Copyright 2004 Polaris Sales Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant improvements in the design and quality of production 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 reference use only. Manufacturer accepts no liability for omissions or inaccuracies.
TABLE OF CONTENTS VEHICLE IDENTIFICATION NUMBERS . . . . . . . . . . . . . . . 5 SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 FEATURES AND CONTROLS . . . . . . . . . . . . . . . . . . . . . . 40 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 EMISSION CONTROL SYSTEMS . . . . . . . . . . . . . . . . . . . 60 MAINTENANCE AND LUBRICATION . . . . . . . . . . . . . . . . 61 POLARIS PRODUCTS . . . . . . . . . . . . . . . . . .
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VEHICLE IDENTIFICATION NUMBERS Record your vehicle’s identification numbers and key number. 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 existing keys, so if both keys are lost, the ignition switch must be replaced.
SAFETY Operator Safety The following signal words and symbols appear throughout this manual and on your vehicle. Become familiar with their meanings before reading the manual. The safety alert symbol, on your vehicle or in this manual, 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.
Operator Safety SAFETY WARNING Failure to follow the warnings in this manual can result in serious injury or death. A Polaris Quadricycle is not a toy and can be hazardous to operate. A collision or rollover can occur quickly, even during routine maneuvers, if you fail to take proper precautions. Read and understand your owner’s manual and all warnings before operating a Polaris Quadricycle. Safety Training When you purchased your new Quadricycle, your dealer offered a hands-on safety training course.
SAFETY Operator Safety Know Your Vehicle and Riding Area You are responsible for your personal safety, the safety of others and the protection of the environment. Read and understand your owner’s manual. It includes important information about Quadricycle safety. Ride responsibly. Know all laws and regulations concerning the operation of this vehicle in your area. Restrictions This vehicle is approved for OFF-ROAD TOWING ONLY. Operating a Quadricycle/trailer combination on public roads is prohibited.
SAFETY Operator Safety WARNING Serious injury or death can result if you do not follow the instructions and procedures listed here and throughout this manual. Read and understand all warnings, cautions and operating procedures in this manual and on the safety labels before operating the Quadricycle. Never operate a Quadricycle without proper instruction. Take a training course. Beginners should receive training from a certified instructor.
SAFETY Operator Safety Always wear an approved helmet that fits properly. 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.
Operator Safety SAFETY Never attempt wheelies, jumps or other stunts. Always inspect your Quadricycle 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.
SAFETY Operator Safety Use caution when operating on rough, slippery or loose terrain. Always follow the procedures outlined 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.
Operator Safety Never operate on hills too steep for the Quadricycle or for your abilities. Practice on smaller hills before attempting larger hills. Avoid climbing hills steeper than 25_. Always follow the procedures outlined in this manual for climbing hills. See page 30. SAFETY > 25_ 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.
SAFETY Operator Safety Always follow the procedures outlined in this manual for braking if you stall or roll backwards 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.
Operator Safety SAFETY Always follow the procedures outlined in this manual 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.
SAFETY Operator Safety Never modify a Quadricycle through improper installation or use of accessories. Never exceed the stated load capacity for your 2/3 Quadricycle. Cargo 1/3 must be properly distributed 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.
Operator Safety SAFETY Always remove the ignition key when the vehicle is not in use to prevent unauthorized use or accidental starting. Always keep combustible materials away from the exhaust system. Exposure of combustibles to hot components could result in a fire. FOR MORE INFORMATION ABOUT QUADRICYCLE SAFETY, call Polaris at 1-800-342-3764.
SAFETY Safety Decals and Locations Warning decals have been placed on the vehicle for your protection. Read and follow the instructions on each decal carefully. If a decal becomes illegible or comes off, contact your Polaris dealer to purchase a replacement. Replacement safety decals are provided by Polaris at no charge. The part number is printed on the decal. C G J G F E D A H B Decal Text Never operate this vehicle on hills steeper than 25 degrees.
Safety Decals and Locations SAFETY B C NO STEP D 19
SAFETY Safety Decals and Locations Decal Text NEVER ride as a passenger. Passengers can cause a loss of control, resulting in SEVERE INJURY or DEATH. WARNING 7172566 E TIRE PRESSURE IN PSI (KPa): FRONT 5 (34.5) 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 F DO NOT TOW FROM RACK OR BUMPER.
SAFETY Safety Decals and Locations ATTENTION S Operation of this vehicle without the air filter element will severely damage the engine. S Clean pre-filter element often, more frequent cleaning required in dusty conditions. Do not operate vehicle without pre-filter. S Specific carburetor jetting and adjustments are required depending on temperature and altitude. See your Owner’s Manual. Factory setting: 40_ to 80_ F. at 0-3000 feet (5_ to 27_ C. at 0-900 meters).
