Polaris Magnum 330 manual

Universal Owner's Manual V ehicle Maintenance and Safety 2003 A TV for R ead this manual carefully . It contains impor tant safety infor mation. This is an adult vehicle only . Operation is prohibited for those under 16 years of age.[...]

W ARNING The engine exhaust from this product contains chemicals known to cause cancer , birth defects or other reproductive harm.[...]

1 We’ve cr eat ed a web si t e j ust f or YOU! S T echnical ti ps S New product introductions S Event schedules S Parts and Se rvice M anual information S Exciting details about The W ay Out Ch e c k it ou t... www .pol ar i sindust r i es. com/ owner[...]

2 Al l i nfor ma t i on i n t his m a nua l i s ba s e d on t he l a t es t pr oduc t da t a a nd s pe c if i c a t i ons a va il a bl e a t the t i me of pr i nt ing. Pol a r i s Indus t r i e s Inc . r e s e r ves t he r i ght to ma ke pr oduc t ch an g es an d imp ro vem en ts th at m ay af fect illu stratio n s o r ex plan atio n s. No par t of[...]

3 WELC O ME Thank you f or purc hasing a P olaris ve hicle , and welc ome to our wor ld-wide fa mily of P olar is owners. W e proudly produce a n exciting line of utility an d re cr ea tional pr oducts. Polar is Recr eational an d Utility V ehicles S Snowmobiles S All- ter ra in vehic les ( A TVs) S P erso nal wat ercraft S V ict or y mo t orcy cl [...]

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5 TABLE OF CONTENTS WELCO ME 3 ................................. T ABLE OF CONT ENT S 5 ...................... VEHICL E IDENTI FI CA TI ON NUM BERS 6 ........ SAFET Y 7 ................................... CONTROL S 37 ............................... FEA TURES 4 8 ............................... OPE RA TION 56 .............................. NOISE EM[...]

6 VE HICLE IDENTIFICATION NUMBERS The vehic le fr ame ve hicle identif ica tion number (VIN) (1) a nd engine ser ial numbe r (2) are important f or mode l identific ation when re gistering your vehic le, when obta ining insuranc e, and w hen orde ring replacem ent p arts . If your vehicl e is sto len, thes e numbers are essenti al to the r ec over [...]

7 SA FETY Operator S afety Age Restr i ctions This vehi cle is an ADUL T VEHIC LE ONL Y . Operati on is p rohibi ted for anyone under 16 years of age . Know Y our V ehi cle As the operator of the ve hicle, you are r esponsible for your pe rsonal saf ety , the safe ty of others, and the prote ction of our e nvironme nt. Read a nd under stand your ow[...]

8 SA FETY Operator S afety The f ollowing signal words a nd symbols appe ar thr oughout this manua l and on your A TV . Y our saf ety is involved w hen the se words and symbols ar e used. Become f amilia r with their me anings bef ore re ading the manua l. The s af et y aler t s ym bol, on your A T V or in t his m anual, alert s y ou to t he pot en[...]

9 SA FETY Operator S afety S Rea d this manua l and a ll labels c ar efully , and follow the ope ra ting proc edure s desc ribed. S Neve r opera te an A TV without proper instruc tion. T ake a training course . Beginners shoul d receive trai ning from a certifi ed inst ructo r . Co n tact an au t ho ri zed P o l aris A TV d ealer o r cal l P olari [...]

10 SA FETY Operator S afety S Alway s hav e th e A TV i ns pect ed b y an aut ho ri zed P ol ari s deal er i f it ’ s been invol ved i n an accident . S Ne ver ope ra te on hills too steep for the A TV or for your abilitie s. Pra ctic e on sma ller hills bef or e atte mpting lar ge r hills. S Alwa ys follow prope r proc edur es for c limbing hill[...]

11 SA FETY Operator S afety S W et bra kes ma y have re duce d stopping ability . T est your br ake s afte r lea ving wa ter . If n ec essa ry , apply them lightly se ver al times to a llow frict i on t o dry o ut t he pad s. S Always che ck for obstac les or people behind the A TV befor e oper at- in g i n revers e. Wh en i t’ s s afe to pro cee[...]

