POLARIS TRAIL BOSS User Manual

GENERAL INFORMATION

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Model Identification 1.2.......................

Serial Number Location 1.2...................

Replacement Keys 1.3.......................

Machine Dimensions 1.3.....................

Publication Numbers 1.3.....................

Paint Codes 1.3.............................

Specifications - Trail Boss 330 1.4--1.5.............

Specifications - Trail Blazer 330 1.6--1.7............

Specs

Special Tools 1.8............................

Standard Torque Specifications 1.9............

Tap / Drill Charts 1.10.........................

Decimal Equivalent Chart 1.10.................

Unit of Measure Conversion Table 1.11..........

Glossary of Terms 1.12........................

1.1

GENERAL INFORMATION

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MODEL IDENTIFICATION

The machine model number must be used with any correspondence regarding warranty or service.

Machine Model Number Identification

A09CA32AA

Emissions &

Year Designation

Basic Chassis Designation Engine Designation

Model Option

ENGINE DESIGNATION NUMBERS

ES32PFE Single, Air Cooled, SOHC 4 Stroke, Electric Start..................

VIN IDENTIFICATION

World Mfg. ID

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 4XAAA

Vehicle Descriptor

32A*9P0 00000

Vehicle Identifier

Body Style

Powertrain

Emissions

Engine

Check Digit

Model Year

Plant No.

Individual Serial No.

* This could be either a number or a letter

ENGINE SERIAL NUMBER LOCATION

Whenever corresponding about an engine, be sure to refer to the engine model number and serial number. This information can be found on the sticker applied to the recoil housing on the right side of engine.(A) An additional number is stamped on the center top of crankcase beneath the cylinder coolant elbow.

UNIT MODEL NUMBER AND SERIAL NUMBER LOCATION

Themachinemodelnumber andserialnumberare important for vehicle identification. The machine serial number is stamped on the lower left side of the frame tube.(B)

Front

TRANSMISSION I.D. NUMBER LOCA

TION

The transmission I.D. number is located on top of the transmission, right side of machine.

1.2

PUBLICATION NUMBERS

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GENERAL INFORMATION

Year Model Model No. Owner’s

Manual PN

2009 Trail Boss 330 A09CA32AA 9921784 9921774 2009 Trail Blazer 330 A09BA32AA 9921773 9921787

NOTE: When ordering service parts be sure to use the correct parts manual. NOTE: Some manuals can be found at the Polaris website: www.polarisindustries.com or purchased from

www.purepolaris.com.

Parts

Manual PN

PAINT CODES

FRAME COLOR - P067 Medium Gloss Black 9440 / 8520147.

REPLACEMENT KEYS

Replacement keys can be made from the original key. To identify which series the key is, take the first two digits on the original key and refer to the chart to the right for the proper part number.

Shouldbothkeysbecomelost, ignition switch replacement is required.

Series # Part Number

20 4010278

31XX

KEY COVER

P/N 5433534

Key Series Number

21 4010278 22 4010321 23 4010321 27 4010321 28 4010321 31 4110141 32 4110148 67 4010278 68 4010278

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MODEL: 2009 TRAILBOSS 330..........

MODEL NUMBER: A09CA32AA. ENGINE MODEL: ES32PFE..

Category

Length 75 in./191 cm Width 46 in./117 cm Height 46 in./117 cm Wheel Base 48 in./121.9 cm Ground Clearance 5.5./13.97 cm Dry Weight 488 lbs./221 kg Gross Vehicle Weight 830 lbs./377 kg

Front Rack Capacity (Accessory)

Rear Rack Capacity (Accessory)

Towing Capacity Hitch TongueWeight

(Accessory) Body Style

Dimension

30 lbs./13.6 kg

60 lbs./27.2 kg

850 lbs./385 kg

85 lbs./14 kg

Gen III

1.6

MODEL: 2009 TRAILBLAZER 330..........

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MODEL NUMBER: A09BA32AA. ENGINE MODEL: ES32PFE..

Engine

Platform Fuji 4 stroke, Single Cylinder Engine Model Number ES32PFE Engine Displacement 329cc Number of Cylinders 1 Bore & Stroke (mm) 78.5 x 68 mm CompressionRatio 9.2:1 Compression Pressure 70--90 psi Engine Idle Speed 1300 ± 100 Rpm Cooling System/Capacity Oil/ Air w/ fan assist

1.9qts./1.8 ltr Overheat Warning HOT Light on Panel Lubrication Wet Sump Oil Requirements Polaris 2W--50 Exhaust System USFS Approved

Carburetion

Carburetor model Mikuni BST 34mm Main Jet 122.5 Pilot Jet 42.5 Jet Needle 4HB48--3 Needle Jet P--4 (829) Pilot Screw 2 Turns Out

(Initial starting point, may vary

for each ATV) Pilot Air Jet 160 Float Height 13 ± 1 mm (0.51 ± 0.40“) Fuel Delivery Fuel Pump Fuel Capacity / Requirement 3.25 gal. (12.3 L)

87 Octane (minimum)

89 Oxygenated

Electrical

Alternator Output 200 w @ 5000 RPM Voltage Regulator 3--Phase Lights : Head 55 watts

Brake 26.9 watts

GENERAL INFORMATION

Drivetrain

Transmission Type Inline H/N/R Transmission Capacity 11.3 oz. (335 ml) Gear Ratio : High

Rev. Final

Chain Type 520 O--Ring Clutch Type PVT Non EBS Belt 3211077

Steering / Suspension

Front Suspension / Shock A--arm / MacPherson Strut Front Travel 8.2 in. / 20.83 cm Rear Suspension

Style / Shock Rear Travel 10.5 in. / 26.67 cm Ground Clearance 5.5in. / 13.97 cm Shock Preload Adjustment

Front / Rear Turning Radius 83in./211cm Toe Out 1/8 -- 1/4 in / 3 -- 6.35 mm

Progressive Rate Swingarm /

Twin Tube Gas Charged

Wheels / Brakes

JETTING CHART

Altitude

Meters

(Feet)

