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Polaris Trail Boss 330 Quadricycle User's Manual

1. TROUBLESHOOTING Contact your Polaris dealer for service if you re unable to identify solutions using the following charts Possible Cause Solution Possible Cause Solution Engine Pings or Knocks Possible Cause Solution Poor quality or low octane fuel Replace with recommended fuel Incorrect spark plug gap or heat range Set gap to specs or replace plugs 105 TROUBLESHOOTING Possible Cause Solution Mechanical failure Engine Runs Irregularly Stalls or Misfires Possible Cause Solution Other mechanical failure Possible Lean Fuel Mixture Cause Solution Possible Rich Fuel Mixture Cause Solution 106 Kinked or plugged fuel vent line Inspect and replace TROUBLESHOOTING Engine Stops or Loses Power Possible Cause Solution Kinked or plugged fuel vent line Water present in fuel old fuel Overuse of choke Fouled or defective spark plugs Worn or defective spark plug wires Incorrect spark plug gap or heat range Loose ignition connections Low battery voltage Reverse speed limiter malfunction Electronic throttle control malfunction Other mechanical failure Overheated engine Clean radiator screen and core if equipped Clean engine exterior See your Polaris dealer 107 SPECIFICATIONS 2005 Trail Boss 330 Quadricycle Body Su Gros Vehicle WE Fst Capa Transmssion OF M 1 61 oil change only Front Rack Rear Rack Tongue WEE Towing Rating Unbraked Trailer Towing Capacit
2. e Clean pre filter element often more frequent cleaning required in dusty conditions Do not operate vehicle without pre filter e 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 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 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 pro
3. wes 4 CAUTION 10 11 12 Hot oil may result in serious burns Do not allow hot oil to contact skin Reinstall the drain plug with a new sealing washer g T 19 N m Place towels under the oil filter Using an oil filter wrench 4 turn the filter counterclockwise to remove it Clean the filter sealing area on the engine 69 MAINTENANCE AND LUBRICATION Oil and Filter Change 13 Lubricate the filter o ring 14 Install the new oil filter After the filter contacts the engine surface turn it 1 2 turn by hand 15 Remove the dipstick 4 y 16 Add two 95 liter bottles of 2 0W 40 oil VA 17 Reinstall the dipstick 18 Start the engine Allow it to idle for two minutes 19 Turn the engine off 20 Check for oil leaks 21 Check the oil level Add oil as needed to bring the level between the minimum MIN and maximum MAX marks lt gt 22 Discard used oil and filter properly 70 MAINTENANCE AND LUBRICATION Engine Oil Cooler Maintenance The oil cooling system requires little maintenance fae other than keeping the cooler 1 free of mud and debris CAUTION Do not use a high pressure washer to remove debris from the cooler The pressure may damage the cooling fins Use only low pressure water 71 MAINTENANCE AND LUBRICATION Transmission Oil Check See page 65 for recommended lubricants See page 103 for the part numbers of Polaris prod
4. 2 Slow down before driving onto slippery surfaces Use extra caution 3 Bealert Watch the trail Avoid quick sharp turns NOTE To correct a rear wheel skid turn the handlebars in the same 26 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 Bealert Watch the terrain Use extra caution Never operate over large obstacles ak 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 n Avoid going down a hill at an angle which can cause the vehicle to pitch sharply to one side Drive straight downhill Shift your weight rearward Apply the foot brake slightly to aid in slowing Know how to use the hand brake Always follow the procedures outlined in this manual for driving
5. 39 Driving Through Water 34 35 Driving Uphill 30 31 E Electromagnetic Interference 60 Electronic Throttle Control 42 EMISSION CONTROL SYSTEMS 60 Engine Fogging 101 Engine Stop Switch 41 Equipment Modifications 8 ETC bach seo bade he wat kg ee weet 42 Exhaust Emission Control System 60 Eye Protections as sS 23 116 F FEATURES AND CONTROLS 40 54 Foot Brake 44 Luel PAIGE vues xd ex 84 Fuel Stabilizer 100 Duel I30E oi vene rA Re tie ae 47 Fuel Valve ia iia ee AS 47 G Gear Selector i c DERE ra 48 H Handlebar Adjustment 77 Hauling Cargo 38 39 Hazard Warning Switch 43 86 Helmet 23 High Beam Adjustment 87 enor oie ee autre vd aea ees 42 Hour Meter lt onan osencdu hos tek 52 IMMELSION 5 csse 92 03 Indicator Lamp Replacement 88 Instrument Cluster 50 54 Instruments 4 2 es 40 43 J Jet ne hatt 22e 110 K 2492344 baw 22 L Light SWUNG 41 L M ETE 66 88 Lubrication Recommendations 65 M Main Switch 40 MAINTENANCE AND LUBRICATION 61 102 Maintenance Chart Key 61 MAINTENANCE RECORD 113 115 Making Turns 25 Master Cylinder Foot Brake TS Master Cylinder Han
6. Chain Always inspect the drive chain before operating the vehicle Check for damaged or missing o rings or damaged rollers Check for correct slack adjustment Maintain the stone guard to rear sprocket clearance at 3 mm Lubricate the outer surfaces of the roller regularly Lubricate the drive chain as outlined in the Lubrication Chart on page High pressure water may damage components Do not use high pressure water See page 99 Rear Drive Chain Slack Adjusting or operating the vehicle with improper rear drive chain slack can result in severe damage to the transmission and drive components Always make sure the slack is within the stated specifications Check the amount of chain slack in three different locations by moving the vehicle slightly forward Measure the chain slack at the tightest of the three positions At this point the chain should have 4 8 9 5 mm deflection Use the following procedure if adjustment is required 1 Loosen the chain guide 2 Loosen the two eccentric locking bolts 1 3 Loosen the caliper mounting bolt located on the left side of the swing arm 4 Insert a pin punch 2 through the sprocket hub and into the eccentric housing 83 MAINTENANCE AND LUBRICATION Drive Chain Rear Drive Chain Slack vp 10 Roll the vehicle forward or backward to adjust the chain slack to the proper tension See the illustration for proper splice link clip openi
7. TAL CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION WHETHER ARISING OUT OF EXPRESS IMPLIED WARRANTY OR ANY OTH ER CONTRACT NEGLIGENCE OR OTHER TORT OR OTHERWISE Some states do not permit the exclusion or limitation of incidental or consequential damages or implied warranties so the above limitations or exclusions may not apply to you if inconsistent with controlling state law 111 WARRANTY LIMITATIONS OF WARRANTIES AND REMEDIES ALL IMPLIED WARRANTIES INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE LIMITED IN DURATION TO THE ABOVE TWO YEAR WARRAN TY PERIOD POLARIS FURTHER DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY Some states do not allow limitations on how long an im plied warranty lasts so the above limitation may not apply to you if inconsistent with con trolling state law HOW TO OBTAIN WARRANTY SERVICE If your Quadricycle requires warranty service you must take it to a Polaris dealer authorized to repair Polaris Quadricycles When requesting warranty service you must present your copy of the Warranty Registration form to the dealer THE COST OF TRANSPORTA TION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY Polaris suggests that you use your original selling dealer however you may use any Polaris Servicing Dealer to perform warranty service Please work with your dealer to resolve any warranty issues Should your dealer requi
8. centered and operate with extra caution CARRYING A LOAD on only one rack may cause the vehicle to overturn Split the load between the front rack and rear rack with 1 3 in the front and 2 8 in the back Do not exceed load ca pacities See specifications beginning on page 108 e SECURE ALL LOADS BEFORE OPERATING Unsecured loads can create unstable operating conditions which could result in loss of control of the vehicle e OPERATE ONLY WITH STABLE AND SAFELY ARRANGED LOADS When handling off centered loads that cannot be centered securely fasten the load and operate with extra caution Always attach the tow load to the hitch point designated for your vehicle WHEN LOAD EXTENDS BEYOND RACK SIDES stability and maneuverability may be adversely affected causing the ma chine to overturn Use extreme caution e TOWING is approved OFF ROAD ONLY Operating a Quadri cycle trailer combination on public roads is prohibited TOWING SPEED should never exceed 16 km h Never exceed 8 km h when towing loads in rough terrain while cornering or while ascending or descending hills SAFETY Driving Safely Hauling Cargo and Towing Towing Towing is approved OFF ROAD ONLY Operating a Quadricycle trailer combination on public roads is prohibited Do not exceed the maximum capacities when towing Do not tow any trailer on a grade steeper than 15 Trail Boss 330 Maximum Towed Load Maximum Vertical Hitch QUADRICYCLE Level Gr
9. culo leia o manual do propriet rio Innan du k r detta fordon l s handboken SAFETY 19 SAFETY Safety Decals and Locations Decal Text AWARNING NEVER ride as a passenger NEVER ride as a passenger Passengers can cause a loss of control resulting e in cause in SEVERE INJURY or DEATH resultingin SEVERE INJURY or DEATH 7172566 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 Ibs 34 kg Rear 125 Ibs 57 kg 7172666 SAFETY Safety Decals and Locations Operation of this vehicle e Specific without the air filter carburetor jetting element will severely damage the and adjustments are required engine depending on temperature and altitude See your Owner s Manual Clean pre filter element often more frequent cleaning required in dusty conditions Factory setting Do not te vehicle with nee 40 to 80 F at 0 3000 feet pre filter 5 to 27 C at 0 900 meters 7170007 H Decal Text H e Operation of this vehicle without the air filter element will severely damage the engine
