Page 3 - to the owner’s manual on the next page. If you cannot locate this card,; The engine exhaust from this product contains; WARNING
A card containing important ATV safety information should be attached to the owner’s manual on the next page. If you cannot locate this card, or if it has been removed, please call 1-800-342-3764 for assistance. The engine exhaust from this product contains chemicals known to the State of California...
Page 4 - WELCOME; RANGER
1 WELCOME Thank you for purchasing a Polaris vehicle, and welcome to our world-wide family of Polaris owners. We proudly produce an exciting line of utility and recreational products. S Snowmobiles S All-terrain vehicles (ATVs) S RANGER utility vehicles S Victory motorcycles We believe Polaris sets ...
Page 6 - TABLE OF CONTENTS
3 TABLE OF CONTENTS KNOW YOUR VEHICLE 5 . . . . . . . . . . . . . . . . . . . . . SAFETY 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FEATURES AND CONTROLS 31 . . . . . . . . . . . . . . . OPERATION 41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EMISSION CO...
Page 8 - KNOW YOUR VEHICLE; Vehicle Identification Numbers
5 KNOW YOUR VEHICLE As the operator of the vehicle, you are responsible for your personal safety, the safety of others, and the protection of our environment. Read and understand your owner’s manual, which includes valuable information about all aspects of your vehicle, including safe operating proc...
Page 9 - SAFETY; Operator Safety; vehicle handles differently than other vehicles, such as; Age Restrictions; RiderCourse
6 SAFETY Operator Safety WARNING Failure to follow the warnings contained in this manual can result in serious injury or death.A Polaris ATV is not a toy and can be hazardous to operate. This vehicle handles differently than other vehicles, such as motorcycles and cars. A collision or rollover can o...
Page 10 - The following signal words and symbols appear throughout this; safety alert symbol; safety alert warning; safety alert caution; CAUTION; caution
7 SAFETY Operator Safety The following signal words and symbols appear throughout this manual and on your ATV. Your safety is involved when these words and symbols are used. Become familiar with their meanings before reading the manual. The safety alert symbol , on your vehicle or in this manual, al...
Page 11 - Serious injury or death can result if you do not follow these; Take a training
8 SAFETY Operator Safety WARNING Serious injury or death can result if you do not follow these instructions and procedures, which are outlined in further detail within your owner’s manual. S Read this manual and all labels carefully, and follow the operating procedures described. S Never operate an ...
Page 13 - FOR MORE INFORMATION ABOUT ATV SAFETY, call the Con-; Equipment Modifications; The addition of certain accessories, including (but not limited
10 SAFETY Operator Safety S Wet brakes may have reduced stopping ability. Test your brakes after leaving water. If necessary, apply them lightly several times to allow friction to dry out the pads. S Always check for obstacles or people behind the ATV before operat- ing in reverse. When it’s safe to...
Page 14 - not know how to operate the ATV properly in different situations; offered by Polaris through the SVIA. They should; contact ATV; abilities, or judgment needed to operate an ATV safely and could
11 SAFETY Operator Safety WARNING POTENTIAL HAZARDOperating this ATV without proper instruction.WHAT CAN HAPPENThe risk of an accident is greatly increased if the operator does not know how to operate the ATV properly in different situations and on different types of terrain.HOW TO AVOID THE HAZARDB...
Page 17 - could seriously affect operator; visibility and operating conditions, and your experience.
14 SAFETY Operator Safety WARNING POTENTIAL HAZARDOperating the ATV after consuming alcohol or drugs.WHAT CAN HAPPENConsumption of alcohol and/or drugs could seriously affect operator judgment. Reaction time may be slower and operator balance and perception could be affected.Consuming alcohol and/or...
Page 18 - the chance of an accident,; schedules described in the owner’s manual.
15 SAFETY Operator Safety WARNING POTENTIAL HAZARDAttempting wheelies, jumps and other stunts.WHAT CAN HAPPENAttempting stunts increases the chance of an accident, including an overturn.HOW TO AVOID THE HAZARDNever attempt wheelies, jumps, or other stunts. Avoid exhibition driving. WARNING POTENTIAL...
Page 20 - caution when operating on
17 SAFETY Operator Safety WARNING POTENTIAL HAZARDFailure to use extra caution when operating on excessively rough, slippery or loose terrain.WHAT CAN HAPPENOperating on excessively rough, slippery or loose terrain could cause loss of traction or loss of control, which could result in an accident or...
