Polaris Magnum 330 2x4 manual

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A car d cont aining import ant A TV saf ety infor mat ion should be at tac hed to t he owner ’s manual on t he next page. If you c annot loc ate t his c ard, or if it has been rem oved, please call 1- 800-342-3764 f or as sist ance. The engine exhaust from this product contains chemic als know n to cause cancer , birth defects or other reproducti[...]

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2 Copyr ight 2004 Pol a r is Sa l e s Inc . All inf or m a t i on c ont a ine d wi thi n t his publ i c a t ion i s ba se d on t he la te st pr oduct i nfor ma ti on a t the t ime of publ ic at ion. Due t o c ons t a nt imp ro v emen ts in the desig n and q u ality o f p r oduc ti on c omponent s, s ome mi nor d iscrepan cies may resu lt b etween t[...]

3 WELC O ME Thank you f or purcha sing a Polaris vehic le, and welc ome to our wor ld-wide fa mily of Pola ris owner s. W e proudly produc e an exciting line of utility an d re cre ationa l pr oducts. Polar is Recr eatio nal and Utility V ehicles S Snowmobiles S All- ter rain ve hicles ( A TVs) S W at ercraft S V ict ory m ot orcy cles S RANGER uti[...]

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5 TABLE OF CONTENTS WELCO ME 3 ................................. VEHICL E IDENT IF ICA TIO N NUMBERS 7 ........ SAFET Y 8 ................................... FEA TURES AND CONTROLS 34 ............... OPE RA T ION 50 .............................. EMI SSION CONTRO L SYSTEMS 67 ............ MAINTENANCE AND LUBRICA TION 68 ......... POLARIS PRODUCTS 1[...]

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7 VE HICLE IDENTIFICATION NUMBERS Recor d your A TV’ s identif ication numbe rs an d key numbe r in the sp aces pr ovi ded . Rem ov e th e spare k ey and st ore i t i n a s afe pl ace. Y our ke y ca n be duplica ted only by ma ting a Polar is key blank w ith one of your ex isting keys, so if both ke ys are lost, the ignition switch mu st be rep l[...]

8 SA FETY Operator S afety W ARNING Failur e to f ollow t he warnings c ontained in t his m anual can res ult in serious injury or deat h. A Polar is A T V is not a t oy and can be haz ardous t o operat e. This vehicle handles differ ently than ot her v ehicles, suc h as motorcycles and cars. A collision o r rollover can occur quickly , even during[...]

9 SA FETY Operator S afety The f ollowing signal wor ds and symbols appe ar throughout this manua l and on your A TV . Y our saf ety is involve d when the se words and symbols ar e used. Become f amiliar w ith their mea nings be fore re ading the manual. The safet y alert s ymbol , on your vehic le or in t his manual, alert s you t o the pot ent ia[...]

10 SA FETY Operator S afety W ARNING Serious injury or deat h can res ult if you do not follow thes e inst ruct ions and pr ocedures , whic h are out lined in fur ther detail within y our owner ’s manual. S Rea d this manual and a ll lab els ca ref ully , and follow the oper ating proc edure s describe d. S Neve r operate a n A TV without proper [...]

11 SA FETY Operator S afety S Alway s have t he A TV i nsp ected b y an aut hori zed P ol aris d ealer i f it ’ s been involved i n an accident. S Ne ver ope rate on hills too steep for the A TV or for your a bilities. Pra ctice o n smalle r hills befo re a ttempting lar ger hills. S Alwa ys f ollow prope r proce dures for c limbing hills. Chec k[...]

12 SA FETY Operator S afety S W et br ake s may ha ve reduc ed stopping ability . T est your bra kes a fter lea ving wate r . If ne cessa ry , apply the m lightly se ver al times to allow frict io n to d ry out t he pad s. S Always che ck for obstac les or pe ople behind the A TV be fore oper at- in g in rev erse. When i t’ s s afe to pro ceed in[...]

13 SA FETY Operator S afety W ARNING POTENTI AL HAZ ARD Oper ating t his A T V wit hout proper ins tr uct ion. WHA T CAN H APPEN The r isk of an acc ident is great ly inc reased if t he operator does not k now how to oper ate t he A T V proper ly in differ ent s ituat ions and on different t ypes of t err ain. HOW T O A VOID TH E HA ZA RD Beginning[...]

14 SA FETY Operator S afety W ARNING POTENTI AL HAZ ARD Carry ing a passenger on an AT V . WHA T CAN H APPEN Carry ing a passenger great ly reduces t he operat or ’s ability to balance and cont rol t he A TV , which could caus e an accident and injury t o t he operat or and/or pas senger . HOW T O A VOID TH E HA ZA RD Never c arry a pass enger . [...]

15 SA FETY Operator S afety W ARNING POTENTI AL HAZ ARD Oper ating t his A T V on public st reet s, r oads or highways. WHA T CAN H APPEN The A T V c ould collide with anot her v ehicle. HOW T O A VOID TH E HA ZA RD Never oper ate t he A T V on any public st reet , road or highway , including dirt and gr avel roads . In many st ates it’s illegal [...]

16 SA FETY Operator S afety W ARNING POTENTI AL HAZ ARD Oper ating t he A T V af ter consum ing alcohol or dr ugs. WHA T CAN H APPEN Consumpt ion of alcohol and/ or drugs could ser iously aff ect operat or judgment . Reac tion t ime m ay be slower and operat or balance and per cept ion could be affec ted. Consuming alc ohol and/or drugs befor e or [...]

17 SA FETY Operator S afety W ARNING POTENTI AL HAZ ARD At tem pting wheelies , jum ps and other st unts . WHA T CAN H APPEN At tem pting s tunt s inc reases the c hance of an acci dent, including an over tur n. HOW T O A VOID TH E HAZ ARD Never at tem pt wheelies, jumps, or ot her st unts . Avoid exhibit ion driving. W ARNING POTENTI AL HAZ ARD Fa[...]

18 SA FETY Operator S afety W ARNING POTENTI AL HAZ ARD Removing hands f rom t he handlebars or f eet f rom the f oot rest s during operat ion. WHA T CAN H APPEN Removing ev en one hand or f oot c an reduce abilit y t o cont rol t he vehicle or could c ause loss of balanc e and eject ion fr om t he A T V . If t he operator ’ s foot is not f irml [...]

