Owners Manual
Page 5
... time of Polaris Industries Inc. Due to constant improvements in the design and quality of the depictions and/or procedures contained within this publication are registered trademarks of publication. No liability can be accepted for reference use only. Printed in this publication is expressly prohibited. Depictions and/or procedures in U.S.A. 2010 Trail Boss 330/Trail Blazer 330 International Owner's Manual...
... time of Polaris Industries Inc. Due to constant improvements in the design and quality of the depictions and/or procedures contained within this publication are registered trademarks of publication. No liability can be accepted for reference use only. Printed in this publication is expressly prohibited. Depictions and/or procedures in U.S.A. 2010 Trail Boss 330/Trail Blazer 330 International Owner's Manual...
Owners Manual
Page 18
... use or accidental starting the engine. Handling Gasoline Gasoline is highly flammable and explosive under certain conditions. • Always exercise extreme caution whenever handling gasoline. • Always refuel with soap and water and change clothing. • Turn the fuel valve off whenever the vehicle is stored. • Do not overfill the tank. For more information about safety, contact an authorized Polaris dealer or visit...
... use or accidental starting the engine. Handling Gasoline Gasoline is highly flammable and explosive under certain conditions. • Always exercise extreme caution whenever handling gasoline. • Always refuel with soap and water and change clothing. • Turn the fuel valve off whenever the vehicle is stored. • Do not overfill the tank. For more information about safety, contact an authorized Polaris dealer or visit...
Owners Manual
Page 20
... 25 degrees 25°. SAFETY Safety Labels and Locations Discretionary Warning WARNING • Never operate this ATV on hilly terrain, use throttle and brakes gradually, and shift weight uphill. • REVERSE operation can be dangerous even at low speeds. To prevent loss of control, avoid sudden braking or sharp turns. 7175511 General Warning + + Discretionary Warning Rack Warning, Front and Rear (Trail Boss) WARNING • DO NOT TOW FROM RACK OR BUMPER. Steering becomes difficult.
... 25 degrees 25°. SAFETY Safety Labels and Locations Discretionary Warning WARNING • Never operate this ATV on hilly terrain, use throttle and brakes gradually, and shift weight uphill. • REVERSE operation can be dangerous even at low speeds. To prevent loss of control, avoid sudden braking or sharp turns. 7175511 General Warning + + Discretionary Warning Rack Warning, Front and Rear (Trail Boss) WARNING • DO NOT TOW FROM RACK OR BUMPER. Steering becomes difficult.
Owners Manual
Page 30
... in -line fuel filter should be replaced by your dealer after every 100 hours of 87=(R+ M/2) octane. ON OFF 27 Do not attempt to the fuel tank. Refer to the engine starting procedure on page 32 for correct choke and throttle settings during starting a cold engine. FEATURES AND CONTROLS Choke The choke assists in starting . OFF: For vehicle storage and when transporting. Fuel Valve Fuel Filter The in a well...
... in -line fuel filter should be replaced by your dealer after every 100 hours of 87=(R+ M/2) octane. ON OFF 27 Do not attempt to the fuel tank. Refer to the engine starting procedure on page 32 for correct choke and throttle settings during starting a cold engine. FEATURES AND CONTROLS Choke The choke assists in starting . OFF: For vehicle storage and when transporting. Fuel Valve Fuel Filter The in a well...
Owners Manual
Page 33
...-ride inspection checklist. Pull only light loads. 7. PVT Break-in (Clutches/Belt) Break in the clutches and belt by operating at full throttle or high speeds for extended periods during the break-in more than following the procedures for these components. Fill the fuel tank with vehicle operation and handling. 4. Change both the oil and the filter at sustained idle. 5. Add oil if necessary. 3. Do not operate...
...-ride inspection checklist. Pull only light loads. 7. PVT Break-in (Clutches/Belt) Break in the clutches and belt by operating at full throttle or high speeds for extended periods during the break-in more than following the procedures for these components. Fill the fuel tank with vehicle operation and handling. 4. Change both the oil and the filter at sustained idle. 5. Add oil if necessary. 3. Do not operate...