Page 23 - turning as hills could cause
20 SAFETY Operator Safety WARNING POTENTIAL HAZARDImproperly crossing hills and turning on hills.WHAT CAN HAPPENImproperly crossing or turning as hills could cause loss of control or overturn.HOW TO AVOID THE HAZARDNever attempt to turn the ATV around on any hill until you’ve mastered the turning te...
Page 24 - or improperly dismounting
21 SAFETY Operator Safety WARNING POTENTIAL HAZARDStalling, rolling backwards or improperly dismounting while climbing a hill.WHAT CAN HAPPENThe vehicle could overturn.HOW TO AVOID THE HAZARDMaintain steady speed when climbing a hill.If all forward speed is lost:Keep your weight uphill.Apply the sin...
Page 25 - trees when possible. If unavoidable, use extreme caution and; caution to reduce the chance of skidding or sliding out of control.; people behind the ATV. When it’s safe to proceed, back slowly.
22 SAFETY Operator Safety WARNING POTENTIAL HAZARDImproperly operating over obstacles.WHAT CAN HAPPENOperating over obstacles could cause loss of control or overturn.HOW TO AVOID THE HAZARDBefore operating in a new area, check for obstacles.Avoid operating over large obstacles such as rocks and fall...
Page 26 - unavoidable to enter water that exceeds the recommended
23 SAFETY Operator Safety WARNING POTENTIAL HAZARDOperating the ATV through deep or fast-flowing water.WHAT CAN HAPPENTires may float, causing loss of traction and loss of control, which could lead to an accident or overturn.HOW TO AVOID THE HAZARDAvoid operating the ATV through deep or fast-flowing...
Page 27 - accessories. All parts and accessories added to the vehicle must
24 SAFETY Operator Safety WARNING POTENTIAL HAZARDOperating the ATV with improper modifications.WHAT CAN HAPPENImproper installation of accessories or modification of the ATV may cause changes in handling which could lead to an accident.HOW TO AVOID THE HAZARDNever modify the ATV through improper in...
Page 29 - Fuel Safety
26 SAFETY Fuel Safety WARNING Gasoline is highly flammable and explosive under certain conditions. S Always exercise extreme caution whenever handling gasoline. S Always refuel with the engine stopped, and outdoors or in a well ventilated area. S Do not smoke or allow open flames or sparks in or nea...
Page 30 - Safety Decals and Locations; ATV, always read and follow the instructions of the decals
1 2 27 SAFETY Safety Decals and Locations Warning decals have been placed on the ATV for your protection. Read and follow the instructions of the decals on the ATV carefully. If any of the decals depicted in this manual differ from the decals on your ATV, always read and follow the instructions of t...
Page 33 - Safe Riding Gear
30 SAFETY Safe Riding Gear Always wear clothing suited to the type of riding. ATV riding requires special protective clothing for comfort and to reduce the chance of injury. 1. Helmet Wearing a helmet can prevent a severe head injury. Whenever riding a Polaris vehicle, always wear a helmet that meet...
Page 34 - FEATURES AND CONTROLS; Electrical Switches; RUN; OFF
31 FEATURES AND CONTROLS Electrical Switches WARNING Activating the override switch while the throttle is open can cause loss of control, resulting in severe injury or death. Do not activate the override switch while the throttle is open. Override Switch (1) (Reverse Speed Limiter) - This vehicle is...
Page 35 - Light Switches; ON; Indicator Lights; time the ATV is used.; Transmission Neutral Indicator
32 FEATURES AND CONTROLS Light Switches WARNING Operating the ATV on streets or roads, especially in darkness, could result in an accident and serious injury or death.Your ATV is not equipped with highway-approved lights. It’s designed for and must be used for off-road use only . Use caution and dri...
Page 36 - Throttle Lever; Engine speed and vehicle movement
33 FEATURES AND CONTROLS Throttle Lever WARNING Do not start or operate an ATV with sticking or improperly operating throttle controls, which could cause an accident and lead to severe injury or death.Always contact your dealer for service repairs if throttle problems arise.Failure to check or maint...
Page 37 - Brake Lever; Operating the ATV with a spongy brake lever can result in loss of
34 FEATURES AND CONTROLS Brake Lever WARNING Operating the ATV with a spongy brake lever can result in loss of braking, which could cause an accident. Never operate the ATV with a spongy-feeling brake lever. The front and rear brakes are applied by squeezing the brake lever (1) toward the handlebar....
Page 38 - Brakes; Check the brake fluid level in the
35 FEATURES AND CONTROLS Brakes Check the brake fluid level in the master cylinder before each use of the ATV. The master cylinder (1) is located on the left handlebar.The fluid level can be seen through an indicator window (2) on the top of the master cylinder. This “eye” will appear dark when the ...
