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
2
TABLE OF CONTENTS
VEHICLE IDENTIFICATION NUMBERS . . . . . . . . . . . . . . . 5 SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 FEATURES AND CONTROLS . . . . . . . . . . . . . . . . . . . . . . 40 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 EMISSION CONTROL SYSTEMS . . . . . . . . . . . . . . . . . . . 60 MAINTENANCE AND LUBRICATION . . . . . . . . . . . . . . . . 61 POLARIS PRODUCTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108 WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111 MAINTENANCE RECORD . . . . . . . . . . . . . . . . . . . . . . . . 113 INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
3
4
VEHICLE IDENTIFICATION NUMBERS
Record your vehicle’s identification numbers and key number. Remove the spare key and store it in a safe place. Your key can be duplicated only by mating a Polaris key blank with one of your existing keys, so if both keys are lost, the ignition switch must be replaced.
31XX
3
2
Vehicle Model Number:
Frame VIN (1):
Engine Serial Number (2):
(right front side of engine crankcase)
Key Number (3):
5
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.
6
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.
7
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.
8
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 Quadri cycle.
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.
9
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 Quadri cycle.
Never operate at |
|
|
|
excessive speeds. Travel |
20 |
30 |
|
and turn at speeds |
|||
10 |
40 |
||
appropriate for the terrain, |
|||
visibility, operating |
0 |
50 |
|
conditions and your |
|
|
experience.
10
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.
11
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 Quadri |
cyclehas 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.
12
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 |
> 25_ |
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.
13
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.
14
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 Quadri cycle.
Maintain the proper tire pressure.
15
SAFETY
Operator Safety
Never modify a
Quadricycle through improper installation
or use of accessories.
Never exceed the stated |
|
|
|
|
load capacity for your |
|
2/3 |
2/3 |
|
Quadricycle. Cargo |
|
|||
1/3 |
1/3 |
|||
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 Quadri cycle and
could result in loss of control, accident, and/or injury.
Avoid sudden turns or swift movement of the
handlebars.
16
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.
17
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.
C
G
J
G
F
E
D
A H
B
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.
A
18
SAFETY
Safety Decals and Locations
B C
NO STEP
D
19
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.
WARNING
7172566
E
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
F
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
G
20
SAFETY
Safety Decals and Locations
S Operation of this vehicle |
ATTENTION |
S Specific |
||
|
||||
without the air filter |
|
carburetor jetting |
||
element will severely damage the |
and adjustments are required |
|||
engine. |
depending on temperature |
|||
S Clean pre-filter element often, |
and altitude. See your Owner’s |
|||
Manual. |
||||
more frequent cleaning |
||||
|
|
|||
required in dusty conditions. |
|
Factory setting: |
||
Do not operate vehicle without |
40 _to 80_ F. at 0-3000 feet |
|||
pre-filter. |
||||
(5_ to 27_ C. at 0-900 meters). |
||||
|
|
|||
|
|
7170007 |
||
H
Decal Text (H)
SOperation of this vehicle without the air filter element will severely damage the engine.
SClean pre-filter element often, more frequent cleaning required in dusty conditions. Do not operate vehicle without pre-filter.
SSpecific 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
J
21
SAFETY
Safety Decals and Locations
Hitch Decal
TRAILER MAX WEIGHT:
850 LBS. (386 KG) ON LEVEL GROUND
HITCH MAX. VERTICAL WEIGHT: 85 LBS. (39 KG)
7170915
Recoil Decal
Recoil handle must be firmly seated to prevent water entry.
Drain starter motor if water enters. See owner’s manual
7172562
22
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 |
2 |
|
||
Wear off-road style g |
loves 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.
23
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.
24
SAFETY
Driving Safely
Making Turns
1.To make a turn, steer in the direction of the turn, leaning your upper body to the inside of the turn while supporting your weight on the outer footrest. Use the same leaning technique for turning in reverse.
2.Practice turning at slow speeds before attempting to turn at faster speeds.
Never operate at |
|
|
|
excessive speeds. Travel |
20 |
30 |
|
and turn at speeds |
|||
10 |
40 |
||
appropriate for the terrain, |
|||
visibility, operating |
0 |
50 |
|
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.
25
SAFETY
Driving Safely
Driving on Slippery Surfaces
Whenever driving on slippery or loose surfaces such as wet trails, gravel, snow or ice, follow these precautions:
1.Slow down before driving onto slippery surfaces.
2.Use extra caution.
3.Be alert. Watch the trail. Avoid quick, sharp turns.
NOTE: To correct a rear wheel skid, turn the handlebars in the same direction as the skid and shift body weight forward.
Always follow the procedures outlined in this manual for
operating on slippery or loose surfaces. Use extra caution.
Always avoid skidding or sliding.
26
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.
27
SAFETY
Driving Safely
Driving Downhill
Whenever descending a hill, follow these precautions:
1.Check the terrain carefully.
2.Avoid hills with excessively slippery or loose surfaces.
3.Never go down a hill at high speed.
4.Slow down.
5.Avoid going down a hill at an angle, which can cause the
vehicle to pitch sharply to one side.
6.Drive straight downhill.
7.Shift your weight rearward.
8.Apply the foot brake slightly to aid in slowing.
9.Know how to use the hand brake.
Always follow the procedures outlined in this manual for driving
downhill and for braking on hills.
Never operate at |
|
|
|
excessive speeds. Travel |
20 |
30 |
|
and turn at speeds |
|||
10 |
40 |
||
appropriate for the terrain, |
|||
visibility, operating |
0 |
50 |
|
conditions and your |
|
|
experience.
28
Loading...