0--1800

(0--6000)

above 1800

(above 6000)

AMBIENT TEMPERATURE

Below 40°F

Below 5°C

127.5 122.5

120

CLUTCH CHART

Shift

Weight 10 RH

(5630709)

20--40

(5631356)

Blu/Grn

Meters

(Feet)

Altitude

0--1800

(0--6000)

1800--3700

(6000--12000)

Drive

Spring

(7041157)

2.68/1

3.05/1

11/40 78P

Front -- n/a

Rear -- Cam

+40°Fto+80°F

+5°Cto+28°C

Driven Spring

Black

(7041782)

Black

(7041782)(7041157)

115

Driven

Helix

(5131446)

45°

2--2

45°

2--2

1.7

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SPECIAL TOOLS

PART NUMBER TOOL DESCRIPTION CHAPTER TOOL USED IN

PA--44689 Valve Clutch Adjuster 2

2870872 Shock Spanner Wrench 2, 5

8712100DX or 8712500 Tachometer 2,10

2200634 Valve Seat Reconditioning Kit 3 2870390 Piston Support Block 3 2870159 FlywheelPuller 3 2871293 Slotted Nut Socket 3

PV--43527 OIl Filter Wrench 3

2872314 CarburetorFloat Adjustment Tool 4 2870975 Mity Vact Pressure Test Tool 4, 9 2870871 BallJoint Replacement Tool 5 2870623 Shock Absorber Spring Compression Tool 5 2871573 LH Strut Spring Compressor 5 2871574 RH Strut Spring Compressor 5 2870506 Clutch Puller 6 9314177 Clutch Holding Wrench 6 2871358 ClutchHolding Fixture 6 2870341 Drive Clutch Spider Removal and Install Tool 6 2870654 Clutch Offset Alignment Tool 6 2870913 Driven Clutch Puller 6 2870910 Roller Pin Tool 6 2871226 ClutchBushing Replacement Tool Kit 6 2870386 Piston Pin Puller 6 8700220 Clutch Compression Tool 6 2871710 10” Center Distance Tool 8

PV--43568 Fluket77 Digital Multimeter 10

2870630 Timing Light 10 2870836 Battery Hydrometer 10

8712100 or 8712500 Tachometer 10

NOTE: Polaris dealers can order the tools listed above through the SPX Service T ools catalog.

1.8

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STANDARD TORQUE SPECIFICATIONS

Thefollowing torquespecificationsare tobeused as a generalguideline. FOR SPECIFICTORQUE VALUESOF FASTENERS Refer to exploded views in the appropriate section. There are exceptions in the steering,

suspension, and engine sections.

Bolt Size Threads/In Grade 2 Grade 5 Grade 8

T orque in. lbs. (Nm)

#10 - 24 27 (3.1) 43 (5.0) 60 (6.9).............. ................ ..............

#10 - 32 31 (3.6) 49 (5.6) 68 (7.8).............. ................ ..............

T o rque ft. lbs. (Nm)*

1/4 - 20 5 (7) 8 (11) 12 (16).............. .................. ................

1/4 - 28 6 (8) 10 (14) 14 (19).............. .................. ..............

5/16 - 18 11 (15) 17 (23) 25 (35).............. ................ ..............

5/16 - 24 12 (16) 19 (26) 29 (40).............. ................ ..............

3/8 - 16 20 (27) 30 (40) 45 (62).............. ................ ..............

3/8 - 24 23 (32) 35 (48) 50 (69).............. ................ ..............

7/16 - 14 30 (40) 50 (69) 70 (97).............. ................ ..............

7/16 - 20 35 (48) 55 (76) 80 (110).............. ................ ..............

1/2 - 13 50 (69) 75 (104) 110 (152).............. ................ .............

1/2 - 20 55 (76) 90 (124) 120 (166).............. ................ .............

Metric / Torque

6 x 1.0 72-78 In. lbs. 8 x 1.25 14-18ft. lbs. 10 x 1.25 26-30 ft. lbs..... ......

1.9

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SAE TAP DRILL SIZES

Thread Size/Drill Size Thread Size/Drill Size

#0-80 3/64 #1-64 53 #1-72 53 #2-56 51 #2-64 50 #3-48 5/64 #3-56 45 #4-40 43 #4-48 42 #5-40 38 #5-44 37 #6-32 36 #6-40 33 #8-32 29 #8-36 29 #10-24 24 #10-32 21 #12-24 17 #12-28 4.6mm 1/4-20 7 1/4-28 3 5/16-18 F 5/16-24 I 3/8-16 O 3/8-24 Q 7/16-14 U 7/16-20 25/64

1/2-13 27/64 1/2-20 29/64 9/16-12 31/64 9/16-18 33/64 5/8-11 17/32 5/8-18 37/64 3/4-10 21/32 3/4-16 1 1/16 7/8-9 49/64 7/8-14 13/16 1-8 7/8 1-12 59/64 1 1/8-7 63/64 1 1/8-12 1 3/64 11/4-7 17/64 1 1/4-12 1 11/64 11/2-6 111/32 1 1/2-12 1 27/64 13/4-5 19/16 1 3/4-12 1 43/64 2-4 1/2 1 25/32 2-12 1 59/64 2 1/4-4 1/2 2 1/32 21/2-4 21/4 23/4-4 21/2 3-4 2 3/4

METRIC TAP DRILL SIZES

Tap Size Drill Size Decimal

Equiva-

lent

3x.50 3x.60 4x.70 4x.75 5x.80 5x.90 6 x 1.00 7 x 1.00 8 x 1.00 8 x 1.25 9 x 1.00 9 x 1.25 10 x 1.25 10 x 1.50 11 x 1.50 12 x 1.50 12 x 1.75

#39 3/32 #30 1/8 #19 #20 #9 16/64 J 17/64 5/16 5/16 11/32 R 3/8 13/32 13/32

0.0995

0.0937

0.1285

0.125

0.166

0.161

0.196

0.234

0.277

0.265

0.3125

0.3437

0.339

0.375

0.406

Nearest

Fraction

3/32 3/32 1/8 1/8 11/64 5/32 13/64 15/64 9/32 17/64 5/16 5/16 11/32 11/32 3/8 13/32 13/32

DECIMAL EQUIVALENTS

1/64 .0156................