19 SA FETY Operator S afety W ARNING POTENTI AL HAZ ARD Failu re t o use e xtra caut ion when operat ing on exces sively r ough, slippery or loos e ter rain. WHA T CAN H APPEN Operatin g on excessi vely rough, s lippery or loose ter rain could c ause loss of tr act ion or loss of c ontr ol, which could r esult in an accident or ov ert urn. HOW T O [...]

20 SA FETY Operator S afety W ARNING POTENTI AL HAZ ARD Oper ating on ex cess ively s teep hills . WHA T CAN H APPEN The v ehicle may over tur n. HOW T O A VOID TH E HA ZA RD Never oper ate on hills too s teep f or t he A T V or f or y our abilit ies. Never oper ate t he A T V on hills s teeper than 25 _ . Prac tic e on smaller hills bef ore at tem[...]

21 SA FETY Operator S afety W ARNING POTENTI AL HAZ ARD T rav eling downhill improper ly . WHA T CAN H APPEN Im properly descending a hill could caus e loss of cont rol or overt urn. HOW T O A VOID TH E HAZ ARD Always follow pr oper procedur es for t rav eling down hills as des cribed in the owner ’ s m anual. NOT E: A spec ial tec hnique is requ[...]

22 SA FETY Operator S afety W ARNING POTENTI AL HAZ ARD Im properly c ross ing hills and tur ning on hills. WHA T CAN H APPEN Im properly cr ossing or tur ning as hills c ould cause loss of cont rol or overt urn. HOW T O A VOID TH E HAZ ARD N e v e ra t t e m p tt ot u r nt h e A TV around on any hill unt il you’ve m ast ered t he tur ning tec hn[...]

23 SA FETY Operator S afety W ARNING POTENTI AL HAZ ARD St alling, r olling backwar ds or improper ly dismount ing while climbing a hill. WHA T CAN H APPEN The v ehicle could ov ert urn. HOW T O A VOID TH E HAZ ARD Maint ain st eady speed when climbing a hill. If all f orward s peed is lost: Keep your weight uphill. Apply t he single lev er brak e [...]

24 SA FETY Operator S afety W ARNING POTENTI AL HAZ ARD Im properly operat ing over obst acles. WHA T CAN H APPEN Oper ating ov er obst acles could c ause loss of c ontr ol or over tur n. HOW T O A VOID TH E HA ZA RD Bef ore operat ing in a new ar ea, chec k f or obst acles . Avoid operating ov er lar ge obst acles s uch as r ocks and fallen tr ees[...]

25 SA FETY Operator S afety W ARNING POTENTI AL HAZ ARD Oper ating t he A T V t hrough deep or f ast -f lowing wat er . WHA T CAN H APPEN T ires m ay float , c ausing loss of t rac tion and loss of c ontr ol, which could lead t o an accident or overt urn. HOW T O A VOID TH E HA ZA RD Avoid operating t he A T V t hrough deep or f ast -f lowing wat e[...]

26 SA FETY Operator S afety W ARNING POTENTI AL HAZ ARD Oper ating t he A T V wit h improper modif icat ions. WHA T CAN H APPEN Im proper ins tallat ion of acces sories or m odific ation of t he A T V may c ause changes in handling which c ould lead to an ac cident . HOW T O A VOID TH E HA ZA RD Never m odify the A T V t hrough im proper ins tallat[...]

27 SA FETY Operator S afety W ARNING Leaving t he keys in the ignit ion can lead t o unaut horized us e of the v ehicle res ulting in s erious injur y or deat h. Alway s rem ove the ignit ion key when the v ehicle is not in us e. W ARNING Af ter any over tur n or acc ident, have a qualif ied ser vice dealer inspect t he entir e vehicle f or pos sib[...]

28 SA FETY Safety D ecals and Locations W arning d ecals have been pl aced on the A TV for your protection. R ead and fo ll ow th e ins tru cti on s of th e decals an d ot her warni ng s on t he A TV careful ly . If an y of t he d ecals s ho wn i n t his man ual di f fer fro m the decal s on your A TV , al ways read and foll ow the inst ructi ons o[...]

29 SA FETY Safety D ecals and Locations Lo cati o n A Lo cati o n B Lo cati o n C Lo cati o n D Lo cati o n E (on models with racks) Lo cati o n E (on m odels wit h st orage box) Operat ing this A TV if you are under the age of 16 i ncreases your ch ance of severe i nj ury or death. NEVER ope ra te t his ATV if y ou a re under age 1 6. 7172559 W AR[...]

30 SA FETY Safety D ecals and Locations IMPROPER TIR E PRESSUR E OR OVER LOADING can c ause loss of control resulti ng in SEVERE IN JURY OR DEA TH. T IRE PRESSURE (PSI): FRO N T ___ RE AR ___ M AXI MUM WEI GHT CAP ACITY (G ros s V ehic le W eight) IN CLU DIN G MAC HI NE , DRI VER A ND C AR GO I S ____ LBS. Reduc e s peed and allow gr eater dis tanc[...]

31 SA FETY Safety D ecals and Locations Lo cati o n H ALL WHE EL DRIVE SWITCH Do not push s witch t o engage A WD if the rear wheels are spinning. This m ay c ause sev ere drive s haft and clut ch damage. See your Owner ’s Manual. 7079780 Reverse Speed is limited. Reverse ov erride is cont rolled by t he override s witch. See your Owner ’s Manu[...]

32 SA FETY Safe Ridi ng Gear Always we ar c lothing suited to the t ype of riding. A TV riding re quire s spec i al prote ctive clothing for comf ort and to reduc e the cha nce of injury . 1. Helm et Y our he lmet is the most impor tant pie ce of prote ctive ge ar for sa fe riding. A hel met can p revent a s evere head in ju ry . S elect an app rov[...]

33 SA FETY Fuel Safety W ARNING Gas oline is highly f lamm able and explosiv e under cer tain condit ions. S Always exerc ise ex tr eme caut ion whenever handling gasoline. S Always ref uel with t he engine st opped, and outdoor s or in a well vent ilated ar ea. S Do not s moke or allow open fl ames or spark s in or near the area where r efueling i[...]

