Polaris ATV 2001, trail boss 325, 2001 ATV Owner's Manual
2001
Universal Owner’s Safety
and Maintenance Manual
ATV
Read this manual carefully. It c ontains important safety information.
This is an adult vehicle only.
Operation is prohibited for those under 16 years of age.
The engine exhaust from this
product contains chemicals known
to cause cancer, birth defects or
other reproductive harm.
WARNING
FOREWORD
Congratulations and thank you fromPolaris Industries Inc. for purchasing one of our all-terrain vehicles (ATVs). Built with American
engineering and manufacturing know-how, it is designed to provide superior riding comfort, enjoyment, and safety.
This manual is furnished to ensure that the operator is aware of
safe operating procedures. It also includes information about the
general care and maintenance of your ATV.
Carefully read the following pages. If you have any questions regarding this ATV contact a Polaris dealer for assistance. Remember, Polaris dealers have the knowledge and facilities to provide
you with the best service possible.
PROTECT YOUR SPORT
Know all local, state/province riding laws;
Respect your vehicle;
Respect the environment; and
You will gain the respect of others.
We also advise you to strictly follow the recommended maintenance program as outlined. This preventive maintenance program is designedto ensure that allcritical componentson this ATV
are thoroughly inspected at various intervals.
All information in this manual is based upon the latest product data
and specifications available at the time of printing. Polaris Industries Inc. reserves the right to make productchanges and improvements which may affect illustrations or explanations.
No part of thismanualshallbe reproduced or used without the written permission of Polaris Industries Inc.
Illustrations included in this manual are general
representations of parts having a similar function. Your
AN ATV IS NOT A TOY AND CAN BE HAZARDOUS TO OPERATE. An ATV handles differentlyfrom other vehicles includingmo-
torcycles and cars. A collision or rollover can occur quickly, even
during routine maneuvers such as turning and driving on hills or
over obstacles, if you fail to take proper precautions.
SERIOUS INJURY OR DEATH can result if you do not follow
these instructions:
• Read this manual and all labelscarefullyand followtheoperating
procedures described.
• Never operate an ATV without proper instruction. Take a train-
ing course. Beginners should receive training from a certified
instructor. Contact an authorized Polaris ATV dealer or call Polaris at 1-800-342-3764 to find out about the training courses
nearest you.
• Never allow anyone under 16 years of age to operate this ATV.
• Never permit a guest to operate this ATV unless the guest has
read this manual and all product labels, and has completed a
certified training course.
• Alwaysavoidoperatingan ATV on anypaved surfaces,including
sidewalks, driveways, parking lots and streets.
• Never operate an ATV on any public street, road or highway,
even a dirt or gravel one.
• Never operate an ATV without wearing an approved helmet that
fits properly. You should also wear eye protection (goggles or
face shield),gloves,boots, long-sleeved shirt or jacket, and long
pants.
• Never consume alcohol or drugs before or while operating this
ATV.
• Never operate at excessive speeds. Always travel at a speed
whichisproperfor the terrain, visibility and operating conditions,
and your experience.
• Never attempt wheelies, jumps or other stunts.
• Always inspect your ATV each time you use it to make sure it is
in safe operating condition. Always follow the inspection and
maintenance procedures and schedules described in this
manual.
• Always keep both hands on the handlebarsand both feet on the
footrests of the ATV during operation.
• Always go slowly and be extra careful when operating on unfamiliar terrain. Always be alert to changing terrain conditions
when operating the ATV.
• Never operate on excessively rough, slippery or loose terrain.
• Always follow proper procedures for turning as described in this
manual. Practice turningat lowspeeds beforeattemptingto turn
at faster speeds. Do not turn at excessive speed.
• Always have the ATV checked by an authorized Polaris dealer
if it has been involved in an accident.
• Never operate the ATV on h ills too steep for the ATV or for your
abilities. Practice on smaller hills before attempting larger hills.
• Always follow proper procedures for climbing hills as described
in this manual. Check the terrain carefully before you start up
any hill. Never climb hills with excessively slippery or loose surfaces. Shift your weight forward. Never open the throttle suddenly or make sudden gear changes. Never go over the top of
any hill at high speed.
• Always follow proper procedures for going down hills and for
braking on hills as described in this manual. Check the terrain
carefully before you start down any hill. Shift your weight backward. Never go down a hill at high speed. Avoid going down a
hill at an angle which would cause the vehicle to lean sharply to
one side. Go straight down the hill where possible.
• Always follow proper procedures for crossing the side of a hillas
described in this manual. Avoid hills with excessively slippery or
loose surfaces. Shift your weight to the uphill side of the ATV.