1/32 .0312 1 mm = .0394″........... ...

3/64 .0469................

1/16 .0625...........

5/64 .0781 2 mm = .0787″................ ...

3/32 .0938...........

7/64 .1094 3 mm = .1181″.............. ...

1/8. .1250...

9/64 .1406................

5/32 .1563 4 mm = .1575″........... ...

11/64 .1719...............

3/16 .1875 5 mm = .1969″........... ...

13/64 .2031...............

7/32 .2188...........

15/64 .2344 6 mm = .2362″............... ...

1/4 .25....

17/64 .2656 7 mm = .2756″............... ...

9/32 .2813...........

19/64 .2969...............

5/16 .3125 8 mm = .3150″........... ...

21/64 .3281...............

11/32 .3438 9 mm = .3543″.......... ...

23/64 .3594...............

3/8 .375....

25/64 .3906 10 mm = .3937″............... ...

13/32 .4063.........

27/64 .4219 11 mm = .4331″............... ...

7/16 .4375...........

29/64 .4531...............

15/32 .4688 12 mm = .4724″......... ...

31/64 .4844...............

1/2 .5 13 mm = .5118.... ..............

33/64 .5156...............

17/32 .5313.........

35/64 .5469 14 mm = .5512″............... ...

9/16 .5625...........

37/64 .5781 15 mm = .5906″............... ...

19/32 .5938.........

39/64 .6094...............

5/8 .625 16 mm = .6299″.... ............

41/64 .6406...............

21/32 .6563 17 mm = .6693″......... ...

43/64 .6719..............

1/16 .6875..........

45/64 .7031 18 mm = .7087″............... ...

23/32 .7188.........

47/64 .7344 19 mm = .7480″............... ...

3/4 .75....

49/64 .7656...............

25/32 .7813 20 mm = .7874″......... ...

51/64 .7969...............

13/16 .8125 21 mm = .8268″......... ...

53/64 .8281...............

27/32 .8438.........

55/64 .8594 22 mm = .8661″............... ...

7/8 .875....

57/64 .8906 23 mm = .9055″............... ...

29/32 .9063.........

59/64 .9219..............

15/16 .9375 24 mm = .9449″......... ...

61/64 .9531...............

31/32 .9688 25 mm = .9843......... ...

63/64 .9844...............

11.0.....

1.10

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CONVERSION TABLE

Unit of Measure Multiplied by Converts to

ft. lbs. x12 =in.lbs. in. lbs. x .0833 = ft. lbs. ft. lbs. x 1.356 =Nm in. lbs. x .0115 =kg-m Nm x .7376 = ft.lbs. kg-m x 7.233 = ft. lbs. kg-m x 86.796 =in.lbs. kg-m x10 =Nm in. x 25.4 =mm mm x .03937 =in. in. x2.54 =cm mile (mi.) x1.6 =km km x .6214 = mile (mi.) Ounces (oz) x 28.35 = Grams (g) Fluid Ounces (fl. oz.) x 29.57 = Cubic Centimeters (cc) Cubic Centimeters (cc) x .03381 = Fluid Ounces (fl. oz.) Grams (g) x 0.035 = Ounces (oz) lb. x .454 =kg kg x 2.2046 =lb. Cubic inches (cu in) x 16.387 = Cubic centimeters (cc) Cubic centimeters (cc) x 0.061 = Cubic inches (cu in) Imperial pints (Imp pt) x 0.568 = Liters (l) Liters (l) x1.76 = Imperial pints (Imp pt) Imperial quarts (Imp qt) x 1.137 = Liters (l) Liters (l) x0.88 = Imperial quarts (Imp qt) Imperial quarts (Imp qt) x 1.201 = US quarts (US qt) US quarts (US qt) x 0.833 = Imperial quarts (Imp qt) US quarts (US qt) x 0.946 = Liters (l) Liters (l) x 1.057 = US quarts (US qt) US gallons (US gal) x 3.785 =Liters (l) Liters (l) x 0.264 = US gallons (US gal) Pounds - force per square inch (psi) x 6.895 = Kilopascals (kPa) Kilopascals (kPa) x 0.145 = Pounds - force per square inch (psi) Kilopascals (kPa) x0.01 = Kilograms - force per square cm Kilograms - force per square cm x 98.1 = Kilopascals (kPa)

π (3.14) xR2x H (height) = Cylinder Volume

°Cto°F: 9 (°C + 40) ÷ 5-40=°F °Fto°C: 5 (°F + 40) ÷ 9-40=°C

1.11

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GLOSSARY OF TERMS

ABDC: After bottom dead center. ACV: Alternating current voltage. Alternator: Electrical generator producing voltage alternating current. ATDC: After top dead center. BBDC: Before bottom dead center. BDC: Bottom dead center. BTDC: Before top dead center. CC: Cubic centimeters. Center Distance: Distance between center of crankshaft and center of driven clutch shaft. Chain Pitch: Distance between chain link pins (No.35 = 3/8″ or1 cm). Polaris measures chainlength in number of pitches. CI: Cubic inches. Clutch Buttons: Plastic bushings which aid rotation of the movable sheave in the drive and driven clutch. ClutchOffset: Drive anddriven clutchesare offset sothatdrive beltwill staynearly straightas it movesalong the clutchface. Clutch Weights: Three levers in the driveclutch which relative to theirweight, profile and engine RPMcause thedrive

clutch to close and grip the drive belt. Crankshaft Run-Out: Run-out or “bend” of crankshaft measured with a dial indicator while crankshaft is supported between centers on V blocks or resting in crankcase. Measure at various points especially at PTO.

DCV: Direct current voltage. Dial Bore Gauge: A cylinder measuring instrument which uses a dial indicator. Good for showing taper and

out-of-round in the cylinder bore.

Electrical Open: Open circuit. An electrical circuit which isn’t complete. Electrical Short: Short circuit. Anelectrical circuit which is completed before the current reaches the intended load.