12 SA FETY Operator S afety POTENTI AL HAZ A RD Oper at ing t his A T V wit hout proper inst r uct ion. WHA T CAN H APPEN The r isk of an ac cident is gr eat ly inc reas ed if the oper at or does not know how t o oper ate t he A T V properly in differ ent sit uat ions and on diff erent t ypes of t er rain. HOW T O A VOID TH E HAZ ARD Beginning and [...]

13 SA FETY Operator S afety POTENTI AL HAZ A RD Carry ing a pass enger on an A T V . WHA T CAN H APPEN Carry ing a passenger great ly r educes t he operat or ’ s ability t o balance and cont r ol t he A T V , whic h could c ause an ac cident and injury t o t he oper at or and/ or passenger . HOW T O A VOID TH E HAZ ARD Never c arr y a pas senger [...]

14 SA FETY Operator S afety POTENTI AL HAZ A RD Oper at ing an A T V on paved s urf ac es, including s idewalks , paths , parki ng lots , and driveway s. WHA T CAN H APPEN A TV tir es ar e designed f or off-r oad use. O perat ing on pav ed surf ac es m ay s erious ly aff ect t he handling and cont rol of t he A TV and could result in loss of cont r[...]

15 SA FETY Operator S afety POTENTI AL HAZ A RD Oper at ing this A T V on public st reet s , r oads or highways . WHA T CAN H APPEN The A T V could collide wit h anot her vehicle. HOW T O A VOID TH E HAZ ARD Never oper at e t he A TV on any public st reet , road or highway , including dirt and gr avel r oads. In m any s t at es it ’s illegal to o[...]

16 SA FETY Operator S afety POTENTI AL HAZ A RD Oper at ing t his A T V wit hout wearing an appr oved helm et , eye prot ect ion and pr ot ect iv e clot hing. WHA T CAN H APPEN Oper at ing an A T V wit hout an approv ed helmet incr eases the risk of a sever e head injury or deat h in t he event of an accident . Oper at ing wit hout eye prot ec t io[...]

17 SA FETY Operator S afety POTENTI AL HAZ A RD Oper at ing t he A TV af ter cons uming alc ohol or dr ugs. WHA T CAN H APPEN Consumpt ion of alcohol and/ or drugs could ser iously affect operat or judgm ent . React ion t ime m ay be s lower and oper at or balance and perc ept ion could be aff ect ed. Consuming alc ohol and/ or dr ugs bef or e or w[...]

18 SA FETY Operator S afety POTENTI AL HAZ A RD At t empt ing wheelies , jum ps and ot her st unt s. WHA T CAN H APPEN At t empt ing s t unts incr eases the c hance of an acc ident , including an overt ur n. HOW T O A VOID TH E HAZ ARD Never att em pt wheelies, jum ps, or ot her st unts . Avoid exhibition driving. W ARNING[...]

19 SA FETY Operator S afety POTENTI AL HAZ A RD Failur e t o inspec t the A T V bef or e operat ing. Failur e t o proper ly m aintain t he A T V . WHA T CAN H APPEN Poor m aint enance inc reas es t he pos sibilit y of an ac cident or equipment damage. HOW T O A VOID TH E HAZ ARD Always inspec t y our A T V befor e each us e t o make s ure it ’s i[...]

20 SA FETY Operator S afety POTENTI AL HAZ A RD Failur e t o use ex t ra c aution when oper at ing t he A T V on unf amiliar terrai n. WHA T CAN H APPEN Unfamiliar t errain ma y c ont ain hidden rocks, bumps, o r holes that could caus e loss of cont rol or overt ur n. HOW T O A VOID TH E HAZ ARD T ravel s lowly and use ex t ra c aut ion when operat[...]

21 SA FETY Operator S afety POTENTI AL HAZ A RD Failur e t o use ex t ra c aution when oper at ing on exc ess ively rough, slipper y or loose t err ain. WHA T CAN H APPEN Oper at ing on exc ess ively r ough, slipper y or l oose t err ain could cause los s of t rac t ion or los s of cont r ol, whic h could r esult in an accident or ov ert ur n. HOW [...]

22 SA FETY Operator S afety POTENTI AL HAZ A RD T urning impr operly . WHA T CAN H APPEN Im proper t urns c ould caus e loss of c ont rol and lead t o a c ollision or overt ur n. HOW T O A VOID TH E HAZ ARD Always f ollow proper procedur es f or tur ning as des cr ibed in t he owner ’s manual. Prac t ice t ur ning at slow speeds befor e at t empt[...]

