front of the

vehicle, perpendicular to the

rear tires.

3. Tie an elastic string around the

stands, making sure the string

just touches the side surface of

the rear tires on each side of

the vehicle and goes around the

stands in front of the vehicle (2).

4. Measure the distance from the

string to the rim at the front

and rear of the front rim (3).

The rear measurement should

be 2 to 3 mm more than the

front measurement.

NOTE: If you discover improper

alignment, see your Polaris

dealer for service.

WARNING

Do not attempt to adjust alignment. All steering adjustments

should be performed by an authorized Polaris dealer.

Rear Springs

The rear shock absorber springs are

adjustable. Use the spanner wrench (1) in

the tool kit.

Rotate the adjuster (2) clockwise to increase

or counterclockwise to decrease spring

tension.

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE AND LUBRICATION

Steering / Suspension

Steering Assembly

Check the steering assembly of

the vehicle periodically for loose

nuts and bolts. If loose nuts and

bolts are found, see your Polaris

dealer for service before

operating the vehicle.

Handlebar Adjustment

1. Remove the two hex

screws (1) from the

instrument panel (2).

Remove the instrument

panel.

2. Loosen (do not

remove) all four

handlebar bolts.

3. Adjust the handlebar

to the desired height.

14-17 N-m

NOTE: Make sure the

handlebars do

not contact the

gas tank or any part of

the machine when turned

fully to the left or right.

4. Torque the two front bolts (3), then torque the two rear bolts (4).

=14-17 N-m

NOTE: A gap of up to 3 mm should remain at the rear bolts.

WARNING

Improper adjustment of the handlebars or incorrect torquing of

the adjuster block tightening bolts can cause limited steering or

loosening of the handlebars, resulting in loss of control. Follow

the adjustment procedures exactly, or see your Polaris dealer for

service.

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE AND LUBRICATION

Carburetor Idle Adjustment

IMPORTANT: 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. Jetting is

required only when operating below 4 degrees C. at 1800 meters and

lower.

NOTE: Operating the engine with improper jetting can cause poor

performance, overheating or engine damage. See your

Polaris dealer for more information about jetting.

If necessary, the carburetor can be

adjusted.

1. Place the transmission in neutral.

2. Lock the mechanical parking

brake.

3. Operate the engine for about five minutes.

4. Adjust the carburetor idle screw (1)

clockwise to raise RPM or

counterclockwise to lower RPM.

+ RPM

-- R P M

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE AND LUBRICATION

Throttle Cable Freeplay Adjustment

1. Locate the throttle cable

adjuster (1) on the

handlebar.

2. Slide the boots (2) off

the cable adjuster

sleeve (3). Loosen the

adjuster (4).

3. Turn the adjuster until 1.6-3.2 mm

of freeplay exists at the lever.

NOTE: Move the throttle lever

back and forth while

adjusting.

1.6-3.2 mm

4. Tighten the adjuster.

Slide the boots (2) over

the cable adjuster until

they touch at the

midpoint of the adjuster.

NOTE: Engine RPM should

not increase when

steering is turned full

left or right. Readjust

cable freeplay if this

occurs.

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE AND LUBRICATION

Side Panel Removal

NOTE: Side panel removal may be difficult until the locking tabs and

receivers have been snapped and unsnapped a few times.

1. Remove the seat.

2. Grasp the rear of the side

panel near the rear cab. Pull

the panel forward and outward

quickly and firmly to

disengage the rear tabs.

3. Place your hand on top of the

side panel behind the fuel

tank. Push down quickly and

firmly to disengage the top

rear tabs.

4. Pull the side panel upward to

disengage the front tabs.

Reinstallation

5. Align the tabs with the slots

on the front cab.

6. Push the panel upward and

forward until the tabs lock.

7. Bend the rear of the side panel

and insert the two tabs into the

rear cab slots.

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE AND LUBRICATION

Wheel Removal / Installation

CAUTION

Operating with improperly installed wheels will affect vehicle

handling and could cause an accident resulting in serious injury or

death. Always use original equipment size and type when

replacing tires. Install wheels properly.

1. Position the vehicle on a

level surface.

2. Place the transmission in

gear.

3. Lock the mechanical

parking brake.

4. Loosen the wheel nuts

slightly.

5. Safely place jackstands

under the vehicle.

6. Remove the wheel nuts

and remove the wheel.

7. Place the wheel on the hub.

8. Install the wheel nuts

finger tight.

9. Carefully remove the jackstands.

10. Torque the wheel nuts.

=37 N-m Front Wheel

=68 N-m Rear Wheel

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE AND LUBRICATION

Tires

Tire Tread Depth

Always replace tires when tread

depth is worn to 3 mm or less.

3 mm

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 decal on your

vehicle and in the specifications section of the owner’s manual

beginning on page 108.

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.

Wheel and Hub Tightening

Wheel hub and bearing tightness and spindle nut retention are critical

items. These services must be performed by an authorized dealer.

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE AND LUBRICATION

Drive Chain

Always inspect the drive chain before operating the vehicle. Check for

damaged or missing o-rings or damaged rollers. Check for correct slack

adjustment. Maintain the stone guard-to-rear sprocket clearance at 3

mm. Lubricate the outer surfaces of the roller regularly.

Lubricate the drive chain as outlined in the Lubrication Chart on page

65.

High pressure water may damage components. Do not use high

pressure water. See page 99.