(i.e. a bare wire touching the chassis).

End Seals: Rubber seals at each end of the crankshaft. Engagement RPM: Engine RPM at which the drive clutch engages to make contact with the drive belt. ft.: Foot/feet. Foot Pound: Ft. lb. A force of one pound at the end of a lever one foot in length, applied in a rotational direction. g: Gram. Unit of weight in the metric system. gal.: Gallon. ID: Inside diameter. in.: Inch/inches. Inch Pound: In. lb. 12 in. lbs. = 1 ft. lb.

kg/cm2: Kilograms per square centimeter. kg-m: Kilogram meters. Kilogram/meter: A force of one kilogram at the end of a lever one meter in length, applied in a rotational direction. lorltr: Liter.

lbs/in2: Pounds per square inch. Left or Right Side: Always referred to based on normal operating position of the driver. m: Meter/meters. Mag: Magneto. Magnetic Induction: As a conductor (coil) is moved through a magnetic field, a voltage will be generated in the

windings. Mechanical energy is converted to electrical energy in the stator.

mi.: Mile/miles. mm: Millimeter. Unit of length in the metric system. 1mm = approximately .040″. Nm: Newton meters. OD: Outside diameter . Ohm: The unit of electrical resistance opposing current flow. oz.: Ounce/ounces. Piston Clearance: Total distance between piston and cylinder wall. psi.: Pounds per square inch. PTO: Power take off. PVT: Polaris Variable Transmission (Drive Clutch System) qt.: Quart/quarts. Regulator: Voltage regulator. Regulates battery charging system output at approx. 14.5 DCV as engine RPM increases. Reservoir T ank: Thefill tank in the liquid cooling system. Resistance: In the mechanical sense, friction or load. In the electrical sense, ohms, resulting in energy conversion to heat. RPM: Revolutions per minute. SeizedPiston: Gallingofthe sides ofa piston. Usuallythereis atransferofaluminumfromthepistonontothecylinderwall.

Possible causes: 1)improper lubrication; 2)excessive temperatures; 3) insufficient piston clearance; 4) stuck piston rings.

Stator Plate: The plate mounted under the flywheel supporting the battery charging coils. TDC: Top dead center. Piston’s most outward travel from crankshaft. Volt: The unit of measure for electrical pressure of electromotive force. Measured by a voltmeter in parallel with the circuit. Watt: Unit of electrical power. Watts = amperes x volts. WOT: Wide open throttle.

1.12

MAINTENANCE

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Periodic Maintenance Chart 2.2-2.5...............

Recommended Maintenance Products 2.6--2.7......

Pre-Ride Inspection 2.8......................

ATV Component Locations 2.9................

Lubricant and Maintenance Quick Reference 2.10-2.11

Transmission Lubrication 2.12..................

Lubrications/Grease Points 2.13................

Transmission Linkage Adjustment 2.13..........

Throttle Operation / Choke Adjustment 2.14......

Carburetor Adjustments 2.15-2.16...................

ETC Switch Adjustment 2.16--2.17...................

Fuel System 2.17-2.18.............................

Compression Test 2.18........................

Battery Maintenance 2.19......................

Ignition / Sparkplug 2.20.......................

Air Filter Service 2.20-2.21.........................

Air Box Sediment Tube Service 2.22............

Recoil Housing/PVT Drying 2.22................

Oil Level/Change/Filter 2.23-2.24....................

Valve Clearance 2.24-2.25.........................

Steering and Toe Alignment 2.25-2.27...............

Exhaust System Maintenance 2.28.............

Brake System Service 2.28-2.29....................

Drive Chain and Sprocket Service 2.29-2.32..........

Suspension Service / Controls 2.32-2.33.............

Wheel Removal / Installation 2.33--2.34...............

Tire Inspection 2.34...........................

2.1

MAINTENANCE

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PERIODIC MAINTENANCE CHART

Careful periodic maintenance will help keep your vehicle in the safest, most reliable condition. Inspection, adjustment and lubrication of important components are explained in the periodic maintenance chart.

Inspect, clean, lubricate, adjust and replace parts as necessary. When inspection reveals the need for replacement parts, use genuine Polaris parts available from your Polaris dealer.

NOTE: Service and adjustments are critical. If you’re not familiar with safe service and adjustment

procedures, have a qualified dealer perform these operations.

Maintenance intervals in the following chart are based upon average riding conditions and an average vehicle speedofapproximately10 milesperhour. Vehiclessubjectedto severeuse mustbe inspectedandservicedmore frequently.

Severe Use Definition

G Frequent immersion in mud, water or sand G Racing or race-style high RPM use G Prolonged low speed, heavy load operation G Extended idle G Short trip cold weather operation

Pay special attention to the oil level. A rise in oil level during cold weather can indicate contaminants collecting in the oil sump or crankcase. Change oil immediately if the oil level begins to rise. Monitor the oil level, and if it continues to rise, discontinue use and determine the cause or see your dealer.

Maintenance Chart Key

The following symbols denote potential items to be aware of during maintenance:

H= CAUTION: Due to the nature of these adjustments, it is recommended this service be performed

by an authorized Polaris dealer.

"= SEVERE USE ITEM ----If vehicle is subjected to severe use, decrease interval by 50%

(Severe Use is defined as frequent vehicle immersion in mud, water or sand, racing or race-style high rpm use, prolonged low speed - heavy load operation or extended idle. More preventative maintenance is required under these conditions. Fluid changes, cable, chain and chassis lubrication are required more frequently. For engine oil, short trip cold weather riding also constitutes severe use. Pay special attention to oil level. A rising oil level in cold weather can indicate contaminants collecting in the oil sump or crankcase. Change oil immediately and monitor level. If oil level begins to rise, discontinue use and determine cause.)

E= Emission Control System Service (California). NOTE: Inspection may reveal the need for replacement parts. Always use genuine Polaris parts.

WARNING: Improperly performing the procedures marked with a

to serious injury or death. Have an authorized Polaris dealer perform these services.