SAFETY Safety Decals and Locations Hitch Decal TRAILER MAX WEIGHT: 850 LBS. (386 KG) ON LEVEL GROUND HITCH MAX. VERTICAL WEIGHT: 85 LBS. (39 KG) 7170915 Recoil Decal Recoil handle must be firmly seated to prevent water entry. Drain starter motor if water enters.
SAFETY Safe Riding Gear Always wear protective clothing to reduce the chance of injury. 1. Helmet Always wear a helmet that meets or exceeds established safety standards. A helmet can prevent a severe head injury. 1 2. Eye Protection Wear shatterproof goggles 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. 2 3 5 4. Boots Wear strong over-the-calf boots with heels, like moto-cross boots. 5.
SAFETY Driving Safely Driving Procedures 1. Sit upright. Keep your feet on the footrests. Keep both hands on the handlebars. 2. Start the engine and allow it to warm up, then shift the transmission into gear. 3. Check your surroundings and determine your path of travel. 4. Release the parking brake. 5. Slowly squeeze the throttle lever toward the handlebar to begin driving. Squeeze the throttle lever further to increase speed. 6. Drive slowly.
SAFETY Driving Safely Making Turns 1. To make a turn, steer in the direction of the turn, leaning your upper body to the inside of the turn while supporting your weight on the outer footrest. Use the same leaning technique for turning in reverse. 2. Practice turning at slow 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.
SAFETY Driving Safely Driving on Slippery Surfaces Whenever driving on slippery or loose surfaces such as wet trails, gravel, snow or ice, follow these precautions: 1. Slow down before driving onto slippery surfaces. 2. Use extra caution. 3. Be alert. Watch the trail. Avoid quick, sharp turns. NOTE: To correct a rear wheel skid, turn the handlebars in the same direction as the skid and shift body weight forward.
Driving Safely SAFETY Driving Over Obstacles 1. Always check for obstacles before operating in a new area. Serious injury or death can result if your vehicle comes in contact with a hidden obstacle. 2. Be alert. Watch the terrain. Use extra caution. 3. Never operate over large obstacles. 4. Avoid hazards such as logs, rocks and low branches. Always follow the procedures outlined in this manual for operating over obstacles.
SAFETY Driving Safely Driving Downhill Whenever descending a hill, follow these precautions: 1. Check the terrain carefully. 2. Avoid hills with excessively slippery or loose surfaces. 3. Never go down a hill at high speed. 4. Slow down. 5. Avoid going down a hill at an angle, which 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.
Driving Safely SAFETY Sidehilling Avoid crossing the side of a hill (sidehilling) if possible. If sidehilling is necessary, follow these precautions: 1. Slow down. 2. Avoid hills with excessively slippery or loose surfaces. 3. Shift your weight uphill. 4. Avoid crossing the sides of steep hills. 5. Keep your feet on the footrests. 6. Steer slightly into the hill.
SAFETY Driving Safely Driving Uphill Whenever traveling uphill, follow these precautions: 1. Avoid steep hills (25_ maximum). 2. Check the terrain carefully. 3. Avoid hills with excessively slippery or loose surfaces. 4. Shift your weight uphill. 5. Drive straight uphill. 6. Keep your 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.
Driving Safely SAFETY Driving Uphill If all forward speed is lost: Keep your weight uphill. If the vehicle begins rolling downhill, never apply engine power. Never apply the hand brake while rolling backwards. Apply the foot brake gradually. When fully stopped, apply the hand brake as 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.
SAFETY Driving Safely Turning Around on a Hill If the vehicle stalls while climbing a hill, never back down the hill! Use the K-turn to turn around. 2.4 m 1. Stop the vehicle. Keep your weight uphill. 2. Lock the hydraulic parking 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.
Driving Safely SAFETY Turning Around on a Hill 8. Lock the hydraulic parking brake. Remount from the uphill side. Keep your weight uphill. 9. Apply the foot brake. 10. With the transmission still in forward, start the engine. 11. Squeeze and release the brake lever to release the parking 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.
SAFETY Driving Safely Driving Through Water Follow these procedures when operating through water: 1. Check water depth and current before crossing. 2. Avoid operating in water deeper than the bottom of the footrests (1). If it’s unavoidable, travel slowly, balance your weight carefully and avoid sudden movements. Maintain a slow and steady forward motion. Do not make sudden turns, stops or throttle changes. 1 3. Choose a crossing where both banks have gradual inclines. 4. Drive slowly. 5.
Driving Safely SAFETY Driving Through Water CAUTION If the vehicle stops while fully submerged, major engine damage can result if the machine is not thoroughly inspected. Take the vehicle to your dealer before starting the engine. If your vehicle becomes fully immersed, and it’s impossible to take it to a dealer before starting it, follow the steps described on page 92. Have the vehicle serviced by your dealer promptly.
