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Polaris 2x4 User's Manual

1. 32 SAFETY oeca ccc see old etre 8 33 Safety Decals and Locations 28 31 Safety Training 8 Severe Use 0 00000 68 Side Panel Removal 98 Sidehilling 0 000 60 Spark Arrestor 67 84 Spark Plugs 00 82 SPECIFICATIONS 109 114 Starting a Cold Engine 52 Starting a Warm Engine 53 Starting the Engine 52 53 Steering Assembly 94 Stop Switch 0 0 0 20 0 000 35 Storage Tips 104 105 T TABLE OF CONTENTS 5 Taillight Brakelight Lamp Replacement 81 Throttle Cable Freeplay 97 Throttle Lever 0 36 Tire Tread Depth 101 Toe Alignment 93 Transmission Gear Selector 42 Transmission Oil 77 Transporting an ATV 107 Trip Meter 00 0 47 TROUBLESHOOTING 115 118 Turning Around ona Hill 62 Vv VEHICLE IDENTIFICATION NUMBERS 7 Vehicle Immersion 83 Ww WARRANTY 119 121 Washing the ATV 103 Waxing the ATV 103 WELCOME gt i ceri censire setas 3 Wheel Installation 100 Wheel Nut Torque Specifications 100 Wheel Removal 99 123
2. 06 96 Choke tetee nas Peers E eae 41 Chrome Wheel Care 106 Cleaning and Storage 103 107 Cleaning the ATV 103 Clutching Chart 2X4 111 Clutching Chart 4X4 114 Cold Weather Operation 53 CONTROLS 0 34 49 Corrosion 0 000e 106 Crankcase Emission Control System 67 D Diagnostic Mode 49 Driving Downhill 61 Driving in Reverse 65 Driving on Slippery Surfaces 58 Driving Over Obstacles 64 Driving Procedures 54 Driving Safely 54 66 Driving Through Water 63 Driving Uphill 59 122 E Electrical Switches 34 35 Electromagnetic Interference 67 EMISSION CONTROL SYSTEMS 67 Engaging Front Gearcase 44 Engine Fogging 105 Equipment Modifications 12 Exhaust Emission Control System 67 F FEATURES josiashint tret beds 34 49 Front Gearcase Oil 78 Front Wheel Hub Tightening 101 Fuel Filter 41 Fuel Safety c5 dct cea e crises 33 Fuel Stabilizer 104 Fuel Fank ei oger isk ena ee 41 Fuel Valve s o 3 eteeni aneren 41 G Gear Selector 00 42 Gearcase Oil Front 78 Gearcase Oil Rear 79 Gearcase Specification Chart 76 H Handlebars 95 Hauling Cargo 56 57
3. e 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 Location G Under Seat 30 SAFETY Safety Decals and Locations 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 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 ALL WHEEL DRIVE SWITCH Do not push switch to engage AWD if the rear wheels are spinning This may cause severe drive shaft and clutch damage See your Owner s Manual LOCATE AND READ OWNER S MANUAL FOLLOW ALL INSTRUCTIONS AND WARNINGS IF OWNER S MANUAL IS
4. Poor engine performance Check for fouled plugs or foreign material in gas tank fuel lines or carburetor Contact your dealer for service 115 TROUBLESHOOTING Contact your Polaris dealer for service if you re unable to identify solutions 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 8 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 116 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 Kinked or plugged fuel vent line Inspect and replace 117 TROUBLESHOOTING Engine Stops or Loses Power Possible Cause Solution Kinked or plugged fuel vent l
5. Always use extra caution on rough slippery or loose terrain 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 19 SAFETY Operator Safety 4 amp WARNING 20 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 WARNING POTENTIAL HAZARD Climbing hills improperly WHAT CAN HAPPEN Improper hill climbing could cause loss of control or overturn HOW TO AVOID THE HAZARD Always follow proper procedures for climbing hills as described in the owner s manual Always check the terrain carefully before ascending any hill Never operate the ATV on hills steeper than 25 Never climb hills with excessively slippery or loose surfaces Shift your weight forward Never open 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 pe
6. from the top of the fill hole We recommend the use of Premium AGL Synthetic Gearcase Lubricant Refer to the gearcase specifications chart on page 76 See page 108 for the part numbers of Polaris products Oil Check The transmission fill plug 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 and check the oil level 3 Add the recommended oil as needed 4 Reinstall the fill plug Torque to specification Oil Change The transmission drain plug is located on the bottom left hand side of the machine 1 Remove the propshaft shield if equipped from the right side of the vehicle to access the fill plug 2 Remove the fill plug 3 Remove the transmission drain plug and drain the oil into an appropriate container Discard used oil properly Clean and reinstall the drain plug Torque to specification Add the recommended fluid Reinstall the fill plug Torque to specification Check for leaks Reinstall the propshaft shield if equipped QOS OU 77 MAINTENANCE AND LUBRICATION Front Gearcase Oil Always check and change the front gearcase oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 68 Refer to the gearcase specifications chart on page 76 See page 108 for the part numbers of Polaris products Oil Check We recommend the use of Polaris Premium Demand Drive Hub Fluid in models wit
7. 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 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 119 WARRANTY WARRANTY COVERAGE AND EXCLUSIONS 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 pres
8. Headlight Adjustment 80 Headlight Lamp Replacement 80 Helmet 3 e603 gsc need ene cae aes 32 High Range 00 86 Hour Meter 47 l Instrument Cluster 45 49 J Jetting Chart 2X4 111 Jetting Chart 4X4 0 114 K KTU ege eee bas E aE E 62 L Light Switch 000 34 TA GNIS vs ses ic sepia yeeie we dae 80 81 Low Range cess erus cre aiaee 86 Lubrication Guide 72 M Main Switch 35 MAINTENANCE AND LUBRICATION 68 107 Maintenance Record 73 Making Turns 55 Master Cylinder 37 N Noise Emission Control System 67 6 Odometer 00005 47 Oil Change 0 8 75 76 OilbCheek rase Sela whee 75 OPERATION 50 66 Operator Safety 8 27 Override Switch 34 P Parking Brake 39 Parking on an Incline 66 Periodic Maintenance Chart 68 71 POLARIS PRODUCTS 108 Pre Ride Inspection 51 Premium 4 Synthetic Lubricant 74 Programmable Service Interval 48 PVTEDYINE fect erent ove tbr eS ace 87 PVT System 08 86 87 R Rear Gearcase Oil 79 Rear Spring 000 94 Recoil Housing 85 Recoil Starter 43 Rider Information Center 46 49 INDEX S Safe Riding Gear
9. MISSING CONTACT A POLARIS DEALER FOR A REPLACEMENT 1997 2000 7172560 7079780 Applicable AWD Models Location H amp WARNING Pushing reverse OVERRIDE MANUFACTURED BY POLARIS IND INC override button may cause sudden increases in power and traction if too much throttle is applied Loss of control or forward flipover may result especially in AWD See Owner s Manual 7172564 AWD Models SWITCH Reverse Speed is limited Reverse override is controlled by the override switch See your Owner s Manual 7079906 2WD Models DATE VIN THIS VEHICLE IS AN ALL TERRAIN VEHICLE AND IS NOT INTENDED FOR USE ON PUBLIC ROADS CE V HICULE EST UN V HICULE TOUT TERRAIN QUI N EST PAS DESTINE A ETRE UTILISE SUR LES CHEMINS PUBLICS PATENT NOTICE Mfd by Al Terrain Vehicle Division Polaris Industries Inc under one or more of the following patents Other patents pending U S Patents 4697665 5036939 5975624 6016943 6092877 6149540 6224134 6270106 6340186 0378080 0389440 0400143 Canadian Certification Decal 7171492 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
10. System 4 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 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 set
11. 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 53 OPERATION Driving Safely Driving Procedures 54 Sit upright with both feet on the footrests and both hands on the handlebars Start the engine and allow it to warm up then shift the transmission into gear Check your surroundings and determine your path of travel Release the parking brake Slowly depr