Never attempt to turn the ATV around on any hill until you have
mastered the turning technique described in this manual on level ground. Avoid crossing the side of a steep hill if possible.
• Always use proper procedures if you stall or roll backwardswhen
climbing a hill. To avoid stalling, maintain a steady speed when
climbing a hill. If you stall or roll backwards, follow the special
procedureforbrakingdescribedin thismanual. Dismounton the
uphill side or to either side if pointed straight uphill. Turn the ATV
around and remount, following the procedure described in this
manual.
• Always check for obstacles before operating in a new area. Never attempt to operate over large obstacles, such as large rocks
or fallen trees. Alwaysfollowproper procedures when operating
over obstacles as described in this manual.
• Always be careful of skidding or sliding. On slippery surfaces,
such as ice, go slowly and be very cautious in order to reduce
the chance of skidding or sliding out of control.
• Avoid operating the ATV through deep or fast flowing water. If
you cannot avoid water which exceeds the recommended maximum depth (pg. NO TAG), go slowly, balance your weight carefully avoiding sudden movements, maintain a slow and steady
forward motion, do not make sudden turns or stops, and do not
make sudden throttle changes.
• Wet brakes may have reduced stopping ability. Test your brakes
after leaving water. If necessaryapply them lightly several times
to let friction dry out the pads.
• Always be sure there are no obstacles or people behind you
when you operate in reverse. When it is safe to proceed in reverse, go slowly. Avoid turning at sharp angles in reverse.
• Always use the size and type tires specified in this manual. Always maintain proper tire pressure as described in this manual.
• Never modify an ATV through improper installation or use of accessories.
• Never exceed the stated load capacity foran ATV. Cargo should
be properly distributed and securely attached. Reduce speed
and follow instructionsin this manual for carryingcargo or pulling
a trailer. Allow greater distance for braking.
FOR MORE INFORMATION ABOUT ATV SAFETY, call the Consumer Product Safety Commission at 1-800-638-2772, or Polaris
Additional Important Information...
Due to our concern for the safety of our customersand the general
public, Polaris hereby strongly recommends and requests that
consumers not have installed on a Polaris ATV any equipment
which is intended to increase the speed or power of the vehicle; or
make any other modifications to the vehicle for these purposes.
Any modificationsto the original equipment of the ATV substantially increase the risk of bodily injury. Please be aware that these
modifications may create a substantial safety hazard.
Polaris hereby informs you that the warranty on your ATV is terminated if any such equipment has been added to the ATV or any
modifications have been made to the ATV which increase its
speed or power.
We also advise you to strictly follow the recommended maintenance program outlined in this manual. This preventive maintenance program is designed to ensure that all critical components
on the ATV are thoroughly inspected by your dealer at various
mileage intervals.
NOTE:
The addition of certain accessories including (but not limited to)
mowers, blades, tires, sprayers, or large racks may change the
handling characteristics of the ATV.
Be certain any accessoriesadded to this ATVhave been approved
by Polaris.
Familiarize yourself with their function and affect on the ATV.
The Polaris Preferred
Registered Owners
(PRO) Family
Your Owners Program
As the owner of a new Polaris vehicle, you are entitled to a FREE
two- year membership in the Polaris PRO Family---the Preferred
Registered Owners Family. It’s an owners program for Polaris
owners like you, people who have chosen the finest recreational
vehicle available, people who share an interest in Polaris and its
products.
Once your new vehicle’s warranty is registered, you will receive a
PRO Family membership packet that will include:
A letter of welcome to the PRO Family
A PRO Family card with your name and membership number
A colorful sticker of the PRO logo
A PRO merchandise brochure and order form.
As a PRO Family member, you’re entitled to opportunities such as:
A free subscription to PRO Spirit, the official magazine of the
PRO Family
The chance to buy insurance for your Polaris vehicle. The toll-
free insurance telephone number is: 1-800-473-0111
The chance to arrangetravelthrough the Polaris TravelCenter.
The toll-free travel telephone number is: 1-800-267-1915
The chance to apply to serve on PRO Consumer Councils that
provide input into the Polaris vehicles of the future
The chance to serve as a PRO Field Evaluator and provide
feedback on your new vehicle
The chance to take part in national PRO snowmobile, ATV or
personal watercraft rides
The chance to purchase exclusive PRO Family merchandise
And more!
To order PRO merchandise, complete the order form you receive
with your membership packet, take the form to your Polaris dealer
and pay for the merchandise. The merchandise will be shipped directly to your home from the PRO merchandise fulfillment center.
Watch for your PRO membership packet and the next issue of
PRO Spirit magazine. This quarterly magazine will keep you informed about Polaris news and events, and special PRO merchandise, travel, and ride opportunities.