Rear Drive Chain Slack

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.

Check the amount of chain slack

in three different locations by

moving the vehicle slightly

forward. Measure the chain slack

at the tightest of the three

positions. At this point the chain

should have 4.8-9.5 mm

deflection.

4.8 - 9.5 mm

Use the following procedure if

adjustment is required.

1. Loosen the chain guide.

2. Loosen the two eccentric

locking bolts (1).

3. Loosen the caliper mounting

bolt located on the left side

of the swing arm.

4. Insert a pin punch (2)

through the sprocket hub

and into the eccentric

housing.

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE AND LUBRICATION

Drive Chain

Rear Drive Chain Slack

5. Roll the vehicle forward or

backward to adjust the chain slack

to the proper tension. See the

illustration for proper splice link

clip opening position (1).

6. Tighten the eccentric locking bolts

to 61 N-m.

7. Tighten the caliper mounting bolt to 20 N-m.

8. Remove the pin punch.

9. Roll the vehicle forward, checking chain tension in several places

around the chain. The chain is adjusted correctly when the tightest

portion of the chain has approximately 10 mm deflection.

10. Position the chain guide to allow 3 mm clearance and tighten the

retaining bolt to 7 N-m.

Fuel Filter

Replace the in-line fuel filter at the intervals

outlined in the Periodic Maintenance Chart

beginning on page 61. Do not attempt to

clean the fuel filter.

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE AND LUBRICATION

Air Filter

1. Position the vehicle on a

level surface.

2. Place the transmission in

gear.

3. Lock the mechanical

parking brake.

4. Remove the seat.

5. Unlatch the air box clips (1).

Remove the air box cover.

6. Loosen the hose clamp (2)

and remove the filter (3).

7. Remove the pre-filter (4) from the

filter (5). Wash the pre-filter in

soapy water. Rinse and air dry.

NOTE: Replace the filter if needed.

8. Reverse the steps to reinstall all

components.

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE AND LUBRICATION

Lights

WARNING

Poor lighting can result in loss of control or an accident. Lights

become dirty during normal operation. Wash the headlights and

tail lights frequently.

Hot components can cause serious burns to skin. Do not service

the headlamps until they’ve cooled.

Headlight Replacement

When servicing a halogen lamp,

do not touch the lamp with bare

fingers. Hold the plastic part (1)

of the lamp. Oil from your skin

leaves a residue, causing a hot

spot that will shorten the life of

the lamp.

1. Place the transmission in gear.

2. Lock the mechanical parking

brake.

3. Turn the back of the

headlight counterclockwise.

4. Remove the headlamp (2).

5. Apply dielectric grease to

the socket.

6. Install the new headlamp.

7. Turn the back of the

headlight clockwise to

reinstall.

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE AND LUBRICATION

Lights

High Beam Adjustment

7.6 m

5.1 cm

1. Position the vehicle on a level surface. The headlight should be

approximately 7.6 meters from a wall.

2. Place the transmission in

neutral.

3. Lock the mechanical parking

brake.

4. Measure the distance from the

floor to the center of the

headlight and make a mark on

the wall at the same height.

NOTE: Include rider weight on the seat when measuring.

5. Start the engine. Turn the headlight switch to high beam.

6. Observe the headlight aim on the wall. The most intense part of

the headlight beam should be aimed 5.1 cm below the mark placed

on the wall.

7. Loosen the pivot bolt and adjust the beam.

8. Tighten the bolt.

=3 N-m

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE AND LUBRICATION

Lights

Taillight/Signal Light Replacement

1. Place the transmission in gear.

2. Lock the mechanical parking

brake.

3. Rotate the taillight socket

counterclockwise to remove it.

4. Remove the lamp.

5. Apply dielectric grease to the

socket.

6. Install the new lamp.

7. Test the lamp for proper

operation.

8. Reinstall all components in reverse order.

9. Rotate the turn signal socket

counterclockwise to remove it.

10. Remove the lamp.

11. Apply dielectric grease to the

socket.

12. Install the new lamp.

13. Test the lamp for proper operation..

14. Reinstall all components in reverse order.

Indicator Lamp Replacement

1. Remove the instrument panel.

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

1/4 turn counterclockwise.

3. Remove the lamp. Use a needle-nose plier or similar tool.

4. Install the new lamp. Turn the lamp clockwise 1/4 turn.

5. Reinstall the instrument panel.

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE AND LUBRICATION

Recoil Housing Drain

Always drain the recoil housing (1)

after operating the vehicle in wet

conditions. Always remove the drain

plug before storing the vehicle.

NOTE: Water will enter the recoil

housing if the starter

handle (2) is disengaged

from the rope guide when

under water.

1. Place the transmission in gear.

2. Lock the mechanical parking

brake.

3. Using a wrench, remove the

drain screw (3) on the bottom of

the recoil housing.

4. Reinstall the screw after draining

the housing.

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE AND LUBRICATION

Spark Plugs

1. Remove the left side panel.

See page 80.

2. Remove the spark

plug wire (1). Use the

spark plug wrench (2)

to remove the spark

plug (3). Turn the plug

counterclockwise to

remove it.

3. Inspect the electrodes for

wear and carbon buildup.

Replace worn or fouled

plugs. Verify that the gap

is at specification before

installation.

4. Reinstall the spark plug.

=19 N-m

5. Reinstall the spark plug

wire.

