Polaris Trail Boss 330 Quadricycle - Manuals

7 SAFETY Operator Safety WARNING Failure to follow the warnings in this manual can result in serious injury or death.A Polaris Quadricycle is not a toy and can be hazardous to operate. A collision or rollover can occur quickly, even during routine maneuvers, if you fail to take proper precautions.Re...

8 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 an...

17 SAFETY Operator Safety Always remove the ignition key when the vehicle is not in use to prevent unauthorized use or accidental starting. Always keep combustible materials away from the exhaust system. Exposure of combustibles to hot components could result in a fire. FOR MORE INFORMATION ABOUT QU...

A B C D F G H E G J 18 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...

19 SAFETY Safety Decals and Locations NO STEP B C D

E 7172566 WARNING F G 20 SAFETY Safety Decals and Locations Decal Text NEVER ride as a passenger.Passengers can cause a loss of control, resulting in SEVERE INJURY or DEATH. TIRE PRESSURE IN PSI (KPa): FRONT 5 (34.5) REAR 5 (34.5) MAXIMUM WEIGHT CAPACITY (Gross Vehicle Weight) INCLUDING MACHINE, DRI...

J 21 SAFETY Safety Decals and Locations Decal Text (H) S Operation of this vehicle without the air filter element will severely damage the engine. S Clean pre-filter element often, more frequent cleaning required in dusty conditions. Do not operate vehicle without pre-filter. S Specific carburetor j...

22 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

1 2 3 4 5 23 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...

24 SAFETY Driving Safely Driving Procedures 1. Sit upright. Keep your feet on the footrests. Keep both hands on the handlebars. 2. Start the engine and allow it to warm up, then shift the transmission into gear. 3. Check your surroundings and determine your path of travel.4. Release the parking brak...

50 40 0 10 20 30 25 SAFETY Driving Safely Making Turns 1. To make a turn, steer in the direction of the turn, leaning your upper body to the inside of the turn while supporting your weight on the outer footrest. Use the same leaning technique for turning in reverse. 2. Practice turning at slow speed...

26 SAFETY Driving Safely Driving on Slippery Surfaces Whenever driving on slippery or loose surfaces such as wet trails, gravel, snow or ice, follow these precautions:1. Slow down before driving onto slippery surfaces.2. Use extra caution.3. Be alert. Watch the trail. Avoid quick, sharp turns. NOTE:...

27 SAFETY Driving Safely Driving Over Obstacles 1. Always check for obstacles before operating in a new area. Serious injury or death can result if your vehicle comes in contact with a hidden obstacle. 2. Be alert. Watch the terrain. Use extra caution.3. Never operate over large obstacles.4. Avoid h...

50 40 0 10 20 30 28 SAFETY Driving Safely Driving Downhill Whenever descending a hill, follow these precautions:1. Check the terrain carefully.2. Avoid hills with excessively slippery or loose surfaces. 3. Never go down a hill at high speed. 4. Slow down.5. Avoid going down a hill at an angle, which...

29 SAFETY Driving Safely Sidehilling Avoid crossing the side of a hill (sidehilling) if possible. If sidehilling is necessary, follow these precautions:1. Slow down.2. Avoid hills with excessively slippery or loose surfaces.3. Shift your weight uphill.4. Avoid crossing the sides of steep hills.5. Ke...

< 25 _ 30 SAFETY Driving Safely Driving Uphill Whenever traveling uphill, follow these precautions:1. Avoid steep hills (25 _ maximum). 2. Check the terrain carefully. 3. Avoid hills with excessively slippery or loose surfaces.4. Shift your weight uphill.5. Drive straight uphill. 6. Keep your fee...

> 25 _ 31 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 w...

2.4 m 32 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. 1. Stop the vehicle. Keep your weight uphill.2. Lock the hydraulic parking brake.3. Leave the transmission in forward gear. Turn the engine of...

> 25 _ 33 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 ...

1 34 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 ...

35 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 tak...

36 SAFETY Driving Safely Driving in Reverse Follow these precautions when operating in reverse:1. Avoid backing downhill.2. Always check for obstacles or people behind the vehicle before backing. 3. Drive slowly.4. Apply the foot brake lightly for stopping. 5. Avoid turning at sharp angles. 6. Never...