SAFETY Driving Safely Driving in Reverse Follow these precautions when operating in reverse: 1. Avoid backing downhill. 2. Always check for obstacles or people behind the vehicle before backing. 3. Drive slowly. 4. Apply the foot brake lightly for stopping. 5. Avoid turning at sharp angles. 6. Never apply the throttle suddenly. 7. Do not use the override switch unless additional power is required for vehicle movement. Use with caution.
Driving Safely SAFETY Parking on an Incline Avoid parking on an incline. If it’s unavoidable, follow these precautions: 1. Turn the engine off. 2. Place the transmission in gear. 3. Lock the mechanical parking brake. 4. Always block the rear wheels on the downhill side. 5. Turn the fuel valve off.
SAFETY Driving Safely Hauling Cargo and Towing WARNING Overloading the vehicle or carrying or towing cargo improperly can alter vehicle handling and may cause loss of control or brake instability. Always follow these precautions when hauling cargo. S Read and understand the load distribution warnings listed on the vehicle warning labels. S Never exceed the stated load capacity for this vehicle. S REDUCE SPEED AND ALLOW GREATER DISTANCES FOR BRAKING WHEN HAULING CARGO OR TOWING.
SAFETY Driving Safely Hauling Cargo and Towing 2/3 1/3 Towing Towing is approved OFF-ROAD ONLY. Operating a Quadricycle/trailer combination on public roads is prohibited. Do not exceed the maximum capacities when towing. Do not tow any trailer on a grade steeper than 15°. Trail Boss 330 QUADRICYCLE Maximum Towed Load (Level Ground) Maximum Vertical Hitch Weight 386 kg 38.
FEATURES AND CONTROLS Controls/Instruments (2) (4) (3) (5) (1) (1) Main Key Switch Turn the main key switch off to stop the engine and end all electrical power to the vehicle. Turn the switch on to engage the starter. After starting the engine, release the key to the RUNNING LIGHTS position. Turn the switch to LIGHTS ON to switch the headlights on. WARNING Do not attach a large key fob or key ring to the main switch.
FEATURES AND CONTROLS Controls/Instruments (3) Engine Stop Switch (3) Move the stop switch to the OFF position to stop the engine. All electrical power to the vehicle will end. The engine will not start or run when the switch is in the OFF position. Move the stop switch to the ON (RUN) position before attempting to start the engine. (4) Light Switch OFF (4) Toggle the lights from high beam to low beam.
FEATURES AND CONTROLS Controls/Instruments (6) (10) (11) (13) (13) (12) (8) (9) (7) (14) (6) Electronic Throttle Control (ETC) (6) ETC causes the engine to stop if the throttle cable sticks in 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.
FEATURES AND CONTROLS Controls/Instruments (9) Hazard Warning Switch Push the hazard warning switch to cause all turn indicators to flash simultaneously. Use this feature to alert others of an emergency or other situation requiring caution. (9) (10) Rear Brake Lever The left brake lever operates the hydraulic rear brakes only. See page 44. (11) Parking Brake Lever The right brake lever is used as a mechanical parking brake only. See page 45.
FEATURES AND CONTROLS Brakes Foot Brake The all-wheel foot brake (1) is located on the right footrest. The foot brake operates both front and rear brakes. Press the brake pedal forward with your foot to engage the all-wheel brakes. The master cylinder (2) is located near the foot brake. Inspect and maintain the brake fluid level as outlined in this manual. See pages 56 and 75. 2 1 Rear Brake Lever 1 The left brake lever (1) operates the 2 hydraulic rear brakes only.
Brakes FEATURES AND CONTROLS WARNING Operating the Quadricycle while the parking brake is engaged could result in an accident and serious injury or death. Always check to be sure the parking brake is disengaged before operating. Locking the Parking Brake (Mechanical) The right brake lever is used as a mechanical parking brake only. It is not intended to be used as a brake lever. 1. Squeeze the right brake 2 1 lever (1) toward the 3 handlebar. 2.
FEATURES AND CONTROLS Steering Lock Lock the steering to prevent unauthorized use or theft of the vehicle. 1. Turn the handlebars to the full left position. 2. Insert the steering lock key and turn it clockwise. 3. Remove the key. 4. Reverse the procedure to unlock the steering. NOTE: 46 Place the steering lock keys in a safe place. The lock must be replaced if the keys are lost.
Fuel Tank FEATURES AND CONTROLS The fuel tank filler cap (1) is located directly below the handlebar. Refuel with either leaded or unleaded gasoline with a minimum of 87 octane. WARNING S Gasoline is highly flammable and explosive under certain conditions. S Use extreme caution whenever handling gasoline. S Refuel with the engine stopped. Refuel outdoors or in a well ventilated area. S Never fill a fuel container while it’s in the cargo box.
FEATURES AND CONTROLS Transmission Gear Selector The transmission gear selector (1) is located on the right side of the vehicle. Whenever the vehicle is left unattended, place the transmission in gear and lock the mechanical parking brake. F: Forward Gear N: Neutral R: Reverse 1 R N F 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.
