Polaris Trail Boss 330 Quadricycle Owner'S Manual Download

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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 regularly.
Lubricate the drive chain as outlined in the Lubrication Chart on page

65.
High pressure water may damage components. Do not use high

pressure water. See page 99.

Rear Drive Chain Slack

Adjusting or operating the vehicle with improper rear drive chain slack

can result in severe damage to the transmission and drive components.

Always make sure the slack is within the stated specifications.
Check the amount of chain slack

in three different locations by

moving the vehicle slightly

forward. Measure the chain slack

at the tightest of the three

positions. At this point the chain

should have 4.8-9.5 mm

deflection.
Use the following procedure if

adjustment is required.
1. Loosen the chain guide.
2. Loosen the two eccentric

locking bolts (1).

3. Loosen the caliper mounting

bolt located on the left side

of the swing arm.

4. Insert a pin punch (2)

through the sprocket hub

and into the eccentric

housing.

4.8 - 9.5 mm

Summary of Contents for Trail Boss 330 Quadricycle

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Page 4: ...screpancies may result between the actual vehicle and the information presented in this publication Depictions and or procedures in this publication are intended for reference use only Manufacturer accepts no liability for omissions or inaccuracies Any reprinting or reuse of the depictions and or procedures contained within whether whole or in part is expressly prohibited Printed in U S A 2005 Tra...

Page 5: ...NTIFICATION NUMBERS 5 SAFETY 6 FEATURES AND CONTROLS 40 OPERATION 55 EMISSION CONTROL SYSTEMS 60 MAINTENANCE AND LUBRICATION 61 POLARIS PRODUCTS 103 TROUBLESHOOTING 104 SPECIFICATIONS 108 WARRANTY 111 MAINTENANCE RECORD 113 INDEX 116 ...

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Page 7: ...are key and store it in a safe place Your key can be duplicated only by mating a Polaris key blank with one of your existing keys so if both keys are lost the ignition switch must be replaced Vehicle Model Number Frame VIN 1 Engine Serial Number 2 right front side of engine crankcase Key Number 3 1 31XX 3 2 ...

Page 8: ...al alerts you to the potential for personal injury WARNING The safety alert warning indicates a potential hazard that may result in serious injury or death CAUTION The safety alert caution indicates a potential hazard that may result in minor personal injury or damage to the vehicle CAUTION A caution indicates a situation that may result in damage to the vehicle NOTE A note will alert you to impor...

Page 9: ...ings before operating a Polaris Quadricycle Safety Training When you purchased your new Quadricycle your dealer offered a hands on safety training course You were also provided with printed materials that explain safe operating procedures Review this information on a regular basis If you purchased a used Polaris Quadricycle from a party other than a Polaris dealer please request free safety traini...

Page 10: ...our area Restrictions This vehicle is approved for OFF ROAD TOWING ONLY Operating a Quadricycle trailer combination on public roads is prohibited Equipment Modifications The warranty on your Polaris Quadricycle may be terminated if any equipment has been added or if any modifications have been made that increase speed or power NOTE The addition of certain accessories including but not limited to m...

Page 11: ... without proper instruction Take a training course Beginners should receive training from a certified instructor Contact an authorized Polaris Quadricycle dealer or call Polaris at 1 800 342 3764 Never permit others to operate the Quadricycle unless they have read and understand this manual and all product labels and have completed a certified safety training course Never allow anyone under 16 yea...

Page 12: ...Wear eye protection goggles or face shield gloves boots long sleeves and long pants Never consume alcohol or drugs before or while operating a Quadricycle Never operate at excessive speeds Travel and turn at speeds appropriate for the terrain visibility operating conditions and your experience ...

Page 13: ...icycle before each use to verify that it s in safe operating condition Follow the inspection and maintenance procedures outlined in this manual See page 56 Keep both hands on the handlebars Keep your feet on the footrests Always travel slowly when operating on unfamiliar terrain Use extra caution ...

Page 14: ...lined in this manual for turning See page 25 Never turn sharply at excessive speeds which can lead to vehicle overturn If a Quadricycle has been involved in an accident always have an authorized Polaris dealer inspect the entire vehicle for possible damage including but not limited to brake throttle and steering systems ...

Page 15: ...he procedures outlined in this manual for climbing hills See page 30 Always follow the procedures outlined in this manual for driving downhill and for braking on hills See page 28 Always follow the procedures outlined in this manual for crossing the side of a hill See page 29 Never attempt to turn the Quadricycle around on any hill until you ve mastered on level ground the turning technique outlin...

Page 16: ...kwards while climbing a hill Never back down a hill See page 31 Always follow the procedures outlined in this manual for operating over obstacles See page 27 Always follow the procedures outlined in this manual for operating on slippery or loose surfaces Use extra caution Always avoid skidding or sliding See page 26 ...

Page 17: ...al for driving through water Never drive through deep or fast flowing water See page 34 Always follow the procedures outlined in this manual for driving in reverse See page 36 Always use the size and type of tires specified for your Quadricycle Maintain the proper tire pressure ...