J could result in component failure and lead

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Periodic Maintenance Chart

MAINTENANCE

Item Maintenance Interval

(whichever comes first)

Hours Calendar Miles

(Km)

Steering

Front suspension

Rear suspension Tires

Brake fluid level

Brake lever travel Brake systems Drive Chain Wheels/fasteners Frame fasteners

Engine oil level

Air filter, pre-filter

Air box sediment

tube Coolant

Pre-Ride Pre-Ride Pre-Ride Pre-Ride Pre-Ride Pre-Ride Pre-Ride Pre-Ride Pre-Ride Pre-Ride Pre-Ride

Daily Daily

Daily

Make adjustments as needed.

Inspect; clean often Drain deposits when visible

Check level daily, change coolant every 2 years

(if applicable) Headlamp/tail

lamp

Air filter,

main element Recoil housing

Daily Weekly Weekly

Check operation; apply dielectric grease if replacing

Inspect; replace as needed Drain water as needed, check often if operating

in wet conditions

Brake pad wear 10 H Monthly 60 (100) Inspect periodically

Battery 20 H Monthly 125 (200) Check terminals; clean; test

Front gearcase oil

25 H Monthly 155 (250) Inspect level; change yearly

(if equipped)

Middle gearcase

25 H Monthly 155 (250) Inspect level; change yearly

oil (if equipped)

Rear gearcase oil

25 H Monthly 155 (250) Inspect level; change yearly

(if equipped)

Transmission oil 25 H Monthly 155 (250) Inspect level; change yearly

Remarks

" Perform these procedures more often for vehicles subjected to severe use. E Emission Control System Service (California) J Have an authorized Polaris dealer perform these services.

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MAINTENANCE

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MAINTENANCE AND LUBRICATION

Periodic Maintenance Chart

Item Maintenance Interval

Hours Calendar Miles

Engine breather

filter (if equipped)

Engine oil change

(break-in)

General lubrication

Shift Linkage 50 H 6M 310 (500) Inspect, lubricate, adjust

Steering 50 H 6M 310 (500) Lubricate

Front suspension 50 H 6M 310 (500) Lubricate

Rear suspension 50 H 6M 310 (500) Lubricate Carburetor float

bowl

Throttle Cable/

ETC Switch

Choke cable 50 H 6M 310 (500) Inspect; adjust; lubricate; replace if necessary

E E

Carburetor air intake ducts/ flange

Drive belt 50 H 6M 310 (500) Inspect; adjust; replace as needed Cooling system

(if applicable)

Engine oil change 100 H 6M 620

Oil filter change 100 H 6M 620

Oil tank vent hose 100 H 12 M 620

Valve clearance 100 H 12 M 620

25 H Monthly 155 (250) Inspect; replace if necessary 25 H 1M 155 (250) Perform a break-in oil change at one month 50 H 3M 310 (500) Lubricate all grease fittings, pivots, cables, etc.

50 H 6M 310 (500) Drain bowl periodically and prior to storage 50 H 6M 310 (500) Inspect; adjust; lubricate; replace if necessary

50 H 6M 310 (500) Inspect ducts for proper sealing/air leaks

50 H 6M 310 (500) Inspect coolant strength

(whichever comes first)

(Km)

(1000) (1000) (1000) (1000)

seasonally; pressure test system yearly

Perform a break-in oil change at 25 hours/one month

Replace with oil change Inspect routing, condition Inspect; adjust

Remarks

" Perform these procedures more often for vehicles subjected to severe use. E Emission Control System Service (California) J Have an authorized Polaris dealer perform these services.

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Periodic Maintenance Chart

MAINTENANCE

Item Maintenance Interval

Hours Calendar Miles

Fuel system 100 H 12 M 620

Fuel filter 100 H 12 M 620

Radiator (if applicable)

Cooling hoses (if applicable)

Engine mounts 100 H 12 M 620 Exhaust muffler/

pipe

Spark plug 100 H 12 M 620

Ignition Timing 100 H 12 M 620

Wiring 100 H 12 M 620

Clutches (drive and driven)

Front wheel bearings

Brake fluid 200 H 24 M 1240 Spark arrestor 300 H 36 M 1860

Idle speed

Toe adjustment

Auxiliary brake

Headlight aim

100 H 12 M 620 100 H 12 M 620

100 H 12 M 620

100 H 12 M 620 100 H 12 M 1000

(whichever comes first)

(Km)

(1000)

(1000) (1000) (1000) (1000) (1000) (1000) (1000) (1000)

(1000) (1600) (2000) (3000)

Remarks

Check for leaks at tank cap, lines, fuel valve, filter, pump, carburetor; replace lines every two years

Replace yearly Inspect; clean external

surfaces Inspect for leaks

Inspect Inspect Inspect; replace as needed Inspect Inspect for wear, routing,

security; apply dielectric grease to connectors subjected to water, mud, etc.

Inspect; clean; replace worn parts Inspect; replace as needed Change every two years Clean out Adjust as needed

Inspect periodically; adjust when parts are replaced

Inspect daily; adjust as needed Adjust as needed

" Perform these procedures more often for vehicles subjected to severe use. E Emission Control System Service (California) J Have an authorized Polaris dealer perform these services.

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POLARIS LUBES/FLUIDS FOR TRAILBOSS 330 MODELS

Pure Polaris Lubricants and Maintenance Kits can be purchased at your local Polaris dealer.