Recoil Starter FEATURES AND CONTROLS If the battery is too weak to start the engine, use the recoil starter (1). Follow the starting procedures on page 57, cranking the engine with the recoil starter instead of the main key switch. 1. Grasp the recoil starter rope handle tightly. Pull slightly until the starter mechanism engages. 2. Pull the rope abruptly to start the engine. 1 CAUTION Extending the starter rope too far will cause damage to the recoil assembly.
FEATURES AND CONTROLS Instrument Cluster The instrument cluster senses vehicle speed from the right front wheel. It measures distance as well as hours of operation. It also includes a reverse speed limiter function that limits reverse speed to about 11-14 km/h. See page 40 for additional information. 3 2 1 1. Rider Information Center 2. Speedometer needle (In addition to showing vehicle speed, the needle flashes when a warning condition exists.) 3.
FEATURES AND CONTROLS Instrument Cluster Rider Information Center The rider information center is located in the instrument cluster. All segments will light up for 2.5 seconds at start-up. NOTE: If the instrument cluster fails to illuminate, a battery over-voltage condition may have caused it to 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.
FEATURES AND CONTROLS Instrument Cluster Rider Information Center The reverse override button on the left handlebar is also the mode button. Use the mode button to toggle through the four (4) standard modes of the rider information center. NOTE: The transmission cannot be in reverse. Mode 1 - Odometer The odometer records the total distance traveled by the vehicle since manufacture. Mode 2 -Trip Meter The trip meter records the distance traveled on each trip if it’s reset before each trip.
FEATURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode The diagnostic mode is for informational purposes only. Please return your Quadricycle to your dealer for all major repairs. The wrench icon will display when the gauge is in the diagnostic mode. Steps to enter the diagnostic mode: 1. Turn the main key switch off and wait 10 seconds. 2. Shift the transmission into neutral or park. 3. Hold the mode button and turn the main key switch on. 4.
FEATURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode Screen 5: Programmable service interval The programmable service interval provides a convenient reminder when routine maintenance is due. This feature is pre-set at 50 hours. You must enable the programmable service interval before it can be used. When set, the hours of operation are subtracted from the set hours until 0 is reached.
Break-In Period OPERATION The break-in period for your new Polaris Quadricycle is the first ten hours of operation, or the time it takes to use the first two full tanks of gasoline. No single action on your part will increase the life and performance of your Quadricycle more than following the procedures for a proper break-in. Careful treatment of a new engine will result in more efficient performance and a longer life.
OPERATION Pre-Ride Inspection Pre-Ride Checklist Item Remarks See Page Brake system Ensure proper operation 74 Brake fluid Ensure proper level 75 Foot brake Ensure proper operation 44 Front suspension Inspect, lubricate if necessary 65 Rear suspension Inspect, lubricate if necessary 65 Steering Ensure free operation Tires Inspect condition and pressure 82 Wheels / fasteners Inspect, ensure fastener tightness 81 Drive chain Inspect condition, lubricate frequently 83 Frame nuts, b
Starting the Engine OPERATION WARNING Engine exhaust contains poisonous carbon monoxide and can cause loss of consciousness resulting in serious injury or death. Never run an engine in an enclosed area or indoors. CAUTION Operating the vehicle immediately after starting could cause engine 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.
OPERATION Starting the Engine 7. Turn the ignition key to the ON position to engage the starter. Activate the starter for a maximum of five seconds, releasing the key when 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.
Polaris Variable Transmission OPERATION Preventing Belt Slip / Failure Belt slip creates heat that destroys belts and causes outer clutch covers to fail. Avoid heavy pulling and extended low speed operation. WARNING Do not modify any component of the PVT system. Doing so may reduce its strength so that a failure may occur at a high speed. The PVT system has been precision balanced. Any modification will cause the system to be out of balance, creating vibration and additional loads on components.
EMISSION CONTROL SYSTEMS Noise Emission Control System Do not modify the engine, intake or exhaust components, as doing so may affect compliance with governmental noise level requirements. Spark Arrestor Your Polaris vehicle has a spark arrestor that was designed for on-road and off-road operation. It is required that this spark arrestor remain installed and functional when the vehicle is operated. Crankcase Emission Control System This engine is equipped with a closed crankcase system.
MAINTENANCE AND LUBRICATION Periodic Maintenance Chart Maintenance intervals in the following chart are based upon average riding conditions. Vehicles subjected to severe use must be inspected and serviced more frequently. Severe Use Definition S Frequent immersion in mud, water or sand S Racing or race-style high RPM use S Prolonged low speed, heavy load operation S Extended idle S Short trip cold weather operation NOTE: Service and adjustments are critical.
MAINTENANCE AND LUBRICATION Periodic Maintenance Chart Perform all services at whichever maintenance interval is reached first.