23 SA FETY Operator S afety POTENTI AL HAZ A RD Climbing hills im proper ly . WHA T CAN H APPEN Im proper hill clim bing could c ause loss of cont rol or overt ur n. HOW T O A VOID TH E HAZ ARD Always f ollow proper pr ocedur es f or clim bing hills as described in the owner ’ s m anual. Always chec k t he t err ain car ef ully bef ore as cending[...]

24 SA FETY Operator S afety POTENTI AL HAZ A RD T raveling downhill im properly . WHA T CAN H APPEN Im proper ly des cending a hill c ould caus e loss of c ont rol or overt ur n. HOW T O A VOID TH E HAZ ARD Always f ollow proper pr ocedur es f or t raveling down hills as descr ibed in t he owner ’s manual. NOT E : A s pecial t echnique is requir [...]

25 SA FETY Operator S afety POTENTI AL HAZ A RD Im proper ly c ros sing hills and tur ning on hills. WHA T CAN H APPEN Im proper ly c ros sing or tur ning as hills could caus e loss of c ont rol or overt ur n. HOW T O A VOID TH E HAZ ARD Never at t em pt to t ur n the A T V around on any hill unt il y ou’ve mast er ed t he t urning t echnique ( o[...]

26 SA FETY Operator S afety POTENTI AL HAZ A RD St alling, rolling back wards or improper ly dis mount ing while climbing a hill. WHA T CAN H APPEN The v ehicle c ould over t urn. HOW T O A VOID TH E HAZ ARD Maint ain st eady speed when climbing a hill. If all f orwar d speed is lost: Keep your weight uphill. Apply t he s ingle lever brak e gradual[...]

27 SA FETY Operator S afety POTENTI AL HAZ A RD Im proper ly oper at ing over obst acles . WHA T CAN H APPEN Oper at ing over obst acles could c ause los s of cont r ol or ov ert urn. HOW T O A VOID TH E HAZ ARD Bef ore oper at ing in a new area, chec k f or obst acles . Avoid operating ov er lar ge obst ac les s uch as rock s and f allen tr ees wh[...]

28 SA FETY Operator S afety POTENTI AL HAZ A RD Oper at ing t he A TV t hrough deep or fas t -f lowing wat er . WHA T CAN H APPEN T ires may f loat , c ausing loss of t rac t ion and loss of cont rol, which could lead t o an ac cident or ov ert ur n. HOW T O A VOID TH E HAZ ARD Avoid operating t he A T V thr ough deep or f as t- f lowing wat er . I[...]

29 SA FETY Operator S afety POTENTI AL HAZ A RD Oper at ing this A T V wit h improper t ir es, or wit h improper or unev en tire pressu re. WHA T CAN H APPEN Use of impr oper t ir es, or oper at ion of t he A T V wit h im proper or uneven t ire pr ess ure, could c ause los s of c ontr ol or ac cident . HOW T O A VOID TH E HAZ ARD Always use t he si[...]

30 SA FETY Operator S afety POTENTI AL HAZ A RD Ov erloading t he A T V or car ry ing/t owing c argo im proper ly . WHA T CAN H APPEN Ov erloading and t owing c an caus e changes in vehicle handling, which could lead t o los s of cont r ol or an ac cident . HOW T O A VOID TH E HAZ ARD Never ex ceed t he s t ated load c apacit y for t his A T V . Ca[...]

31 SA FETY Operator S afety Af t er any overt ur n or ac cident , have a qualif ied s erv ice dealer inspect t he ent ire v ehicle f or possible dam age, including ( but not limi ted to) brake s, t hrottle an d steeri ng systems. Saf e operat ion of t his r ider- act iv e vehicle r equires good judgement and physic al sk ills. Per sons with c ognit[...]

32 SA FETY Safety D ecals and Locations W arning d ecals h ave been placed on th e A TV for your prot ecti on. Read an d fo ll o w th e in st ru cti o ns o n each decal carefu ll y . If a decal bec omes ille gible o r c omes of f, conta ct your Polar is dea ler to purc hase a repl acem ent . R ep l acemen t safety decals are pro vi ded b y P ol ari[...]