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POLARIS LUBRICANTS,MAINTENANCE AND SERVICE PRODUCTS

Part No. Description

Engine Lubricant

2870791 FoggingOil (12 oz. Aerosol) 2876244 Engine Oil (Quart)Premium 4 Synthetic

2W--50 (4--Cycle) (12 Count)

2876245 Engine Oil (Gallon) Premium 4 Synthetic

2W--50 (4--Cycle) (4 Count)

Gearcase / Transmission Lubricants

2873602 Premium Synthetic AGL Gearcase Lube

(12 oz. bottle)(12 Count)

2873603 Premium Synthetic AGL Gearcase Lube

(1 Gal.) (4 Count)

2876160 Premium ATV Angle Drive Fluid

(32 oz.) (12 Count)

2872276 Premium ATVAngle Drive Fluid

(2.5 Gal) (2 Count)

2870465 Oil Pump for 1 Gallon Jug 2871654 Premium Demand Drive Hub Fluid

(8 oz.) (12 Count)

Grease / Specialized Lubricants

2871322 Premium All Season Grease

(3 oz. cartridge)(24 Count)

2871423 Premium All Season Grease

(14 oz. cartridge)(10 Count)

2871460 StarterDrive Grease (12 Count) 2871515 Premium U-Joint Lube (3 oz.) (24 Count) 2871551 Premium U-Joint Lube (14 oz.) (10 Count) 2871312 Grease Gun Kit 2871329 DielectricGrease (Nyogelt)

Coolant

2871323 60/40 Coolant (Gallon) (6 Count) 2871534 60/40 Coolant (Quart) (12 Count)

Part No. Description

Additives / Sealants / Thread Locking Agents /

Misc.

2874275 Loctitet Primer N, Aerosol 2871956 Loctitet Thread Sealant 565

(50 ml.)(6 Count)

2871950 Loctitet Threadlock 242

(6 ml.)(12 Count)

2871951 Loctitet Threadlock 262

(50 ml.) (10 Count)

2871953 Loctitet Threadlock 271

(6 ml.)(12 Count)

2871326 Premium Carbon Clean

(12 oz.) (12 Count)

2870652 Fuel Stabilizer (16 oz.) (12 Count) 2871957 Black RTV Silicone Sealer

(3 oz. tube) (12 Count)

2871958 Black RTV Silicone Sealer

(11 oz. cartridge) (12 Count)

2872189 DOT 4 Brake Fluid (12 Count) 2871557 CrankcaseSealant, 3-Bond 1215 (5oz.)

NOTE: The number count indicated by each part

number in the table above indicates the number of units that are shipped with each order.

NOTE: Each item can be purchased separately at your local Polaris dealer.

POLARIS LUBRICANT SYMBOL IDENTIFICATON

AGL

Polaris DOT 4 Brake Fluid

Polaris Sythetic Gearcase Lube

AGL

U--Joint

Polaris U--Joint Lube

2W/50

Polaris Sythetic OW--40 Oil

DHF

Polaris Demand Drive Hub Fluid

Polaris All Season Grease

ADF

Polaris ATV Angle Drive Fluid

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PRE-RIDE / DAILY INSPECTION

Perform the following pre-ride inspection daily, and when servicing the vehicle at each scheduled maintenance.

G Tires - check condition and pressures G Fuel and oil tanks - fill both tanks to their proper level; Do not overfill oil tank G All brakes - check operation (includes auxiliary brake) G Throttle - check for free operation G Headlight/Taillight/Brakelight - check operation of all indicator lights and switches G Engine stop switch - check for proper function G Wheels - check for loose wheel nuts G Air cleaner element - check for dirt or water; clean or replace G Steering - check for free operation, noting any unusual looseness in any area

G Loose parts - visually inspect vehicle for any damaged or loose nuts, bolts or fasteners G Engine coolant - check for proper level at the recovery bottle

COLD WEATHER KITS FOR 4 STROKE ATVS

Engine Heater -- (PN 2871507)

ACCESSORY ENGINE HEATER

2.8

TRAIL BOSS 330 COMPONENT LOCATIONS

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Brake Fluid Reservoir

Brake Lever

Light Control & Run Switch

Fuel Valve

Front Rack

Reverse Override

Choke

Rear Axle & Drive Sprocket

MAINTENANCE

Display

Throttle

Ignition/Key

Headlights

Transmission

Engine Recoil

Right Side View

Oil Dipstick

Muffler

Auxiliary Brake

PVT Cover

Gear Shifter

Front Rack

Engine

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MAINTENANCE QUICK REFERENCE

Ill.

1 Engine Oil Polaris 2W--50

2 Transmission PolarisAGL Lu-

3 Brake Fluid Polaris DOT 3

4 DriveChain Polaris Chain

NOTE: Refer to Page 2.6 for the Polaris Lubricant Identification table.

Item Lube Rec. Method Frequency*

Add oil to proper level. Change after1st month, 6 months or 100

Synthetic

Add lube to FULL level on dip-

bricant

Brake Fluid

Lube or O-Ring chain lube

Dipstick

2W/50

stick. Fill master cylinder reservoir to in-

dicated level inside reservoir. See Page 2.29.

Apply to chain link plates and rollers.

hours thereafter; Change more often (25-50 hours) in extremely dirty conditions, or short trip cold weather operation.

Change annually ©

As required. Change fluid every 2 years.

As required*

Transmission Dipstick

AGL

Operating Range

Full

1. Engine Oil

Parking Brake Lock

3. Brake Fluid

2. Transmission

Reservoir

4. Rear Drive Chain

2.10

MAINTENANCE QUICK REFERENCE CONT’D

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MAINTENANCE

5. Ball Joint

8. Axle Housing

4. Front Wheel Bearings

6. Tie Rod Ends

7. Swingarm Pivots

NOTE: Refer to Page 2.6 for the Polaris Lubricant Identification table.

Ill.

4 FrontWheel Bear-

ings

5 Ball Joint Polaris All Season

6 Tie Rod Ends Polaris All Season

7 Swing Arm Bush-

ings

8 Rear Axle Housing Polaris All Season

* More often under severe use, such as operated in water or under severe loads.

¡ Semi-annually or 50 hours of operation (refer to Maintenance Schedule for additional information) © Annually or 100 hours of operation (refer to Maintenance Schedule for additional information) ¢ Grease conforming to NLGI No. 2, such as Polaris Premium All Season Grease, Conoco Superlube M or

Mobilegrease Special

Item Lube Rec. Method Frequency*

Grease¢

Grease¢ Polaris All Season

Grease¢

Locate grease fitting on back side of struts and grease with grease gun.

Lift boot. Clean away dirt and grease. Apply fresh grease by hand and reassemble.