Owners Manual
Page 34
... 20 20 22 72 69 21 76 77 8 31 Always inspect the vehicle before operating increases the risk of an accident. Item Hand brake Brake fluid Foot brake Front suspension Rear suspension Steering/steering lock Tires Wheels/fasteners Frame nuts, bolts, fasteners Fuel and oil Throttle Indicator lights/switches Engine stop switch Mirrors Drive chain Air filter, pre-filter Air box sediment tube Headlamp Brake light/taillight Riding gear Remarks Ensure proper operation Ensure proper level Ensure proper operation Inspect, lubricate...
... 20 20 22 72 69 21 76 77 8 31 Always inspect the vehicle before operating increases the risk of an accident. Item Hand brake Brake fluid Foot brake Front suspension Rear suspension Steering/steering lock Tires Wheels/fasteners Frame nuts, bolts, fasteners Fuel and oil Throttle Indicator lights/switches Engine stop switch Mirrors Drive chain Air filter, pre-filter Air box sediment tube Headlamp Brake light/taillight Riding gear Remarks Ensure proper operation Ensure proper level Ensure proper operation Inspect, lubricate...
Owners Manual
Page 55
... for wear, routing, security; clean; MAINTENANCE Periodic Maintenance Chart Item Maintenance Interval (whichever comes first) Hours Calendar X Engine mounts Exhaust muffler/ pipe E E Q Spark plug Q Ignition Timing Remarks Miles (Km) 1000 (1600) Inspect 1000 (1600) Inspect 1000 (1600) Inspect; replace worn parts 1000 (1600) Inspect; replace as needed 100 H 100 H 100 H 100 H 100 H 12 M 12 M 12 M 12 M 12 M X Wiring Q Clutches (drive and driven) bearings 100 H 100 H 200 H 300 H 12...
... for wear, routing, security; clean; MAINTENANCE Periodic Maintenance Chart Item Maintenance Interval (whichever comes first) Hours Calendar X Engine mounts Exhaust muffler/ pipe E E Q Spark plug Q Ignition Timing Remarks Miles (Km) 1000 (1600) Inspect 1000 (1600) Inspect 1000 (1600) Inspect; replace worn parts 1000 (1600) Inspect; replace as needed 100 H 100 H 100 H 100 H 100 H 12 M 12 M 12 M 12 M 12 M X Wiring Q Clutches (drive and driven) bearings 100 H 100 H 200 H 300 H 12...
Owners Manual
Page 70
Lock the parking brake. 2. Place a suitable stand under the footrest frame to raise the wheel slightly off during operation, which could result in gear. Lower the vehicle to specification (page 68). MAINTENANCE Tires Wheel Removal 1. Place the wheel on the wheel hub with tapered rear wheel nuts, make sure the tapered ends of the nuts fit into the tapers on the wheels. 3. Torque the wheel nuts to the...
Lock the parking brake. 2. Place a suitable stand under the footrest frame to raise the wheel slightly off during operation, which could result in gear. Lower the vehicle to specification (page 68). MAINTENANCE Tires Wheel Removal 1. Place the wheel on the wheel hub with tapered rear wheel nuts, make sure the tapered ends of the nuts fit into the tapers on the wheels. 3. Torque the wheel nuts to the...
Owners Manual
Page 74
... engine idle speed is calibrated at the factory for each 300 meter increase in elevation. Idle Adjuster 71 Tip: Continuous operation of its power for optimal performance at altitudes ranging from your area. Turn the screw in gear. MAINTENANCE Carburetor Your Polaris vehicle is not satisfactory, and all other conditions are required for conditions in your Polaris dealer, are favorable, the carburetor can cause poor performance, overheating...
... engine idle speed is calibrated at the factory for each 300 meter increase in elevation. Idle Adjuster 71 Tip: Continuous operation of its power for optimal performance at altitudes ranging from your area. Turn the screw in gear. MAINTENANCE Carburetor Your Polaris vehicle is not satisfactory, and all other conditions are required for conditions in your Polaris dealer, are favorable, the carburetor can cause poor performance, overheating...
Owners Manual
Page 78
... weight on . 6. Start the engine. Place the transmission in neutral. 3. Turn the headlight on the seat when measuring. 5. Measure the distance from a wall. 2. Lock the parking brake. 4. Use the following procedure to the left or right. 75 MAINTENANCE Lights Headlight Beam Adjustment The headlight beam can be two inches (5 cm) below the mark on a level surface with the headlight approximately 25 ft. (7.6 m) from the floor to the center...