19 N-m

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE AND LUBRICATION

Spark Plugs

Spark Plug Condition

Normal

The insulator tip is tan or brown. There are few combustion deposits.

The electrodes are not burned or eroded. This indicates the proper type

and heat range for the engine and the service.

NOTE: The tip should not be white. A white insulator tip indicates

overheating, caused by use of an improper spark plug or

incorrect carburetion adjustments.

Fouled

The insulator tip is black. A damp 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 consumption,

improper use of the choke, or incorrect carburetion adjustments.

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE AND LUBRICATION

Vehicle Immersion

CAUTION

If the vehicle stops while fully submerged, major engine damage

can result if the machine is not thoroughly inspected. Take the

vehicle to your dealer before starting the engine.

If your vehicle has been totally submerged in water and it’s impossible

to have it serviced before further operation, perform the following

procedure.

1. Move the vehicle out of

the water.

RES

2. Turn the fuel valve off.

OFF

3. Remove the spark plug.

See page 90.

4. Drain any water found in

the air box.

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE AND LUBRICATION

Vehicle Immersion

5. Loosen the carburetor drain screw (1) and

drain the carburetor.

6. Turn the ignition key to the ON

position to engage the starter.

Engage the starter for only 2-3

seconds.

7. Tighten the carburetor drain screw.

8. Reinstall the spark plug.

=19 N-m

RES

9. Turn the fuel valve on.

OFF

10. Attempt to start the engine. If necessary, repeat the drying

procedure.

11. Have the vehicle serviced by your dealer promptly, whether you

succeed in starting it or not.

NOTE: If water has been ingested into the PVT, follow the procedure

for drying out the PVT. See page 59.

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE AND LUBRICATION

Spark Arrestor

Occasionally, the spark arrestor may accumulate carbon, which can

restrict the exhaust if left unattended. Purge the spark arrestor.

WARNING

Allow components to cool sufficiently before servicing. The

exhaust system can get extremely hot. Never run the engine in

an enclosed area or indoors. Exhaust contains poisonous carbon

monoxide gas. Never go under the vehicle while it’s inclined.

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.

1. Remove the arrestor clean-out plug

from the bottom of the muffler.

2. Place the transmission in neutral.

3. Lock the mechanical parking

brake.

4. Start the engine.

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE AND LUBRICATION

Spark Arrestor

5. Quickly squeeze and

release the throttle lever

several times to purge

carbon from the system.

6. If carbon comes out of the

exhaust, cover or plug the

exhaust outlet (1). Wear

leather gloves for

protection.

7. Lightly tap on the exhaust

pipe with a rubber mallet

while repeating step 5.

8. If particles are still

suspected to be in the

muffler, elevate the rear

of the vehicle 30 cm

higher than the front.

30 cm

9. Lock the mechanical

parking brake.

10. Block the wheels.

11. Repeat steps 5 to 7 until no more particles are expelled.

12. Turn the engine off. Allow the arrestor to cool.

13. Reinstall the arrestor plug and remove the exhaust outlet cover or

plug.

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE AND LUBRICATION

Battery

WARNING

Improperly connecting or disconnecting battery cables can cause

sparks which could result in an explosion, causing serious injury or

death. When removing the battery, always disconnect the negative

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

negative (black) cable last.

Battery Removal

1. Place the transmission in gear.

2. Lock the mechanical parking

brake.

3. Disconnect the battery hold-down strap. Remove the battery cover.

4. Disconnect the black negative (--) cable first.

5. Disconnect the red positive (+) cable last.

6. Lift and remove the battery.

Battery Installation

Always install a fully charged battery. See page 97.

1. Place the battery in the battery holder.

2. Verify that cables are routed properly.

3. Connect the red positive (+) cable first.

4. Connect the black negative (--) cable last.

5. Install the battery cover.

6. Attach the hold-down strap.

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE AND LUBRICATION

Battery

Battery Storage

Whenever the vehicle is not used for a period of three months or more,

remove the battery from the vehicle. Verify 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.

NOTE: Battery charge can be maintained by using a Polaris Battery

Tendert charger (P/N 2871076) or by charging about once a

month to make up for normal self-discharge. Battery

Tendert can be left connected during the storage period,

and will automatically charge the battery if the voltage drops

below a pre-determined point.

Battery Charging

The following battery charging instructions apply only to the

installation of an activated, sealed battery. Read all instructions before

proceeding with the installation of this battery.

A sealed battery is already filled with electrolyte. It has been sealed

and is fully charged at the factory. Always keep a sealed battery fully

charged.

S DO NOT pry the sealing strip off.

S DO NOT add any other fluid to this battery.

S A fully charged battery will register 12.8 V or higher.

1. Check battery voltage with

a voltmeter or multimeter.

2. If voltage is low, recharge

the battery at 1.2 amps or

less until the voltage is

12.8 or greater.

NOTE: When using an automatic

charger, refer to the charger

manufacturer’s instructions for

recharging. When using a

constant current charger, follow

the guidelines on page 98.

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE AND LUBRICATION

Battery

Battery Charging Chart (Constant Current Charger)

State of

Charge

Voltage

Action

Charge Time*

(Using constant current

charger @ standard amps

specified on top of battery)

100%

12.8-13.0 volts

12.5-12.8 volts

None, check at

3 mos. from date of

manufacture

None required

75%-100%

May need slight

charge, if no

charge given,

check in 3 months

3-6 hours

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

At least 20 hours

NOTE: Always verify battery condition before and one to two hours

after charging.

