Owners Manual
Page 6
... between the actual vehicle and the information presented in part, is based on the latest product information at the time of publication. No liability can be accepted for reference use only. Copyright 2009 Polaris Sales Inc. Printed in this publication. Depictions and/or procedures in U.S.A. 2010 TRAIL BOSS 330/TRAIL BLAZER 330 Owner's Manual P/N 9922460 2 POLARIS, THE WAY OUT, TRAIL BOSS and TRAIL BLAZER are intended...
... between the actual vehicle and the information presented in part, is based on the latest product information at the time of publication. No liability can be accepted for reference use only. Copyright 2009 Polaris Sales Inc. Printed in this publication. Depictions and/or procedures in U.S.A. 2010 TRAIL BOSS 330/TRAIL BLAZER 330 Owner's Manual P/N 9922460 2 POLARIS, THE WAY OUT, TRAIL BOSS and TRAIL BLAZER are intended...
Owners Manual
Page 37
... a minimum pump octane number of the vehicle, below the fender. Choke Fuel Guage Fuel Tank Cap Fuel Valve The fuel valve is located on the left side of 87=(R+ M/2) octane. ON: For normal operation. Refuel on page 41 for correct choke and throttle settings during starting. Do not attempt to the fuel tank. Remove the fuel tank cap to add fuel to clean the fuel filter. Refer to the engine starting a cold engine. Fuel Valve Fuel Filter The in...
... a minimum pump octane number of the vehicle, below the fender. Choke Fuel Guage Fuel Tank Cap Fuel Valve The fuel valve is located on the left side of 87=(R+ M/2) octane. ON: For normal operation. Refuel on page 41 for correct choke and throttle settings during starting. Do not attempt to the fuel tank. Remove the fuel tank cap to add fuel to clean the fuel filter. Refer to the engine starting a cold engine. Fuel Valve Fuel Filter The in...
Owners Manual
Page 41
... clutches and drive belt will ensure a longer life and better performance. Fill the fuel tank with vehicle operation and handling. 4. Do not operate at first. See page 40. 6. Avoid aggressive acceleration and high speed operation during the break-in the safe operating range. 3. Always exercise extreme caution whenever handling gasoline. 2. Drive slowly at sustained idle. 5. Vary the throttle positions. Change both the oil and the filter...
... clutches and drive belt will ensure a longer life and better performance. Fill the fuel tank with vehicle operation and handling. 4. Do not operate at first. See page 40. 6. Avoid aggressive acceleration and high speed operation during the break-in the safe operating range. 3. Always exercise extreme caution whenever handling gasoline. 2. Drive slowly at sustained idle. 5. Vary the throttle positions. Change both the oil and the filter...
Owners Manual
Page 59
... models are available for ATV use. Accessory hitch kits are equipped with cargo. Always attach a towed load to maintain stable driving conditions. Always install Polaris-approved (or equivalent) accessories designed for other models. Always read and understand the load distribution warnings on the front of the TRAIL BLAZER. NOTICE: Using an improper hitch or exceeding the maximum hitch weight capacity can result in the specifications section of the vehicle...
... models are available for ATV use. Accessory hitch kits are equipped with cargo. Always attach a towed load to maintain stable driving conditions. Always install Polaris-approved (or equivalent) accessories designed for other models. Always read and understand the load distribution warnings on the front of the TRAIL BLAZER. NOTICE: Using an improper hitch or exceeding the maximum hitch weight capacity can result in the specifications section of the vehicle...
