Polaris Trail Blazer 2004 Owner'S Manual Download

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MAINTENANCE AND LUBRICATION

Adjustments

Wheel Installation

1. Place the transmission in gear

and lock the parking brake.

2. Place the wheel on the wheel

hub with the valve stem toward

the outside and the rotation

arrows on the tire pointing

toward forward rotation.

3. Install the wheel nuts and finger

tighten.

4. Lower the vehicle to the ground.
5. Torque the wheel nuts according to the wheel nut torque

specifications chart.

NOTE:

All nuts that have a cotter pin installed must be serviced by an

authorized Polaris dealer.

Wheel Nut Torque Specifications

Check the wheel nut torques occasionally and when they’ve been

loosened for maintenance service.

Bolt Size

Specification

Front 3/8

″

20 ft. lbs. (27 Nm)

Rear 3/8

″

20 ft. lbs. (27 Nm)

Rear 1/2

″

50 ft. lbs. (68 Nm)

Summary of Contents for Trail Blazer 2004

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Page 3: ...ed 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 kno...

Page 4: ...ted a Web site just for you S Technical tips S New product introductions S Event schedules S Parts and Service Manual information S Exciting details about The Way Out Check it out www polarisindustrie...

Page 5: ...uction components some minor discrepancies may result between the actual vehicle and the information presented in this publication Depictions and or procedures in this publication are intended for ref...

Page 6: ...king it the finest machine we ve ever produced For safe and enjoyable operation of your vehicle be sure to follow the instructions and recommendations in this owner s manual Your manual contains instr...

Page 7: ...4...

Page 8: ...E 3 VEHICLE IDENTIFICATION NUMBERS 6 SAFETY 7 FEATURES AND CONTROLS 36 OPERATION 48 EMISSION CONTROL SYSTEMS 67 MAINTENANCE AND LUBRICATION 68 SPECIFICATIONS 107 POLARIS PRODUCTS 110 TROUBLESHOOTING 1...

Page 9: ...s are essential to the recovery and identification of your vehicle Remove the spare key and store it in a safe place Your key can be duplicated only by mating a Polaris key blank with one of your exis...

Page 10: ...laris dealer you can request this free safety training from any authorized Polaris dealer A Polaris ATV is an off road vehicle Familiarize yourself with all laws and regulations concerning the operati...

Page 11: ...n your ATV or in this manual alerts you to the potential for personal injury The safety alert warning indicates a potential hazard that may result in serious injury or death The safety alert caution i...

Page 12: ...es boots a long sleeved shirt or jacket and long pants S Never consume alcohol or drugs before or while operating an ATV S Never operate at excessive speeds Travel at speeds appropriate for the terrai...

Page 13: ...attempt to turn the ATV around on any hill until you ve mastered on level ground the turn ing technique outlined in this manual Avoid crossing the side of a steep hill when possible S Always use prope...

Page 14: ...or accidental starting FOR MORE INFORMATION ABOUT ATV SAFETY call the Con sumer Product Safety Commission at 1 800 638 2772 or call Polaris at 1 800 342 3764 Equipment Modifications We are concerned...

Page 15: ...e operating techniques described in the owner s manual For more information about the training course contact an authorized ATV dealer or call Polaris at 1 800 342 3764 POTENTIAL HAZARD Failure to fol...

Page 16: ...the operator s ability to balance and control the ATV which could cause an accident and injury to the operator and or passenger HOW TO AVOID THE HAZARD Never carry a passenger The purpose of the long...

Page 17: ...HAT CAN HAPPEN ATV tires are designed for off road use Operating on paved surfaces may seriously affect the handling and control of the ATV and could result in loss of control accident and or injury H...

Page 18: ...roads or highways WHAT CAN HAPPEN The ATV could collide with another vehicle HOW TO AVOID THE HAZARD Never operate the ATV on any public street road or highway including dirt and gravel roads In many...

Page 19: ...ases the risk of a severe head injury or death in the event of an accident Operating without eye protection could result in an accident and could increase the chance of a severe injury in the event of...

Page 20: ...while operating an ATV could result in an accident causing severe injury or death HOW TO AVOID THE HAZARD Never consume alcohol or drugs before or while operating an ATV POTENTIAL HAZARD Operating the...