34 FEATURE S AND CO NTROLS Electr ical S witches W ARNING Oper ating t he A T V on st reet s or roads, espec ially in dark ness, could res ult in an ac cident and ser ious injury or deat h. Y our A T V is not equipped wit h highway-appr oved light s. I t’s designed f or and mus t be us ed for of f -road use only . Use cau t ion and drive at reduc[...]

35 FEATURE S AND CO NTROLS Electr ical S witches 3. Engine St op Swit ch - The engine will not start o rr u nw h e nt h es w i t c hi si nt h e OFF position. Its purpose is to provide the oper ator with a quick mea ns of engine shutdown in c ase of a n eme rg enc y . T o stop the engine , slide the stop switch e ither right or lef t to the OFF posi[...]

36 FEATURE S AND CO NTROLS Throttle Lever Eng in e speed an d veh icl e moveme nt a re c ontrolled by pre ssing the throttle le ver . The throttle le ver (1) is spring lo aded. E ngi ne s peed return s to idle when the le ve r is releas ed. This A TV is e quipped with Polar is Ele ctronic Thr ottle Control (ETC), which is designe d to reduc e the r[...]

37 FEATURE S AND CO NTROLS Br akes Master Cylinder Ch eck t he b rake flu id lev el i n th e mas ter cy li nd er befo re each use of the A TV . The master cyl in der (1 ) is lo cated on t he l eft handle bar . V iew the fluid le vel through the indica t or window (2) on the top of the maste r cylinder . This eye will appe ar dar k when the fluid le[...]

38 FEATURE S AND CO NTROLS Br ake Lever The fro nt and rear brak es are app li ed by squ eezin g t he b rake lev er (1) towar d the handleba r . The front and re ar brak es ar e hydraulic ally ac tivated di sc t yp e brakes t hat are acti vat ed b y only one lever . Alway s tes t brake lev er travel an d maste r cylinder f luid level bef ore ridi n[...]

39 FEATURE S AND CO NTROLS Park in g Brak e W ARNING Oper ating t he A T V while t he parking br ake is engaged c ould result in an accident and ser ious injury or deat h. Always c heck t o be sure t he park ing brake is disengaged bef ore oper ating. Setting the P arking Br ake 1. S queeze an d rel ease t he b rake leve r (1) two or thre e times, [...]

40 FEATURE S AND CO NTROLS Auxiliary Brake W ARNING Aggres sively applying t he auxiliar y brak e when backing down a hill may c ause rear t ipover , which could r esult in serious injury or death. Use caut ion when applying t he auxiliar y brak e. Do not aggress ively apply t he auxiliary brake when going f orwar d. T he rear wheels may skid and s[...]

41 FEATURE S AND CO NTROLS Choke The choke a ssists in star ting a cold engine . Refer to the engine sta rting proc edur e on page 52 for cor rec t choke and throttle settings during star ting. Fuel V alve The f uel v alv e (1) i s l ocat ed o n t he left s ide o f the veh icle on the side pa nel. It has thre e positions: OFF: For vehicle stor age [...]

42 FEATURE S AND CO NTROLS Autom atic T r ansm ission Gear Selector The transmission ge ar se lec t or (1) is locate d on the right side of the vehic l e. H: High Gear N: Neutral L: Low Gear R: Rev er se P: Pa rk T o s hift i nto HIGH or P ARK, you must first apply the auxilia ry brake to ac tivate the high/par k lock-out mec hanism. Whe n shifting[...]

43 FEATURE S AND CO NTROLS Recoil S tarter If the ba tter y has be en draine d or dama ged and ca nnot start the engine , use of the re coil starte r (1) will allow ve hicle ope ration until re pairs can be ma de. The rec oil star ter is locate d on the right side of t he m achi ne. Polaris 4- cycle engine s are equippe d with automa tic deco mpres[...]

44 FEATURE S AND CO NTROLS All W heel Dr ive S ystem (D omestic Models) Polar is 4 whe el drive domestic model A TVs ar e equippe d with a unique, Polar is exc lusive, All W heel Driv e (A WD) Sy st em acti vat ed by a switch ( 1) on the r ight handlebar . Eng age t he A WD when the r ear wheel s l ose t ract ion . When t he A WD s wit ch i s off, [...]

45 FEATURE S AND CO NTROLS Instrum ent Cluster (Magnum 330) Y our A TV is equipped w ith an instrume nt c luster tha t se nses ve hicle spee d from the r ight front whee l . The instr ument c l uster mea sure s distanc e in miles a s well as hour s of opera tion. It also inc ludes a re verse spee d limiter f unction tha t limits the A TV’ s spee [...]

46 FEATURE S AND CO NTROLS Instrum ent Cluster (Magnum 330) Ri der Infor ma tion Center The r ider info rma tion ce nter is loca t e d in the lowe r portion of the instrume nt cluster . 1. Gea r Indica t or - As the shift leve r is move d, this will indicate the gea r the mach in e is i n: H = High R ange L = Low Range N = Neutral R = Reverse P=P a[...]

47 FEATURE S AND CO NTROLS Instrum ent Cluster (Magnum 330) Ri der Infor ma tion Center The r ider inf orma tion ce nter ha s 4 standar d modes: Mode 1 - Odometer Mode 2 - T ripme ter Mode 3 - T otal Servic e Hours Mode 4 - P rogr ammable se rvice inte rva l The re ver se override button on the left handleb ar is also the mode button . NOT E: I f u[...]

48 FEATURE S AND CO NTROLS Instrum ent Cluster (Magnum 330) Ri der Infor ma tion Center Mo de 4 - Progr ammab le Service Int e rval The purpose of the progr ammable se rvic e inter val is to pr ovide the consume r and deale r with a c onvenient reminde r for routine mainte nance . When your vehic l e lea ves the fac t ory , this fe ature is turne d[...]

49 FEATURE S AND CO NTROLS Instrum ent Cluster (Magnum 330) Ri der Infor ma tion Center Dia gnosti c Mode The diagnostic mode is for infor mational purposes only . P lea se re turn your A TV to your deale r for all major re pairs. T o enter the diagnostic s m ode : 1. T urn the ke y switch of f and wa it 20 sec onds. 2. Set the pa rk bra ke and shi[...]