12. in serious or DEATH injury or death 7172566 NO STEP BA Location D Location C AWARNING DO NOT TOW FROM RACK OR BUMPER Vehicle damage or tipover may result causing severe injury or death Tow only from tow hooks or hitch Max Rack Loads Front 90 Ibs 41 kg Rear 180 Ibs 82 kg 7172572 Location E on models with racks 4 amp 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 Location E on models with storage box 29 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 PSI FRONT REAR _ MAXIMUM WEIGHT CAPACITY Gross Vehicle Weight INCLUDING MACHINE DRIVER AND CARGO IS LBS 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 and firmly secured to the racks with dual racks load distribution 1 3 front 2 3 rear is best For stability on rough or hilly terrain reduce speed and cargo Do not block headlight Be careful if load extends over the side of the rack Read Owner s Manual for more detailed loading information Location F
13. is in AWD When in AWD the front gearcase will automatically engage when the rear wheels lose traction When the rear wheels regain traction the front gearcase will automatically disengage NOTE The override switch allows activation of AWD in reverse if the AWD switch is on See page 34 There is no limit to the length of time the vehicle may remain in AWD Engaging Front Gearcase The AWD switch may be turned on or off while the vehicle is moving Initially the vehicle s electronic 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 while the rear wheels are spinning may cause severe drive shaft and gearcase damage Always switch to AWD while the rear wheels have traction or are at rest 44 FEATURES AND CONTROLS Instrument Cluster Magnum 330 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 approxim
14. 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 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 MET NOTE If you discover improper alignment see your Polaris dealer for service 93 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 NOTE Accessory springs are available through your Polaris dealer 94 MAINTENANCE AND LUBRICATION Adjustments 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 resulting in loss of control and possible serious personal injury or death Follow the adjustment procedures exactly or see your Polaris dealer fo
15. 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 WARRANTY COVERAGE AND EXCLUSIONS LIMITATIONS OF WARRANTIES 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
16. 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 the 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
17. 200 miles or one month whichever comes first 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 See Page Ensure proper operation Ensure proper level Ensure proper operation 40 Inspect lubricate if necessary Inspect lubricate if necessary i E 5 Pre Ride Checklist Brake system lever travel Ensure free operation nspect condition and pressure nspect ensure tightness o o Ensure proper levels ie 4 ee nspect ensure fastener tightness Ensure proper operation Ensure operation Ensure proper operation inspec en os Drain deposits whenever visible Headlamp Check operation apply dielectric grease when lamp is replaced Brake light tail lamp Check operation apply dielectric 81 grease when lamp is replaced Riding gear Wear helmet goggles protective 32 clothing Coolant level if applicable Ensure proper level Coolant hoses if applicable Inspect for leaks Q N 51 OPERATION Starting the Engine 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 Place the transmission in PARK and lock the parking brake Make sure the fuel valve is on Sit on the vehicle
18. ATV 22 SAFETY Operator Safety amp 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 Keep your weight uphill Apply the single lever brake gradually When fully stopped apply the auxiliary 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 auxiliary rear brake while rolling backwards Apply the single lever brake gradually When fully stopped apply the auxiliary 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 62 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 trees 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 CA
19. 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 65 OPERATION Driving Safely Parking on an Incline Avoid parking on an incline if possible If it s unavoidable follow these precautions 1 Turn the engine off 1 Place the transmission in PARK 2 Set the parking brake 3 Always block the rear wheels on the downhill side See illustration 4 Shut off the fuel supply 66 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 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 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 4 amp WAR
20. Di Wie PELARIS 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 e 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 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 9919487 Rev 01 es PE2LARIS 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 Es PesLARIS For 50 years
21. Equipment Modifications We are concerned for the safety of our customers and for the general public Therefore we 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 12 SAFETY Operator Safety amp WARNING 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 ow
22. If any 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 NOTE Your ATV may not have all of the decals shown Decals vary depending on the model 28 SAFETY Safety Decals and Locations 4 amp WARNING AWARNING 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 e Use OVERRIDE for reverse speed limiter with caution To prevent loss of control never activate override button with open throttle Operating this ATV if you are under the age of 16 increases your chance of severe injury or death NEVER operate this ATV if you are under age 16 When this ATV is not in operation or unattended place shift in the park position 7172561 Location A 7172559 Location B AWARNING AWARNING Moving parts hazard under belt clutch guard To prevent serious injury do not operate vehicle NEVER ride as a passenger F Passengers can cause with guard removed a loss of control Do not modify engine or clutch Doing so can resulting in cause part failure possible imbalance and SEVERE INJURY excessive engine RPM which can result
23. N 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 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 SAFETY Operator Safety 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 63 travel 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 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 Operating this ATV with improper tires or with improp
24. NING The installation of devices that effectively increase exhaust emissions beyond their legal limits will void all manufacturer warranties and may violate laws governing the registration and operation of this vehicle 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 Electromagnetic Interference This spark ignition system complies with Canadian ICES 002 67 MAINTENANCE AND LUBRICATION 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 Some models are equipped with a speedometer that has a programmable service interval mode This important feature will help you determine when maintenance service is due See page 48 for instructions Maintenance intervals in the following charts are based
25. SPECIFICATIONS a ccteitvev awe otdw en daar 109 TROUBLESHOOTING 2 005 115 WARRANTY acnsvaows Gennes cee ene w ener 119 INDEX verraai Gai eras a a Gil ted hie chan stan 122 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 right front side of engine crankcase Key Number 2 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 a
26. Screw the dipstick completely in The dipstick must be screwed completely in to ensure an accurate reading Remove the dipstick and read the oil level Maintain the oil level in the normal safe operating range 2 Do not overfill Oil and Filter Change 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 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 CAUTION Hot oil can cause serious burns to skin Do not allow hot oil to come into contact with skin 75 MAINTENANCE AND LUBRICATION Oil and Filter Change 5 Place a drain pan beneath the engine crankcase and remove the drain plug 6 Allow the oil to drain completely 7 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 8 Reinstall the drain plug and torque to 14 ft Ibs 19 Nm 9 Place shop towels beneath the oil filter Using an oil filter wrench turn the filt