Page 21: ...RD Attempting wheelies jumps and other stunts WHAT CAN HAPPEN Attempting stunts increases the chance of an accident including an overturn HOW TO AVOID THE HAZARD Never attempt wheelies jumps or other...

Page 22: ...cedures and schedules described in the owner s manual POTENTIAL HAZARD Removing hands from the handlebars or feet from the footrests during operation WHAT CAN HAPPEN Removing even one hand or foot can...

Page 23: ...on unfamiliar terrain WHAT CAN HAPPEN Unfamiliar terrain may contain hidden rocks bumps or holes that could cause loss of control or overturn HOW TO AVOID THE HAZARD Travel slowly and use extra cauti...

Page 24: ...y rough slippery or loose terrain could cause loss of traction or loss of control which could result in an accident or overturn HOW TO AVOID THE HAZARD Do not operate on excessively rough slippery or...

Page 25: ...ed in the owner s manual Practice turning at slow speeds before attempting to turn at faster speeds Never turn at excessive speed POTENTIAL HAZARD Operating on excessively steep hills WHAT CAN HAPPEN...

Page 26: ...r s manual Always check the terrain carefully before ascending any hill Never operate the ATV on hills steeper than 25_ Never climb hills with excessively slippery or loose surfaces Shift your weight...

Page 27: ...aveling down hills as described in the owner s manual NOTE A special technique is required when braking while traveling downhill See page 58 Always check the terrain carefully before you descending a...

Page 28: ...n the ATV around on any hill until you ve mastered the turning technique on level ground as described in the owner s manual See page 59 Use extra caution when turning on any hill Avoid crossing the si...

Page 29: ...stopped apply the auxiliary rear brake as well then lock the parking brake If the ATV begins rolling backwards Keep weight uphill Never apply engine power Never apply the auxiliary rear brake while r...

Page 30: ...as rocks and fallen trees when possible If unavoidable use extreme caution and always follow proper procedures as outlined in the owner s manual POTENTIAL HAZARD Skidding or sliding WHAT CAN HAPPEN Sk...

Page 31: ...ght carefully avoid sudden movements and maintain a slow and steady forward motion Do not make sudden turns or stops and do not make sudden throttle changes Wet brakes may have reduced stopping abilit...

Page 32: ...r the ATV POTENTIAL HAZARD Operating the ATV with improper modifications WHAT CAN HAPPEN Improper installation of accessories or modification of the ATV may cause changes in handling which could lead...

Page 33: ...rgo or pulling a trailer Allow a greater distance for braking Always follow the instructions in the owner s manual for carrying cargo or pulling a trailer See page 64 POTENTIAL HAZARD Operating on fro...

Page 34: ...ons with cognitive or physical disabilities who operate this vehicle have an increased risk of overturn and loss of control which could result in severe injury or death CAUTION Always keep combustible...

Page 35: ...prevent flipover on hilly terrain when going up or down use throttle and brakes gradually DREVERSE operation can bedangerous evenat lowspeeds Steeringbe comes difficult To prevent flipover avoid sudd...

Page 36: ...d Locations WARNING Improper ATV use can result in SEVERE INJURY or DEATH ALWAYS USE AN APPROVED HELMET AND PROTECTIVE GEAR NEVER USE ON PUBLIC ROADS NEVER CARRY PASSENGERS NEVER USE WITH DRUGS OR ALC...

Page 37: ...t on Eccentric Bolts To 30 Ft Lbs For models without a hitch To 40 Ft Lbs For models with a hitch 7078572 MANUFACTURED BY POLARIS IND INC DATE VIN THIS VEHICLE IS AN ALL TERRAIN VEHICLE AND IS NOT INT...

Page 38: ...stitute label ANSI z90 1 or the Snell Memorial Foundation label 2 Eye Protection Do not depend on sunglasses for proper eye protection A pair of goggles or a helmet face shield offer the best protecti...

Page 39: ...sition Release the key when the engine starts NOTE Turning off the main switch will shut off all electrical power to the vehicle including the lights Engine Stop Switch 3 The engine will not start or...

