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1. Always block the rear wheels on the downhill side as shown in illustration Shut off the fuel supply 69 OPERATION PVT System The basic operation of the Polaris PVT system is dependent on engine speed and vehicle torque requirements As engine speed increases the force exerted on the movable drive sheave by the flyweights also increases This in turn increases the amount of pinch applied to the drive belt Similarly if the engine speed decreases the amount of centrifugal force decreases reducing the amount of belt pinch On Polaris ATVs the approximate gear ratio difference between high and low range is 1 2 25 This difference in gearing affects the operation of the PVT especially at speeds less than 7 MPH due to the system s dependence on engine speed For example when operating at a ground speed of 3 MPH in low range the engine speed would be around 3000 RPM This is well above the engagement speed of 1200 1400 RPM However in high range at 3 MPH the engine would be running at only 1500 RPM Whenever operating this close to the engagement speed the engine may be running at a speed too low to provide the pinch needed to prevent belt slip Belt slip is responsible for creating the excessive heat that destroys belts and causes outer clutch covers to fail By switching to low range while operating at low ground speeds the air temperature in the clutch cover is reduced by almost 160 degrees Reducing
2. Always follow proper procedures as described in the owner s manual Avoid hills with excessively slippery or loose surfaces Shift your weight to the uphill side of the ATV SAFETY Operator Safety 4 WARNING POTENTIAL HAZARD Stalling rolling backwards or improperly dismounting while climbing a hill WHAT CAN HAPPEN The vehicle could overturn HOW TO AVOID THE HAZARD Maintain steady speed when climbing a hill If all forward speed is lost Spo yee Keep your weight uphill Apply the front brake or the single lever brake gradually When fully stopped apply the rear brake as well then lock the parking brake If the ATV begins rolling backwards Keep weight uphill Never apply engine power Never apply the rear brake while rolling backwards Apply the front brake or single lever brake gradually When fully stopped apply the rear brake as well and then lock the parking brake Dismount on uphill side or to either side if ATV is pointed straight uphill Turn the ATV around and remount following the procedure described in the owner s manual See page 64 23 SAFETY Operator Safety 4 amp WARNING 24 POTENTIAL HAZARD Improperly operating over obstacles WHAT CAN HAPPEN Operating over obstacles could cause loss of control or overturn HOW TO AVOID THE HAZARD Before operating in a new area check for obstacles Avoid operating over large obstacles such as rocks and fallen tree
3. For 50 years we ve been helping Polaris customers find The Way Out It s been a fun ride But then after all these years That s what we re all about Visit our Web site at www polarisindustries com POLARIS The Way Out Ss a gt o a ri A a od O 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 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 2005 ATP Owner s Manual P N 9919515 2 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 Polaris Recreational and Utility Vehicles e Snowmobiles e All terrain vehicles ATVs e Watercraft e Victory motorcycles e RANGER utility vehicles We believe Polaris sets a standard of excellence for all utility and recreational vehicles manufactured in the world today Many years of experience have gone
4. The emissions from the exhaust of this vehicle are controlled by engine design including factory set fuel delivery and ignition The engine and related components must be maintained at Polaris specifications to achieve optimal performance Adjustment to engine idle is the only adjustment Polaris recommends that the operator perform Any other adjustments should be performed by an authorized Polaris dealer The emissions label 1 is located on the recoil cover Electromagnetic Interference This spark ignition system complies with Canadian ICES 002 72 MAINTENANCE AND LUBRICATION Accessories Auxiliary power outlets provide 12V power for operating accessories such as hand held spot lights See your Polaris dealer Periodic Maintenance Chart Careful periodic maintenance will help keep your vehicle in the safest most reliable condition Inspection adjustment and lubrication of important components are explained in the periodic maintenance chart Inspect clean lubricate adjust and replace parts as necessary When inspection reveals the need for replacement parts use genuine Polaris parts available from your Polaris dealer NOTE Service and adjustments are critical If you re not familiar with safe service and adjustment procedures have a qualified dealer perform these operations Maintenance intervals in the following chart are based upon average riding conditions and an average vehicle speed of approximately 10
5. 1 Stop and lock the parking brake while keeping body weight uphill 2 Leave transmission in forward and shut off the engine 3 Dismount on the uphill side of the vehicle or on the left if the vehicle is pointing straight uphill 4 Staying uphill of the vehicle turn the handlebars full left 5 While holding the brake lever release the parking brake lock and slowly allow the vehicle to roll around to your right until it s pointing across the hill or slightly downward 6 Lock the parking brake and remount the vehicle from the uphill side keeping body weight uphill 7 Restart the engine with the transmission still in forward 8 Release the parking brake and proceed slowly controlling speed with the brake until the vehicle is on more level ground 64 OPERATION Driving Safely Driving Through Water 2 b Tan eb Oy lane i SS 22 D 6 Your ATV can operate through water with a maximum recommended depth equal to the bottom of the footrests 1 Follow these procedures when operating through water Determine water depths and current before crossing Choose a crossing where both banks have gradual inclines Proceed slowly avoiding rocks and obstacles if possible After crossing dry the brakes by applying light pressure to the lever until braking action is normal PORE NOTE Avoid operating the vehicle through deep or fast flowing water If you cannot avoid water that exceeds the recommended ma
6. 2 is free from defects in materials and workmanship which may cause it to fail to conform with those regulations as applicable according to the terms and conditions stated below 131 WARRANTY California Emission Control Warranty Statement Warranty Period This warranty period begins on the date which the LSI engine is delivered to the origi nal retail purchaser and ends two years after that date During this two year period POLARIS warrants to the original retail purchaser and each subsequent purchaser that the LSI engine is free from defect in material and workmanship that can cause the failure of a warranted emission related part What is Covered Under This Warranty Repair and or replacement of any warranted emission related part will be performed at no charge provided the work is performed at an authorized dealer There will also be no charge for any diagnostic labor performed at an authorized dealer which leads to the determination that a warranted emission related part is defective Any warranted part which is not scheduled for replacement as required maintenance or which is scheduled only for regular inspection to the effect of repair or replace as necessary shall be warranted for the warranty period Any warranted part which is scheduled for replacement as required maintenance shall be warranted for the period of time up to the first scheduled replacement of that part This warranty shall apply only towards the repair rep
7. 2 2 1800 3700 Blue Gray 6000 12000 PN 5631357 PN 7042202 PN 7041782 5133701 2 2 125 SPECIFICATIONS ATP 500 4X4 Gross Vehicle Weight Fuel Capacity Towing Capacity Hitch Tongue Capacity Front Rack amp Compartment Capacity Rear Box Capacity Overall Length Overall Width Overall Height Wheelbase Ground Clearance Dry Weight Minimum Turning Radius Transmission Oil Capacity Front Gearcase Oil Capacity Rear Gearcase Oil Capacity Engine Oil Capacity Coolant Capacity Engine Displacement Bore x Stroke Pilot Jet Main Jet Needle Jet Jet Needle Pilot Screw Alternator Output Compression Ratio Starting System Carburetor Ignition System Ignition Timing Spark Plug Gap 126 tongue weight not to exceed 400 Ibs 181 kg may vary for each ATV SPECIFICATIONS ATP 500 4X4 Lubrication System Dry Sump Shift Type Side Lever H L N R P Gear Reduction Reverse Grill 2 single beam 27 watt Jetting ATP 500 Altitude AMBIENT Below 40 F 40 Fand above TEMPERATURE Below 5 C 5 C to amp above Meters 0 1800 Feet 0 6000 Clutching ATP 500 6000 12000 Altitude Shift Drive Clutch Driven Helix Weight Spring Clutch Spring Meters 0 1800 10 BH Blue Green White Yellow EBS Feet 0 6000 PN 5630711 PN 7041157 PN 7041635 5132751 1800 3700 10 RH Blue Green White Yellow EBS 6000 12000 PN 5630709 PN 7041157 PN 7041635 5132751 EBS models require no he
8. Do not tow any trailer on a grade steeper than 15 Towing Load Vertical Hitch Level Ground Weight ATP 330 4X4 1000 Ibs 454 kg 100 Ibs 45 4 kg ATP 500 4X4 1225 Ibs 556 kg 120 Ibs 54 4 kg Belt Life Use low forward gear when hauling or towing heavy cargo to extend belt life 56 OPERATION Hauling Cargo Dumping Cargo 1 2 3 4 Select a level site to dump the cargo box Do not attempt to dump or unload the vehicle while parked on an incline Place the transmission in park and set the parking brake Dismount the vehicle Lower the tailgate amp WARNING CN AU If cargo weight is placed toward the rear of the cargo box the load may dump unexpectedly and cause serious injury When loading cargo always position the weight as far forward and as low as possible Pull the cargo box release lever upward Lift the front of the cargo box and dump the cargo Lower the cargo box and make sure the release latch is secured Secure the tailgate A WARNING Operating with the cargo box in the raised position can cause serious injury and damage to the vehicle The cargo box could close unexpectedly and injure the driver The rear tires will also catch the rear of the bed damaging the vehicle and creating hazardous driving conditions Never operate this vehicle with the cargo box in the raised position 57 OPERATION Driving Safely Driving Procedures ZAN Z a ey ae d ASD E
9. If any of the above terms are void because of state or federal law all other warranty terms will remain in effect Lubricants 1 Mixing oil brands or using non recommended oil may cause engine damage We recom mend the use of Polaris engine oil 2 Damage resulting from the use of non recommended lubricants may not be covered by warranty 129 WARRANTY Exported Vehicles EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW THERE IS NO WARRANTY OR SERVICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD OUTSIDE THE COUNTRY OF THE SELLING DEALER S AUTHORIZED LOCATION This policy does not apply to vehicles that have received authorization for export from Polaris Industries Dealers may not give authorization for export You should consult an authorized dealer to determine this vehicle s warranty or service bulletin coverage if you have any questions This policy does not apply to vehicles registered to government officials or military per sonnel on assignment outside the country of the selling dealer s authorized location This policy does not apply to Safety Recalls How to Get Service In the Country where your vehicle was purchased Warranty or Service Bulletin repairs must be done by an authorized Polaris dealer If you move or are traveling within the country where your vehicle was purchased Warranty or Service Bulletin repairs may be requested from any authorized Polaris dealer who sells the same line as your vehicle Outside t
10. Starting a Cold Engine 53 Starting a Warm Engine 54 Starting the Engine 53 54 Steering Assembly 93 Stop SWitchi severe acura ai ee e 34 Storages Tips s yiera tar dase red 114 116 T TABLE OF CONTENTS 5 Tachometer 000005 48 Taillight Brakelight Lamp Replacement 103 Throttle Cable Freeplay 96 Throttle Levees asor aratan an 35 Tire Tread Depth 100 Toe Alignment 0 92 Towing Capacities 56 Transmission Gear Selector 42 Transmission Oil 0 85 Transporting the ATV 116 Trip Meter 2 scree sce 3 wale Ceres bees 48 TROUBLESHOOTING 120 123 Turning Around ona Hill 64 V VEHICLE IDENTIFICATION NUMBERS 0004 6 Vehicle Immersion 107 Ww WARRANTY 05 128 135 Washing the ATV 113 Waxing the ATV 113 WELCOME 0 000000 00 3 Wheel Installation 99 Wheel Nut Torque Specifications 99 Wheel Removal 98 137
11. 500 pest lubricate adjust 310 600 a 310 600 310 600 Carburetor float 50 H 310 500 Drain bowl periodically and bowl prior to storage Throttle Cable 310 500 Inspect adjust lubricate ETC Switch replace if necessary Choke cable 310 500 Inspect adjust lubricate replace if necessary Carburetor air 310 500 Inspect ducts for proper intake ducts sealing air leaks flange Drive belt 310 500 ppe adjust replace as needed 310 500 Inspect coolant strength seasonally pressure test system yearly 620 1000 Perform a break in oil change at 25 hours one month E 620 1000 Replace with oil change Oil tank vent hose 100 H 620 1000 Inspect routing condition 100 H 620 1000 Inspect adjust p Perform these procedures more often for vehicles subjected to severe use E Emission Control System Service California m Have an authorized Polaris dealer perform these services Cooling system if applicable Engine oil change 100 H Oil filter change 100 H 75 MAINTENANCE AND LUBRICATION Periodic Maintenance Chart Maintenance Interval whichever comes first Calendar Miles Km Fuel system 100 H 620 1000 Check for leaks at tank cap lines fuel valve filter pump carburetor replace lines every two years E Fuel filter 100 H 620 1000 Replace yearly Radiator 100 H 12M 620 1000 Inspect clean external if applicable surfaces Cooling hoses 100 H 12M 620 1000 Inspect for l
12. 88 89 Engine Fogging 115 Equipment Modifications 11 Exhaust Emission Control System 72 F FEATURES AND CONTROLS 33 50 Filter Systems treere serio atts 101 Front Gearcase Oil 86 Front Wheel Hub Tightening 100 FUEL Filter M2 iene oie don iaae 40 Fuel Safety 00000 41 Fuel Stabilizer 0 0 0000 114 Fuel Tank prestes Ree ied Ra a et 40 Fuel Valves vais acd ss gh tie yes G 40 G Gear Selector 0000 42 H Handlebars oe popp ente eoi e Tea 94 Hauling Cargo 55 57 Headlight Adjustment Lower 103 Headlight Housing Replacement 104 Headlight Lamp Replacement Lower 103 Headlight Lamp Replacement Pod 102 Feline tse epee Sane e pede eet pee 32 High Beam Adjustment 105 High R ng seescocireceveiciweiies 70 Hour Meter 00 0000s 48 l Instrument Cluster 46 50 J Jetting ATP 330 0 0 125 Jetting ATP 500 0 127 K K T ene E EES 64 L Light Switches senose aenn aana 34 Lights erisera dasa does 102 105 Load Distribution 56 Low Range 00000 70 Lubrication Recommendations 77 87 M Main Switch 00 33 MAINTENANCE AND LUBRICATION 73 117 Maintenance Record 78 Making Turns 0 0 59 N Noise Emission Control System 72 O Odometer iae
13. Pone g Air filter pre filter fre We Inspect clean often Air box sediment Daily Drain deposits when visible tube Coolant Daily Check level daily change if applicable coolant every 2 years Headlamp tail Daily Check operation apply lamp dielectric grease if replacing Air filter Weekly Inspect replace as needed main element Recoil housing Weekly Drain water as needed check often if operating in wet conditions A Brake pad wear Monthly 60 100 Inspect periodically Battery 20H Monthly 125 200 Check terminals clean test Front gearcase oil 25H Monthly 155 250 Inspect level change yearly if equipped Middle gearcase 25H Monthly 155 250 Inspect level change yearly oil if equipped Rear gearcase oil 25H Monthly 155 250 Inspect level change yearly if equipped Transmission oil 25H Monthly 155 250 Inspect level change yearly p Perform these procedures more often for vehicles subjected to severe use E Emission Control System Service California m Have an authorized Polaris dealer perform these services 74 MAINTENANCE AND LUBRICATION Periodic Maintenance Chart Be al Interval Be al comes first paa O km O km Pe tg breather Monthly 155 250 Inspect replace if necessary BES if equipped Engine oil change 155 250 Perform a break in oil break in change at one month General 310 500 Lubricate all fittings pivots lubrication cables etc Shift Linkage 310
14. To access the recovery bottle remove the left side panel See page 97 Maintain the coolant level between the minimum and maximum marks on the bottle when the fluid is cool 4 amp WARNING Escaping steam can cause severe burns Never remove the pressure cap while the engine is warm or hot Always allow the engine to cool before removing the pressure cap Radiator Coolant Level ATP 500 Checking the radiator coolant level is required only if the cooling system has been drained for maintenance and or repair However if the recovery bottle has run dry the level in the radiator should also be inspected Add coolant if necessary 1 Using the tool provided remove the four screws securing the front compartment 1 Remove the front cover 2 by placing your fingers under the front of the cover and pulling upward 2 Remove the pressure cap 3 Using a funnel slowly add coolant as necessary through the radiator filler neck 4 Replace the pressure cap and secure the front cover NOTE Use of anon standard pressure cap will not allow the recovery system to function properly Contact your dealer for the correct replacement part 89 MAINTENANCE AND LUBRICATION Adjustments Brakes The front brakes are hydraulic disc brakes activated by moving the brake lever toward the handlebar These brakes are self adjusting 4 amp WARNING Never store or use a partial bottle of brake fluid Brake fluid is hygros
15. during operation PVT Drying There may be some instances when water is accidently ingested into the PVT system Use the following instructions to dry it out before operating 1 Remove the drain plug and allow the water to drain Replace the drain plug 2 Start the engine and shift the transmission into park Apply varying throttle for 10 15 seconds to expel the moisture and air dry the belt and clutches Do not hold the throttle wide open for more than 10 seconds 3 Allow the engine RPM to settle to idle speed then shift the transmission to the lowest available range 4 Test for belt slippage If the belt slips repeat the process Take the vehicle to your dealer for service as soon as possible 71 EMISSION CONTROL SYSTEMS Noise Emission Control System Do not modify the engine intake or exhaust components as doing so may affect compliance with state and local noise level requirements Spark Arrestor Your Polaris vehicle has a spark arrestor that was tested and approved in accordance with the USDA Forest Service Standard 5100 1C Federal law requires that this spark arrestor be installed and functional when the vehicle is operated on public lands Crankcase Emission Control System This engine is equipped with a closed crankcase system Blow by gases are forced back to the combustion chamber by the intake system The system does not allow the blow by gases to enter the atmosphere Exhaust Emission Control System