Page 39 - Parking Brake; Operating the ATV while the parking brake is engaged could; Setting the Parking Brake; Important Safeguards
36 FEATURES AND CONTROLS Parking Brake WARNING Operating the ATV 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. Setting the Parking Brake 1. Squeeze and release the brake lever two ...
Page 40 - Auxiliary Brake; Aggressively applying the rear brake when backing downhill may; reduce
37 FEATURES AND CONTROLS Auxiliary Brake WARNING Aggressively applying the rear brake when backing downhill may cause rear tipover, which could result in serious injury or death.Use caution when applying the auxiliary brake. Do not aggressively apply the auxiliary brake when going forward. The rear ...
Page 41 - Choke; There’s about a 7 to 10 mile; Fuel Tank; Do; Fuel Filter
38 FEATURES AND CONTROLS Choke The choke assists in starting a cold engine. Refer to the engine starting procedure on page 43 for correct choke and throttle settings during starting. Fuel Valve The fuel valve (1) is located on the left side of the vehicle, below the fender. It has three positions:OF...
Page 42 - Automatic Transmission Gear Selector; is located on the right side of the; Shifting gears with the engine speed above idle or while the; gear and lock the parking brake.
39 FEATURES AND CONTROLS Automatic Transmission Gear Selector The transmission gear selector (1) is located on the right side of the vehicle.F: ForwardN: NeutralR: Reverse CAUTION Shifting gears with the engine speed above idle or while the vehicle is moving could cause transmission damage.To change...
Page 43 - Recoil Starter; stop pulling immediately
40 FEATURES AND CONTROLS Recoil Starter If the battery has been drained or damaged and cannot start the engine, use of the recoil starter (1) will allow vehicle operation until repairs can be made. The recoil starter is located on the right side of the machine.Polaris 4-cycle engines are equipped wi...
Page 44 - Excessive heat build-up during the first three hours of operation; Engine and Drivetrain Break-in
41 OPERATION Break-In Period The break-in period for your new Polaris ATV 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 is as important as following the procedures for a proper break-in. Careful treatment of a new...
Page 45 - If a proper inspection is not done before each use, severe injury
42 OPERATION Pre-Ride Inspection WARNING If a proper inspection is not done before each use, severe injury or death could result. Always inspect the vehicle before each use to ensure it’s in proper operating condition. Pre-Ride Checklist Item Remarks See Page Brake system / lever travel Ensure prope...
Page 46 - OPERATION; Starting the Engine; Position the vehicle on a level
43 OPERATION Starting the Engine WARNING Engine exhaust contains poisonous carbon monoxide and can cause loss of consciousness resulting in severe injury or death. Never run an engine in an enclosed area. 1. Position the vehicle on a level surface. 2. Place the transmission in neutral. 3. Lock the p...
Page 48 - Driving Safely; Driving Procedures
45 OPERATION Driving Safely Driving Procedures 1. Sit upright with both feet on the footrests and 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...
Page 49 - Hauling Cargo; Always read and understand the load distribution warnings on all; Maximum Towing Capacities; Refer to the specifications at the rear of this manual for towing
46 OPERATION Driving Safely Hauling Cargo Accessory racks and hitches are available from your Polaris dealer. Always read and understand the load distribution warnings on all warning labels, and never exceed the specified weight capacities for the vehicle. Maximum Towing Capacities Refer to the spec...
Page 51 - Making Turns; rear wheels equally at all times. This means that the wheel on the; Practice making turns at slow speeds before attempting to; Turning at sharp angles or at excessive speeds can result in
48 OPERATION Driving Safely Making Turns Your Polaris ATV is equipped with a solid rear axle, which drives both rear wheels equally at all times. This means that the wheel on the outside of the turn must travel a greater distance than the inside wheel when turning and the inside tire must slip tract...
Page 52 - Driving on Slippery Surfaces; quick, sharp turns which can cause skids.; Failure to exercise care when operating on slippery surfaces can
49 OPERATION Driving Safely Driving on Slippery Surfaces Whenever riding on slippery surfaces such as wet trails or loose gravel, or during freezing weather, follow these precautions:1. Slow down when entering slippery areas.2. Maintain a high level of alertness, reading the trail and avoiding quick...