WARNING

An overheated battery may explode, causing serious 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.

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE AND LUBRICATION

Cleaning the Vehicle

Keeping the vehicle clean will extend the life of components.

S Use a garden hose and a pail of mild soap and water

S Use a professional-type washing mitten, cleaning the upper body

first and the lower parts last.

S Rinse with clean water frequently.

S Wipe the vehicle dry with a chamois.

S Do not use high pressure water.

High pressure water may damage components. If a high pressure wash

system must be used, exercise extreme care to avoid directing water

onto the wheel bearings, transmission seals, body panels, brakes and

warning labels. Grease all fittings immediately after washing, and

allow the vehicle to run for a while to evaporate any water that may

have entered the engine or exhaust system.

NOTE: If warning and safety labels are damaged, contact your

Polaris dealer for free replacements.

Waxing the Vehicle

Wax the vehicle with any non-abrasive automotive paste wax. Avoid

harsh cleaners since they can scratch the finish.

CAUTION

Some products, including insect repellants and chemicals, will

damage plastic surfaces. Use caution when using these products

near plastic surfaces.

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE AND LUBRICATION

Storing the Vehicle

See page 103 for the part numbers of Polaris products.

Clean the Vehicle

See page 99.

Stabilize the Fuel

1. Fill the fuel tank.

2. Add Polaris Carbon Clean Fuel Treatment or Polaris Fuel

Stabilizer. Follow the instructions on the container. (Carbon Clean

Plus will reduce the possibility of bacterial growth in the fuel

system.) Allow 15-20 minutes of operation for the stabilizer to

disperse through the fuel in the tank and carburetor.

3. Turn the fuel valve off.

4. Drain the carburetor bowl.

Change Oil and Filter

Change the oil and filter. See page 68.

Air Filter / Air Box

Inspect and clean (or replace) the pre-cleaner and air filter. Clean the air

box and drain the sediment tube. See page 85.

Check / Change Fluids

Inspect fluid levels and change fluids if necessary.

S Transmission oil

S Engine oil

S Brake fluid

Drain the Recoil Housing

See page 89.

Battery Storage

Remove the battery. Make sure that it’s fully charged. See page 97.

100

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE AND LUBRICATION

Storing the Vehicle

Engine Fogging

Use Polaris Engine Fogging Oil. Follow label directions carefully.

CAUTION

Starting the engine during the storage period will disturb the

protective oil film, which can lead to engine damage. Never start

the engine during the storage period.

Storage Area / Cover

1. Make sure tire pressure is at specification.

2. Using suitable supports under the frame, raise the vehicle slightly

so that the tires are not touching the ground.

3. Be sure the storage area is well ventilated.

4. Cover the machine with an appropriate cover. Do not use plastic or

coated materials, as they do not allow proper ventilation to prevent

condensation, corrosion and oxidation.

Accessories

Auxiliary power outlets provide 12V power for operating accessories

such as hand held spot lights. See your Polaris dealer for more

information about accessories.

101

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE AND LUBRICATION

Transporting the Vehicle

Follow these procedures when transporting the vehicle.

1. Turn the engine off.

Remove the key to prevent

loss during transporting.

2. Place the transmission in gear.

3. Lock the mechanical

parking brake.

RES

4. Turn the fuel valve off.

5. Be sure the fuel cap, oil cap and

seat are installed correctly.

OFF

6. Attach the FRAME of the

Quadricycle to the transporting

unit securely using suitable straps

or rope.

102

Download from Www.Somanuals.com. All Manuals Search And Download.

POLARIS PRODUCTS

Part No.

Description

Engine Lubricant

2870791

2871281

2871844

Fogging Oil (355 ml Aerosol)

Premium 4 Synthetic 0W-40 (4-Cycle) Engine Oil (.95 l)

Premium 4 Synthetic 0W-40 (4-Cycle) Engine Oil (3.8 l)

Gearcase / Transmission Lubricants

Premium AGL Synthetic Gearcase Lube (.95 l)

Premium AGL Synthetic Gearcase Lube (3.8 l)

Premium ATV Angle Drive Fluid (237 ml)

Premium ATV Angle Drive Fluid (.95 l)

Pump for 3.8 liter jug

2873602

2873603

2871653

2872276

2870465

2871654

2872277

Premium Demand Drive Hub Fluid (237 ml)

Premium Demand Drive Hub Fluid (9.5 l)

Grease / Specialized Lubricants

Premium All Season Grease (89 ml cartridge)

Premium All Season Grease (414 ml cartridge)

Starter Drive Grease

Premium U-Joint Lube (89 ml)

Premium U-Joint Lube (414 ml)

Grease Gun Kit

Dielectric Grease (Nyogelt)

Chain Lube (185 ml aerosol)

Chain Lube (473 ml aerosol)

2871322

2871423

2871460

2871515

2871551

2871312

2871329

2872073

2872348

Additives / Miscellaneous

Brake and Clutch Cleaner

Carbon Clean Plus (355 ml)

Fuel Stabilizer (473 ml)

DOT3 Brake Fluid

2872889

2871326

2870652

2870990

2872893

2871956

Engine Degreaser

LOCTITE 565 Thread Sealant

103

Download from Www.Somanuals.com. All Manuals Search And Download.

TROUBLESHOOTING

Drive Belt and Cover Problems

Possible Cause

Solution

Driving the vehicle onto a Avoid stopping on the ramp or creeping slowly up the

pickup or tall trailer.

ramp.

