Polaris 9922462, Trail Boss 330 International User Manual
Pantone 425 C
WARNING
Improper vehicle use can result in SEVERE INJURY or DEATH.
ALWAYS USE
AN APPROVED
HELMET AND
PROTECTIVE
GEAR
NEVER USE
ON PUBLIC
ROADS
NEVER CARRY
PASSENGERS
NEVER USE
WITH DRUGS
OR ALCOHOL
NEVER operate:
S without proper training or instruction.
S at speeds too fast for your skills or the conditions.
S on public roads - a collision can occur with another
vehicle.
S with a passenger - passengers affect balance and
steering and increase risk of losing control.
ALWAYS:
S use proper riding techniques to avoid vehicle
overturns on hills and rough terrain and in turns.
S avoid paved surfaces - pavement may seriously affect
handling and control.
READ OWNER'S MANUAL.
FOLLOW ALL INSTRUCTIONS AND WARNINGS.
For your nearest Polaris dealer,
visit www.polarisindustries.com
Polaris Sales Inc.,
2100 Hwy. 55, Medina, MN 55340
U.S.A.
Part No. 9922462 Rev 01
Printed in U.S.A.
The text is printed on 100% recycled
with 40% post-consumer waste (PCW).
WELCOME
Thank you for purchasing a Polaris vehicle, and welcome to our worldwide family of Polaris owners. We proudly produce an exciting line of
utility and recreational products.
• Snowmobiles
• All-terrain vehicles (ATVs)
• RANGER
• Victory Motorcycles
Always follow the instructions and recommendations in this manual.
The manual contains instructions for minor maintenance, but information about major repairs is outlined in the Polaris Service Manual and
should be performed only by a factory-certified Master Service Dealer
(MSD) technician. Please see your dealer for all of your service needs
during (and after) the warranty period.
For more information about Polaris, visit us online at
www.polarisindustries.com.
®
utility vehicles
®
®
1
POLARIS, THE WAY OUT, TRAIL BOSS and TRAIL BLAZER are registered trademarks of Polaris Industries Inc.
Copyright 2009 Polaris Sales Inc. All information contained within this publication is
based on the latest product information at the time of publication. Due to constant
improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this publication. Depictions and/or procedures in this publication are intended for reference use
only. No liability can be accepted for omissions or inaccuracies. Any reprinting or reuse
of the depictions and/or procedures contained within, whether whole or in part, is
expressly prohibited.
Printed in U.S.A.
2010 Trail Boss 330/Trail Blazer 330 International Owner’s Manual
P/N 9922462
2
TABLE OF CONTENTS
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Features and Controls . . . . . . . . . . . . . . . . . . . 20
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Emission Control Systems . . . . . . . . . . . . . . . 48
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Polaris Products. . . . . . . . . . . . . . . . . . . . . . . . 97
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . 98
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . 102
Declaration of Conformity . . . . . . . . . . . . . . . 106
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Maintenance Log . . . . . . . . . . . . . . . . . . . . . . 111
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
3
INTRODUCTION
The following signal words and symbols appear throughout this manual
and on your vehicle. Your safety is involved when these words and symbols are used. Become familiar with their meanings before reading the
manual.
The safety alert symbol indicates a potential personal injury hazard.
WARNING
A WARNING indicates a hazardous situation which, if not avoided, may result in
death or serious injury.
CAUTION
A CAUTION indicates a hazardous situation which, if not avoided, may result in
minor or moderate injury.
NOTICE
A NOTICE indicates a situation that may result in property damage.
The Prohibition Safety Sign indicates an action NOT to take in order
to avoid a hazard.
The Mandatory Action Sign indicates an action that NEEDS to be
taken to avoid a hazard.
4
INTRODUCTION
WARNING
Failure to follow the warnings in this manual can result in serious injury or death.
This Polaris vehicle is not a toy and can be hazardous to operate. A collision or
rollover can occur quickly, even during routine maneuvers, if you fail to take
proper precautions.
Read and understand your owner's manual and all warnings before operating
this Polaris vehicle.
Safety Training
When you purchased your new Polaris vehicle, your dealer offered a
hands-on safety training course. You were also provided with printed
materials that explain safe operating procedures. Review this information on a regular basis.
If you purchased a used Polaris vehicle from a party other than a Polaris
dealer, please request free safety training from any authorized Polaris
dealer.