16. eee es 124 WARRANTY cca Scat er nE wid te shi N wm be 128 INDEX a Sine it eek era a epee a wt atone ee 136 VEHICLE IDENTIFICATION NUMBERS Record your ATV s identification numbers and key number in the spaces provided 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 Key Number 3 SAFETY Operator Safety 4 amp WARNING Failure to follow the warnings contained in this manual can result in serious injury or death A Polaris ATV is not a toy and can be hazardous to operate This vehicle handles differently than other vehicles such as motorcycles and cars A collision or rollover can occur quickly even during routine maneuvers like turning or driving on hills or over obstacles if you fail to take proper precautions Read and understand your owner s manual and all warnings before operating a Polaris ATV Age Restrictions This vehicle is an ADULT VEHICLE ONLY Operation is prohibited for anyone under 16 years of age Know Your Vehicle As the operator of the vehicle you are responsible for your personal safety the safety of others and the protection of our environment Read and understand your owner s manual which includes valuable information about all aspects of your vehicle including
17. in safe operating condition Always follow the inspection and maintenance procedures and schedules described in the owner s manual 4 amp WARNING POTENTIAL HAZARD Removing hands from the handlebars or feet from the footrests during operation WHAT CAN HAPPEN Removing even one hand or foot can reduce ability to control the vehicle or could cause loss of balance and ejection from the ATV If the operator s foot is not firmly planted on the footrest it could come into contact with the rear wheels and lead to accident or injury HOW TO AVOID THE HAZARD Always keep both hands on the handlebars and both feet on the footrests of the ATV during operation 17 SAFETY Operator Safety 4 amp WARNING 18 POTENTIAL HAZARD Failure to use extra caution when operating the ATV on unfamiliar terrain WHAT CAN HAPPEN Unfamiliar terrain may contain hidden rocks bumps or holes that could cause loss of control or overturn HOW TO AVOID THE HAZARD Travel slowly and use extra caution when operating on unfamiliar terrain Always be alert to changing terrain conditions WARNING POTENTIAL HAZARD Failure to use extra caution when operating on excessively rough slippery or loose terrain WHAT CAN HAPPEN Operating on excessively rough slippery or loose terrain could cause loss of traction or loss of control which could result in an accident or overturn HOW TO AVOID THE HAZARD Do not operate on exce
18. into the engineering design and development of your Polaris vehicle making it the finest machine we ve ever produced For safe and enjoyable operation of your vehicle be sure to follow the instructions and recommendations in this owner s manual Your manual contains instructions for minor maintenance but information about major repairs is outlined in the Polaris Service Manual and should be performed only by a Factory Certified Master Service Dealer MSD Technician Your Polaris dealer knows your vehicle best and is interested in your total satisfaction Be sure to return to your dealership for all of your service needs during and after the warranty period We also take great pride in our Parts Apparel and Accessories PAA products available through our online store at www purepolaris com Have your accessories and clothing delivered right to your door POLARIS and POLARIS THE WAY OUT are registered trademarks of Polaris Industries Inc TABLE OF CONTENTS WEECOME ikasto rinon aa Be PS Wiest beanies Be oa 3 VEHICLE IDENTIFICATION NUMBERS 6 SAFETY soina s vce thb eran cuss E AEE hese Sue 7 FEATURES AND CONTROLS 0 000 33 OPERATION aes Civ tee a was Rie oon Sad 51 EMISSION CONTROL SYSTEMS 72 MAINTENANCE AND LUBRICATION 73 POLARIS PRODUCTS wiiniewieweiwonerencan seeks 119 TROUBLESHOOTING vec ieee besa adrenals s 120 SPECIFICATIONS eurie y oe ces eu etgu ine
19. is in PARK and repeat steps 3 and 4 until no more particles are expelled when the engine is revved Stop the engine and allow the arrestor to cool Reinstall the arrestor plug and remove the outlet cover or plug MAINTENANCE AND LUBRICATION Recoil Housing To prevent possible engine damage always drain the recoil housing 1 after operating the ATV in very wet conditions This should also be done before storing the ATV NOTE Water will enter the recoil housing if the starter handle is disengaged from the rope guide when under water The drain screw is located at the bottom of the recoil housing Use a wrench to remove the screw Be sure to reinstall the screw after draining the housing NOTE Do not open the crankcase drain unless the engine has ingested water Some engine oil will be lost if the crankcase drain is opened 109 MAINTENANCE AND LUBRICATION Battery A WARNING Improperly connecting or disconnecting battery cables can result in an explosion and cause 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 2 3 4 Disconnect the battery hold down strap and remove the battery cover Disconnect the black negative battery cable first Disconnect the red positive battery cable next Lift the battery out of the ATV Battery Installation When in
20. later LSI engines are warranted for two 2 years If any emission related part on your LSI engine is defective the part will be repaired or replaced by POLARIS Owner s Warranty Responsibilities e As the LSI engine owner you are responsible for the performance of the required maintenance listed in your Owner s Safety and Maintenance Manual herein Own er s Manual POLARIS recommends that you retain all receipts covering mainten ance on your LSI engine but POLARIS cannot deny warranty solely for the lack of receipts or for your failure to ensure the performance of all scheduled maintenance e As the LSI engine owner you should however be aware that POLARIS may deny you warranty coverage if your LSI engine or a part has failed due to abuse neglect improper maintenance or unapproved modifications e You are responsible for presenting your LSI engine to a dealer authorized by POLARIS as soon as a problem exists The warranty repairs should be completed in a reasonable amount of time not to exceed 30 days If you have any questions regarding your warranty rights and responsibilities you should contact the Polaris Warranty Department at 1 763 417 8650 Limited Warranty California Only POLARIS warrants to the owner of 2004 and later LSI engines that the LSI engine 1 has been designed built and equipped at the time of manufacture so as to conform with the applicable regulations of the California Air Resources Board and
21. safe operating procedures Safety Training When you purchased your new ATV your dealer offered a hands on safety training course that covers all aspects of vehicle safety You were also provided with printed materials that explain safe operating procedures You should review this information on a regular basis If you purchased a used Polaris ATV from a party other than a Polaris dealer you can request this free safety training from any authorized Polaris dealer A Polaris ATV is an off road vehicle Familiarize yourself with all laws and regulations concerning the operation of this vehicle in your area We strongly advise you to strictly follow the recommended maintenance program outlined in your owner s manual This preventive maintenance program is designed to ensure that all critical components on your vehicle are thoroughly inspected at specific intervals SAFETY Operator Safety The following signal words and symbols appear throughout this manual and on your ATV Your safety is involved when these words and symbols are used Become familiar with their meanings before reading the manual A A 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 d
22. the rear tires See illustration 3 Tie an elastic string around the stands making sure the string just touches the side surface of the rear tires on each side of the vehicle and goes around the stands in front of the vehicle 2 4 Measure the distance from the string to the rim at the front and rear of the front rim 3 Rear measurement should be 1 16 1 8 2 to 3 cm more than the front measurement NOTE If you discover improper alignment see your Polaris dealer for service MET 92 MAINTENANCE AND LUBRICATION Adjustments Steering Assembly The steering assembly of the ATV should be checked periodically for loose nuts and bolts If loose nuts and bolts are found see your Polaris dealer for service before operating the vehicle Camber and Caster The camber and caster are non adjustable Rear Spring The rear shock absorber spring is adjusted by rotating the adjuster 1 either clockwise or counterclockwise to increase or decrease spring tension 1 NOTE Accessory springs are available through your Polaris dealer 93 MAINTENANCE AND LUBRICATION Adjustments Handlebars If desired the handlebars can be adjusted for rider preference 4 amp WARNING Improper adjustment of the handlebars or incorrect torquing of the adjuster block tightening bolts can cause limited steering or loosening of the handlebars resulti
23. the temperature inside the clutch cover extends the life of the PVT components belt cover etc When To Use Low Range vs High Range Following is a guideline for when to use low range and high range Low Range e When basic operation is at speeds less than 7 MPH e For heavy pulling e When operating in rough terrain swamps mountains etc at low ground speeds High Range e When basic operation is at speeds greater than 7 MPH e When operating at high ground speeds 70 OPERATION PVT System amp WARNING Failure to comply with the instructions in this warning can result in severe injury or death 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 The PVT system rotates at high speeds creating large amounts of force on clutch components Extensive engineering and testing has been conducted to ensure the safety of this product However as the owner you have the following responsibilities to make sure this system remains safe Always follow all recommended maintenance procedures See your dealer as outlined in the owner s manual This PVT system is intended for use on Polaris products only Do not install it in any other product Always make sure the PVT housing is securely in place
24. where sidehilling is necessary follow these precautions 1 Slow down 2 Lean into the hill transferring your upper body weight toward the hill while keeping your feet on the footrests 3 Steer slightly into the hill to maintain vehicle directions NOTE Ifthe vehicle begins to tip quickly turn the front wheel downhill if possible or dismount on the uphill side immediately 62 OPERATION Driving Safely Driving Downhill Whenever descending a hill follow these precautions 1 Proceed directly downhill 2 Transfer your weight to the rear of the vehicle 3 Slow down 4 Apply the brakes slightly to aid in slowing Familiarize yourself with operation of the auxiliary rear brake pedal for additional braking in the event of normal service brake loss 4 amp WARNING Excessive speed can cause loss of control and lead to serious injury or death Always operate slowly when traveling downhill 63 OPERATION Driving Safely Turning Around on a Hill 4 amp WARNING Improper hill climbing procedures could cause loss of control or overturn and result in serious injury or death Avoid climbing steep hills 25 maximum Use extreme caution when operating on hills and follow proper operating procedures outlined in the owner s manual If the vehicle stalls while climbing a hill never back it down the hill One maneuver that can be used when it s necessary to turn around while climbing a hill is the K turn
25. ATP 330 AKAs ATP 500 axa POLARIS The Way Out Read this manual carefully It contains important safety information This is an adult vehicle only Operation is prohibited for those under 16 years of age AWARNING Improper vehicle use can result in SEVERE INJURY or DEATH ALWAYS USE NEVER USE NEVER CARRY NEVER USE AN APPROVED ON PUBLIC PASSENGERS WITH DRUGS HELMET AND ROADS OR ALCOHOL PROTECTIVE GEAR NEVER Operate without proper training or instruction e Operate on public roads A collision can occur with another vehicle e Operate at speeds too fast for your skills or the conditions e Use ALCOHOL or DRUGS before or while operating this vehicle e Carry Passengers ALWAYS e Avoid paved surfaces which may adversely affect handling and control e Use proper RIDING TECHNIQUES to avoid vehicle overturns on hills and rough terrain and in turns e Wear eye protection helmet and protective apparel READ OWNER S MANUAL FOLLOW ALL INSTRUCTIONS AND WARNINGS Part No 9919515 Rev 02 ca PELARIS PRINTED IN THE USA The Way Out AWARNING The engine exhaust from this product contains chemicals known to cause cancer birth defects or other reproductive harm A card containing important ATV safety information should be attached to the owner s manual on the next page If you cannot locate this card or if it has been removed please call 1 800 342 3764 for assistance PesLARIiIS
26. DC and pour approximately two ounces of Polaris oil into the cylinder 3 Apply dielectric grease to the inside of the spark plug cap and install the cap onto the plug 4 Turn the engine over several times to ensure coverage of piston rings cylinder walls and crankshaft bearings 5 Treat the fuel system with Polaris Carbon Clean 6 If Polaris fuel system additive is not used fuel tank fuel lines and carburetor should be completely drained of gasoline To eliminate any fuel remaining in the carburetor run the engine until it stops Lubricate Inspect all cables and lubricate with Polaris Cable Lubricant Follow lubrication guidelines in the maintenance section of the service or owner s manual to completely grease and lubricate the entire vehicle with Polaris Premium All Season Grease 115 MAINTENANCE AND LUBRICATION Cleaning and Storage Storage Tips Battery Storage Remove the battery from the vehicle and ensure that it s fully charged before placing it in storage See page 111 for instructions Engine Anti Freeze Test engine coolant strength and change if necessary Coolant should be replaced every two years Storage Area Covers Set the tire pressure and safely support the ATV with the tires 1 2 off the ground Be sure the storage area is well ventilated and cover the machine with a genuine Polaris ATV cover NOTE Do not use plastic or coated materials They do not allow enough ventilation to prevent conden
27. FEATURES AND CONTROLS 4 amp WARNING Do not start or operate an ATV with sticking or improperly operating throttle controls which could cause an accident and lead to severe injury or death Always contact your dealer for service repairs if throttle problems arise Failure to check or maintain proper operation of the throttle system can result in an accident if the throttle lever sticks during operation Always check the lever for free movement and return before starting the engine Also check occasionally during operation Throttle Lever Engine speed and vehicle movement are controlled by pressing the throttle lever The throttle lever 1 is spring loaded Engine speed returns to idle when the lever is released This ATV is equipped with 1 Polaris Electronic Throttle Control ETC which is designed to reduce the risk of a frozen or stuck throttle If the throttle cable should stick in an open position when the operator releases the throttle lever the engine will stop and power to the rear wheels will cease 4 amp WARNING The Electronic Throttle Control ETC stops the engine in the event of a throttle system malfunction and is provided for your safety Do not attempt to modify the ETC system or replace it with any after market throttle mechanisms 35 FEATURES AND CONTROLS Brake Lever The front and rear brakes are applied by squeezing the brake lever 1 toward the handlebar The front and rear brakes are hy
28. PM slightly with the throttle to aid in warm up When the engine idles smoothly push the choke all the way in 53 OPERATION Starting the Engine Starting a Warm Engine Warm engines do not normally require the use of the choke Using the choke can cause the spark plug to become wet fouled 1 Position the vehicle on a level surface with the transmission in park 2 Lock the parking brake turn the fuel tank valve to ON sit on the vehicle and turn the engine stop switch to RUN 3 Ifthe engine has cooled to a point where it does not readily start intermittent use of the choke button pulled half way out may be necessary 4 Ifthe engine is over choked when warm depress the throttle lever fully while cranking to aid in starting 5 Release the throttle lever immediately after the engine starts If the engine does not start and all conditions are favorable change the spark plug and try again Cold Weather Operation for 4 Cycle Engines If the ATV is used year round check the oil level frequently A rising oil level could indicate the accumulation of water in the bottom of the oil tank Water in the bottom of the tank can lead to engine damage and must be drained Water accumulation increases as outside temperature decreases See your Polaris dealer for engine heater kits which provide quicker warm ups and easier starting in colder weather 54 OPERATION Hauling Cargo A WARNING Overloading the vehicle or ca
29. RANTIES AND REMEDIES The Polaris limited warranty excludes any failures that are not caused by a defect in material or workmanship This warranty does not cover accidental damage normal wear and tear abuse or improper handling This warranty also does not cover any ATV that has been al tered structurally modified neglected improperly maintained used for racing or used for purposes other than for which it was manufactured or for any damages which occur during trailer transit or as a result of unauthorized service or the use of unauthorized parts In addi tion this warranty does not cover physical damage to paint or finish stress cracks tearing or puncturing of upholstery material corrosion or defects in parts components or the ATV due to fire explosions or any other cause beyond Polaris control This warranty does not cover the use of unauthorized lubricants chemicals or fuels that are not compatible with the ATV The exclusive remedy for breach of this warranty shall be at Polaris exclusive option repair or replacement of any defective materials or components or products THE REMEDIES SET FORTH IN THIS WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CON TRACT NEGLIGENCE OR OTHER TORT OR OTHERWISE Some states do
30. RES 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 Ifthe instrument cluster fails to illuminate a battery over voltage may have occurred and the instrument cluster may have shut off to protect the electrical system If this occurs take the ATV to your Polaris dealer for proper diagnosis 1 Gear Indicator As the shift lever is moved this indicator shows the gear the transmission is in H High Range 3 4 5 6 L Low Range N Neutral R Reverse P Park if equipped 92 2 AWD Indicator This indicator illuminates when the electrical portion of the AWD system is enabled 8 Engine Hour Display Indicator 1 4 Service Interval Diagnostic Mode Indicator Low Battery and Over Voltage This warning usually indicates that the ATV is being operated at an RPM too low to keep the battery charged A low battery warning may also occur under normal operation if the machine is at idle and high electrical load lights cooling fan accessories is applied Driving at a higher RPM or connecting a battery charger will usually clear the warning 6 Odometer Tachometer Tripmeter Hour Meter 7 Check Engine Warning Indicator The word HOT will display alphanumerically when the engine is overheating Do not continue to operate the ATV is this warning appears or serious engine damage could resul