10. lights from high beam to low beam NOTE The lights do not operate unless the main key switch is on and the engine stop switch is in the RUN position 5b Throttle lever Press the throttle lever to increase engine speed and vehicle movement Release the lever to reduce engine speed and vehicle movement 4 WARNING Failure to check or maintain proper operation of the throttle system can result in an accident if the throttle lever sticks during operation Check the lever for proper operation before starting the engine Check occasionally during operation Do not start or operate a Quadricycle with sticking or improperly operating throttle controls Contact your dealer for repair if throttle problems arise 41 FEATURES AND CONTROLS Controls Instruments UA 0 6 Electronic Throttle Control ETC 6 ETC causes the engine to stop if the throttle cable sticks in an open position when the operator releases the throttle lever 4 WARNING The Electronic Throttle Control ETC stops the engine in the event of a throttle system malfunction Do not modify the ETC system or replace it with other throttle mechanisms 7 Choke Knob The choke assists in starting a cold engine See page 57 8 Horn Pe Press the horn button to alert others of your presence 42 FEATURES AND CONTROLS Controls Instruments 9 Hazard Warning Switch Push the hazard warning switch to cause all turn i
11. of bacterial growth in the fuel system Allow 15 20 minutes of operation for the stabilizer to disperse through the fuel in the tank and carburetor 3 Turn the fuel valve off 4 Drain the carburetor bowl Change Oil and Filter Change the oil and filter See page 68 Air Filter Air Box Inspect and clean or replace the pre cleaner and air filter Clean the air box and drain the sediment tube See page 85 Check Change Fluids Inspect fluid levels and change fluids if necessary e Transmission oil e Engine oil Brake fluid Drain the Recoil Housing See page 89 Battery Storage Remove the battery Make sure that it s fully charged See page 97 100 MAINTENANCE AND LUBRICATION Storing the Vehicle Engine Fogging Use Polaris Engine Fogging Oil Follow label directions carefully CAUTION Starting the engine during the storage period will disturb the protective oil film which can lead to engine damage Never start the engine during the storage period Storage Area Cover 1 Make sure tire pressure is at specification 2 Using suitable supports under the frame raise the vehicle slightly so that the tires are not touching the ground 3 sure the storage area is well ventilated 4 Cover the machine with an appropriate cover Do not use plastic or coated materials as they do not allow proper ventilation to prevent condensation corrosion and oxidation Accessories Auxiliary power outlets provi
12. purging 1 Remove the arrestor clean out plug from the bottom of the muffler 2 Place the transmission in neutral 3 Lock the mechanical parking brake 4 Start the engine 94 MAINTENANCE AND LUBRICATION Spark Arrestor 5 Quickly squeeze and release the throttle lever several times to purge carbon from the system 6 carbon comes out of the exhaust cover or plug the exhaust outlet 1 Wear leather gloves for protection 7 Lightly tap on the exhaust pipe with a rubber mallet while repeating step 5 8 If particles are still suspected to be in the muffler elevate the rear of the vehicle 30 cm higher than the front 9 Lock the mechanical parking brake 10 Block the wheels 11 Repeat steps 5 to 7 until no more particles are expelled 12 Turn the engine off Allow the arrestor to cool 13 Reinstall the arrestor plug and remove the exhaust outlet cover or plug 95 MAINTENANCE AND LUBRICATION Battery 4 WARNING Improperly connecting or disconnecting battery cables can cause sparks which could result in an explosion causing serious injury or death When removing the battery always disconnect the negative black cable first When reinstalling the battery always connect the negative black cable last Battery Removal 1 2 LEE Place the transmission in gear Lock the mechanical parking brake Disconnect the battery hold down strap Remove the battery cov
13. spark plug wire 1 Use the spark plug wrench 2 to remove the spark plug 3 Turn the plug counterclockwise to remove it 3 Inspect the electrodes for wear and carbon buildup Replace worn or fouled plugs Verify that the gap is at specification before installation 4 Reinstall the spark plug T 19 N m 5 Reinstall the spark plug wire 90 78 Q Ai ay 19 N m MAINTENANCE AND LUBRICATION Spark Plugs Spark Plug Condition Normal The insulator tip is tan or brown There are few combustion deposits The electrodes are not burned or eroded This indicates the proper type and heat range for the engine and the service NOTE The tip should not be white A white insulator tip indicates overheating caused by use of an improper spark plug or incorrect carburetion adjustments Fouled The insulator tip is black A damp film covers the firing end There may be a carbon layer over the entire nose Generally the electrodes are not worn General causes of fouling are excessive oil consumption improper use of the choke or incorrect carburetion adjustments 91 MAINTENANCE AND LUBRICATION Vehicle Immersion CAUTION If the vehicle stops while fully submerged major engine damage can result if the machine is not thoroughly inspected Take the vehicle to your dealer before starting the engine If your vehicle has been totally submerged in water and it s impossible to have it serviced be
14. spark arrestor that was designed for on road and off road operation It is required that this spark arrestor remain installed and functional when the vehicle is operated Crankcase Emission Control System This engine is equipped with a closed crankcase system Blow by gases are forced back to the combustion chamber by the intake system The system does not allow the blow by gases to enter the atmosphere Exhaust Emission Control System The emissions from the exhaust of this vehicle are controlled by engine design including factory set fuel delivery and ignition The engine and related components must be maintained at Polaris specifications to achieve optimal performance The emissions label 1 is located on the recoil cover Adjustment to engine idle is the only adjustment recommended that the operator perform Any other adjustments should be performed by an authorized Polaris dealer Electromagnetic Interference This spark ignition system complies with USA requirements Canadian ICES 002 and European directives 89 336 EEC and 97 24 EC 60 MAINTENANCE AND LUBRICATION Periodic Maintenance Chart Maintenance intervals in the following chart are based upon average riding conditions Vehicles subjected to severe use must be inspected and serviced more frequently severe Use Definition e Frequent immersion in mud water or sand e Racing or race style high RPM use Prolonged low speed heavy load operatio
15. the mode button override button until the total changes to 0 NOTE The trip meter displays a decimal point but the odometer does not Mode 3 Hour Meter The hour meter logs the total hours the engine has been in operation Mode 4 Tachometer The tachometer displays engine RPM Small fluctuations in the RPM are normal due to changes in humidity temperature and elevation 52 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode The diagnostic mode is for informational purposes only Please return your Quadricycle to your dealer for all major repairs The wrench icon will display when the gauge is in the diagnostic mode Steps to enter the diagnostic mode Turn the main key switch off and wait 10 seconds Shift the transmission into neutral or park Hold the mode button and turn the main Key switch on Release the switch as soon as the display is activated Use the mode button to toggle through the six 6 diagnostic screens Three 3 ways to leave the diagnostic mode n e Shift the transmission out of neutral e Turn the main key switch off and on e Move the tires Screen 1 Battery voltage Screen 2 Tachometer Screen 3 AWD diagnostic This screen indicates whether or not current is flowing through the AWD system Screen 4 Gear circuit diagnostic This screen displays the resistance value in ohms being read at the gear switch input o3 FEATURES AND
16. very important in ensuring trouble free operation Purchasing a machine in the crate or without proper dealer set up will void your warranty coverage LIMITATIONS OF WARRANTIES AND REMEDIES The Polaris limited warranty excludes any failures that are not caused by a defect in material or workmanship This warranty does not cover accidental damage normal wear and tear abuse or improper handling This warranty also does not cover any Quadricycle that has been altered structurally modified neglected improperly maintained used for racing or used for purposes other than for which it was manufactured orfor any damages which occur during trailer transit or as a result of unauthorized service or the use of unauthorized parts In addition this warranty does not cover physical damage to paint or finish stress cracks tearing or puncturing of upholstery material corrosion or defects in parts components or the vehicle due to fire explosions or any other cause beyond Polaris control This warranty does not cover the use of unauthorized lubricants chemicals or fuels that are not compatible with the Quadricycle The exclusive remedy for breach ofthis warranty shall be at Polaris exclusive option repair or replacement of any defective materials or compo nents or products THE REMEDIES SET FORTH IN THIS WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WAR RANTY POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDEN
17. CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode Screen 5 Programmable service interval The programmable service interval provides a convenient reminder when routine maintenance is due This feature is pre set at 50 hours You must enable the programmable service interval before it can be used When set the hours of operation are subtracted from the set hours until 0 is reached The wrench icon will flash quickly for five seconds each time the engine is started as a reminder that service is due Setting the Service Interval 1 Press and hold the mode override button until the wrench icon flashes Release the button 2 Press the button once to advance the setting by one hour Press and hold the button to advance the hours at a faster pace 3 When the desired time increment is displayed release the button When the wrench stops flashing service hours are set NOTE If you scroll past the intended number hold the button down until the count turns over to O You can then reset the number Disabling the Service Interval 1 Toggle to the service interval mode 2 Press and hold the mode button for approximately seven 7 seconds The service interval is disabled when the word OFF displays Screen 6 Miles Kilometers toggle The display in the tripmeter and odometer can be changed to display either kilometers or miles The current display mode will be shown as either KM or MP 1 Press and hold th
18. Handlebar The master cylinder 1 is located on the left handlebar View the fluid level through the indicator window eye on the top of the master cylinder A dark eye 2 indicates a full fluid level A clear eye 3 indicates a low fluid level Master Cylinder Foot Brake The foot brake master cylinder 4 is located under the right rear fender View the fluid level through the reservoir body Fluid level is full at the MAX mark Add brake fluid if the level reaches the MIN mark 4 WARNING Once open a bottle of brake fluid absorbs moisture from the air which causes the boiling temperature of the brake fluid to drop This can lead to early brake fade and the possibility of accident Do not store opened brake fluid Properly discard any unused portion 19 MAINTENANCE AND LUBRICATION Steering Suspension Toe Alignment Use the following procedure to check the toe alignment of the vehicle The recommended toe alignment is 3 6 mm toe out 1 Set the handlebars in a 8 i straight ahead position 2 Place stands 1 in front of the vehicle perpendicular to the Ss Se rear tires SS 4 S 3 Tie an elastic string around the stands making sure the string just touches the side surface of the rear tires on each side of the vehicle and goes around the stands in front of the vehicle 2 4 Measure the distance from the string to the rim a
19. 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 Ifa 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 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 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 bac
20. MM S S S 2005 Trail Boss Quadricycle Owner s Manual for Maintenance and Safety a The Way Out Read this manual carefully It contains important safety information This is an adult vehicle only Operation is prohibited for those under 16 years of age Before you operate this vehicle read the owner s manual Lesen Sie die Bedienungsanleitung bevor Sie dieses Fahrzeug fahren Antes de conducir este vehiculo lea el Manual del Propietario Lire le manuel du propri taire avant d utiliser ce v hicule Prima di usare il veicolo leggete il manuale di istruzioni Lue aina kayttoohjekirja ennen taman ajoneuvon k ytt Antes de utilizar este ve culo leia o manual do propriet rio Innan du k r detta fordon l s handboken CD CE CID FID CP CS 7173025 For your nearest Polaris dealer C POLARIS call 1 800 POLARIS u Ine Srey anes or visit www polarisindustries com Polaris Sales Inc 2100 Hwy 55 Medina MN 55340 U S A Phone 1 763 417 8650 Fax 1 763 542 0599 Part No 9919822 Rev 01 Printed in U S A A GA d For 50 years we ve been AED ES s helping Polaris customers EE find The Way Out LA a i It s been a fun ride But then after all these years That s what we re all about Visit our Web site at www polarisindustries com POLARIS The Way Out C v F ae Tow a j I Copyright 2004 Pola
21. Spring Spring Setting Meters 0 1800 10RH Blue Green Black 40 5630709 7041157 7041782 5131446 242 1800 3700 20 40 Blue Green Black 40 5631356 7041157 7041782 5131446 2 2 110 WARRANTY LIMITED WARRANTY Polaris Industries Inc 2100 Highway 55 Medina MN 55340 gives a TWO YEAR LIM ITED WARRANTY on all components of the Polaris Quadricycle against defects in materi al or workmanship This warranty covers the parts and labor charges for repair or replacement of defective parts which are covered by this warranty This warranty begins on the date of purchase This warranty is transferrable to another consumer during the warranty period through a Polaris dealer REGISTRATION At the time of sale the Warranty Registration Form must be completed by your dealer and submitted to Polaris within ten days Upon receipt of this registration Polaris will record the registration for warranty THE PURCHASER MUST COMPLETE A QUADRI CYCLE SAFETY TRAINING COURSE PROVIDED BY THE DEALER IN ORDER TO HAVE VALID WARRANTY ON THE QUADRICYCLE No verification of registra tion will be sent to the purchaser as the copy of the Warranty Registration Form will be the warranty entitlement If you have not signed the original registration and received the cus tomer copy please contact your dealer immediately NO WARRANTY COVERAGE WILL BE ALLOWED UNLESS YOUR QUADRICYCLE IS REGISTERED WITH PO LARIS Initial dealer preparation and set up of your vehicle is
22. aillight socket counterclockwise to remove it Remove the lamp Apply dielectric grease to the socket Install the new lamp Test the lamp for proper operation Reinstall all components in reverse order Rotate the turn signal socket counterclockwise to remove it 05 SKS Remove the lamp Apply dielectric grease to the socket Install the new lamp Test the lamp for proper operation Reinstall all components in reverse order Indicator Lamp Replacement 1 2 gt 88 Remove the instrument panel Using a small straight blade screwdriver turn the base of the bulb 1 4 turn counterclockwise Remove the lamp Use a needle nose plier or similar tool Install the new lamp Turn the lamp clockwise 1 4 turn Reinstall the instrument panel MAINTENANCE AND LUBRICATION Recoil Housing Drain Always drain the recoil housing 1 after operating the vehicle in wet conditions Always remove the drain plug before storing the vehicle NOTE Water will enter the recoil housing if the starter handle 2 is disengaged from the rope guide when under water 1 Place the transmission in gear Lock the mechanical parking brake 3 Using a wrench remove the drain screw 3 on the bottom of the recoil housing 4 Reinstall the screw after draining the housing 89 MAINTENANCE AND LUBRICATION Spark Plugs 1 Remove the left side panel See page 80 2 Remove the
23. ain 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 4 amp WARNING Serious injury or death can result if you do not follow the instructions and procedures listed here and throughout this manu
24. al 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 10 SAFETY Operator Safety Never attempt wheelies jumps or other stunts amp 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
25. arting the Engine 57 58 SIGEHBP 2 04 stesse Eae cero 76 Steering Assembly 77 LOCK aas 46 SOP S WIHCD GC aed Ee 41 Storing the Vehicle 100 101 SUSPENSION ic os e vx er aU dau 76 Symbol Identification 65 T TABLE OF CONTENTS 3 Tachom ier Eee sith sas 22 Tale pce detta ded teen 88 Throttle Cable Freeplay 79 Throttle lever eei e E ERE 41 Tire Tread Deptli i sin 82 Ri pc esata 82 Toe Alignment 76 Torque Symbol 65 TONE orian Soda SiS 38 39 TransmisSiOfia 2 orte as 59 Transmission Oil Change 73 Transmission Oil Check 72 Transporting the Vehicle 102 Tp Melt o eva gad a enne es 52 TROUBLESHOOTING 104 107 Turn Indicator iud ep hoe Sees 43 Turning Around on a Hill 32 33 V VEHICLE IDENTIFICATION NUMBERS lt 522 Wiese WES 5 Vehicle Immersion 92 93 W E teeny 111 112 Waxing the Vehicle 99 Wheel Hub Tightening 82 Wheel Installation 81 Wheel Removal 117
26. ble adjuster until they touch at the idpoint of the adjuster midpoint of the adjuster 3 c Locate the throttle cable adjuster 1 on the handlebar Slide the boots 2 off the cable adjuster sleeve 3 Loosen the adjuster 4 Turn the adjuster until 1 6 3 2 mm of freeplay exists at the lever NOTE Move the throttle lever back and forth while adjusting t 1 6 3 2 mm NOTE Engine RPM should not increase when steering is turned full left or right Readjust cable freeplay if this 7 N OCCUIS 2 2 MAINTENANCE AND LUBRICATION Side Panel Removal NOTE Side panel removal may be difficult until the locking tabs and receivers have been snapped and unsnapped a few times 1 Remove the seat Grasp the rear of the side panel near the rear cab Pull the panel forward and outward quickly and firmly to disengage the rear tabs 3 Place your hand on top of the side panel behind the fuel tank Push down quickly and firmly to disengage the top rear tabs 4 Pull the side panel upward to disengage the front tabs Reinstallation 5 Align the tabs with the slots on the front cab 6 Push the panel upward and forward until the tabs lock 7 Bend the rear of the side panel and insert the two tabs into the rear cab slots 80 MAINTENANCE AND LUBRICATION Wheel Removal Installation CAUTION Operating with improperly installed wheels will affect vehicle handling and c
27. d on a hill Always block the wheels to prevent rolling Locking the Parking Brake Hydraulic The hydraulic parking brake lock is a temporary lock Do not rely on the hydraulic parking brake when leaving the vehicle unattended Always lock the mechanical parking brake 1 2 Move the park brake lock 2 to Squeeze the left brake lever 1 the locked position This will prevent the lever from returning to the released position To release the parking brake lock squeeze and release the brake lever The parking brake will release automatically 45 FEATURES AND CONTROLS Steering Lock 7 Lock the steering to prevent unauthorized use or theft of the vehicle 1 Turn the handlebars to the full left position 2 Insert the steering lock key and turn it clockwise 3 Remove the key 4 Reverse the procedure to unlock the steering NOTE Place the steering lock keys in a safe place The lock must be replaced if the keys are lost 46 FEATURES AND CONTROLS Fuel Tank The fuel tank filler cap 1 is located directly below the handlebar Refuel with either leaded or unleaded gasoline with a minimum of 87 octane 4 WARNING e Gasoline is highly flammable and explosive under certain conditions e Use extreme caution whenever handling gasoline e Refuel with the engine stopped Refuel outdoors or in a well ventilated area e Never fill a fuel container while it s in the cargo box Static e