Age Restrictions
This vehicle is an ADULT VEHICLE ONLY. Operation is prohibited
for anyone under 16 years of age.
Restrictions
This vehicle is approved for OFF-ROAD TOWING ONLY. Towing a
trailer with this vehicle on public roads is prohibited.
Equipment Modifications
The warranty on your Polaris vehicle may be terminated if any equipment has been added, or if any modifications have been made, that
increase speed or power. The addition of certain accessories, including
(but not limited to) mowers, blades, tires, sprayers and large racks may
change vehicle handling. Use only Polaris-approved accessories. Know
their function and effect on the vehicle.
5
INTRODUCTION
####
VIN
Key Number
Vehicle Identification Numbers
Record your vehicle's identification numbers and key number in the
spaces provided. Remove the spare key and store it in a safe place. An
ignition key can be duplicated only by ordering a Polaris key blank
(using your key number) and mating it with one of your existing keys.
The ignition switch must be replaced if all keys are lost.
Vehicle Model Number: ___________________________________________________
Frame VIN: ____________________________________________________________
Engine Serial Number: ___________________________________________________
(right front side of engine crankcase)
Key Number: ___________________________________________________________
6
SAFETY
WARNING
Failure to operate the vehicle properly can result in a collision, loss of control,
accident or overturn, which may result in serious injury or death. Heed all safety
warnings outlined in this section of the owner’s manual. See the OPERATION
section of the owner’s manual for proper operating procedures.
Equipment Modifications
We strongly recommend that consumers do not install on a Polaris vehicle any equipment that may increase the speed or power of the vehicle,
or make any other modifications to the vehicle for these purposes.
The warranty on your Polaris vehicle is terminated if any equipment has
been added to the vehicle, or if any modifications have been made to the
vehicle, that increase its speed or power.
The addition of certain accessories, including (but not limited to) mowers, blades, tires, sprayers, or large racks, may change the handling characteristics of the vehicle. Use only Polaris-approved accessories, and
familiarize yourself with their function and effect on the vehicle.
7
SAFETY
Helmet
Eye Protection
Gloves
Boots
Long Pants
Long
Sleeves
E
4
051039
0006.31
Safe Riding Gear
Always wear appropriate clothing when riding a Polaris vehicle. Wear
protective clothing for comfort and to reduce the chance of injury.
Helmet
Wearing a helmet can prevent a severe head injury. Whenever riding a
Polaris vehicle, always wear a helmet that meets or exceeds established
safety standards.
Approved helmets in the USA and Canada bear a U.S. Department of
Transportation (DOT) label.
Approved helmets in Europe, Asia and Oceania
bear the ECE 22.05 label. The ECE mark consists
of a circle surrounding the letter E, followed by the
distinguishing number of the country which has
granted approval. The approval number and serial
number will also be displayed on the label.
8
SAFETY
Safe Riding Gear
Eye Protection
Do not depend on eyeglasses or sunglasses for eye protection. Whenever riding a Polaris vehicle, always wear shatterproof goggles or use a
shatterproof helmet face shield. Polaris recommends wearing approved
Personal Protective Equipment (PPE) bearing markings such as VESC
8, V-8, Z87.1, or CE. Make sure protective eye wear is kept clean.
Gloves
Off-road style gloves with knuckle pads are the best for comfort and
protection.
Boots
The best footwear is a pair of sturdy over-the-calf boots with low heels.
Clothing
Always wear long sleeves and long pants to protect arms and legs.
Riding pants with kneepads and a jersey with shoulder pads provide the
best protection.
9
SAFETY
Operator Safety
Read and understand all warnings, cautions
and operating procedures in this manual and
on the safety labels before operating the
vehicle.
Never operate this vehicle without proper
instruction. Take a training course. Beginners
should receive training from a certified
instructor. Contact an authorized Polaris
dealer or visit the Polaris web site at
www.polarisindustries.com.
Never permit others to operate the vehicle unless they have read and 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.
10
Operator Safety
Always wear an approved helmet that fits
properly. Wear eye protection (goggles or face
shield), gloves, boots, long sleeves and long
pants.
Never consume alcohol or drugs before or while
operating this vehicle.
Never operate at excessive speeds. Travel
and turn at speeds appropriate for the terrain,
visibility, operating conditions and your
experience.
SAFETY
Never attempt jumps or other stunts.