31. allation of this battery The sealed battery is already filled with electrolyte and has been sealed and fully charged at the factory Do not ever pry the sealing strip off or add any other fluid to this battery The single most important thing about maintaining a sealed battery is to keep it fully charged Since the battery is sealed and the sealing strip cannot be removed you must use a voltmeter or multimeter to measure DC voltage For a refresh charge follow all instructions carefully 1 Check the battery voltage with a voltmeter or multimeter A fully charged battery will register 12 8 V or higher 2 Ifthe voltage is less than 12 8 volts recharge the battery at 1 2 amps or less until thebattery voltage is 12 8 or greater NOTE When using an automatic charger refer to the charger manufacturer s instructions for recharging When using a constant current charger use the following guidelines for recharging 4 amp WARNING An overheated battery may explode causing severe injury or death Always watch charging times carefully Stop charging if the battery becomes very warm to the touch Allow it to cool before resuming charging 111 MAINTENANCE AND LUBRICATION Battery Battery Charging NOTE Always verify battery condition before and 1 2 hours after the end of charging State of Voltage Charge Time Charge Using constant current charger standard amps specified on top of battery 100 12 8 13 0 volts None ch
32. amage to the vehicle CAUTION A caution indicates a situation that may result in damage to the vehicle NOTE A note will alert you to important information or instructions SAFETY Operator Safety 4 amp WARNING Serious injury or death can result if you do not follow these instructions and procedures which are outlined in further detail within your owner s manual e Read this manual and all labels carefully and follow the operating procedures described e Never operate an ATV without proper instruction Take a training course Beginners should receive training from a certified instructor Contact an authorized Polaris ATV dealer or call Polaris at 1 800 342 3764 to find out about the training courses nearest you e Never allow anyone under 16 years of age to operate this ATV e Never permit a guest to operate the ATV unless the guest has read this manual and all product labels and has completed a certified safe ty training course e Always avoid operating an ATV on paved surfaces including side walks driveways parking lots and streets e Never operate an ATV on a public street road or highway including a dirt or gravel road e Never operate an ATV without wearing an approved helmet that fits properly Always wear eye protection goggles or face shield gloves boots a long sleeved shirt or jacket and long pants e Never consume alcohol or drugs before or while operating an ATV e Never operate at excessive s
33. ance your weight carefully avoid sudden movements and maintain a slow and steady forward motion Do not make sudden turns or stops and do not make sudden throttle changes Wet brakes may have reduced stopping ability Always test the brakes after leaving water If necessary apply them several times to let friction dry out the pads 4 amp WARNING POTENTIAL HAZARD Improperly operating in reverse WHAT CAN HAPPEN The ATV could collide with an obstacle or person resulting in severe injury HOW TO AVOID THE HAZARD Before shifting into reverse gear always check for obstacles or people behind the ATV When it s safe to proceed back slowly 25 SAFETY Operator Safety 4 amp WARNING 26 POTENTIAL HAZARD Operating this ATV with improper tires or with improper or uneven tire pressure WHAT CAN HAPPEN Use of improper tires or operation of the ATV with improper or uneven tire pressure could cause loss of control or accident HOW TO AVOID THE HAZARD Always use the size and type of tires specified in the owner s manual for the ATV Always maintain proper tire pressure WARNING POTENTIAL HAZARD Operating the ATV with improper modifications WHAT CAN HAPPEN Improper installation of accessories or modification of the ATV may cause changes in handling which could lead to an accident HOW TO AVOID THE HAZARD Never modify the ATV through improper installation or use of accessories All parts and accessor
34. and Filter Change ATP 500 CAUTION If the ATV is left without oil in the system for extended periods the oil pump may lose its prime which could result in engine damage Always replace the oil and filter within a few hours of draining the oil Do not allow the vehicle to be without oil overnight 1 Obtain the correct oil filter and an adequate supply of oil so the oil and filter change can be completed without interruption 2 Position the vehicle on a level surface Clean the area around the drain plug at the bottom of the oil tank and the bottom of the engine 3 Run the engine for two to three minutes then turn it off 4 amp CAUTION Hot oil can cause serious burns to skin Do not allow hot oil to come into contact with skin 80 MAINTENANCE AND LUBRICATION Lubrication Recommendations Engine Oil Oil and Filter Change ATP 500 4 Place a drain pan beneath the oil tank and remove the drain plug 1 Allow the oil to drain completely 5 Install a new sealing washer 2 on the oil drain plug NOTE The sealing surfaces on the drain plug and the oil tank should be clean and free of burrs nicks or scratches 6 Reinstall the drain plug and torque to 14 17 ft Ibs 19 23 Nm 7 Disconnect the lower oil delivery hose and remove the screen fitting 3 from the oil tank Clean and reinstall the fitting torquing to 25 ft Ibs 34 Nm Reattach the oil line NOTE The fitting threads must be sealed with L
35. bout jetting the ATV for conditions in your area If the engine idle speed is not satisfactory and all other conditions are favorable the ee carburetor can be adjusted Sw 1 Warm up the engine by running the YE vehicle for approximately five minutes 2 Place the transmission in gear with the parking brake applied 3 Adjust the carburetor idle screw 1 either in or out until the desired idle RPM is reached Turning the screw in clockwise will raise RPM Turning the screw out counterclockwise will lower RPM 95 MAINTENANCE AND LUBRICATION Adjustments Throttle Cable Freeplay Throttle cable freeplay is adjusted at the handlebar 1 Slide the boots 1 off the inline cable adjuster sleeve 2 Loosen the adjuster locknut 3 2 Turn the adjuster until 1 16 to 1 8 16 32 cm freeplay is achieved at the thumb lever NOTE While adjusting freeplay be sure to flip the throttle lever back and forth 3 Tighten the locknut and slide the boots over the cable adjuster until they touch at the midpoint of the adjuster 1 2 3 1 96 1 MAINTENANCE AND LUBRICATION Adjustments Side Panel Removal NOTE Side panel removal may be difficult until the locking tabs and receivers have been snapped and unsnapped a few times Remove the seat Grasp the rear of the side panel near the rear cab With a quick and firm motion pull the panel forward and outward to disengage the two rear tabs Place yo
36. braking on hills Check the terrain carefully before you start down a hill Shift your weight backward Never go down a hill at high speed Avoid going down a hill at an angle which would cause the vehicle to lean sharply to one side Travel straight down the hill when pos sible e Always follow proper procedures for crossing the side of a hill Avoid hills with excessively slippery or loose surfaces Shift your weight to the uphill side of the ATV Never attempt to turn the ATV around on any hill until you ve mastered on level ground the turn ing technique outlined in this manual Avoid crossing the side of a steep hill when possible e Always use proper procedures if you stall or roll backwards while climbing a hill To avoid stalling maintain a steady speed when climbing a hill If you stall or roll backwards follow the special pro cedure for braking described in this manual Always dismount on the uphill side or to either side if the ATV is pointed straight uphill Turn the ATV around and remount following the procedure de scribed in this manual e Always check for obstacles before operating in a new area Never attempt to operate over large obstacles such as rocks or fallen trees Always follow proper procedures when operating over obstacles as described in this manual e Always be careful of skidding or sliding On slippery surfaces like ice travel slowly and use extra caution to reduce the chance of skid ding or sliding out
37. cee cisegeee deeds 110 112 Battery Charging 111 112 Battery Installation 110 Battery Removal 110 Battery Storage 111 116 Belt Lifer irera cet GE e nek 42 Brake Fluid 0000 37 Brake Lever writen re Gea Bek Be 36 BEAR CS onse Stl 5 ok Sg Sad Cute nase 90 Break In Period 0 51 Breather Filter Hose ATP 500 101 C Camber and Caster 93 CarbU etOT nene epig eari eoe e aneas ians 95 CHOK E E E 40 Chrome Wheel Care 117 Cleaning and Storage 113 117 Cleaning the ATV 113 Clutching ATP 330 125 Clutching ATP 500 127 Cold Weather Operation 54 Coolant ATP 500 aaan 88 Coolant Level ATP 500 89 Cooling System Operation ATP 500 88 Corrosion 0 0 0 0 eee eee 117 Crankcase Emission Control System 72 D Diagnostic Mode 49 50 Driving Downhill 63 Driving in Reverse 68 Driving on Slippery Surfaces 60 Driving Over Obstacles 67 Driving Procedures 58 Driving Safely 58 69 Driving Through Water 65 66 Driving Uphill 00 61 Dumping Cargo 0 57 136 Electrical Switches EMISSION CONTROL SYSTEMS 72 Engaging the Front Gearcase 45 Engine Cooling System
38. ces including sidewalks paths parking lots and driveways WHAT CAN HAPPEN ATV tires are designed for off road use Operating on paved surfaces may seriously affect the handling and control of the ATV and could result in loss of control accident and or injury HOW TO AVOID THE HAZARD Avoid operating the ATV on pavement If it s unavoidable travel slowly and avoid sudden turns or stops WARNING POTENTIAL HAZARD Operating this ATV on public streets roads or highways we WHAT CAN HAPPEN The ATV could collide with another vehicle HOW TO AVOID THE HAZARD Never operate the ATV on any public street road or highway including dirt and gravel roads In many states it s illegal to operate ATVs on public streets roads and highways SAFETY Operator Safety 4 amp WARNING POTENTIAL HAZARD Operating this ATV without wearing an approved helmet eye protection and protective clothing WHAT CAN HAPPEN Operating an ATV without an approved helmet increases the risk of a severe head injury or death in the event of an accident Operating without eye protection could result in an accident and could increase the chance of a severe injury in the event of an accident HOW TO AVOID THE HAZARD Always wear an approved helmet that fits properly Always wear eye protection goggles or face shield gloves boots long sleeved shirt or jacket and long pants amp WARNING POTENTIAL HAZARD Opera
39. chemicals known to cause cancer birth defects or other reproductive harm Operate this vehicle only outdoors or in well ventilated areas 41 FEATURES AND CONTROLS Automatic Transmission Gear Selector The transmission gear selector 1 is located on the right side of the vehicle H High Gear L Low Gear N Neutral R Reverse P Park To shift into HIGH or PARK you must first apply the auxiliary brake to activate the high park lock out mechanism When shifting out of HIGH or PARK it s not necessary to apply the brake CAUTION Shifting gears with the engine speed above idle or while the vehicle is moving could cause transmission damage To change gears stop the vehicle and with the engine idling move the lever to the desired gear Apply the auxiliary brake before attempting to shift into high gear or park Whenever the ATV is left unattended always place the transmission in park and lock the parking brake vD Zr I Maintaining shift linkage adjustment is important to assure proper transmission function See your dealer if you experience any shifting problems Belt Life To extend belt life use low forward gear in heavy pulling situations and when operating at less than seven miles per hour for extended periods of time If towing the vehicle is necessary shift the transmission into neutral for better mobility and to prevent damage to the belt 42 FEATURES AND CONTROLS Recoil Starter If the ba
40. copic meaning it rapidly absorbs moisture from the air The moisture causes the boiling temperature of the brake fluid to drop which can lead to early brake fade and the possibility of accident or severe injury After opening a bottle of brake fluid always discard any unused portion The following checks are recommended to keep the brake system in good operating condition Check more often if brakes are used heavily under normal operation 1 Always keep brake fluid at an adequate level see page 37 NOTE Under normal operation the 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 and the diaphragm should be replaced Always fill the reservoir as needed whenever the cover is loosened or removed to ensure proper aaa operation Use Polaris DOT 3 brake fluid Do not overfill 4 amp WARNING An over full master cylinder may cause brake drag or brake lock up which could result in serious injury or death Maintain brake fluid at the recommended level Do not overfill 2 Check the brake system for fluid leaks 3 Check the brakes for excessive travel or spongy feel 4 Check the friction pads for wear damage and looseness 5 Check the security and surface condition of the disc NOTE Change the brake pads when f they re worn to 3 64 1 cm 3 64 1 cm 90 MAINTENANCE AND LUBRICATION Adjustmen
41. de quick dismounting of the vehicle If all forward speed is lost Keep your weight uphill Apply the front brake or the single lever brake gradually When fully stopped apply rear brake as well then lock the park brake If the ATV begins rolling backwards Keep your weight uphill Never apply engine power Never apply the rear brake while rolling backwards Apply the front brake or single lever brake gradually When fully stopped apply the rear brake as well and then lock the parking brake Dismount on uphill side or to either side if ATV is pointed straight uphill Turn the ATV around and remount following the procedure described on page 64 4 WARNING Braking and handling are greatly affected when operating in hilly terrain Improper procedure could cause loss of control or overturn and result in serious injury or death Avoid climbing steep hills 25 maximum Use extreme caution when operating on hills and follow proper operating procedures outlined in the owner s manual gt 61 OPERATION Driving Safely Sidehilling 4 amp WARNING Improperly crossing hills or turning on hills can result in loss of control or vehicle overturn resulting in severe injury or death Avoid crossing the side of a hill when possible Follow proper procedures as outlined in the owner s manual Sidehilling can be a dangerous type of driving and should be avoided if at all possible If you do enter into a situation
42. dipstick 17 Dispose of used filter and oil properly Oil Pump Priming This priming procedure must be performed whenever the oil hose connection between the oil tank and pump inlet has been disconnected 1 Clamp or pinch off the vent line 1 o approximately 2 5 cm from the oil 5 cm tank 2 between the end of the oil ae tank vent fitting and the vent line s pressure relief slit 3 2 Run the engine for 10 20 seconds 3 Remove the vent line clamp If the line is bled properly you should hear a rush of air indicating that the line is properly primed and ready for operation If you do not hear air the line has not bled and you ll need to repeat the priming procedure 2 1 82 MAINTENANCE AND LUBRICATION Lubrication Recommendations Engine Oil Oil Check ATP 330 The oil fill is located on the left side of the engine 1 Maintain the oil level in the safe operating range 2 Do not overfill 1 2 3 4 J Position the machine on a level surface Start the engine and let it idle for 20 30 seconds Stop the engine Remove the dipstick and wipe it dry with a clean cloth sE E V 2 Screw the dipstick completely in Remove the dipstick and read the oil level Add the recommended oil as needed Oil and Filter Change ATP 330 CAUTION If the ATV is left without oil in the system for extended periods the oil pump may lose its prime which could result
43. djustments are required Clean pre filter element often depending on temperature more frequent cleaning required and altitude See your Owner s in dusty conditions Do not Manual operate vehicle without pre tilter Factory setting Operation of this vehicle without 3 oF P engine breather filter s can cause 40 to 80 F at 0 3000 feet engine damage Consult owner s 5 to 27 C at 0 900 meters manual or dealer for details 7079902 Under seat ATP 500 31 SAFETY Safe Riding Gear Always wear clothing suited to the type of riding ATV riding requires special protective clothing for comfort and to reduce the chance of injury 1 Helmet Your helmet is the most important piece of protective gear for safe riding A helmet can prevent a severe head injury Select an approved helmet that meets or exceeds your state s safety standards and bears either the Department of Transportation DOT label the American National Standards Institute label ANSI 290 1 or the Snell Memorial Foundation label 2 Eye Protection Do not depend on sunglasses for proper eye protection A pair of goggles or a helmet face shield offer the best protection for your eyes They should be kept clean and be of shatterproof design bearing the markings z2 1 or VESC 8 3 Gloves Off road style gloves with knuckle pads are the best for comfort and protection 4 Boots The best footwear is a pair of strong over the calf boots with
44. draulically activated disc type brakes that are activated by only one lever 4 amp WARNING Operating the ATV with a spongy brake lever can result in loss of braking which could cause an accident Never operate the ATV with a spongy feeling brake lever Always test brake lever travel and master cylinder fluid level before riding When squeezed the lever should feel firm Any sponginess would indicate a possible fluid leak or low master cylinder fluid level which must be corrected before SE riding Contact your dealer for proper diagnosis and repairs 36 FEATURES AND CONTROLS Brake Fluid Check the brake fluid level in the master cylinder before each use of the ATV The master cylinder 2 is located on the left handlebar The fluid level can be seen through an indicator window 3 on the top of the master cylinder This eye will appear dark when the fluid level is full When fluid needs to be added the eye will be clear 4 amp WARNING An over full master cylinder may cause brake drag or brake lock up which could result in serious injury or death Maintain brake fluid at the recommended level Do not overfill NOTE When checking the fluid level the ATV must be on level ground with the handlebars straight If the fluid level is low add DOT 3 brake fluid only DO NOT OVERFILL See page 119 for the part numbers of Polaris products 4 amp WARNING Never store or use a partial bottle of brake fluid Brake f