37 SAFETY Driving Safely Parking on an Incline Avoid parking on an incline. If it’s unavoidable, follow these precautions: 1. Turn the engine off.2. Place the transmission in gear.3. Lock the mechanical parking brake.4. Always block the rear wheels on the downhill side.5. Turn the fuel valve off.

38 SAFETY Driving Safely Hauling Cargo and Towing WARNING 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. S Read and understand the load distribution warn...

2/3 1/3 39 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 QUADRIC...

(1) (3) (4) (5) (2) 40 FEATURES AND CONTROLS Controls/Instruments (1) Main Key Switch 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 ...

1 2 44 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. Inspec...

1 2 3 1 2 45 FEATURES AND CONTROLS Brakes 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 lev...

46 FEATURES AND CONTROLS Steering Lock 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 stee...

RES ON OFF 1 2 47 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. WARNING S Gasoline is highly flammable and explosive under certain conditions. S Use extreme caution whe...

1 F N R 48 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 Shift...

1 49 FEATURES AND CONTROLS Recoil Starter If the battery is too weak to start 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 u...

50 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 informat...

5 3 2 1 4 6 51 FEATURES AND CONTROLS Instrument 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: If the instrument cluster fails to illuminate, a battery over-voltage condition may have c...

52 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 - Od...

53 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 d...

54 FEATURES AND 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 ...

55 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 pr...

RES ON OFF 1 57 OPERATION Starting the Engine 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 e...

59 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. WARNING Do not modify any component of the PVT system. Doing so may reduce its strength s...

60 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 spark arrestor that was designed for on-road and off-road operatio...

61 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 S Frequent immersion in mud, water or sand S Racing ...

65 MAINTENANCE AND LUBRICATION Torque Symbol = Torque the item as specified. Lubrication Recommendations Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart beginning on page 61. Items not listed in the chart should be lubricated at the General Lubrication ...

66 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 0W-40. Oil may need to be changed more frequently if Polaris Premium 4 is not used. See page 103 for the p...

67 MAINTENANCE AND LUBRICATION Oil Check 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 30 seconds. 5. Turn the engine off. 6. Remove the dipstick. Wipe it clean. 7. Reinstall the dipst...

68 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: S operation in dusty...

4 69 MAINTENANCE AND LUBRICATION Oil and Filter Change 6. Place a drain pan under the vehicle. 7. Remove the drain plug.8. Drain the oil. CAUTION Hot oil may result in serious burns. Do not allow hot oil to contact skin. 9. Reinstall the drain plug with a new sealing washer. = 19 N-m 10. Place towel...

70 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.16. Add two .95 liter bottles of 0W/40 oil. 17. Reinstall the dipstick. 18. Start the ...

1 71 MAINTENANCE AND LUBRICATION Engine Oil Cooler Maintenance The oil cooling system requires little maintenance 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 l...

72 MAINTENANCE AND LUBRICATION Transmission Oil Check See page 65 for recommended lubricants. See page 103 for the part numbers of Polaris products.1. Position the vehicle on a level surface. 2. Place the transmission in gear. 3. Lock the mechanical parking brake. 4. Remove the dipstick. Wipe it cle...

73 MAINTENANCE AND LUBRICATION Transmission Oil Change 1. Position the vehicle on a level surface. 2. Place the transmission in gear. 3. Lock the mechanical parking brake. 4. Loosen the jam nut (1).5. Turn the adjuster bolt (2) inward. 6. Remove the drain plug (3). Wipe it clean. 7. Drain the fluid ...

1 mm 74 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 th...

2 3 1 Min Max 4 75 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 wo...

2 1 76 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 straight-ahead position. 2. Place stands (1) in front of the vehicle, perpendicular...

2 1 3 4 14-17 N-m 77 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. Remo...

1 + RPM -- RPM 78 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 bec...

1 3 2 4 2 1.6-3.2 mm 2 4 2 2 2 79 MAINTENANCE AND LUBRICATION Throttle Cable Freeplay Adjustment 1. Locate the throttle cable adjuster (1) on the handlebar. 2. Slide the boots (2) off the cable adjuster sleeve (3). Loosen the adjuster (4). 3. Turn the adjuster until 1.6-3.2 mm of freeplay exists at ...

80 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.2. Grasp the rear of the side panel near the rear cab. Pull the panel forward and outward quickly and firml...