Locate grease fitting on swing arm and grease with grease gun.

Locate grease fitting on eccentric and grease with grease gun.

Semi-annually

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TRANSMISSION LUBRICATION

The transmission lubricant level should be checked and changed in accordance with the maintenance schedule.

G Be sure vehicle is level before

proceeding.

G Check vent hose to be sure it is

routed properly and unobstructed.

G Follow instructions on following

pages to check / change transmission lubricant.

TRANSMISSION SPECIFICATIONS

Specified Lubricant:

Polaris AGL Gearcase Lubricant:

(PN 2873603) (Gallon) (PN 2873602) (12 oz.)

Capacity: 11.3 oz. (335 ml) Drain Plug / Fill Plug T orque:

14 ft. lbs. (19.4 Nm)

Transmission

Dipstick

Full

Operating

Range

TRANSMISSION FLUID CHANGE/TORQUE ST

ADJUSTMENT

1. Remove skid plate (if necessary).

2. Place a drain pan beneath the transmission oil drain plug area.

3. Loosen jam nut (A).

4. Turn adjuster bolt (B) in to allow the removal of drain plug.

5. Removethedrainplug andwipethe magneticend clean to remove accumulated metallic filings.

6. After the oil has drained completely, install a new sealing washer and install the drain plug. Torque to 14 ft. lbs. (19.3 Nm).

7. Turn adjuster bolt (B) out until it touches the frame, and then an additional 1/2 turn.

PVT Cover

To check the level:

1. Remove dipstick and wipe clean.

Forward

8. Tighten the jam nut securely while holding the adjuster bolt.

9. Addthe proper lubricant through the dipstick hole until the oil level is between the upper and lower

2. Reinstall dipstick completely, remove and check the level. Add the proper lubricant as required to bring level into operating range as shown.

limits. Do not overfill.

10. Check for leaks.

11.ReinstallskidplateifremovedinStep1.

Drain Plug

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LUBRICATION / GREASE POINTS

As shown on Page 2.8, there are only five grease zerks onthe TrailBoss,two front balljoints,two onthe swing are pivots, and one on the rear axle housing.

Swing Arm Pivot

Each Side

Ball Joint Zerk

Each Side

Ball Joint Zerk

TRANSMISSION GEARSHIFT LINKAGE

ADJUSTMENT/

INSPECTION

Linkage rod will rotate

1/8 -1/4 turn if rod ends

are tightened properly.

Parallel

Correctly Tightened

Jam Nut

G Ifshiftingproblems areencountered,

thetransmission linkagemayrequire adjustment.

G Visually check for contact of shift

lever to shifter opening in the front fender. Ensure shift linkage or shift lever is not contacting the frame or exhaust components.

G Tightenshiftlinkage rodendjam nuts

properly after adjustment. You should be able to rotate the linkage rod between 1/8 and 1/4 turn after both jam nuts are tight.

G The transmission shift linkage

should be periodically inspected for wear and parts replaced as required to remove excess play from shift linkage.

G Refer to Transmission chapter for

more information.

Incorrectly Tightened

Jam Nut

NOTE: Therod end must be held whentighteningthe jam nut to prevent damage to the rod end.

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SHIFT LINKAGE ADJUSTMENT

1. Inspect shift linkage tie rod ends, clevis and pivot bushings and replace if worn or damaged.

2. Place gear selector in neutral.

3. Loosen rod end adjuster jam nuts (A) on both ends of linkage rod. NOTE: The jam nut closest to the knurled end is Left Hand thread.

Jam Nuts (A)

Linkage Rod

Ill. 1

THROTTLE OPERATION - ALL MODELS

Check for smooth throttle opening and closing in all handlebar positions. Throttle lever operation should be smooth and lever must return freely without binding.

1. Place the gear selector in neutral.

2. Set parking brake.

3. Start the engine and let it idle.

4. Turn handlebars from full right to full left. If idle speed increases at any point inthe turningrange, inspect throttle cable routing and condition. If cable is routed properly and in good condition, repeat adjustment procedure.

5. Replace the throttle cable if worn, kinked, or damaged.

CHOKE (ENRICHER) ADJUSTMENT

4. Turn linkage rod (A) to shorten or lengthen rod until the shift lever is centered on hole in the fender.

5. Hold rod end parallel to mounting surface and tighten jam nuts securely.

Boot

If the choke knob does not stay out when pulled, adjust the choke tension by tightening the tensioner located under the rubber boot between the choke knob and nut. Firmly grasp the rubber boot and tighten until thechoke slides freely but stays out when pulled.

Verify free play of 1/16--3/16” (1.6--4.76 mm) and smooth operation of choke cable.

If smooth choke operation is not obtainable, inspect choke cable for kinks or sharp bends in routing.

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PILOT SCREW

Thepilotsystem suppliesfuelduringengine operation with the throttle valve closed or slightly opened. The fuel/air mixture is metered by pilot screw and discharged into the main bore through the pilot outlet.

CAUTION:

The pilotscrew is calibratedatthe factoryto meetEPA/ CARB regulationsfor air qualitystandards and is sealed with a brass plug to prevent tampering. Removal of the tamper proof plug is not permitted. For service purposes, cleaning of the pilot circuitcan be done only by a certifiedrepairshop to ensure air quality standards are not exceeded.

Pilot Screw location

PILOT SCREW ADJUSTMENT

FRONT (Engine)

Pilot Screw

View -- Right Cover Panel Removed

Pilot Screw

1. Start engine and warm it up to operating temperature (about 10 minutes).

Brass Plug Installed

Brass Plug Removed

2. Turnpilot screw in (clockwise) until lightly seated. Turn screw out the specified number of turns. NOTE: Do not tighten the pilot screw forcefully against the seat or the screw and/or seat will be permanently damaged.

The pilot screw is set at the factory. Each carburetor will have a slightly different pilot screw setting, the adjustments below are the recommended settings, the settings may differ from these recommendations.

Pilot Screw Adjustment: Trailboss 330 -- 2 Turns Out

3. Connect an accurate tachometer that will read in increments of + or -- 50 RPM such as the PET 2100DX (PN 8712100DX) or the PET 2500 (PN

8712500).