27. UBRICATION 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 installation of this battery The sealed battery is already filled with electrolyte and has been sealed and fully charged at the factory Never 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 tha
28. afety 4 amp WARNING 18 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 WARNING 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 by HOW TO AVOID THE HAZARD Travel slowly and use extra caution when operating on unfamiliar terrain Always be alert to changing terrain conditions SAFETY Operator Safety 4 amp 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 excessively rough slippery or loose terrain until you ve learned and practiced the skills necessary to control the ATV on such terrain
29. 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 will 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 or snow ingestion into the 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
30. and pull the choke knob 1 out until it stops If the knob doesn t stay where positioned increase the tension by rotating the tension adjusting nut 2 clockwise NOTE The variable choke is fully on when 2 ie Cc 3 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 Move the engine stop switch to RUN NOTE Do not press the throttle while starting the engine 4 52 Turn the ignition key past the ON position to engage the starter for a maximum of five seconds Release the key when the engine starts If it doesn t start release the key and wait five seconds Activate the starter for another five seconds Repeat until the engine starts If the engine slows or stops position the choke knob half way in to allow proper engine warm up Vary the engine RPM slightly with the throttle to aid in warm up When the engine idles smoothly push the choke all the way in CAUTION Operating the vehicle immediately after starting could cause engine damage Allow the engine to warm up for several minutes before operating the vehicle OPERATION Starting the Engine Starting a Warm Engine Warm engines do not normally require the use of the choke Excessive use of the
31. 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 wheel 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 Ibs 37 Nm Rear Wheel Nuts 27 ft Ibs 37 Nm 100 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 A 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 amp WARNING Use of non standard size or type of tires or improper tire inflation may adversely affect vehicle maneuverability and cause loss of control resulting in serious
32. ately 7 9 mph see page 34 1 Rider Information Center Speedometer needle in addition to depicting vehicle speed this needle will flash to signal a fault condition 3 Speedometer CAUTION Washing the ATV with a high pressure washer may cause water to enter the instrument cluster and cause damage to the electronic components 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 Do not allow insect sprays to come into contact with the lens 45 FEATURES AND CONTROLS Instrument Cluster Magnum 330 Rider Information Center The rider information center is located in the lower portion of the instrument cluster 1 Gear Indicator As the 2 3 4 shift lever is moved this will indicate the gear the machine is in H High Range L Low Range N Neutral R Reverse P Park E or blank Error The 1 error message usually means the gear selector is in between gears It can however also indicate that the transmission switch needs repair 2 High Engine Coolant Temperature Do not continue to operate the ATV is this warning appears or serious engine damage could result 3 Hour Meter 4 Service Interval Miscellaneous Service Warnings 5 Low Battery and Over Voltage This warning usually indicates that the ATV is being operated at an RPM too low to kee
33. ating procedures outlined in the owner s manual 25 Maximum 59 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 the most dangerous type of driving encountered and should be avoided if at all possible If you do enter into a situation 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 60 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 using the single brake ever NOTE 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 sl
34. ation performance and protection NOTE See page 108 for the part numbers of Polaris products Premium 4 possesses unsurpassed film strength over the widest possible temperature range It resists viscosity and frictional breakdown in ambient temperatures from 40 F to 120 F 40 to 49 C 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 synthetic Oil or another OW 40 API certified SH oil Never substitute or mix oil brands 74 MAINTENANCE AND LUBRICATION Engine Oil Check The oil dipstick 1 is located on the left side of the engine NOTE Arising oil level between PONS checks in cool weather driving can indicate contaminants such as gas or moisture collecting in the crankcase If the oil level is over the full safe mark change the oil immediately Position the ATV 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
35. c start Dry the spark plug and reinstall or replace it with a new plug Tighten the carburetor drain screw 1 Turn the fuel valve on Attempt to start the engine If necessary repeat the drying procedure Take the ATV to your dealer 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 87 for drying out the PVT 83 MAINTENANCE AND LUBRICATION Spark Arrestor 4 amp WARNING 84 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 1 from the bottom of the muffler Place the transmission in PARK and start the engine 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 parti
36. 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 48 FEATURES AND CONTROLS Instrument Cluster Magnum 330 Rider Information Center Diagnostic Mode The diagnostic mode is for informational purposes only Please return your ATV to your dealer for all major repairs To enter the diagnostics mode 1 Turn the key switch off and wait 20 seconds 2 Set the park brake and shift the transmission to neutral 3 Hold the mode reverse override button and turn the key switch on The initial screen displayed looks similar to the top illustration and 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 The first 1 screen 1 displays battery voltage Screen two 2 is the tachometer for setting idle speed If this needs adjustment please contact your dealer As long as the center is in the 2 diagnostic mode 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 OPERATION Break In Period The break in period for you
37. ck the parking brake see page 39 2 Make sure the engine stop switch is set to RUN and the main key switch is in the ON position NOTE Ifthe engine is cold use the choke as outlined on page 52 3 Grasp the recoil starter rope handle 2 firmly and pull slowly so you can feel the engine strokes NOTE Every other stroke will be a compression stroke and will make the rope harder to pull When a compression stroke is found continue pulling the rope just until the engine rolls past the stroke then stop pulling immediately 4 Allow the recoil rope to rewind into the recoil assembly then pull the rope abruptly and forcefully to start the engine 5 Repeat steps 3 4 if necessary CAUTION Extending the recoil starter rope until it stops can 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 System Domestic Models Polaris 4 wheel drive domestic model ATVs are equipped with a unique Polaris exclusive All Wheel Drive AWD System activated by a switch 1 on the right handlebar Engage the AWD when the rear wheels lose traction When the AWD switch is off the ATV is in 2 wheel drive at all times When the switch is on the ATV
38. cles are still suspected to be in the muffler elevate the rear of the vehicle one foot higher than the front Set the parking brake and block the wheels Make sure the vehicle 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 crankcase drain is opened 85 MAINTENANCE AND LUBRICATION 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 th
39. e 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 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 86 MAINTENANCE AND LUBRICATION PVT
