Polaris 9922462 Guide

Pantone 425 C
WARNING
Improper vehicle use can result in SEVERE INJURY or DEATH.
NEVER operate:
Swithout proper training or instruction.
Sat speeds too fast for your skills or the conditions.
Son public roads - a collision can occur with another
vehicle.
Swith a passenger - passengers affect balance and
steering and increase risk of losing control.
ALWAYS:
Suse proper riding techniques to avoid vehicle
overturns on hills and rough terrain and in turns.
Savoid paved surfaces - pavement may seriously affect
handling and control.
READ OWNER'S MANUAL.
FOLLOW ALL INSTRUCTIONS AND WARNINGS.
ALWAYS USE
AN APPROVED
HELMET AND
PROTECTIVE
GEAR
NEVER USE
ON PUBLIC
ROADS
NEVER CARRY
PASSENGERS
NEVER USE
WITH DRUGS
OR ALCOHOL
For your nearest Polaris dealer,
visit www.polarisindustries.com
Polaris Sales Inc.,
2100 Hwy. 55, Medina, MN 55340
U.S.A.
Part No. 9922462 Rev 01
Printed in U.S.A.

The text is printed on 100% recycled
with 40% post-consumer waste (PCW).

1
WELCOME
Thank you for purchasing a Polaris vehicle, and welcome to our world-
wide family of Polaris owners. We proudly produce an exciting line of
utility and recreational products.
• Snowmobiles
• All-terrain vehicles (ATVs)
•RANGER®utility vehicles
• Victory Motorcycles®
Always follow the instructions and recommendations in this manual.
The manual contains instructions for minor maintenance, but informa-
tion about major repairs is outlined in the Polaris Service Manual and
should be performed only by a factory-certified Master Service Dealer®
(MSD) technician. Please see your dealer for all of your service needs
during (and after) the warranty period.
For more information about Polaris, visit us online at
www.polarisindustries.com.

2
POLARIS, THE WAY OUT, TRAIL BOSS and TRAIL BLAZER are registered trade-
marks of Polaris Industries Inc.
Copyright 2009 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 discrep-
ancies may result between the actual vehicle and the information presented in this publi-
cation. Depictions and/or procedures in this publication are intended for reference use
only. No liability can be accepted 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.
2010 Trail Boss 330/Trail Blazer 330 International Owner’s Manual
P/N 9922462

3
TABLE OF CONTENTS
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Features and Controls . . . . . . . . . . . . . . . . . . . 20
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Emission Control Systems . . . . . . . . . . . . . . . 48
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Polaris Products. . . . . . . . . . . . . . . . . . . . . . . . 97
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . 98
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . 102
Declaration of Conformity . . . . . . . . . . . . . . . 106
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Maintenance Log . . . . . . . . . . . . . . . . . . . . . . 111
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

4
INTRODUCTION
The following signal words and symbols appear throughout this manual
and on your vehicle. Your safety is involved when these words and sym-
bols are used. Become familiar with their meanings before reading the
manual.
The safety alert symbol indicates a potential personal injury hazard.
WARNING
A WARNING indicates a hazardous situation which, if not avoided, may result in
death or serious injury.
CAUTION
A CAUTION indicates a hazardous situation which, if not avoided, may result in
minor or moderate injury.
NOTICE
A NOTICE indicates a situation that may result in property damage.
The Prohibition Safety Sign indicates an action NOT to take in order
to avoid a hazard.
The Mandatory Action Sign indicates an action that NEEDS to be
taken to avoid a hazard.

5
INTRODUCTION
Failure to follow the warnings in this manual can result in serious injury or death.
This Polaris vehicle 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
this Polaris vehicle.
Safety Training
When you purchased your new Polaris vehicle, your dealer offered a
hands-on safety training course. You were also provided with printed
materials that explain safe operating procedures. Review this informa-
tion on a regular basis.
If you purchased a used Polaris vehicle from a party other than a Polaris
dealer, please request free safety training from any authorized Polaris
dealer.
Age Restrictions
This vehicle is an ADULT VEHICLE ONLY. Operation is prohibited
for anyone under 16 years of age.
Restrictions
This vehicle is approved for OFF-ROAD TOWING ONLY. Towing a
trailer with this vehicle on public roads is prohibited.
Equipment Modifications
The warranty on your Polaris vehicle may be terminated if any equip-
ment has been added, or if any modifications have been made, that
increase speed or power. The addition of certain accessories, including
(but not limited to) mowers, blades, tires, sprayers and large racks may
change vehicle handling. Use only Polaris-approved accessories. Know
their function and effect on the vehicle.
WARNING