Page 40: ...nic Throttle Control ETC stops the engine in the event of a throttle system malfunction and is provided for your safety Do not attempt to modify the ETC system or replace it with any after market thro...

Page 41: ...TE The taillight is on whenever the main switch key is on Turn the key off to prevent battery drain 1 Transmission Neutral Indicator 2 Transmission Reverse Indicator 3 Oil Warning indicates a low oil...

Page 42: ...d Always fill the reservoir as needed whenever the cover is loosened or removed to ensure proper diaphragm operation We recommend the use of Polaris DOT 3 brake fluid Do not overfill 3 If the fluid le...

Page 43: ...ke lever travel and master cylinder fluid level before riding When squeezed the lever should feel firm Any sponginess would indicate a possible fluid leak or low master cylinder fluid level which must...

Page 44: ...he parking brake may relax if left on for a long period of time Al ways block the wheels to prevent rolling S Always block the wheels on the downhill side of the ATV if leaving it parked on a hill Ano...

Page 45: ...without skidding Check the brake fluid level frequently for the auxiliary brake system The reservoir is located under the seat or near the foot brake Maintain the fluid level between the maximum and m...

Page 46: ...usted NOTE There s about a 7 to 10 mile 11 2 to 16 km range on reserve gas Always refill the gas tank as soon as possible after using the reserve supply Always return valve to ON position after refuel...

Page 47: ...o not overfill the tank Do not fill the tank neck S If gasoline spills on your skin or clothing immediately wash it off with soap and water and change clothing S Never start the engine or let it run i...

Page 48: ...ations section beginning on page 107 for capacities Mixing brands or using a non recommended oil may cause serious engine damage We recommend the use of Polaris Premium Synthetic 2 cycle oil for your...

Page 49: ...N Neutral R Reverse Whenever the ATV is left unattended always place the transmission in gear and lock the parking brake 1 F N R Shifting gears with the engine speed above idle or while the vehicle i...

Page 50: ...sition NOTE If the engine is cold use the choke as outlined on page 51 4 Reach under the side panel and grasp the starter rope handle 2 firmly and pull slowly so you can feel the engine strokes NOTE E...

Page 51: ...engine Perform the following procedures carefully CAUTION Excessive heat build up during the first three hours of operation will damage close fitted engine parts Do not operate at full throttle or hi...

Page 52: ...he oil tank with the recommended oil 3 Drive slowly at first Vary the throttle positions 4 Perform regular checks on fluid levels controls and areas outlined on the daily pre ride inspection checklist...

Page 53: ...ine stop switch Check for proper function 8 Wheels Check for tightness of wheel nuts and axle nuts check that axle nuts are secured by cotter pins 9 Drive chain Check condition and slack refer to driv...

Page 54: ...witch to RUN NOTE Do not press the throttle while starting the engine 4 Turn the ignition key past the ON position to engage the starter for a maximum of five seconds Release the key when the engine s...

Page 55: ...the fuel tank valve to ON sit on the vehicle and turn the engine stop switch to RUN 3 If the engine has cooled to a point where it does not readily start intermittent use of the choke pulled half way...

Page 56: ...to warm up then shift the transmission into gear 3 Check your surroundings and determine your path of travel 4 Release the parking brake 5 Slowly depress the throttle with your right thumb and begin...

Page 57: ...ion of the turn leaning your upper body to the inside of the turn while supporting your weight on the outer footrest This technique alters the balance of traction between the rear wheels allowing the...

Page 58: ...trail and avoiding quick sharp turns which can cause skids 3 Correct a skid by turning the handlebars in the direction of the skid and shifting your body weight forward WARNING Failure to exercise ca...

Page 59: ...TV begins rolling backwards Keep your weight uphill Never apply engine power Never apply the auxiliary rear brake while rolling backwards Apply the single lever brake gradually When fully stopped appl...

Page 60: ...ard the hill while keeping your feet on the footrests 3 Steer slightly into the hill to maintain vehicle directions NOTE If the vehicle begins to tip quickly turn the front wheel downhill if possible...