33 SA FETY Safety D ecals and Locations See your O wner ’s Manual Supplement f or s pecif ic ations . IMPROPER TIR E PRESSU RE O R O VERLOAD ING c an cause loss of control resulti ng in SEVERE INJU RY OR D EA TH . T IRE PRESSURE (PSI): FRO N T ___ RE AR ___ M AXI MUM W EIGHT CAP ACITY (G r os s V ehic le W eight) IN CLU D IN G MA CH IN E , DR IVE[...]

34 SA FETY Safety D ecals and Locations A TTEN TION D Oper ation of t his v ehic le wit hout the filter element will s ev er ely damage the engine. D Clean air filter of ten, more frequent c leaning r equired in dus ty c onditions Under Seat Mov ing parts haz ar d under belt -c lutc h guard. T o prev ent s er ious injury, do not operate v ehic le w[...]

35 SA FETY Safety D ecals and Locations ALL WHE EL DRIVE SWITCH Do not push s witc h to engage A WD if t he rear wheels are s pinning. This m ay caus e sev ere drive s haf t and clut c h damage. See your Owner ’s Manual. 7079780 MANUFACTURED BY : PO LARIS IN D DA TE: VIN: TH IS VEH IC L E IS AN AL L TERR AIN VEH IC LE AN D I S NO T I NTENDE D FOR[...]

36 SA FETY Safe Riding Gear Always we ar c l othing suited to the t ype of riding. A TV riding requir es spec ial protec tive clothing for comfor t and to reduc e t he cha nce of injury . 1. Helm et Y our he lmet is the most importa nt piec e of prote ctive ge ar for saf e riding. A hel m et can prev ent a s evere head i nj ury . S elect an ap pro [...]

37 CONTROLS Electr i cal Switches Act iv at ing t he overr ide swit c h while t he t hrot t le is open c an caus e loss of c ontr ol, res ulting in s ever e injury or deat h. Do not ac t ivat e the ov err ide swit c h while the t hr ot t le is open. W ARNING Ov erri d e S wi tch (1) (Reve rse Spee d Limiter ) - This vehic l e is equipped with a re [...]

38 CONTROLS Throttle Lever Eng i ne s peed an d veh i cle moveme nt ar e controlle d by pre ssing the throttle leve r . The throttle le ver (1) is spring lo aded . En gi n e sp eed ret u rns to idle when the le ver is releas ed . This A TV is e quipped w ith Polar i s Elec tronic Thr ottle Control (ETC), which is designe d to reduc e the r isk of a[...]

39 CONTROLS Light S witches The light sw itch is loca t ed on the left h and l ebar (1). It ’ s us ed t o tu rn the lights on a nd of f and to switc h the lights fr om HI to LO on mode ls equippe d with HI- LO beams. NOTE: The lights won’ t work unless the key is i n the “on” position and the shut-of f switch is in the “run” position. B[...]

40 CONTROLS Br ake Lever The fro nt an d rear b rakes are app l i ed by sq ueezi ng t he b rake l ever ( 1) towar d the handlebar . The fr ont and re ar br ake s are hydr aulic ally activa ted di s c ty pe b rak es t h at are act i v ated by only one lever . Alway s tes t b rake lev er travel an d maste r cylinder f luid level be fore ridi ng. When[...]

41 CONTROLS Park in g Brak e Setting the P arking B rake 1. S qu eeze and rel ease t h e brak e leve r (1) two or three times, then sq ueeze an d h ol d . 2. Push the par k brake loc k (2) forw ard to engage the br ake . Rel eas e t he b rak e lev er . 3. T o rele ase the par king brake loc k, sq ueeze an d r eleas e t he b rak e leve r . It will r[...]

42 CONTROLS Auxiliary Brake The a uxiliary bra ke (1), is loca ted on the i nside of the right floor boa rd a nd is opera ted by the right foot. The auxilia ry bra ke serve s as a backup to the main bra ke system if the main system be come s i noper ative . If the r ea r whe els slide while using the a uxiliary br ake, r educe brak e ped al pres su[...]

43 CONTROLS Choke The choke a ssists i n starting a cold e ngine. Refe r to the engine star ting proc edure o n page 59 for cor rec t choke and throttle settings during star ting. Fuel V alve The f uel val ve (1 ) i s l o cat ed o n t he l eft s id e of the vehic le, either be low the fende r or on t he side pane l. It has three positions: OFF: For[...]

