Polaris Trail Blazer, Service Manual

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ENGINE
Engine Installation
Engine Installation Notes
After the engine is installed in the frame, review this checklist and perform all steps that apply.
General Items
1. Install previously removed components using new gaskets, seals, and fasteners where applicable.
2. Perform regular checks on fluid levels, controls, and all important areas on the vehicle as outlined in the daily
pre-ride inspection checklist (refer to Chapter 2 or the Owner’s Safety and Maintenance Manual).
PVT System
1. Adjust center distance of drive and driven clutch. (Chapter 6)
2. Adjust clutch offset, alignment, and belt deflection. (Chapter 6)
3. Clean clutch sheaves thoroughly and inspect inlet and outlet ducts for proper routing and sealing. (Chapter 6)
Transmission
1. Inspect transmission operation and adjust linkage if necessary. Refer to Chapter 2 and Chapter 8.
Exhaust
1. Replace exhaust gaskets. Seal connections with high temp silicone sealant.
2. Check to be sure all springs are in good condition.
Bleed Cooling System
1. Remove radiator cap and slowly add coolant to top of filler neck.
2. Fill coolant reservoir tank to full mark.
3. Loosen bleed screw at top of cylinder head (400) until all air is purged from engine. Tighten bleed screw.
4. Install radiator cap and squeeze coolant lines to force air out of system.
5. Again remove radiator cap and slowly add coolant to top of fill neck.
6. Start engine and observe coolant level in the radiator. Allow air to purge and top off as necessary. Reinstall
radiator cap and bring engine to operating temp. Check level in reservoir tank after engine is cool and add
coolant if necessary.
Engine Break In Period - 2 Cycle
2 Cycle Engine Break-In Period is defined as the first 3 hours of engine operation, or one full tank of fuel.
1. (2 - Cycle) Pre-mix the first FULL tank of fuel at a 40:1 ratio with Polaris Premium 2 Cycle Lubricant.
2. Fill the oil tank with Polaris injection oil. Never substitute or mix oil brands. Serious engine damage can result.
3. Bleed oil pump thoroughly. Refer to Chapter 2.
4. Verify proper oil usage from oil tank during the first tank of fuel. Instruct operator to observe oil level in tank
during the first tank of fuel. If the level has not dropped, repeat the oil pump bleeding procedure, fill the tank
with pre-mix, and investigate problem (oil tank vent or supply line restriction, pump problem, etc.).
5. Avoid prolonged idle, heavy loads, or periods of sustained full throttle. Use low gear if available. Vary throttle
settings during the break in period.
Engine Break In Period - 4 Cycle
4 Cycle Engine Break-In Period is defined as the first 10 hours of engine operation, or 2 full tanks of fuel.
1. Use only Polaris Premium 4 All Season synthetic oil, or API certified “SH” oil. Never substitute or mix oil
brands. Serious engine damage can result.
2. Use fuel with a minimum octane of 87 (R+M)/2 method.
3. Change break-in oil and filter at 20 hours or 500 miles, whichever comes first.