MAINTENANCE AND LUBRICATION Periodic Maintenance Chart Item Carburetor float bowl Maintenance Interval Remarks (whichever comes first) Hours Calendar Kilometers 50 6M 500 Drain bowl periodically and prior to storage J Throttle Cable/ 50 6M 500 Inspect; adjust; lubricate; replace if necessary J Choke cable 50 6M 500 Inspect; adjust; lubricate; replace if necessary 50 6M 500 Inspect ducts for proper sealing/air leaks 50 6M 500 Inspect; adjust; replace as needed " Engine oil change
MAINTENANCE AND LUBRICATION Periodic Maintenance Chart Item Maintenance Interval (whichever comes first) Hours Calendar Kilometers Remarks J Clutches (drive 100 12 M 1000 Inspect; clean; replace worn parts J Front wheel 100 12 M 1600 Inspect; replace as needed J Brake fluid 200 24 M 2000 Change every two years 300 36 M 3000 Clean out and driven) bearings Spark arrestor E Idle speed -- Adjust as needed J Toe adjustment -- Inspect periodically; adjust when parts are replaced " F
MAINTENANCE AND LUBRICATION Torque Symbol =Torque the item as specified. Lubrication Recommendations Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart beginning on page 61. Items not listed in the chart should be lubricated at the General Lubrication 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.
MAINTENANCE AND LUBRICATION Engine Oil Polaris Premium 4 Synthetic Oil is the only oil recommended for use in this engine. Use of another API certified “SH” oil is acceptable as long as it’s 0W-40. Oil may need to be changed more frequently if Polaris Premium 4 is not used. See page 103 for the 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.
MAINTENANCE AND LUBRICATION Oil Check 1. Position the vehicle on a level surface. 2. Place the transmission in neutral. 3. Lock the mechanical parking brake. R N F 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.
MAINTENANCE AND LUBRICATION Oil and Filter Change Always change the engine oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 61. Always change the oil filter when changing oil. Change the oil more often if the vehicle is routinely subjected to: S operation in dusty or wet conditions. S operation when air temperature is below -12° C. S short trips at -12° to -1° C. (engine fails to reach operating temperature).
MAINTENANCE AND LUBRICATION Oil and Filter Change 6. Place a drain pan under the vehicle. 7. Remove the drain plug. 8. Drain the oil. CAUTION Hot oil may result in serious burns. Do not allow hot oil to contact skin. 9. Reinstall the drain plug with a new sealing washer. =19 N-m 10. Place towels under the oil filter. 11. Using an oil filter wrench (4), turn the filter counterclockwise to remove it. 4 12. Clean the filter sealing area on the engine.
MAINTENANCE AND LUBRICATION Oil and Filter Change 13. Lubricate the filter o-ring. 14. Install the new oil filter. After the filter contacts the engine surface, turn it 1/2 turn by hand. 15. Remove the dipstick. 16. Add two .95 liter bottles of 0W/40 oil. 17. Reinstall the dipstick. 18. Start the 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.
MAINTENANCE AND LUBRICATION Engine Oil Cooler Maintenance The oil cooling system requires little maintenance other than keeping the cooler (1) free of mud and debris. 1 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.
MAINTENANCE AND LUBRICATION Transmission Oil Check See page 65 for recommended lubricants. See page 103 for the part numbers of Polaris products. 1. Position the vehicle on a level surface. 2. Place the transmission in gear. 3. Lock the mechanical parking brake. R 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.
MAINTENANCE AND LUBRICATION Transmission Oil Change 1. Position the vehicle on a level surface. 2. Place the transmission in gear. 3. Lock the mechanical parking brake. R 4. Loosen the jam nut (1). 5. Turn the adjuster bolt (2) inward. 6. Remove the drain plug (3). Wipe it clean. N F 1 2 3 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.
MAINTENANCE AND LUBRICATION Brakes Under normal operation, a diaphragm extends into the reservoir as fluid level drops. If the fluid level is low and the diaphragm is not extended, a leak is likely. The brake system should be inspected by your dealer. Fill the reservoir as needed whenever the cover is loosened or removed to ensure proper diaphragm operation. Use Polaris DOT 3 brake fluid. Do not overfill. NOTE: Reservoir levels will decrease as brake pads become worn.
Brakes MAINTENANCE AND LUBRICATION Brake Fluid Check Check brake fluid levels before each use of the vehicle. The brakes should feel firm when they’re applied. Spongy or weak brakes may indicate a fluid leak or low fluid level. A low fluid level may also mean that brake pads are worn and need to be replaced. Do not operate the vehicle with spongy or weak brakes. See your dealer for service. Master Cylinder (Handlebar) The master cylinder (1) is located on the left handlebar.
MAINTENANCE AND LUBRICATION Steering / Suspension Toe Alignment Use the following procedure to check the toe alignment of the vehicle. The recommended toe alignment is 3-6 mm toe out. 1. Set the handlebars in a straight-ahead position. 2. Place stands (1) in front of the vehicle, perpendicular to the rear tires. 3.