44 CONTROLS Fuel Safety Gas oline is highly flam mable and ex plosiv e under c ert ain condit ions. S Always exer cis e ext rem e caut ion whenev er handling gas oline. S Always ref uel wit h t he engine st opped, and out doors or in a well vent ilat ed area. S Do not s mok e or allow open f lam es or spark s in or near t he area where r ef ueling [...]

45 CONTROLS Oil Injection T ank - 2 - Cycle Mod els Models with 2- cyc l e e ngines ha ve oil injec tion. The oil inje ction tan k fille r c ap (1 ) is loca ted on the f ront of the v ehic le. T ank ca pac ity is two quarts (1.9 l.). Mixi ng brands or using a non- rec omm ended oil may c ause s erious engine damage. We recom mend t he use of Polar [...]

46 CONTROLS Autom atic T ransm ission Gear Selector The tra nsmission gear se lec tor (1) is locate d on the right side of the vehi cl e. S hi ft p at t erns v ary , depe nding on your model. H: High Gear N: Neutral L: Low G ear R: Rev ers e P: Pa rk Whe never the A TV is left unatte nded, always place the tr ansmission in gea r with the parking br[...]

47 CONTROLS Recoil S tar ter If the batter y is wea k and c annot star t t he engine , use of the rec oil star ter (1) w ill allow vehic le oper ation until re pairs ca n be mad e. Th e recoi l st art er i s l o cat ed on the right side of the machine . Polaris 4- cycle engine s ar e equippe d with automa tic deco mp ress o rs. Th i s m akes reco i[...]

48 FEATURE S All W heel Dr ive (A W D) S ystem Polar is 4 whe el drive A TVs ar e equippe d with a unique, Polaris excl us i ve, Dem and 4 Dri v e (A WD) sy st em t h at ’ s acti vat ed b y a swi tch (1) on the right handleba r . When the s w i t c hi so f f ,t h eA T Vi si n2w h e e l drive a t all times. W hen the switc h is on, the A TV is in [...]

49 FEATURE S All W heel Dr ive (A W D) S ystem Di sengagi ng Whe el Hubs Although the hubs norma lly disengage when ope rating in r eve rse, one or both hubs may o ccasional ly rem ain engaged. If th e handlebars pull to one side , it’ s likely tha t one fr ont hub is engage d . If both hubs ar e eng aged, s t eeri ng effort in creases b ut rem a[...]

50 FEATURE S Indicator Li ghts The conf iguration of the indica t or li ghts dif fers with individual models. Not eve ry model is equippe d with all of the lights, and the lights on some models appe ar in the spee domete r . The inf orma tion i n your owner ’ s m anua l supplement and on this pa ge will help you identif y the lights and their fun[...]

51 FEATURE S In st rume nt C lus te r Y our A TV is e quipped w ith an instr ument c luster tha t sense s vehic le spee d fr om the r ight front whe el. The instr ument c luster me asure s distanc e in miles a s we ll as hours of oper ation. It a lso includes a re ver se spee d limiter f unction that limits the A TV’ s speed to appr oximate ly 7-[...]

52 FEATURE S In st rume nt C lus te r Ri der Infor mati on C enter The r ider infor mation ce nter is locate d in the lowe r portion of the instrume nt cluster . 1. Gea r Indica tor - As the shift leve r is moved, this will indicate the gea r the mach i ne i s in : H = High R ange L = Low Range N = Neutral R = Reverse P=P a r k Eo rb l a n k =E r r[...]

53 FEATURE S In st rume nt C lus te r Ri der Infor mati on C enter The r ider info rmation c enter has 4 sta ndard mode s: Mode 1 - Odometer Mode 2 - T ripme ter Mode 3 - T otal Servic e Hours Mode 4 - P rogr amma ble ser vice inte rva l The re ver se overr i de button on the left handleb ar is also the mode button . NOTE: I f using t he mode butto[...]

54 FEATURE S In st rume nt C lus te r Ri der Infor mati on C enter Mo de 4 - Prog rammable S ervice Int erval The purpose of the progr ammable ser vice interv al is to provide the consume r and de aler with a c onvenie nt reminde r for routine mainte nanc e. When your vehic le leave s the fac tory , this fea ture is turne d of f. Y ou must ena ble [...]