4. Set idle speed to 1200 RPM. Always check throttle cable freeplay after adjusting idle speed and adjust if necessary.

5. Slowly turn mixture screw clockwise using the pilot screw wrench until engine begins to miss.

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6. Slowly turn mixture screw counterclockwise until idle speed increases to maximum RPM. Continue turning counterclockwise until idle RPM begins to drop.

7. Center the pilot screw between thepoints in Step 5 and 6.

8. Re adjust idle speed if not within specification.

IDLE SPEED ADJUSTMENT

1. Start engine and warm it up thoroughly.

CV Carburetor

Idle Screw

confirm adjustment.

Boot

Adjuster

Sleeve

Direction

of travel

3. Tighten locknut and slide boots over cable adjuster until they touch at the middle point of the adjuster.

4. Withengine running, turn the handlebars fromfull left to full right with transmission in neutral. Engine RPM should not change and the engine should not die. If either of these occur, return to the first step.

Lock-

nut

1/16″ -1/8″

Freeplay

Boot

THROTTLE OPERATION

To remove the ETC cover:

Idle Speed:

1300 ± 100 RPM

2. Adjust idle speed by turning the idle adjustment screw in (clockwise) to increase or out (counterclockwise) to decrease RPM. (Refer to Ill. at right).

NOTE: Adjusting theidle speed affects throttle cable freeplay and electronic throttle control (ETC) adjustment. Always check throttle cable freeplay after adjusting idle speed and adjust if necessary.

ELECTRONIC THROTTLE CONTROL (ETC THROTTLE

CABLE

SWITCH)/

ADJUSTMENT

1. Slide the boots off inline cable adjuster sleeve.

Loosen adjuster locknut.

2. With handlebars centered and wheels pointing

forward, turn adjuster sleeve until 1/16″ -1/8″ freeplay is achieved at the thumb lever. After making any adjustment, “flip” the lever slightly to

1. Use a medium flat blade screwdriver and insert blade into the pockets of the cover starting on the #1 position.

2. Twistscrewdriver slightly while lifting onthecover to release snap.

3. Repeat procedure at the other five locations as shown. NOTE: Do not attempt to remove cover until all latch points are released.

Check for smooth throttle opening and closing in all handlebar positions. Throttle lever operation should be smooth and lever must return freely without binding. Replace the throttle cable if worn, kinked, or

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damaged.

NOTE: When replacing the cover, check for correct placement of cover O-ring.

FUEL SYSTEM

WARNING

Gasoline is extremely flammable and explosive under certain conditions.

FUEL LINES

Fuel Lines

Fuel Pump

Pulse Line

Ill.1

1. Check fuel lines for signs of wear, deterioration, damage or leakage. Replace if necessary.

2. Besurefuel linesare routed properly andsecured with cable ties. CAUTION: Make sure lines are not kinked or pinched.

3. Replace all fuel lines every two years.

G Always stop the engine and refuel

outdoors or in a well ventilated area.

G Do not smoke or allow open flames

or sparks in or near the area where refueling is performed or where gasoline is stored.

G Donot overfill the tank. Donot fill the

tank neck.

G If you get gasoline in your eyes or if

you swallow gasoline, seek medical attention immediately.

G If you spill gasoline on your skin or

clothing, immediately wash it off with soapand water and change clothing.

G Never start the engine or let it run in

an enclosed area. Engine exhaust fumes are poisonous and can result loss of consciousness or death in a short time.

G Never drain the float bowl when the

engine is hot. Severe burns may result.

VENT LINES

1. Check fuel tank, oil tank, carburetor, battery and transmission vent lines for signs of wear, deterioration, damage or leakage. Replace every two years.

2. Be sure vent lines are routed properly and secured with cable ties. CAUTION: Make sure lines are not kinked or pinched.

FUEL FILTER

The fuel filter should be replaced in accordance with the Periodic Maintenance Chart. The fuel filter is located between the fuel pump and carburetor.

1. Shut off fuel supply at fuel valve.

2. Remove line clamps at both ends of the filter.

3. Remove fuel lines from filter.

4. Install new filter and clamps onto fuel lines with arrow pointed in direction of fuel flow.

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Arrow Indicates Direction

of Flow

RES

OFF

To Carburetor

Fuel Valve

5. Install clamps on fuel line.

6. Turn fuel valve ON.

7. Start engine and inspect for leaks.

CARBURETOR DRAINING

The carburetor float bowl should be drained periodically to remove moisture or sediment from the bowl, or before extended periods of storage.

Drain tube

attached

here

Drain Screw

NOTE: Thebowl drain screwis located onthebottom left side of the float bowl.

1. Turn fuel valve to the off position.

2. Place a clean container beneath the bowl drain spigot or bowl drain hose.

3. Turn drain screw out two turns and allow fuel in the float bowl and fuel line to drain completely.

4. Inspect the drained fuel for water or sediment.

5. Tighten drain screw.

6. Turnfuelvalveto“ON”.

7. Start machine and check for leaks.

NOTE: If there is a tube attached, it must be reattached as this will effect engine performance.

COMPRESSION TEST

NOTE: This Polaris 4-Strokeengine is equipped with

an automatic decompressor. Compression readings will vary in proportion to cranking speed during the test. Average compression (measured) is about

70--90 psi

Smooth idle generally indicates good compression. Low engine compression is rarely a factor in running condition problems above idle speed. Abnormally high compression can be caused by a decompressor malfunction, or worn or damaged exhaust cam lobes. Inspect camshaft and automatic decompression mechanism if compression is abnormally high.

A cylinder leakage test isthe best indication ofengine condition on models with automatic decompression. Follow tester manufacturer’s instructions to perform a cylinder leakage test. (Never use high pressure leakagetesters ascrankshaft seals may dislodgeand leak).

during a compression test.

Cylinder Compression

Standard 70--90 PSI

Cylinder Leakage

Service Limit: 10 %

(Inspect for cause if leakage exceeds 10%)

2.18

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