40. e dish soap type cleaners only High pressure washers may force water past seals Fuel Stabilizer Polaris Carbon Clean is a fuel stabilizer and fuel system dryer It cleans the fuel system the combustion chamber and the exhaust ports It also prevents bacterial growth and promotes better starting after the storage period 1 Fill the fuel tank with fuel and add Polaris Carbon Clean or Fuel Stabilizer Follow the instructions on the container for the recommended amounts 2 Start the engine and allow it to run for 15 20 minutes so the stabilizer can disperse through the fuel in the tank and carburetor 3 Stop the engine turn the fuel valve off and drain the carburetor bowl Oil and Filter Warm the engine and change the oil and filter Air Filter Air Box Inspect and clean or replace the pre cleaner and air filter Clean the air box and drain the sediment tube Recoil Housing Remove the recoil housing drain plug and drain any moisture Engine Anti Freeze Test engine coolant strength and change if necessary Coolant should be replaced every two years 104 MAINTENANCE AND LUBRICATION Cleaning and Storage Storage Tips See page 108 for the part numbers of Polaris products Fluid Levels Inspect the following fluid levels and change if necessary engine oil transmission oil brake fluid change every two years or as needed if fluid looks dark or contaminated Engine 1 Remove the spark plug and pour 2 3 tablespoo
41. e 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 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 109 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 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 99 MAINTENANCE AND LUBRICATION Adjustments 4 amp WARNING Improperly installed wheels can adversely affect tire wear and vehicle handling which can result in serious injury or death Always ensure that all nuts
42. eath CAUTION The safety alert caution indicates a potential hazard that may result in minor personal injury or damage 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 jack
43. ect replace as needed main element Recoil housing Weekly Drain water as needed check often if operating in wet conditions A Brake pad wear Monthly 100 160 Inspect periodically Battery 20H Monthly 200 320 Check terminals clean test Front gearcase oil 25H Monthly 250 400 Inspect level change yearly if equipped Rear gearcase oil 25H Monthly 250 400 Inspect level change yearly if equipped Transmission oil 25H Monthly 250 400 Inspect level change yearly Engine breather 25H Monthly 250 400 Inspect clean if needed filter if equipped 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 69 MAINTENANCE AND LUBRICATION Periodic Maintenance Chart Throttle Cable Maintenance Interval whichever comes first Calendar Miles Km 50 H 500 800 Lubricate all fittings pivots cables etc 50 H ETC Switch Choke cable General lubrication Carburetor float bowl 500 800 Drain bowl periodically and prior to storage 500 800 Inspect adjust lubricate replace if necessary 500 800 Inspect adjust lubricate replace if necessary Carburetor air 500 800 Inspect ducts for proper intake ducts sealing air leaks flange 500 800 Inspect adjust replace as needed 1000 1600 Inspect coolant strength seasonally pressure test sys
44. ent condensation and may promote corrosion and oxidation 105 MAINTENANCE AND LUBRICATION Cleaning and Storage Chrome Wheel Care if equipped Proper maintenance will protect chrome wheels from corrosion 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 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 106 MAINTENANCE AND LUBRICATION Cleaning and Storage Transporting an ATV Follow these procedures when transporting an ATV 1 Turn off the engine and remove the key to prevent loss during transporting 2 Turn the fuel valve off 3 Be sure the fuel cap oil cap a
45. ent 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 If any of the above terms are void because of state or federal law all other warranty terms will remain in effect Engine Oil 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 120 WARRANTY Exported Vehicles EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW THERE IS NO WAR RANTY OR SERVICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD OUTSIDE THE COUNTRY OF THE SELLING DEALER S AUTHORIZED LOCA TION 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
46. er counterclockwise to remove 10 Using a clean dry cloth clean the filter sealing surface on the crankcase 11 Lubricate the gasket on the new filter with a film of engine oil Check to make sure the gasket is in good condition 12 Install the new filter and turn by hand until the filter gasket contacts the sealing surface then turn and additional 1 2 turn 13 Remove the dipstick and fill the sump with the recommended oil Refer to the specifications section beginning on page 109 for capacities 14 Place the gear selector in PARK and lock the parking brake 15 Start the engine and let it idle for one to two minutes Stop the engine and inspect for leaks 16 Recheck the oil level and add oil as necessary to bring the level to the upper mark on the dipstick 17 Dispose of used filter and oil properly Gearcase Specification Chart Gearcase Lubricant Capacity Fill Plug Drain Plug Torque Torque Transmission Premium AGL Synthetic 13 5 oz 14 ft Ibs 14 ft Ibs Gearcase Lubricant 400 ml 19 Nm 19 Nm Front Gearcase Premium Demand Drive 5 oz 8 10 ft Ibs 11 ft Ibs Hub Fluid 148 ml 11 13 Nm 15 Nm Rear Gearcase Premium ATV Angle 10 oz 14 ft Ibs 14 ft Ibs Drive Fluid 300 ml 19 Nm 19 Nm 76 MAINTENANCE AND LUBRICATION Transmission Oil Always check and change the transmission oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 68 Maintain the oil level 1 5 8
47. er 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 for the ATV Always maintain proper tire pressure as specified 25 SAFETY Operator Safety 4 amp WARNING 26 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 accessories 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 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 Allow a greater distance for braking Always follow the instructions in the owner s manual for car
48. ervice 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 4 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 36 FEATURES AND CONTROLS Brakes Master Cylinder Check the brake fluid level in the master cylinder before each use of the ATV The master cylinder 1 is located on the left handlebar View the fluid level through the indicator window 2 on the top of the master cylinder This eye will appear dark when the fluid level is full When fluid is low the eye will be clear NOTE When checking the fluid level position the ATV on level ground with the handlebars turned so the top of the reservoir is level If the fluid level is low add DOT 3 brake fluid DO NOT OVERFILL See page 108 for the part numbers of Polaris products 4 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 4 amp WARNING After opening a bottle of brake fluid always discard any
49. ery surfaces like ice travel slowly and use extra caution to reduce the chance of skid ding or sliding out of control 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 11 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 tire pressure as recommended 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
50. ess clockwise B to secure Headlight Adjustment 1 Loosen the nuts C that secure the lower headlamps Adjust the headlamps as needed 2 Tighten the nuts 80 MAINTENANCE AND LUBRICATION Lights Taillight Brakelight Lamp Replacement If the taillight brakelight does not work the lamp may need to be replaced 1 Remove the taillight lens cover mounting screws Remove the lens cover and gasket and set aside for reassembly 2 Remove the lamp 1 Apply dielectric grease to the socket and install a new bulb 4 Test the taillight brakelight for proper operation 5 Reinstall the gasket and lens cover 81 MAINTENANCE AND LUBRICATION Spark Plugs Refer to the specifications section beginning on page 109 for spark plug and gap specifications 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 p