81 MAINTENANCE AND LUBRICATION Wheel Removal / Installation CAUTION Operating with improperly installed wheels will affect vehicle handling and could cause an accident resulting in serious injury or death. Always use original equipment size and type when replacing tires. Install wheels properly. 1. ...

3 mm 82 MAINTENANCE AND LUBRICATION Tires Tire Tread Depth Always replace tires when tread depth is worn to 3 mm or less. 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 accide...

83 MAINTENANCE AND LUBRICATION Drive 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...

84 MAINTENANCE AND LUBRICATION Drive Chain Rear Drive Chain Slack 5. Roll the vehicle forward or backward to adjust the chain slack to the proper tension. See the illustration for proper splice link clip opening position (1). 6. Tighten the eccentric locking bolts to 61 N-m. 7. Tighten the caliper m...

1 2 3 4 5 85 MAINTENANCE AND LUBRICATION Air Filter 1. Position the vehicle on a level surface. 2. Place the transmission in gear. 3. Lock the mechanical parking brake. 4. Remove the seat. 5. Unlatch the air box clips (1). Remove the air box cover. 6. Loosen the hose clamp (2) and remove the filter ...

1 2 86 MAINTENANCE AND LUBRICATION Lights 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....

87 MAINTENANCE AND LUBRICATION Lights High Beam Adjustment 1. Position the vehicle on a level surface. The headlight should be approximately 7.6 meters from a wall. 2. Place the transmission in neutral. 3. Lock the mechanical parking brake. 4. Measure the distance from the floor to the center of the...

88 MAINTENANCE AND LUBRICATION Lights Taillight/Signal Light Replacement 1. Place the transmission in gear.2. Lock the mechanical parking brake. 3. Rotate the taillight socket counterclockwise to remove it. 4. Remove the lamp.5. Apply dielectric grease to the socket. 6. Install the new lamp.7. Test ...

1 2 3 89 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 ...

2 3 1 19 N-m 90 MAINTENANCE AND LUBRICATION Spark Plugs 1. Remove the left side panel. See page 80. 2. Remove the 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. Repla...

91 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 whi...

RES ON OFF 92 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 a...

94 MAINTENANCE AND LUBRICATION Spark Arrestor Occasionally, the spark arrestor may accumulate carbon, which can restrict the exhaust if left unattended. Purge the spark arrestor. WARNING Allow components to cool sufficiently before servicing. The exhaust system can get extremely hot. Never run the e...

96 MAINTENANCE AND LUBRICATION Battery 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, alw...

97 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 rec...

98 MAINTENANCE AND LUBRICATION Battery Battery Charging Chart (Constant Current Charger) State of Charge Voltage Action Charge Time* (Using constant current charger @ standard amps specified on top of battery) 100% 12.8-13.0 volts None, check at 3 mos. from date of manufacture None required 75%-100%...

99 MAINTENANCE AND LUBRICATION Cleaning the Vehicle Keeping the vehicle clean will extend the life of components. S Use a garden hose and a pail of mild soap and water S Use a professional-type washing mitten, cleaning the upper body first and the lower parts last. S Rinse with clean water frequentl...

100 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. Fill the fuel tank.2. Add Polaris Carbon Clean Fuel Treatment or Polaris Fuel Stabilizer. Follow the instructions on the container. (Carbon ...

101 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...

RES ON OFF 102 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...

103 POLARIS PRODUCTS Part No. Description Engine Lubricant 2870791 Fogging Oil (355 ml Aerosol) 2871281 Premium 4 Synthetic 0W-40 (4-Cycle) Engine Oil (.95 l) 2871844 Premium 4 Synthetic 0W-40 (4-Cycle) Engine Oil (3.8 l) Gearcase / Transmission Lubricants 2873602 Premium AGL Synthetic Gearcase Lube...

104 TROUBLESHOOTING Drive Belt and Cover Problems Possible Cause Solution Driving the vehicle onto a pickup or tall trailer. Avoid stopping on the ramp or creeping slowly up the ramp. Starting out going up a steep incline. Perform the K-turn as described on page 32. Driving at low RPM or low ground ...

105 TROUBLESHOOTING Contact your Polaris dealer for service if you’re unable to identify solutions using the following charts. Engine Does Not Rotate Possible Cause Solution Blown fuse Replace fuse Low battery voltage Recharge battery to 12.5 VDC Loose battery connections Check all connections and t...