Enjoy your new Polaris vehicle, and welcome to the family--The
Polaris PRO Family.
CONTENTS
UNDERSTANDING WARNINGS 1-2..........................
SAFETY WARNING AND OPERATION DECALS 3-11...........
DAILY PRE-RIDE INSPECTION 12...........................
OPERATION WARNINGS 13-33..............................
VEHICLE IDENTIFICATION NUMBERS 34.....................
CONTROL AND PARTS FUNCTIONS 35-65...................
STARTING THE ENGINE 66.................................
VEHICLE BREAK IN PERIOD 67-69..........................
RIDING GEAR 70...........................................
CARRYING LOADS 71-73...................................
DAILY PRE-RIDE INSPECTION 74...........................
RIDING 75-88..............................................
PVT System 89-91..........................................
BA TTERY 92-94............................................
NOISE EMISSION CONTROL SYSTEM REGULATION 95.......
MAINTENANCE 96-168.....................................
TROUBLE SHOOTING 167-172.............................
WARRANTY 173-175.......................................
INDEX 176-177............................................
UNDERSTANDING WARNINGS
ATTENTION:
This is an ADULT VEHICLE ONLY; not a toy. Operation is prohibited for anyone under 16 years of age. READANDUNDERSTAND
W ARNINGS AND OWNER’S MANUAL BEFORE OPERATION.
KNOW YOUR VEHICLE BEFORE YOU BEGIN RIDING!.
Read this manual thoroughly referring to the various areas which
are being discussed on your machine. Operating this vehicle carries with it responsibilities for your personal safety, the safety of
others, and the protection of our environment.
SAFETY TRAINING.
When you purchased this vehicle your dealer presented a handson safety training course covering all aspects of ATV safety. In
addition, you were provided with certain printed material which
instructs you on safe operating procedures.
You should reviewthis information on a regular basis. In the event
youpurchaseda used Polaris ATVfroma partyotherthan a Polaris
dealer, you can obtain this safety training at no charge from any
authorized Polaris dealer.
Failure to follow the warnings contained in this manual can result
in SEVERE INJURY OR DEATH.
NOTE: Illustrations used in this manual are for general representation only. Your model may differ.
UNDERSTANDING WARNINGS
SAFETY ALERT
WARNINGS identify special instructions or procedures
which, if not correctly followed, could result in personal injury, or loss of life. Read all WARNINGS in this manual carefully.
Follow their instructions to remain safe.
The following precautionary signal words are used throughout this
manual to convey the following messages:
This is the safety alert symbol. When you
see this symbol on your machine or in this
manual,be alert to the potential for personal
injury. Your safety is involved!
Indicates a p o t en tial hazard which could result in
severe injury or death .
Indicates a po t en tial hazard wh ich may result in minor personal injury or damage to the ATV.
NOTE
The word “NOTE:” in this manu a l will
alert you to key information or
Indicates a situation that can result in damage to
the machine.
SAFETY WARNING AND OPERATION DECALS
NOTE:
Warning decals have been placed on the vehicle for your protection. Read and follow the instructions on each decal carefully. In
the event any decal becomes illegible or comes off, contact your
Polaris dealer for a replacement. Any safety decal needing replacement will be provided by Polaris at no charge. The part number is printed on the decal.
1
SAFETY WARNING AND OPERATION DECALS
1
7079083
E1997
IF OWNER’S MANUAL IS MISSING, CONTACT
YOUR POLARIS DEALER FOR A REPLACEMENT.
WARNING
SAFETY WARNING AND OPERATION DECALS
2
3
SAFETY WARNING AND OPERATION DECALS
F Never operate this ATV on HILLS steeper than 25 degrees
To prevent flipover on hilly terrain, when going up or down,
use throttle and brakes gradually.
25°
F REVERSE operation can be dangerous even at low speeds.
Steering becomes difficult. To prevent flipover, avoid sudden
braking or sharp turns.
F Use OVERRIDE for reverse speed limiter with caution. To prevent
loss of control, never activate override button with open throttle.
F PARKING BRAKE may relax when used for more than 5 minutes.
When parking on grades, leave shift in forward.
7079085
3
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.
7078253
UNDER
2
3
WARNING
SAFETY WARNING AND OPERATION DECALS
4
5
6
SAFETY WARNING AND OPERATION DECALS
4
5
(Refer to your Owner’s Manual Supplement for your vehicle’s
specifications.)
IMPROPER TIRE PRESSURE OR OVERLOADING can cause loss of
control resulting in SEVERE INJURY OR DEATH.