MAINTENANCE AND LUBRICATION Steering / Suspension Steering Assembly Check the steering assembly of the vehicle periodically for loose nuts and bolts. If loose nuts and bolts are found, see your Polaris dealer for service before operating the vehicle. Handlebar Adjustment 1. Remove the two hex screws (1) from the instrument panel (2). Remove the instrument panel. 2. Loosen (do not remove) all four handlebar bolts. 3. Adjust the handlebar to the desired height.
MAINTENANCE AND LUBRICATION Carburetor Idle Adjustment IMPORTANT: Your Polaris vehicle is calibrated at the factory for optimal performance at altitudes ranging from zero to 1800 meters and at temperatures of 4 degrees C. or higher. Above 1800 meters the engine air/fuel mixture becomes too rich and the engine loses approximately 3% of its power for each 300 meter increase in elevation.
MAINTENANCE AND LUBRICATION Throttle Cable Freeplay Adjustment 1. Locate the throttle cable adjuster (1) on the handlebar. 2. Slide the boots (2) off the cable adjuster sleeve (3). Loosen the adjuster (4). 1 2 3 2 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. 1.6-3.2 mm 4. Tighten the adjuster. Slide the boots (2) over the cable adjuster until they touch at the midpoint of the adjuster.
MAINTENANCE AND LUBRICATION Side Panel Removal NOTE: Side panel removal may be difficult until the locking tabs and receivers have been snapped and unsnapped a few times. 1. Remove the seat. 2. Grasp the rear of the side panel near the rear cab. Pull the panel forward and outward quickly and 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.
MAINTENANCE AND LUBRICATION Wheel Removal / Installation CAUTION Operating with improperly installed wheels will affect vehicle handling and could cause an accident resulting in serious injury or death. Always use original equipment size and type when replacing tires. Install wheels properly. 1. Position the vehicle on a level surface. 2. Place the transmission in gear. 3. Lock the mechanical parking brake. R N F 4. Loosen the wheel nuts slightly. 5. Safely place jackstands under the vehicle. 6.
MAINTENANCE AND LUBRICATION Tires Tire Tread Depth Always replace tires when tread depth is worn to 3 mm or less. 3 mm WARNING Operating your vehicle with worn tires, improperly inflated tires, non-standard tires or improperly installed tires will affect vehicle handling and could cause an 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.
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.
MAINTENANCE AND LUBRICATION Drive Chain Rear Drive Chain Slack 5. Roll the vehicle forward or backward to adjust the chain slack to the proper tension. See the illustration for proper splice link clip opening position (1). 6. Tighten the eccentric locking bolts to 61 N-m. 1 7. Tighten the caliper mounting bolt to 20 N-m. 8. Remove the pin punch. 9. Roll the vehicle forward, checking chain tension in several places around the chain.
MAINTENANCE AND LUBRICATION Air Filter 1. Position the vehicle on a level surface. 2. Place the transmission in gear. 3. Lock the mechanical parking brake. R N F 4. Remove the seat. 5. Unlatch the air box clips (1). Remove the air box cover. 1 6. Loosen the hose clamp (2) and remove the filter (3). 3 2 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.
MAINTENANCE AND LUBRICATION Lights WARNING Poor lighting can result in loss of control or an accident. Lights become dirty during normal operation. Wash the headlights and tail lights frequently. Hot components can cause serious burns to skin. Do not service the headlamps until they’ve cooled. Headlight Replacement When servicing a halogen lamp, do not touch the lamp with bare fingers. Hold the plastic part (1) of the lamp.
Lights MAINTENANCE AND LUBRICATION High Beam Adjustment 7.6 m x x 5.1 cm 1. Position the vehicle on a level surface. The headlight should be approximately 7.6 meters from a wall. 2. Place the transmission in neutral. 3. Lock the mechanical parking R N F brake. 4. Measure the 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.
MAINTENANCE AND LUBRICATION Lights Taillight/Signal Light Replacement 1. Place the transmission in gear. 2. Lock the mechanical parking brake. R N F 3. Rotate the taillight socket counterclockwise to remove it. 4. Remove the lamp. 5. Apply dielectric grease to the socket. 6. Install the new lamp. 7. Test the lamp for proper operation. 8. Reinstall all components in reverse order. 9. Rotate the turn signal socket counterclockwise to remove it. 10. Remove the lamp. 11.
MAINTENANCE AND LUBRICATION Recoil Housing Drain 2 Always drain the recoil housing (1) after operating the vehicle in wet conditions. Always remove the drain plug before storing the vehicle. NOTE: 1 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. R N F 3. Using a wrench, remove the drain screw (3) on the bottom of the recoil housing. 4.
MAINTENANCE AND LUBRICATION Spark Plugs 1. Remove the left side panel. See page 80. 1 2. Remove the spark plug wire (1). Use the spark plug wrench (2) to remove the spark plug (3). Turn the plug counterclockwise to remove it. 3. Inspect the electrodes for wear and carbon buildup. 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.