45. e country where the vehicle was purchased will continue to be covered by the basic warranty For questions call Polaris Customer Assistance United States 1 763 417 8650 Canada 1 204 925 7100 130 WARRANTY California Emission Control Warranty Statement Your Warranty Rights and Obligations The California Air Resources Board and Polaris Industries Inc 2100 Highway 55 Medina Minnesota 55340 herein POLARIS are pleased to explain the emission control system warranty on your 2004 and later Large Spark Ignition Engine herein LSI engine The California Air Resources Board has designated this engine for this vehicle as an LSI engine which produces 25 and greater horsepower and the vehicle has a six 6 or four 4 wheel drive and or a round steering wheel In California this LSI engine must be designed built and equipped to meet the state s stringent anti smog stan dards Polaris must warrant the emission control system on your LSI engine for the peri od of time described below provided there has been no abuse neglect or improper maintenance of your LSI engine Your emission control system includes parts such as the carburetor and the ignition sys tem Also included may be hoses connectors and other emission related assemblies Where a warrantable condition exists POLARIS will repair your LSI engine at no cost to you including diagnosis parts and labor Manufacturer s Warranty Coverage The 2004 and
46. e e a 48 Oil Change ATP 330 83 84 Oil Change ATP 500 80 82 Oil Check ATP 330 83 Oil Check ATP 500 80 Oil Cooler ATP 330 88 Oil Pump Priming 82 Oil Engines fat lain aoe cas geohes 79 84 Oil Front Gearcase 86 Oil Rear Gearcase 87 Oil Transmission 85 OPERATION 4 51 71 Operator Safety 7 27 Override Switch 0 0 33 P Parking Brake 0 0 38 Parking on an Incline 69 Periodic Maintenance Chart 73 76 POLARIS PRODUCTS 119 Pre Ride Inspection 52 Premium 4 Synthetic Oil 79 PVT Drying reesen ianen 71 PV T Systems cassis Meee is 70 71 R Radiator Coolant Level ATP 500 89 Rear Gearcase Oil 87 Rear Spring 0 0 0 0 0 ee 93 Recoil Housing 109 Recoil Starter isaer enta e 43 Rider Information Center 47 50 S Safe Riding Gear 32 SAFETY tians bette e babies 7 32 Safety Decals and Locations 28 31 S Safety Training 04 7 Side Panel Removal 97 SidehWin ge weier daseerigherdass tate 62 Spark Arrestor 72 108 Spark Plug Removal and Replacement 106 Spark Plugs 0000 106 SPECIFICATIONS 124 127 Speedo Mode Switch 33
47. eaks if applicable p gt Evaine mounts 7007 soo Exhaust muffler 100 H 12M 620 1000 Inspect pipe H Spark plug 100 H 620 1000 Inspect replace as needed Wiring 100 H 620 1000 Inspect for wear routing security apply dielectric grease to connectors subjected to water mud etc eee drive 100 H 620 1000 Inspect clean replace worn HE akon parts Front wheel 100 H 1000 1600 Inspect replace as needed bearings m Brake fluid 200 H 1240 2000 Change every two years Searkarestor E 860 8000 Efese Astaro Toe adjustment Inspect periodically adjust when parts are replaced Auxiliary brake Inspect daily adjust as needed _ Headlight aim Adjust as needed p Perform these procedures more often for vehicles subjected to severe use E Emission Control System Service California m Have an authorized Polaris dealer perform these services 76 MAINTENANCE AND LUBRICATION Lubrication Recommendations Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart beginning on page 73 Items not listed in the chart should be lubricated at the General Lubrication interval Lubrication Chart Key p gt More often under severe use such as wet or dusty conditions Polaris Premium All Season Grease or grease conforming to NLG No 2 such as Conoco Superlube M or Mobilegrease Special e Use Polaris Premium U Joint Lube every 500 miles before long periods o
48. ean and reinstall the drain plug Torque to 14 ft Ibs 19 Nm 4 Add 13 5 oz 400 ml of the recommended oil Reinstall the fill plug Torque to 14 ft Ibs 19 Nm 6 Check for leaks mn 85 MAINTENANCE AND LUBRICATION Lubrication Recommendations Front Gearcase Oil Always check and change the front gearcase oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 73 Maintain the oil level 3 4 below the fill plug opening We recommend the use of Polaris Premium Demand Drive Hub Fluid See page 119 for the part numbers of Polaris products Oil Check 1 Position the vehicle on a level surface 2 Remove the fill plug 1 3 View the oil level and add the recommended oil as needed 4 Reinstall the fill plug Torque to 8 10 ft Ibs 11 14 Nm Oil Change 1 Position the vehicle on a level surface 2 Remove the fill plug Yo Place a drain pan beneath the gearcase Remove the gearcase drain plug 2 and drain the oil Clean and reinstall the drain plug Torque to 11 ft Ibs 15 Nm Add 5 oz 148 ml of the recommended gearcase oil Reinstall the fill plug Torque to 8 10 ft Ibs 11 14 Nm Check for leaks SCO Ge 86 MAINTENANCE AND LUBRICATION Lubrication Recommendations Rear Gearcase Oil Always check and change the rear gearcase oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 73 Maintain the oil level at the bottom of
49. eck at None required 3 mos from date of manufacture 75 100 12 5 12 8 volts May need slight 3 6 hours charge if no charge given check in 3 months 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 5 volts or less Needs Charge At least 20 hours 112 MAINTENANCE AND LUBRICATION Cleaning and Storage See page 119 for the part numbers of Polaris products Cleaning the ATV Keeping your ATV clean will not only improve its appearance but it can also extend the life of various components With a few precautions your ATV can be cleaned much like an automobile Washing the ATV The best and safest way to clean your ATV is with a garden hose and a pail of mild soap and water Use a professional type washing mitten cleaning the upper body first and the lower parts last Rinse with water frequently and dry with a chamois to prevent water spots NOTE If warning and safety labels are damaged contact your a Polaris dealer for free replacement Polaris does not recommend the use of a high pressure type car wash system for washing the ATV If a high pressure system is used exercise extreme care to avoid water damage to the wheel bearings transmission seals body panels brakes and warning labels NOTE Grease all zerk fittings immediately after washing and allow the vehicle to run for a while to evaporate any water that may have entered the
50. ed below which are based on the procedures described in the Owner s Manual Maintenance Schedule Key p gt Perform these procedures more frequently for vehicles subjected to severe use E Emission Control System Service California m Have an authorized Polaris dealer perform these services 133 WARRANTY California Emission Control Warranty Statement Maintenance Schedule Maintenance Interval whichever comes first Calendar Miles Km Engine oil level Pre Ride Make adjustments as need ed See Pre Ride Checklist on page 52 g Air filter pre filter EE a Inspect clean often Air box sediment Daily Drain deposits when visible tube Air filter Weekly Inspect replace as needed main element Engine breather 25 H Monthly 155 250 Inspect replace if necessary filter if equipped 25H 50 H 50 H 50 H 310 500 Inspect adjust lubricate replace if necessary Engine oil change 155 250 Perform a break in oil break in change at one month Throttle Cable lubri ETC Switch Choke cable 310 500 Inspect adjust lubricate replace if necessary Carburetor air intake ducts 310 500 Inspect ducts for proper sealing air leaks Engine oil change 100 H 620 1000 Perform a break in oil change at 25 hours one month g Oil filter change 100 H Bag 620 1000 Replace with oil change g Oil tank vent hose 100 H Kag 620 1000 Inspect routing condition flange 100 H 620 1000 Inspect adjust Fuel syste
51. en the throttle suddenly while traveling uphill The ATV could flip over backwards Never go over the top of any hill at high speed An obstacle a sharp drop or another vehicle or person could be on the other side of the hill SAFETY Operator Safety 4 WARNING POTENTIAL HAZARD Traveling downhill improperly WHAT CAN HAPPEN Improperly descending a hill could cause loss gt of control or overturn ree HOW TO AVOID THE HAZARD Always follow proper procedures for traveling down hills as described in the owner s manual NOTE A special technique is required when braking while traveling downhill See page 63 Always check the terrain carefully before descending a hill Shift your weight backward Never travel down a hill at high speed Avoid traveling down a hill at an angle which would cause the vehicle to lean sharply to one side Travel straight down the hill when possible 21 SAFETY Operator Safety 4 amp WARNING 22 POTENTIAL HAZARD Improperly crossing hills and turning on hills WHAT CAN HAPPEN Improperly crossing or turning as hills could cause loss of control or overturn HOW TO AVOID THE HAZARD Never attempt to turn the ATV around on any hill until you ve mastered the turning technique on level ground as described in the owner s manual See page 64 Use extra caution when turning on any hill Avoid crossing the side of a steep hill When crossing the side of a hill
52. engine or exhaust system Waxing the ATV Your ATV can be waxed with any non abrasive automotive paste wax Avoid the use of harsh cleaners since they can scratch the body finish CAUTION Certain products including insect repellants and chemicals will damage plastic surfaces Use caution when using these products near plastic surfaces 113 MAINTENANCE AND LUBRICATION Cleaning and Storage Storage Tips See page 119 for the part numbers of Polaris products CAUTION Starting the engine during the storage period will disturb the protective film created by fogging and damage could occur Never start the engine during the storage period Clean the Exterior Make necessary repairs and then clean the ATV thoroughly with mild soap and warm water to remove all dirt and grime Don t use harsh detergents or high pressure washers Some detergents deteriorate rubber parts Use dish soap type cleaners only High pressure washers may force water past seals Stabilize the Fuel Fill the fuel tank Add Polaris Carbon Clean Fuel Treatment or Polaris Fuel Stabilizer Follow the instructions on the container for the recommended amount Carbon clean will also 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 Turn the fuel valve off and drain the carburetor bowl Oil and Filter Warm the engine and change the oil and f
53. et 50 OPERATION Break In Period The break in period for your new Polaris ATV is defined as 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 is as important as following the procedures for a proper break in Careful treatment of a new engine will result in more efficient performance and longer life for the engine Perform the following procedures carefully CAUTION Excessive heat build up during the first three hours of operation will damage close fitted engine parts Do not operate at full throttle or high speeds for extended periods during the first three hours of use Use of any oils other than those recommended by Polaris may cause serious engine damage We recommend the use of Polaris Premium 4 Synthetic Oil for your 4 cycle engine 1 Fill the fuel tank with gasoline See page 40 ADD 8 OZ NORMAL EUs ee 2 Check the oil level on the dipstick See pages 1 80 and 83 Add Polaris Premium 4 Synthetic Oil if necessary to maintain the oil level in the normal safe operating range 1 3 Drive slowly at first Select an open area that allows room to familiarize yourself with vehicle operation and handling 4 Vary throttle positions Do not operate at sustained idle 5 Perform regular checks on fluid levels controls and areas outlined on the daily pre ride inspection checklist See page 52 6 Pull only light loads 7 During the b
54. f storage or after pressure washing or submerging e f o j e Engine Polaris Premium 4 Synthetic Add to proper level on dip ow40 stick Brakes DOT 3 fluid only Maintain level between fill lines See page 37 Transmission Premium AGL Synthetic Gear See Page 85 case Lube Front Gearcase Polaris Premium Demand See Page 86 Drive Hub Fluid Rear Gearcase Premium ATV Angle Drive See page 87 Fluid Front Prop Shaft Grease Grease fittings U joints Front Prop Shaft Yoke Grease Grease fittings 3 pumps maximum Ball Joint p gt XGrease Locate fitting on back side of struts and grease with grease gun 77 MAINTENANCE AND LUBRICATION Periodic Maintenance Record Use the following chart to record periodic maintenance Maintenance Servicing Servicing Interval Date Dealer Performed or Person 78 MAINTENANCE AND LUBRICATION Lubrication Recommendations Engine Oil Always check and change the engine oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 73 Always change the oil filter whenever changing oil Premium 4 Synthetic Oil Polaris Premium 4 All Season Synthetic engine oil has been specially formulated for use in Polaris 4 cycle engines It s a fully synthetic high performance multi viscosity oil designed to provide the ultimate in lubrication performance and protection See page 119 for the part numbers of Polaris products Premium 4 possesses unsurpassed film strength o
55. for service as soon as possible whether you succeed in starting it or not NOTE If water has been ingested into the PVT follow the procedure on page 71 for drying out the PVT 107 MAINTENANCE AND LUBRICATION Spark Arrestor A 108 WARNING Failure to heed the following warnings while servicing the spark arrestor could result in serious injury or death Do not perform service on the spark arrestor while the system is hot Exhaust system temperatures can reach 1000 F Allow components to cool sufficiently before proceeding Remove any combustible materials from the area Wear eye protection and leather work gloves Do not stand behind or in front of the vehicle while purging Never run the engine in an enclosed area Exhaust contains poisonous carbon monoxide gas Never go under the vehicle while it s inclined Remove the arrestor clean out plug s 1 from the bottom of the LJ muffler Place the transmission in PARK and start the engine Za RG 2 Purge carbon from the system by momentarily revving the engine several times If carbon is expelled cover or plug the exhaust outlet 2 and rap on the pipe around the cleanout plug while revving the engine several more times If particles are still suspected to be in the muffler back the vehicle onto an incline so the rear of the vehicle is one foot higher than the front Set the parking brake and block the wheels Make sure the vehicle
56. grade to remove it Gently rub the affected areas with the steel wool until the corrosion has been removed Clean and polish the wheel as outlined above 117 118 NOTES POLARIS PRODUCTS Part No Description Engine Lubricant 2870791 Fogging Oil 12 oz Aerosol 2871281 Premium 4 Synthetic OW 40 4 Cycle Engine Oil qt 2871844 Premium 4 Synthetic OW 40 4 Cycle Engine Oil gal 2873602 2873603 2871653 2872275 2870465 2871654 2872277 2871322 2871423 2871460 2871515 2871557 2871312 2871329 2872073 2872348 2871323 60 40 Coolant gal 2871534 60 40 Coolant qt 119 TROUBLESHOOTING Drive Belt and Cover Problems Driving the ATV onto a Shift transmission to low range during loading of the ATV pickup or tall trailer in to prevent belt burning high range Starting out going up a When starting out on an incline use low range or dis steep incline mount the ATV after first applying the park brake and perform the K turn as described on page 64 Driving at low RPM or Drive at a higher speed or use low range more frequently low ground speed at The use of low range is highly recommended for cooler approximately 3 7 MPH PVT operating temperatures and longer component life Insufficient warm up of Warm the engine at least 5 minutes With the transmission ATVs exposed to low am in park advance the throttle to about 1 8 throttle in short bient temperatures bursts 5 to 7 times The belt w
57. he Country where your vehicle was purchased If you are traveling temporarily outside the country where your vehicle was purchased you should take your vehicle to an authorized Polaris dealer You must show the dealer photo identification from the country of the selling dealer s authorized location as proof of residence Upon residence verification the servicing dealer will be authorized to per form the warranty repair If You Move If you move to another country be sure to contact Polaris Customer Assistance and the customs department of the destination country before you move Vehicles importation rules vary considerably from country to country You may be required to present docu mentation of your move to Polaris Industries in order to continue your warranty cover age You may also be required to obtain documentation from Polaris Industries in order to register your vehicle in your new country How to Get Service If Purchased From A Private Party If you purchase a Polaris product from a private citizen outside of the country in which the vehicle was originally purchased all warranty coverage will be denied Notice If your vehicle is registered outside of the country where it was purchased and you have not followed the procedure set out above your vehicle will no longer be eligible for war ranty or service bulletin coverage of any kind Vehicles registered to Government officials or military personnel on assignment outside of th
58. heels like moto cross boots 5 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 32 FEATURES AND CONTROLS Electrical Switches 4 amp WARNING Activating the override switch while the throttle is open can cause loss of control resulting in severe injury or death Do not activate the override switch while the throttle is open Speedo Mode Override Switch 1 Reverse Speed Limiter This switch if pressed while in any gear but reverse will change the display mode of the speedometer if equipped To gain additional power while operating in reverse depress the override switch before opening the throttle NOTE The override switch also allows activation of All Wheel Drive in reverse if the AWD switch is on Main Switch 2 To start the engine slide the stop switch to the center RUN position and turn the main key switch clockwise past the ON position Release the key when the engine starts NOTE Turn off the main switch to end all electrical power to the vehicle including the cooling fan and lights 4 amp WARNING Leaving the keys in the ignition can lead to unauthorized use of the vehicle resulting in serious injury or death Always remove the ignition key when the vehicle is not in use 4 WARNING A large key fob or key ring may contact the gas tank cap causing an interruption to the electrica
59. iately visible Travel with caution in unfamiliar terrain 67 OPERATION Driving Safely Driving in Reverse Follow these precautions when operating in reverse 1 Always avoid backing downhill 2 Back slowly 3 When in reverse apply the brakes lightly for stopping 4 Avoid turning at sharp angles in reverse 5 Never open the throttle suddenly while backing 4 amp WARNING Failure to use caution when operating in reverse can result in serious injury or death Before shifting into reverse always check for obstacles or people behind the vehicle When it s safe to proceed back slowly Do not use the override switch unless additional power is required for vehicle movement Use with caution Avoid backing on inclines and avoid turning at sharp angles NOTE Most Polaris ATVs are equipped with a reverse speed limiter The override button should be used with caution as rearward vehicle speed is greatly increased Do not operate at wide open throttle Open the throttle just enough to maintain a desired speed CAUTION Excessive throttle operation while in the speed limit mode may cause fuel to build in the exhaust resulting in engine popping and or engine damage 68 OPERATION Driving Safely Parking on an Incline Avoid parking on an incline if possible If it s unavoidable follow these precautions 1 1 2 3 Turn the engine off Place the transmission in park Set the parking brake