Page 61: ...vehicle 3 Slow down 4 Apply the brakes slightly to aid in slowing using the single brake lever NOTE Familiarize yourself with operation of the auxiliary rear brake pedal for additional braking in the...

Page 62: ...ing the brake lever release the parking brake lock and slowly allow the vehicle to roll around to your right until it s pointing across the hill or slightly downward 6 Lock the parking brake and remou...

Page 63: ...g 2 Choose a crossing where both banks have gradual inclines 3 Proceed slowly avoiding rocks and obstacles if possible 4 After crossing dry the brakes by applying light pressure to the lever until bra...

Page 64: ...make sudden throttle changes If your vehicle becomes immersed and it s impossible to take it to a dealer before starting it follow the steps described on page 95 Have the vehicle serviced by your deal...

Page 65: ...the terrain you re traveling on Be constantly alert for hazards such as logs rocks and low hanging branches Severe injury or death can result if your vehicle comes in contact with a hidden obstacle No...

Page 66: ...increased Do not operate at wide open throttle Open the throttle just enough to maintain a desired speed WARNING Failure to use caution when operating in reverse can result in serious injury or death...

Page 67: ...ver exceed the weight capacities outlined in the specifications section of the owner s manual and on the safety decals Cargo weight should be evenly distributed 1 3 on the front rack and 2 3 on the re...

Page 68: ...SECURED BEFORE OPERATING Unsecured loads can create unstable operating conditions which could result in loss of control of the vehicle S OPERATE ONLY WITH STABLE AND SAFELY ARRANGED LOADS When handlin...

Page 69: ...parking on an incline if possible If it s unavoidable follow these precautions 1 Turn the engine off 2 Place the transmission in gear 3 Set the parking brake 4 Always block the rear wheels on the dow...

Page 70: ...rvice Standard 5100 1C Exhaust Emission Control System The emissions from the exhaust of this vehicle are controlled by engine design including factory set carburetion and ignition The engine and rela...

Page 71: ...following charts are based upon average riding conditions and an average vehicle speed of approximately 10 miles per hour Vehicles subjected to severe use such as operation in wet or dusty areas shou...

Page 72: ...Pre Ride Pre Ride Replace coolant every two years Fuel and oil tanks Pre Ride Pre Ride Fill to proper levels Throttle Pre Ride Pre Ride Check operation Lights Pre Ride Pre Ride Check operation Engine...

Page 73: ...ts cables etc Oil Pump Cable 50 hrs 6 months Inspect adjust lubricate replace if required Carburetor float bowl 50 hrs 6 months Drain bowl periodically and prior to storage J Throttle Cable ETC Switch...

Page 74: ...Shift selector box 200 hrs 24 months Change lubricant every two years J Brake fluid 200 hrs 24 months Change every two years Spark arrestor 300 hrs 36 months Clean out J Front and rear wheel bearings...

Page 75: ...CE AND LUBRICATION Periodic Maintenance Record Use the following chart to record periodic maintenance Maintenance Interval Performed Servicing Date Servicing Dealer or Person Remarks 10 hrs 20 hrs 50...

Page 76: ...Item Lube Method Frequency Engine Polaris Injection Oil Fill oil tank See page 45 As needed when refueling Brakes DOT 3 fluid only Maintain level between fill lines See page 39 As required change eve...

Page 77: ...rough the life of the unit Your dealer will be able to assist you with that selection based on your operating conditions and riding style Never mix Polaris premium 2 cycle oils with any other brand of...

Page 78: ...forward of the headlight Check the oil before each use of the vehicle Refill the oil when refueling 1 Position the ATV on a level surface 2 Remove the oil tank cap and inspect the oil level in the ta...

Page 79: ...the recommended gearcase oil to bring the level within the safe operating range on the dipstick 4 Reinstall the dipstick Transmission Oil Change 1 Place a drain pan beneath the transmission oil drain...

Page 80: ...the engine at idle hold the lever up for thirty seconds to purge all air from the system CAUTION If the oil supply line has been disconnected from the pump or if the oil reservoir and supply line have...

Page 81: ...6 32 cm of throttle lever travel before the throttle slide starts to open 3 Place very slight pressure on the throttle lever 2 until all freeplay is removed from the throttle cable to the point where...