MAINTENANCE AND LUBRICATION Spark Plugs Spark Plug Condition Normal The insulator tip is tan or brown. There are few combustion deposits. The electrodes are not burned or eroded. This indicates the proper type and heat range for the engine and the service. NOTE: The tip should not be white. A 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.
MAINTENANCE AND LUBRICATION Vehicle Immersion CAUTION If the vehicle stops while fully submerged, major engine damage can result if the machine is not thoroughly inspected. Take the vehicle to your dealer before starting the engine. If your vehicle has been totally submerged in water 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. RES OFF ON 3. Remove the spark plug. See page 90. 4.
MAINTENANCE AND LUBRICATION Vehicle Immersion 5. Loosen the carburetor drain screw (1) and drain the carburetor. 1 6. Turn the ignition key to the ON position to engage the starter. Engage 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. RES OFF ON 10. Attempt to start the engine. If necessary, repeat the drying procedure. 11.
MAINTENANCE AND LUBRICATION Spark Arrestor Occasionally, the spark arrestor may accumulate carbon, which can restrict the exhaust if left unattended. Purge the spark arrestor. WARNING Allow components to cool sufficiently before servicing. The exhaust system can get extremely hot. Never run the 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.
MAINTENANCE AND LUBRICATION Spark Arrestor 5. Quickly squeeze and release the throttle lever several times to purge carbon from the system. 6. If carbon comes out of the exhaust, cover or plug the exhaust outlet (1). Wear leather gloves for 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.
MAINTENANCE AND LUBRICATION Battery WARNING Improperly connecting or disconnecting battery cables can cause sparks which could result in an explosion, causing serious injury or death. When removing the battery, always disconnect the negative (black) cable first. When reinstalling the battery, always connect the negative (black) cable last. Battery Removal 1. Place the transmission in gear. 2. Lock the mechanical parking brake. 3. 4. 5. 6. R N Disconnect the battery hold-down strap.
Battery MAINTENANCE AND LUBRICATION Battery Storage Whenever the vehicle is not used for a period of three months or more, remove the battery from the vehicle. Verify that it’s fully charged, and store it out of the sun in a cool, dry place. Check battery voltage each month during storage and recharge as needed to maintain a full charge. NOTE: Battery charge can be maintained by using a Polaris Battery Tendert charger (P/N 2871076) or by charging about once a month to make up for normal self-discharge.
MAINTENANCE AND LUBRICATION Battery Battery Charging Chart (Constant Current Charger) State of Charge Voltage 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 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.
MAINTENANCE AND LUBRICATION Cleaning the Vehicle Keeping the vehicle clean will extend the life of components. S Use a garden hose and a pail of mild soap and water S Use a professional-type washing mitten, cleaning the upper body first and the lower parts last. S Rinse with clean water frequently. S Wipe the vehicle dry with a chamois. S Do not use high pressure water. High pressure water may damage components.
MAINTENANCE AND LUBRICATION Storing the Vehicle See page 103 for the part numbers of Polaris products. Clean the Vehicle See page 99. Stabilize the Fuel 1. Fill the fuel tank. 2. Add Polaris Carbon Clean Fuel Treatment or Polaris Fuel Stabilizer. Follow the instructions on the container. (Carbon Clean Plus will reduce the possibility of bacterial growth in the fuel system.) Allow 15-20 minutes of operation for the stabilizer to disperse through the fuel in the tank and carburetor. 3.
MAINTENANCE AND LUBRICATION Storing the Vehicle Engine Fogging Use Polaris Engine Fogging Oil. Follow label directions carefully. CAUTION Starting the engine during the storage period will disturb the protective oil film, which can lead to engine damage. Never start the engine during the storage period. Storage Area / Cover 1. Make sure tire 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.
MAINTENANCE AND LUBRICATION Transporting the Vehicle Follow these procedures when transporting the vehicle. 1. Turn the engine off. Remove the key to prevent loss during transporting. 2. Place the transmission in gear. 3. Lock the mechanical parking brake. R N F 4. Turn the fuel valve off. 5. Be sure the fuel cap, oil cap and seat are installed correctly. RES OFF ON 6. Attach the FRAME of the Quadricycle to the transporting unit securely using suitable straps or rope.
POLARIS PRODUCTS Part No. Description 2870791 2871281 2871844 Engine Lubricant Fogging Oil (355 ml Aerosol) Premium 4 Synthetic 0W-40 (4-Cycle) Engine Oil (.95 l) Premium 4 Synthetic 0W-40 (4-Cycle) Engine Oil (3.8 l) 2873602 2873603 2871653 2872276 2870465 2871654 2872277 Gearcase / Transmission Lubricants Premium AGL Synthetic Gearcase Lube (.95 l) Premium AGL Synthetic Gearcase Lube (3.8 l) Premium ATV Angle Drive Fluid (237 ml) Premium ATV Angle Drive Fluid (.95 l) Pump for 3.