60. ies added to the vehicle must be genuine Polaris Industries Inc or equivalent components designed for use on this ATV and should be installed and used according to approved instructions See your authorized Polaris ATV dealer for more information WARNING POTENTIAL HAZARD Operating on frozen bodies of water WHAT CAN HAPPEN Severe injury or death can result if the ATV and or the operator fall through the ice HOW TO AVOID THE HAZARD Never operate the ATV on a frozen body of water SAFETY Operator Safety A A WARNING Leaving the keys in the ignition can lead to unauthorized use of the vehicle resulting in serious injury or death Always remove the ignition key when the vehicle is not in use WARNING After any overturn or accident have a qualified service dealer inspect the entire vehicle for possible damage including but not limited to brakes throttle and steering systems WARNING Safe operation of this rider active vehicle requires good judgement and physical skills Persons with cognitive or physical disabilities who operate this vehicle have an increased risk of overturn and loss of control which could result in severe injury or death CAUTION Exhaust system components are very hot during and after use of the vehicle Hot components can cause serious burns and fire Do not touch hot exhaust system components Always keep combustible materials away from the exhaust system Use caution when traveling th
61. ill become more flexible and prevent belt burning Slow and easy clutch en Use the throttle quickly and effectively for efficient enga gagement gement Towing pushing at low Use low range only RPM low ground speed Utility use plowing snow Use low range only dirt etc Stuck in mud or snow Shift the transmission to low range and carefully use fast aggressive throttle application to engage clutch WARNING Excessive throttle may cause loss of control and vehicle overturn Climbing over large ob Shift the transmission to low range and carefully use fast jects from a stopped posi brief aggressive throttle application to engage clutch tion WARNING Excessive throttle may cause loss of control and vehicle overturn Belt slippage from water Shift the transmission to park Using the throttle vary the or snow ingestion into the engine RPM from idle to full throttle Repeat several PVT system times as required During this procedure the throttle should not be held at the full position for more than 10 seconds Clutch seals should be inspected for damage if repeated leaking occurs Clutch malfunction Contact your Polaris dealer for inspection of clutch com ponents Poor engine performance Check for fouled plugs or foreign material in gas tank fuel lines or carburetor Contact your dealer for service 120 TROUBLESHOOTING Contact your Polaris dealer for service if you re unable to identify so
62. ilter Air Filter Air Box Inspect and clean or replace the pre cleaner and air filter Clean the air box and drain the sediment tube Breather Filter Inspect and clean or replace the breather filter Fluid Levels Inspect the following fluid levels and change if necessary front gearcase transmission brake fluid change every two years or as required if fluid looks dark or contaminated Drain the Recoil Housing Remove the recoil housing drain plug and drain any moisture 114 MAINTENANCE AND LUBRICATION Cleaning and Storage Storage Tips See page 119 for the part numbers of Polaris products Fog the Engine Remove the spark plug and add 2 3 tablespoons of Premium 4 Synthetic 0W40 engine oil To access the plug hole use a section of clear 1 4 hose and a small plastic squeeze bottle filled with the pre measured amount of oil NOTE Do this carefully If you miss the plug hole oil will drain from the spark plug cavity into the hole at the front of the cylinder head and appear to be an oil leak Install the spark plug and pull the engine over slowly with the recoil starter Oil will be forced in and around the piston rings and ring lands coating the cylinder with a protective film of fresh oil If you choose not to use Polaris Fogging Oil perform the following procedure 1 Support the front end of the machine so the engine is level or tilted slightly rearward 2 Remove the spark plug s Rotate the piston to B
63. in engine damage Always replace the oil and filter within a few hours of draining the oil Do not allow the vehicle to be without oil overnight Obtain the correct oil filter and an adequate supply of oil so the oil and filter change can be completed without interruption Position the vehicle on a level surface Clean the area around the drain plug on the bottom of the engine crankcase Run the engine for two to three minutes until warm Stop the engine 4 CAUTION 5 6 he Contact with hot oil may result in serious burns Do not allow hot oil to come into contact with skin Place a drain pan beneath the engine crankcase and remove the drain plug Allow the oil to drain completely Install a new sealing washer on the drain plug NOTE The sealing surfaces on the drain plug and crankcase should be clean and free of burrs nicks or scratches 83 MAINTENANCE AND LUBRICATION Lubrication Recommendations Engine Oil Oil and Filter Change ATP 330 8 9 10 11 12 13 14 15 16 17 84 Reinstall the drain plug Torque to 14 ft lbs 19 Nm Place shop towels beneath the oil filter Using an oil filter wrench turn the filter counterclockwise to remove Using a clean dry cloth clean the filter sealing surface on the crankcase Lubricate the gasket on the new filter with a film of engine oil Check to make sure the gasket is in good condition Install the new filter and turn by hand un
64. increases the expanding heated excess coolant is forced out of the radiator past the pressure cap and into the recovery bottle As engine coolant temperature decreases the contracting cooled coolant is drawn back up from the tank past the pressure cap and into the radiator NOTE Some coolant level drop on new machines is normal as the system is purging itself of trapped air Observe coolant levels and maintain as recommended by adding coolant to the recovery bottle Coolant ATP 500 To ensure that the coolant maintains its ability to protect the engine we recommend that the system be completely drained every two years and a fresh mixture of antifreeze and water added Polaris recommends the use of Polaris Premium 60 40 anti freeze coolant or a 50 50 mixture of high quality aluminum compatible anti freeze coolant and distilled water Polaris Premium 60 40 is already premixed and ready to use Do not dilute with water See page 119 for the part numbers of Polaris products NOTE Always follow the manufacturer s mixing recommendations for the freeze protection required in your area Any time the cooling system has been drained for maintenance or repair replace the coolant If the recovery bottle has run dry the level in the radiator should be inspected Add coolant as needed 88 MAINTENANCE AND LUBRICATION Engine Cooling System Coolant Level ATP 500 The recovery bottle 1 is located on the left side of the machine
65. ine Starting a Cold Engine 4 amp WARNING Engine exhaust contains poisonous carbon monoxide and can cause loss of consciousness resulting in severe injury or death Never run an engine in an enclosed area CAUTION Operating the vehicle immediately after starting could cause engine damage Allow the engine to warm up for several minutes before operating the vehicle 1 Place the transmission in park and lock the parking brake 2 Turn the fuel tank valve on we Sit on the vehicle 4 Pull the choke knob out until it stops 1 NOTE The variable choke is fully on when the knob is pulled completely out The choke is off when the knob is pushed completely in The choke can be adjusted gradually depending on how much choke is needed for starting Be sure the choke is off during operation as excess fuel washing into the engine oil will increase wear on engine components 5 Turn the engine stop switch to RUN NOTE Do not press the throttle while starting the engine 6 Turn the ignition key past the ON position to engage the starter Activate the starter for a maximum of five seconds releasing the key when the vehicle starts If the engine does not start release the starter and wait five seconds Then activate the starter for another five seconds Repeat this procedure until the engine starts 7 Ifthe engine slows or stops position the choke knob half way in to allow proper engine warm up 8 Vary the engine R
66. ion may adversely affect vehicle maneuverability and cause loss of control resulting in serious injury or death Maintain proper tire pressure as outlined in this owner s manual When replacing a tire always use original equipment size and type 1 8 3 cm 100 MAINTENANCE AND LUBRICATION Filter Systems Air Filter 1 Remove the seat release the 1 clips and remove the air 2 box cover O Loosen the clamp and remove the filter Remove the fabric type pre filter 1 from the main filter 2 Wash the pre filter in soapy water then rinse and let dry Reinstall the pre filter over the main filter Replace the main filter if necessary Reinstall the filter into the air box and tighten the clamp Do not over tighten the clamp as filter damage could occur Breather Filter Hose ATP 500 1 NOTE It s not necessary to remove the 2 3 4 CAUTION Operation of your vehicle without a breather filter can cause engine damage Always reinstall the breather filter after removing for service Remove the clamps and pull the filter 1 out of the hoses lower hose from the engine Inspect the filter for debris Blow gently through the filter in the direction of the arrow to check for clogging Replace if needed Check the hoses for cracks deterioration abrasion or leaks Replace as needed Reinstall the filter and secure the clamps NOTE The filter is effective with the arrow poi
67. ith a loaded ve hicle Avoid terrain or situations that may require backing down hill e Always attach the tow load to the hitch point e The vehicle should never exceed 10 mph 16 kph while towing a load on a level surface Vehicle speed should never exceed 5 mph 8 kph when towing loads in rough terrain while cornering or while ascending or descending a hill e Do not obstruct the headlight when loading the front rack 55 OPERATION Hauling Cargo Load Distribution aN Sp ay E gt rar S oA eo y EL Your ATV has been designed to carry or tow a certain amount of load Always read and understand the load distribution warnings listed on the warning labels and never exceed the specified weights Cargo weight should be mounted as low as possible When operating over rough or hilly terrain reduce speed and cargo to maintain stable driving conditions 1 Always load the cargo box with the load as far forward as possible 2 Always operate the vehicle with extreme caution whenever hauling or towing loads Balance handling and control may be affected 3 Slow down 4 The cargo box dump latch must be securely latched before loading and operating Unintentional box tilting will result if weight is placed in the rear of the box and the latch is not secured Maximum Towing Capacities Do not exceed the following maximum capacities when towing Maximum grade while trailer towing is 15
68. ition the ATV is in AWD and the differential is locked When in AWD the front gearcase will automatically engage any time the rear wheels lose traction When the rear wheels regain traction the front gearcase will automatically disengage There is no limit to the length of time the vehicle may remain in AWD NOTE The override switch allows activation of AWD in reverse if the AWD switch is on See page 33 When the switch is on TURF right position the differential is open allowing the inside wheel to rotate independently from the outside wheel during turns Operate your Polaris ATP in TURF mode only to protect smooth level surfaces from tire damage Otherwise switch out of TURF mode 4 amp WARNING Operating in TURF mode when on sloped uneven or loose terrain could cause loss of control and result in serious injury or death One rear wheel may slip and lose traction or may lift up and grab when it touches the ground again Do NOT operate in TURF mode when climbing or descending hills when sidehilling or when operating on uneven loose or slippery terrain conditions such as sand gravel ice snow obstacles and water crossings Simply switch the All Wheel Drive AWD system out of TURF mode whenever it is not required 44 FEATURES AND CONTROLS All Wheel Drive AWD System Engaging the Front Gearcase The AWD switch may be turned on or off while the vehicle is moving Initially the vehicle s electro
69. l system and an unexpected engine shut down during operation This could result in serious injury or goa Do not attach a large key fob or key ring to the main switch 33 FEATURES AND CONTROLS Electrical Switches Engine Stop Switch 3 The engine will not start or run when the switch is in the OFF OFF RUN OFF position Its purpose is to provide the operator with a quick means of engine La shutdown in case of an emergency To stop 4 the engine slide the stop switch either right or left to the OFF position NOTE Turning off the engine stop switch will shut off all electrical power to the vehicle with the exception of the cooling fan on some models On those models use the main switch to shut off the power to the cooling fan ae gt OY 4 Light Switches The light switch is located on the left handlebar 1 It s used to turn the lights on and off and to switch the lights from HI to LO on models equipped with HI LO beams NOTE The lights won t work unless the key is in the ON position and the shut off switch is in the RUN position 4 amp WARNING Operating the ATV on streets or roads especially in darkness could result in an accident and serious injury or death Your ATV is not equipped with highway approved lights It s designed for and must be used for off road use only Use caution and drive at reduced speeds in conditions of reduced visibility such as fog rain and darkness 34
70. lacement and or adjustment of the component parts listed below Emission Related Parts Covered Under This Warranty 1 Fuel Metering System i Carburetor and internal parts and or pressure regulator or fuel injection system ii Air fuel ratio feedback and control system if applicable iii Cold start enrichment system if applicable iv Regulator assy gaseous fuel if applicable 2 Air Induction System i Intake manifold if applicable ii Air filter 3 Ignition System i Spark plugs ii Magneto or electronic ignition system iii Spark advance retard system if applicable 4 Exhaust manifold if applicable 5 Miscellaneous Items Used in Above Systems i Electronic controls if applicable ii Hoses belts connectors and assemblies iii Filter lock assy gaseous fuel if applicable If an authorized dealer determines that other LSI engine components have been damaged due to the failure of a warranted emission related part during the warranty period POLARIS will repair and or replace the necessary components 132 WARRANTY California Emission Control Warranty Statement What is Not Covered Under This Warranty This warranty does not cover any emission related part which malfunctions fails or is damaged due to alterations and or modifications such as changing adding or removing parts When the LSI engine is being serviced under warranty POLARIS and any of its authorized dealers shall not be liable for a
71. laris at 1 800 342 3764 WARNING POTENTIAL HAZARD Failure to follow the age recommendations for this ATV WHAT CAN HAPPEN Severe injury and or death could occur if a child under the minimum age recommendation operates an ATV Even though a child may be within the recommended age group for operating some ATVs he she may not have the skills abilities or judgment needed to operate an ATV safely and could be susceptible to accident or injury HOW TO AVOID THE HAZARD No one under the age of 16 should operate a Polaris ATV Operator Safety 4 amp WARNING POTENTIAL HAZARD Carrying a passenger on an ATV WHAT CAN HAPPEN Carrying a passenger greatly reduces the operator s ability to balance and control the ATV which could cause an accident and injury to the operator and or passenger HOW TO AVOID THE HAZARD Never carry a passenger The purpose of the long seat is to allow the operator to shift position as needed during operation It is not intended for carrying passengers amp WARNING POTENTIAL HAZARD Carrying a passenger in the cargo box WHAT CAN HAPPEN A passenger riding in the cargo box could be ejected from the vehicle unexpectedly or may contact moving components both of which can result in severe injury or death HOW TO AVOID THE HAZARD Never allow passengers to ride in the cargo box 13 SAFETY Operator Safety 4 amp WARNING 14 POTENTIAL HAZARD Operating an ATV on paved surfa
72. lix spring adjustment 127 WARRANTY LIMITED WARRANTY Polaris Industries Inc 2100 Highway 55 Medina MN 55340 gives a SIX MONTH LIM ITED WARRANTY on all components of the Polaris All Terrain Vehicle ATV against de fects 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 war ranty period through a Polaris dealer REGISTRATION At the time of sale the Warranty Registration Form must be completed by your dealer and submitted to Polaris within ten days Upon receipt of this registration Polaris will record the registration for warranty THE PURCHASER MUST COMPLETEAN ATV SAFETY TRAINING COURSE PROVIDED BY THE DEALER IN ORDER TO HAVE VALID WARRANTY ON THE ATV No verification of registration will be sent to the purchaser as the copy of the Warranty Registration Form will be the warranty entitlement If you have not signed the original registration and received the customer copy please contact your dealer immediately NO WARRANTY COVERAGE WILL BE ALLOWED UNLESS YOUR ATV IS REGISTERED WITH POLARIS Initial dealer preparation and set up of your ATV is very important in ensuring trouble free operation Purchasing a machine in the crate or without proper dealer set up will void your warranty coverage LIMITATIONS OF WAR
73. luid is hygroscopic meaning it rapidly absorbs moisture from the air The moisture causes the boiling temperature of the brake fluid to drop which can lead to early brake fade and the possibility of accident or severe injury After opening a bottle of brake fluid always discard any unused portion 37 FEATURES AND CONTROLS Parking Brake 4 amp WARNING Operating the ATV 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 1 Squeeze and release the brake lever 1 two or three times then squeeze and hold at full stroke Push the park brake lock 2 forward to engage the brake Release the brake lever To release the parking brake lock squeeze and release the brake lever It will return to its unlocked position Important Safeguards Always place the gear shifter in park before engaging the parking brake The parking brake may relax if left on for a long period of time Al ways block the wheels to prevent rolling Never depend on the parking brake alone if the ATV is parked on a hill Always block the wheels on the downhill side of the ATV to prevent rolling Another option is to park the ATV in a sidehill posi tion 38 FEATURES AND CONTROLS Auxiliary Brake 4 amp WARNING Aggressively applying the rear brake when backing down a hill may cause rear tipover which c
