Polaris Trail Boss 330 Quadricycle User manual

2
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. Any reprinting
or reuse of the depictions and/or procedures contained within, whether whole or in part,
is expressly prohibited.
Printed in U.S.A.
2005 Trail Boss 330 Quadricycle Owner’s Manual P/N 9919822

3
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 103............................
TROUBLESHOOTING 104............................
SPECIFICATIONS 108................................
WARRANTY 111.....................................
MAINTENANCE RECORD 113........................
INDEX 116..........................................

4

5
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.
Vehicle Model Number:
Frame VIN (1):
Engine Serial Number (2):
(right front side of engine crankcase)
Key Number (3):
1
31XX
3
2

6
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.
CAUTION
The safety alert caution indicates a potential hazard that may
result in minor personal injury or damage to the vehicle.
CAUTION
Acaution indicates a situation that may result in damage to the
vehicle.
NOTE:
Anote will alert you to important information or instructions.

7
SAFETY
Operator 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. You were also provided with printed
materials that explain safe operating procedures. Review this
information on a regular basis.
If you purchased a used Polaris Quadricycle from a party other than a
Polaris dealer, please request free safety training from any authorized
Polaris dealer.
Age Restriction
This vehicle is an ADULT VEHICLE ONLY. Operation is prohibited
for anyone under 16 years of age.

8
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.
Equipment Modifications
The warranty on your Polaris Quadricycle may be terminated if any
equipment has been added, or if any modifications have been made,
that increase speed or power.
NOTE: The addition of certain accessories, including (but not limited
to) mowers, blades, tires, sprayers and large racks may
change vehicle handling. Use only Polaris-approved
accessories. Know their function and effect on the vehicle.

<
9
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.
Contact an authorized Polaris Quadricycle
dealer or call Polaris at 1-800-342-3764.
Never permit others to operate the Quadricycle unless they have
read and understand this manual and all product labels, and have
completed a certified safety training course.
Never allow anyone under 16 years
of age to operate this vehicle.
Never carry a passenger. The
purpose of the long seat is to allow
the operator to shift position.

50
40
0
10
20 30
10
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.

11
SAFETY
Operator 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.

12
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.

>25_
13
SAFETY
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.
Always follow the procedures
outlined in this manual for driving
downhill and for braking on
hills. See page 28.
Always follow the procedures
outlined in this manual for crossing
the side of a hill. See page 29.
Never attempt to turn the Quadricycle
around on any hill until you’ve
mastered (on level ground) the
turning technique outlined in this
manual.

14
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.

15
SAFETY
Operator 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.

2/3
1/3
2/3
1/3
16
SAFETY
Operator Safety
Never modify a
Quadricycle through
improper installation
or use of accessories.
Never exceed the stated
load capacity for your
Quadricycle. 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 the Quadricycle on
a frozen body of water.
Operating on paved surfaces may
seriously affect the handling and
control of the Quadricycle and
could result in loss of control,
accident, and/or injury.
Avoid sudden turns or swift
movement of the
handlebars.

17
SAFETY
Operator 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.

A
B
C
D
F
G
H
E
G
J
18
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.
Decal Text
Never operate this vehicle on
hills steeper than 25 degrees.
To prevent flipover on hilly
terrain, when going up or
down, use throttle and brakes
gradually.
A