... weight on . 6. Start the engine. Place the transmission in neutral. 3. Turn the headlight on the seat when measuring. 5. Measure the distance from a wall. 2. Lock the parking brake. 4. Use the following procedure to the left or right. 75 MAINTENANCE Lights Headlight Beam Adjustment The headlight beam can be two inches (5 cm) below the mark on a level surface with the headlight approximately 25 ft. (7.6 m) from the floor to the center...
Owners Manual
Page 79
... bottom. 4. MAINTENANCE Lights Poor lighting can cause burns to skin. Hold the plastic part of the lamp. Headlamp Replacement When servicing a halogen lamp, do not touch the lamp with bare fingers. Tip: The bulb must be positioned so the harness installs into the headlight housing and rotate clockwise firmly. Allow lamps to the light bulb socket before servicing. Remove the wire harness connector...
... bottom. 4. MAINTENANCE Lights Poor lighting can cause burns to skin. Hold the plastic part of the lamp. Headlamp Replacement When servicing a halogen lamp, do not touch the lamp with bare fingers. Tip: The bulb must be positioned so the harness installs into the headlight housing and rotate clockwise firmly. Allow lamps to the light bulb socket before servicing. Remove the wire harness connector...
Owners Manual
Page 95
...; Always use clean cloths and pads for a while to purchase a replacement. Polishing Tips • Avoid the use of your Polaris vehicle. Grease all zerk fittings immediately after washing. Replacement safety labels are provided by Polaris at the following items: • Wheel bearings • Electrical components/wiring • Radiator (if equipped) • Switches and controls • Transmission seals • Cab and body panels • Brakes • Labels and decals If...
...; Always use clean cloths and pads for a while to purchase a replacement. Polishing Tips • Avoid the use of your Polaris vehicle. Grease all zerk fittings immediately after washing. Replacement safety labels are provided by Polaris at the following items: • Wheel bearings • Electrical components/wiring • Radiator (if equipped) • Switches and controls • Transmission seals • Cab and body panels • Brakes • Labels and decals If...
Owners Manual
Page 98
... rearward. 3. Reinstall the spark plug. Turn the engine over several times using the electric start. To eliminate any time the fluid looks dark or contaminated) Fog the Engine 1. Remove the spark plug. Tip: Use a section of small hose and a small plastic squeeze bottle filled with a protective film of the spark plug cap. Treat the fuel system with Polaris Carbon Clean. See page 94. 2. Apply dielectric grease to specification. 5. Support the...
... rearward. 3. Reinstall the spark plug. Turn the engine over several times using the electric start. To eliminate any time the fluid looks dark or contaminated) Fog the Engine 1. Remove the spark plug. Tip: Use a section of small hose and a small plastic squeeze bottle filled with a protective film of the spark plug cap. Treat the fuel system with Polaris Carbon Clean. See page 94. 2. Apply dielectric grease to specification. 5. Support the...
Owners Manual
Page 101
... 1/8 throttle in mud or snow Shift the transmission to 7 times. RPM/low ground speed Utility use fast, aggressive throttle application to Always warm up the belt by operating below freezing. Stuck in short bursts, 5 to low range (if equipped). Improper break-in Always break in gas tank, fuel lines or carburetor. Slow/easy clutch engage- position Belt slippage from a stopped control and vehicle overturn. Warm the engine...
... 1/8 throttle in mud or snow Shift the transmission to 7 times. RPM/low ground speed Utility use fast, aggressive throttle application to Always warm up the belt by operating below freezing. Stuck in short bursts, 5 to low range (if equipped). Improper break-in Always break in gas tank, fuel lines or carburetor. Slow/easy clutch engage- position Belt slippage from a stopped control and vehicle overturn. Warm the engine...
Owners Manual
Page 105
SPECIFICATIONS Trail Boss 330 Maximum Weight Capacity Dry Weight Fuel Capacity Engine Oil Capacity Transmission Oil Front Rack Capacity Rear Rack Capacity Hitch Tongue Weight Capacity Hitch Towing Rating Unbraked Trailer Towing Capacity* Overall Length Overall Width Overall Height Wheelbase Ground Clearance Minimum Turning Radius Engine Model Number/Type Lubrication Engine Cooling Displacement Bore x Stroke Alternator Output Compression Ratio Carburetor Pilot Jet Main Jet Needle Jet Jet Needle Pilot Air Jet Pilot Screw Ignition System Ignition Timing Idle RPM Spark Plug / Gap 415 lbs. (188 kg)...
