Owners Manual
Page 18
... to support the weight and moving force of the vehicle, you and your cargo, together with soap and water and change clothing. • Turn the fuel valve off with any other vehicles in your vehicle. Always remove the ignition key when the vehicle is stored or parked. Allow a greater distance for your party. See page 26. Do not fill the tank neck. • If...
... to support the weight and moving force of the vehicle, you and your cargo, together with soap and water and change clothing. • Turn the fuel valve off with any other vehicles in your vehicle. Always remove the ignition key when the vehicle is stored or parked. Allow a greater distance for your party. See page 26. Do not fill the tank neck. • If...
Owners Manual
Page 30
...: For vehicle storage and when transporting. Refer to the engine starting procedure on page 32 for correct choke and throttle settings during starting a cold engine. FEATURES AND CONTROLS Choke The choke assists in starting . Fuel Tank Cap Always refuel with the engine stopped, and outdoors or in -line fuel filter should be replaced by your dealer after every 100 hours of 87=(R+ M/2) octane. Choke Fuel Gauge Fuel Tank Cap Fuel Valve The fuel valve is located...
...: For vehicle storage and when transporting. Refer to the engine starting procedure on page 32 for correct choke and throttle settings during starting a cold engine. FEATURES AND CONTROLS Choke The choke assists in starting . Fuel Tank Cap Always refuel with the engine stopped, and outdoors or in -line fuel filter should be replaced by your dealer after every 100 hours of 87=(R+ M/2) octane. Choke Fuel Gauge Fuel Tank Cap Fuel Valve The fuel valve is located...
Owners Manual
Page 33
... light loads. 7. Check the fluid level of the transmission after the first 25 hours of use. Vary the throttle positions. Pull only light loads. Fill the fuel tank with vehicle operation and handling. 4. PVT Break-in (Clutches/Belt) Break in the clutches and belt by operating at 25 hours. 8. Do not operate at full throttle or high speeds for these components. Change both the oil and the filter...
... light loads. 7. Check the fluid level of the transmission after the first 25 hours of use. Vary the throttle positions. Pull only light loads. Fill the fuel tank with vehicle operation and handling. 4. PVT Break-in (Clutches/Belt) Break in the clutches and belt by operating at 25 hours. 8. Do not operate at full throttle or high speeds for these components. Change both the oil and the filter...
Owners Manual
Page 34
... vehicle before operating increases the risk of an accident. Item Hand brake Brake fluid Foot brake Front suspension Rear suspension Steering/steering lock Tires Wheels/fasteners Frame nuts, bolts, fasteners Fuel and oil Throttle Indicator lights/switches Engine stop switch Mirrors Drive chain Air filter, pre-filter Air box sediment tube Headlamp Brake light/taillight Riding gear Remarks Ensure proper operation Ensure proper level Ensure proper operation Inspect, lubricate if necessary Inspect, lubricate if necessary Unlock the steering; ensure free operation Inspect condition...
... vehicle before operating increases the risk of an accident. Item Hand brake Brake fluid Foot brake Front suspension Rear suspension Steering/steering lock Tires Wheels/fasteners Frame nuts, bolts, fasteners Fuel and oil Throttle Indicator lights/switches Engine stop switch Mirrors Drive chain Air filter, pre-filter Air box sediment tube Headlamp Brake light/taillight Riding gear Remarks Ensure proper operation Ensure proper level Ensure proper operation Inspect, lubricate if necessary Inspect, lubricate if necessary Unlock the steering; ensure free operation Inspect condition...
Owners Manual
Page 48
... gravity of the operator, accessories, loads in the rack or box and the load on the trailer tongue. CARRY LOADS AS LOW ON THE RACK AS POSSIBLE. When handling off-centered loads that extend over rough or hilly terrain, reduce speed and cargo to the vehicle, include the weight of the vehicle and creates a less stable operating condition. Unsecured loads can create...
... gravity of the operator, accessories, loads in the rack or box and the load on the trailer tongue. CARRY LOADS AS LOW ON THE RACK AS POSSIBLE. When handling off-centered loads that extend over rough or hilly terrain, reduce speed and cargo to the vehicle, include the weight of the vehicle and creates a less stable operating condition. Unsecured loads can create...