TIRE PRESSURE (PSI): FRONT ___ REAR ___
MAXIMUM WEIGHT CAPACITY (Gross Vehicle Weight)
INCLUDING MACHINE, DRIVER AND CARGO IS ____ LBS.
Reduce speed and allow greater distance for braking when carrying
cargo. Overloading or carrying tall, off-center, or unsecured loads
will increase your risk of losing control. Loads should be centered,
carried as low as possible, and firmly secured to the racks. with
dual racks, load distribution 1/3 front 2/3 rear is best. For stability
on rough or hilly terrain, reduce speed and cargo. Do not block
headlight. Be careful if load extends over the side of the rack.
Read Owner’s Manual for more detailed loading information
(on rear of seat)
6
WARNING
WARNING
SAFETY WARNING AND OPERATION DECALS
7
8
ATTENTION
DOPERATION OF THIS VEHICLE WITHOUT
THE FILTER ELEMENT WILL SEVERELY
DAMAGE THE ENGINE.
DCLEAN AIR FILTER OFTEN, MORE FRE-
QUENT CLEANING REQUIRED IN
DUSTY CONDITIONS.
DLiutilisation de ce véhicule sous liélément
filtre endommage sévèrement le moteur.
DNettoyer souvent le filtre à air, surtout dans
des situations poussiereuses.
7072791
(Under Seat)
7
8
Moving par ts hazard under belt-clutch guard. To
prevent serious injury, do not operate vehicle with
guard rem oved.
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.
WARNING
SAFETY WARNING AND OPERATION DECALS
9
10
DO NO T TOW FRO M RA CK O R B UMPER.
vehicle dam age or tipover m ay r esult causing sever e
injury or death. Tow only from tow hooks or hitch.
Maximum Front Rack Load 90 lbs.
7079102
DO NO T TOW FRO M RA CK O R B UMPER.
vehicle dam age or tipover m ay r esult causing sever e
injury or death. Tow only from tow hooks or hitch.
Maximum Rear Rack Load 180 lbs.
7079110
10
9
WARNING
WARNING
SAFETY WARNING AND OPERATION DECALS
ALL WHEEL
DRIVE
SWITCH
Do not push switch to
engage AWD if the rear
wheels are spinning.
This may cause severe
drive shaft and clutch
damage.
See your Owner ’s
Manual.
7074935
MANUFACTURED
BY: POLARIS IND
DATE:
VIN:
THIS VEHICLE IS AN ALL TERRAIN VEHICLE AND
IS NOT INTENDED FOR USE ON PUBLIC ROADS.
PRINTED IN U.S.A.
7077185
CE VÉHICULE EST UN VÉHICULE TOUT TERRAIN
QUI NiEST PAS DESTINÉ À ÊTRE UTILISÉ SUR
LES CHEMINS PUBLICS.
ATTENTION
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 26° C. at 0-900 meters). 7073761
TRAILER MAX.
WEIGHT 850 LBS.
HITCH MAX. VERTICAL
WEIGHT 30 LBS.
POIDS MAX. DE
REMORQUE 386 KG.
POIDS MAX.
VERTICAL D’ATTACHE
14 KG.
OVERRIDE
SWITCH
Reverse override
and all wheel drive
activation in reverse
is controlled by the
override switch.
See your Owner’s
Manual.
7076273
Reverse Speed is
limited.
Reverse override is
controlled by the
override switch.
See your Owner’s
Manual.
OVERRIDE
SWITCH
7076274
AWD Models 2WD Models
7077542
TRAILER MAX WEIGHT:
1225 LBS. (556 KG) ON LEVEL GROUND
850 LBS. (368 KG) UP TO 15° GRADE
HITCH MAX. VERTICAL WEIGHT: 35 LBS. (16KG)
7072533
Chain Freeplay Is Important.
Adjust Freeplay to 3/16″ -- 3 / 8 ″
DO NOT Overtension. See
Owner’s Manual.
Torque Nut on Eccentric Bolts:
To 30 Ft. Lbs.(For models
without a hitch).
To 60 Ft. Lbs. (For m odels with
ahitch.
7078572
DAILY PRE-RIDE INSPECTION
Use the following checklist to verifyyour machine is in properworking order each time you ride.