51. ess the throttle with your right thumb and begin driving Vehicle speed is controlled by the amount of throttle opening Drive slowly Practice maneuvering and using the throttle and brakes on level surfaces OPERATION Driving Safely Making Turns Your Polaris ATV is equipped with a solid rear axle that drives both rear wheels equally at all times This means that the wheel on the outside of the turn must travel a greater distance than the inside wheel when turning and the inside tire must 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 rear 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 Never turn at high speeds 55 OPERATION Driving Safely Hauling Cargo 2 3 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 evenly distributed 1 3 on the front a
52. et and long pants e Never consume alcohol or drugs before or while operating an ATV e Never operate at excessive speeds 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 10 SAFETY Operator Safety Always have the ATV inspected by an authorized Polaris dealer if it s been involved in an accident Never operate on hills too steep for the ATV or for your abilities Practice on smaller hills before attempting larger hills 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 gea
53. h centralized Hilliard gearcases domestic models Maintain the level at the bottom of the fill plug threads 1 1 Position the ATV on a level surface 2 Remove the fill plug 2 and check g the oil level 1 3 Add the recommended oil as needed A 4 Reinstall the fill plug Torque to specification Oil Change 1 Check the vent hose 3 to be sure it s unobstructed and routed properly 2 Support the vehicle securely with a jackstand and remove the front tire on the driver s side 3 Remove the drain plug 4 located on the bottom of the gearcase and drain the oil into a suitable container The drain plug is accessible through the skid plate Discard used oil properly 4 Clean and reinstall drain plug using a new sealing washer Torque to specification 5 Remove the fill plug 3 and add the recommended fluid DO NOT OVERFILL Overfilling may cause excess drag which can lead to unwanted engagement 6 Reinstall the fill plug Torque to specification 78 MAINTENANCE AND LUBRICATION Rear Gearcase Oil Oil Check Always check and change the rear gearcase oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 68 Maintain the rear gearcase oil level at the bottom of the fill hole threads 1 We recommend the use of Polaris Premium ATV Angle Drive Fluid Refer to the gearcase specifications chart on page 76 See page 108 for the part numbers of Polaris products 1 Pos
54. iliary 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 92 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 2 De straight ahead position BE N Se NOTE The steering frog can be pes O used as an indicator of ang whether the handlebars Bey are straight The frog Nees should always point straight back from the steering post Place stands 1 in front of the vehicle perpendicular to the rear tires See illustration Tie an elastic
55. ine 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 malfunction Electronic throttle control malfunction Other mechanical failure Overheated engine Clean radiator screen and core if equipped Clean engine exterior See your Polaris dealer 118 WARRANTY LIMITED WARRANTY Polaris Sales Inc 2100 Highway 55 Medina MN 55340 gives a SIX MONTH LIMITED WARRANTY on all components of the Polaris All Terrain Vehicle ATV against defects in material or workmanship Polaris also gives a one year limited warranty on the final drive chain for failure due to defects 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
56. 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 101 MAINTENANCE AND LUBRICATION Ad Air 1 2 3 102 justments Filter Service Remove the seat Release the clips and remove the air box cover 1 Loosen the clamp and remove the filter Remove the fabric type pre filter 2 from the main filter 3 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 needed Reinstall the filter into the air box and tighten the clamp Do not over tighten the clamp as filter damage could occur poa fee ae 7 MAINTENANCE AND LUBRICATION Accessories Auxiliary power outlets provide 12V power for operating accessories such as hand held spot lights See your Polaris dealer Cleaning and Storage See page 108 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 Rin
57. ition the ATV on a level surface 2 Remove the gearcase fill plug 2 and check the oil level 3 Add the recommended oil as needed 4 Reinstall the fill plug Torque to specification 5 Check for leaks Oil Change 1 Remove the drain plug 3 located on the bottom of the gearcase Catch and discard the used oil properly 2 Clean and reinstall the drain plug with a new sealing washer Torque to specification 3 Remove the fill plug and add the recommended gearcase oil Reinstall the fill plug Torque to specification 5 Check for leaks 79 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 peprecerient 1 Turn the back of the headlight harness in a counter 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 harn
58. k 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 if shifting into HIGH or PARK Whenever the ATV is left unattended always place the transmission in PARK and lock the parking brake 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 UD Zr I 42 FEATURES AND CONTROLS Recoil Starter If the battery has been drained or 2 1 damaged and cannot start the aA Co ES a engine use of the recoil starter 1 ANSO A a on LN will allow vehicle operation until C 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 reducing the amount of compression during starting The decompressor senses when the engine is spinning fast enough to start and restores compression when running 1 Position the vehicle on a level surface place the transmission in PARK and lo
59. ke Maintain the fluid level between the maximum and minimum marks 40 FEATURES AND CONTROLS Choke The choke assists in starting a cold engine Refer to the engine starting procedure on page 52 for correct choke and throttle settings during starting Fuel Valve The fuel valve 1 is located on the left side of the vehicle on the side panel It has three positions OFF For vehicle storage and when transporting ON For normal operation RES For reserve supply if main supply is exhausted NOTE There s about a 7 to 10 mile 11 2 to 16 km range on reserve gas Always 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 Refer to the specifications section beginning on page 109 for tank capacity Fuel Filter The in line fuel filter should be replaced by your dealer after every 100 hours of operation or annually Do not attempt to clean the fuel filter 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 N Neutral L Low Gear R Reverse P Park To shift into HIGH or PARK you must first apply the auxiliary brake to activate the high park loc
60. mum recommended depth equal to the bottom of the footrests 1 Follow these procedures when operating through water 1 Determine water depths and current before crossing 2 Choose a crossing where both banks have gradual inclines 3 Proceed slowly avoiding rocks and obstacles if possible 4 After crossing dry the brakes by applying light pressure to the lever until braking action is normal After running the vehicle in water it s critical to have it serviced as outlined in the maintenance chart See page 68 The following areas need special attention engine oil transmission oil front and rear gearcases and all grease fittings 4 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 NOTE Avoid operating the vehicle through deep or fast flowing water If you cannot avoid water that exceeds the recommended maximum 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 If your vehicle becomes immersed and it s impossible to take it to a dealer before starting it follow the steps described on page 83 Have the