Page 18: ...uted and securely attached Reduce speed and follow the instructions in this manual for carrying cargo or towing Allow a greater distance for braking Never operate the Quadricycle on a frozen body of water Operating on paved surfaces may seriously affect the handling and control of the Quadricycle and could result in loss of control accident and or injury Avoid sudden turns or swift movement of the...

Page 19: ...le is not in use to prevent unauthorized use or accidental starting Always keep combustible materials away from the exhaust system Exposure of combustibles to hot components could result in a fire FOR MORE INFORMATION ABOUT QUADRICYCLE SAFETY call Polaris at 1 800 342 3764 ...

Page 20: ...carefully If a decal becomes illegible or comes off contact your Polaris dealer to purchase a replacement Replacement safety decals are provided by Polaris at no charge The part number is printed on the decal Decal Text Never operate this vehicle on hills steeper than 25 degrees To prevent flipover on hilly terrain when going up or down use throttle and brakes gradually A ...

Page 21: ...19 SAFETY Safety Decals and Locations NO STEP B C D ...

Page 22: ... 5 REAR 5 34 5 MAXIMUM WEIGHT CAPACITY Gross Vehicle Weight INCLUDING MACHINE DRIVER AND CARGO IS 845 LBS 383 kg MAXIMUM CARGO CAPACITY 200 LBS 91 kg Read Owner s Manual for more detailed loading information 7173301 DO NOT TOW FROM RACK OR BUMPER Vehicle damage or tipover may result causing severe injury or death Tow only from tow hooks or hitch Max Rack Loads Front 75 lbs 34 kg Rear 125 lbs 57 kg...

Page 23: ..._ to 80_ F at 0 3000 feet 5_ to 27_ C at 0 900 meters OVERRIDE SWITCH Reverse speed is limited Reverse override is controlled by the override switch See your Owner s Manual 7079906 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...

Page 24: ...tch 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 ...

Page 25: ...les or a shatterproof helmet face shield Use a lens anti fogging product to keep them clean 3 Gloves Wear off road style gloves with knuckle pads 4 Boots Wear strong over the calf boots with heels like moto cross boots 5 Clothing Wear long sleeves and long pants to protect arms and legs Riding pants with kneepads and a jersey with shoulder pads provide the best protection Do not wear loose clothin...

Page 26: ...it 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 squeeze the throttle lever toward the handlebar to begin driving Squeeze the throttle lever further to increase speed 6 Drive slowly Practice maneuvering and using the throttle and brakes on level surfaces ...

Page 27: ...Use the same leaning technique for turning in reverse 2 Practice turning at slow speeds before attempting to turn at faster speeds Never operate at excessive speeds Travel and turn at speeds appropriate for the terrain visibility operating conditions and your experience Always follow the procedures outlined in this manual for turning Never turn sharply at excessive speeds which can lead to vehicle...

Page 28: ...n before driving onto slippery surfaces 2 Use extra caution 3 Be alert Watch the trail Avoid quick sharp turns NOTE To correct a rear wheel skid turn the handlebars in the same direction as the skid and shift body weight forward Always follow the procedures outlined in this manual for operating on slippery or loose surfaces Use extra caution Always avoid skidding or sliding ...

Page 29: ... 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 hazards such as logs rocks and low branches Always follow the procedures outlined in this manual for operating over obstacles ...

Page 30: ...ng down a hill at an angle which can cause the vehicle to pitch sharply to one side 6 Drive straight downhill 7 Shift your weight rearward 8 Apply the foot brake slightly to aid in slowing 9 Know how to use the hand brake Always follow the procedures outlined in this manual for driving downhill and for braking on hills Never operate at excessive speeds Travel and turn at speeds appropriate for the...

Page 31: ... crossing the sides of steep hills 5 Keep your feet on the footrests 6 Steer slightly into the hill NOTE If the vehicle begins to tip quickly turn the front wheels downhill if possible or dismount on the uphill side immediately Always follow the procedures outlined in this manual for crossing the side of a hill Never attempt to turn the Quadricycle around on any hill until you ve mastered on level...

Page 32: ...th excessively slippery or loose surfaces 4 Shift your weight uphill 5 Drive straight uphill 6 Keep your feet on the footrests 7 Drive at a steady rate of speed to avoid stalling 8 Be alert Be prepared to take emergency action This may include dismounting quickly 9 Never open the throttle suddenly or make sudden gear changes 10 Never go over the top of a hill at high speed ...

Page 33: ...e hand brake as well Lock the hydraulic parking brake Dismount on the uphill side or to either side if the vehicle is pointed straight uphill Turn the vehicle around and remount following the procedure described on page 32 Always follow the procedures outlined in this manual for climbing hills Avoid climbing hills steeper than 25_ Always follow the procedures outlined in this manual for braking if...

