Polaris Trail Boss 330 Owner's Manual

Copyright 2004 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. Manufacturer accepts no liability for omissions or inaccuracies. Any reprinting or reuse of the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited.

Printed in U.S.A.

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

TABLE OF CONTENTS

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

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

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

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

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

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

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

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

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

W ARRANTY 111.....................................

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

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

VEHICLE IDENTIFICATION NUMBERS

Record your vehicle’s identification numbers and key number. Remove the spare key and store it in a safe place. Your key can be duplicated only by mating a Polaris key blank with one of your existing keys, so if both keys are lost, the ignition switch must be replaced.

Vehicle Model Number:

Frame VIN (1):

Engine Serial Number (2): (right front side of engine crankcase)

Key Number (3):

31XX

SAFETY

Operator Safety

The following signal words and symbols appear throughout this manual and on your vehicle. Become familiar with their meanings

before reading the manual.

The safety alert symbol, on your vehicle or in this manual, alerts you to the potential for personal injury.

WARNING

The safety alert warning indicates a potential hazard that may result in serious injury or death.

CAUTION

The safety alert caution indicates a potential hazard that may result in minor personal injury or damage to the vehicle.

CAUTION

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

NOTE:

A note will alert you to important information or instructions.

SAFETY

Operator Safety

WARNING

Failure to follow the warnings in this manual can result in serious injury or death.

A Polaris Quadricycle is not a toy and can be hazardous to operate. A collision or rollover can occur quickly, even during routine maneuvers, if you fail to take proper precautions.

Read and understand your owner’s manual and all warnings before operating a Polaris Quadricycle.

Safety Training

When you purchased your new Quadricycle, your dealer offered a hands-on safety training course. You were also provided with printed materials that explain safe operating procedures. Review this information on a regular basis.

If you purchased a used Polaris Quadricycle from a party other than a Polaris dealer, please request free safety training from any authorized Polaris dealer.

Age Restriction

This vehicle is an ADULT VEHICLE ONLY. Operation is prohibited for anyone under 16 years of age.

SAFETY

Operator Safety

Know Your Vehicle and Riding Area

You are responsible for your personal safety, the safety of others and the protection of the environment. Read and understand your owner’s manual. It includes important information about Quadricycle safety.

Ride responsibly. Know all laws and regulations concerning the operation of this vehicle in your area.

Restrictions

This vehicle is approved for OFF-ROAD TOWING ONLY. Operating a Quadricycle/trailer combination on public roads is prohibited.

Equipment Modifications

The warranty on your Polaris Quadricycle may be terminated if any equipment has been added, or if any modifications have been made, that increase speed or power .

NOTE: The addition of certain accessories, including (but not limited

to) mowers, blades, tires, sprayers and large racks may change vehicle handling. Use only Polaris-approved accessories. Know their function and effect on the vehicle.

SAFETY

Operator Safety

WARNING

Serious injury or death can result if you do not follow the instructions and procedures listed here and throughout this manual.

Read and understand all warnings, cautions and operating procedures in this manual and on the safety labels before operating the Quadricycle.

Never operate a Quadricycle without proper instruction. Take a training course. Beginners should receive training from a certified instructor. Contact an authorized Polaris Quadricycle dealer or call Polaris at 1-800-342-3764.

Never permit others to operate the Quadricycle unless they have read and understand this manual and all product labels, and have completed a certified safety training course.

Never allow anyone under 16 years of age to operate this vehicle.

Never carry a passenger. The purpose of the long seat is to allow the operator to shift position.

SAFETY

Operator Safety

Always wear an approved helmet that fits properly . Wear eye protection (goggles or face shield), gloves, boots, long sleeves and long pants.

Never consume alcohol or drugs before or while operating a Quadricycle.

Never operate at excessive speeds. Travel and turn at speeds appropriate for the terrain, visibility, operating conditions and your experience.

SAFETY

Operator Safety

Never attempt wheelies, jumps or other stunts.

Always inspect your Quadricycle before each use to verify that it’s in safe operating condition. Follow the inspection and maintenance procedures outlined in this manual. See page 56.