Page 53 - Driving Uphill; terrain. Improper procedure could cause loss of control or
50 OPERATION Driving Safely Driving Uphill WARNING Braking and handling are greatly affected when operating in hilly terrain. Improper procedure could cause loss of control or overturn and result in serious injury or death.Avoid climbing steep hills (25 _ maximum). Use extreme caution when operating...
Page 54 - This may include quick dismounting of the vehicle.
51 OPERATION Driving Safely Driving Uphill Whenever traveling uphill, follow these precautions:1. Always travel straight uphill.2. Avoid steep hills (25 _ maximum). 3. Keep both feet on the footrests.4. Transfer your weight forward.5. Proceed at a steady rate of speed and throttle opening.6. Remain ...
Page 55 - Driving Downhill; slightly; Familiarize yourself with operation of the auxiliary rear brake; Excessive speed can cause loss of control and lead to serious
52 OPERATION Driving Safely Driving Downhill Whenever descending a hill, follow these precautions:1. Proceed directly downhill.2. Transfer your weight to the rear of the vehicle.3. Slow down.4. Apply the brakes slightly to aid in slowing, using the single brake lever. NOTE: Familiarize yourself with...
Page 56 - Sidehilling; control or vehicle overturn, resulting in severe injury or death.; while keeping your feet on the footrests.; If the vehicle begins to tip, quickly turn the front wheel
53 OPERATION Driving Safely Sidehilling WARNING Improperly crossing hills or turning on hills can result in loss of control or vehicle overturn, resulting in severe injury or death. Avoid crossing the side of a hill when possible. Follow proper procedures as outlined in the owner’s manual. Sidehilli...
Page 57 - Turning Around on a Hill; vehicle is pointing straight uphill.
8’ (2.4 m) 54 OPERATION Driving Safely Turning Around on a Hill If the vehicle stalls while climbing a hill, never back it down the hill! Use the K-turn to turn around. 1. Stop and lock the parking brake while keeping body weight uphill.2. Leave the transmission in forward and shut off the engine.3....
Page 58 - Driving Through Water; critical
55 OPERATION Driving Safely Driving Through Water Your ATV can operate through water with a maximum recommended depth equal to the bottom of the footrests (1). Follow these procedures when operating through water:1. Determine water depths and current before crossing. 2. Choose a crossing where both ...
Page 59 - Driving Over Obstacles; Be constantly alert for hazards such as logs, rocks and low hanging; Severe injury or death can result if your vehicle comes in contact
56 OPERATION Driving Safely Driving Over Obstacles Be alert! Look ahead and learn to read the terrain you’re traveling on. Be constantly alert for hazards such as logs, rocks and low hanging branches. WARNING Severe injury or death can result if your vehicle comes in contact with a hidden obstacle. ...
Page 60 - Driving in Reverse; Follow these precautions
57 OPERATION Driving Safely Driving in Reverse Follow these precautions when operating in reverse:1. Always avoid backing downhill. 2. Back slowly.3. When in reverse, apply the brakes lightly for stopping. 4. Avoid turning at sharp angles in reverse. 5. Never open the throttle suddenly while backing...
Page 61 - Parking on an Incline; Avoid parking on an incline if possible. If it’s unavoidable, follow
58 OPERATION Driving Safely Parking on an Incline Avoid parking on an incline if possible. If it’s unavoidable, follow these precautions:1. Turn the engine off.1. Place the transmission in gear.2. Set the parking brake.3. Always block the rear wheels on the downhill side. See illustration. 4. Shut o...
Page 62 - EMISSION CONTROL SYSTEMS; Noise Emission Control System
59 EMISSION CONTROL SYSTEMS Noise Emission Control System Do not modify the engine, intake or exhaust components, as doing so may affect compliance with U.S.A. EPA noise control requirements (40 CFR 205) and local noise level requirements. Operation on Public Lands in the U.S.A. Your Polaris vehicle...
Page 63 - MAINTENANCE; Periodic Maintenance Chart; Service and adjustments are important for proper vehicle; Severe Use Definition
60 MAINTENANCE Periodic Maintenance Chart Careful periodic maintenance will help keep your vehicle in the safest, most reliable condition. Inspection, adjustment and lubrication of important components are explained in the periodic maintenance chart.Inspect, clean, lubricate, adjust and replace part...
Page 64 - Maintenance Chart Key; not void the emissions warranty but may affect emissions.); Improperly performing the procedures marked with a
61 MAINTENANCE Periodic Maintenance Chart Maintenance Chart Key " Perform these procedures more frequently for vehicles subjected to severe use. E Emission-related service (Failure to conduct this maintenance will not void the emissions warranty but may affect emissions.) J Have an authorized Po...