11
SAFETY
Operator Safety
Always inspect your Polaris vehicle before each
use to verify that it's in safe operating condition.
Follow the inspection and maintenance procedures
outlined in this manual. See page 31.
Keep both hands on the handlebars. Keep
your feet on the footrests.
Always travel slowly when operating on
unfamiliar terrain. Use extra caution.
Use caution when operating on rough, slippery
or loose terrain.
Always follow the procedures outlined in this
manual for turning. See page 35.
Never turn sharply at excessive speeds,
which can lead to vehicle overturn.
12
SAFETY
+25°
Operator Safety
If the vehicle has been involved in an accident, always have an authorized
Polaris dealer inspect the entire vehicle for possible damage, including (but not
limited to) brake, throttle and steering systems.
Never operate on hills too steep for the vehicle or
for your abilities. Practice on smaller hills before
attempting larger hills. Avoid climbing hills steeper
than 25°.
Always follow the procedures outlined in this
manual for climbing hills. See page 37.
Always follow the procedures outlined in this
manual for driving downhill and for braking on
hills. See page 39.
Always follow the procedures outlined in this
manual for crossing the side of a hill. See page
38.
Never attempt to turn the vehicle around on any
hill until you've mastered (on level ground) the
turning technique outlined in this manual.
Always follow the procedures outlined in this
manual for braking if you stall or roll backwards
while climbing a hill. Never back down a hill. See
page 40.
13
SAFETY
Operator Safety
Always follow the procedures outlined in this manual for operating over
obstacles. See page 42.
Always follow the procedures outlined in this manual for operating on slippery or
loose surfaces. Use extra caution. Always avoid skidding or sliding. See page
36.
Always follow the procedures outlined in this
manual for driving through water. Never drive
through deep or fast-flowing water. See page 41.
Always follow the procedures outlined in this manual for driving in reverse. See
page 43.
Always use the size and type of tires specified for
your vehicle. Maintain the proper tire pressure.
Never modify this Polaris vehicle
through improper installation or use of
accessories.
Operating on paved surfaces may affect the handling and control of the vehicle
and could result in loss of control. Avoid sudden turns or swift movement of the
handlebars.
14
SAFETY
Operator Safety
Never exceed the stated load capacity for your vehicle. Cargo must be properly
distributed and securely attached. Reduce speed and follow the instructions in
this manual for carrying cargo or towing. Allow a greater distance for braking.
Never operate this vehicle on a frozen body of water.
Always remove the ignition key when the vehicle is not in use to prevent
unauthorized use or accidental starting.
Always unlock the steering before starting the engine. See page 26.
Handling Gasoline
Gasoline is highly flammable and explosive under certain conditions.
• Always exercise extreme caution whenever handling gasoline.
• Always refuel with the engine stopped, and outdoors or in a well ventilated
area.
• Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored.
• Do not overfill the tank. Do not fill the tank neck.
• If gasoline spills on your skin or clothing, immediately wash it off with soap
and water and change clothing.
• Turn the fuel valve off whenever the vehicle is stored or parked.
Hot components can cause serious burns and fire. Do not touch hot exhaust
system components. Always keep combustible materials away from the exhaust
system.
For more information about safety, contact an authorized
Polaris dealer or visit the Polaris web site at
www.polarisindustries.com.
15
SAFETY
Safety Labels and Locations
Warning labels have been placed on the vehicle for your protection.
Read and follow the instructions on each label carefully. If any of the
labels shown in this manual differ from the labels on your vehicle,
always read and follow the instructions of the labels on the vehicle.
If an informational or graphic label becomes illegible or comes off, contact your Polaris dealer to purchase a replacement. Replacement safety
labels are provided by Polaris at no charge. The part number is printed
on the label.
General Warning
WARNING
Improper ATV use can result in SEVERE INJURY or DEATH
ALWAYS USE AN APPROVED HELMET AND PROTECTIVE GEAR
NEVER USE ON PUBLIC ROADS
NEVER CARRY PASSENGERS
NEVER USE WITH DRUGS OR ALCOHOL
NEVER operate:
• without proper training or instruction
• at speeds too fast for your skills or the conditions
• on public roads - a collision can occur with another vehicle
• with a passenger - passengers affect balance and steering and increase risk
of losing control
ALWAYS:
• use proper riding techniques to avoid vehicle overturns on hills and rough terrain and in turns
• avoid paved surfaces - pavement may seriously affect handling and control
LOCATE AND READ OWNER’S MANUAL.