TROUBLESHOOTING Drive Belt and Cover Problems Possible Cause Solution Driving the vehicle onto a Avoid stopping on the ramp or creeping slowly up the pickup or tall trailer. ramp. Starting out going up a steep incline. Perform the K-turn as described on page 32. Driving at low RPM or Drive at a slightly higher speed. Avoid creeping. low ground speed (at approximately 3-7 MPH). Insufficient warm-up of vehicles exposed to low ambient temperatures. Warm the engine at least 5 minutes.
TROUBLESHOOTING Contact your Polaris dealer for service if you’re unable to identify solutions using the following charts. Engine Does Not Rotate Possible Cause Solution Blown fuse Replace fuse Low battery voltage Recharge battery to 12.
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 your Polaris dealer Incorrect ignition timing See your Polaris dealer Mechanical failure See your Polaris dealer Engine Runs Irregularly, Stalls or Misfires Possible Cause Solution Fouled or defective sp
TROUBLESHOOTING Engine Stops or Loses Power Possible Cause Solution Out of fuel Turn fuel valve to reserve, refuel Kinked or plugged fuel vent line Inspect and replace Water present in fuel / old fuel Replace with new fuel Overuse of choke Inspect, clean and/or replace spark plugs Fouled or defective spark plugs Inspect, clean and/or replace spark plugs Worn or defective spark plug wires See your Polaris dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs Loose ig
SPECIFICATIONS 2005 Trail Boss 330 Quadricycle Capacities Gen IV 438 kg 12.35 l 335 ml 1.8 l (incl. oil cooler ) 1.6 l (oil change only) Front Rack 34.1 kg Rear Rack 56.7 kg Tongue Weight 38.6 kg Towing Rating 386 kg Unbraked Trailer Towing Capacity* 573 kg Turn Radius 190.5 cm Ground Clearance 14 cm Height 116.8 cm Length 190.5 cm Width 116.8 cm Seat Height 86.4 cm Dry Weight 229 kg Wheel Base 125.
SPECIFICATIONS 2005 Trail Boss 330 Quadricycle Drive System Type Shift Type Gear Reduction - Reverse Gear Reduction - Forward Final Drive (ratio) Drive Chain Front Tires Rear Tires Drive System PVT Side Lever (F/N/R) 3.05/1 2.68/1 11/40 78P 520 O-Ring 23 x 7-10 (34.5 KPa) 22 x 12-10 (34.5 KPa) Suspension and Brakes Front Suspension: Mac Strut 17 cm travel Rear Suspension: Progressive Rate 22.
SPECIFICATIONS 2005 Trail Boss 330 Quadricycle Jetting Chart Altitude AMBIENT TEMPERATURE Below 5° C +5°C and above Meters 0-1800 127.5 122.
WARRANTY LIMITED WARRANTY Polaris Industries Inc., 2100 Highway 55, Medina, MN 55340, gives a TWO YEAR LIMITED WARRANTY on all components of the Polaris Quadricycle against defects in material or workmanship. This warranty covers the parts and labor charges for repair or replacement of defective parts which are covered by this warranty. This warranty begins on the date of purchase. This warranty is transferrable to another consumer during the warranty period through a Polaris dealer.
WARRANTY LIMITATIONS OF WARRANTIES AND REMEDIES ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE) ARE LIMITED IN DURATION TO THE ABOVE TWO YEAR WARRANTY PERIOD. POLARIS FURTHER DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY. Some states do not allow limitations on how long an implied warranty lasts, so the above limitation may not apply to you if inconsistent with controlling state law.
MAINTENANCE RECORD DATE MILES/KM TECHNICIAN SERVICE PERFORMED / COMMENTS 113
MAINTENANCE RECORD DATE 114 MILES/KM TECHNICIAN SERVICE PERFORMED / COMMENTS
MAINTENANCE RECORD DATE MILES/KM TECHNICIAN SERVICE PERFORMED / COMMENTS 115
INDEX A F Accessories . . . . . . . . . . . . . . . . . . . 101 Age Restriction . . . . . . . . . . . . . . . . . . 7 Air Filter . . . . . . . . . . . . . . . . . . . . . . 85 FEATURES AND CONTROLS . . 40-54 Foot Brake . . . . . . . . . . . . . . . . . . . . 44 Fuel Filter . . . . . . . . . . . . . . . . . . . . . 84 Fuel Stabilizer . . . . . . . . . . . . . . . . . 100 Fuel Tank . . . . . . . . . . . . . . . . . . . . . 47 Fuel Valve . . . . . . . . . . . . . . . . . . . . . 47 B Battery . . . . . . .
INDEX N S Noise Emission Control System . . . . 60 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 . . . . . . . . . .