Starting out going up a

steep incline.

Perform the K-turn as described on page 32.

Driving at low RPM or

low ground speed (at

approximately 3-7 MPH).

Drive at a slightly higher speed. Avoid creeping.

Insufficient warm-up of

vehicles exposed to low

ambient temperatures.

Warm the engine at least 5 minutes. Place the transmission

in neutral. Lock the parking brake. Advance the throttle to

about 1/8 throttle in short bursts, 5 to 7 times. The belt

will become more flexible and prevent belt burning.

Slow and easy clutch en- Use the throttle quickly and effectively for efficient en-

gagement.

Towing/pushing at low

RPM/low ground speed.

Install a one tooth smaller counter shaft sprocket.

Stuck in mud or snow.

Carefully use fast, aggressive throttle application to en-

gage clutch. WARNING: Excessive throttle may cause

loss of control and vehicle overturn.

Climbing over large ob-

Carefully use fast, brief, aggressive throttle application to

jects from a stopped posi- engage clutch. WARNING: Excessive throttle may cause

tion.

loss of control and vehicle overturn.

Belt slippage from water

Dry out the PVT as outlined on page 59. Inspect clutch

or snow ingestion into the seals for damage if repeated leaking occurs.

PVT system.

Clutch malfunction.

Contact your Polaris dealer for inspection of clutch com-

ponents.

Poor engine performance. Check for fouled plugs or foreign material in gas tank,

fuel lines, or carburetor. Contact your dealer for service.

104

Download from Www.Somanuals.com. All Manuals Search And Download.

TROUBLESHOOTING

Contact your Polaris dealer for service if you’re unable to identify

solutions using the following charts.

Engine Does Not Rotate

Possible Cause

Solution

Blown fuse

Replace fuse

Low battery voltage

Recharge battery to 12.5 VDC

Check all connections and tighten

Loose battery connections

Loose solenoid / starter connections

Engine Rotates, Fails to Start

Possible Cause

Solution

Out of fuel

Turn fuel valve to reserve, refuel

Inspect and clean or replace

Drain the fuel system and refuel

Turn the fuel valve on

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

Crankcase filled with water or fuel

Overuse of choke

Replace with new fuel

Inspect plug(s), replace if necessary

Inspect plug(s), verify stop switch is on

Immediately see your Polaris dealer

Inspect, clean and/or replace spark plugs

Replace the filter

Clogged fuel filter

Low battery voltage

Recharge battery to 12.5 VDC

See your Polaris dealer

Mechanical failure

Engine Pings or Knocks

Possible Cause

Poor quality or low octane fuel

Incorrect ignition timing

Solution

Replace with recommended fuel

See your Polaris dealer

Incorrect spark plug gap or heat range

Set gap to specs or replace plugs

105

Download from Www.Somanuals.com. All Manuals Search And Download.

TROUBLESHOOTING

Engine Backfires

Possible Cause

Weak spark from spark plugs

Incorrect spark plug gap or heat range

Old or non-recommended fuel

Incorrectly installed spark plug wires

Incorrect ignition timing

Solution

Inspect, clean and/or replace spark plugs

Set gap to specs or replace plugs

Replace with new fuel

See your Polaris dealer

Mechanical failure

See your Polaris dealer

Engine Runs Irregularly, Stalls or Misfires

Possible Cause

Fouled or defective spark plugs

Worn or defective spark plug wires

Incorrect spark plug gap or heat range

Loose ignition connections

Water present in fuel

Solution

Inspect, clean and/or replace spark plugs

See your Polaris dealer

Set gap to specs or replace plugs

Check all connections and tighten

Replace with new fuel

Low battery voltage

Recharge battery to 12.5 VDC

Inspect and replace

Kinked or plugged fuel vent line

Incorrect fuel

Replace with recommended fuel

Inspect and clean or replace

See your Polaris dealer

Clogged air filter

Reverse speed limiter malfunction

Electronic throttle control malfunction

Other mechanical failure

See your Polaris dealer

Possible Lean Fuel Mixture 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 Polaris dealer

Possible Rich Fuel Mixture 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 Polaris dealer

106

Download from Www.Somanuals.com. All Manuals Search And Download.

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 present in fuel / old fuel

Overuse of choke

Replace with new fuel

Inspect, clean and/or replace spark plugs

See your Polaris 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 plugs

Check all connections and tighten

Recharge battery / Check charging system

Replace with recommended fuel

Inspect, clean or replace

Incorrect fuel

Clogged air filter

Reverse speed limiter malfunction

Electronic throttle control malfunction

Other mechanical failure

Overheated engine

See your Polaris dealer

Clean radiator screen and core if equipped

Clean engine exterior

See your Polaris dealer

107

Download from Www.Somanuals.com. All Manuals Search And Download.