55 FEATURE S In st rume nt C lus te r Ri der Infor mati on C enter Dia gnos tic Mode The diagnostic mode is for infor mational purposes only . Please r eturn your A TV to your deale r for a ll major repa irs. T o enter the dia gnostics mode: 1. T urn the ke y switch of f and wa i t 20 seconds. 2. Set the pa rk bra ke and shift the tra nsmission to [...]

56 OPERATION Br eak -In Per iod 2 - Cyc le E ngines The bre ak-in per iod for your new Polaris A TV is define d as the time it take s t o use the fir st tank of f uel. No single a ction on your pa rt is as importa nt as following the proce dures for a prope r brea k-in. Car eful treat m ent of a n ew en gi n e wil l resu l t i n mo re ef fi cien t [...]

57 OPERATION Br eak -In Per iod 4 - Cyc le E ngines The br ea k-in pe riod for your new Polar is A TV is def ined a s the fir st ten hours of oper ation, or the time it take s to use the first two full tanks of gasoline . No single ac tion on your par t is as impor tant as f ollowing the proc edur es for a prope r brea k-in. Care ful trea tment of [...]

58 OPERATION Pr e - R ide Inspection Use the f ollowing chec klist to verify tha t your vehic l e is in prope r wor king condition be fore each u s e. Item/Inspection Pr ocedu re 1. T ires - Che ck condition and pr essures. 2. Fuel and o il tanks - Fill both tanks to their prope r lev els. 3. All bra kes - Che ck ope ration, ad justment and f luid [...]

59 OPERATION Star ting the Engi ne S tar ting a Cold E ngine 1. Place the tr ansmission in neutra l and lock the park ing brake . 2. T urn the fuel tank valve on. 3. Sit on the vehicle. 4. Pull the c hoke knob out until it st op s (1). NOTE: The va riable c hoke is fully on when the knob is pulled comple tely out. The c hoke is of f when the knob i[...]

60 OPERATION Star ting the Engi ne S tar ting a W arm E ngine W ar m engines do not normally re quire the use of the c hoke. Using the choke c an ca use the spar k plug to become we t foule d. 1. Position the vehicle on a leve l surfa ce with the tra nsmission in neutr al. 2. Lock the par king brak e, turn the f uel tank va l ve to “ on”, sit o[...]

61 OPERATION Hauling Cargo Y our A TV ha s been designe d to carr y or tow a ce rta in amount of load . Always r ea d and unde rstand the l oad distr ibution war nings listed on the warning l abels , and never exceed the weight s speci fied i n your owner ’ s manua l supplement. Car go we ight should be eve nly distribute d (1/3 on the fr ont and[...]

62 OPERATION Hauling Cargo Hauling cargo im proper ly c an alt er v ehicle handling and m ay caus e loss of c ont rol or brak e inst ability and res ult in ser ious injury or death. Alway s f ollow t hes e prec autions when hauling car go: S REDUCE SPEED AN D ALLO W G REA TER DI ST ANCE FO R BRAKING WHEN HAULING C ARGO. S CARG O WE I G HT DIS T RIB[...]

63 OPERATION Driving Safely Driving Pr o cedu res 1. Sit upright with both fee t on the footrests a nd both hands on the handle bar s. 2. Start the engine and allow it t o wa rm up, then shift t he tra nsmission into gea r . 3. Check your surroundings and de termine your path of tra vel. 4. Relea se t he parking bra ke. 5. Slowly depre ss t he thro[...]

64 OPERATION Driving Safely Making T urns Some Pola ris A TV s ar e e quipped with a solid rea r axle , which dr ives both re ar w hee ls equa lly at all time s. This mea ns that the w hee l on the outside of the turn must travel a gre ater dista nce than the inside whee l whe n turning and the inside tir e must slip tra ction slightly . T o make a[...]

65 OPERATION Driving Safely Dr iving on Slipp ery S u rfaces When ever rid i ng o n sl i pp ery su rfaces s uch as wet t rail s o r lo os e gravel , or du rin g freezi ng weat h er , fo l lo w th ese precau t i on s: 1. Slow down when e ntering slippe ry are as. 2. Mai nt ai n a h i gh l evel of alert nes s , readin g t he t rai l an d av oi d in g[...]