Owners Manual
Page 53
... authorized POLARIS dealer perform these services. Perform all services at whichever maintenance interval is reached first. Item Maintenance Interval (whichever comes first) Hours Calendar Steering Front suspension Rear suspension Tires Brake fluid level Brake lever travel Brake system Drive chain Wheels/fasteners Frame fasteners Engine oil level Ź Air filter, pre-filter E Air box sediment tube Headlamp/tail lamp Ź Air filter, main E element Recoil housing (if applicable) Ź Brake pad wear D Daily Daily Daily Weekly Weekly Pre-Ride Miles (Km...
... authorized POLARIS dealer perform these services. Perform all services at whichever maintenance interval is reached first. Item Maintenance Interval (whichever comes first) Hours Calendar Steering Front suspension Rear suspension Tires Brake fluid level Brake lever travel Brake system Drive chain Wheels/fasteners Frame fasteners Engine oil level Ź Air filter, pre-filter E Air box sediment tube Headlamp/tail lamp Ź Air filter, main E element Recoil housing (if applicable) Ź Brake pad wear D Daily Daily Daily Weekly Weekly Pre-Ride Miles (Km...
Owners Manual
Page 54
... cap, lines, fuel valve, filter, pump, carburetor; test Inspect; replace lines every two years Ź Perform these services. 51 E Emission-Related Service D Have an authorized POLARIS dealer perform these procedures more often for vehicles subjected to storage Inspect; adjust; MAINTENANCE Periodic Maintenance Chart Item Maintenance Interval (whichever comes first) Hours Calendar Battery Ź Engine breather E filter (if equipped) Ź Engine oil change Ź Transmission oil Ź General lubrication Carburetor float bowl D Throttle Cable/ E Throttle Release Switch...
... cap, lines, fuel valve, filter, pump, carburetor; test Inspect; replace lines every two years Ź Perform these services. 51 E Emission-Related Service D Have an authorized POLARIS dealer perform these procedures more often for vehicles subjected to storage Inspect; adjust; MAINTENANCE Periodic Maintenance Chart Item Maintenance Interval (whichever comes first) Hours Calendar Battery Ź Engine breather E filter (if equipped) Ź Engine oil change Ź Transmission oil Ź General lubrication Carburetor float bowl D Throttle Cable/ E Throttle Release Switch...
Owners Manual
Page 70
... vehicles with the valve stem toward the outside and the rotation arrows on the tire pointing toward forward rotation. 2. Always ensure that have a cotter pin installed. Lower the vehicle to specification (page 68). Torque the wheel nuts to the ground. 4. Lock the parking brake. 2. Remove the wheel. Position the vehicle on the wheels. 3. Remove the wheel nuts. 5. Place the wheel on the wheel hub with tapered rear wheel nuts...
... vehicles with the valve stem toward the outside and the rotation arrows on the tire pointing toward forward rotation. 2. Always ensure that have a cotter pin installed. Lower the vehicle to specification (page 68). Torque the wheel nuts to the ground. 4. Lock the parking brake. 2. Remove the wheel. Position the vehicle on the wheels. 3. Remove the wheel nuts. 5. Place the wheel on the wheel hub with tapered rear wheel nuts...
Owners Manual
Page 74
.... Carburetor/Engine Idle RPM Adjustment If the engine idle speed is calibrated at the factory for optimal performance at altitudes ranging from your area. Although this power cannot be adjusted. 1. Place the transmission in your POLARIS dealer, are favorable, the carburetor can be regained, adjustments to the carburetor and drive system can cause poor performance, overheating or PVT or engine damage. Start the engine and allow...
.... Carburetor/Engine Idle RPM Adjustment If the engine idle speed is calibrated at the factory for optimal performance at altitudes ranging from your area. Although this power cannot be adjusted. 1. Place the transmission in your POLARIS dealer, are favorable, the carburetor can be regained, adjustments to the carburetor and drive system can cause poor performance, overheating or PVT or engine damage. Start the engine and allow...
Owners Manual
Page 78
MAINTENANCE Lights Headlight Beam Adjustment The headlight beam can be two inches (5 cm) below the mark on the wall at the same height. Position the vehicle on the seat when measuring. 5. Include rider weight on a level surface with the headlight approximately 25 ft. (7.6 m) from the floor to the center of the headlight beam should be adjusted slightly upward or downward. Lock the parking brake. 4. The...