28. de 12V power for operating accessories such as hand held spot lights See your Polaris dealer for more information about accessories 101 MAINTENANCE AND LUBRICATION Transporting the Vehicle Follow these procedures when transporting the vehicle 1 Turn the engine off Remove the key to prevent loss during transporting 2 Place the transmission in gear 3 Lock the mechanical parking brake 4 Turn the fuel valve off 5 sure the fuel cap oil cap and seat are installed correctly 6 Attach the FRAME of the Quadricycle to the transporting unit securely using suitable straps or rope 102 POLARIS PRODUCTS Part No Description Engine Lubricant Fogging Oil 355 ml Aerosol Premium 4 Synthetic OW 40 4 Cycle Engine Oil 95 1 Premium 4 Synthetic OW 40 4 Cycle Engine Oil 3 8 1 No NM co NINIS O N A S NM mM N N N N N co Co CO NT SN N Bl N a NI ol 4 oi NINI mM rp iN N o o v a GI M o o 103 TROUBLESHOOTING Drive Belt and Cover Problems Possible Cause Solution Driving the vehicle onto a Avoid stopping on the ramp or creeping slowly up the pickup or tall trailer ramp Starting out going up a Perform the K tur
29. dlebar 75 MAIN OIS 2 058 43 N Noise Emission Control System 60 O Odometer cpress weeds oes eas 22 OIC DANOG eas 68 70 OIPCHCC seuramaan teens 67 Los ves bist web 71 Oil Filter Change 68 70 Oils ENSING os Ss 66 OPERATION 55 59 Operator 5 6 17 Override Switch 40 Parking Brake Hydraulic 45 Parking Brake Mechanical 45 Parking on an Incline 37 Periodic Maintenance Chart 61 64 POLARIS PRODUCTS 103 Pre Ride Inspection 56 PVT Diy Liebes eV ARS 59 P3 UI SV 59 R Rear Drive Chain Slack 83 84 Rear SptIOSS sce sw eae 76 Recoil Housing 89 Recoil Starter 43 49 Restrictions x set ver EAE ov ee ese 8 Rider Information Center 51 54 Riding Gear 23 S safe Riding 23 SAME ante anos ana ae 6 39 Safety Decals and Locations 18 22 Safety Training 7 DEVEIG WSS Soe 61 Side Panel Removal 80 SICCHUINNG en eo docete ex E 29 Sis tial tres 88 Spark 60 94 95 Spark PUPS ceca ip sures dore oie 90 91 INDEX S SPECIFICATIONS 108 110 Speedometer Mode Switch 40 Springs Rear scs crus soto 76 St
30. 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 28 SAFETY Driving Safely Sidehilling Avoid crossing the side of a hill sidehilling if possible If sidehilling is necessary follow these precautions Slow down Avoid hills with excessively slippery or loose surfaces Shift your weight uphill Avoid crossing the sides of steep hills Keep your feet on the footrests Steer slightly into the hill NOTE If the vehicle begins tip quickly turn the front wheels downhill if possible or dismount on the uphill side immediately Always follow the procedures outlined in this manual for crossing the side of a hill Never attempt to turn the Quadricycle around on any hill until you ve mastered on level ground the turning technique outlined in this manual 29 SAFETY Driving Safely Driving Uphill Whenever traveling uphill follow these precautions Avoid steep hills 25 maximum Check the terrain carefully Avoid hills with excessively slippery or loose surfaces Shift your weight uphill Drive straight uphill Keep your feet on the footrests Drive at a steady rate of speed to avoid stalling Be alert Be prepared to take emergency action This may include dismounting quickly 9 Never open the throttle suddenly or make sudden gear chan
31. ds Always follow the procedures outlined in this manual for driving through water Never drive through deep or fast flowing water 34 SAFETY Driving Safely Driving Through Water CAUTION If the vehicle stops while fully submerged major engine damage can result if the machine is not thoroughly inspected Take the vehicle to your dealer before starting the engine If your vehicle becomes fully immersed and it s impossible to take it to a dealer before starting it follow the steps described on page 92 Have the vehicle serviced by your dealer promptly NOTE If water has been ingested into the transmission PVT follow the procedure on page 59 35 SAFETY Driving Safely Driving in Reverse Follow these precautions when operating in reverse 1 2 Avoid backing downhill Always check for obstacles or people behind the vehicle before backing Drive slowly Apply the foot brake lightly for stopping Avoid turning at sharp angles Never apply the throttle suddenly Do not use the override switch unless additional power is required for vehicle movement Use with caution NOTE Reverse speed is greatly increased when the override switch 36 is used Do not operate at full throttle Apply just enough throttle to maintain the desired speed CAUTION Excessive throttle operation while in the speed limit mode may cause fuel to build in the exhaust resulting in engine popping and or
32. e mode button until the letters flash 2 Press and release the mode button once When the display stops flashing the mode has been set 54 OPERATION Break In Period The break in period for your new Polaris Quadricycle is the first ten hours of operation or the time it takes to use the first two full tanks of gasoline No single action on your part will increase the life and performance of your Quadricycle more than following the procedures for a proper break in Careful treatment of a new engine will result in more efficient performance and a longer life Do not operate at full throttle or high speeds for extended periods during the first three hours of use Perform the following procedures carefully 1 Fill the fuel tank with gasoline 2 Check the oil level on the dipstick Add oil if necessary See page 67 3 Select an open area that allows room to familiarize yourself with vehicle operation and handling 4 Drive slowly Vary throttle positions Do not operate at sustained idle 5 Perform regular checks on fluid levels controls and areas outlined on the daily pre ride inspection checklist See page 56 6 Pull only light loads 7 Perform the break in oil change at one month 55 OPERATION Pre Ride Inspection Pre Ride Checklist See Page Ensure proper operation 74 Ensure proper level Eom Ensure proper operation 44 Inspect lubricate if necessary Inspect lubricate if necessary Ensure fre
33. e operation Brake system Brake fluid Foot brake Front suspension Rear suspension Steering nspect condition and pressure EC 82 nspect ensure fastener tightness 83 ae 47 67 14 75 44 82 Wheels fasteners 81 nspect condition lubricate frequently 83 40 1 85 88 23 Drive chain Frame nuts bolts fasteners Inspect ensure tightness Fuel and oil Ensure proper levels 47 67 Ensure proper operation 41 79 Ensure operation ndicator lights switches Engine stop switch Ensure proper operation 4 Air filter pre filter Inspect clean Air box sediment tube Drain deposits whenever visible 40 at 85 Ea Check operation apply Polaris dielec Headlamp tric grease when lamp is replaced Check operation apply Polaris dielec tric grease when lamp is replaced Wear helmet goggles protective Brake light tail lamp Riding gear Frame nuts bolts fasteners I Throttle o O 2 c 56 OPERATION Starting the Engine 4 amp WARNING Engine exhaust contains poisonous carbon monoxide and can cause loss of consciousness resulting in serious injury or death Never run an engine in an enclosed area or indoors CAUTION Operating the vehicle immediately after starting could cause engine damage Allow the engine to warm up for several minutes before operating 1 Position the vehicle on a level surface 2 Sit on the vehicle 3 Lock the mechanical
34. e to roll around to your right until it s pointing across the hill or slightly downward 32 SAFETY Driving Safely Turning Around on a Hill 8 Lock the hydraulic parking brake Remount from the uphill side Keep your weight uphill 9 Apply the foot brake 10 With the transmission still in forward start the engine 11 Squeeze and release the brake lever to release the parking brake 12 Release the foot brake and drive slowly downhill Control speed with the foot brake until the vehicle is on level ground Always follow the procedures outlined in this manual for climbing hills See page 30 Always follow the procedures outlined in this manual for crossing the side of a hill See page 29 33 SAFETY Driving Safely Driving Through Water Follow these procedures when operating through water 1 Check water depth and current before crossing 2 Avoid operating in water deeper than the bottom of the footrests 1 If it s unavoidable travel slowly balance your weight carefully and avoid sudden movements Maintain a Slow and steady forward motion Do not make sudden turns stops or throttle changes 3 Choose a crossing where both banks have gradual inclines 4 Drive slowly d Avoid rocks and obstacles 6 Wet brakes may have reduced stopping ability Always test your brakes after leaving water If necessary apply them lightly several times to allow friction to dry out the pa
35. engine damage Always follow the procedures outlined in this manual for driving in reverse SAFETY Driving Safely Parking on an Incline Avoid parking on an incline If it s unavoidable follow these precautions 1 2 3 4 5 Turn the engine off Place the transmission in gear Lock the mechanical parking brake Always block the rear wheels on the downhill side Turn the fuel valve off 37 SAFETY Driving Safely Hauling Cargo and Towing 4 WARNING 38 Overloading the vehicle or carrying or towing cargo improperly can alter vehicle handling and may cause loss of control or brake instability Always follow these precautions when hauling cargo e Read and understand the load distribution warnings listed on the vehicle warning labels e Never exceed the stated load capacity for this vehicle e REDUCE SPEED AND ALLOW GREATER DISTANCES FOR BRAKING WHEN HAULING CARGO OR TOWING Use ex treme caution when applying brakes Avoid situations that re quire backing downhill e When operating over rough or hilly terrain reduce speed cargo and towed load to maintain stable driving conditions Do not obstruct the headlight when loading the front rack e CARRY LOADS AS LOW ON THE RACK AS POSSIBLE Car rying a load high on the rack raises the center of gravity of the vehicle and creates a less stable operating condition Reduce load weight when cargo is high Secure off centered loads that cannot be