Owners Manual
Page 64
... duct for wear, routing, security; apply dielectric grease to connectors subjected to severe use. clean; adjust; replace as needed 1000 (1600) Inspect 1000 (1600) Inspect for proper sealing/air leaks Inspect; MAINTENANCE Periodic Maintenance Chart Item Maintenance Interval (whichever comes first) Hours Calendar E Carburetor air intake ducts/flange Drive belt X Engine oil change X Oil filter change at tank cap, lines, fuel valve, filter, pump, carburetor; Q Front wheel Q Brake fluid Spark arrestor Idle speed Q Toe adjustment Headlight aim X Perform these services. 60
... duct for wear, routing, security; apply dielectric grease to connectors subjected to severe use. clean; adjust; replace as needed 1000 (1600) Inspect 1000 (1600) Inspect for proper sealing/air leaks Inspect; MAINTENANCE Periodic Maintenance Chart Item Maintenance Interval (whichever comes first) Hours Calendar E Carburetor air intake ducts/flange Drive belt X Engine oil change X Oil filter change at tank cap, lines, fuel valve, filter, pump, carburetor; Q Front wheel Q Brake fluid Spark arrestor Idle speed Q Toe adjustment Headlight aim X Perform these services. 60
Owners Manual
Page 76
... the ground. 4. Remove the wheel. Install the wheel nuts finger tight. Lock the parking brake. 2. WARNING! Torque the wheel nuts to the ground. 4. WARNING! Remove the wheel nuts. 5. Lower the vehicle to specification (page 73). Position the vehicle on the tire pointing toward forward rotation. 2. Place the transmission in an accident or overturn. Do not service axle nuts that all nuts are torqued to specification. 72 On vehicles with the valve stem...
... the ground. 4. Remove the wheel. Install the wheel nuts finger tight. Lock the parking brake. 2. WARNING! Torque the wheel nuts to the ground. 4. WARNING! Remove the wheel nuts. 5. Lower the vehicle to specification (page 73). Position the vehicle on the tire pointing toward forward rotation. 2. Place the transmission in an accident or overturn. Do not service axle nuts that all nuts are torqued to specification. 72 On vehicles with the valve stem...
Owners Manual
Page 80
... engine air/fuel mixture becomes overly rich and the engine loses approximately 3% of the engine without proper jetting when required can be made to raise RPM. Carburetor/Engine Idle RPM Adjustment If the engine idle speed is calibrated at the factory for optimal performance at altitudes ranging from your area. Idle Adjuster 76 Lock the parking brake. 2. MAINTENANCE Carburetor Your Polaris ATV is not satisfactory, and all other conditions...
... engine air/fuel mixture becomes overly rich and the engine loses approximately 3% of the engine without proper jetting when required can be made to raise RPM. Carburetor/Engine Idle RPM Adjustment If the engine idle speed is calibrated at the factory for optimal performance at altitudes ranging from your area. Idle Adjuster 76 Lock the parking brake. 2. MAINTENANCE Carburetor Your Polaris ATV is not satisfactory, and all other conditions...
Owners Manual
Page 85
... light bulb socket before servicing. 2. Headlamp Replacement When servicing a halogen lamp, don't touch the lamp with bare fingers. Oil from the back of the headlight. Headlight and taillight lenses become dirty during normal operation. Clean lights frequently and replace burned out lamps promptly. Tip: The bulb must be positioned so the harness installs into the headlight housing and rotate clockwise firmly. Install the replacement bulb...
... light bulb socket before servicing. 2. Headlamp Replacement When servicing a halogen lamp, don't touch the lamp with bare fingers. Oil from the back of the headlight. Headlight and taillight lenses become dirty during normal operation. Clean lights frequently and replace burned out lamps promptly. Tip: The bulb must be positioned so the harness installs into the headlight housing and rotate clockwise firmly. Install the replacement bulb...
Owners Manual
Page 101
... the water stream at no charge. 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 an informational or graphic label becomes illegible or comes off, contact your vehicle. • Always use clean cloths and pads for...
... the water stream at no charge. 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 an informational or graphic label becomes illegible or comes off, contact your vehicle. • Always use clean cloths and pads for...