Page 82: ...e system for fluid leaks 3 Check the brakes for excessive travel or spongy feel 4 Check the friction pads for wear damage and looseness 5 Check the security and surface condition of the disc NOTE Inst...

Page 83: ...illustration 3 Tie an elastic string around the stands making sure the string just touches the side surface of the rear tires on each side of the vehicle and goes around the stands in front of the veh...

Page 84: ...d bolts are found see your Polaris dealer for service before operating the vehicle Camber and Caster The camber and caster are non adjustable Rear Spring The rear shock absorber spring is adjusted by...

Page 85: ...freeplay is adjusted at the handlebar 1 Slide the boots 1 off the inline cable adjuster sleeve 2 Loosen the adjuster locknut 3 2 Turn the adjuster until 1 16 to 1 8 freeplay is achieved at the thumb l...

Page 86: ...or performance overheating or engine damage See your Polaris dealer for more information about jetting the ATV for conditions in your area If the engine idle speed is not satisfactory and all other co...

Page 87: ...wheel 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 injur...

Page 88: ...l the wheel nuts and finger tighten 4 Lower the vehicle to the ground 5 Torque the wheel nuts according to the wheel nut torque specifications chart NOTE All nuts that have a cotter pin installed must...

Page 89: ...ARNING Operating the vehicle with worn tires will increase the possibility of skidding which could lead to loss of control and serious injury or death Always replace tires when the tread depth measure...

Page 90: ...the stone guard to rear sprocket clearance at 1 8 3 cm 4 Regularly lubricate the drive chain with Polaris chain lube or SAE 80 90 lube See page 110 for the part numbers of Polaris products Cylinder He...

Page 91: ...deflection Use the following procedure if adjustment is required 1 Loosen the chain guide 2 Loosen the two eccentric locking bolts 1 3 Loosen the caliper mounting bracket bolt located on the left sid...

Page 92: ...without the hitch and 45 ft lbs 61 Nm for machines with a hitch 3 Tighten the caliper mount bolt to 10 12 ft lbs 14 17 Nm 4 Remove the pin punch 5 Roll the ATV forward checking chain tension in sever...

Page 93: ...box 3 Tighten the clamp Do not overtighten as filter damage could occur 4 Check the cover gasket and replace if needed Be sure the cover is seated properly then snap the clips onto the cover 5 Reinst...

Page 94: ...y remove the bulb from the housing 4 Apply dielectric grease to the light bulb socket before installing the new bulb Insert the new bulb into the housing and reinstall the retention screw Reinstall th...

Page 95: ...ht 4 Observe the headlight aim on the wall The most intense part of the headlight beam should be aimed 8 20 3 cm below the mark placed on the wall NOTE Include rider weight on the seat when measuring...

Page 96: ...w lamp 3 Test the taillight brakelight to see that it s working 4 Reinstall the gasket and lens cover Indicator Lamp Replacement 1 Remove the instrument panel if necessary to access the back of the in...

Page 97: ...ndicates overheating caused by use of an improper spark plug or incorrect carburetion adjustments 2 Wet Fouled The wet fouled insulator tip is black A damp oil film covers the firing end There may be...

Page 98: ...gine over several times using the electric start 8 Dry the spark plug and reinstall or replace it with a new plug 9 Reinstall the bowl drain 10 Reinstall the crankcase drain screw 11 Turn the fuel val...

Page 99: ...hicle is in neutral and repeat steps 3 and 4 until no more particles are expelled when the engine is revved 6 Stop the engine and allow the arrestor to cool Reinstall the arrestor plug and remove the...

Page 100: ...also be done before storing the ATV Water will enter the recoil housing if the starter handle is disengaged from the rope guide when under water The recoil handle must be behind the heat shield for it...

Page 101: ...unning at only about 1500 RPM with an engagement speed of about 1400 RPM Whenever operating this close to the engagement point the engine may be running at a speed too low to provide the adequate pinc...

Page 102: ...G 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 occu...

Page 103: ...also hinder vehicle performance Follow the battery charging instructions on page 101 before installing the battery 1 Ensure that the battery is fully charged 2 Set the battery in the battery holder 3...