Keep both hands on the handlebars. Keep your feet on the footrests.

Always travel slowly when operating on unfamiliar terrain. Use extra caution.

SAFETY

Operator Safety

Use caution when operating on rough, slippery or loose terrain.

Always follow the procedures outlined in this manual for turning. See page 25.

Never turn sharply at excessive speeds, which can lead to vehicle overturn.

If a Quadricycle has been involved in an accident, always have an authorized Polaris dealer inspect the entire vehicle for possible damage, including (but not limited to) brake, throttle and steering systems.

>25_

SAFETY

Operator Safety

Never operate on hills too steep for the Quadricycle or for your abilities. Practice on smaller hills before attempting larger hills. Avoid climbing hills steeper than 25_.

Always follow the procedures outlined in this manual for climbing hills. See page 30.

Always follow the procedures outlined in this manual for driving downhill and for braking on hills. See page 28.

Always follow the procedures outlined in this manual for crossing the side of a hill. See page 29.

Never attempt to turn the Quadricycle around on any hill until you’ve mastered (on level ground) the turning technique outlined in this manual.

SAFETY

Operator Safety

Always follow the procedures outlined in this manual for braking if you stall or roll backwards while climbing a hill. Never back down a hill. See page 31.

Always follow the procedures outlined in this manual for operating over obstacles. See page 27.

Always follow the procedures outlined in this manual for operating on slippery or loose surfaces. Use extra caution. Always avoid skidding or sliding. See page 26.

SAFETY

Operator Safety

Always follow the procedures outlined in this manual for driving through water. Never drive through deep or fast-flowing water. See page 34.

Always follow the procedures outlined in this manual for driving in reverse. See page 36.

Always use the size and type of tires specified for your Quadricycle. Maintain the proper tire pressure.

2/3

1/3

2/3

1/3

SAFETY

Operator Safety

Never modify a Quadricycle through improper installation or use of accessories.

Never exceed the stated load capacity for your Quadricycle. Cargo must be properly distributed and securely attached. Reduce speed and follow the instructions in this manual for carrying cargo or towing. Allow a greater distance for braking.

Never operate the Quadricycle on a frozen body of water.

Operating on paved surfaces may seriously affect the handling and control of the Quadricycle and could result in loss of control, accident, and/or injury. Avoid sudden turns or swift movement of the handlebars.

SAFETY

Operator Safety

Always remove the ignition key when the vehicle is not in use to prevent unauthorized use or accidental starting.

Always keep combustible materials away from the exhaust system. Exposure of combustibles to hot components could result in a fire.

FOR MORE INFORMATION ABOUT QUADRICYCLE SAFETY,

call Polaris at 1-800-342-3764.

SAFETY

Safety Decals and Locations

Warning decals have been placed on the vehicle for your protection. Read and follow the instructions on each decal carefully. If a decal becomes illegible or comes off, contact your Polaris dealer to purchase a replacement. Replacement safety decals are provided by Polaris at no charge. The part number is printed on the decal.

Decal Text

Never operate this vehicle on hills steeper than 25 degrees. To prevent flipover on hilly terrain, when going up or down, use throttle and brakes gradually .

SAFETY

Safety Decals and Locations

NO STEP

7172566

WARNING

SAFETY

Safety Decals and Locations

Decal Text

NEVER ride as a passenger. Passengers can cause

a loss of control, resulting in SEVERE INJURY or DEATH.

TIRE PRESSURE IN PSI (KPa):

FRONT 5 (34.5) REAR 5 (34.5)

MAXIMUM WEIGHT CAPACITY (Gross Vehicle Weight)

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

MAXIMUM CARGO CAPACITY 200 LBS. (91 kg)

Read Owner’s Manual for more detailed loading information.

7173301

DO NOT TOW FROM RACK OR BUMPER.

Vehicle damage or tipover may result causing severe injury or death. Tow only from tow hooks or hitch. Max. Rack Loads: Front 75 lbs. (34 kg) Rear 125 lbs. (57 kg)

7172666

SAFETY

Safety Decals and Locations

Decal Text (H)

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

damage the engine.