SPECIFICATIONS

2005 Trail Boss 330 Quadricycle

Capacities

Body Style

Gross Vehicle Weight

Fuel Capacity

Transmission Oil

Engine Oil Capacity

Gen IV

438 kg

12.35 l

335 ml

1.8 l (incl. oil cooler )

1.6 l (oil change only)

Front Rack

Rear Rack

Tongue Weight

Towing Rating

34.1 kg

56.7 kg

38.6 kg

386 kg

Unbraked Trailer Towing Capacity* 573 kg

Turn Radius

Ground Clearance

Height

190.5 cm

14 cm

116.8 cm

Length

190.5 cm

Width

116.8 cm

Seat Height

Dry Weight

Wheel Base

86.4 cm

229 kg

125.7 cm

Engine & Cooling

Engine Model Number / Type

Lubrication

ES-32PFE-103 / 4 Cycle, Single Cylinder

Wet Sump

Bore x Stroke

Displacement

Compression Ratio

Engine Cooling

Alternator Output (watts)

Carburetion

78.5 x 68

329

9.2/1

Air with fan assisted oil cooler

200w @5000 rpm

BST34

Main Jet

120

Pilot Jet

42.5

Needle Jet

Pilot Air Jet

P-0M (829)

160

Pilot Screw

Jet Needle

2 3/16 turns

4HB48-3

Ignition

DC CDI

Timing

Spark Plug Type / Gap

24° ± 2° @ 5000 RPM

BKR6E / .9 mm

* Based on EU Directive 76/432/EC

108

Download from Www.Somanuals.com. All Manuals Search And Download.

SPECIFICATIONS

2005 Trail Boss 330 Quadricycle

Drive System

Drive System Type

Shift Type

PVT

Side Lever (F/N/R)

3.05/1

Gear Reduction - Reverse

Gear Reduction - Forward

Final Drive (ratio)

Drive Chain

2.68/1

11/40 78P

520 O-Ring

Front Tires

23 x 7-10 (34.5 KPa)

22 x 12-10 (34.5 KPa)

Suspension and Brakes

17 cm travel

Rear Tires

Front Suspension: Mac Strut

Rear Suspension: Progressive Rate 22.9 cm travel

Swing Arm

Shock Adjustment

Brake System

CAM

Hydraulic disc front and rear, fixed disc,

hydraulic floating caliper

Hand Brake

Hydraulic, left-hand apply, rear caliper only,

equipped w/temporary hydraulic lock

Foot Brake

Hydraulic, single apply, all-wheel

Parking Brake

Right-hand apply w/mechanical lock, floating

caliper system, disc brake

Features

2 Hi/Lo 60w/55w

2x8.26w

2x26.9w

12V 14 AH

LCD

Headlight

Taillight

Brake Light

Battery

Instrument Cluster

Electric Start

High Beam Indicator

High Temp Indicator

Neutral Indicator

Reverse Indicator

Tool Kit

Standard

109

Download from Www.Somanuals.com. All Manuals Search And Download.

SPECIFICATIONS

2005 Trail Boss 330 Quadricycle

Jetting Chart

Altitude

AMBIENT

TEMPERATURE

Below 5° C

+5°C and above

Meters

0-1800

127.5

120

122.5

115

1800-3700

Clutching Chart

Altitude

Shift

Weight

Drive Clutch Driven Clutch

Helix/Spring

Setting

Spring

Meters

0-1800

10RH

5630709

Blue/Green

7041157

Black

7041782

5131446

2+2

1800-3700

20-40

5631356

Blue/Green

7041157

Black

7041782

5131446

2+2

110

Download from Www.Somanuals.com. All Manuals Search And Download.

WARRANTY

LIMITED WARRANTY

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

ITED WARRANTY on all components of the Polaris Quadricycle againstdefects inmateri-

al 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 istransferrable toanother consumerduring thewarranty

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. THE PURCHASER MUST COMPLETE A QUADRI-

CYCLE SAFETY TRAINING COURSE PROVIDED BY THE DEALER IN ORDER

TO HAVE VALID WARRANTY ON THE QUADRICYCLE. No verification of registra-

tion will be sent to the purchaser as the copy of the Warranty Registration Form will be the

warranty entitlement. If you have not signed the original registration and received the “cus-

tomer copy”, please contact your dealer immediately. NO WARRANTY COVERAGE

WILL BE ALLOWED UNLESS YOUR QUADRICYCLE IS REGISTERED WITH PO-

LARIS.

Initial dealer preparation and set-up of your vehicle is very important in ensuring trouble-

free operation. Purchasing a machine in the crate or without proper dealer set-up will void

your warranty coverage.

LIMITATIONS OF WARRANTIES AND REMEDIES

The Polaris limited warranty excludes any failures that are not caused by a defect in material

or workmanship. This warranty does not cover accidental damage, normal wear and tear,

abuse or improper handling. This warranty also does not cover any Quadricycle that has

been altered structurally, modified, neglected, improperly maintained, used for racing, or

used for purposes other thanfor whichit wasmanufactured, orfor anydamages whichoccur

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.

This warranty does not cover the use of unauthorized lubricants, chemicals, or fuels that are

not compatible with the Quadricycle. The exclusive remedy forbreach ofthis warranty shall

be, at Polaris’ exclusive option, repair or replacement of any defective materials, or compo-

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

ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WAR-

RANTY. POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDEN-

TAL, CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION,

WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTH-

ER 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.

111

Download from Www.Somanuals.com. All Manuals Search And Download.

WARRANTY

LIMITATIONS OF WARRANTIES AND REMEDIES

ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE IMPLIED

WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR

PURPOSE) ARE LIMITED IN DURATION TO THE ABOVE TWO YEAR WARRAN-

TY PERIOD. POLARIS FURTHER DISCLAIMS ALL EXPRESS WARRANTIES NOT

STATED IN THIS WARRANTY. Some states do not allow limitations on how long an im-

plied warranty lasts, so the above limitation may not apply to you if inconsistent with con-

trolling state law.