106 TROUBLESHOOTING Engine Backfires Possible Cause Solution Weak spark from spark plugs Inspect, clean and/or replace spark plugs Incorrect spark plug gap or heat range Set gap to specs or replace plugs Old or non-recommended fuel Replace with new fuel Incorrectly installed spark plug wires See you...

107 TROUBLESHOOTING Engine Stops or Loses Power Possible Cause Solution Out of fuel Turn fuel valve to reserve, refuel Kinked or plugged fuel vent line Inspect and replace Water present in fuel / old fuel Replace with new fuel Overuse of choke Inspect, clean and/or replace spark plugs Fouled or defe...

108 SPECIFICATIONS 2005 Trail Boss 330 Quadricycle Capacities Body Style Gen IV Gross Vehicle Weight 438 kg Fuel Capacity 12.35 l Transmission Oil 335 ml Engine Oil Capacity 1.8 l (incl. oil cooler ) 1.6 l (oil change only) Front Rack 34.1 kg Rear Rack 56.7 kg Tongue Weight 38.6 kg Towing Rating 386...

110 SPECIFICATIONS 2005 Trail Boss 330 Quadricycle Jetting Chart Altitude AMBIENT TEMPERATURE Below 5 ° C +5 ° C and above Meters 0-1800 127.5 122.5 1800-3700 120 115 Clutching Chart Altitude Shift Weight Drive Clutch Spring Driven Clutch Spring Helix/Spring Setting Meters 0-1800 10RH 5630709 Blue/G...

111 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 defec...

112 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 N...

113 MAINTENANCE RECORD DATE MILES/KM TECHNICIAN SERVICE PERFORMED / COMMENTS

116 INDEX A Accessories 101 . . . . . . . . . . . . . . . . . . . Age Restriction 7 . . . . . . . . . . . . . . . . . . Air Filter 85 . . . . . . . . . . . . . . . . . . . . . . B Battery 96-98 . . . . . . . . . . . . . . . . . . . . . Battery Charging 97-98 . . . . . . . . . . . . . . Battery Insta...

7 SAFETY Operator Safety WARNING Failure to follow the warnings in this manual can result in serious injury or death.A Polaris Quadricycle is not a toy and can be hazardous to operate. A collision or rollover can occur quickly, even during routine maneuvers, if you fail to take proper precautions.Re...

8 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 an...

17 SAFETY Operator Safety Always remove the ignition key when the vehicle is not in use to prevent unauthorized use or accidental starting. Always keep combustible materials away from the exhaust system. Exposure of combustibles to hot components could result in a fire. FOR MORE INFORMATION ABOUT QU...

A B C D F G H E G J 18 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...

19 SAFETY Safety Decals and Locations NO STEP B C D

E 7172566 WARNING F G 20 SAFETY Safety Decals and Locations Decal Text NEVER ride as a passenger.Passengers can cause a loss of control, resulting in SEVERE INJURY or DEATH. TIRE PRESSURE IN PSI (KPa): FRONT 5 (34.5) REAR 5 (34.5) MAXIMUM WEIGHT CAPACITY (Gross Vehicle Weight) INCLUDING MACHINE, DRI...

J 21 SAFETY Safety Decals and Locations Decal Text (H) S Operation of this vehicle without the air filter element will severely damage the engine. S Clean pre-filter element often, more frequent cleaning required in dusty conditions. Do not operate vehicle without pre-filter. S Specific carburetor j...

22 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

1 2 3 4 5 23 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...

24 SAFETY Driving Safely Driving Procedures 1. Sit upright. Keep your feet on the footrests. Keep both hands on the handlebars. 2. Start the engine and allow it to warm up, then shift the transmission into gear. 3. Check your surroundings and determine your path of travel.4. Release the parking brak...

50 40 0 10 20 30 25 SAFETY Driving Safely Making Turns 1. To make a turn, steer in the direction of the turn, leaning your upper body to the inside of the turn while supporting your weight on the outer footrest. Use the same leaning technique for turning in reverse. 2. Practice turning at slow speed...