FOLLOW ALL INSTRUCTIONS AND WARNINGS.
7175376
16
Safety Labels and Locations
+
General
Warning
+
Discretionary
Warning
Rack Warning
+
+
Discretionary Warning
WARNING
• Never operate this ATV on
HILLS steeper than 25 degrees
25°. To prevent overturn on
hilly terrain, use throttle and
brakes gradually, and shift
weight uphill.
• REVERSE operation can be
dangerous even at low speeds.
Steering becomes difficult. To
prevent loss of control, avoid
sudden braking or sharp turns.
7175511
Rack Warning, Front
and Rear (Trail Boss)
WARNING
• DO NOT TOW FROM RACK
OR BUMPER. Vehicle damage
or tipover may result causing
severe injury or death. Tow
only from tow hooks or hitch.
• Max Rack Loads: Front 75 lbs.
(34 kg) Rear 125 lbs. (57 kg)
7172666
SAFETY
17
SAFETY
+
Clutch Cover
Warning
+
Age 16 Warning
+
“No Passenger”
Warning
+
Tire Pressure/Load
Warning
Safety Labels and Locations
“No Passenger” Warning
WARNING
NEVER ride as a passenger.
Passengers can cause a loss of control, resulting in SEVERE INJURY or
DEATH.
7175378
Tire Pressure/Load Warning (Trail Boss)
WARNING
Improper tire pressure or overloading can cause loss of control.
Loss of control can result in severe injury or death.
• Cold tire pressure:
Front: 4.0 psi (27.6 kPa)
Rear: 3.0 psi (20.7 kPa)
• Maximum weight capacity: 415 lbs. (188 kg)
Tire Pressure/Load Warning (Trail Blazer)
WARNING
Improper tire pressure or overloading can cause loss of control.
Loss of control can result in severe injury or death.
• Cold tire pressure:
Front: 4.0 psi (27.6 kPa)
Rear: 3.0 psi (20.7 kPa)
• Maximum weight capacity: 275 lbs. (125 kg)
18
7175444
7175443
SAFETY
Safety Labels and Locations
Age 16 Warning
WARNING
Operating this ATV if you are under the age of 16 increases your chance of
severe injury or death.
NEVER operate this ATV if you are under age 16.
7175374
Clutch Cover Warning
WARNING
• Moving parts hazard under belt-clutch guard. To prevent serious injury, do not
operate vehicle with guard removed.
• Do not modify engine or clutch. Doing so can cause part failure, possible
imbalance, and excessive engine RPM, which can result in serious injury or
death.
NO STEP
7172563
Reverse Override Warning
WARNING
Improper use of override button can lead to loss of control resulting in severe
injury or death. Do not activate override while throttle is engaged. Always apply
throttle gradually, while in reverse.
7175486
19
FEATURES AND CONTROLS
Override
Switch
Engine
Stop
Switch
Headlight
Switch
Horn
Switch
Hazard
Switch
Switches
Engine Stop Switch
The engine will not start
or run when the switch is
in the OFF position.
OFF
RUN
Push the stop switch
down to stop the engine
quickly. Pull the stop
switch up to the RUN
position before attempting to start the engine.
Both the main switch and
the engine stop switch
will shut off all electrical power to the vehicle, including lights.
Override Switch
This vehicle is equipped with a reverse speed limiter system. To gain
additional wheel speed while backing, release the throttle and press the
override switch.
Pressing the override switch while the throttle is open can cause loss of control,
which may result in serious injury or death. Always release the throttle before
pressing the override switch.
20
FEATURES AND CONTROLS
Main Key Switch
Switches
Headlight Switch
The lights do not operate unless the main key switch is on and the
engine stop switch is in the RUN position.
High Beam
Low Beam
Turn Signal Switch
Push the toggle switch either left or right to activate the corresponding turn signal light. The indicator on the pod will also
flash. Return the toggle to the center position and push it inward
to end the signal.
Hazard Switch
Push the hazard warning switch to cause all turn signal lights to
flash simultaneously. Use this feature to alert others of an emer-
gency or other situation requiring caution.
Horn Switch
Press the horn switch to sound the horn.
Main Key Switch
Use the main key switch to start the engine. See page 32 for starting procedures.