74. lutions using the following charts Engine Doesn t Turn Over Possible Cause Solution Tripped circuit breaker Reset the breaker Low battery voltage Recharge battery to 12 5 VDC Loose solenoid connections Check all connections and tighten Engine Turns Over Fails to Start Possible Cause Solution Turn fuel valve to reserve refuel Mechanical failure Engine Pings or Knocks Possible Cause Solution Poor quality or low octane fuel Replace with recommended fuel Incorrect ignition timing See your Polaris dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs 121 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 Mechanical failure Engine Runs Irregularly Stalls or Misfires Possible Weak Spark Cause Solution Other mechanical failure Possible Lean Fuel Mixture Cause Solution Possible Rich Fuel Mixture Cause Solution 122 Kinked or plugged fuel vent line Inspect and replace TROUBLESHOOTING Engine Stops or Loses Power Possible Cause Solution Kinked or plugged fuel vent line Water present in fuel Overuse of choke Fouled or defective spark plugs Worn or defective spark plug wires Incorrect spark plug gap or heat range Loose ignition connections Low battery voltage Clogged air filter Reverse speed limiter malfunc
75. lways refill the gas tank as soon as possible after using the reserve supply Always return valve to the ON position after refueling Fuel Tank The fuel tank filler cap 2 is located directly below the handlebar Use either leaded or unleaded gasoline with a minimum pump octane number of 87 R M 2 octane Fuel Filter Have your dealer change the in line fuel filter after every 100 hours of operation or annually Do not attempt to clean the fuel filter 40 FEATURES AND CONTROLS Fuel Safety 4 amp WARNING Gasoline is highly flammable and explosive under certain conditions e Always exercise extreme caution whenever handling gasoline e Always refuel with the engine stopped and outdoors or in a well ventilated area e Never fill a gas container while it s in the cargo box Static elec tricity between the box and container could cause a spark e Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored e Do not overfill the tank Do not fill the tank neck e If gasoline spills on your skin or clothing immediately wash it off with soap and water and change clothing e Never start the engine or let it run in an enclosed area Engine exhaust fumes are poisonous and can cause loss of conscious ness or death in a short time e Turn the fuel valve off whenever the ATV is stored or parked 4 WARNING The engine exhaust from this product contains
76. m 100 H 620 1000 Check for leaks at tank cap lines fuel valve filter pump carburetor replace lines every two years Fuel filter 100 H 620 1000 Replace yearly H Spark plug 100 H 620 1000 Inspect replace as needed 134 1M 12M 12M 12M 12M 12M 2M WARRANTY California Emission Control Warranty Statement Repair and Replacement of Emission Related Parts It is recommended that only LSI engine replacement parts which have been authorized and approved by POLARIS should be used in the performance of any warranty maintenance or repairs of emission related parts These replacement parts will be provided at no charge if the part is still under warranty How to File a Warranty Claim Where to Get Warranty Service All repairs qualifying under this Limited Warranty must be performed by a dealer who sold you the LSI engine or a dealer authorized by POLARIS In the event that any emission related part is found to be defective during the warranty period you must notify the Polaris Warranty Department at 1 763 417 8650 and you will be advised of the appropriate dealer where the warranty repair is to be performed 135 INDEX A ACCESS OFICS 30 S35 ahane Asa EAA 73 Adjustments 90 100 Age Restrictions 0 7 Air Filtet se ereere a seks hg p Singe 101 All Wheel Drive 44 45 Auxiliary Brake 39 91 DAW Dis rose ice aon ed eae do eco Dies 44 45 B Battery 256
77. miles per hour Vehicles subjected to severe use must be inspected and serviced more frequently Severe Use Definition e Frequent immersion in mud water or sand e Racing or race style high RPM use e Prolonged low speed heavy load operation e Extended idle e Short trip cold weather operation Pay special attention to the oil level A rise in oil level during cold weather can indicate contaminants collecting in the oil sump or crankcase Change oil immediately if the oil level begins to rise Monitor the oil level and if it continues to rise discontinue use and determine the cause or see your dealer Maintenance Chart Key p Perform these procedures more frequently for vehicles subjected to severe use E Emission Control System Service California m Have an authorized Polaris dealer perform these services 4 amp WARNING Improperly performing the procedures marked with a m could result in component failure and lead to serious injury or death Have an authorized Polaris dealer perform these services 73 MAINTENANCE AND LUBRICATION Periodic Maintenance Chart Perform all services at whichever maintenance interval is reached first Maintenance Interval whichever comes first Calendar Miles Km Pre Ride ie a Make adjustments as need Farner a A cro eee i Dp Brake furdtevel_ Pre Ride fp Brake overtavel Pre Ride Brake systems Pre Ride Whesisfesteners Pre Ride Frame faatenere
78. mly secured to the rack For stability on rough or hilly terrain reduce speed and cargo Do not block head light Be careful if load extends over the side of the rack or box Read Owner s Manual for more detailed loading information ATP 330 7172568 F 4 WARNING IMPROPER TIRE PRESSURE OR OVERLOADING can cause loss of control resulting in SEVERE INJURY OR DEATH 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 1500 LBS 680 kg Reduce speed and allow greater distance for braking when carrying cargo Overloading or carrying tall off center or unsecured loads will increase your risk of losing control Loads should be centered carried as low as possible in box and firmly secured to the rack For stability on rough or hilly terrain reduce speed and cargo Do not block head light Be careful if load extends over the side of the rack or box Read Owner s Manual for more detailed loading information ATP 500 7172574 F 4 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 combined Front Rack and container Load 90 Ibs 41 kg 7172569 SAFETY Safety Decals and Locations AWARNING e Moving parts hazard under belt clutch guard To prevent serious injury do not operate vehicle with guard removed Do not modify engine or cl
79. ng in loss of control and possible serious personal injury or death Follow the adjustment procedures exactly or see your Polaris dealer for service 1 Remove the instrument panel and locate 1 the handlebar bolts 1 8 2 Loosen the four bolts and adjust the handlebar to the desired height Be oF sure the handlebars do not contact the gas tank or any other part of the machine when turned fully to the left Ce or right 3 Torque the front two bolts to 10 12 ft Ibs 14 17 Nm then torque the rear two bolts A gap of up to 1 8 will remain at the rear bolts 94 MAINTENANCE AND LUBRICATION Adjustments Carburetor Your Polaris ATV is calibrated at the factory for optimal performance at altitudes ranging from zero to 6 000 feet 1800 m and temperatures of 40 degrees F 4 degrees C or higher Above 6000 feet 1800 m the engine air fuel mixture becomes overly rich and the engine loses approximately 3 of its power for each 1000 foot 304 8 m increase in elevation Although this power cannot be regained adjustments to the carburetor and drive system can be made to allow more efficient operation Optional jets available from your Polaris dealer are required for operation above 6 000 feet and temperatures below 40 degrees F 4 degrees C NOTE Continuous operation of the engine without proper jetting when required can cause poor performance overheating or engine damage See your Polaris dealer for more information a
80. nic system will not enable the AWD until the engine RPM is below 3100 Once enabled the AWD remains enabled until the AWD switch is turned off If the switch is turned off while the front gearcase is moving it will not disengage until the rear wheels regain traction Engage the AWD switch before getting into conditions where front wheel drive may be needed If the rear wheels are spinning release the throttle before switching to AWD CAUTION Switching to AWD or from TURF to 2X4 while the rear wheels are spinning may cause severe drive shaft and gearcase damage Always switch to AWD or to TURF from 2X4 while the rear wheels have traction or are at rest 45 FEATURES AND CONTROLS Instrument Cluster Your ATV is equipped with an instrument cluster that senses vehicle speed from the right front wheel The instrument cluster measures distance in miles as well as hours of operation It also includes a reverse speed limiter function that limits the ATV s speed to approximately 7 9 mph Refer to page 33 for additional information P amp SLARIS 1 Rider Information Center Speedometer needle in addition to showing vehicle speed the needle flashes when a warning condition exists 3 Speedometer CAUTION To prevent damage wash the ATV by hand or with a garden hose using mild soap Do not use alcohol to clean the instrument cluster Immediately clean off any gasoline that splashes on the instrument cluster 46 FEATU
81. not per mit the exclusion or limitation of incidental or consequential damages or implied warranties so the above limitations or exclusions may not apply to you if inconsistent with controlling state law 128 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 SIX MONTH WARRAN TY PERIOD POLARIS FURTHER DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY Some states do not allow limitations on how long an im plied warranty lasts so the above limitation may not apply to you if inconsistent with con trolling state law HOW TO OBTAIN WARRANTY SERVICE If your ATV requires warranty service you must take it to a Polaris dealer authorized to re pair Polaris ATVs When requesting warranty service you must present your copy of the Warranty Registration form to the dealer THE COST OF TRANSPORTATION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY Polaris suggests that you use your original selling dealer however you may use any Polaris Servicing Dealer to perform war ranty service Please work with your dealer to resolve any warranty issues Should your dealer require any additional assistance they will contact the appropriate personnel at Polaris This warranty gives you specific legal rights and you may also have other rights which vary from state to state
82. nting in either direction 101 MAINTENANCE AND LUBRICATION Lights When servicing a halogen lamp don t touch the lamp with bare fingers Oil from your skin leaves a residue causing a hot spot that will shorten the life of the lamp 4 amp WARNING Poor lighting while driving can result in severe injury or death Headlight and taillight lenses become dirty during normal operation Wash the headlights frequently to maintain lighting quality Hot components can cause serious burns to skin Do not service the headlamps until they ve cooled sufficiently Headlight Lamp Replacement ATP 500 1 Remove the three screws on the headlight pod 2 Using a small flat blade screwdriver push in on the lock tabs through the two small openings at the front of the headlight pod 3 Lift the pod slightly while depressing the tabs 4 Lift the pod cover and disconnect the speedometer harnesses from the speedometer Unplug the indicator light harness and remove the pod cover 5 Unplug the headlamp from the wiring harness Be sure to pull on the connector not on the wiring 6 Grasp the bulb housing and turn counterclockwise to remove lamp 7 Apply dielectric grease to the light bulb socket before installing the new bulb 8 Reverse the previous steps to replace the lamp and reassemble the pod 102 MAINTENANCE AND LUBRICATION Lights Lower Headlight Lamp pep OLEME 1 Turn the back of the headlight harness in a counte
83. ny loss of use of the LSI engine for any damage to goods or loss of time or inconvenience This limited warranty also does not apply to any emission related part which malfunctions fails or is damaged due to failure to follow the maintenance and operating instructions specified in the 2004 and later Owner s Manual including a Improper or inadequate maintenance of any warranted emission related part b Improper installation adjustment or repair of the LSI engine or any warranted emission related part unless performed by an authorized dealer c Failure to use recommended fuel as specified in the 2004 and later Owner s Manual d Repairs and diagnosis performed outside of an authorized dealer e Use of parts which are not authorized by POLARIS Maintenance Schedule The LSI engine owner is responsible for having all scheduled inspection and maintenance services performed at the intervals specified in the 2004 and later Owner s Manual and to retain records of these services as having been performed These records should be transferred to each subsequent owner of the LSI engine POLARIS cannot deny a claim solely because there are no records of scheduled maintenance however a warranty claim may be denied if the failure to perform the scheduled maintenance and inspection resulted in the failure of a warranted emission related part As a minimum the LSI engine owner is responsible for the scheduled inspection and maintenance describ
84. octite PST 505 or PTFE seal tape The fitting must also line up with the mark 4 on the rear side of the oil tank 8 Place shop towels beneath the oil filter Using an oil filter wrench turn the filter 1 counterclockwise and remove 9 Lubricate the gasket on the new filter with a film of new engine oil Check to make sure the gasket is in good condition Also make sure the gasket from the old filter is not still on the engine 10 Install the new filter and tighten by hand 1 2 to 3 4 turn after gasket contacts the engine 81 MAINTENANCE AND LUBRICATION Lubrication Recommendations Engine Oil Oil and Filter Change ATP 500 11 Approximately one cup of engine oil will remain in the crankcase To drain remove the drain plug on the lower right side of the crankcase NOTE The sealing surfaces on the drain plug and crankcase should be clean and free of burrs nicks or scratches 12 After draining reinstall the drain plug 13 Remove the dipstick 2 and add ts on ee two quarts 1 9 1 of Polaris Premium 4 synthetic oil Reinstall the dipstick NOTE Ifthe sump is not drained add about 1 3 4 quarts 1 6 I initially 14 Place the gear selector in park and set the parking brake 15 Prime the oil pump using the procedure below Then stop the engine and inspect for leaks 16 Re check the oil level on the dipstick and add oil as necessary to bring the level to the upper full mark on the
85. of control e Avoid operating the ATV through deep or fast flowing water If it s unavoidable travel slowly balance your weight carefully avoid sud den movements and maintain a slow and steady forward motion Do not make sudden turns or stops and do not make sudden throttle changes 10 SAFETY Operator Safety e Wet brakes may have reduced stopping ability Test your brakes after leaving water If necessary apply them lightly several times to allow friction to dry out the pads e Always check for obstacles or people behind the ATV before operat ing in reverse When it s safe to proceed in reverse move slowly and avoid turning at sharp angles e Always use the size and type of tires specified for your ATV and always maintain proper tire pressure e Never modify an ATV through improper installation or use of acces sories e Never exceed the stated load capacity for your ATV 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 e Always remove the ignition key when the vehicle is not in use to prevent unauthorized use or accidental starting FOR MORE INFORMATION ABOUT ATV SAFETY call the Con sumer Product Safety Commission at 1 800 638 2772 or call Polaris at 1 800 342 3764 Equipment Modifications We are concerned for the safety of our customers and for the general public Therefore we
86. om the locking tabs Lift the adjusting knob up to remove from the locking tabs 13 cm Carefully pull the assembly up and out of pod Reverse the steps to install the new housing and reassemble the pod TE The distance from the headlamp parting line to the end of the adjustment knob stop is 5 1 8 13 cm See illustration Adjust the headlight aim by turning the adjusting knob MAINTENANCE AND LUBRICATION Lights High Beam Adjustment The headlight beam can be adjusted to any position desired by turning the adjusting knob on the bottom right side of the headlight pod 1 Position the vehicle on a level surface with the headlight approximately 25 ft 7 6 m from a wall 2 Remove the two screws on the lower front corners of the headlight pod 3 Using a small flat blade screwdriver push in on the lock tab through the two small openings at the front of the headlight pod 4 Lift the pod slightly while depressing the tabs 5 Remove the screw in the back of the headlight pod 6 Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height 7 Start the engine and turn the headlight switch to high beam 8 Observe the headlight aim on the wall The most intense part of the headlight beam should be aimed two inches 5 1 cm below the mark placed on the wall NOTE Include rider weight on the seat when measuring 9 Adjust the beam to the desired position by t
87. ould result in serious injury or death If the rear brake is applied aggressively while moving forward the rear wheels may skid and slide sideways causing loss of control and serious injury or death Always use caution when applying the auxiliary foot brake Do not apply the auxiliary foot brake aggressively The auxiliary foot brake 1 is located on the inside of the right floor board and is operated by the right foot The auxiliary LEZ Se 7 brake serves as a backup to the ot ABs main brake system if the main Boe E system becomes inoperative It pam activates the rear brakes only N ee eles 1 If the rear wheels slide while using the auxiliary brake reduce brake pedal pressure to brake the rear wheels without skidding Check the brake fluid level frequently for the auxiliary brake system The reservoir is located under the seat or near the foot brake Maintain the fluid level between the maximum and minimum marks 39 FEATURES AND CONTROLS Choke The choke assists in starting a cold engine Refer to the engine starting procedure on page 53 for correct choke and throttle settings during starting Fuel Valve The fuel valve 1 is located on the left side RES panel It has three positions OFF For vehicle storage and when transporting OFF ON For normal operation RES For reserve supply if main ON supply is exhausted NOTE There s about a 7 to 10 mile 11 2 to 16 km range on reserve gas A