26 SAFETY Driving Safely Driving on Slippery Surfaces Whenever driving on slippery or loose surfaces such as wet trails, gravel, snow or ice, follow these precautions:1. Slow down before driving onto slippery surfaces.2. Use extra caution.3. Be alert. Watch the trail. Avoid quick, sharp turns. NOTE:...

27 SAFETY Driving Safely Driving Over Obstacles 1. Always check for obstacles before operating in a new area. Serious injury or death can result if your vehicle comes in contact with a hidden obstacle. 2. Be alert. Watch the terrain. Use extra caution.3. Never operate over large obstacles.4. Avoid h...

50 40 0 10 20 30 28 SAFETY Driving Safely Driving Downhill Whenever descending a hill, follow these precautions:1. Check the terrain carefully.2. Avoid hills with excessively slippery or loose surfaces. 3. Never go down a hill at high speed. 4. Slow down.5. Avoid going down a hill at an angle, which...

29 SAFETY Driving Safely Sidehilling Avoid crossing the side of a hill (sidehilling) if possible. If sidehilling is necessary, follow these precautions:1. Slow down.2. Avoid hills with excessively slippery or loose surfaces.3. Shift your weight uphill.4. Avoid crossing the sides of steep hills.5. Ke...

< 25 _ 30 SAFETY Driving Safely Driving Uphill Whenever traveling uphill, follow these precautions:1. Avoid steep hills (25 _ maximum). 2. Check the terrain carefully. 3. Avoid hills with excessively slippery or loose surfaces.4. Shift your weight uphill.5. Drive straight uphill. 6. Keep your fee...

> 25 _ 31 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 w...

2.4 m 32 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. 1. Stop the vehicle. Keep your weight uphill.2. Lock the hydraulic parking brake.3. Leave the transmission in forward gear. Turn the engine of...

> 25 _ 33 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 ...

1 34 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 ...

35 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 tak...

36 SAFETY Driving Safely Driving in Reverse Follow these precautions when operating in reverse:1. Avoid backing downhill.2. Always check for obstacles or people behind the vehicle before backing. 3. Drive slowly.4. Apply the foot brake lightly for stopping. 5. Avoid turning at sharp angles. 6. Never...

37 SAFETY Driving Safely Parking on an Incline Avoid parking on an incline. If it’s unavoidable, follow these precautions: 1. Turn the engine off.2. Place the transmission in gear.3. Lock the mechanical parking brake.4. Always block the rear wheels on the downhill side.5. Turn the fuel valve off.

38 SAFETY Driving Safely Hauling Cargo and Towing WARNING 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. S Read and understand the load distribution warn...

2/3 1/3 39 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 QUADRIC...

(1) (3) (4) (5) (2) 40 FEATURES AND CONTROLS Controls/Instruments (1) Main Key Switch 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 ...

1 2 44 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. Inspec...

1 2 3 1 2 45 FEATURES AND CONTROLS Brakes 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 lev...

46 FEATURES AND CONTROLS Steering Lock 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 stee...

RES ON OFF 1 2 47 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. WARNING S Gasoline is highly flammable and explosive under certain conditions. S Use extreme caution whe...

1 F N R 48 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 Shift...

1 49 FEATURES AND CONTROLS Recoil Starter If the battery is too weak to start 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 u...

50 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 informat...

5 3 2 1 4 6 51 FEATURES AND CONTROLS Instrument 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: If the instrument cluster fails to illuminate, a battery over-voltage condition may have c...

52 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 - Od...

53 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 d...

54 FEATURES AND 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 ...

55 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 pr...

RES ON OFF 1 57 OPERATION Starting the Engine 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 e...

59 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. WARNING Do not modify any component of the PVT system. Doing so may reduce its strength s...

60 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 spark arrestor that was designed for on-road and off-road operatio...

61 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 S Frequent immersion in mud, water or sand S Racing ...

65 MAINTENANCE AND LUBRICATION Torque Symbol = Torque the item as specified. Lubrication Recommendations Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart beginning on page 61. Items not listed in the chart should be lubricated at the General Lubrication ...

66 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 0W-40. Oil may need to be changed more frequently if Polaris Premium 4 is not used. See page 103 for the p...

67 MAINTENANCE AND LUBRICATION Oil Check 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 30 seconds. 5. Turn the engine off. 6. Remove the dipstick. Wipe it clean. 7. Reinstall the dipst...

68 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: S operation in dusty...