Page 34: ...brake 3 Leave the transmission in forward gear Turn the engine off 4 Dismount on the uphill side of the vehicle or on the left if the vehicle is pointing straight uphill 5 Stay uphill of the vehicle and turn the handlebars full left 6 Squeeze the brake lever to release the parking brake 7 Slowly release the brake lever and allow the vehicle to roll around to your right until it s pointing across t...

Page 35: ...in forward start the engine 11 Squeeze and release the brake lever to release the parking brake 12 Release the foot brake and drive slowly downhill Control speed with the foot brake until the vehicle is on level ground Always follow the procedures outlined in this manual for climbing hills See page 30 Always follow the procedures outlined in this manual for crossing the side of a hill See page 29 ...

Page 36: ...vements Maintain a slow and steady forward motion Do not make sudden turns stops or throttle changes 3 Choose a crossing where both banks have gradual inclines 4 Drive slowly 5 Avoid rocks and obstacles 6 Wet brakes may have reduced stopping ability Always test your brakes after leaving water If necessary apply them lightly several times to allow friction to dry out the pads Always follow the proc...

Page 37: ...roughly inspected Take the vehicle to your dealer before starting the engine If your vehicle becomes fully immersed and it s impossible to take it to a dealer before starting it follow the steps described on page 92 Have the vehicle serviced by your dealer promptly NOTE If water has been ingested into the transmission PVT follow the procedure on page 59 ...

Page 38: ...e suddenly 7 Do not use the override switch unless additional power is required for vehicle movement Use with caution NOTE Reverse speed is greatly increased when the override switch is used Do not operate at full throttle Apply just enough throttle to maintain the desired speed CAUTION Excessive throttle operation while in the speed limit mode may cause fuel to build in the exhaust resulting in e...

Page 39: ...ine 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 ...

Page 40: ...ght when cargo is high Secure off centered loads that cannot be centered and operate with extra caution S CARRYING A LOAD on only one rack may cause the vehicle to overturn Split the load between the front rack and rear rack with 1 3 in the front and 2 3 in the back Do not exceed load ca pacities See specifications beginning on page 108 S SECURE ALL LOADS BEFORE OPERATING Unsecured loads can creat...

Page 41: ...F 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 QUADRICYCLE Maximum Towed Load Level Ground Maximum Vertical Hitch Weight 386 kg 38 6 kg ...

Page 42: ...e main switch It may contact the gas tank cap when turning causing an interruption to the electrical system and an unexpected engine shut down during operation This could result in serious injury or death 2 Speedometer Mode Override Switch Reverse Speed Limiter To gain additional power while operating in reverse cancel the reverse speed limit function by pressing the override switch before opening...

Page 43: ...unless the main key switch is on and the engine stop switch is in the RUN position 5 Throttle lever Press the throttle lever to increase engine speed and vehicle movement Release the lever to reduce engine speed and vehicle movement WARNING Failure to check or maintain proper operation of the throttle system can result in an accident if the throttle lever sticks during operation Check the lever fo...

Page 44: ...n an open position when the operator releases the throttle lever WARNING The Electronic Throttle Control ETC stops the engine in the event of a throttle system malfunction Do not modify the ETC system or replace it with other throttle mechanisms 7 Choke Knob The choke assists in starting a cold engine See page 57 8 Horn Press the horn button to alert others of your presence ...

Page 45: ...rake Lever The right brake lever is used as a mechanical parking brake only See page 45 12 Turn Indicator Push the toggle switch either left or right to activate the corresponding turn signal Return the toggle to the center position to end the signal 13 Mirrors Use the mirrors to assist in traffic maneuvers Always check and adjust the mirrors before driving the Quadricycle 14 Instrument Panel View...

Page 46: ...ear brakes only Squeeze the brake lever toward the handlebar to apply the rear brakes If the rear wheels begin to skid or slide while using this brake reduce lever pressure Inspect and maintain the brake fluid level in the master cylinder 2 as recommended See pages 56 and 75 WARNING Aggressively applying the rear brake when backing down a hill may cause rear tipover Aggressively applying the rear ...

Page 47: ... lock squeeze and release the brake lever The parking brake will release automatically NOTE The parking brake may relax if left on for a long period of time Always block the wheels to prevent rolling Never depend on the parking brake alone if the vehicle is parked on a hill Always block the wheels to prevent rolling Locking the Parking Brake Hydraulic The hydraulic parking brake lock is a temporar...

Page 48: ... or theft of the vehicle 1 Turn the handlebars to the full left position 2 Insert the steering lock key and turn it clockwise 3 Remove the key 4 Reverse the procedure to unlock the steering NOTE Place the steering lock keys in a safe place The lock must be replaced if the keys are lost ...

Page 49: ...park S Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored S Do 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 Turn the fuel valve off whenever the vehicle is stored or parked Fuel Valve The fuel valve 2 is located on ...