66 OPERATION Driving Safely Driving Uphill Whe neve r tra veling uphill, follow these precau t io n s: 1. Alwa ys trave l stra ight uphill. 2. A void stee p hills (25 _ ma ximum). 3. Kee p both fe et on the f ootrests. 4. T ransfe r your weight forwa rd. 5. P roceed at a s t eady rat e of speed and throttle ope ning. 6. Rem ai n alert an d be p rep[...]

67 OPERATION Driving Safely Sidehilling Sidehilling ca n be a d ange rous type of driving and should be avoided if at a ll possible. If you do e nter into a situation wher e sidehilling is neces sary , fo l lo w t h ese p recaut i on s : 1. Sl ow down. 2. Lea n into the hill, transfe rring your uppe r body we ight toward the hill while kee ping you[...]

68 OPERATION Driving Safely Driving Downh ill Whe never de sce nding a hill, follow the se pr ecaut i on s: 1. P roceed d i rectl y d own h ill. 2. T ransf er your we ight to the rea r of the vehic le. 3. Sl ow down. 4. Apply the brakes slightly to aid in slowing, using the single bra ke leve r . NOTE: Fa miliar ize your self with ope ra tion of th[...]

69 OPERATION Driving Safely T urning A round on a H ill If the ve hicle stalls while c limbing a hill, neve r back it down the hill! One mane uver that c an be use d when it’ s nece ssary to tur n around while c limbing a hill is the K-turn: 1. Stop and lock the pa rking brake while kee ping body weight uphill. 2. Lea ve tra nsmission in forwa rd[...]

70 OPERATION Driving Safely Dr iving Thr ough W ater Y our A TV c an ope rate through water with a maximum re comme nded depth e qual to the bottom of the footr ests (1). Follow th ese p roced ures when oper ating through water: 1. De ter mine wa ter depths a nd curr ent bef ore cr ossing. 2. Choose a crossing where both banks have gra dual incline[...]

71 OPERATION Driving Safely Dr iving Over Obstacles Be al ert! Loo k ahead an d learn t o read t h e terrai n yo u’re tr avel i ng o n. Be con s tan t l y alert fo r hazards s u ch as l og s, ro cks and l o w hang i ng bran ches . Sever e injury or deat h can r esult if your vehicle c omes in cont act with a hidden obs t acle. Not all obst acles [...]

72 OPERATION Driving Safely Dr iving in Reverse F ol l ow t hes e precaut i on s when o perat i ng i n rev erse: 1. Always avoid ba cking downhill. 2. Back slowly . 3. When i n revers e, apply the brake s lightly for stopping. 4. A void turning at shar p angle s in rever se. 5. Ne ver open the throttle suddenly while ba cking. NOTE: Most Polar is A[...]

73 OPERATION Driving Safely P a r k i n go na nI n c l i n e A void parking on a n incline if possible . If it’ s unavoida ble, follow th es e precau ti o ns : 1. T urn the engine of f. 1. Place the tr ansmission in gear . 2. Set t he parking bra ke. 3. Always block the rea r wheels on the downhill side. See illustra tion. 4. Shut of f the fuel s[...]

74 NOISE EMIS SION CO NTROL SYSTEM R EG U LA T IO N T AM P ERING WITH NOIS E C ONTROL S YS TEM P R OHIBITED! U.S . F ede ral law prohibits the following ac ts or t he ca using there of: (1) T he re moval or rende ring inopera tive by any pe rson other than f or pu rpo ses of m ai n t enan ce, repai r , or rep l acem ent of an y d evi ce o r ele men[...]

75 MAINTENANCE AND LUBRICATION Accessor ies Auxilia ry power outle ts provide 12V power f or oper ating access ori es such a s hand he ld spot lights. Ac ce ssory outle ts are availa ble for all models. Contact your Polar is deale r for more informa tion. Po laris has a wi de range of addit i onal acces sori es avai labl e for your A TV . S ee your[...]

76 MAINTENANCE AND LUBRICATION Pe r iodic Mai ntenance Sc hedule Hours of ope ration ar e ba sed on a 10 mph ave rage . If se rvic e is due a t 20 hours, the e quivale nt odometer re ading would be 200 miles. P erform al l serv i ces at whi chev er readin g is reached fi rs t. Item Hours/ Mile s Fr equency Remarks Brake S ystem Pre- Ride Pr e-Ri de[...]