36. ening of the handlebars resulting in loss of control Follow the adjustment procedures exactly or see your Polaris dealer for service Tf MAINTENANCE AND LUBRICATION Carburetor Idle Adjustment IMPORTANT Your Polaris vehicle is calibrated at the factory for optimal performance at altitudes ranging from zero to 1800 meters and at temperatures of 4 degrees C or higher Above 1800 meters the engine air fuel mixture becomes too rich and the engine loses approximately 3 of its power for each 300 meter increase in elevation Although this power cannot be regained adjustments to the carburetor and drive system can be made to allow more efficient operation Optional jets and clutch components available from your Polaris dealer are required for operation above 1800 meters Jetting is required only when operating below 4 degrees C at 1800 meters and lower NOTE Operating the engine with improper jetting can cause poor performance overheating or engine damage See your Polaris dealer for more information about jetting If necessary the carburetor can be adjusted 1 Place the transmission in neutral 2 Lock the mechanical parking brake 3 Operate the engine for about five minutes 4 Adjust the carburetor idle screw 1 clockwise to raise RPM or counterclockwise to lower RPM 78 MAINTENANCE AND LUBRICATION Throttle Cable Freeplay Adjustment 1 4 Tighten the adjuster Slide the boots 2 over 2 2 the ca
37. er Disconnect the black negative cable first Disconnect the red positive cable last Lift and remove the battery Battery Installation Always install a fully charged battery See page 97 p c 96 Place the battery in the battery holder Verify that cables are routed properly Connect the red positive cable first Connect the black negative cable last Install the battery cover Attach the hold down strap MAINTENANCE AND LUBRICATION Battery Battery Storage Whenever the vehicle is not used for a period of three months or more remove the battery from the vehicle Verify that it s fully charged and store it out of the sun in a cool dry place Check battery voltage each month during storage and recharge as needed to maintain a full charge NOTE Battery charge can be maintained by using a Polaris Battery Tender charger P N 2871076 or by charging about once a month to make up for normal self discharge Battery Tender can be left connected during the storage period and will automatically charge the battery if the voltage drops below a pre determined point Battery Charging The following battery charging instructions apply only to the installation of an activated sealed battery Read all instructions before proceeding with the installation of this battery A sealed battery is already filled with electrolyte It has been sealed and is fully charged at the factory Always keep a
38. fore further operation perform the following procedure 1 Move the vehicle out of the water 2 Turn the fuel valve off 3 Remove the spark plug See page 90 4 Drain any water found in the air box 92 MAINTENANCE AND LUBRICATION Vehicle Immersion 5 Loosen the carburetor drain screw 1 and drain the carburetor 6 Turn the ignition key to the ON position to engage the starter Engage the starter for only 2 3 seconds 7 Tighten the carburetor drain screw 8 Reinstall the spark plug T 19 N m 9 Turn the fuel valve on RES OFF lt ON 10 Attempt to start the engine If necessary repeat the drying procedure 11 Have the vehicle serviced by your dealer promptly whether you succeed in starting it or not NOTE If water has been ingested into the PVT follow the procedure for drying out the PVT See page 59 93 MAINTENANCE AND LUBRICATION Spark Arrestor Occasionally the spark arrestor may accumulate carbon which can restrict the exhaust if left unattended Purge the spark arrestor 4 WARNING Allow components to cool sufficiently before servicing The exhaust system can get extremely hot Never run the engine in an enclosed area or indoors Exhaust contains poisonous carbon monoxide gas Never go under the vehicle while it s inclined Remove any combustible materials from the area Wear eye protection and leather work gloves Do not stand behind or in front of the vehicle while
39. ges 10 Never go over the top of a hill at high speed ot ee ee 30 SAFETY Driving Safely Driving Uphill If all forward speed is lost Keep your weight uphill If the vehicle begins rolling downhill never apply engine power Never apply the hand brake while rolling backwards Apply the foot brake gradually When fully stopped apply the hand brake as well Lock the hydraulic parking brake Dismount on the uphill side or to either side if the vehicle is pointed straight uphill Turn the vehicle around and remount following the procedure described on page 32 Always follow the procedures outlined in this manual for climbing hills Avoid climbing hills steeper than 25 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 31 SAFETY Driving Safely Turning Around on a Hill If the vehicle stalls while climbing a hill never back down the hill Use the K turn to turn around Stop the vehicle Keep your weight uphill Lock the hydraulic parking brake Leave the transmission in forward gear Turn the engine off E a Dismount on the uphill side of the vehicle or on the left if the vehicle is pointing straight uphill a Stay uphill of the vehicle and turn the handlebars full left Squeeze the brake lever to release the parking brake Slowly release the brake lever and allow the vehicl
40. hen servicing a halogen lamp do not touch the lamp with bare fingers Hold the plastic part 1 of the lamp Oil from your skin leaves a residue causing a hot spot that will shorten the life of the lamp 1 Place the transmission in gear Lock the mechanical parking brake 3 Turn the back of the headlight counterclockwise 4 Remove the headlamp 2 5 Apply dielectric grease to the socket 6 Install the new headlamp 7 Turn the back of the headlight clockwise to reinstall 86 MAINTENANCE AND LUBRICATION Lights High Beam Adjustment 7 6 m a e 5 1 Position the vehicle a level surface The headlight should be approximately 7 6 meters from a wall Place the transmission in neutral Lock the mechanical parking brake Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height NOTE Include rider weight on the seat when measuring 5 Start the engine Turn the headlight switch to high beam Observe the headlight aim on the wall The most intense part of the headlight beam should be aimed 5 1 cm below the mark placed on the wall Loosen the pivot bolt and adjust the beam Tighten the bolt T 3 N m 87 MAINTENANCE AND LUBRICATION Lights Taillight Signal Light Replacement 1 2 10 11 12 13 14 Place the transmission in gear Lock the mechanical parking brake Rotate the t
41. kly Inspect replace as needed Weekly Monthly Monthly Drain water as needed check often if operating in wet conditions Inspect periodically Check terminals clean test Inspect level change yearly Inspect replace if necessary 1M Perform a break in oil change at one month 3M Lubricate all fittings pivots cables etc p Perform these procedures more often for vehicles subjected to severe use E Emission Control System Service B Have authorized Polaris dealer perform these services Recoil housing Brake pad wear Battery Transmission oil Engine breather filter Engine oil change break in General lubrication 10 20 25 25 25 0 5 62 MAINTENANCE AND LUBRICATION Periodic Maintenance Chart Maintenance Interval whichever comes first 500 Drain bowl periodically and prior to storage 500 Inspect adjust lubricate replace if necessary 500 Inspect adjust lubricate replace if necessary Carburetor float bowl Throttle Cable ETC Switch Choke cable Carburetor air intake ducts flange Inspect ducts for proper sealing air leaks Drive belt Inspect adjust replace as needed 1000 Perform a break in oil change at one month 1000 Replace with oil change 1000 Inspect adjust 1000 Check for leaks at tank cap lines fuel valve filter pump carburetor replace lines every two years 1000 Replace yearly Exhaust muffler 100 12M 1000 Inspect pipe Spark p
42. kwards 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 Quadricycle Maintain the proper tire pressure 15 SAFETY Operator Safety 16 Never modify 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
43. le Keeping the vehicle clean will extend the life of components Use a garden hose and a pail of mild soap and water Use a professional type washing mitten cleaning the upper body first and the lower parts last e Rinse with clean water frequently e Wipe the vehicle dry with a chamois Do not use high pressure water High pressure water may damage components If a high pressure wash system must be used exercise extreme care to avoid directing water onto the wheel bearings transmission seals body panels brakes and warning labels Grease all fittings immediately after washing and allow the vehicle to run for a while to evaporate any water that may have entered the engine or exhaust system NOTE If warning and safety labels are damaged contact your Polaris dealer for free replacements Waxing the Vehicle Wax the vehicle with any non abrasive automotive paste wax Avoid harsh cleaners since they can scratch the finish CAUTION Some products including insect repellants and chemicals will damage plastic surfaces Use caution when using these products near plastic surfaces 99 MAINTENANCE AND LUBRICATION Storing the Vehicle See page 103 for the part numbers of Polaris products Clean the Vehicle See page 99 Stabilize the Fuel 1 Full the fuel tank 2 Add Polaris Carbon Clean Fuel Treatment or Polaris Fuel Stabilizer Follow the instructions on the container Carbon Clean Plus will reduce the possibility