Page 50: ...t unattended place the transmission in gear and lock the mechanical parking brake F Forward Gear N Neutral R Reverse CAUTION Shifting gears with the engine speed above idle or while the vehicle is moving can cause transmission damage Stop the vehicle release the throttle and move the lever to the desired gear See your dealer if you experience any shifting problems ...

Page 51: ...r rope handle tightly Pull slightly until the starter mechanism engages 2 Pull the rope abruptly to start the engine CAUTION Extending the starter rope too far will cause damage to the recoil assembly Do not extend the starter rope so far that it stops If the starter rope handle is not seated properly water may enter the recoil housing and damage components Make sure the handle is fully seated on ...

Page 52: ...t 11 14 km h See page 40 for additional information 1 Rider Information Center 2 Speedometer needle In addition to showing vehicle speed the needle flashes when a warning condition exists 3 Speedometer CAUTION To prevent damage to the instrument cluster wash the Quadricycle by hand or with a garden hose using mild soap Do not use alcohol to clean the instrument cluster Immediately wash off any gas...

Page 53: ...shut down to protect the electrical system If this occurs take the Quadricycle to your Polaris dealer 1 Gear Indicator As the shift lever is moved this indicator shows the gear the transmission is in H High Range Forward N Neutral R Reverse 2 Engine Hour Display Indicator 3 Service Interval Diagnostic Mode Indicator 4 Odometer Tachometer Tripmeter Hour Meter 5 Check Engine Warning Indicator HOT wi...

Page 54: ...cle since manufacture Mode 2 Trip Meter The trip meter records the distance traveled on each trip if it s reset before each trip To reset the trip meter select the trip meter mode Press and hold the mode button override button until the total changes to 0 NOTE The trip meter displays a decimal point but the odometer does not Mode 3 Hour Meter The hour meter logs the total hours the engine has been...

Page 55: ...utral or park 3 Hold the mode button and turn the main key switch on 4 Release the switch as soon as the display is activated 5 Use the mode button to toggle through the six 6 diagnostic screens Three 3 ways to leave the diagnostic mode S Shift the transmission out of neutral S Turn the main key switch off and on S Move the tires Screen 1 Battery voltage Screen 2 Tachometer Screen 3 AWD diagnostic...

Page 56: ...to advance the setting by one hour Press and hold the button to advance the hours at a faster pace 3 When the desired time increment is displayed release the button When the wrench stops flashing service hours are set NOTE If you scroll past the intended number hold the button down until the count turns over to 0 You can then reset the number Disabling the Service Interval 1 Toggle to the service ...

Page 57: ...fe Do not operate at full throttle or high speeds for extended periods during the first three hours of use Perform the following procedures carefully 1 Fill the fuel tank with gasoline 2 Check the oil level on the dipstick Add oil if necessary See page 67 3 Select an open area that allows room to familiarize yourself with vehicle operation and handling 4 Drive slowly Vary throttle positions Do not...

Page 58: ...ss 81 Drive chain Inspect condition lubricate frequently 83 Frame nuts bolts fasteners Inspect ensure tightness Fuel and oil Ensure proper levels 47 67 Throttle Ensure proper operation 41 79 Indicator lights switches Ensure operation 40 Engine stop switch Ensure proper operation 41 Air filter pre filter Inspect clean 85 Air box sediment tube Drain deposits whenever visible Headlamp Check operation...

Page 59: ...ine damage Allow the engine to warm up for several minutes before operating 1 Position the vehicle on a level surface 2 Sit on the vehicle 3 Lock the mechanical parking brake 4 Turn the fuel valve on 5 Move the engine stop switch to RUN 6 If the engine is cold pull the choke knob 1 out until it stops A warm engine will not require the use of the choke FULL ON HALF ON OFF NOTE Make sure the choke i...

Page 60: ...n the engine starts NOTE Do not press the throttle while starting the engine 8 If the engine does not start release the starter and wait five seconds 9 Repeat steps 7 and 8 until the engine starts 10 If the engine slows or stops position the choke knob half way in 11 Vary engine RPM slightly with the throttle When the engine idles smoothly push the choke all the way in ...

Page 61: ...onsibilities to make sure this system remains safe S Always follow all recommended maintenance procedures See your dealer as outlined in the owner s manual S This PVT system is intended for use on Polaris products only Do not install it in any other product S Always make sure the PVT housing is securely in place during operation PVT Drying If water is ingested into the PVT system dry it before ope...

Page 62: ...n chamber by the intake system The system does not allow the blow by gases to enter the atmosphere Exhaust Emission Control System The emissions from the exhaust of this vehicle are controlled by engine design including factory set fuel delivery and ignition The engine and related components must be maintained at Polaris specifications to achieve optimal performance The emissions label 1 is locate...

Page 63: ... are critical If you are not familiar with safe service and adjustment procedures have a qualified Polaris dealer perform these operations The programmable service interval mode on the instrument cluster will help determine when maintenance service is due See page 54 Maintenance Chart Key Perform these procedures more frequently for vehicles subjected to severe use E Emission Control System Servic...