50 OPERATION Br eak - In P er iod The br ea k-in per iod for your ne w Polaris 4- cycle A TV is defined a s t he firs t t e n hours of opera tion, or the time it ta kes to use the first two full tanks of ga soline. No single ac tion on your part is as impor tant as following the proc edures for a pr oper bre ak-in. Care ful trea tment of a new e ng[...]

51 OPERATION Pr e -Ride Inspection W ARNING If a proper inspec tion is not done bef ore eac h use, sever e injury or deat h could res ult. A lways ins pect the v ehicle bef ore each us e to ens ure it ’ s in proper operat ing condit ion. Pre - Ride Che ck li st Item Remarks See Page Br ake system / lever t ravel Ensure proper oper ati on 37, 38 B[...]

52 OPERATION Star ti ng the Engi ne S tar ting a Col d Engine W ARNING Engine exhaus t c ontains poisonous c arbon monox ide and can cause los s of consc iousnes s res ulting in s evere injur y or deat h. Never r un an engine in an enclosed ar ea. 1. Place the tr ansmission in P ARK and lock the par king br ake . Make sure the fue l valve is on. 2.[...]

53 OPERATION Star ti ng the Engi ne S tar ting a W ar m E ngine W ar m engines do not nor mally re quire the use of the c hoke. Exce ssive use of the choke ca n cause the spa rk plug to become we t fouled. 1. Position the vehicle on a leve l surfac e with the transmission in PA R K . 2. Lock t he park in g brake, t urn t he fuel t ank val ve to ON [...]

54 OPERATION Driving Safely Driving Pr o cedures 1. Sit upright with both feet on the footre sts and both hands on the handle bars. 2. Start the engine and allow it to warm up, then shif t the tra nsmission into gea r . 3. Check your sur roundings and dete rmine your path of trav el. 4. Relea se t he par king brake. 5. Slowly depre ss the throttle [...]

55 OPERATION Driving Safely Making T urns Y our Pola ris A TV is equippe d with a solid re ar a xle tha t drive s both re ar wh ee ls equally a t all times. This me ans that the whe el on the outside of the turn must tra vel a greate r distance tha n the inside wheel whe n turning and the inside tir e must slip trac tion slightly . T o make a turn,[...]

56 OPERATION Driving Safely Hauling Cargo Y our A TV has bee n designed to ca rry or tow a c er tain a m ount of loa d. Always r ea d and understa nd the load distr ibution war nings listed on th e warnin g lab els , and n ever exceed t he sp ecifi ed weig ht s. Car go we i ght should be e venly distribute d (1/3 on the fr ont and 2/3 on the r ea r[...]

57 OPERATION Driving Safely Hauling Cargo W ARNING S REDUCE SPEED AND ALLO W G REA T ER DIST ANCES FO R BRAKING WHEN HAULING C ARGO. S CARG O W EI G HT DI ST RI BUT IO N should be 1/ 3 on the f ront rack and 2/ 3 on the r ear rac k. When oper ating ov er r ough or hilly t errain, reduc e speed and car go to m aintain s table dr iving condit ions. C[...]

58 OPERATION Driving Safely Dr iving on Slippe r y Surfaces When ever ridi ng o n sl ip pery su rfaces su ch as wet t rail s or lo os e gravel, or du rin g freezing weat her , fol lo w th ese precaut io ns : 1. Slow down when e nter ing slippery a reas. 2. Mai nt ain a hi gh lev el o f al ertnes s, read in g t he t rail an d avo id in g qu ick, s h[...]

59 OPERATION Driving Safely Driving Uphill Whe neve r tra veling uphill, f ollow these precau ti on s: 1. Alwa ys trave l straight uphill. 2. A void stee p hills (25 _ maximum) . 3. Kee p both feet on the footre sts. 4. T ransfe r your weight forwa rd. 5. P roceed at a s tead y rate of speed and throttle ope ning. 6. Rem ai n al ert and b e p repar[...]

60 OPERATION Driving Safely Sidehilling W ARNING Im properly cros sing hills or t urning on hills c an result in loss of cont rol or v ehicle over tur n, r esult ing in sever e injury or deat h. Avoid cross ing the s ide of a hill when pos sible. F ollow proper procedur es as out lined in t he owner ’s manual. Sidehilling ca n be the most danger [...]

61 OPERATION Driving Safely Driving Downh ill Whe never de scending a hill, follow these pr ecauti on s: 1. P roceed di rect ly d ownh ill. 2. T ransf er your we ight to the re ar of the ve hicle. 3. Sl ow down. 4. Apply the brakes slightly to aid in slowing, using the single bra ke leve r . NOT E: F amiliar ize your self with oper ation of t he au[...]

62 OPERATION Driving Safely T urni ng Ar ound on a Hi ll W ARNING Im proper hill c limbing pr ocedures could caus e loss of cont rol or overt urn and r esult in seri ous injury or deat h. Avoid climbing st eep hills ( 25 _ maximu m). Use ext rem e caut ion when operat ing on hills, and follow pr oper operat ing procedur es out lined in the owner ?[...]

63 OPERATION Driving Safely Dr iving Thr ough W ater Y our A TV can ope rate thr ough wa ter with a maximum re commende d depth equa l to the bottom of t he footr ests (1). Follow these proce dures when oper ating through wa ter: 1. Dete rmine water de pths and curren t befo re cr ossing. 2. Choose a crossing wher e both banks have gradua l incline[...]

64 OPERATION Driving Safely Dr ivin g Over Obstacles Be al ert! L ook ah ead and l earn to read t he terrai n yo u’re trav eli ng o n. Be con st ant ly al ert fo r hazards s uch as l og s, r ocks an d lo w hang in g bran ches . W ARNING Sever e injury or death c an result if your v ehicle com es in cont act with a hidden obs tac le. Not all obst [...]

65 OPERATION Driving Safely Dr ivin g in Rever se F oll ow t hese pr ecauti on s when op erati ng i n revers e: 1. Alwa ys a void bac king downhill. 2. Back slowly . 3. Whe n in rever se, apply the bra kes lightly f or stopping. 4. A void turning at sha rp a ngles in re verse . 5. Ne ver ope n the throttle suddenly while bac king. W ARNING Failur e[...]