SPECIFICATIONS Trail Boss 330 Maximum Weight Capacity Dry Weight Fuel Capacity Engine Oil Capacity Transmission Oil Front Rack Capacity Rear Rack Capacity Hitch Tongue Weight Capacity Hitch Towing Rating Unbraked Trailer Towing Capacity* Overall Length Overall Width Overall Height Wheelbase Ground Clearance Minimum Turning Radius Engine Model Number/Type Lubrication Engine Cooling Displacement Bore x Stroke Alternator Output Compression Ratio Carburetor Pilot Jet Main Jet Needle Jet Jet Needle Pilot Air Jet Pilot Screw Ignition System Ignition Timing Idle RPM Spark Plug / Gap 415 lbs. (188 kg)...
Owners Manual
Page 106
SPECIFICATIONS Trail Boss 330 Driving System Type Shift Type Gear Reduction, Reverse Gear Reduction, Forward Drive Ratio, Final Drive Chain Tires/Pressure, Front Tires/Pressure, Rear Front Suspension Rear Suspension Shock Adjustment Brakes, Front and Rear Brake, Auxiliary Brake, Parking Headlight Taillights Brake Light Battery Indicators Automatic PVT (Polaris Variable Transmission) Side Lever (F/N/R) 3.05:1 2.68:1 3.64:1 520 O-Ring 23 x 7-10 (4 psi/27.6 kPa) 22 x 11-10 (3 psi/20.7 kPa) MacPherson strut with 8.2" (21 cm) travel Progressive rate with 10.5" (26.7 cm) travel CAM Single-Control ...
SPECIFICATIONS Trail Boss 330 Driving System Type Shift Type Gear Reduction, Reverse Gear Reduction, Forward Drive Ratio, Final Drive Chain Tires/Pressure, Front Tires/Pressure, Rear Front Suspension Rear Suspension Shock Adjustment Brakes, Front and Rear Brake, Auxiliary Brake, Parking Headlight Taillights Brake Light Battery Indicators Automatic PVT (Polaris Variable Transmission) Side Lever (F/N/R) 3.05:1 2.68:1 3.64:1 520 O-Ring 23 x 7-10 (4 psi/27.6 kPa) 22 x 11-10 (3 psi/20.7 kPa) MacPherson strut with 8.2" (21 cm) travel Progressive rate with 10.5" (26.7 cm) travel CAM Single-Control ...
Owners Manual
Page 107
SPECIFICATIONS Trail Blazer 330 Maximum Weight Capacity Dry Weight Fuel Capacity Engine Oil Capacity Transmission Oil Front Rack Capacity (Accessory) Rear Rack Capacity (Accessory) Hitch Tongue Weight Capacity Hitch Towing Rating Unbraked Trailer Towing Capacity* Overall Length Overall Width Overall Height Wheelbase Ground Clearance Minimum Turning Radius Engine Model Number/Type Lubrication Engine Cooling Displacement Bore x Stroke Alternator Output Compression Ratio Carburetor Pilot Jet Main Jet Needle Jet Jet Needle Pilot Air Jet Pilot Screw Ignition System Ignition Timing Idle RPM Spark ...
SPECIFICATIONS Trail Blazer 330 Maximum Weight Capacity Dry Weight Fuel Capacity Engine Oil Capacity Transmission Oil Front Rack Capacity (Accessory) Rear Rack Capacity (Accessory) Hitch Tongue Weight Capacity Hitch Towing Rating Unbraked Trailer Towing Capacity* Overall Length Overall Width Overall Height Wheelbase Ground Clearance Minimum Turning Radius Engine Model Number/Type Lubrication Engine Cooling Displacement Bore x Stroke Alternator Output Compression Ratio Carburetor Pilot Jet Main Jet Needle Jet Jet Needle Pilot Air Jet Pilot Screw Ignition System Ignition Timing Idle RPM Spark ...