MAINTENANCE Lights Headlight Beam Adjustment The headlight beam can be two inches (5 cm) below the mark on the wall at the same height. Position the vehicle on the seat when measuring. 5. Include rider weight on a level surface with the headlight approximately 25 ft. (7.6 m) from the floor to the center of the headlight beam should be adjusted slightly upward or downward. Lock the parking brake. 4. The...
Owners Manual
Page 79
... the bulb housing and turn it counterclockwise to the light bulb socket before servicing. Wash the headlights and taillights frequently. Remove the wire harness connector from your skin leaves a residue, causing a hot spot that will shorten the life of the lamp. Reinstall the connector to the back of the lamp. 1. Oil from the back of control or an accident. MAINTENANCE Lights Poor lighting...
... the bulb housing and turn it counterclockwise to the light bulb socket before servicing. Wash the headlights and taillights frequently. Remove the wire harness connector from your skin leaves a residue, causing a hot spot that will shorten the life of the lamp. Reinstall the connector to the back of the lamp. 1. Oil from the back of control or an accident. MAINTENANCE Lights Poor lighting...
Owners Manual
Page 95
.... Old or reused cloths and pads may contain dirt particles that may damage components and could remove paint and decals. Avoid directing the water stream at no charge. Replacement safety labels are provided by POLARIS at the following items: • Wheel bearings • Electrical components/wiring • Radiator (if equipped) • Switches and controls • Transmission seals • Cab and body panels • Brakes • Labels and decals...
.... Old or reused cloths and pads may contain dirt particles that may damage components and could remove paint and decals. Avoid directing the water stream at no charge. Replacement safety labels are provided by POLARIS at the following items: • Wheel bearings • Electrical components/wiring • Radiator (if equipped) • Switches and controls • Transmission seals • Cab and body panels • Brakes • Labels and decals...
Owners Manual
Page 98
... pre-measured amount of the spark plug cap. Reinstall the spark plug. Torque to the inside of oil. 4. To eliminate any fuel remaining in the Periodic Maintenance Chart beginning on page 49. • Demand drive unit (if equipped) • Transmission • Brake fluid (change every two years and any time the fluid looks dark or contaminated) Fog the Engine 1. Apply dielectric grease to specification. 5. Oil will be completely drained...
... pre-measured amount of the spark plug cap. Reinstall the spark plug. Torque to the inside of oil. 4. To eliminate any fuel remaining in the Periodic Maintenance Chart beginning on page 49. • Demand drive unit (if equipped) • Transmission • Brake fluid (change every two years and any time the fluid looks dark or contaminated) Fog the Engine 1. Apply dielectric grease to specification. 5. Oil will be completely drained...
Owners Manual
Page 101
... a stopped control and vehicle overturn. Operate 5 miles (8 km) or more when temperature is below 30 mph (48 warm up belt km/h) for one mile (1.6 km). TROUBLESHOOTING Drive Belt Wear/Burn Possible Cause Starting out going up a steep incline Driving at low RPM or ground speed (3-7 MPH) Insufficient warm-up at least 5 minutes. Use the throttle quickly and effectively. Inspect clutch seals for fouled plugs or...
... a stopped control and vehicle overturn. Operate 5 miles (8 km) or more when temperature is below 30 mph (48 warm up belt km/h) for one mile (1.6 km). TROUBLESHOOTING Drive Belt Wear/Burn Possible Cause Starting out going up a steep incline Driving at low RPM or ground speed (3-7 MPH) Insufficient warm-up at least 5 minutes. Use the throttle quickly and effectively. Inspect clutch seals for fouled plugs or...
Owners Manual
Page 105
SPECIFICATIONS TRAIL BOSS 330 INTERNATIONAL Maximum Weight Capacity Dry Weight Fuel Capacity Engine Oil Capacity Transmission Oil Front Rack Capacity Rear Rack Capacity Hitch Tongue Weight Capacity Hitch Towing Rating Unbraked Trailer Towing Capacity* Overall Length Overall Width Overall Height Wheelbase Ground Clearance Minimum Turning Radius Engine Model Number/Type Lubrication Engine Cooling Displacement Bore x Stroke Alternator Output Compression Ratio Carburetor Pilot Jet Main Jet Needle Jet Jet Needle Pilot Air Jet Pilot Screw Ignition System Ignition Timing Idle RPM Spark Plug / Gap * ...