66 OPERATION Driving Safely P a r k i n go na nI n c l i n e A void par king on an inc line if possible. If it’ s unavoidable , follow th ese p recaut io ns: 1. T urn the engine of f. 1. Place the tr ansmission in P ARK. 2. Set t he par king br ake . 3. Always block the rea r wheels on the downhill side. See illustra tion. 4. Shut of f the fue l [...]

67 EMISSION C ON TR OL SYSTEMS Noise E mi ssion Contr ol System Do not modif y the engine, intake o r exhaust compone nts, as doing so may af fec t c omplianc e with state and loca l noise le vel re quireme nts. Cr ankcase E mission C ontrol S ystem This engine is equipped with a close d crankc ase system. Blow-by gase s are f orce d back to the c [...]

68 MAINTENANCE AND LUBRICATION Per iodic Maintenance C hart Care ful periodic mainte nance will help kee p your ve hicle in the safe st, most relia ble condition. Inspe ction, adjustment a nd lubrica tion of importa nt components ar e expla i ne d in the pe riodic mainte nance c har t. Ins pect , clean , lub ricat e, adj us t and repl ace p arts as[...]

69 MAINTENANCE AND LUBRICATION Per iodic Maintenance C hart P erform all s ervi ces at whi chever mai nt enance in terv al is reached fi rst . Item Maint enance Inter val (w hichev er c omes f irs t) Remarks Hours C alendar Miles (Km) J Steer ing -- Pre- Ride -- Mak e adjustments as need- e d S e e P r e R i d e C h e c k l i s t " Front s us [...]

70 MAINTENANCE AND LUBRICATION Per iodic Maintenance C hart Item Maint enance Inter val (w hichev er c omes f irs t) Remarks Hours C alendar Miles (Km) " Gener al lubric ation 50 H 3M 500 ( 800) Lubricate all f ittings , piv ots , c ables, et c. Car buretor float bowl 50 H 6M 500 ( 800) Drain bowl per iodic ally and prior t o st orage J E Thro[...]

71 MAINTENANCE AND LUBRICATION Per iodic Maintenance C hart Item Maint enance Inter val (w hichev er c omes f irs t) Remarks Hours C alendar Miles (Km) " Wirin g 100 H 12 M 1000 (1600) Ins pec t for w ear , routing, s ecur ity ; apply dielec tr ic greas e to c onnec tors s ubject ed to water , mud, etc . J Clutc hes ( driv e and driv en) 100 H[...]

72 MAINTENANCE AND LUBRICATION Lubr ication Gui de Chec k and lubric ate all c omponents a t the inte rvals outline d in the Periodic Ma intena nce Cha rt beginning on page 68. Items not liste d in the cha rt should be l ubric ated at the Gene ral Lubrica tion interval. Item Lube Method Engine O il Premium 4 S ynt hetic 0W40 See page 75. Brak es D [...]

73 MAINTENANCE AND LUBRICATION Per iod ic Maintenan ce Recor d Use t he fol l owin g chart t o record peri odi c mai nt enance. Maintenance In terval Perfo rmed Se rv icing Date Ser vic ing Dealer or Pe rs on Remarks[...]

74 MAINTENANCE AND LUBRICATION Pr em ium 4 S ynthetic Lubr icant Polaris Pre mium 4 All Sea son synthetic engine oil has be en spe cially for m ula ted for use in Polar i s 4-c ycle e ngines. It’ s a fully synthetic, high per forman ce , multi-visc osity oil de signed to provide the ultima te in l ub ricat io n perform ance and p rot ecti on. NOT[...]

75 MAINTENANCE AND LUBRICATION Engi ne Oil C heck The o il dipstick ( 1) is loca ted on the lef t side of the engine. NOT E: A rising oil lev el between check s in cool weat her dr iving can indicat e cont aminant s such as gas or mois tur e coll ecting in the cra nkcase . If the oi l le vel i s ove r the full/ saf e mar k, change t he oil immediat[...]

76 MAINTENANCE AND LUBRICATION Oil and Filter Change 5. Place a dr ain pan bene ath t he engine c rankca se and remove the dra in plug. 6. Allow the oil to dra in complete ly . 7. Insta ll a new se aling washe r on the dra i n plug. NOT E: T he sealing s urf aces on t he drain plug and c rankc ase should be clean and f ree of burr s, nicks or sc ra[...]

77 MAINTENANCE AND LUBRICATION T r ansmission Oil Always che ck and cha nge the t ra nsmission oil at t he inte rva ls outline d in the P e riodic Mainte nance Chart beginning on page 68. Mainta in the oil le vel 1 5/8” from the top of the fill hole. W e re comme nd the use of Pr emi um AGL Sy nt heti c Gearcase Lub rican t. R efer to th e gearca[...]

78 MAINTENANCE AND LUBRICATION Front Gear case Oil Alway s ch eck and chang e th e front gearcas e oi l at th e in terv als outlined in the Periodic Mainte nance Cha rt beginning on page 68. Refer to the g earcase s peci ficat io ns chart on p age 7 6. S ee pag e 108 for the pa rt numbers of Polaris pr oducts. Oil Check W e rec ommend the use of Po[...]

79 MAINTENANCE AND LUBRICATION Rear Gear case Oil Oil Check Alway s ch eck and chang e th e rear gea rca se oil a t the inter vals outlined in th e P eriod ic M ain ten ance C hart beginning on pa ge 68. Mainta in the rea r gea rcase oil le vel a t t he bottom of the fill hole threa ds (1). W e rec ommend the use of Polaris Premium A TV Angle Dr iv[...]

80 MAINTENANCE AND LUBRICATION Lights Whe n servic ing a ha logen lamp, don’ t touch the la mp with bar e finger s. Oil fr om your skin le aves a re sidue, causing a hot spot tha t will shorten the life of the la mp. W ARNING Poor light ing while driv ing can res ult in s evere injur y or deat h. Headlight and t aillight lenses bec ome dirt y dur[...]

81 MAINTENANCE AND LUBRICATION Lights T aillight/Brakelight Lamp Replacement If the taillight/br akelight does not wor k the lamp may ne ed to be repl aced. 1. Remove the ta illight lens cove r mounting scre ws. Remove the lens c over and gaske t and set aside f or rea ssembly . 2. Remove the lamp (1). 3. Apply dielec tric grea se to t he so cket a[...]