Owners Manual
Page 104
... oil. 7. Remove the spark plug. Pour 2-3 tablespoons (30-40 ml) of oil. 4. Apply dielectric grease to specification. 5. To eliminate any fuel remaining in the Periodic Maintenance Chart beginning on page 57. • Demand drive unit (if equipped) • Transmission • Brake fluid (change every two years and any time the fluid looks dark or contaminated) Fog the Engine 1. Reinstall the spark plug. Change fluids as recommended in the carburetor, run the engine...
... oil. 7. Remove the spark plug. Pour 2-3 tablespoons (30-40 ml) of oil. 4. Apply dielectric grease to specification. 5. To eliminate any fuel remaining in the Periodic Maintenance Chart beginning on page 57. • Demand drive unit (if equipped) • Transmission • Brake fluid (change every two years and any time the fluid looks dark or contaminated) Fog the Engine 1. Reinstall the spark plug. Change fluids as recommended in the carburetor, run the engine...
Owners Manual
Page 108
... transmission in neutral, advance the throttle to about 1/8 throttle in mud or snow Shift the transmission to 7 times. position Belt slippage from a stopped control and vehicle overturn. Poor engine performance Check for fouled plugs or foreign material in a new belt and/or clutch. TROUBLESHOOTING Drive Belt Wear/Burn Possible Cause Starting out going up a steep incline Driving at low RPM or ground speed (3-7 MPH) Insufficient warm-up belt km/h) for one mile (1.6 km). Slow/easy clutch...
... transmission in neutral, advance the throttle to about 1/8 throttle in mud or snow Shift the transmission to 7 times. position Belt slippage from a stopped control and vehicle overturn. Poor engine performance Check for fouled plugs or foreign material in a new belt and/or clutch. TROUBLESHOOTING Drive Belt Wear/Burn Possible Cause Starting out going up a steep incline Driving at low RPM or ground speed (3-7 MPH) Insufficient warm-up belt km/h) for one mile (1.6 km). Slow/easy clutch...
Owners Manual
Page 112
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 114
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 115
SPECIFICATIONS TRAIL BLAZER 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 BLAZER 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 116
... 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 120
... to repair Polaris ATVs. We recommend the use of the Warranty Registration form to normal use and when maintenance and installation are void because of state or federal law, all other rights which vary from the use of the above limitation may not be covered by warranty. HOW TO OBTAIN WARRANTY SERVICE If your ATV. 2. Engine Oil 1. When requesting warranty service you...
... to repair Polaris ATVs. We recommend the use of the Warranty Registration form to normal use and when maintenance and installation are void because of state or federal law, all other rights which vary from the use of the above limitation may not be covered by warranty. HOW TO OBTAIN WARRANTY SERVICE If your ATV. 2. Engine Oil 1. When requesting warranty service you...
Owners Manual
Page 121
If you should consult an authorized dealer to Polaris Industries in your new country. 117 Upon residence verification, the servicing dealer will be required to present documentation of your vehicle was purchased: Warranty or Service Bulletin repairs must show the dealer photo identification from any questions. You may be authorized to Safety Recalls. This policy does not apply to...
If you should consult an authorized dealer to Polaris Industries in your new country. 117 Upon residence verification, the servicing dealer will be required to present documentation of your vehicle was purchased: Warranty or Service Bulletin repairs must show the dealer photo identification from any questions. You may be authorized to Safety Recalls. This policy does not apply to...
Owners Manual
Page 123
... of engine operation, 5000 kilometers (3100 miles) of the vehicle owner. EPA Emissions Limited Warranty This emissions limited warranty is to the evaporative emission control system. 119 Environmental Protection Agency emission regulations. WARRANTY U.S.A. The warranty period for evaporative emissions Fuel Tank Fuel Cap Fuel Line Fuel Line Fittings Clamps* Pressure Relief Valves* Control Valves* Control Solenoids* Electronic Controls Vacuum Control Diaphragms* Control Cables* Control Linkages* Purge Valves Vapor Hoses Liquid/Vapor Separator Carbon Canister Canister Mounting Brackets...