Page 64: ...ir box sediment tube Daily Drain deposits when visible Headlamp tail lamp Daily Check operation apply dielectric grease if replacing E Air filter main element Weekly Inspect replace as needed Recoil housing Weekly Drain water as needed check often if operating in wet conditions J Brake pad wear 10 Monthly 100 Inspect periodically Battery 20 Monthly 200 Check terminals clean test Transmission oil 2...

Page 65: ...eak in oil change at one month E Oil filter change 100 6 M 1000 Replace with oil change J E Valve clearance 100 12 M 1000 Inspect adjust J E Fuel system 100 12 M 1000 Check for leaks at tank cap lines fuel valve filter pump carburetor replace lines every two years J E Fuel filter 100 12 M 1000 Replace yearly Engine mounts 100 12 M 1000 Inspect Exhaust muffler pipe 100 12 M 1000 Inspect J E Spark p...

Page 66: ...200 24 M 2000 Change every two years Spark arrestor 300 36 M 3000 Clean out E Idle speed Adjust as needed J Toe adjustment Inspect periodically adjust when parts are replaced J Foot brake and rear brake Inspect daily adjust as needed J Mechanical parking brake Inspect daily adjust cable as needed Headlight aim Adjust as needed Perform these procedures more often for vehicles subjected to severe us...

Page 67: ...should be lubricated at the General Lubrication interval Item Lube Method Engine Polaris Premium 4 Synthetic 0W40 See page 66 Brakes DOT 3 fluid only See page 74 Transmission Premium AGL Synthetic Gearcase Lube See Page 72 Drive chain s O ring chain lube or SAE 80 90 Lubricate as often as required and before each ride in wet conditions 1 Ball Joint Premium U Joint Grease Locate fittings and grease...

Page 68: ...changed more frequently if Polaris Premium 4 is not used See page 103 for the part numbers of Polaris products Always check and change the engine oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 61 CAUTION Using a non recommended oil may cause serious engine damage Use only Polaris Premium 4 All Season Synthetic Oil or an API certified 0W 40 SH oil Never substitute...

Page 69: ...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 dipstick completely 8 Remove the dipstick Check the oil level 9 Add oil as needed to bring the level between the minimum and maximum marks F N R ...

Page 70: ...2 to 1 C engine fails to reach operating tempera ture CAUTION If the Quadricycle is left without oil in the system for extended periods the oil pump may lose its prime which could result in engine damage Always replace the oil and filter within a few hours of draining the oil Do not allow the vehicle to be without oil overnight 1 Use Polaris recommended products S Oil filter S 0W 40 oil 1 Position...

Page 71: ...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 towels under the oil filter 11 Using an oil filter wrench 4 turn the filter counterclockwise to remove it 12 Clean the filter sealing area on the engine ...

Page 72: ... 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 engine Allow it to idle for two minutes 19 Turn the engine off 20 Check for oil leaks 21 Check the oil level Add oil as needed to bring the level between the minimum MIN and maximum MAX marks 22 Discard used oil and filter properly ...

Page 73: ...tenance 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 low pressure water ...

Page 74: ...tion the vehicle on a level surface 2 Place the transmission in gear 3 Lock the mechanical parking brake 4 Remove the dipstick Wipe it clean 5 Reinstall the dipstick completely 6 Remove the dipstick Check the oil level 7 Maintain the level between the minimum MIN and maximum MAX marks 8 Add fluid as needed Do not overfill 9 Reinstall the dipstick F N R ...

Page 75: ...d 6 Remove the drain plug 3 Wipe it clean 7 Drain the fluid into a drain pan 8 Install a new sealing washer Reinstall the drain plug 19 N m 9 Turn the adjuster bolt outward until it touches the frame and then turn an additional 1 2 turn 10 Tighten the jam nut securely while holding the adjuster bolt 11 Remove the dipstick 12 Add 335 ml of the recommended fluid 13 Reinstall the dipstick 14 Check fo...

Page 76: ... the handlebars straight If the fluid level is low check brake pad thickness before adding brake fluid DO NOT OVERFILL Brake Check Perform the following checks to keep the brake systems in good operating condition Check more often if brakes are used heavily during normal operation WARNING Do not overfill the reservoirs An over full master cylinder may cause brake drag or brake lock up which could ...

Page 77: ...ndlebar View the fluid level through the indicator window eye on the top of the master cylinder A dark eye 2 indicates a full fluid level A clear eye 3 indicates a low fluid level Master Cylinder Foot Brake The foot brake master cylinder 4 is located under the right rear fender View the fluid level through the reservoir body Fluid level is full at the MAX mark Add brake fluid if the level reaches ...

Page 78: ... side of the vehicle and goes around the stands in front of the vehicle 2 4 Measure the distance from the string to the rim at the front and rear of the front rim 3 The rear measurement should be 2 to 3 mm more than the front measurement NOTE If you discover improper alignment see your Polaris dealer for service WARNING Do not attempt to adjust alignment All steering adjustments should be performe...