6
INTRODUCTION
Vehicle Identification Numbers
Record your vehicle's identification numbers and key number in the
spaces provided. Remove the spare key and store it in a safe place. An
ignition key can be duplicated only by ordering a Polaris key blank
(using your key number) and mating it with one of your existing keys.
The ignition switch must be replaced if all keys are lost.
Vehicle Model Number: ___________________________________________________
Frame VIN: ____________________________________________________________
Engine Serial Number: ___________________________________________________
(right front side of engine crankcase)
Key Number: ___________________________________________________________
####
VIN
Key Number

7
SAFETY
Failure to operate the vehicle properly can result in a collision, loss of control,
accident or overturn, which may result in serious injury or death. Heed all safety
warnings outlined in this section of the owner’s manual. See the OPERATION
section of the owner’s manual for proper operating procedures.
Equipment Modifications
We strongly recommend that consumers do not install on a Polaris vehi-
cle any equipment that may increase the speed or power of the vehicle,
or make any other modifications to the vehicle for these purposes.
The warranty on your Polaris vehicle is terminated if any equipment has
been added to the vehicle, or if any modifications have been made to the
vehicle, that increase its speed or power.
The addition of certain accessories, including (but not limited to) mow-
ers, blades, tires, sprayers, or large racks, may change the handling char-
acteristics of the vehicle. Use only Polaris-approved accessories, and
familiarize yourself with their function and effect on the vehicle.
WARNING

8
SAFETY
Safe Riding Gear
Always wear appropriate clothing when riding a Polaris vehicle. Wear
protective clothing for comfort and to reduce the chance of injury.
Helmet
Wearing a helmet can prevent a severe head injury. Whenever riding a
Polaris vehicle, always wear a helmet that meets or exceeds established
safety standards.
Approved helmets in the USA and Canada bear a U.S. Department of
Transportation (DOT) label.
Approved helmets in Europe, Asia and Oceania
bear the ECE 22.05 label. The ECE mark consists
of a circle surrounding the letter E, followed by the
distinguishing number of the country which has
granted approval. The approval number and serial
number will also be displayed on the label.
Helmet
Eye Protection
Gloves
Boots
Long Pants
Long
Sleeves
E
4
051039
0006.31

9
SAFETY
Safe Riding Gear
Eye Protection
Do not depend on eyeglasses or sunglasses for eye protection. When-
ever riding a Polaris vehicle, always wear shatterproof goggles or use a
shatterproof helmet face shield. Polaris recommends wearing approved
Personal Protective Equipment (PPE) bearing markings such as VESC
8, V-8, Z87.1, or CE. Make sure protective eye wear is kept clean.
Gloves
Off-road style gloves with knuckle pads are the best for comfort and
protection.
Boots
The best footwear is a pair of sturdy over-the-calf boots with low heels.
Clothing
Always 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.

10
SAFETY
Operator Safety
Read and understand all warnings, cautions
and operating procedures in this manual and
on the safety labels before operating the
vehicle.
Never operate this vehicle without proper
instruction. Take a training course. Beginners
should receive training from a certified
instructor. Contact an authorized Polaris
dealer or visit the Polaris web site at
www.polarisindustries.com.
Never permit others to operate the vehicle unless they have read and under-
stand this manual and all product labels, and have completed a certified safety
training course.
Never allow anyone under 16 years of age to
operate this vehicle.
Never carry a passenger.

11
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 this vehicle.
Never operate at excessive speeds. Travel
and turn at speeds appropriate for the terrain,
visibility, operating conditions and your
experience.
Never attempt jumps or other stunts.

12
SAFETY
Operator Safety
Always inspect your Polaris vehicle before each
use to verify that it's in safe operating condition.
Follow the inspection and maintenance procedures
outlined in this manual. See page 31.
Keep both hands on the handlebars. Keep
your feet on the footrests.
Always travel slowly when operating on
unfamiliar terrain. Use extra caution.
Use caution when operating on rough, slippery
or loose terrain.
Always follow the procedures outlined in this
manual for turning. See page 35.
Never turn sharply at excessive speeds,
which can lead to vehicle overturn.