Page 67 - Lubrication Recommendations; The a-arms and lower control arms are lubricated at the; Lubrication Chart Key
64 MAINTENANCE Lubrication Recommendations Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart beginning on page 60. Items not listed in the chart should be lubricated at the General Lubrication interval. NOTE: The a-arms and lower control arms are lubricat...
Page 69 - Engine Oil; oil filter whenever changing oil.; Oil Recommendations; Polaris recommends the use of Polaris PS-4 PLUS Performance; Mixing brands or using a non-recommended oil may cause; Oil Check
66 MAINTENANCE Engine Oil Always check and change the engine oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 60. Always change the oil filter whenever changing oil. Oil Recommendations Polaris recommends the use of Polaris PS-4 PLUS Performance Synthetic 2W-50 4-cyc...
Page 70 - Oil and Filter Change; Contact with hot oil may result in serious burns. Do not allow hot
67 MAINTENANCE Engine Oil Oil and Filter Change 1. Position the vehicle on a level surface.2. Clean the area around the drain plug.3. Run the engine for two to three minutes until warm. Stop the engine. CAUTION Contact with hot oil may result in serious burns. Do not allow hot oil to come into conta...
Page 71 - Transmission Oil; We recommend the use
68 MAINTENANCE Transmission Oil Always check and change the transmission oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 60. Maintain the oil level at the bottom of the fill hole threads. We recommend the use of Premium AGL Synthetic Gearcase Lubricant. See page 107...
Page 72 - Oil Change
69 MAINTENANCE Transmission Oil Oil Change 1. Place a drain pan beneath the transmission oil drain plug area. 2. Loosen the jam nut (A).3. Turn the adjuster bolt (B) in to allow the removal of the drain plug (C). 4. Remove the drain plug and wipe the magnetic end clean to remove accumulated metallic...
Page 73 - Toe Alignment; Severe injury or death can result from improper toe alignment and
A B 70 MAINTENANCE Toe Alignment WARNING Severe injury or death can result from improper toe alignment and adjustment. Do not attempt to adjust tie rod alignment. All tie rod adjustments should be performed by an authorized Polaris dealer. Use the following procedure to check the toe alignment of th...
Page 74 - The front and rear brakes are hydraulic disc brakes, activated by
71 MAINTENANCE Brakes The front and rear brakes are hydraulic disc brakes, activated by moving the single brake lever toward the handlebar. These brakes are self-adjusting.The following checks are recommended to keep the brake system in good operating condition. Check more often if brakes are used h...
Page 75 - Pads should be changed when; Since this is a rear brake only, it will not be as effective as; Steering Assembly; Accessory springs are
72 MAINTENANCE Brakes 1. Check the brake system for fluid leaks.2. Check the brakes for excessive travel or spongy feel. 3. Check the friction pads for wear, damage and looseness. 4. Check the security and surface condition of the disc. NOTE: Pads should be changed when worn to 3/64 ″ (.1 cm). Auxil...
Page 76 - Throttle Cable Freeplay; While adjusting
1 2 3 73 MAINTENANCE Throttle Cable Freeplay Throttle cable freeplay is adjusted at the handlebar.1. Locate the throttle cable adjuster on the handlebar. 2. Squeeze the end of the rubber boot (1) and slide it far enough to expose the end of the inline cable adjuster (2). 3. Loosen the locknut (3).4....
Page 77 - Handlebars; Improper adjustment of the handlebars or incorrect torquing of
74 MAINTENANCE Handlebars WARNING Improper adjustment of the handlebars or incorrect torquing of the adjuster block tightening bolts can cause limited steering or loosening of the handlebars, resulting in loss of control and possible serious personal injury or death. Follow the adjustment procedures...
Page 78 - Carburetor; Continuous operation of the engine without proper jetting
75 MAINTENANCE Carburetor IMPORTANT: Your Polaris ATV is calibrated at the factory for optimal performance at altitudes ranging from zero to 6,000 feet (1800 m) and temperatures of +40 degrees F. (4 degrees C.) or higher. Above 6000 feet (1800 m) the engine air/fuel mixture becomes overly rich and t...
Page 79 - Wheels; Operating your ATV with worn tires, improperly inflated tires,; Wheel Removal; Stop the engine, place the transmission in gear and lock the
76 MAINTENANCE Wheels WARNING Operating your ATV with worn tires, improperly inflated tires, non-standard tires or improperly installed tires will affect vehicle handling and could cause an accident resulting in serious injury or death.Maintain proper tire pressure as described on the decal on your ...