44. lectricity between the box and container could cause a spark Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored Do not overfill the tank Do not fill the tank neck f gasoline spills on your skin or clothing immediately wash it off with soap and water and change clothing e Turn the fuel valve off whenever the vehicle is stored or parked Fuel Valve The fuel valve 2 is located on the left side panel RES OFF OFF le Turn the valve off before storage and when transporting ON Turn the valve on for normal operation RES Turn the valve to the reserve setting if the main fuel supply is exhausted Refuel as soon as possible Reserve fuel range is about 11 16 km NOTE Return the valve to the ON position after refueling 47 FEATURES AND CONTROLS Transmission Gear Selector The transmission gear selector 1 is located on the right side of the vehicle Whenever the vehicle is left unattended place the transmission in gear and lock the mechanical parking brake F Forward Gear N Neutral R Reverse CAUTION Shifting gears with the engine speed above idle or while the vehicle is moving can cause transmission damage Stop the vehicle release the throttle and move the lever to the desired gear See your dealer if you experience any shifting problems 48 FEATURES AND CONTROLS Recoil Starter If the battery is too
45. lug bd Eu 1000 Inspect replace as needed Wiring 1 1 1000 Inspect for wear routing security apply dielectric grease to connectors subjected to water mud etc p Perform these procedures more often for vehicles subjected to severe use E Emission Control System Service B Have an authorized Polaris dealer perform these services Engine oil change Oil filter change Valve clearance Fuel system 6M 6M 6M 6M 6M 6M 6M 12M 12M 12M 2M 2M 2M 50 50 50 50 50 100 100 100 100 Fuel filter 100 100 100 00 63 MAINTENANCE AND LUBRICATION Periodic Maintenance Chart Maintenance Interval whichever comes first a drive 12M 1000 Inspect clean replace worn ect parts Front wheel 1600 Inspect replace as needed bearings Brake fluid 2000 Change every two years sw 0 Efese OO a Toe adjustment Inspect periodically adjust when parts are replaced Foot brake and Inspect daily adjust as rear brake needed Mechanical Inspect daily adjust cable as parking brake needed Headightaim Adustas needec p Perform these procedures more often for vehicles subjected to severe use E Emission Control System Service B Have an authorized Polaris dealer perform these services 64 MAINTENANCE AND LUBRICATION Torque Symbol T Torque the item as specified Lubrication Recommendations Check and lubricate all components at the inter
46. ment Cluster Rider Information Center The rider information center is located in the instrument cluster All segments will light up for 2 5 seconds at start up NOTE Ifthe instrument cluster fails to illuminate a battery over voltage condition may have caused it to shut down to protect the electrical system If this occurs take the Quadricycle to your Polaris dealer 1 Gear Indicator As 2 3 4 the shift lever is moved this indicator shows the gear the transmission is in H High Range E Forward Trip N Neutral Oda R Reverse Engine Hour Display Indicator 1 Service Interval Diagnostic Mode Indicator Odometer Tachometer Tripmeter Hour Meter san E qe Check Engine Warning Indicator HOT will display when the engine is overheating Turn off the engine or serious damage could result 6 Mode Indicator 51 FEATURES AND CONTROLS Instrument Cluster Rider Information Center The reverse override button on the left handlebar is also the mode button Use the mode button to toggle through the four 4 standard modes of the rider information center NOTE The transmission cannot be in reverse Mode 1 Odometer The odometer records the total distance traveled by the vehicle since manufacture Mode 2 Trip Meter The trip meter records the distance traveled on each trip if it s reset before each trip To reset the trip meter select the trip meter mode Press and hold
47. n e Extended idle e Short trip cold weather operation NOTE Service and adjustments are critical If you are not familiar with safe service and adjustment procedures have a qualified Polaris dealer perform these operations The programmable service interval mode on the instrument cluster will help determine when maintenance service is due See page 54 Maintenance Chart Key p Perform these procedures more frequently for vehicles subjected to severe use E Emission Control System Service m Have an authorized Polaris dealer perform these services A WARNING Improperly performing the procedures marked with a m could result in component failure and lead to serious injury or death Have an authorized Polaris dealer perform these services 61 MAINTENANCE AND LUBRICATION Periodic Maintenance Chart Perform all services at whichever maintenance interval is reached first Maintenance Interval whichever comes first Steering Make adjustments as need ed See Pre Ride Checklist Front suspension on page 56 Rear suspension Tires Brake fluid level Brake lever travel Brake systems Wheels fasteners Drive chain MEL MEE EET MEN NONE lis NN OCT BM iini T T Lee Frame fasteners Engine oil level Air filter pre filter Air box sediment tube Headlamp tail lamp Air filter main element Daily Check operation apply dielectric grease if replacing Wee
48. n as described on page 32 steep incline Driving at low RPM or Drive at a slightly higher speed Avoid creeping low ground speed at approximately 3 7 MPH Insufficient warm up of Warm the engine at least 5 minutes Place the transmission vehicles exposed to low in neutral Lock the parking brake Advance the throttle to ambient temperatures about 1 8 throttle in short bursts 5 to 7 times The belt will become more flexible and prevent belt burning Slow and easy clutch en Use the throttle quickly and effectively for efficient en gagement gagement Towing pushing at low Install a one tooth smaller counter shaft sprocket RPM low ground speed Stuck in mud or snow Carefully use fast aggressive throttle application to en gage clutch WARNING Excessive throttle may cause loss of control and vehicle overturn Climbing overlarge ob Carefully use fast brief aggressive throttle application to jects from a stopped posi engage clutch WARNING Excessive throttle may cause tion loss of control and vehicle overturn Belt slippage from water Dry out the PVT as outlined on page 59 Inspect clutch or snow ingestion into the seals for damage if repeated leaking occurs PVT system Clutch malfunction Contact your Polaris dealer for inspection of clutch com ponents Poor engine performance Check for fouled plugs or foreign material in gas tank fuel lines or carburetor Contact your dealer for service 104
49. ndicators to flash simultaneously Use this ht feature to alert others of an emergency or other situation requiring caution 9 10 Rear Brake Lever D left brake lever operates the hydraulic rear brakes only See page 11 Parking Brake Lever The right brake lever is used as a mechanical parking brake only See page 45 12 Turn Indicator Push the toggle switch either left or right to activate the corresponding turn signal Return the toggle to the center position to end the signal 13 Mirrors Use the mirrors to assist in traffic maneuvers Always check and adjust the mirrors before driving the Quadricycle ES 14 Instrument Panel View certain vehicle functions on the instrument panel The corresponding lights illuminate when the feature is activated Left Turn Engine Hot Neutral HighBeam Right Turn 43 FEATURES AND CONTROLS Brakes Foot Brake The all wheel foot brake 1 is located on the right footrest The foot brake operates both front and rear brakes Press the brake pedal forward with your foot to engage the all wheel brakes The master cylinder 2 is located near the foot brake Inspect and maintain the brake fluid level as outlined in this manual See pages 56 and 75 Rear Brake Lever The left brake lever 1 operates the hydraulic rear brakes only Squeeze the brake lever toward the handlebar to apply the rear brakes If the rear wheel
50. nds 5 Turn the engine off 6 Remove the dipstick Wipe it clean 7 Reinstall the dipstick completely 8 Remove the dipstick Check the oil level 9 Add oil as needed to bring the level between the minimum and maximum marks gt 67 MAINTENANCE AND LUBRICATION Oil and Filter Change Always change the engine oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 61 Always change the oil filter when changing oil Change the oil more often if the vehicle is routinely subjected to operation in dusty or wet conditions e operation when air temperature is below 12 C e short trips at 12 to 1 C engine fails to reach operating tempera ture 4 CAUTION If the Quadricycle is left without oil in the system for extended periods the oil pump may lose its prime which could result in engine damage Always replace the oil and filter within a few hours of draining the oil Do not allow the vehicle to be without oil overnight 1 Use Polaris recommended products e Oil filter e 0W 40 oil 1 Position the vehicle on a level surface 2 Place the transmission in neutral 3 Lock the mechanical parking brake 4 Start the engine Allow it to idle for two minutes 5 Turn the engine off 68 MAINTENANCE AND LUBRICATION Oil and Filter Change 6 7 8 Place a drain pan under the vehicle Remove the drain plug Drain the oil
51. ng position 1 Tighten the eccentric locking bolts 2A to 61 N m CH Tighten the caliper mounting bolt to 20 N m Remove the pin punch Roll the vehicle forward checking chain tension in several places around the chain The chain is adjusted correctly when the tightest portion of the chain has approximately 10 mm deflection Position the chain guide to allow 3 mm clearance and tighten the retaining bolt to 7 N m Fuel Filter outlined in the Periodic Maintenance Chart Replace the in line fuel filter at the intervals Uu beginning on page 61 Do not attempt to clean the fuel filter 84 MAINTENANCE AND LUBRICATION Air Filter 1 2 NOTE Replace the filter if needed 8 Position the vehicle on a level surface Place the transmission in gear Lock the mechanical parking brake Remove the seat Unlatch the air box clips 1 Remove the air box cover Loosen the hose clamp 2 and remove the filter 3 Remove the pre filter 4 from the filter 5 Wash the pre filter in soapy water Rinse and air dry Reverse the steps to reinstall all components 85 MAINTENANCE AND LUBRICATION Lights 4 WARNING Poor lighting can result in loss of control or an accident Lights become dirty during normal operation Wash the headlights and tail lights frequently Hot components can cause serious burns to skin Do not service the headlamps until they ve cooled Headlight Replacement W