HOW TO OBTAIN WARRANTY SERVICE

If your Quadricycle requires warranty service, you must take it to a Polaris dealer authorized

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

copy of the Warranty Registration form to the dealer. (THE COST OF TRANSPORTA-

TION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY). Polaris suggests

that youuse youroriginal 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 personnel 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.

112

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE RECORD

DATE

MILES/KM

TECHNICIAN

SERVICE PERFORMED / COMMENTS

113

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE RECORD

DATE

MILES/KM

TECHNICIAN

SERVICE PERFORMED / COMMENTS

114

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE RECORD

DATE

MILES/KM

TECHNICIAN

SERVICE PERFORMED / COMMENTS

115

Download from Www.Somanuals.com. All Manuals Search And Download.

INDEX

Accessories . . . . . . . . . . . . . . . . . . . 101

Age Restriction . . . . . . . . . . . . . . . . . .

Air Filter . . . . . . . . . . . . . . . . . . . . . . 85

FEATURES AND CONTROLS . . 40-54

Foot Brake . . . . . . . . . . . . . . . . . . . . 44

Fuel Filter . . . . . . . . . . . . . . . . . . . . . 84

Fuel Stabilizer . . . . . . . . . . . . . . . . . 100

Fuel Tank . . . . . . . . . . . . . . . . . . . . . 47

Fuel Valve . . . . . . . . . . . . . . . . . . . . . 47

Battery . . . . . . . . . . . . . . . . . . . . . 96-98

Battery Charging . . . . . . . . . . . . . . 97-98

Battery Installation . . . . . . . . . . . . . . 96

Battery Removal . . . . . . . . . . . . . . . . 96

Battery Storage . . . . . . . . . . . . . 97, 100

Brake Fluid . . . . . . . . . . . . . . . . . . . . 75

Brake Lever, Parking . . . . . . . . . 43, 45

Brake Lever, Rear . . . . . . . . . . . . . 43-44

Brake, Foot . . . . . . . . . . . . . . . . . . . . 44

Brakes . . . . . . . . . . . . . . . . 44-45, 74-75

Break-In Period . . . . . . . . . . . . . . . . . 55

Gear Selector . . . . . . . . . . . . . . . . . . . 48

Handlebar Adjustment . . . . . . . . . . . 77

Hauling Cargo . . . . . . . . . . . . . . . . 38-39

Hazard Warning Switch . . . . . . . . . . 43

Headlights . . . . . . . . . . . . . . . . . . . . . 86

Helmet . . . . . . . . . . . . . . . . . . . . . . . 23

High Beam Adjustment . . . . . . . . . . . 87

Horn . . . . . . . . . . . . . . . . . . . . . . . . . 42

Hour Meter . . . . . . . . . . . . . . . . . . . . 52

Carburetor . . . . . . . . . . . . . . . . . . . . . 78

Cleaning the Vehicle . . . . . . . . . . . . . 99

Clutching Chart . . . . . . . . . . . . . . . . 110

Controls . . . . . . . . . . . . . . . . . . . . 40-43

Cooler Maintenance . . . . . . . . . . . . . 71

Crankcase Emission Control System . 60

Immersion . . . . . . . . . . . . . . . . . . . 92-93

Indicator Lamp Replacement . . . . . . 88

Instrument Cluster . . . . . . . . . . . . . 50-54

Instruments . . . . . . . . . . . . . . . . . . 40-43

Diagnostic Mode . . . . . . . . . . . . . . 53-54

Drive Chain . . . . . . . . . . . . . . . . . 83-84

Driving Downhill . . . . . . . . . . . . . . . 28

Driving in Reverse . . . . . . . . . . . . . . 36

Driving on Slippery Surfaces . . . . . . 26

Driving Over Obstacles . . . . . . . . . . . 27

Driving Procedures . . . . . . . . . . . . . . 24

Driving Safely . . . . . . . . . . . . . . . . 24-39

Driving Through Water . . . . . . . . . 34-35

Driving Uphill . . . . . . . . . . . . . . . 30-31

Jetting Chart . . . . . . . . . . . . . . . . . . 110

K-Turn . . . . . . . . . . . . . . . . . . . . . . . 32

Light Switch . . . . . . . . . . . . . . . . . . . 41

Lights . . . . . . . . . . . . . . . . . . . . . . 86-88

Lubrication Recommendations . . . . . 65

Electromagnetic Interference . . . . . . . 60

Electronic Throttle Control . . . . . . . . 42

EMISSION CONTROL SYSTEMS . 60

Engine Fogging . . . . . . . . . . . . . . . 101

Engine Stop Switch . . . . . . . . . . . . . 41

Main Switch . . . . . . . . . . . . . . . . . . . 40

MAINTENANCE AND

LUBRICATION . . . . . . . . . 61-102

Maintenance Chart Key . . . . . . . . . . . 61

MAINTENANCE RECORD . . 113-115

Making Turns . . . . . . . . . . . . . . . . . . 25

Master Cylinder (Foot Brake) . . . . . . 75

Master Cylinder (Handlebar) . . . . . . . 75

Mirrors . . . . . . . . . . . . . . . . . . . . . . . 43

Equipment Modifications . . . . . . . . . .

ETC . . . . . . . . . . . . . . . . . . . . . . . . . 42

Exhaust Emission Control System . . 60

Eye Protection . . . . . . . . . . . . . . . . . . 23

116

Download from Www.Somanuals.com. All Manuals Search And Download.