82 MAINTENANCE AND LUBRICATION Spar k P lugs Refe r to t he spe cifica tions sec tion beginning on page 109 for spark plug and g ap speci fi cati ons . CAUTION Using non-r ecomm ended spark plugs c an result in ser ious engine damage. Alway s use P olaris- recom mended spar k plugs. Spar k plug condition is indica tive of e ngine ope ration. The sp[...]

83 MAINTENANCE AND LUBRICATION V eh ic le I mmersi on CAUTION If your vehic le becomes immer sed, major engine dam age can result if the m achine is not t horoughly ins pect ed. T ake t he vehicle t o your dealer bef ore s tart ing t he engine. If it’ s impossible to take your A TV to a deale r bef ore sta rting it, follow the steps outlined belo[...]

84 MAINTENANCE AND LUBRICATION Spar k Ar r estor W ARNING Failur e to heed t he f ollowing warnings while s ervic ing the s park arres tor could r esult in ser ious injury or deat h. Do no t pe rform service on the sp ark arrestor whi le the system is hot. Exhaust system t em peratures ca n reach 1000 ° F . A llow component s t o cool s ufficient [...]

1 85 MAINTENANCE AND LUBRICATION Recoil Hou sing T o prevent possible engine dama ge, alwa ys drain the re coil housing (1) af ter opera ting t he A TV in ve ry we t conditions. This should also be done befor e storing the A TV . NOT E: Water will enter t he recoil housing if the s tar ter handle is disengaged f rom the r ope guide when under water[...]

86 MAINTENANCE AND LUBRICATION PV T System The basic ope ration of the P olar is PVT system is de pende nt on engine sp eed and veh icl e to rque req ui rement s . As eng in e speed in creases , t he forc e exer ted on the m ovable d rive shea ve by t he flywe ights also incr ease s. This, in turn, incr ease s the a mount of “pinc h” applie d t[...]

87 MAINTENANCE AND LUBRICATION PV T System W ARNING Failur e to c omply wit h t he inst ruct ions in t his warning c an result in sever e injury or deat h. Do not modify any component of th e PVT system. Doing so may reduce it s s tr ength s o that a f ailure may occur at a high s peed. The PVT system has been precisio n balanced. Any modif icat io[...]

88 MAINTENANCE AND LUBRICATION Batter y W ARNING Im properly connec ting or disconnec ting bat t ery c ables can r esult in an explosion and c ause ser ious injury or deat h. When remov ing the bat t ery , always dis connect t he negativ e (black ) cable f irst . W hen reinst alling t he batt ery , always connect t he negativ e (black ) cable las t[...]

89 MAINTENANCE AND LUBRICATION Batter y Batter y Stor age Whe never the ve hicle is not use d for a per iod of three months or more, remo ve t he bat t ery from th e veh icl e, ensu re th at i t’ s ful ly charged, and st ore it ou t of t he sun i n a cool , d ry pl ace. Ch eck bat tery v ol tag e each mo nt h du rin g st orage and r echarge as ne[...]

90 MAINTENANCE AND LUBRICATION Batter y Bat tery Cha rgin g NOT E: A lways v erif y bat ter y condit ion bef ore and 1-2 hour s af ter the end of c harging. Stat e of Char ge Vo l t a g e Acti on Charge T ime* (Us ing cons tant cur rent char ger @ standar d amps spec ified on top of battery) 100% 12.8- 13.0 volt s None, check at 3 mos. fr om date o[...]

91 MAINTENANCE AND LUBRICATION Adju stmen ts Br akes The front and re ar brake s are hydra ulic disc brakes, activa ted by moving the single brake le ver towar d t he handle bar . These bra kes ar e self -adjusting. The fo ll owi ng checks are recom men ded t o k eep t he brak e sys tem i n good oper ating condition. Chec k more of ten if bra kes a[...]

92 MAINTENANCE AND LUBRICATION Adju stmen ts Auxiliary Brake The auxilia ry brake is a hydraulic disc br ake. The rea r brake syste m is self -adjusting and r equire s no maint enan ce ot her t han p erio di c check s of t he pad s fo r wear . Change the bra ke pads when they’re wor n to 3/64 ″ (. 1 cm). Ins pect the b rake d is c spl in e and [...]

93 MAINTENANCE AND LUBRICATION Adju stmen ts W ARNING Sever e injury or death c an result f rom improper toe alignm ent and adjust ment . Do not at tem pt t o adjust t ie rod alignment . All t ie rod adjust ment s should be per for med by an aut horiz ed Polaris dealer . T oe Ali gnm ent Use the following proce dure to chec k the toe alignment of t[...]

94 MAINTENANCE AND LUBRICATION Adju stmen ts Steer in g Assem b ly The ste er ing assembly of the A TV should be che cked pe riodica lly for loose nuts and bolts. If loose nuts and bolts are found, see your Polaris dea l er f or servic e befo re ope ra ting the vehicle. Cam b er and Caster The ca m ber a nd caste r are non- adjustable . Rear S prin[...]

95 MAINTENANCE AND LUBRICATION Adju stmen ts W ARNING Im proper adjust ment of t he handlebars or inc orrec t tor quing of the adjus ter block t ight ening bolts can caus e limit ed st eering or loosening of the handlebar s, result ing in los s of c ontr ol and possible s erious per sonal injur y or deat h. Follow t he adjust ment procedur es exact[...]

96 MAINTENANCE AND LUBRICATION Adju stmen ts Ca r buretor IMPOR T ANT : Y our Polar i s A TV is calibr ated a t the f actory f or optimal pe rf orma nce at a ltitudes ra nging from ze ro to 6,000 fee t (1800 m) a nd temper ature s of +40 degre es F . (4 degre es C. ) or highe r . Above 6000 fe et (1800 m) the e ngine air/f uel mixture bec omes over[...]