52. oosened or removed to ensure proper diaphragm operation Use Polaris DOT 3 brake fluid Do not overfill NOTE Reservoir levels will decrease as brake pads become worn When checking the fluid level the vehicle must be on level ground with the handlebars straight If the fluid level is low check brake pad thickness before adding brake fluid DO NOT OVERFILL Brake Check Perform the following checks to keep the brake systems in good operating condition Check more often if brakes are used heavily during normal operation 4 amp WARNING Do not overfill the reservoirs An over full master cylinder may cause brake drag or brake lock up which could cause brake loss or loss of control Maintain brake fluid at the recommended level 1 Check the brake systems regularly for fluid leaks 2 Check the brakes for excessive travel or spongy feel 3 Check the brake pads for wear damage or looseness Replace pads when they are worn to 1 mm 4 Check the security and surface condition of the brake discs 1mm 74 MAINTENANCE AND LUBRICATION Brakes Brake Fluid Check Check brake fluid levels before each use of the vehicle The brakes should feel firm when they re applied Spongy or weak brakes may indicate a fluid leak or low fluid level A low fluid level may also mean that brake pads are worn and need to be replaced Do not operate the vehicle with spongy or weak brakes See your dealer for Service Master Cylinder
53. ould cause an accident resulting in serious injury or death Always use original equipment size and type when replacing tires Install wheels properly 1 Position the vehicle on a level surface 9 2 Place the transmission in gear 3 Lock the mechanical parking brake R N 4 Loosen the wheel nuts slightly 5 Safely place jackstands under the vehicle 6 Remove the wheel nuts and remove the wheel 7 Place the wheel on the hub 8 Install the wheel nuts finger tight 9 Carefully remove the jackstands 10 Torque the wheel nuts T 37 N m Front Wheel 268 N m Rear Wheel 81 MAINTENANCE AND LUBRICATION Tires Tire Tread Depth Always replace tires when tread depth is worn to 3 mm or less 4 WARNING Operating your vehicle with worn tires improperly inflated tires non standard tires or improperly installed tires will affect vehicle handling and could cause an accident Maintain proper tire pressure as described on the decal on your vehicle and in the specifications section of the owner s manual beginning on page 108 Use only original equipment size and type when replacing tires Make sure the wheels are installed properly Replace tires when the tread depth measures 3 mm or less Wheel and Hub Tightening Wheel hub and bearing tightness and spindle nut retention are critical items These services must be performed by an authorized dealer 82 MAINTENANCE AND LUBRICATION Drive
54. ound Weight 386 kg 38 6 kg 39 FEATURES AND CONTROLS Controls Instruments 1 Main Key Switch D poo Turn the main key switch off to stop the engine and end all electrical power to the vehicle Turn the switch on to engage the starter After starting the engine release the key to the RUNNING LIGHTS position Turn the switch to LIGHTS ON to switch the headlights on WARNING Do not attach a large key fob or key ring to the main switch It may contact the gas tank cap when turning causing an interruption to the electrical system and an unexpected engine shut down during operation This could result in serious injury or death 2 Speedometer Mode Override Switch Reverse Speed Limiter To gain additional power while operating in reverse cancel the reverse speed limit function by pressing the override switch before opening the throttle PIN 40 WARNING Activating the override switch with the throttle open and while operating in reverse can cause loss of control Do not activate the override switch while the throttle is open FEATURES AND CONTROLS Controls Instruments 3 Engine Stop Switch Xa Move the stop switch to the OFF position to stop the engine All electrical power to the vehicle will end The engine will not start or run when the switch is in the OFF position Move the stop switch to the ON RUN position before attempting to start the engine 4 Light Switch Toggle the
55. parking brake 4 Turn the fuel valve on 5 Move the engine stop switch to RUN 6 If the engine is cold pull the choke knob 1 out until it stops A warm engine will not require the use of the choke FULL ON HALF ON OFF Bex NOTE Make sure the choke is off during operation Excess fuel washing into the engine oil will increase wear on engine components 57 OPERATION Starting the Engine 7 Turn the ignition key to the ON position to engage the starter Activate the starter for a maximum of five seconds releasing the key when the engine starts NOTE Do not press the throttle while starting the engine 6 Ifthe engine does not start release the starter and wait five seconds 9 Repeat steps 7 and 8 until the engine starts 10 If the engine slows or stops position the choke knob half way in 11 Vary engine RPM slightly with the throttle When the engine idles smoothly push the choke all the way in 58 OPERATION Polaris Variable Transmission Preventing Belt Slip Failure Belt slip creates heat that destroys belts and causes outer clutch covers to fail Avoid heavy pulling and extended low speed operation 4 WARNING Do not modify any component of the PVT system Doing so may reduce its strength so that a failure may occur at a high speed The PVT system has been precision balanced Any modification will cause the system to be out of balance creating vibration and additional load
56. re any additional assistance they will contact the appropriate personnel at Polaris This warranty gives you specific legal rights and you may also have other rights which vary from state to state If any of the above terms are void because of state or federal law all other warranty terms will remain in effect 112 MAINTENANCE RECORD 113 MAINTENANCE RECORD 114 MAINTENANCE RECORD 115 INDEX A ACCESSONIES cs pads yess Soa eS 101 Age ReSmichon 7 Seis 85 B etos refte teats 96 98 Battery Charging 97 98 Battery Installation 96 Battery Removal 96 Battery Storage 97 100 brake 2 eto or E fs T3 Brake Lever Parking 43 45 Brake Lever Rear 43 44 Brake 44 Bi ak eS asit Redes 44 45 74 75 Break In Period 29 C Carburetor ceo eoe 78 Cleaning the Vehicle 99 CTIutehing Chart eo sso 110 Contool 4 lt s 3 ht Pacey bs 40 43 Cooler Maintenance 71 Crankcase Emission Control System 60 D Diagnostic Mode 53 54 Dive Hain 83 84 Driving Downhill 28 Driving in Reverse 36 Driving on Slippery Surfaces 26 Driving Over Obstacles 27 Driving Procedures 24 Driving Safely 24
57. 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 Decal Text Never operate this vehicle on hills steeper than 25 degrees e Nevar operate ee To prevent flipover on hilly oes terrain when going Up OF 1 prevent flipover on down use throttle and brakes hilly terrain when going up or down use throttle gradually and brakes gradually 18 Safety Decals and Locations 2004 Before you operate this vehicle read the owner s manual Lesen Sie die Bedienungsanleitung bevor Sie dieses Fahrzeug fahren Antes de conducir este vehiculo lea el Manual del Propietario Lire le manuel du propri taire avant d utiliser ce v hicule Prima di usare il veicolo leggete il manuale di istruzioni Lue aina k ytt ohjekirja ennen taman ajoneuvon k ytt Antes de utilizar este ve
58. ris 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 E SUE 6 FEATURES AND CONTROLS 40 OPERATION costes cx dn den Og eu CE RR Pat 55 EMISSION CONTROL SYSTEMS 60 MAINTENANCE AND LUBRICATION 61 POLARIS PHOBUCGTS 235 xxu Rb e m ses 103 TROUBLESHOOTING pr reor eene 104 SPECIFICATIONS ws xpi as was sc lon CE ae 108 WARRANTY x babet P d E PRA RD hd 111 MAINTENANCE RECORD 113 INDEX PER 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
59. s begin to skid or slide while using this brake reduce lever pressure Inspect and maintain the brake fluid level in the master cylinder 2 as recommended See pages 56 and 75 4 WARNING Aggressively applying the rear brake when backing down a hill may cause rear tipover Aggressively applying the rear brake while moving forward may cause the rear wheels to skid and result in loss of control Read this owner s manual and understand the operation of all brake systems on this vehicle Always use caution whenever applying only the rear brakes 44 FEATURES AND CONTROLS Brakes A WARNING Operating the Quadricycle while the parking brake is engaged could result in an accident and serious injury or death Always check to be sure the parking brake is disengaged before operating Locking the Parking Brake Mechanical The right brake lever is used as a mechanical parking brake only It is not intended to be used as a brake lever Squeeze the right brake lever 1 toward the handlebar Move the park brake lock 2 toward the handlebar until the peg 3 fits into the slot on the lever Release the lock lever To release the parking brake lock squeeze and release the brake lever The parking brake will release automatically NOTE The parking brake may relax if left on for a long period of time Always block the wheels to prevent rolling Never depend on the parking brake alone if the vehicle is parke