21
FEATURES AND CONTROLS
Neutral Indicator
Reverse
Indicator
High Temperature Warning
(displays if engine overheats)
Turn Signal/Hazard Indicators
High Beam Indicator
Mirrors
Use the mirrors to assist in traffic maneuvers. Always check and adjust
the mirrors before driving the vehicle.
Indicator Lights
With the engine running, verify the function of all indicator lights before
each use of the vehicle.
Tip: The taillight is on whenever the main switch (key) is on. Turn the key off to
prevent battery drain.
22
FEATURES AND CONTROLS
Electronic Throttle Control
Throttle Lever
Press the throttle lever to
increase engine speed and
vehicle movement. Release the
lever to reduce engine speed
and vehicle movement.
Failure to check or maintain proper operation of the throttle system can result in
an accident if the throttle lever sticks during operation. Check the lever for
proper operation before starting the engine. Check occasionally during
operation.
Do not start or operate a vehicle with sticking or improperly operating throttle
controls. Contact your dealer for repair if throttle problems arise.
Electronic Throttle Control (ETC)
ETC causes the engine to
stop if the throttle cable
sticks in an open position
when the operator releases
the throttle lever.
The Electronic Throttle Control (ETC) stops the engine in the event of a throttle
system malfunction. Do not modify the ETC system or replace it with other
throttle mechanisms.
23
FEATURES AND CONTROLS
Foot Brake
Brakes
Aggressively applying the brakes when backing down a hill may cause rear
tipover. Aggressively applying the brakes while moving forward may cause the
rear wheels to skid and result in loss of control.
Read this owner's manual and understand the operation of all brake systems on
this vehicle. Always use caution whenever applying the brakes.
Foot Brake
The all-wheel foot brake is located
on the right footrest. The foot brake
operates both front and rear brakes.
Press the brake pedal down with
your foot to apply the all-wheel
brakes.
If the rear wheels begin to skid or
slide while using the foot brake,
reduce brake pressure.
Hand Brake Lever
The hand brake operates both
front and rear brakes. Squeeze
the brake lever toward the handlebar to apply the all-wheel
brakes.
If the rear wheels begin to skid
or slide while using the hand
brake, reduce lever pressure.
Operating the vehicle with a spongy brake lever can result in loss of braking,
which could cause an accident. Never operate the vehicle with a spongy-feeling
brake lever. Always contact your dealer for service before operating the vehicle.
24
FEATURES AND CONTROLS
Brakes
Parking Brake
Locking the Parking Brake
1. Place the transmission in gear.
2. Squeeze and release the brake
lever two or three times, then
squeeze and hold.
3. Push the parking brake lock
forward to engage the lock.
4. Release the brake lever.
5. To release the parking brake
lock, squeeze and release the brake lever. It will return to its
unlocked position.
Operating the vehicle while the parking brake is engaged could result in an
accident and serious injury or death. Always release the parking brake lock
before operating.
25
FEATURES AND CONTROLS
Steering Lock
Lock the steering to prevent unauthorized use or theft of the vehicle.
Tip: Place the steering lock
keys in a safe place. The
lock must be replaced if
the keys are lost.
1. Turn the handlebars to
the full left position.
2. Insert the steering lock key and
turn it clockwise.
3. Remove the key.
4. Reverse the procedure to unlock
the steering.
The handlebars are locked in the full left position when the steering is locked.
Always unlock the steering before starting the engine.
26
FEATURES AND CONTROLS
Fuel Tank
Cap
Fuel
Valv e
Fuel
Gauge
OFFON
Choke
Choke
The choke assists in starting a cold
engine. Refer to the engine starting procedure on page 32 for correct choke and throttle settings
during starting.
Fuel Tank Cap
Always refuel with the engine
stopped, and outdoors or in a well
ventilated area. Refuel on a level
surface.
Remove the fuel tank cap to add
fuel to the fuel tank. Use either
leaded or unleaded gasoline with a
minimum pump octane number of
87=(R+ M/2) octane. Do not use
fuel with ethanol content greater
than 10 percent, such as E-85 fuel.
Fuel Valve
The fuel valve is located on the
left side of the vehicle, below the
fender.
ON: For normal operation.
OFF: For vehicle storage and
when transporting.
Fuel Filter
The in-line fuel filter should be
replaced by your dealer after
every 100 hours of operation or
annually. Do not attempt to clean the fuel filter.
27
Loading...