Page 80 - Wheel Installation; Wheel Nut Torque Specifications
77 MAINTENANCE Wheels Wheel Installation 1. Place the transmission in gear and lock the parking brake. WARNING Improperly installed wheels can adversely affect tire wear and vehicle handling, which can result in serious injury or death. Always ensure that all nuts are torqued to specification. Do no...
Page 81 - Front Wheel Hub Tightening; component operations. All service must be performed by your; Tire Tread Depth; Always replace tires when tread; of skidding, which could lead to loss of control and serious injury; may adversely affect vehicle maneuverability and cause loss of
78 MAINTENANCE Wheels Front Wheel Hub Tightening Front wheel bearing tightness and spindle nut retention are critical component operations. All service must be performed by your authorized Polaris dealer. Tire Tread Depth Always replace tires when tread depth is worn to 1/8 ″ (.3 cm) or less. See il...
Page 82 - Drive Chain; 0-90 lube or an approved o-ring chain spray lube. See page 107 for the; Washing the drive chain with a high pressure washer or gasoline
79 MAINTENANCE Drive Chain Polaris ATV drive chains are equipped with o-ring-sealed, permanently greased pins and rollers. However, the outer surfaces of the roller must be lubricated.Always inspect the drive chain prior to operating the vehicle. Check for damaged or missing o-rings or damaged rolle...
Page 83 - Rear Drive Chain Slack; Adjusting or operating the ATV with improper rear drive chain; this point the chain should have 3/16
80 MAINTENANCE Drive Chain Rear Drive Chain Slack CAUTION Adjusting or operating the ATV 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...
Page 84 - Roll the ATV forward or backward; The chain is adjusted correctly when the tightest portion of
81 MAINTENANCE Drive Chain Rear Drive Chain Slack 6. Roll the ATV forward or backward to adjust the chain slack to the proper tension. See the illustration for proper splice link clip opening position (1). 7. Tighten the eccentric locking bolts to 30 ft. lbs. (41 Nm) for machines without the hitch a...
Page 85 - Lights; Poor lighting while driving can result in severe injury or death.; Headlight Lamp Replacement
82 MAINTENANCE Lights When servicing a halogen lamp, don’t touch the lamp with bare fingers. Oil from your skin leaves a residue, causing a hot spot that will shorten the life of the lamp. WARNING Poor lighting while driving can result in severe injury or death. Headlight and taillight lenses become...
Page 86 - Taillight/Brakelight Lamp Replacement
83 MAINTENANCE Lights Taillight/Brakelight Lamp Replacement If the taillight/brakelight does not work the lamp may need to be replaced.1. Remove the taillight lens cover mounting screws. Remove the lens cover and gasket and set aside for reassembly. 2. Remove the lamp (1).3. Apply dielectric grease ...
Page 87 - Air Filter
84 MAINTENANCE Air Filter 1. Remove the seat, release the clips, and remove the air box cover. 2. Loosen the clamp and remove the filter. 3. If equipped, remove the fabric type pre-filter (1) from the main filter (2). Wash the pre-filter in soapy water, then rinse and let dry. Reinstall the pre-filt...
Page 88 - Spark Plugs; Spark Plug Recommendations; Refer to the specifications section beginning on page 104 for the; Plug Condition; Spark Plug Inspection; spark plug counterclockwise to remove it.
85 MAINTENANCE Spark Plugs Spark Plug Recommendations CAUTION Using non-recommended spark plugs can result in serious engine damage. Always use Polaris-recommended spark plugs. Refer to the specifications section beginning on page 104 . Refer to the specifications section beginning on page 104 for t...
Page 89 - Normal Plug; Recoil Housing; crankcase
86 MAINTENANCE Spark Plugs Spark Plug Inspection Normal Plug The normal insulator tip is gray, tan or light brown. There will be 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...
Page 90 - Vehicle Immersion; If your vehicle becomes immersed, major engine damage can; very least, to water below the; If water has been ingested into the PVT, follow the procedure
87 MAINTENANCE Vehicle Immersion CAUTION If your vehicle becomes immersed, major engine damage can result if the machine is not thoroughly inspected. Take the vehicle to your dealer before starting the engine. If it’s impossible to take your ATV to a dealer before starting it, follow the steps outli...
Page 91 - PVT System; NOTE: Avoid heavy pulling and extended low -speed
88 MAINTENANCE PVT System The basic operation of the Polaris PVT system is dependent on engine speed and vehicle torque requirements. As engine speed increases, the force exerted on the movable drive sheave by the flyweights also increases. This, in turn, increases the amount of “pinch” applied to t...