60. s on components The PVT system rotates at high speeds creating large amounts of force on clutch components Extensive engineering and testing has been conducted to ensure the safety of this product However as the owner you have the following responsibilities to make sure this system remains safe e Always follow all recommended maintenance procedures See your dealer as outlined in the owner s manual e This PVT system is intended for use on Polaris products only Do not install it in any other product e Always make sure the PVT housing is securely in place during operation PVT Drying If water is ingested into the PVT system dry it before operating the vehicle Remove the drain plug Drain the water Reinstall the drain plug 2 Place the transmission in neutral Lock the mechanical parking brake Start the engine 3 Apply varying throttle for 10 15 seconds to expel the moisture and air dry the belt and clutches Do not hold the throttle wide open 4 Allow the engine RPM to return to idle speed then shift the transmission to the lowest available range 5 Test for belt slippage If the belt slips repeat the process 6 Take the vehicle to your dealer for service promptly 59 EMISSION CONTROL SYSTEMS Noise Emission Control System Do not modify the engine intake or exhaust components as doing so may affect compliance with governmental noise level requirements Spark Arrestor Your Polaris vehicle has a
61. sealed battery fully charged e DO NOT pry the sealing strip off DO NOT add any other fluid to this battery e A fully charged battery will register 12 8 V or higher 1 Check battery voltage with a voltmeter or multimeter 2 If voltage is low recharge the battery at 1 2 amps or less until the voltage is 12 8 or greater NOTE When using an automatic charger refer to the charger manufacturer s instructions for recharging When using a constant current charger follow the guidelines on page 98 97 MAINTENANCE AND LUBRICATION Battery Battery Charging Chart Constant Current Charger State of Charge Time Charge Using constant current charger standard amps specified on top of battery 100 12 8 13 0 volts None check at None required 3 mos from date of manufacture 75 100 12 5 12 8 volts May need slight 3 6 hours charge if no charge given check in 3 months 50 75 12 0 12 5 volts Needs Charge 5 11 hours 25 50 11 5 12 0 volts Needs Charge At least 13 hours verify state of charge 0 25 11 5 volts or less Needs Charge At least 20 hours NOTE Always verify battery condition before and one to two hours after charging A WARNING An overheated battery may explode causing serious injury or death Always watch charging times carefully Stop charging if the battery becomes very warm to the touch Allow it to cool before resuming charging 98 MAINTENANCE AND LUBRICATION Cleaning the Vehic
62. 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 8 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 4 WARNING The safety alert warning indicates a potential hazard that may result in serious injury or death 4 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 A 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 expl
63. t the front and rear of the front rim 3 The rear measurement should be 2 to 3 mm more than the front measurement NOTE If you discover improper alignment see your Polaris dealer for service 1 4 WARNING Do not attempt to adjust alignment All steering adjustments should be performed by an authorized Polaris dealer Rear Springs The rear shock absorber springs are adjustable Use the spanner wrench 1 in the tool kit Rotate the adjuster 2 clockwise to increase or counterclockwise to decrease spring tension 76 MAINTENANCE AND LUBRICATION Steering Suspension Steering Assembly Check the steering assembly of the vehicle periodically for loose nuts and bolts If loose nuts and bolts are found see your Polaris dealer for service before operating the vehicle Handlebar Adjustment 1 Remove the two hex screws 1 from the instrument panel 2 Remove the instrument panel 2 Loosen do not remove all four handlebar bolts 3 Adjust the handlebar to the desired height NOTE Make sure the handlebars do not contact the gas tank or any part of the machine when turned fully to the left or right 4 Torque the two front bolts 3 then torque the two rear bolts 4 T 214 17 N m NOTE Agap of up to 3 mm should remain at the rear bolts 4 WARNING Improper adjustment of the handlebars or incorrect torquing of the adjuster block tightening bolts can cause limited steering or loos
64. ucts 1 2 3 72 Position the vehicle on a level surface Place the transmission in gear Lock the mechanical parking brake Remove the dipstick Wipe it clean Reinstall the dipstick completely Remove the dipstick Check the oil level Maintain the level between the minimum MIN and maximum MAX marks Add fluid as needed Do not overfill Reinstall the dipstick gt d JN 2 Transmission Oil Change i 2 3 10 11 12 13 14 MAINTENANCE AND LUBRICATION Position the vehicle on a level surface Place the transmission in gear Lock the mechanical parking brake Loosen the jam nut 1 Turn the adjuster bolt 2 inward Remove the drain plug 3 Wipe it clean Drain the fluid into a drain pan Install a new sealing washer Reinstall the drain plug T 19 N m Turn the adjuster bolt outward until it touches the frame and then turn an additional 1 2 turn Tighten the jam nut securely while holding the adjuster bolt Remove the dipstick Dy D Add 335 ml of the recommended fluid Reinstall the dipstick Check for oil leaks 73 MAINTENANCE AND LUBRICATION Brakes Under normal operation a diaphragm extends into the reservoir as fluid level drops If the fluid level is low and the diaphragm is not extended a leak is likely The brake system should be inspected by your dealer Fill the reservoir as needed whenever the cover is l
65. vals outlined in the Periodic Maintenance Chart beginning on page 61 Items not listed in the chart should be lubricated at the General Lubrication interval Polaris Premium 4 See 66 Synthetic OW40 Transmission Premium AGL See Page 72 Synthetic Gearcase Lube Drive chain s O ring chain lube Lubricate as often as required and or SAE 80 90 before each ride in wet conditions Ball Joint Premium U Joint Locate fittings and grease 1 2 Swing Arm Bushings 3 Axle Housing 65 MAINTENANCE AND LUBRICATION Engine Oil Polaris Premium 4 Synthetic Oil is the only oil recommended for use in this engine Use of another API certified SH oil is acceptable as long as it s OW 40 Oil may need to be changed more frequently if Polaris Premium 4 is not used See page 103 for the part numbers of Polaris products Always check and change the engine oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 61 CAUTION Using a non recommended oil may cause serious engine damage Use only Polaris Premium 4 All Season Synthetic Oil or an API certified OW 40 SH oil Never substitute or mix oil brands 66 MAINTENANCE AND LUBRICATION ae Oil Check 1 Position the vehicle on a level surface 2 Place the transmission in neutral 3 Lock the mechanical parking brake ROF 4 Start the engine Allow it to idle for 30 seco
66. vide 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 24 Sit upright Keep your feet on the footrests Keep both hands on the handlebars Start the engine and allow it to warm up then shift the transmission into gear Check your surroundings and determine your path of travel Release the parking brake Slowly squeeze the throttle lever toward the handlebar to begin driving Squeeze the throttle lever further to increase speed Drive slowly Practice maneuvering and using the throttle and brakes on level surfaces 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 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 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
67. weak to start 1 the engine use the recoil starter 1 Follow the starting procedures on page 57 cranking the engine with the recoil starter instead of the main key switch 1 Grasp the recoil starter rope handle tightly Pull slightly until the starter mechanism engages 2 Pull the rope abruptly to start the engine CAUTION Extending the starter rope too far will cause damage to the recoil assembly Do not extend the starter rope so far that it stops If the starter rope handle is not seated properly water may enter the recoil housing and damage components Make sure the handle is fully seated on the recoil housing especially when traveling in wet areas 49 FEATURES AND CONTROLS Instrument Cluster The instrument cluster senses vehicle speed from the right front wheel It measures distance as well as hours of operation It also includes a reverse speed limiter function that limits reverse speed to about 11 14 km h See page 40 for additional information m AN mi 1 Rider Information Center Speedometer needle In addition to showing vehicle speed the needle flashes when a warning condition exists 3 Speedometer CAUTION To prevent damage to the instrument cluster wash the Quadricycle by hand or with a garden hose using mild soap Do not use alcohol to clean the instrument cluster Immediately wash off any gasoline that splashes on the instrument cluster 50 FEATURES AND CONTROLS Instru
68. y Tum Radius Ground Clean High Low Wi Seat Ho Dry Weis Wheel Bae Timing Based on EU Directive 76 432 EC 108 SPECIFICATIONS 2005 Trail Boss 330 Quadricycle Drive System Drive System Type PVT Shift Type Side Lever F N R Gear Reduction Reverse 3 05 1 2 68 1 11 40 78P 520 O Ring 23 x 7 10 34 5 KPa 22 x 12 10 34 5 KPa Suspension and Brakes Gear Reduction Forward Final Drive ratio Drive Chain Front Tires Rear Tires Front Suspension Mac Strut 17 cm travel Rear Suspension Progressive Rate 22 9 cm travel Swing Arm Shock Adjustment Brake System CAM Hydraulic disc front and rear fixed disc hydraulic floating caliper Hand Brake Hydraulic left hand apply rear caliper only equipped w temporary hydraulic lock Foot Brake Parking Brake Hydraulic single apply all wheel Right hand apply w mechanical lock floating caliper system disc brake F eatures 2 Hi Lo 60w 55w 2x5 26w 2x26 9w 12V 14 AH LCD Standard Standard Standard Standard Standard Standard Headlight Taillight Brake Light Battery Instrument Cluster Electric Start High Beam Indicator High Temp Indicator Neutral Indicator Reverse Indicator Tool Kit 109 SPECIFICATIONS 2005 Trail Boss 330 Quadricycle Jetting Chart Altitude AMBIENT Below 5 5 C and above TEMPERATURE Meters 0 1800 127 5 125 Clutching Chart Altitude Shift Drive Clutch Driven Clutch Helix Spring Weight

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