61. n 12 8 volts recharge the battery at 1 2 amps or less until the battery 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 89 MAINTENANCE AND LUBRICATION Battery Battery Charging NOTE Always verify battery condition before and 1 2 hours after the end of charging Voltage Charge Time Using constant current charger standard amps specified on top of battery 100 12 8 13 0 volts None check at None required 3 mos from date of manufacture 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 with At least 20 hours desulfating charger 75 100 12 5 12 8 volts May need slight 3 6 hours charge if no charge given check in 3 months 90 MAINTENANCE AND LUBRICATION Adjustments Brakes The front and rear brakes are hydraulic disc brakes activated by moving the single brake lever toward the handlebar These brakes are self adjusting The following checks are recommended to keep the brake system in good operating c
62. n the OFF position Its OFF RUN T purpose is to provide the operator with a quick Br means of engine shutdown in case of an emergency To stop the engine slide the stop switch either right or left to the OFF position 4 Main Switch 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 5 All Wheel Drive Switch AWD Models Select AWD models do not have an AWD switch These models are continuously in AWD 35 FEATURES AND CONTROLS 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 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 Operating an ATV with sticking or improperly operating throttle controls could cause an accident and lead to severe injury or death Never start or operate an ATV with a sticking or improperly operating throttle Always contact your dealer for s
63. nd 2 3 on the rear and mounted as low as possible When operating over rough or hilly terrain reduce speed and cargo to maintain stable driving conditions Belt Life Use low forward gear when hauling or towing heavy cargo to extend belt life 56 OPERATION Driving Safely Hauling Cargo A WARNING e REDUCE SPEED AND ALLOW GREATER DISTANCES FOR BRAKING WHEN HAULING CARGO e CARGO WEIGHT DISTRIBUTION should be 1 3 on the front rack and 2 3 on the rear rack When operating over rough or hilly terrain reduce speed and cargo to maintain stable driving conditions Carrying loads on one rack only increases the possibility of vehicle overturn e CARRY LOADS AS LOW ON THE RACKS AS POSSIBLE Carrying loads high on the racks raises the center of gravity of the vehicle and creates a less stable operating condition e SECURE ALL LOADS BEFORE OPERATING Unsecured loads can create unstable operating conditions which could result in loss of control of the vehicle e OPERATE ONLY WITH STABLE AND SAFELY ARRANGED LOADS When handling off centered loads that cannot be centered securely fasten the load and operate with extra caution Always attach the tow load to the hitch point designated for your vehicle e HEAVY LOADS CAN CAUSE BRAKING AND CONTROL PROBLEMS Use extreme caution when applying brakes with a loaded vehicle Avoid terrain or situations that may require backing downhill e USE EXTREME CAUTION when operating with loads tha
64. nd seat are installed correctly and securely 4 Always tie the frame of the ATV to the transporting unit securely using suitable be ep straps or rope The rack A er bumper or handlebars do not 4 3 offer enough support for tie down while transporting the unit 5 Always place the transmission in PARK and lock the parking brake 107 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 2872276 2870465 2871654 2872277 2871322 2871423 2871460 2871515 2871557 2871312 2871329 2872073 2872348 2871323 60 40 Coolant gal 2871534 60 40 Coolant qt 108 SPECIFICATIONS 2005 Magnum 330 2X4 Body Spe Gross Vehicle Weigh Fuel Capacity Engine Oil Capacity Transmission Oi Rear Gearease Of weight not to exceed 180 Ibs Tow Capacity Tura Radius Ground Clearance Tenth Width Heh Seat Height Diy Weigh Wheel Base Lubrication Bore x Soke Displacement Compression Ratio Engine Cooling Alternator Output watts Carburetor Main et Pilot Te Needle Pilot Aire Ter Needle eiton Timing Spark Plug Type Gap 109 SPECIFICATIONS 2005 Magnum 330 2X4 Shin Type Front Drive Gaio Front Suspension Mac Strut Rear Suspension Progressive Rate 7 1 in 18 cm travel Swing Arm Shook Adjustmen
65. nd understand your owner s manual which includes valuable information about all aspects of your vehicle including 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 d
66. ner s manual For more information about the training course contact an authorized ATV dealer or call Polaris at 1 800 342 3764 4 amp 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 13 SAFETY Operator Safety 4 amp WARNING 14 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 ee 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 WARNING POTENTIAL HAZARD Operating an ATV on paved surtaces 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 co
67. ns of Premium 4 Synthetic OW40 engine oil into the 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 2 Reinstall the spark plug 3 With the ignition off turn the engine over several times using the recoil starter This will ensure coverage of the piston rings cylinder walls and crankshaft bearings 4 Apply dielectric grease to the inside of the spark plug cap and install the cap onto the plug 5 Treat the fuel system with Polaris Carbon Clean 6 If Polaris fuel system additive is not used drain all fuel from the fuel tank fuel lines and carburetor Eliminate any fuel remaining in the carburetor by running 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 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 prev
68. ntrol 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 SAFETY Operator Safety 4 amp WARNING POTENTIAL HAZARD Operating this ATV on aes public streets roads or os highways Y WHAT CAN HAPPEN ne l The ATV could collide ay 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 4 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 7 A fat IN oS SS Ny rfp i the risk of P ne ee metea OO death in the event of an os Se ee RT 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 15 SAFETY Operator Safety 4 amp WARNING 16 POTENTIAL HAZARD Operating the ATV after consuming alcohol or drugs WHAT CAN HAPPEN Consumption of alcohol and or drugs could seriously affect operato
69. ondition Check more often if brakes are used heavily under normal operation 4 WARNING Never store or use a partial bottle of brake fluid Brake fluid 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 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 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 APA operation Use Polaris DOT 3 brake fluid 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 they re worn to 3 64 1 cm 3 64 1 cm 91 MAINTENANCE AND LUBRICATION Adjustments Aux
70. ont Drive ratio Final Drive ratio Front Suspension Mac Strut Rear Suspension Progressive Rate 7 1 in 18 cm travel Swing Arm Shock Adjustment Aniiny Brake Park Brake Headlight Tait Brake Lah Baten DC Plugin Read Electric Sta High Beam Inicio High Temp Indicator Windshield Neutral Indicator Speedometer Tool Ki 113 SPECIFICATIONS 2005 Magnum 330 4X4 Jetting Chart Altitude AMBIENT Below 40 F 40 F and above TEMPERATURE Below 5 C 5 C and above Meters 0 1800 127 5 Feet 0 6000 1800 3700 6000 12000 Clutching Chart Altitude Shift Drive Clutch Driven Clutch Helix Spring Weight Spring Spring Setting Meters 0 1800 16 Blue Green Black 41 35 Feet 0 6000 5630279 7041157 7041782 5133701 2 2 1800 3700 20 38 Blue Green Black 41 35 6000 12000 5631357 7041157 7041782 5133701 2 2 114 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 62 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
71. ory and all other conditions are favorable the carburetor can be adjusted 1 Warm up the engine by running the vehicle for approximately five minutes 2 Place the transmission in PARK and lock the parking brake 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 96 MAINTENANCE AND LUBRICATION Adjustments Throttle Cable Freeplay The throttle cable adjuster is located at the right 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 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 tiend 97 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 1 98 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 your hand on top of the side panel behind the fuel tank With a quick and firm motion push down on th