Page 79: ...all four handlebar bolts 3 Adjust the handlebar to the desired height NOTE Make sure the handlebars do not contact the gas tank or any part of the machine when turned fully to the left or right 4 Torque the two front bolts 3 then torque the two rear bolts 4 14 17 N m NOTE A gap of up to 3 mm should remain at the rear bolts WARNING Improper adjustment of the handlebars or incorrect torquing of the ...

Page 80: ...e system can be made to allow more efficient operation Optional jets and clutch components available from your Polaris dealer are required for operation above 1800 meters Jetting is required only when operating below 4 degrees C at 1800 meters and lower NOTE Operating the engine with improper jetting can cause poor performance overheating or engine damage See your Polaris dealer for more informati...

Page 81: ...er sleeve 3 Loosen the adjuster 4 3 Turn the adjuster until 1 6 3 2 mm of freeplay exists at the lever NOTE Move the throttle lever back and forth while adjusting 4 Tighten the adjuster Slide the boots 2 over the cable adjuster until they touch at the midpoint of the adjuster NOTE Engine RPM should not increase when steering is turned full left or right Readjust cable freeplay if this occurs ...

Page 82: ...panel forward and outward quickly and firmly to disengage the rear tabs 3 Place your hand on top of the side panel behind the fuel tank Push down quickly and firmly to disengage the top rear tabs 4 Pull the side panel upward to disengage the front tabs Reinstallation 5 Align the tabs with the slots on the front cab 6 Push the panel upward and forward until the tabs lock 7 Bend the rear of the side...

Page 83: ... when replacing tires Install wheels properly 1 Position the vehicle on a level surface 2 Place the transmission in gear 3 Lock the mechanical parking brake 4 Loosen the wheel nuts slightly 5 Safely place jackstands under the vehicle 6 Remove the wheel nuts and remove the wheel 7 Place the wheel on the hub 8 Install the wheel nuts finger tight 9 Carefully remove the jackstands 10 Torque the wheel ...

Page 84: ...se an accident Maintain proper tire pressure as described on the decal on your vehicle and in the specifications section of the owner s manual beginning on page 108 Use only original equipment size and type when replacing tires Make sure the wheels are installed properly Replace tires when the tread depth measures 3 mm or less Wheel and Hub Tightening Wheel hub and bearing tightness and spindle nu...

Page 85: ...perating the vehicle with improper rear drive chain slack can result in severe damage to the transmission and drive components Always make sure the slack is within the stated specifications Check the amount of chain slack in three different locations by moving the vehicle slightly forward Measure the chain slack at the tightest of the three positions At this point the chain should have 4 8 9 5 mm ...

Page 86: ...unting bolt to 20 N m 8 Remove the pin punch 9 Roll the vehicle forward checking chain tension in several places around the chain The chain is adjusted correctly when the tightest portion of the chain has approximately 10 mm deflection 10 Position the chain guide to allow 3 mm clearance and tighten the retaining bolt to 7 N m Fuel Filter Replace the in line fuel filter at the intervals outlined in...

Page 87: ...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 3 7 Remove the pre filter 4 from the filter 5 Wash the pre filter in soapy water Rinse and air dry NOTE Replace the filter if needed 8 Reverse the steps to reinstall all components F N R ...

Page 88: ...ed Headlight Replacement When servicing a halogen lamp do not touch the lamp with bare fingers Hold the plastic part 1 of the lamp Oil from your skin leaves a residue causing a hot spot that will shorten the life of the lamp 1 Place the transmission in gear 2 Lock the mechanical parking brake 3 Turn the back of the headlight counterclockwise 4 Remove the headlamp 2 5 Apply dielectric grease to the...

Page 89: ...e distance from the floor to the center of the headlight and make a mark on the wall at the same height NOTE Include rider weight on the seat when measuring 5 Start the engine Turn the headlight switch to high beam 6 Observe the headlight aim on the wall The most intense part of the headlight beam should be aimed 5 1 cm below the mark placed on the wall 7 Loosen the pivot bolt and adjust the beam ...

Page 90: ...n reverse order 9 Rotate the turn signal socket counterclockwise to remove it 10 Remove the lamp 11 Apply dielectric grease to the socket 12 Install the new lamp 13 Test the lamp for proper operation 14 Reinstall all components in reverse order Indicator Lamp Replacement 1 Remove the instrument panel 2 Using a small straight blade screwdriver turn the base of the bulb 1 4 turn counterclockwise 3 R...

Page 91: ... drain plug before storing the vehicle NOTE Water will enter the recoil housing if the starter handle 2 is disengaged from the rope guide when under water 1 Place the transmission in gear 2 Lock the mechanical parking brake 3 Using a wrench remove the drain screw 3 on the bottom of the recoil housing 4 Reinstall the screw after draining the housing F N R ...