13
SAFETY
Operator Safety
If the vehicle 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.
Never operate on hills too steep for the vehicle 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 37.
Always follow the procedures outlined in this
manual for driving downhill and for braking on
hills. See page 39.
Always follow the procedures outlined in this
manual for crossing the side of a hill. See page
38.
Never attempt to turn the vehicle around on any
hill until you've mastered (on level ground) the
turning technique outlined in this manual.
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 40.
+25°

14
SAFETY
Operator Safety
Always follow the procedures outlined in this manual for operating over
obstacles. See page 42.
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
36.
Always follow the procedures outlined in this
manual for driving through water. Never drive
through deep or fast-flowing water. See page 41.
Always follow the procedures outlined in this manual for driving in reverse. See
page 43.
Always use the size and type of tires specified for
your vehicle. Maintain the proper tire pressure.
Never modify this Polaris vehicle
through improper installation or use of
accessories.
Operating on paved surfaces may affect the handling and control of the vehicle
and could result in loss of control. Avoid sudden turns or swift movement of the
handlebars.

15
SAFETY
Operator Safety
Never exceed the stated load capacity for your vehicle. Cargo 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 this vehicle on a frozen body of water.
Always remove the ignition key when the vehicle is not in use to prevent
unauthorized use or accidental starting.
Always unlock the steering before starting the engine. See page 26.
Handling Gasoline
Gasoline is highly flammable and explosive under certain conditions.
• Always exercise extreme caution whenever handling gasoline.
• Always refuel with the engine stopped, and outdoors or in a well ventilated
area.
• Do not smoke or allow open flames or sparks in or near the area where refu-
eling is performed or where gasoline is stored.
• Do not overfill the tank. Do not fill the tank neck.
• If gasoline spills on your skin or clothing, immediately wash it off with soap
and water and change clothing.
• Turn the fuel valve off whenever the vehicle is stored or parked.
Hot components can cause serious burns and fire. Do not touch hot exhaust
system components. Always keep combustible materials away from the exhaust
system.
For more information about safety, contact an authorized
Polaris dealer or visit the Polaris web site at
www.polarisindustries.com.

16
SAFETY
Safety Labels and Locations
Warning labels have been placed on the vehicle for your protection.
Read and follow the instructions on each label carefully. If any of the
labels shown in this manual differ from the labels on your vehicle,
always read and follow the instructions of the labels on the vehicle.
If an informational or graphic label becomes illegible or comes off, con-
tact your Polaris dealer to purchase a replacement. Replacement safety
labels are provided by Polaris at no charge. The part number is printed
on the label.
General Warning
WARNING
Improper ATV use can result in SEVERE INJURY or DEATH
ALWAYS USE AN APPROVED HELMET AND PROTECTIVE GEAR
NEVER USE ON PUBLIC ROADS
NEVER CARRY PASSENGERS
NEVER USE WITH DRUGS OR ALCOHOL
NEVER operate:
• without proper training or instruction
• at speeds too fast for your skills or the conditions
• on public roads - a collision can occur with another vehicle
• with a passenger - passengers affect balance and steering and increase risk
of losing control
ALWAYS:
• use proper riding techniques to avoid vehicle overturns on hills and rough ter-
rain and in turns
• avoid paved surfaces - pavement may seriously affect handling and control
LOCATE AND READ OWNER’S MANUAL.
FOLLOW ALL INSTRUCTIONS AND WARNINGS.
7175376

17
SAFETY
Safety Labels and Locations
Discretionary Warning
WARNING
• Never operate this ATV on
HILLS steeper than 25 degrees
25°. To prevent overturn on
hilly terrain, use throttle and
brakes gradually, and shift
weight uphill.
• REVERSE operation can be
dangerous even at low speeds.
Steering becomes difficult. To
prevent loss of control, avoid
sudden braking or sharp turns.
7175511
Rack Warning, Front
and Rear (Trail Boss)
WARNING
• 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)
7172666
+
General
Warning
+
Discretionary
Warning
Rack Warning
+
+