Page 92 - PVT Drying; the PVT system. Use the following instructions to dry it out before
89 MAINTENANCE PVT System WARNING Failure to comply with the instructions in this warning can result in severe injury or death.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 ...
Page 93 - Spark Arrestor; Failure to heed the following warnings while servicing the spark
90 MAINTENANCE Spark Arrestor WARNING Failure to heed the following warnings while servicing the spark arrestor could result in serious injury or death.Do not perform service on the spark arrestor while the system is hot. Exhaust system temperatures can reach 1000 ° F. Allow components to cool suffi...
Page 94 - Battery; Your ATV may have either a sealed battery, which requires little; Conventional Battery; Drink large quantities of water or milk. Follow with milk
91 MAINTENANCE Battery Your ATV may have either a sealed battery, which requires little maintenance, or a conventional battery. A sealed battery can be identified by its flat covers on the top of the battery. A conventional battery has six filler caps on the top of the battery.Always keep battery te...
Page 95 - in an explosion and cause serious injury or death. When; Battery Removal; remove battery cover.; tablespoon baking soda and one cup water to prevent damage to
92 MAINTENANCE Battery WARNING Improperly connecting or disconnecting battery cables can result in an explosion and cause 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 l...
Page 96 - Battery Installation; Using a new battery that has not been fully charged can damage the
93 MAINTENANCE Battery Battery Installation Using a new battery that has not been fully charged can damage the battery and result in a shorter life. It can also hinder vehicle performance. Follow the battery charging instructions on pages 95-97 before installing the battery.1. Ensure that the batter...
Page 97 - Battery Storage
94 MAINTENANCE Battery Battery Storage Whenever the vehicle is not used for a period of three months or more, remove the battery from the vehicle, ensure 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 ...
Page 99 - The following battery charging instructions apply only to the; charged battery will register 12.8 V or higher.
96 MAINTENANCE Battery Battery Charging (Sealed Battery) The following battery charging instructions apply only to the installation of a sealed battery. Read all instructions before proceeding with the installation of this battery.The sealed battery is already filled with electrolyte and has been se...
Page 100 - Always verify battery condition before and 1-2 hours after the
97 MAINTENANCE Battery Battery Charging (Sealed Battery) NOTE: Always verify battery condition before and 1-2 hours after the end of charging. 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 ...
Page 101 - Cleaning and Storage; Washing the Vehicle; High water pressure may damage ATV components. Polaris; Washing Tips
98 MAINTENANCE Cleaning and Storage See page 107 for the part numbers of Polaris products. Washing the Vehicle Keeping your ATV clean will not only improve its appearance but it can also extend the life of various components. CAUTION High water pressure may damage ATV components. Polaris recommends ...
Page 102 - If warning and safety labels are damaged, contact your; Polishing the Vehicle; Polishing Tips
99 MAINTENANCE Cleaning and Storage Washing the Vehicle If a high pressure water system is used for cleaning (not recommended), exercise extreme caution. The water may damage components and could remove paint and decals. Avoid directing the water stream at the following items: S Wheel bearings S Rad...
Page 103 - Chrome wheels exposed to road salt (or salt in the air in; Removing Corrosion
100 MAINTENANCE Cleaning and Storage Chrome Wheel Care (if equipped) Proper maintenance will protect chrome wheels from corrosion, preserve wheel life and ensure a ”like new” appearance for many years. NOTE: Chrome wheels exposed to road salt (or salt in the air in coastal areas) are more susceptibl...
Page 104 - Storage Tips; See page 107 for the part numbers of Polaris products.; Starting the engine during the storage period will disturb the; Clean the Exterior; Stabilizer. Follow the instructions on the container for the; Carbon Clean removes water from fuel systems, stabilizes; disperse through the fuel in the tank and carburetor.; Oil and Filter
101 MAINTENANCE Cleaning and Storage Storage Tips See page 107 for the part numbers of Polaris products. CAUTION Starting the engine during the storage period will disturb the protective film created by fogging and damage could occur. Never start the engine during the storage period. Clean the Exter...
Page 105 - Fluid Levels; Use a section of small hose and a small plastic squeeze bottle
102 MAINTENANCE Cleaning and Storage Storage Tips Fluid Levels Inspect the fluid levels. Add or change fluids as recommended in the Periodic Maintenance Chart beginning on page 60. S Transmission fluid S Brake fluid (change every two years and any time the fluid looks dark or contaminated) Fog the E...