SPECIFICATIONS TRAIL BOSS 330 INTERNATIONAL Maximum Weight Capacity Dry Weight Fuel Capacity Engine Oil Capacity Transmission Oil Front Rack Capacity Rear Rack Capacity Hitch Tongue Weight Capacity Hitch Towing Rating Unbraked Trailer Towing Capacity* Overall Length Overall Width Overall Height Wheelbase Ground Clearance Minimum Turning Radius Engine Model Number/Type Lubrication Engine Cooling Displacement Bore x Stroke Alternator Output Compression Ratio Carburetor Pilot Jet Main Jet Needle Jet Jet Needle Pilot Air Jet Pilot Screw Ignition System Ignition Timing Idle RPM Spark Plug / Gap * ...
Owners Manual
Page 106
... Drive Ratio, Final Drive Chain Tires/Pressure, Front Tires/Pressure, Rear Front Suspension Rear Suspension Shock Adjustment Brakes, Front and Rear Brake, Auxiliary Brake, Parking Headlight Taillights Brake Light Battery Indicators Automatic PVT (POLARIS Variable Transmission) Side Lever (F/N/R) 3.05:1 2.68:1 3.64:1 520 O-Ring 23 x 8-12 (5 psi/34.5 kPa) 22 x 11-10 (5 psi/34.5 kPa) MacPherson strut with 8.2" (21 cm) travel Progressive rate with 10.5" (26.7 cm) travel CAM Single-Control Hydraulic Disc Foot-Activated Hydraulic Disc, Rear Wheel Hydraulic lock...
... Drive Ratio, Final Drive Chain Tires/Pressure, Front Tires/Pressure, Rear Front Suspension Rear Suspension Shock Adjustment Brakes, Front and Rear Brake, Auxiliary Brake, Parking Headlight Taillights Brake Light Battery Indicators Automatic PVT (POLARIS Variable Transmission) Side Lever (F/N/R) 3.05:1 2.68:1 3.64:1 520 O-Ring 23 x 8-12 (5 psi/34.5 kPa) 22 x 11-10 (5 psi/34.5 kPa) MacPherson strut with 8.2" (21 cm) travel Progressive rate with 10.5" (26.7 cm) travel CAM Single-Control Hydraulic Disc Foot-Activated Hydraulic Disc, Rear Wheel Hydraulic lock...
Owners Manual
Page 107
SPECIFICATIONS TRAIL BLAZER 330 INTERNATIONAL Maximum Weight Capacity Dry Weight Fuel Capacity Engine Oil Capacity Transmission Oil Front Rack Capacity (Accessory) Rear Rack Capacity (Accessory) Hitch Tongue Weight Capacity Hitch Towing Rating Unbraked Trailer Towing Capacity* Overall Length Overall Width Overall Height Wheelbase Ground Clearance Minimum Turning Radius Engine Model Number/Type Lubrication Engine Cooling Displacement Bore x Stroke Alternator Output Compression Ratio Carburetor Pilot Jet Main Jet Needle Jet Jet Needle Pilot Air Jet Pilot Screw Ignition System Ignition Timing ...
SPECIFICATIONS TRAIL BLAZER 330 INTERNATIONAL Maximum Weight Capacity Dry Weight Fuel Capacity Engine Oil Capacity Transmission Oil Front Rack Capacity (Accessory) Rear Rack Capacity (Accessory) Hitch Tongue Weight Capacity Hitch Towing Rating Unbraked Trailer Towing Capacity* Overall Length Overall Width Overall Height Wheelbase Ground Clearance Minimum Turning Radius Engine Model Number/Type Lubrication Engine Cooling Displacement Bore x Stroke Alternator Output Compression Ratio Carburetor Pilot Jet Main Jet Needle Jet Jet Needle Pilot Air Jet Pilot Screw Ignition System Ignition Timing ...