Owners Manual
Page 109
... VEHICLE SERIES TRADE NAME MODEL YEARS SOUND PRESSURE dB (A) ___KA05__ ___KA09__ ___FA09__ ___VA17__ ___PB20__ ___BA32__ ___CA32__ ___BA50__ ___GJ45__ ___GJ52__, ___GP52__ ___LH27__ ___LH46__ ___MN50__ ___ZN55__ ___ZX55__ ___TN55__, ___DN55__ ___MN76__ ___TN85__, ___DN85__ ___CL76__ ___ZN85__, ___ZX85__ ___RH50__, ___HH50__ ___HH76__ ___WH76__ ___HR__ ___HY__ ___VH76__ Authorized Signatory: OUTLAW 50 OUTLAW 90 SPORTSMAN 90 RZR 170 PHOENIX 200 TRAIL BLAZER 330 TRAIL BOSS 330...
... VEHICLE SERIES TRADE NAME MODEL YEARS SOUND PRESSURE dB (A) ___KA05__ ___KA09__ ___FA09__ ___VA17__ ___PB20__ ___BA32__ ___CA32__ ___BA50__ ___GJ45__ ___GJ52__, ___GP52__ ___LH27__ ___LH46__ ___MN50__ ___ZN55__ ___ZX55__ ___TN55__, ___DN55__ ___MN76__ ___TN85__, ___DN85__ ___CL76__ ___ZN85__, ___ZX85__ ___RH50__, ___HH50__ ___HH76__ ___WH76__ ___HR__ ___HY__ ___VH76__ Authorized Signatory: OUTLAW 50 OUTLAW 90 SPORTSMAN 90 RZR 170 PHOENIX 200 TRAIL BLAZER 330 TRAIL BOSS 330...
Owners Manual
Page 116
... Engine Fogging...95 Engine Idle RPM Adjustment...71 Engine Oil ...54-55 Engine Stop Switch...20 Equipment Modifications ...5, 7 Exhaust Emission Control System . . 48 Eye Protection...9 F Fluid, Brake ...58-59 Foot Brake ...24 Fuel Filter ...27 Fuel Safety ...15 Fuel Tank Cap...27 Fuel Valve...27 C Camber Adjustment ...65 Carburetor ...71 Carburetor Adjustment ...71 Cargo...45-47 Caster Adjustment...65 Choke ...27 Chrome Wheel Care ...93 Cleaning and Storage ...91-96 Clothing ...9 Clutching Chart, Trail Boss ...103 Clutching Chart, Trail...
... Engine Fogging...95 Engine Idle RPM Adjustment...71 Engine Oil ...54-55 Engine Stop Switch...20 Equipment Modifications ...5, 7 Exhaust Emission Control System . . 48 Eye Protection...9 F Fluid, Brake ...58-59 Foot Brake ...24 Fuel Filter ...27 Fuel Safety ...15 Fuel Tank Cap...27 Fuel Valve...27 C Camber Adjustment ...65 Carburetor ...71 Carburetor Adjustment ...71 Cargo...45-47 Caster Adjustment...65 Choke ...27 Chrome Wheel Care ...93 Cleaning and Storage ...91-96 Clothing ...9 Clutching Chart, Trail Boss ...103 Clutching Chart, Trail...
Owners Manual
Page 117
... General Warning...16 Rack Warning, Front and Rear ...17 Reverse Override Warning ...19 Tire Pressure/Load Warning...18 Safety Training ...5 Severe Use ...49 Side Panel Removal...61 Sidehilling ...38 Signal Words ...4 Spark Arrestor ...81 Spark Arrestor Requirements ...48 Spark Plugs ...78-79 Spring Adjustments, Rear ...65 Starting the Engine ...32-33 Steering Assembly...65 Steering Lock...26 M Maintenance Chart...49-52 Mirrors ...22 Modifications...5, 7 N Noise Emission Control System ...48 O Oil, Engine...54-55 Oil, Transmission...56-57 Oil Change, Engine ...55 Oil Level, Engine...54 Oil...
... General Warning...16 Rack Warning, Front and Rear ...17 Reverse Override Warning ...19 Tire Pressure/Load Warning...18 Safety Training ...5 Severe Use ...49 Side Panel Removal...61 Sidehilling ...38 Signal Words ...4 Spark Arrestor ...81 Spark Arrestor Requirements ...48 Spark Plugs ...78-79 Spring Adjustments, Rear ...65 Starting the Engine ...32-33 Steering Assembly...65 Steering Lock...26 M Maintenance Chart...49-52 Mirrors ...22 Modifications...5, 7 N Noise Emission Control System ...48 O Oil, Engine...54-55 Oil, Transmission...56-57 Oil Change, Engine ...55 Oil Level, Engine...54 Oil...