Page 92: ...plug wire 1 Use the spark plug wrench 2 to remove the spark plug 3 Turn the plug counterclockwise to remove it 3 Inspect the electrodes for wear and carbon buildup Replace worn or fouled plugs Verify that the gap is at specification before installation 4 Reinstall the spark plug 19 N m 5 Reinstall the spark plug wire ...

Page 93: ...nd the service NOTE The tip should not be white A white insulator tip indicates overheating caused by use of an improper spark plug or incorrect carburetion adjustments Fouled The insulator tip is black A damp film covers the firing end There may be a carbon layer over the entire nose Generally the electrodes are not worn General causes of fouling are excessive oil consumption improper use of the ...

Page 94: ...thoroughly inspected Take the vehicle to your dealer before starting the engine If your vehicle has been totally submerged in water and it s impossible to have it serviced before further operation perform the following procedure 1 Move the vehicle out of the water 2 Turn the fuel valve off 3 Remove the spark plug See page 90 4 Drain any water found in the air box ...

Page 95: ... the starter for only 2 3 seconds 7 Tighten the carburetor drain screw 8 Reinstall the spark plug 19 N m 9 Turn the fuel valve on 10 Attempt to start the engine If necessary repeat the drying procedure 11 Have the vehicle serviced by your dealer promptly whether you succeed in starting it or not NOTE If water has been ingested into the PVT follow the procedure for drying out the PVT See page 59 ...

Page 96: ...mely hot Never run the engine in an enclosed area or indoors Exhaust contains poisonous carbon monoxide gas Never go under the vehicle while it s inclined Remove any combustible materials from the area Wear eye protection and leather work gloves Do not stand behind or in front of the vehicle while purging 1 Remove the arrestor clean out plug from the bottom of the muffler 2 Place the transmission ...

Page 97: ... protection 7 Lightly tap on the exhaust pipe with a rubber mallet while repeating step 5 8 If particles are still suspected to be in the muffler elevate the rear of the vehicle 30 cm higher than the front 9 Lock the mechanical parking brake 10 Block the wheels 11 Repeat steps 5 to 7 until no more particles are expelled 12 Turn the engine off Allow the arrestor to cool 13 Reinstall the arrestor pl...

Page 98: ...al 1 Place the transmission in gear 2 Lock the mechanical parking brake 3 Disconnect the battery hold down strap Remove the battery cover 4 Disconnect the black negative cable first 5 Disconnect the red positive cable last 6 Lift and remove the battery Battery Installation Always install a fully charged battery See page 97 1 Place the battery in the battery holder 2 Verify that cables are routed p...

Page 99: ...a pre determined point Battery Charging The following battery charging instructions apply only to the installation of an activated sealed battery Read all instructions before proceeding with the installation of this battery A sealed battery is already filled with electrolyte It has been sealed and is fully charged at the factory Always keep a sealed battery fully charged S DO NOT pry the sealing s...

Page 100: ...harge if no charge given check in 3 months 3 6 hours 50 75 12 0 12 5 volts Needs Charge 5 11 hours 25 50 11 5 12 0 volts Needs Charge At least 13 hours verify state of charge 0 25 11 5 volts or less Needs Charge At least 20 hours NOTE Always verify battery condition before and one to two hours after charging WARNING An overheated battery may explode causing serious injury or death Always watch cha...

Page 101: ...se extreme care to avoid directing water onto the wheel bearings transmission seals body panels brakes and warning labels Grease all fittings immediately after washing and allow the vehicle to run for a while to evaporate any water that may have entered the engine or exhaust system NOTE If warning and safety labels are damaged contact your Polaris dealer for free replacements Waxing the Vehicle Wa...

Page 102: ... minutes of operation for the stabilizer to disperse through the fuel in the tank and carburetor 3 Turn the fuel valve off 4 Drain the carburetor bowl Change Oil and Filter Change the oil and filter See page 68 Air Filter Air Box Inspect and clean or replace the pre cleaner and air filter Clean the air box and drain the sediment tube See page 85 Check Change Fluids Inspect fluid levels and change ...

Page 103: ...re pressure is at specification 2 Using suitable supports under the frame raise the vehicle slightly so that the tires are not touching the ground 3 Be sure the storage area is well ventilated 4 Cover the machine with an appropriate cover Do not use plastic or coated materials as they do not allow proper ventilation to prevent condensation corrosion and oxidation Accessories Auxiliary power outlet...

Page 104: ...he 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 Be sure the fuel cap oil cap and seat are installed correctly 6 Attach the FRAME of the Quadricycle to the transporting unit securely using suitable straps or rope F N R ...

Page 105: ... jug 2871654 Premium Demand Drive Hub Fluid 237 ml 2872277 Premium Demand Drive Hub Fluid 9 5 l Grease Specialized Lubricants 2871322 Premium All Season Grease 89 ml cartridge 2871423 Premium All Season Grease 414 ml cartridge 2871460 Starter Drive Grease 2871515 Premium U Joint Lube 89 ml 2871551 Premium U Joint Lube 414 ml 2871312 Grease Gun Kit 2871329 Dielectric Grease Nyogelt 2872073 Chain Lu...