Owners Manual
Page 108
SPECIFICATIONS TRAIL BLAZER 330 INTERNATIONAL Driving System Type Shift Type Gear Reduction, Reverse Gear Reduction, Forward Drive Ratio, Final Drive Chain Tires/Pressure, Front Tires/Pressure, Rear Front Suspension Rear Suspension Shock Adjustment Brakes, Front and Rear Brake, Auxiliary Brake, Parking Headlight Taillights Brake Light Battery Indicators Automatic PVT (POLARIS Variable Transmission) Side Lever (F/N/R) 3.05:1 2.68:1 3.64:1 520 O-Ring 23 x 8-12 (5 psi/34.5 kPa) 22 x 11-10 (5 psi/34.5 kPa) MacPherson strut with 8.2" (21 cm) travel Progressive rate with 10.5" (26.7 cm) travel CAM ...
SPECIFICATIONS TRAIL BLAZER 330 INTERNATIONAL Driving System Type Shift Type Gear Reduction, Reverse Gear Reduction, Forward Drive Ratio, Final Drive Chain Tires/Pressure, Front Tires/Pressure, Rear Front Suspension Rear Suspension Shock Adjustment Brakes, Front and Rear Brake, Auxiliary Brake, Parking Headlight Taillights Brake Light Battery Indicators Automatic PVT (POLARIS Variable Transmission) Side Lever (F/N/R) 3.05:1 2.68:1 3.64:1 520 O-Ring 23 x 8-12 (5 psi/34.5 kPa) 22 x 11-10 (5 psi/34.5 kPa) MacPherson strut with 8.2" (21 cm) travel Progressive rate with 10.5" (26.7 cm) travel CAM ...
Owners Manual
Page 116
... Engine Fogging...95 Engine Idle RPM Adjustment...71 Engine Oil ...54-55 Engine Stop Switch...20 Equipment Modifications ...5, 7 Exhaust Emission Control System . . 48 Eye Protection...9 F Fluid, Brake ...58-59 Foot Brake ...24 Fuel Filter ...27 Fuel Safety ...15 Fuel Tank Cap...27 Fuel Valve...27 C Camber Adjustment ...65 Carburetor ...71 Carburetor Adjustment ...71 Cargo...45-47 Caster Adjustment...65 Choke ...27 Chrome Wheel Care ...93 Cleaning and Storage ...91-96 Clothing ...9 Clutching Chart, TRAIL BOSS ...103 Clutching...
... Engine Fogging...95 Engine Idle RPM Adjustment...71 Engine Oil ...54-55 Engine Stop Switch...20 Equipment Modifications ...5, 7 Exhaust Emission Control System . . 48 Eye Protection...9 F Fluid, Brake ...58-59 Foot Brake ...24 Fuel Filter ...27 Fuel Safety ...15 Fuel Tank Cap...27 Fuel Valve...27 C Camber Adjustment ...65 Carburetor ...71 Carburetor Adjustment ...71 Cargo...45-47 Caster Adjustment...65 Choke ...27 Chrome Wheel Care ...93 Cleaning and Storage ...91-96 Clothing ...9 Clutching Chart, TRAIL BOSS ...103 Clutching...
Owners Manual
Page 117
... ...16 Rack Warning, Front and Rear ...17 Reverse Override Warning ...19 Tire Pressure/Load Alert...18 Safety Training ...5 Severe Use ...49 Side Panel Removal...61 Sidehilling ...38 Signal Words ...4 Spark Arrestor ...81 Spark Arrestor Requirements ...48 Spark Plugs ...78-79 Spring Adjustments, Rear ...65 Starting the Engine ...32-33 Steering Assembly...65 Steering Lock...26 M Maintenance Chart...49-52 Mirrors ...22 Modifications...5, 7 N Noise Emission Control System ...48 O Oil, Engine...54-55 Oil, Transmission...56-57 Oil Change, Engine ...55 Oil Level, Engine...54 Oil Recommendations...
... ...16 Rack Warning, Front and Rear ...17 Reverse Override Warning ...19 Tire Pressure/Load Alert...18 Safety Training ...5 Severe Use ...49 Side Panel Removal...61 Sidehilling ...38 Signal Words ...4 Spark Arrestor ...81 Spark Arrestor Requirements ...48 Spark Plugs ...78-79 Spring Adjustments, Rear ...65 Starting the Engine ...32-33 Steering Assembly...65 Steering Lock...26 M Maintenance Chart...49-52 Mirrors ...22 Modifications...5, 7 N Noise Emission Control System ...48 O Oil, Engine...54-55 Oil, Transmission...56-57 Oil Change, Engine ...55 Oil Level, Engine...54 Oil Recommendations...