88. peeds Travel at speeds appropriate for the terrain visibility and operating conditions and your experience e Never attempt wheelies jumps or other stunts e Always inspect your ATV before each use to make sure it s in safe operating condition Always follow the inspection and maintenance procedures and schedules outlined in your owner s manual e Always keep both hands on the handlebars and both feet on the foot rests of the ATV during operation e Always travel slowly and use extra caution when operating on unfa miliar terrain Be alert to changing terrain conditions e Never operate on excessively rough slippery or loose terrain e Always follow proper turning procedures as described in this manu al Practice turning at low speeds before attempting to turn at faster speeds Do not turn at excessive speeds SAFETY Operator Safety e Always have the ATV inspected by an authorized Polaris dealer if it s been involved in an accident e Never operate on hills too steep for the ATV or for your abilities Practice on smaller hills before attempting larger hills e Always follow proper procedures for climbing hills Check the ter rain carefully before ascend a hill Never climb hills with excessive ly slippery or loose surfaces Shift your weight forward Never open the throttle suddenly or make sudden gear changes Never go over the top of a hill at high speed e Always follow proper procedures for going downhill and for
89. r clockwise direction to loosen A 2 Pull the harness assembly out from the headlight assembly 3 Remove the headlamp and replace with a new headlamp 4 Install the new headlamp and harness assembly into the headlight assembly Turn the headlight harness clockwise B to secure Lower Headlight Adjustment 1 Loosen the nuts C that secure the lower headlamps Adjust the headlamps as needed 2 Tighten the nuts on the headlamps after adjustment is made Taillight Brakelight Lamp Replacement If the taillight brakelight does not work the lamp may need to be replaced Remove the two screws securing the lens assembly Pivot the assembly outward Turn the housing clockwise and remove the bulb Apply dielectric grease to the socket and install a new bulb Reinstall the taillight assembly OY Re 103 MAINTENANCE AND LUBRICATION Lights Headlight Housing Replacement 1 2 NO 10 104 Remove the three screws on the headlight pod Using a small flat blade screwdriver push in on the lock tabs through the two small openings at the front of the headlight pod Lift the pod lightly while depressing the tabs Lift the pod cover Disconnect the speedometer harnesses from the 1 speedometer Unplug the indicator light harness and remove the pod cover Unplug the headlamp from the wiring harness Remove the o ring 1 from the headlight pivot pins F Pull the headlight housing up to release fr
90. reak in period change both the oil and the filter at 25 hours or one month 51 OPERATION Pre Ride Inspection 4 amp WARNING If a proper inspection is not done before each use severe injury or death could result Always inspect the vehicle before each use to ensure it s in proper operating condition Pre Ride Checklist Brake system lever travel Brake fluid Auxiliary brake Ensure proper operation Ensure proper level Ensure proper operation Inspect lubricate if necessary Inspect lubricate if necessary Front suspension Rear suspension oo Isie 0 Y SIs ol 3 2 _ Steering Tires Ensure free operation Inspect condition and pressure Wheels fasteners nspect ensure fastener tightness Frame nuts bolts fasteners Inspect ensure tightness Fuel and oil Ensure proper levels Coolant level ATP 500 Ensure proper level Coolant hoses ATP 500 Inspect for leaks Throttle Indicator lights switches Engine stop switch Air filter pre tfilter Air box sediment tube Headlamp Ensure proper operation Ensure operation ee ee Ensure proper operation Inspect clean Drain deposits whenever visible Check operation apply Polaris dielec 102 tric grease when lamp is replaced Check operation apply Polaris dielec 103 tric grease when lamp is replaced Wear helmet goggles protective clothing Brake light tail lamp Riding gear ie N 52 OPERATION Starting the Eng
91. rough tall grass especially dry grass 27 SAFETY Safety Decals and Locations Warning decals have been placed on the ATV 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 28 SAFETY Safety Decals and Locations 4 amp WARNING A WARNING Never operate this ATV on HILLS steeper than 25 degrees L25 To prevent flipover on hilly terrain when going up or down use throttle and brakes gradually REVERSE operation can be dangerous even at low speeds Steering becomes difficult To prevent flipover avoid sudden braking or sharp turns Use OVERRIDE for reverse speed limiter with caution To prevent Operating this ATV if you are under loss of control never activate override button with open throttle the age of 16 increases your chance of severe injury or death When this ATV is not in operation or unattended place shift in the ae NEVER operate this ATV if you are park position 7172561 under age 16 7172559 4 WARNING Improper ATV use can result in SEVERE INJURY or DEATH DOG ALWAYS USE NEVER USE NEVER CARRY NEVER USE AN APPROVED ON PUBLIC PASSENGERS WITH DRUGS HELMET AND ROADS OR ALCOHOL PROTECTIVE GEAR NEVER operate without proper training or instruction at speeds
92. rrying or towing cargo improperly can alter vehicle handling and may cause loss of control or brake instability Always follow these precautions when hauling cargo e Never exceed the stated load capacity for this vehicle e Reduce speed and allow a greater distance for braking e When operating over rough or hilly terrain reduce speed and cargo to maintain stable driving conditions e WEIGHT DISTRIBUTION in the cargo bed should be as far for ward and as low as possible Carrying a high load raises the center of gravity and creates a less stable operating condition Reduce load weight when cargo is high When handling off centered loads that cannot be centered secure the load and operate with extra caution e ALL LOADS MUST BE SECURED BEFORE OPERATING Unsecured loads may shift and create unstable operating condi tions which could result in loss of control of the vehicle Always be sure that the cargo bed is lowered and latched before mov ing the vehicle e EXTREME CAUTION MUST BE USED when operating with loads extending beyond the rack or cargo bed Stability and maneuverability may be adversely affected causing the ma chine to overturn e Carrying a load on only the front rack or cargo bed may cause an imbalanced condition and increases the possibility of vehicle overturn Balance loads proportionally between the front rack and cargo bed but do not exceed the stated load capacity e Use extreme caution when applying brakes w
93. s when possible If unavoidable use extreme caution and always follow proper procedures as outlined in the owner s manual WARNING POTENTIAL HAZARD Skidding or sliding WHAT CAN HAPPEN Skidding or sliding can cause loss of control If the tires regain traction unexpectedly the ATV could overturn HOW TO AVOID THE HAZARD On slippery surfaces such as ice travel slowly and use extra caution to reduce the chance of skidding or sliding out of control WARNING POTENTIAL HAZARD Overloading the ATV or carrying towing cargo improperly WHAT CAN HAPPEN Overloading and towing can cause changes in vehicle handling which could lead to loss of control or an accident HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this ATV Cargo should be properly distributed and securely attached Reduce speed when carrying cargo or pulling a trailer Allowa greater distance for braking Always follow the instructions in the owner s manual for carrying cargo or pulling a trailer See page 56 SAFETY Operator Safety 4 amp WARNING POTENTIAL HAZARD Operating the ATV through deep or fast flowing water WHAT CAN HAPPEN Tires may float causing loss of traction and loss of control which could lead to an accident or overturn HOW TO AVOID THE HAZARD Avoid operating the ATV through deep or fast flowing water If it s unavoidable to enter water that exceeds the recommended maximum depth see page 65 travel slowly bal
94. sation and may promote corrosion and oxidation Transporting the ATV Follow these procedures when transporting the vehicle 1 Turn off the engine and remove the key to prevent loss during transporting Always place the transmission in park and lock the parking brake Turn the fuel valve off Be sure the fuel cap oil cap and seat are installed correctly Always tie the frame of the ATV to the transporting unit securely using suitable straps or rope Dy gee tS 116 MAINTENANCE AND LUBRICATION Cleaning and Storage Chrome Wheel Care if equipped Proper maintenance will protect chrome wheels from corrosion P bi ols 29 preserve wheel life and ensure a like new appearance for many years 1 Wash chrome rims frequently Use a mild detergent to remove any salt dirt mud or grime Never use abrasive cleaners on plated or painted surfaces Polish the clean chrome wheels periodically Use an automotive grade chrome polish Routinely and liberally apply a weather resistant wax to each polished chrome wheel Choose a product suitable for chrome finishes Read and follow the product labels and instructions Chrome wheels exposed to road salt or salt in the air in coastal areas are more susceptible to corrosion if not properly cleaned Clean chrome wheels more often if they re exposed to salt or other corrosive elements Removing Corrosion If light rust is found on the chrome finish use steel wool 0000 OTT
95. service interval mode is set with the hours when service is due the hours of actual engine operation are subtracted from the set hours until 0 is reached When the counter reaches 0 the wrench icon will flash quickly for 5 seconds each time the vehicle is started as a reminder that the periodic maintenance is due To set the hours press and hold the mode override button until the wrench icon flashes When it begins to flash release the button The setting will increase by one hour each time the button is pressed Pressing and holding the button will allow the numbers to escalate much faster When the desired time increment is displayed release the button and wait for the wrench to stop flashing When the wrench stops blinking your service hours are set NOTE If you scroll past the intended number hold the button down until the count turns over to 0 You can then reset the number If the service interval is enabled on your ATV and you wish to turn it off toggle to the service interval mode Press and hold the mode button for approximately 7 seconds until the word OFF appears in the Rider Information Center Screen 6 Miles Kilometers toggle The display in the tripmeter and odometer can be changed to display either kilometers or miles The current display mode will be shown as KM or MP To change hold in the mode button until the letters flash then press and release the button once When the display stops flashing the mode has been s
96. ssively rough slippery or loose terrain until you ve learned and practiced the skills necessary to control the ATV on such terrain Always use extra caution on rough slippery or loose terrain SAFETY Operator Safety 4 amp WARNING POTENTIAL HAZARD Turning improperly WHAT CAN HAPPEN Improper turns could cause loss of control and lead to a collision or overturn HOW TO AVOID THE HAZARD Always follow proper procedures for turning as described in the owner s manual Practice turning at slow speeds before attempting to turn at faster speeds Never turn at excessive speed 4 amp WARNING POTENTIAL HAZARD Operating on excessively steep hills WHAT CAN HAPPEN The vehicle may overturn HOW TO AVOID THE HAZARD Never operate on hills too steep for the ATV or for your abilities Never operate the ATV on hills steeper than 25 Practice on smaller hills before attempting large hills 19 SAFETY Operator Safety 4 amp WARNING 20 POTENTIAL HAZARD Climbing hills improperly WHAT CAN HAPPEN Improper hill climbing could cause loss of control or overturn X HOW TO AVOID THE HAZARD N Always follow proper procedures for climbing hills as described in the owner s manual Always check the terrain carefully before DARNOS ascending any hill be Never operate the ATV on hills steeper than 25 Never climb hills with excessively slippery or loose surfaces Shift your weight forward Never op
97. stalling a new battery make sure it s fully charged prior to its initial use Using a new battery that has not been fully charged can damage the battery and result in a shorter life It can also hinder vehicle performance Follow the battery charging instructions on page 111 1 DNV Bb 110 before installing the battery Ensure that the battery is fully charged Set the battery in the battery holder Connect and tighten the red positive cable first Connect and tighten the black negative cable last Reinstall the battery cover and attach the hold down strap Verify that cables are properly routed MAINTENANCE AND LUBRICATION Battery Battery Storage Whenever the vehicle is not used for a period of three months or more remove the battery from the vehicle ensure 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 Tender charger PN 2871076 or by charging about once a month to make up for normal self discharge Battery Tender can be left connected during the storage period and will automatically charge the battery if the voltage drops below a pre determined point Battery Charging The following battery charging instructions apply only to the installation of a sealed battery Read all instructions before proceeding with the inst
98. strongly recommend that consumers do not install on a Polaris ATV any equipment that may increase the speed or power of the vehicle or make any other modifications to the vehicle for these purposes Any modifications to the original equipment of the vehicle create a substantial safety hazard and increase the risk of bodily injury The warranty on your Polaris ATV 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 NOTE The addition of certain accessories including but not limited to mowers blades tires sprayers or large racks may change the handling characteristics of the vehicle Use only Polaris approved accessories and familiarize yourself with their function and effect on the vehicle 11 SAFETY Operator Safety 4 amp WARNING 12 POTENTIAL HAZARD Operating this ATV without proper instruction WHAT CAN HAPPEN The risk of an accident is greatly increased if the operator does not know how to operate the ATV properly in different situations and on different types of terrain HOW TO AVOID THE HAZARD Beginning and inexperienced operators should complete the certified training course offered by Polaris Operators should regularly practice the skills learned in the course and the operating techniques described in the owner s manual For more information about the training course contact an authorized ATV dealer or call Po
99. t 8 Mode Indicator 47 FEATURES AND CONTROLS Instrument Cluster Rider Information Center The rider information center has 4 standard modes Mode 1 Odometer Mode 2 Tripmeter Mode 3 Total Service Hours Mode 4 Tachometer The reverse override button on the left handlebar is also the mode button NOTE If using the mode button to program the rider information center or to toggle through the options the machine cannot be in reverse Mode 1 Odometer The odometer records the miles traveled by the ATV Mode 2 Trip Meter The trip meter records the miles traveled by the ATV on each trip if it s reset before each trip To reset the trip meter select the trip meter mode Press and hold the mode button override button until the total changes to 0 NOTE In the Rider Information Center the trip meter display contains a decimal point but the odometer displays without a decimal point Mode 3 Hour Meter This mode logs the total hours the engine has been in operation Mode 4 Tachometer The engine RPM is displayed digitally NOTE Small fluctuations in the RPM from day to day may be normal because of changes in humidity temperature and elevation 48 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode The diagnostic mode is for informational purposes only Please return your ATV to your dealer for all major repairs As long as the gauge is in the diagnostic mode
100. the fill hole We recommend the use of Polaris ATV Angle Drive Fluid See page 119 for the part numbers of Polaris products Oil Check 1 Position the ATV on a level surface 2 Remove the fill plug 1 5 3 View the oil level through the fill hole y 4 Add the recommended oil as needed 5 Reinstall the fill plug Torque to 40 ft Ibs 54 Nm Oil Change 1 Place a drain pan under the drain plug 2 2 Remove the drain plug 3 Drain the oil and dispose of properly 4 Clean the drain plug and inspect the o ring Install a new o ring if signs of tearing or fretting exist 5 Reinstall the drain plug Torque to 40 in Ibs 4 5 Nm 6 Remove the fill plug 7 Add 16 oz 473 ml of the recommended oil 8 Clean the fill plug and inspect the o ring Install a new o ring if it s worn or damaged 9 Reinstall the fill plug Torque to 40 ft Ibs 54 Nm 10 Check for leaks 87 MAINTENANCE AND LUBRICATION Engine Cooling System Oil Cooler ATP 330 The oil cooling system requires little maintenance other than to make sure the cooler is kept free of mud and debris Change the engine oil as recommended in the maintenance schedule Cooling System Operation ATP 500 The engine coolant level is controlled or maintained by the recovery system The recovery system components are the recovery bottle radiator filler neck radiator pressure cap and connecting hose As coolant operating temperature
101. the wrench icon will remain lit To leave the diagnostic mode either shift the machine out of neutral or turn the key switch off and on NOTE Any movement of the tires will also take the machine out of the diagnostic mode To enter the diagnostics mode 1 Turn the key switch off and wait 10 seconds 2 Set the parking brake and shift the transmission into neutral 3 Hold the mode reverse override button and turn the key switch on 4 Release the switch as soon as the display is activated The initial screen display refers to the software version installed in your ATV This information is displayed briefly Use the mode reverse override button to toggle through the diagnostic screens Screen 1 Battery voltage Screen 2 Tachometer Screen 3 AWD diagnostic This gauge indicates whether or not current is flowing through the AWD coil only on models with switchable AWD Screen 4 Gear circuit diagnostic This screen displays the resistance value in ohms being read at the gear switch input of the gauge 49 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode Screen 5 Programmable service interval The purpose of the programmable service interval is to provide the consumer and dealer with a convenient reminder for routine maintenance When your vehicle leaves the factory this feature is set at 50 hours You must enable the programmable service interval before it can be used Once the