Page 106 - Inspect and Lubricate; Do not use plastic or coated materials. They do not allow; Transporting the ATV; frame
103 MAINTENANCE Cleaning and Storage Storage Tips Inspect and Lubricate Inspect all cables and lubricate all areas of the vehicle as recommended in the Periodic Maintenance Chart beginning on page 60. Battery Storage See pages 94-97 for storage and charging procedures. Storage Area/Covers Set the ti...
Page 107 - SPECIFICATIONS
104 SPECIFICATIONS 2008 Trail Blazer 330 Capacities & Dimensions Body Style Gen III Dry Weight 488 lbs. (221 kg) Maximum Weight Capacity 305 lbs. (138 kg) Front Rack Capacity (Accessory) 30 lbs. (14 kg) Rear Rack Capacity (Accessory) 60 lbs. (27 kg) Hitch Towing Rating (Accessory) 850 lbs.(386 k...
Page 109 - Jetting Chart; Clutching Chart
106 SPECIFICATIONS 2008 Trail Blazer 330 Jetting Chart Altitude AMBIENT TEMPERATURE Below 40 ° F (Below 5 ° C) +40 ° F and above (+5 ° C and above) Meters (Feet) 0-1800 (0-6000) 127.5 122.5 1800-3700 (6000-12000) 120 115 Clutching Chart Altitude Shift Weight Drive Clutch Spring Driven Clutch Spring ...
Page 110 - POLARIS PRODUCTS
107 POLARIS PRODUCTS Part No. Description Engine Lubricant 2870791 Fogging Oil (12 oz. Aerosol) 2876244 PS-4 PLUS Performance Synthetic 2W-50 4-Cycle Oil (qt.) 2876245 PS-4 PLUS Performance Synthetic 2W-50 4-Cycle Oil (gal.) Gearcase / Transmission Lubricants 2873602 Premium AGL Synthetic Gearcase L...
Page 111 - TROUBLESHOOTING; solutions using the following charts.; Drive Belt and Cover Problems
108 TROUBLESHOOTING Contact your Polaris dealer for service if you’re unable to identify solutions using the following charts. Drive Belt and Cover Problems Possible Cause Solution Driving onto a pickup or tall trailer in high range Shift transmission to low range during loading of the ATV to preven...
Page 112 - Engine Doesn’t Turn Over
109 TROUBLESHOOTING Engine Doesn’t Turn Over Possible Cause Solution Tripped circuit breaker Reset the breaker Low battery voltage Recharge battery to 12.8 VDC Loose battery connections Check all connections and tighten Loose solenoid connections Check all connections and tighten Engine Turns Over, ...
Page 113 - Engine Backfires
110 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...
Page 114 - Engine Stops or Loses Power
111 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 Replace with new fuel Overuse of choke Inspect, clean and/or replace spark plugs Fouled or defective spark...
Page 115 - WARRANTY; LIMITED WARRANTY; LIMITATIONS OF WARRANTIES AND REMEDIES
112 WARRANTY LIMITED WARRANTY Polaris Sales Inc., 2100 Highway 55, Medina, MN 55340, gives a SIX MONTH LIMITED WARRANTY on all components of the Polaris All Terrain Vehicle (ATV) against defects in material or workmanship. Polaris also gives a one year limited warranty on the final drive chain for f...
Page 116 - WARRANTY COVERAGE AND EXCLUSIONS:; HOW TO OBTAIN WARRANTY SERVICE; SPARK ARRESTOR
113 WARRANTY WARRANTY COVERAGE AND EXCLUSIONS: 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 SIX MONTH WARRAN- TY PERIOD. POLARIS FURTHER...
Page 117 - Exported Vehicles; How to Get Service; Notice
114 WARRANTY Exported Vehicles EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE IS NO WAR- RANTY OR SERVICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD OUTSIDE THE COUNTRY OF THE SELLING DEALER’S AUTHORIZED LOCA- TION.This policy does not apply to vehicles that have received authorization for ex...
Page 119 - MAINTENANCE LOG; Use the following chart to record periodic maintenance.
116 MAINTENANCE LOG Use the following chart to record periodic maintenance. DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS
Page 121 - INDEX
118 INDEX A Age Restrictions 6 . . . . . . . . . . . . . . . . Air Filter 84 . . . . . . . . . . . . . . . . . . . . . Auxiliary Brake 37, 72 . . . . . . . . . . . . B Battery 91-97 . . . . . . . . . . . . . . . . . . . . Battery Charging (Conventional) 95 . . Battery Charging (Sealed) 96-97 . . . ....