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

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

S Specific carburetor jetting and adjustments are required depending

on temperature and altitude. See your Owner’s Manual. Factory setting: 40_ to 80_ F. at 0-3000 feet (5_ to 27_ C. at 0-900 meters).

OVERRIDE

SWITCH

Reverse speed is limited.

Reverse override is controlled by the override switch.

See your Owner’s Manual.

7079906

S Operation of this vehicle

without the air filter element will severely damage the engine.

S Clean pre-filter element often,

more frequent cleaning required in dusty conditions. Do not operate vehicle without pre-filter.

ATTENTION

S Specific

carburetor jetting

7170007

and adjustments are required depending on temperature and altitude. See your Owner’s Manual.

Factory setting:

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

SAFETY

Safety Decals and Locations

Hitch Decal

TRAILER MAX WEIGHT: 850 LBS. (386 KG) ON LEVEL GROUND

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

7170915

Recoil Decal

Recoil handle must be firmly seated to p revent water en try.

Drain starter mo tor if w ater enters. See owner ’s manual

7172562

SAFETY

Safe Riding Gear

Always wear protective clothing to reduce the chance of injury.

1. Helmet

Always wear a helmet that meets or exceeds established safety standards. A helmet can prevent a severe head injury.

2. Eye Protection

Wear shatterproof goggles or a shatterproof helmet face shield. Use a lens anti-fogging product to keep them clean.

3. Gloves

Wear off-road style gloves with knuckle pads.

4. Boots

Wear strong over-the-calf boots with heels, like moto-cross boots.

5. Clothing

Wear long sleeves and long pants to protect arms and legs. Riding pants with kneepads and a jersey with shoulder pads provide the best protection. Do not wear loose clothing that can get entangled in the vehicle, tree branches or shrubs.

SAFETY

Driving Safely

Driving Procedures

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

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

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

4. Release the parking brake.

5. Slowly squeeze the throttle lever toward the handlebar to begin driving. Squeeze the throttle lever further to increase speed.

6. Drive slowly. Practice maneuvering and using the throttle and brakes on level surfaces.

SAFETY

Driving Safely

Making Tu rns

1. To make a turn, steer in the direction of the turn, leaning your upper body to the inside of the turn while supporting your weight on the outer footrest. Use the same leaning technique for turning in reverse.

2. Practice turning at slow speeds before attempting to turn at faster speeds.

Never operate at excessive speeds. Travel and turn at speeds appropriate for the terrain, visibility, operating conditions and your experience.

Always follow the procedures outlined in this manual for turning. Never turn sharply at excessive speeds, which can lead to vehicle overturn.

SAFETY

Driving Safely

Driving on Slipp ery Surfaces

Whenever driving on slippery or loose surfaces such as wet trails, gravel, snow or ice, follow these precautions:

1. Slow down before driving onto slippery surfaces.

2. Use extra caution.

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

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

direction as the skid and shift body weight forward.

Always follow the procedures outlined in this manual for operating on slippery or loose surfaces. Use extra caution. Always avoid skidding or sliding.

SAFETY

Driving Safely

Driving Over Obstacles

1. Always check for obstacles before operating in a new area. Serious injury or death can result if your vehicle comes in contact with a hidden obstacle.

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

3. Never operate over large obstacles.

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

Always follow the procedures outlined in this manual for operating over obstacles.

SAFETY

Driving Safely

Driving Downhill

Whenever descending a hill, follow these precautions:

1. Check the terrain carefully.

2. Avoid hills with excessively slippery or loose surfaces.

3. Never go down a hill at high speed.

4. Slow down.

5. Avoid going down a hill at an angle, which can cause the vehicle to pitch sharply to one side.

6. Drive straight downhill.

7. Shift your weight rearward.

8. Apply the foot brake slightly toaidinslowing.

9. Know how to use the hand brake.

Always follow the procedures outlined in this manual for driving downhill and for braking on hills.

Never operate at excessive speeds. Travel and turn at speeds appropriate for the terrain, visibility, operating conditions and your experience.

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