102. til the filter gasket contacts the sealing surface then turn and additional 1 2 turn Remove the dipstick and fill the sump with 2 quarts 1 9 1 of Polaris Premium 4 synthetic oil Place the gear selector in park and set the parking brake Start the engine and let it idle for one to two minutes Stop the engine and inspect for leaks Recheck the oil level and add oil as necessary to bring the level to the upper mark on the dipstick Dispose of used filter and oil properly MAINTENANCE AND LUBRICATION Lubrication Recommendations Transmission Oil Always check and change the transmission oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 73 Maintain the oil level 1 5 8 from the top of the fill hole We recommend the use of Premium AGL Synthetic Gearcase Lubricant See page 119 for the part numbers of Polaris products Oil Check The transmission fill plug 1 is located on the right side of the machine behind the footwell 1 Position the ATV on a level surface 2 Remove the fill plug 1 3 Check the oil level 4 5 Add the recommended oil as needed Reinstall the fill plug Torque to 14 ft Ibs 19 Nm Oil Change The transmission drain plug 2 is located on the bottom left hand side of the machine behind the footwell 1 Remove the fill plug 2 Remove the transmission drain plug and drain the oil into an appropriate container Discard used oil properly 3 Cl
103. ting the ATV after consuming alcohol or drugs WHAT CAN HAPPEN Consumption of alcohol and or drugs could seriously affect operator judgment Reaction time may be slower and operator balance and perception could be affected Consuming alcohol and or drugs before or while operating an ATV could result in an accident causing severe injury or death HOW TO AVOID THE HAZARD Never consume alcohol or drugs before or while operating an ATV 15 SAFETY Operator Safety 4 amp WARNING POTENTIAL HAZARD Operating the ATV at excessive speeds WHAT CAN HAPPEN Excessive speed increases the operator s chance of losing control of the ATV which can result in an accident HOW TO AVOID THE HAZARD Always operate the ATV at a speed that s proper for the terrain visibility and operating conditions and your experience 4 amp WARNING POTENTIAL HAZARD Attempting wheelies jumps and other stunts WHAT CAN HAPPEN Attempting stunts increases the chance of an accident including an overturn HOW TO AVOID THE HAZARD Never attempt wheelies jumps or other stunts Avoid exhibition driving 16 SAFETY Operator Safety 4 amp WARNING POTENTIAL HAZARD Failure to inspect the ATV before operating Failure to properly maintain the ATV WHAT CAN HAPPEN Poor maintenance increases the possibility of an accident or equipment damage HOW TO AVOID THE HAZARD Always inspect your ATV before each use to make sure it s
104. tion Electronic throttle control malfunction Other mechanical failure Overheated engine Clean radiator screen and core if equipped Clean engine exterior See your Polaris dealer 123 SPECIFICATIONS ATP 330 4X4 Gross Vehicle Weight Fuel Capacity Towing Capacity Hitch Tongue Capacity Front Rack amp Compartment Capacity Rear Box Capacity Overall Length Overall Width Overall Height Wheelbase Ground Clearance Dry Weight Minimum Turning Radius Transmission Oil Capacity Front Gearcase Oil Capacity Rear Gearcase Oil Capacity Engine Oil Capacity Engine Displacement Bore x Stroke Pilot Jet Main Jet Needle Jet Jet Needle Pilot Screw Alternator Output Compression Ratio Starting System Carburetor Ignition System Ignition Timing Spark Plug Gap Lubrication System 124 tongue weight not to exceed 250 lbs 113 kg 48B48 3 3rd clip may vary for each ATV SPECIFICATIONS ATP 330 4X4 Shift Type Side Lever H L N R P Gear Reduction Low 11 57 1 Gear Reduction Reverse 6 84 1 Gear Reduction High 4 41 1 Tire Pressure Front Instrument Cluster Jetting ATP 330 Altitude AMBIENT Below 40 40 Fand above TEMPERATURE Below 5 C 5 C to amp above Meters 0 1800 127 5 Feet 0 6000 1800 3700 6000 12000 Clutching ATP 330 Altitude Drive Clutch Driven Spring Clutch Spring Meters 0 1800 Blue Gray Feet 0 6000 PN 5631356 PN 7042202 PN 7041782 5133701
105. tire wear and vehicle handling which can result in serious injury or death Always ensure that all nuts are torqued to specification Do not service axle nuts that have a cotter pin installed See your Polaris dealer Wheel Installation 1 Place the transmission in park and lock the parking brake 2 Place the wheel on the wheel hub with the valve stem toward the outside and rotation arrows on the tire pointing toward forward rotation 3 Install the wheel nuts and finger tighten 4 Lower the vehicle to the ground 5 Torque the nuts to specification Wheel Nut Torque Specifications Check the wheel nut torques occasionally and when they ve been loosened for maintenance service Front Wheel Nuts 27 ft lbs 37 Nm Rear Wheel Nuts 27 ft lbs 37 Nm 99 MAINTENANCE AND LUBRICATION Adjustments Front Wheel Hub Tightening Front wheel bearing tightness and spindle nut retention are critical component operations All service must be performed by your authorized Polaris dealer Tire Tread Depth Always replace tires when tread depth is worn to 1 8 3 cm or less See illustration 4 amp WARNING Operating the vehicle with worn tires will increase the possibility of skidding AN which could lead to loss of control and serious injury or death Always replace tires when the tread depth measures 1 8 3 cm or less 4 WARNING Use of non standard size or type of tires or improper tire inflat
106. 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 terrain and in turns avoid paved surfaces pavement may seriously affect handling and control LOCATE AND READ OWNER S MANUAL FOLLOW ALL INSTRUCTIONS AND WARNINGS IF OWNER S MANUAL IS MISSING CONTACT A POLARIS DEALER FOR A REPLACEMENT 1997 2000 7172560 A WARNING A WARNING Passengers can be thrown off This can cause serious injury or death e Never carry passengers 471466 Max Box Load 330 ATP 250 Ibs 113 kg Remove flammable material containers from box before filling A WARN ING Max Box Load 500 ATP 400 Ibs 4 8i Ka SAFETY Safety Decals and Locations 4 WARNING IMPROPER TIRE PRESSURE OR OVERLOADING can cause loss of control resulting in SEVERE INJURY OR DEATH 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 1300 LBS 590 kg MAXIMUM CARGO CAPACITY 350 LBS 158 kg Reduce speed and allow greater distance for braking when carrying cargo Overloading or carrying tall off center or unsecured loads will increase your risk of losing control Loads should be centered carried as low as possible in box and fir
107. ts Auxiliary Brake The auxiliary brake is a hydraulic disc brake The rear brake system is self adjusting and requires no maintenance other than periodic checks of the pads for wear Change the brake pads when they re worn to 3 64 1 cm Inspect the brake disc spline and pad wear surface for excessive wear Your vehicle s auxiliary brake system is intended to be used as a backup for the main brake system Should the main system fail the rear brake can be activated by depressing the foot pedal on the inside of the right footrest NOTE Since the auxiliary brake is a rear brake only it will not be as effective for braking as the all wheel single lever system 91 MAINTENANCE AND LUBRICATION Adjustments 4 amp WARNING Severe injury or death can result from improper toe alignment and adjustment Do not attempt to adjust tie rod alignment All tie rod adjustments should be performed by an authorized Polaris dealer Toe Alignment Use the following procedure to check the toe alignment of the vehicle The recommended toe alignment is 1 8 to 1 4 toe out 1 Set the handlebars in a straight ahead position od Oe gh ae oF e amp eo gt a NOTE The steering frog can pes O be used as an indicator ass of whether the aS ey RE handlebars are straight The frog should always point straight back from the steering post 2 Place stands 1 in front of the vehicle perpendicular to
108. ttery is weak and cannot start the engine use of the recoil starter 1 will allow vehicle operation until repairs can be made The recoil starter is located on the right side of the machine Polaris 4 cycle engines are equipped with automatic decompressors This makes recoil starting possible by allowing compression to leak at cranking speeds The decompressor senses when the engine is spinning fast enough to start and restores compression for starting 1 Position the vehicle on a level surface place the transmission in park and lock the parking brake see page 38 2 Grasp the recoil starter rope handle tightly and pull slightly until the starter mechanism engages 3 Pull the rope abruptly to start the engine CAUTION Extending the starter rope too far will cause damage to the recoil assembly Do not extend the starter rope so far that it stops If the starter rope handle is not seated properly water may enter the recoil housing and damage components Make sure the handle is fully seated on the recoil housing especially when traveling in wet areas 43 FEATURES AND CONTROLS All Wheel Drive AWD System Polaris 4 wheel drive ATVs are equipped with ique quipped with a unique ori AWD system activated by a z switch 1 on the right handlebar 1 When the switch is on 2X4 center position the ATV is in two wheel drive at all times and the differential is locked When the switch is on AWD left pos
109. ulator tip is black A damp oil film covers the firing end There may be a carbon layer over the entire nose Generally the electrodes are not worn General causes of fouling are excessive oil use of non recommended injection oil improper use of the choke or incorrect carburetion adjustments Spark Plug Removal and Replacement 1 Remove the spark plug cap 2 Using the special wrench provided in the tool pouch rotate the spark plug counterclockwise to remove 3 Reverse the procedure for spark plug installation Torque to 14 ft Ibs 19 Nm 106 MAINTENANCE AND LUBRICATION Vehicle Immersion CAUTION If your vehicle becomes immersed major engine damage can result if the machine is not thoroughly inspected Take the vehicle to your dealer before starting the engine If it s impossible to take your ATV to a dealer before starting it follow the steps outlined below 1 2 3 8 9 10 11 Move the ATV to dry land or at the very least to water below the foot rests Turn the fuel valve off Remove the spark plug Check the air box and drain if water is present Loosen the carburetor drain screw 1 Turn the engine over several times using the electric start Dry the spark plug and reinstall or replace it with a new plug Tighten the carburetor drain screw Turn the fuel valve on Attempt to start the engine If necessary repeat the drying procedure Take the ATV to your dealer
110. ur hand on top of the side panel behind the fuel tank With a quick and firm motion push down on the side panel to disengage the top rear two tabs Then pull up on the side panel to disengage the front upper and lower tabs To reinstall the side panel align the panel tabs with the slots on the front cab Push the panel upward and forward until the tabs lock Bend the rear of the side panel and insert the two tabs into the rear cab Step 2 Step 3 97 MAINTENANCE AND LUBRICATION Adjustments 4 amp WARNING Operating your ATV with worn tires improperly inflated tires non standard tires or improperly installed tires will affect vehicle handling and could cause an accident resulting in serious injury or death Maintain proper tire pressure as described on the decal on your ATV and in the specifications section of the owner s manual beginning on page 124 Always use original equipment size and type when replacing tires Make sure the wheels are installed properly Always replace tires when the tread depth measures 1 8 3 cm or less Wheel Removal 1 98 Stop the engine place the transmission in park and lock the parking brake Loosen the wheel nuts slightly Elevate the side of the vehicle by placing a suitable stand under the footrest frame Remove the wheel nuts and remove the wheel MAINTENANCE AND LUBRICATION Adjustments WARNING Improperly installed wheels can adversely affect
111. urning the adjustment knob either clockwise or counterclockwise 10 Reinstall the pod Snap pins into tabs Position A z Slip o ring knob in over pin Knob Stop slot and secure in Route plug locking Adjustment over handlebar tabs B 105 MAINTENANCE AND LUBRICATION Spark Plugs e Use the recommended spark plugs for your model see SPECIFICATIONS beginning on page 124 e Make sure the electrode gap meets specifications for your model e Torque spark plugs to 14 ft Ibs 19 Nm CAUTION Using non recommended spark plugs can result in serious engine damage Always use Polaris recommended spark plugs Spark plug condition is indicative of engine operation The spark plug firing end condition should be read after the engine has been warmed up and the vehicle has been driven at higher speeds Immediately check the spark plug for correct color 4 amp WARNING A hot exhaust system and engine can cause serious burns Wear protective gloves when removing a spark plug for inspection 1 Normal The normal insulator tip is gray tan or light brown There will be 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 2 Wet Fouled The wet fouled ins
112. utch Doing so can cause part failure possible imbalance and excessive engine RPM which can result in serious injury or death NO STEP s WARNING e MANUFACTURED ALL WHEEL BY POLARIS IND INC Pushing reverse DRIVE override button DATE SWITCH may cause A sudden increases MIN a aA d Do not push switch to t power engage AWD if the rear raction if too THIS VEHICLE IS AN ALL TERRAIN VEHICLE AND IS NOT wheels are spinnin much throttle is INTENDED FOR USE ON PUBLIC ROADS pinning applied Loss of This may cause severe control or forward CE VEHICULE EST UN VEHICULE TOUT TERRAIN QUI drive shaft and clutch fli N EST PAS DESTIN A ETRE UTILIS SUR LES CHEMINS damage Ipover may PUBLICS See your Owner s result especially in AWD See Manual Owner s Manual 7172564 7078470 7079780 Canadian Certification Decal Operation of this vehicle e Specific without the air filter carburetor jetting element will severely damage and adjustments are required the engine depending on temperature Clean pre filter element often and altitude See your Owner s more frequent cleaning Manual i required in dusty conditions Factory setting Do not operate vehicle without 40 to 80 F at 0 3000 feet pre filter 5 to 27 C at 0 900 meters 7170007 Under seat ATP 330 Operation of this vehicle e Specific without the air filter element carburetor jetting will severely damage the engine and a
113. ver make turns at high speeds 59 OPERATION Driving Safely Driving on Slippery Surfaces Whenever riding on slippery surfaces such as wet trails or loose gravel or during freezing weather follow these precautions 1 2 3 60 Slow down when entering slippery areas Maintain a high level of alertness reading the trail and avoiding quick sharp turns which can cause skids Correct a skid by turning the handlebars in the direction of the skid and shifting your body weight forward Driving with AWD engaged can assist in controlling the vehicle in slippery areas CAUTION Severe damage to drive train may occur if the AWD is engaged while the wheels are spinning Always engage AWD when the wheels have traction or are at rest WARNING Failure to exercise care when operating on slippery surfaces can result in loss of tire traction and cause loss of control accident and serious injury or death Never apply the brakes during a skid Do not operate on excessively slippery surfaces Always reduce speed and use additional caution OPERATION Driving Safely Driving Uphill Whenever traveling uphill follow these precautions 1 Always travel straight uphill 2 Avoid steep hills 25 maximum 3 Keep both feet on the footrests Transfer your weight forward 5 Proceed at a steady rate of speed and throttle opening 6 Remain alert and be prepared to take emergency 25 Maximum action This may inclu
114. ver the widest possible temperature range It resists viscosity and frictional breakdown in ambient temperatures from 40 F to 120 F Its exceptional frictional properties result in more efficient operation more power output and lower fuel consumption Although Polaris Premium 4 is the only oil recommended for use in this engine use of any API certified SH oil is allowable as long as it s OW 40 Oil may need to be changed more frequently if Polaris Premium 4 is not used Follow the manufacturer s recommendations for ambient temperature operation CAUTION Mixing brands or using a non recommended oil may cause serious engine damage We recommend the use of Polaris Premium 4 All Season synthetic oil or API certified SH oil OW 40 Never substitute or mix oil brands Use only OW 40 79 MAINTENANCE AND LUBRICATION Lubrication Recommendations Engine Oil Oil Check ATP 500 The oil tank is located on the left side of the vehicle 1 Position the ATV on a level surface 2 Start the engine and let it idle for 20 30 seconds Stop the engine 3 Remove the dipstick 1 and wipe it dry with a clean cloth 4 Screw the dipstick completely in NOTE The dipstick must be screwed completely in to keep the angle and depth of the stick consistent 5 Remove the dipstick and read the oil fev C mnsoz norna f FULL e Maintain the oil level in the normal operating 2 range 2 Do not overfill Oil
115. ximum depth go slowly balance your weight carefully avoid sudden movements and maintain a slow and steady forward motion Do not make sudden turns or stops and do not make sudden throttle changes 65 OPERATION Driving Safely Driving Through Water After running the vehicle in water it s critical to have it serviced as outlined in the maintenance chart See page 73 The following areas need special attention engine oil transmission oil front and rear gearcases and all grease fittings NOTE If water has been ingested into the PVT follow the procedure on page 71 for drying out the PVT If your vehicle becomes immersed and it s impossible to take it to a dealer before starting it follow the steps described on page 107 Have the vehicle serviced by your dealer promptly CAUTION Major engine damage can result if the vehicle is not thoroughly inspected after operation in water Perform the services outlined in the maintenance chart If your vehicle becomes immersed or is operated in water that exceeds the footrest level take it to your dealer for service before starting the engine 66 OPERATION Driving Safely Driving Over Obstacles Be alert Look ahead and learn to read the terrain Be constantly alert for hazards such as logs rocks and low hanging branches 4 amp WARNING Severe injury or death can result if your vehicle comes in contact with a hidden obstacle Not all obstacles are immed
116. z mre Wise ST 1 Sit upright with both feet on the footrests and 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 depress the throttle with your right thumb and begin driving Vehicle speed is controlled by the amount of throttle opening 6 Drive slowly Practice maneuvering and using the throttle and brakes on level surfaces 58 OPERATION Driving Safely Making Turns Your Polaris ATV is equipped with a rear differential that functions as a solid rear axle driving both rear wheels equally when the ATP is in either 2X4 or 4X4 mode This means that the wheel on the outside of a turn must travel a greater distance than the inside wheel causing the inside tire to slip traction slightly 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 This technique alters the balance of traction between the wheels allowing the turn to be made smoothly The same leaning technique should be used for turning in reverse NOTE Practice making turns at slow speeds before attempting to turn at faster speeds 4 amp WARNING Turning at sharp angles or at excessive speeds can result in vehicle overturn and lead to serious injury Avoid turning at sharp angles Ne

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