4 69 MAINTENANCE AND LUBRICATION Oil and Filter Change 6. Place a drain pan under the vehicle. 7. Remove the drain plug.8. Drain the oil. CAUTION Hot oil may result in serious burns. Do not allow hot oil to contact skin. 9. Reinstall the drain plug with a new sealing washer. = 19 N-m 10. Place towel...

70 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.16. Add two .95 liter bottles of 0W/40 oil. 17. Reinstall the dipstick. 18. Start the ...

1 71 MAINTENANCE AND LUBRICATION Engine Oil Cooler Maintenance The oil cooling system requires little maintenance 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 l...

72 MAINTENANCE AND LUBRICATION Transmission Oil Check See page 65 for recommended lubricants. See page 103 for the part numbers of Polaris products.1. Position the vehicle on a level surface. 2. Place the transmission in gear. 3. Lock the mechanical parking brake. 4. Remove the dipstick. Wipe it cle...

73 MAINTENANCE AND LUBRICATION Transmission Oil Change 1. Position the vehicle on a level surface. 2. Place the transmission in gear. 3. Lock the mechanical parking brake. 4. Loosen the jam nut (1).5. Turn the adjuster bolt (2) inward. 6. Remove the drain plug (3). Wipe it clean. 7. Drain the fluid ...

1 mm 74 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 th...

2 3 1 Min Max 4 75 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 wo...

2 1 76 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 straight-ahead position. 2. Place stands (1) in front of the vehicle, perpendicular...

2 1 3 4 14-17 N-m 77 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. Remo...

1 + RPM -- RPM 78 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 bec...

1 3 2 4 2 1.6-3.2 mm 2 4 2 2 2 79 MAINTENANCE AND LUBRICATION Throttle Cable Freeplay Adjustment 1. Locate the throttle cable adjuster (1) on the handlebar. 2. Slide the boots (2) off the cable adjuster sleeve (3). Loosen the adjuster (4). 3. Turn the adjuster until 1.6-3.2 mm of freeplay exists at ...

80 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.2. Grasp the rear of the side panel near the rear cab. Pull the panel forward and outward quickly and firml...

81 MAINTENANCE AND LUBRICATION Wheel Removal / Installation CAUTION Operating with improperly installed wheels will affect vehicle handling and could cause an accident resulting in serious injury or death. Always use original equipment size and type when replacing tires. Install wheels properly. 1. ...

3 mm 82 MAINTENANCE AND LUBRICATION Tires Tire Tread Depth Always replace tires when tread depth is worn to 3 mm or less. 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 accide...

83 MAINTENANCE AND LUBRICATION Drive 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...

84 MAINTENANCE AND LUBRICATION Drive Chain Rear Drive Chain Slack 5. Roll the vehicle forward or backward to adjust the chain slack to the proper tension. See the illustration for proper splice link clip opening position (1). 6. Tighten the eccentric locking bolts to 61 N-m. 7. Tighten the caliper m...

1 2 3 4 5 85 MAINTENANCE AND LUBRICATION Air Filter 1. Position the vehicle on a level surface. 2. Place the transmission in gear. 3. Lock the mechanical parking brake. 4. Remove the seat. 5. Unlatch the air box clips (1). Remove the air box cover. 6. Loosen the hose clamp (2) and remove the filter ...

1 2 86 MAINTENANCE AND LUBRICATION Lights 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....

87 MAINTENANCE AND LUBRICATION Lights High Beam Adjustment 1. Position the vehicle on a level surface. The headlight should be approximately 7.6 meters from a wall. 2. Place the transmission in neutral. 3. Lock the mechanical parking brake. 4. Measure the distance from the floor to the center of the...

88 MAINTENANCE AND LUBRICATION Lights Taillight/Signal Light Replacement 1. Place the transmission in gear.2. Lock the mechanical parking brake. 3. Rotate the taillight socket counterclockwise to remove it. 4. Remove the lamp.5. Apply dielectric grease to the socket. 6. Install the new lamp.7. Test ...

1 2 3 89 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 ...

2 3 1 19 N-m 90 MAINTENANCE AND LUBRICATION Spark Plugs 1. Remove the left side panel. See page 80. 2. Remove the 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. Repla...

91 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 whi...

RES ON OFF 92 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 a...