INDEX

Noise Emission Control System . . . . 60

SPECIFICATIONS . . . . . . . . . . 108-110

Speedometer Mode Switch . . . . . . . . 40

Springs, Rear . . . . . . . . . . . . . . . . . . 76

Starting the Engine . . . . . . . . . . . . 57-58

Steering . . . . . . . . . . . . . . . . . . . . . . . 76

Steering Assembly . . . . . . . . . . . . . . 77

Steering Lock . . . . . . . . . . . . . . . . . . 46

Stop Switch . . . . . . . . . . . . . . . . . . . . 41

Storing the Vehicle . . . . . . . . . . 100-101

Suspension . . . . . . . . . . . . . . . . . . . . 76

Symbol Identification . . . . . . . . . . . . 65

Odometer . . . . . . . . . . . . . . . . . . . . . 52

Oil Change . . . . . . . . . . . . . . . . . . 68-70

Oil Check . . . . . . . . . . . . . . . . . . . . . 67

Oil Cooler . . . . . . . . . . . . . . . . . . . . . 71

Oil Filter Change . . . . . . . . . . . . . 68-70

Oil . Engine . . . . . . . . . . . . . . . . . . . 66

OPERATION . . . . . . . . . . . . . . . . 55-59

Operator Safety . . . . . . . . . . . . . . . . 6-17

Override Switch . . . . . . . . . . . . . . . . 40

TABLE OF CONTENTS . . . . . . . . . .

Tachometer . . . . . . . . . . . . . . . . . . . . 52

Taillight . . . . . . . . . . . . . . . . . . . . . . . 88

Throttle Cable Freeplay . . . . . . . . . . . 79

Throttle lever . . . . . . . . . . . . . . . . . . 41

Tire Tread Depth . . . . . . . . . . . . . . . . 82

Tires . . . . . . . . . . . . . . . . . . . . . . . . . 82

Toe Alignment . . . . . . . . . . . . . . . . . 76

Torque Symbol . . . . . . . . . . . . . . . . . 65

Towing . . . . . . . . . . . . . . . . . . . . . 38-39

Transmission . . . . . . . . . . . . . . . . . . . 59

Transmission Oil Change . . . . . . . . . 73

Transmission Oil Check . . . . . . . . . . 72

Transporting the Vehicle . . . . . . . . . 102

Trip Meter . . . . . . . . . . . . . . . . . . . . . 52

TROUBLESHOOTING . . . . . . 104-107

Turn Indicator . . . . . . . . . . . . . . . . . . 43

Turning Around on a Hill . . . . . . . 32-33

Parking Brake (Hydraulic) . . . . . . . . 45

Parking Brake (Mechanical) . . . . . . . 45

Parking on an Incline . . . . . . . . . . . . 37

Periodic Maintenance Chart . . . . . 61-64

POLARIS PRODUCTS . . . . . . . . . 103

Pre Ride Inspection . . . . . . . . . . . . . . 56

PVT Drying . . . . . . . . . . . . . . . . . . . 59

PVT System . . . . . . . . . . . . . . . . . . . 59

Rear Drive Chain Slack . . . . . . . . . 83-84

Rear Springs . . . . . . . . . . . . . . . . . . . 76

Recoil Housing . . . . . . . . . . . . . . . . . 89

Recoil Starter . . . . . . . . . . . . . . . 43, 49

Restrictions . . . . . . . . . . . . . . . . . . . . .

Rider Information Center . . . . . . . 51-54

Riding Gear . . . . . . . . . . . . . . . . . . . 23

VEHICLE IDENTIFICATION

Safe Riding Gear . . . . . . . . . . . . . . . . 23

SAFETY . . . . . . . . . . . . . . . . . . . . . 6-39

Safety Decals and Locations . . . . . 18-22

NUMBERS . . . . . . . . . . . . . . . . .

Vehicle Immersion . . . . . . . . . . . . 92-93

Safety Training . . . . . . . . . . . . . . . . . .

Severe Use . . . . . . . . . . . . . . . . . . . . 61

Side Panel Removal . . . . . . . . . . . . . 80

Sidehilling . . . . . . . . . . . . . . . . . . . . 29

Signal Light . . . . . . . . . . . . . . . . . . . 88

Spark Arrestor . . . . . . . . . . . . . 60, 94-95

Spark Plugs . . . . . . . . . . . . . . . . . . 90-91

Warranty . . . . . . . . . . . . . . . . . . 111-112

Waxing the Vehicle . . . . . . . . . . . . . . 99

Wheel Hub Tightening . . . . . . . . . . . 82

Wheel Installation . . . . . . . . . . . . . . . 81

Wheel Removal . . . . . . . . . . . . . . . . 81

117

Download from Www.Somanuals.com. All Manuals Search And Download.

Philips Flat Panel Television 15PF7846 User Manual
Philips Flat Panel Television 17PF9936 User Manual
Philips TV VCR Combo 14PV401 User Manual
Pioneer DVR DVR 540H S User Manual
Porter Cable Nail Gun FN250A User Manual
Poulan Lawn Mower 184564 User Manual
Poulan Trimmer 952711882 User Manual
Poulan Trimmer PP325 User Manual
Powermate Portable Generator PMC543250 User Manual
Pride Mobility Mobility Aid LX10 User Manual