... of engine operation, 5000 kilometers (3100 miles) of the vehicle owner. EPA Emissions Limited Warranty This emissions limited warranty is to the evaporative emission control system. 119 Environmental Protection Agency emission regulations. WARRANTY U.S.A. The warranty period for evaporative emissions Fuel Tank Fuel Cap Fuel Line Fuel Line Fittings Clamps* Pressure Relief Valves* Control Valves* Control Solenoids* Electronic Controls Vacuum Control Diaphragms* Control Cables* Control Linkages* Purge Valves Vapor Hoses Liquid/Vapor Separator Carbon Canister Canister Mounting Brackets...
Owners Manual
Page 127
... ...9 Clutching Chart, TRAIL BOSS ...109 Clutching Chart, TRAIL BLAZER 111 Consumer Product Safety ...7 Corrosion Removal, Chrome ...98 Crankcase Emission Control System 56 F Fluid, Brake ...31-32 Foot Brake, Auxiliary ...30 Fuel Filter ...33 Fuel Safety ...11 Fuel Tank Cap...33 Fuel Valve...33 G Gasoline Handling ...11 Gear Selector ...34 Gloves ...9 H Handlebar Adjustment ...70 Hauling Cargo...54-55 Headlamp Replacement ...81 Headlight Beam Adjustment...80 Headlight Switch ...27 Helmet...8 D Drive Belt Wear/Burn ...104 Drive Chain...77-79 Drive Chain Lubrication ...77 Drive Chain Slack...
... ...9 Clutching Chart, TRAIL BOSS ...109 Clutching Chart, TRAIL BLAZER 111 Consumer Product Safety ...7 Corrosion Removal, Chrome ...98 Crankcase Emission Control System 56 F Fluid, Brake ...31-32 Foot Brake, Auxiliary ...30 Fuel Filter ...33 Fuel Safety ...11 Fuel Tank Cap...33 Fuel Valve...33 G Gasoline Handling ...11 Gear Selector ...34 Gloves ...9 H Handlebar Adjustment ...70 Hauling Cargo...54-55 Headlamp Replacement ...81 Headlight Beam Adjustment...80 Headlight Switch ...27 Helmet...8 D Drive Belt Wear/Burn ...104 Drive Chain...77-79 Drive Chain Lubrication ...77 Drive Chain Slack...
Owners Manual
Page 128
...47 Signal Words ...4 Spark Arrestor ...86 Spark Plugs ...83-84 Spring Adjustments, Rear ...70 Starting the Engine ...41-42 Steering Assembly...69 Storage ...96-101 Switches ...26-27 Engine Stop Switch...26 Headlight Switch ...27 Main Key Switch ...26 K Key Switch...26 K-Turn ...49 L Lights ...80-82 Headlamp Replacement ...81 Headlight Beam Adjustment...80 Indicator Lamp Replacement ...82 Taillight/Brakelight Replacement 82 Lubrication Guide ...61 M Maintenance Chart...57-60 Modifications...9 N Noise Emission Control System ...56 O Oil, Engine...62 Oil, Transmission...64-65 Oil and Filter...
...47 Signal Words ...4 Spark Arrestor ...86 Spark Plugs ...83-84 Spring Adjustments, Rear ...70 Starting the Engine ...41-42 Steering Assembly...69 Storage ...96-101 Switches ...26-27 Engine Stop Switch...26 Headlight Switch ...27 Main Key Switch ...26 K Key Switch...26 K-Turn ...49 L Lights ...80-82 Headlamp Replacement ...81 Headlight Beam Adjustment...80 Indicator Lamp Replacement ...82 Taillight/Brakelight Replacement 82 Lubrication Guide ...61 M Maintenance Chart...57-60 Modifications...9 N Noise Emission Control System ...56 O Oil, Engine...62 Oil, Transmission...64-65 Oil and Filter...