94 MAINTENANCE AND LUBRICATION Spark Arrestor Occasionally, the spark arrestor may accumulate carbon, which can restrict the exhaust if left unattended. Purge the spark arrestor. WARNING Allow components to cool sufficiently before servicing. The exhaust system can get extremely hot. Never run the e...

96 MAINTENANCE AND LUBRICATION Battery 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, alw...

97 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 rec...

98 MAINTENANCE AND LUBRICATION Battery Battery Charging Chart (Constant Current Charger) State of Charge Voltage Action Charge Time* (Using constant current charger @ standard amps specified on top of battery) 100% 12.8-13.0 volts None, check at 3 mos. from date of manufacture None required 75%-100%...

99 MAINTENANCE AND LUBRICATION Cleaning the Vehicle Keeping the vehicle clean will extend the life of components. S Use a garden hose and a pail of mild soap and water S Use a professional-type washing mitten, cleaning the upper body first and the lower parts last. S Rinse with clean water frequentl...

100 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. Fill the fuel tank.2. Add Polaris Carbon Clean Fuel Treatment or Polaris Fuel Stabilizer. Follow the instructions on the container. (Carbon ...

101 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...

RES ON OFF 102 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...

103 POLARIS PRODUCTS Part No. Description Engine Lubricant 2870791 Fogging Oil (355 ml Aerosol) 2871281 Premium 4 Synthetic 0W-40 (4-Cycle) Engine Oil (.95 l) 2871844 Premium 4 Synthetic 0W-40 (4-Cycle) Engine Oil (3.8 l) Gearcase / Transmission Lubricants 2873602 Premium AGL Synthetic Gearcase Lube...

104 TROUBLESHOOTING Drive Belt and Cover Problems Possible Cause Solution Driving the vehicle onto a pickup or tall trailer. Avoid stopping on the ramp or creeping slowly up the ramp. Starting out going up a steep incline. Perform the K-turn as described on page 32. Driving at low RPM or low ground ...

105 TROUBLESHOOTING Contact your Polaris dealer for service if you’re unable to identify solutions using the following charts. Engine Does Not Rotate Possible Cause Solution Blown fuse Replace fuse Low battery voltage Recharge battery to 12.5 VDC Loose battery connections Check all connections and t...

106 TROUBLESHOOTING Engine Backfires Possible Cause Solution Weak spark from spark plugs Inspect, clean and/or replace spark plugs Incorrect spark plug gap or heat range Set gap to specs or replace plugs Old or non-recommended fuel Replace with new fuel Incorrectly installed spark plug wires See you...

107 TROUBLESHOOTING Engine Stops or Loses Power Possible Cause Solution Out of fuel Turn fuel valve to reserve, refuel Kinked or plugged fuel vent line Inspect and replace Water present in fuel / old fuel Replace with new fuel Overuse of choke Inspect, clean and/or replace spark plugs Fouled or defe...

108 SPECIFICATIONS 2005 Trail Boss 330 Quadricycle Capacities Body Style Gen IV Gross Vehicle Weight 438 kg Fuel Capacity 12.35 l Transmission Oil 335 ml Engine Oil Capacity 1.8 l (incl. oil cooler ) 1.6 l (oil change only) Front Rack 34.1 kg Rear Rack 56.7 kg Tongue Weight 38.6 kg Towing Rating 386...

110 SPECIFICATIONS 2005 Trail Boss 330 Quadricycle Jetting Chart Altitude AMBIENT TEMPERATURE Below 5 ° C +5 ° C and above Meters 0-1800 127.5 122.5 1800-3700 120 115 Clutching Chart Altitude Shift Weight Drive Clutch Spring Driven Clutch Spring Helix/Spring Setting Meters 0-1800 10RH 5630709 Blue/G...

111 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 defec...

112 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 N...

113 MAINTENANCE RECORD DATE MILES/KM TECHNICIAN SERVICE PERFORMED / COMMENTS

116 INDEX A Accessories 101 . . . . . . . . . . . . . . . . . . . Age Restriction 7 . . . . . . . . . . . . . . . . . . Air Filter 85 . . . . . . . . . . . . . . . . . . . . . . B Battery 96-98 . . . . . . . . . . . . . . . . . . . . . Battery Charging 97-98 . . . . . . . . . . . . . . Battery Insta...