Page 104: ...battery is already filled with electrolyte and has been sealed and fully charged at the factory Do not ever pry the sealing strip off or add any other fluid to this battery The single most important...

Page 105: ...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 12 5 12 8 volts May need slight charge if no charge given check in 3 mon...

Page 106: ...afety labels are damaged contact your a Polaris dealer for free replacement Polaris does not recommend the use of a high pressure type car wash system for washing the ATV If a high pressure system is...

Page 107: ...ial growth and promotes better starting after the storage period 1 Fill the fuel tank with fuel and add Polaris Carbon Clean or Fuel Stabilizer Follow the instructions on the container for the recomme...

Page 108: ...unces of the recommended oil into the cylinder Reinstall the spark plug 3 Apply dielectric grease to the inside of the spark plug cap and install the cap onto the plug 4 With the ignition off turn the...

Page 109: ...c or coated materials They do not allow enough ventilation to prevent condensation and may promote corrosion and oxidation Transporting an ATV Follow these procedures when transporting an ATV 1 Turn o...

Page 110: ...round Clearance 5 5 14 cm Height 47 in 119 4 cm Length 75 in 190 5 cm Seat Height 34 in 86 4 cm Dry Weight 461 lbs 209 1 kg Wheel Base 48 in 121 9 cm Width 46 in 116 8 cm Engine Cooling Engine Model N...

Page 111: ...sion McPherson Strut w 8 2 20 8 cm travel Rear Suspension Progressive Rate w 10 5 26 7 cm travel Shock Adjustment CAM Front Brake Hydraulic Disc Rear Brake Hydraulic Disc Auxiliary Brake Hydraulic Dis...

Page 112: ...0 130 120 110 1800 2700 6000 9000 125 120 110 100 2700 3700 9000 12000 115 110 100 95 Turn air screw out 1 2 turn CCW from seat Raise needle clip 1 position to lower jet needle Clutching Chart Altitud...

Page 113: ...Lubricant qt 2873603 AGL Synthetic Gearcase Lubricant gal 2873604 AGL Synthetic Gearcase Lubricant 2 5 gal Grease Specialized Lubricants 2871312 Grease Gun Kit Premium All Season 3 oz 2871322 Premium...

Page 114: ...e and prevent belt burning Slow and easy clutch en gagement Use the throttle quickly and effectively for efficient enga gement Towing pushing at low RPM low ground speed Install a one tooth smaller co...

Page 115: ...el system and refuel Fuel valve is turned off Turn the fuel valve on Old or non recommended fuel Replace with new fuel Fouled or defective spark plug s Inspect plug s replace if necessary No spark to...

Page 116: ...e ignition connections Check all connections and tighten Water present in fuel Replace with new fuel Low battery voltage Recharge battery to 12 8 VDC Kinked or plugged fuel vent line Inspect and repla...

Page 117: ...ctive spark plug wires See your Polaris dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs Loose ignition connections Check all connections and tighten Low battery voltage...

Page 118: ...ANTY COVERAGE AND EXCLUSIONS LIMITATIONS OF WARRANTIES AND REMEDIES The Polaris limited warranty excludes any failures that are not caused by a defect in material or workmanship This warranty does not...

Page 119: ...u must present your copy of the Warranty Registration form to the dealer THE COST OF TRANSPORTATION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY Polaris suggests that you use your original selling de...

Page 120: ...ized Polaris dealer You must show the dealer photo identification from the country of the selling dealer s authorized location as proof of residence Upon residence verification the servicing dealer wi...

Page 121: ...53 66 Driving Through Water 60 61 Driving Uphill 56 E Electrical Switches 36 EMISSION CONTROL SYSTEMS 67 Engine Fogging 105 Engine Oil Check 75 Equipment Modifications 11 Exhaust Emission Control Sys...

Page 122: ...Plugs 94 SPECIFICATIONS 107 109 Starting a Cold Engine 51 Starting a Warm Engine 52 S Starting the Engine 51 52 Steering Assembly 81 Stop Switch 36 Storage Tips 104 106 T TABLE OF CONTENTS 5 Taillight...

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