72. owly when traveling downhill 61 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 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 jj Uphill 62 OPERATION Driving Safely Driving Through Water Your ATV can operate through water with a maxi
73. 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 71 MAINTENANCE AND LUBRICATION Lubrication Guide Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart beginning on page 68 Items not listed in the chart should be lubricated at the General Lubrication interval Lube Engine Oil Premium 4 Synthetic OW40 See page 75 DOT 3 fluid only See page 37 1 Transmission Premium AGL Synthetic See page 77 Gearcase Lube 2 Front Gearcase Premium Demand Drive See page 78 Hub Fluid 3 Rear Gearcase Premium ATV Angle Drive See page 79 Fluid 4 Rear Prop Shaft Grease Grease fitting 3 pumps maximum 5 Front Prop Shaft Yoke Grease Grease fitting 8 pumps maximum 6 Ball Joint p gt Grease Locate fitting on back side of struts and grease with grease gun MAINTENANCE AND LUBRICATION Periodic Maintenance Record Use the following chart to record periodic maintenance Maintenance Servicing Servicing Interval Date Dealer Performed or Person 73 MAINTENANCE AND LUBRICATION Premium 4 Synthetic Lubricant 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 lubric
74. p 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 NOTE Ifthe instrument cluster no longer illuminates it s possible that a battery over voltage occurred and the instrument cluster has shut off to protect the electrical system If this occurs take the ATV to your Polaris dealer for proper diagnosis NOTE All segments of the rider information center will light up for 2 5 seconds at start up 46 FEATURES AND CONTROLS Instrument Cluster Magnum 330 Rider Information Center The rider information center has 4 standard modes Mode 1 Odometer Mode 2 Tripmeter Mode 3 Total Service Hours Mode 4 Programmable service interval 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 me
75. r 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 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 SAFETY Operator Safety 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 ey jumps or other stunts Avoid fe exhibition driving 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 in safe operating condition Always follow the inspection and maintenance procedures and schedules described in the owner s manual 17 SAFETY Operator S
76. r 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 4 Transfer your weight forward 5 Proceed at a steady rate of speed and throttle opening 6 Remain alert and be prepared to take emergency action This may include quick dismounting of the vehicle If all forward speed is lost Keep your weight uphill Apply the single lever brake gradually When fully stopped apply the auxiliary 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 auxiliary rear brake while rolling backwards Apply the single lever brake gradually When fully stopped apply the auxiliary 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 62 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 oper
77. r changes Never go over the top of a hill at high speed Always follow proper procedures for going downhill and for 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 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 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 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 Always be careful of skidding or sliding On slipp
78. r new Polaris 4 cycle 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 50 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 CAUTION Mixing brands or using a non recommended oil may cause serious engine damage We recommend the use of Polaris Premium 4 synthetic Oil or another OW 40 API certified SH oil Never substitute or mix oil brands Fill the fuel tank with gasoline See page 41 Check the oil level on the dipstick See page 75 Add Polaris Premium 4 Synthetic Oil if necessary to maintain the oil level in the normal safe operating range 1 Drive slowly at first Select an open area that allows room to familiarize yourself with vehicle operation and handling Vary throttle positions Do not operate at sustained idle Perform regular checks on fluid levels controls and areas outlined on the daily pre ride inspection checklist See page 51 Pull only light loads During the break in period change both the oil and the filter at 20 hours
79. r service Handlebars The handlebars can be adjusted for 1 rider preference 1 Remove the handlebar cover 2 Loosen the four handlebar bolts 1 3 Adjust the handlebar to the desired height Be sure the handlebars do not contact the gas tank or any other part of the machine when turned fully to the left or right 4 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 95 MAINTENANCE AND LUBRICATION Adjustments Carburetor IMPORTANT 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 about jetting the ATV for conditions in your area If the engine idle speed is not satisfact
80. ris sets a standard of excellence for all utility and recreational vehicles manufactured in the world today Many years of experience have gone 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 WELCOME sua ine thet Ace nual weeded yess 3 VEHICLE IDENTIFICATION NUMBERS 7 SAFETY malapro Tr u Ee EE unde eens 8 FEATURES AND CONTROLS 34 OPERATION ri hienn aiaa babi atone dad 50 EMISSION CONTROL SYSTEMS 67 MAINTENANCE AND LUBRICATION 68 POLARIS PRODUCTS 05 108
81. roper 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 insulator 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 82 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 9 10 11 Move the ATV to dry land or at the very least to water below the footrests Check the airbox for any water and dry it if water is present Turn the fuel valve off Remove the spark plug Loosen the carburetor drain screw 1 Turn the engine over several times using the electri
82. rson could be on the other side of the hill SAFETY Operator Safety 4 amp WARNING POTENTIAL HAZARD s Traveling downhill improperly WHAT CAN HAPPEN Improperly descending a hill could cause loss of control or overturn 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 g required when braking while SA ii traveling downhill See page 61 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 POTENTIAL HAZARD IIN Improperly crossing hills and ko SR 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 62 Use extra caution when turning on any hill Avoid crossing the side of a steep hill When crossing the side of a hill 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
83. rying cargo or pulling a trailer See page 56 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 Always keep combustible materials away from the exhaust system Exposure to the hot components could result in a fire 27 SAFETY Safety Decals and Locations Warning decals have been placed on the ATV for your protection Read and follow the instructions of the decals and other warnings on the ATV carefully If any of the decals shown in this manual differ from the decals on your ATV always read and follow the instructions of the decals on the ATV
84. se 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 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 103 MAINTENANCE AND LUBRICATION Cleaning and Storage Storage Tips See page 108 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 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 Us
85. st fumes are poisonous and can cause loss of consciousness 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 chemicals known to cause cancer birth defects or other reproductive harm Operate this vehicle only outdoors or in well ventilated areas 33 FEATURES AND CONTROLS Electrical Switches 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 1 Light Switch Hi Lo Beam Control The lights won t turn on unless the main switch is on 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 2 Override Switch Reverse Speed Limiter This vehicle is equipped with a reverse speed limiter system To gain additional power while backing depress the override switch NOTE The override switch also allows activation of AWD in reverse if the AWD switch is on 34 FEATURES AND CONTROLS Electrical Switches 3 Engine Stop Switch The engine will not start or run when the switch is i