Page 106: ...e the throttle quickly and effectively for efficient en gagement Towing pushing at low RPM low ground speed Install a one tooth smaller counter shaft sprocket Stuck in mud or snow Carefully use fast aggressive throttle application to en gage clutch WARNING Excessive throttle may cause loss of control and vehicle overturn Climbing over large ob jects from a stopped posi tion Carefully use fast brie...

Page 107: ...l Drain the fuel 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 spark plug Inspect plug s verify stop switch is on Crankcase filled with water or fuel Immediately see your Polaris dealer Overuse of choke Inspect clean and or replace spark plugs Clogg...

Page 108: ...nition connections Check all connections and tighten Water present in fuel Replace with new fuel Low battery voltage Recharge battery to 12 5 VDC Kinked or plugged fuel vent line Inspect and replace Incorrect fuel Replace with recommended fuel Clogged air filter Inspect and clean or replace Reverse speed limiter malfunction See your Polaris dealer Electronic throttle control malfunction See your P...

Page 109: ...res 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 Recharge battery Check charging system Incorrect fuel Replace with recommended fuel Clogged air filter Inspect clean or replace Reverse speed limiter malfunction See your Polaris dealer Electronic throttle control malf...

Page 110: ... Height 116 8 cm Length 190 5 cm Width 116 8 cm Seat Height 86 4 cm Dry Weight 229 kg Wheel Base 125 7 cm Engine Cooling Engine Model Number Type ES 32PFE 103 4 Cycle Single Cylinder Lubrication Wet Sump Bore x Stroke 78 5 x 68 Displacement 329 Compression Ratio 9 2 1 Engine Cooling Air with fan assisted oil cooler Alternator Output watts 200w 5000 rpm Carburetion BST34 Main Jet 120 Pilot Jet 42 5...

Page 111: ...cm travel Shock Adjustment CAM Brake System Hydraulic disc front and rear fixed disc hydraulic floating caliper Hand Brake Hydraulic left hand apply rear caliper only equipped w temporary hydraulic lock Foot Brake Hydraulic single apply all wheel Parking Brake Right hand apply w mechanical lock floating caliper system disc brake Features Headlight 2 Hi Lo 60w 55w Taillight 2x8 26w Brake Light 2x26...

Page 112: ... 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 Green 7041157 Black 7041782 40 5131446 2 2 1800 3700 20 40 5631356 Blue Green 7041157 Black 7041782 40 5131446 2 2 ...

Page 113: ...DIES The Polaris limited warranty excludes any failures that are not caused by a defect in material or workmanship This warranty does not cover accidental damage normal wear and tear abuse or improper handling This warranty also does not cover any Quadricycle that has been altered structurally modified neglected improperly maintained used for racing or used for purposes other thanfor whichit wasma...

Page 114: ...take it to a Polaris dealer authorized to repair Polaris Quadricycles When requesting warranty service you must present your copy of the Warranty Registration form to the dealer THE COST OF TRANSPORTA TION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY Polaris suggests that youuse youroriginal sellingdealer however you mayuse anyPolaris ServicingDealer to perform warranty service Please work with y...

Page 115: ...113 MAINTENANCE RECORD DATE MILES KM TECHNICIAN SERVICE PERFORMED COMMENTS ...

Page 116: ...114 MAINTENANCE RECORD DATE MILES KM TECHNICIAN SERVICE PERFORMED COMMENTS ...

Page 117: ...115 MAINTENANCE RECORD DATE MILES KM TECHNICIAN SERVICE PERFORMED COMMENTS ...

Page 118: ...ctromagnetic Interference 60 Electronic Throttle Control 42 EMISSION CONTROL SYSTEMS 60 Engine Fogging 101 Engine Stop Switch 41 Equipment Modifications 8 ETC 42 Exhaust Emission Control System 60 Eye Protection 23 F FEATURES AND CONTROLS 40 54 Foot Brake 44 Fuel Filter 84 Fuel Stabilizer 100 Fuel Tank 47 Fuel Valve 47 G Gear Selector 48 H Handlebar Adjustment 77 Hauling Cargo 38 39 Hazard Warning...

Page 119: ...e Panel Removal 80 Sidehilling 29 Signal Light 88 Spark Arrestor 60 94 95 Spark Plugs 90 91 S SPECIFICATIONS 108 110 Speedometer Mode Switch 40 Springs Rear 76 Starting the Engine 57 58 Steering 76 Steering Assembly 77 Steering Lock 46 Stop Switch 41 Storing the Vehicle 100 101 Suspension 76 Symbol Identification 65 T TABLE OF CONTENTS 3 Tachometer 52 Taillight 88 Throttle Cable Freeplay 79 Thrott...

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Polaris Trail Boss 330 Quadricycle, Owner'S Manual

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