Item/Inspection Procedure
1. Tires - check condition and pressures
2. Fuel and oil tanks - fill both tanks to their proper levels
3. All brakes - check operation, adjustment and fluid level (includes auxiliary brake)
4. Throttle - check for free operation and closing
5. Headlight/Taillight/Brakelight - check operation of all indicator
lights and switches
6. Engine stop switch - check for proper function
7. Wheels- check for tightness of wheel nuts and axle nuts;check
that axle nuts are secured by cotter pins
8. Drive chain - condition and slack; refer to drive chain adjustment
9. Air cleaner element - check for dirt; clean or replace
10. Steering - check for free operation noting any unusual looseness in any area
11. Loose parts - visually inspect vehicle for any damaged components or loose nuts/bolts or fasteners
12. Operators helmet, goggles and clothing
13. Engine coolant - (Liquid Cooled Models Only) check for proper
level at the recovery bottle
You must inspect your ATV each time before riding to ensure
it is in proper working order. If proper inspection is not done,
severe injury or death could result.
OPERATION WARNINGS
POTENTIAL HAZARD
Operating this ATV without proper instruction.
WHAT CAN
HAPPEN
The risk of an accident is greatly increased if the operator
does not know how to operate the ATV properly in different situations and on different types of terrain.
HOW TO AVOID THE
HAZARD
Beginningand inexperiencedoperators should complete
the certified training course offered by Polaris Industries
Inc. They should then regularlypractice the skills learned
in the course and the operating techniques described in
the Owner’s Manual.
For more information about the training course, contact
an authorized ATV dealer or call Polaris at
1-800-342-3764.
POTENTIAL
HAZARD
Failure to follow the age recommendations for this ATV.
WHAT CAN
HAPPEN
Use by children of ATVs that are not recommended for
their age can lead to severe injury or death of the child.
Even though a child may be within the age group for
which some ATVs are recommended, he or she may not
have the skills, abilities, or judgment needed to operate
the ATV safely and may be involved in a serious accident.
HOW TO AVOID THE
HAZARD
No one under 16 should operate a Polaris ATV.
WARNING
WARNING
OPERATION WARNINGS
POTENTIAL HAZARD
Carrying a passenger on this ATV.
WHAT CAN
HAPPEN
Greatly reduces your ability to balance and control this
ATV.
Could cause an accident, resulting in harm to you and/or
your passenger.
HOW TO AVOID THE
HAZARD
Never carry a passenger. The long seat is to allow the operator to shift position as needed during operation. It is not
for carrying passengers.
WARNING
OPERATION WARNINGS
POTENTIAL HAZARD
Operating this ATV on paved surfaces, including side-
walks, paths, parking lots, and driveways.
WHAT CAN
HAPPEN
The ATV tires are designed for off-road use. Paved
surfaces may seriously affect handling and control of
the ATV, and may cause the vehicle to go out of control.
HOW TO AVOID THE
HAZARD
Avoid operating the ATV on pavement whenever possible. If you must ride on a paved surface,go slowly and
do not make sudden turns or stops.
WARNING
OPERATION WARNINGS
POTENTIAL HAZARD
Operating this ATV on public streets, roads or high-
ways.
WHAT CAN
HAPPEN
You can collide with another vehicle.
HOW TO AVOID THE
HAZARD
Never operate this ATV on any public street, road or
highway, even a dirt or gravel one.
In many states it is illegal to operate ATVs on public
streets, roads and highways.
WARNING
OPERATION WARNINGS
POTENTIAL HAZARD
Operating this ATV without wearing an approved helmet,
eye protection and protective clothing.
WHAT CAN
HAPPEN
Operating without an approved helmet increases your
chances of a severe head injury or death in the event of
an accident.
Operating without eye protection can resultin an accident
and increasesyourchancesof a severeinjury in the event
of an accident.
HOW TO AVOID THE
HAZARD
Always wear an approved helmet which fits properly.
You should also wear: eye protection (goggles or face
shield); gloves; boots; long-sleeved shirt or jacket; and
long pants.
WARNING
OPERATION WARNINGS
POTENTIAL HAZARD
Operating this ATV after consuming alcohol or drugs.
WHAT CAN
HAPPEN
Could seriously affect your judgment.
Could cause you to react more slowly.
Could affect your balance and perception.
Could result in an accident.
HOW TO AVOID THE
HAZARD
Neverconsume alcohol or drugs before or while driving
this ATV.
POTENTIAL
HAZARD
Operating this ATV at excessive speeds.
WHAT CAN
HAPPEN
Increases your chances of losing control of the ATV,
which can result in an accident.
HOW TO AVOID THE
HAZARD
Always travel at a speed which is proper for the terrain,
visibility and operating conditions; and your experience.
WARNING
WARNING
OPERATION WARNINGS
POTENTIAL HAZARD
Attempting wheelies, jumps and other stunts.
WHAT CAN
HAPPEN
Increases the chance of an accident, including an overturn.
HOW TO AVOID THE
HAZARD
Never attempt stunts, such as wheelies or jumps. Don’t
try to show off.
WARNING
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