97 MAINTENANCE AND LUBRICATION Adju stmen ts Thr ottle C able Fr eepla y The throttle c able ad juster is loca t e d at the right handleb ar . 1. Slide the boots (1) of f t he inline ca ble adjuster sle eve (2) . Loosen the adjuste r locknut (3). 2. T urn the adjuster until 1/16 ″ to 1/8 ″ freeplay i s achi eved at t he th um b lev er . NOT E: [...]

98 MAINTENANCE AND LUBRICATION Adju stmen ts S ide P anel Re m oval NOT E: S ide panel remov al may be diff icult until t he lock ing tabs and receiv ers hav e been snapped and uns napped a few t imes . 1. Remove the sea t. 2. Grasp the rea r of the side pan el near t he rear cab . W it h a quic k and firm motion, pull th e panel forward an d out w[...]

99 MAINTENANCE AND LUBRICATION Adju stmen ts W ARNING Oper ating y our A T V wit h worn t ires, impr operly inf lat ed tir es, non-st andard t ires or impr operly inst alled tir es will affect v ehicle handling and could caus e an accident res ulting in s erious injur y or death. Maint ain proper t ire pr essur e as desc ribed on t he decal on your[...]

100 MAINTENANCE AND LUBRICATION Adju stmen ts W ARNING Im properly inst alled wheels c an advers ely affec t t ire wear and vehicle handling, which c an result in ser ious injury or deat h. Always ensure t hat all nuts are t orqued t o specif icat ion. Do not serv ice axle nut s t hat have a cot t er pin inst alled. See y our Polaris dealer . Wheel[...]

101 MAINTENANCE AND LUBRICATION Adju stmen ts Fr ont W heel Hub T ightening Front whee l bea ring tightne ss and spindle nut rete ntion are cr itica l compone nt operations. All se rvice must be pe rf ormed by your aut ho rized P ol aris deal er . Ti re T read Depth Alway s repl ace t i res when tread depth is wor n t o 1/8 ″ ( .3 cm) or less. Se[...]

102 MAINTENANCE AND LUBRICATION Adju stmen ts Air Filter Service 1. Remove the sea t. 2. Rele ase the c lips and remove the a ir box cover ( 1). 3. Loosen the cla mp and re move the filte r . 4. Remove the f abric type pre -filte r (2) f rom the main filte r (3) . W ash the pr e-f ilter in soapy wa ter , then rinse a nd let dry . 5. Reinsta ll the [...]

103 MAINTENANCE AND LUBRICATION Accessor ies Auxilia ry powe r outlets provide 12V powe r for oper ating access ories such a s ha nd held spot lights. See your Pola ris dea ler . Cleaning a nd Stor age See page 108 for the pa rt numbers of Polaris products. Cleaning th e A TV Kee ping your A TV cle an will not only improve its appe ara nce but it c[...]

104 MAINTENANCE AND LUBRICATION Cleaning a nd Stor age Sto ra ge Ti ps See page 108 for the pa rt numbers of Polaris products. CAUTION St art ing the engine dur ing the s tor age period will dist urb t he prot ect ive f ilm cr eated by f ogging and damage could oc cur . Never st art t he engine during t he st orage period. Exterio r Make nec essar [...]

105 MAINTENANCE AND LUBRICATION Cleaning a nd Stor age Sto ra ge Ti ps See page 108 for the pa rt numbers of Polaris products. Flu id Levels Inspe ct the following fluid l ev els and cha nge if nece ssary: engine oil; tran sm is si on o il ; brak e flui d (chan ge every two y ears or as need ed if fluid looks dar k or conta minated) . Engine 1 . Re[...]

106 MAINTENANCE AND LUBRICATION Cleaning a nd Stor age Chr ome W heel Ca re (if equi pped) P roper mai nt enance wil l pro tect ch rome wheel s from corro si on, pres erve wheel l ife and ens ure a “l ike n ew” appearan ce for m any years. 1. W ash chrome r ims f re quently . Use a mild dete rg ent to remove a ny salt, dirt, mud or grime . Neve[...]

107 MAINTENANCE AND LUBRICATION Cleaning a nd Stor age T rans por ting an A TV Follow these proce dures when tra nsporting an A TV . 1. T urn off the e ngine and remo ve t he key t o prev ent loss during tra nsporting. 2. T urn the fuel valve of f. 3. Be s ure t he fu el cap , o il cap and seat are in st all ed correct ly an d secu rely . 4. Alwa y[...]

108 POLARIS PRODUCTS Part No. Descr ipti on Engine Lubr icant 2870791 Fogging O il ( 12 oz. A erosol ) 2871281 Prem ium 4 Synt heti c 0W -40 ( 4-Cycl e) Engi ne Oil (qt .) 2871844 Prem ium 4 Synt heti c 0W -40 ( 4-Cycl e) Engi ne Oil (gal .) Gear case / T ransm issi on Lubri cants 2873602 Prem ium AGL Synt heti c Gear case Lube (qt .) 2873603 Prem [...]

109 SPECIFIC ATIO NS 2005 Magnum 330 2X 4 Capac ities Body Styl e Gen I V Gro ss V eh icle W eig h t 1060 l bs . ( 481 kg) F uel C ap acity 3.2 ga l . ( 12.1 l ) Engi ne Oi l Ca pac it y 1.9 qt s . ( 1.8 l ) Transm issio n Oi l 13. 5 oz. (400 m l ) Rear G earcase Oil 10 oz . ( 300 ml ) Fr ont Ra c k 90 l bs . ( 40.8 kg) Rear R ack 180 l bs . ( 81.6[...]

11 0 SPECIFIC ATIO NS 2005 Magnum 330 2X 4 Drive S ystem Dr ive Sys te m T ype PVT Shi ft T ype Side Le ve r Fro n t D rive (ratio ) 3.1/ 1 Fr ont T ir e s 2 4x8 - 1 2( 4p s i ) Rear Tires 24 x 1 1-12 ( 3 psi ) Sus pe ns ion and Br akes Fr ont Sus pe ns i on: Ma c Str ut 6.7 i n. ( 17 cm ) t ra vel Re a r Sus pens ion: Pr ogre ss ive Ra te Swing Ar[...]