86. t Auxiliary Brake Park Brake Headlight Tail Brake Lah Baten DC Pug m Read Electric Sta High Beam Indicator High Temp Indicator Windshield Neutral Indicator Speedometer Tool Kil 110 SPECIFICATIONS 2005 Magnum 330 2X4 Jetting Chart Altitude AMBIENT Below 40 F 40 F and above TEMPERATURE Below 5 C 5 C and above Meters 0 1800 127 5 Feet 0 6000 1800 3700 6000 12000 Clutching Chart Altitude Shift Drive Clutch Driven Clutch Helix Spring Weight Spring Spring Setting Meters 0 1800 16 Blue Green Black 41 35 Feet 0 6000 5630279 7041157 7041782 5133701 2 2 1800 3700 20 38 Blue Green Black 41 35 6000 12000 5631357 7041157 7041782 5133701 2 2 111 SPECIFICATIONS 2005 Magnum 330 4X4 Body Style Gen IV 1100 1s COOKE 325 gal 231 Tas 08 135 07 G00 mi 507 48 mi 100z G00 mi 50 Tos GOS ke 180 s GL Ke 100 Ibs 45 4 kg Rear rack weight and tongue weight not to exceed 180 lbs 1000 Tbs 454 ke 71 in 180 cm unloaded 6775 071 em BI in 205 7 em a6 in 168cm 16 in 168 em 34 in 6A om 1975 in 126 4 cm G37 Ths C89 ke ES32PFE103 4 Cycle Single Cylinder Wer Sump 785x68 329cc 92 1 Full Stroke Air with fan assisted oil cooler 200w 5000 rpm TT BST34 CV TPS 1225 723 mB T0 2C DCCDI 307 2 5000 RPM NGK BKR6E 036 in 9 mm 112 SPECIFICATIONS 2005 Magnum 330 4X4 Drive Sytem Type Shit Type Fr
87. t extend over the rack sides Stability and maneuverability may be adversely affected causing the vehicle to overturn e DO NOT BLOCK THE FRONT HEADLIGHT BEAM when carrying loads on the front rack e DO NOT TRAVEL FASTER THAN THE RECOMMENDED SPEEDS Vehicle should never exceed 10 mph 16 kph while towing a load on a level grass 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 57 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 58 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 Drive with AWD engaged AWD models to 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 allow the rear wheels to stop spinning before engaging AWD or engage AWD before wheels begin to lose traction 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 Neve
88. tem yearly Drive belt Cooling system if applicable Engine oil change 100 H Oil filter change 100 H Valve clearance 100 H Fuel system filter 1000 1600 Perform a break in oil change at one month 1000 1600 Replace with oil change 1000 1600 Inspect adjust 1000 1600 Check for leaks at tank cap lines fuel valve filter pump carburetor replace lines every two years 1000 1600 Inspect clean external surfaces Cooling hoses 1000 1600 Inspect for leaks if applicable Exhaust muffler 100 H 12M 1000 1600 Inspect pipe Spark plug 100 H 1000 1600 Inspect replace 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 Radiator if applicable 70 MAINTENANCE AND LUBRICATION Periodic Maintenance Chart Maintenance Interval whichever comes first Peres Miles Km Wiring 100 hia 1000 1600 Inspect for wear routing security apply dielectric grease to connectors subjected to water mud etc Pan drive 100 H 1000 1600 Inspect clean replace worn WE anon parts Front wheel 100 H 1000 1600 Inspect replace as needed bearings m Brake ua 200 24M 000 6200 Change every wo years Sparkarrestor soo som 3000 4800 Cleanout Efese o O OO Aust asrecded Toe adjustment Inspect periodically adjust Mee E MEC A asco
89. ter 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 47 FEATURES AND CONTROLS Instrument Cluster Magnum 330 Rider Information Center Mode 4 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 turned off You must enable the programmable service interval before it can be used Once the 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
90. the brake lever la yin HEH To release the parking brake lock squeeze and release the brake lever It will return to its unlocked position Important Safeguards The parking brake may relax if left on for a long period of time Al ways block the wheels to prevent rolling Always block the wheels on the downhill side of the ATV if leaving it parked on a hill Another option is to park the ATV in a sidehill position Never depend on the parking brake alone if the ATV is parked on a hill Always block the wheels to prevent rolling 39 FEATURES AND CONTROLS Auxiliary Brake 4 amp WARNING Aggressively applying the auxiliary brake when backing down a hill may cause rear tipover which could result in serious injury or death Use caution when applying the auxiliary brake Do not aggressively apply the auxiliary brake when going forward The rear wheels may skid and slide sideways causing loss of control and serious injury or death The auxiliary brake 1 is located on the inside of the right floor board and is operated by the right foot The auxiliary brake serves as a backup to the main brake system if the main system becomes inoperative 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 bra
91. tle to idle speed then shift the transmission to the lowest available range 4 Test for belt slippage If the belt slips repeat the process 5 Take the vehicle to your dealer for service as soon as possible 87 MAINTENANCE AND LUBRICATION Battery 4 amp 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 installing 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 89 before installing the battery 1 ON ROO 88 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 L
92. unused portion Never store or use a partial bottle Brake fluid 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 37 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 hydraulically activated disc type brakes that are activated by only one 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 riding Contact your dealer for proper diagnosis and repairs 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 38 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 Setting the Parking Brake 1 Squeeze and release the brake 1 2 lever 1 two or three times then squeeze and hold Push the park brake lock 2 forward to engage the brake Release
93. upon average riding conditions and an average vehicle speed of approximately 10 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 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 68 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 Pe Make adjustments as need Farner a 8 Sere ch pe p e CEA CE Pern Pre Ride Whestafesteners Pre Ride Frame fasteners o e g Air filter pre filter HRR 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 Insp
94. vehicle serviced by your dealer at the first opportunity 63 OPERATION Driving Safely Driving Over Obstacles Be alert Look ahead and learn to read the terrain you re traveling on 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 immediately visible Travel with caution in unfamiliar terrain 64 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
95. 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 Find out more about our exciting once in a lifetime 50th Anniversary celebration Go to www polarisindustries com and look for the 50th Anniversary link This is a ride you don t want to miss POLARIS The Way Out ef F En i i E a axe i ps 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 Magnum 330 2X4 4X4 Owner s Manual P N 9919487 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 Pola
96. 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 offi cials or military personnel on assignment outside of the 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 121 INDEX A AccessorieS 0 eee 103 Adjustments 91 102 Age Restrictions 8 Alt Filter seese rasna aes 102 All Wheel Drive 44 All Wheel Drive Switch 35 Auxiliary Brake 40 92 AWD Switch 000 35 B Battery 2 035 ee ieee vies bd 88 90 Battery Charging 89 90 Battery Installation 88 Battery Removal 88 Battery Storage 0 89 Belt Lite i Sper tee Sean 42 Brake Lever 63 3 3 oe a eed dens 38 Brakes oyee doy tents subtests 37 91 Break In Period 50 Cc Camber and Caster 94 Carburetor
97. 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 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 SAFETY 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 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 exhau

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