111 SPECIFIC ATIO NS 2005 Magnum 330 2X 4 Jetting Chart Altitu d e AMBIENT TEMPERA TURE Below 40 ° F (B elow 5 ° C) +40 ° F and above (+5 ° C and above) Meters (F eet) 0-1800 (0- 6000) 127.5 122. 5 1800-3700 (6000- 12000) 120 11 5 Cl utching C hart Altitude Shi ft W eight Driv e C lutch Sprin g Driven Cl utch Sprin g Helix /Spring Setting Meter[...]

11 2 SPECIFIC ATIO NS 2005 Magnum 330 4X 4 Capac ities Body Styl e Gen I V Gro ss V eh icle W eig h t 1 100 lbs . ( 499 kg) F uel C ap acity 3.25 ga l . ( 12.3 l ) Engi ne Oi l Ca pac it y 1.9 qt s . ( 1.8 l ) Transm issio n Oi l 13.5 oz . ( 400 ml ) F ron t G earcase Oil (C en tralized H illiard ) 5 oz. (148 m l) Rear G earcase Oil 10 oz. (300 m l[...]

11 3 SPECIFIC ATIO NS 2005 Magnum 330 4X 4 Drive S ystem Dr ive Sys te m T ype PVT Shi ft T ype Side Le ve r Fro n t D rive (ratio ) 3.7/ 1 Fi nal D riv e (ratio) 3.1/ 1 Fr ont T ir e s 2 4x8 - 1 2( 4p s i ) Rear Tires 24 x 1 1-12 ( 3 psi ) Sus pe ns ion and Br akes Fr ont Sus pe ns i on: Ma c Str ut 6.7 i n. ( 17 cm ) t ra vel Re a r Sus pens ion:[...]

11 4 SPECIFIC ATIO NS 2005 Magnum 330 4X 4 Jetting Chart Altitu d e AMBIENT TEMPERA TURE Below 40 ° F (B elow 5 ° C) +40 ° F and above (+5 ° C and above) Meters (F eet) 0-1800 (0- 6000) 127.5 122. 5 1800-3700 (6000- 12000) 120 11 5 Cl utching C hart Altitude Shi ft W eight Driv e C lutch Sprin g Driven Cl utch Sprin g Helix /Spring Setting Mete[...]

11 5 TROUB LES HOOTIN G Dr ive Belt and Cover Pr ob lems Po ssib l e Cause Solu tion Dr ivi ng the A TV onto a p icku p o r tall trailer in hi gh ra nge . Shi ft t ra ns mi ss ion t o low r ange duri ng loa ding of the A TV t o pre vent be l t burni ng. St a r ti ng out goi ng up a steep in cline. Whe n st ar ti ng out on a n inc li ne, us e low r [...]

11 6 TROUB LES HOOTIN G Contac t your P ola ris dea ler for se rvice if you’r e unable to i dentif y solutions using the follow i ng ch ar ts. Engine Doesn’t T u r n Over Po ssibl e Cause Sol uti on Trip ped circuit b reak er Reset th e b reak er Lo w b attery v o ltag e Re c har ge ba tt er y to 12. 8 VDC Loos e ba tt e r y conne c ti ons Ch e[...]

11 7 TROUB LES HOOTIN G Engine Backfir es Po ssibl e Cause Sol uti on W e a k spa rk f rom s par k plugs In spect, clean an d/o r replace spark p lu g s In correct sp ark plu g g ap o r heat rang e Se t ga p to s pec s or re pla ce pl ugs Ol d or non- re comm e nded f uel Re pl a c e wi t h new fue l In correctly in stalled sp ark p lug w ires Se e[...]

11 8 TROUB LES HOOTIN G E ngine S tops or Lose s Pow er Po ssibl e Cause Sol uti on Out of fuel Tu rn fuel v alve to reserve, refu el Ki nked or plugge d fue l vent l ine In spect an d replace W ater p resent in fuel Re pl a c e wi t h new fue l Ove rus e of choke In sp ect, clean and /o r rep lace spark p lu gs Foul e d or def ec ti ve s par k plu[...]

11 9 WARRANTY LI MIT ED W ARRANTY Pol a r is Sa le s I nc ., 2100 Highw a y 55, Me dina , M N 55340, gi ves a SI X MON TH LI MI TED W ARRANTY on al l com pone nts of t he Pol ar is Al l T e rr a in V e hic le ( A TV) aga ins t def ec ts i n ma te ri al or wor kmans hi p. Pola ri s a ls o give s a one ye a r l i mi te d war ra nty on t he f ina l dr[...]

120 WARRANTY W ARRANT Y COVERAGE AND EXCL USIONS: LIMI T A TIO NS OF W ARRANTIE S AND REMEDI ES ALL IM P LI ED W ARRANTIES ( INCLUDING BUT NOT LI MITED T O THE I MPLI ED W ARRANTIES OF MERCHANT ABILI TY AND FI TNESS FOR A P AR TICULAR PURPOSE) ARE LI MITED I N DURA TION TO THE ABOVE SIX MONTH W ARRAN- TY PERI OD. POLARI S FUR THER DISCLAI MS ALL EX[...]

121 WARRANTY Exported V ehicles EXCEPT WHERE SPECI FICALL Y REQUIRED BY LA W , THERE IS NO W AR- RANTY OR SER VICE BULLETI N COVERAGE ON THIS VEHI CLE IF I T IS SOLD OUTSIDE THE COUNTR Y OF THE SELLING DEALER’ S AUTHORIZED LOCA- TION. T his po licy d o es n ot ap ply to v eh icles that hav e receiv ed au tho rizatio n fo r e xpor t f r om Pol a r[...]

122 INDEX A Accesso ries 1 0 3 .................. Adj ust ment s 91-102 ............... Ag e R estrictio ns 8 ................ Air F ilter 1 02 .................... All W hee l Drive 44 ............... All W hee l Drive Swi tch 3 5 ......... Au x iliary B rak e 40 , 9 2 ............ A WD S w itch 3 5 .................. B Ba tt er y 88-90 ..........[...]

123 INDEX L Light Sw i tc h 34 .................. Li ghts 80- 81 ..................... Low Ra nge 86 ................... Lubr ic a t ion G uide 72 .............. M Main S witch 3 5 .................. MAINTENANCE AND LUBRI CA TION 68- 107 ........ Ma int ena nce R e cor d 73 ............ Ma king T urns 55 ................. Ma st er Cyl inde r 37 ...[...]