77 MAINTENANCE AND LUBRICATION Pe r iodic Mai ntenance Sc hedule Item Hours/ Mile s Fr equency Remarks T a illig h t/bra k e lig h t Pre- Ride Pr e-Ride Check operati on dail y; ap- ply P olar is diel ectr ic grease to socket when repl aced " L Air filte r , mai n elem ent W eekly W eekly Inspect ; repl ace as needed " T ransmi ssion oi l[...]

78 MAINTENANCE AND LUBRICATION Pe r iodic Mai ntenance Sc hedule Item Hours/ Mile s Fr equency Remarks Carbur etor f loat bowl 50 hr s. 6 mont hs Drain bowl peri odical ly and pri or to stor age J Throt tl e Cable/ ETC Swit ch 50 hrs. 6 months Inspect ; adjust ; lubr icat e; r eplace if necessar y L Choke (enr icher ) cable 50 hr s. 6 mont hs I nsp[...]

79 MAINTENANCE AND LUBRICATION Pe r iodic Mai ntenance Sc hedule Item Hours/ Mile s Fr equency Remarks J L Fuel system 100 hours 12 months Check f or l eaks at t ank cap, li nes, fuel val ve, fi lt er , pump and car bur etor ; r e- place l ines ever y two year s J Fuel fi lt er 100 hr s. 12 mont hs Replace annual ly Radiat or 100 hrs. 12 m onths I [...]

80 MAINTENANCE AND LUBRICATION Lubr icat ion Re com mendati ons NOTE: Hour s are based on 10 mph ave ra ge. If se rvice i s due at 20 hours, the e quivale nt odometer re ading would be 200 miles. P erf orm all serv i ces at wh ich ever read in g i s reached fi rs t . Lubr ica tion C har t Ke y " More often unde r seve re use , such a s wet or [...]

81 MAINTENANCE AND LUBRICATION Lubr icat ion Re com mendati ons (4) (1) (5) (2) (2) (3)[...]

82 MAINTENANCE AND LUBRICATION Lubr icat ion Re com mendati ons Item Lube M ethod Fr equency (6) Demand 4 Hubs - All Wheel Dr iv e A TV s Prem ium Hub Lube Remov e set s c rew in hubs . R otate wheels to 4 O ’c loc k pos ition. If lubr i- c ant is not v is ible add mor e. Reins tall se t scre w . Annually or at 100 hrs . (7) Fro nt Drive Ax le (U[...]

83 MAINTENANCE AND LUBRICATION Lubr icat ion Re com mendati ons (7) (9) (8) (6) 4 O’clock posit ion (6) (1 1) (10) (12) (14) (15) (13) (13)[...]

84 MAINTENANCE AND LUBRICATION Per io dic Maint enance Record Use t he fo l lo wi ng ch art to record p eri od ic m ai nt en ance. Maintenance In t erval Perfo rmed Se rvic ing Date Se rvic ing Dealer or Pe rson Remarks 10 hrs. 20 hrs. 50 hrs. 100 hrs.[...]

85 MAINTENANCE AND LUBRICATION Lubr ication R ecom m endations P olar is 2 - Cycl e Lubri cants Polar is P remium 2-c ycle lubric ants ar e the most advanc ed for mulation of oils, specific ally designed for toda y’ s 2-cyc le engine s. Our ongoing lab a nd field tests ha ve re sulted in a ne w gen era tion of 2-c ycle lubric ants. Polar is Premi[...]

86 MAINTENANCE AND LUBRICATION Lubr ication R ecom m endations Pr emium 4 S ynth etic Oil Polaris Pre mium 4 All Sea son Synthetic e ngine oil ha s been spe cially for mulate d for use in Polaris 4-c ycle e ngines. It’ s a fully synthetic, high per for manc e, multi-viscosity oil de signed to pr ovide the u ltimate in lu bri cat i on p erform an [...]

87 MAINTENANCE AND LUBRICATION Lubr ication R ecom m endations Oil an d Filter Chan ge 4 - Cyc le Engine s With Ex terna l O il T ank 1. Position the vehicle on a leve l surf ace. 2. Clean the ar ea ar ound the dra in plug, which is loca ted on e ither the bottom of t he oil t ank or on the bottom of t he engine . 3. Run the engine for two to thr e[...]

88 MAINTENANCE AND LUBRICATION Lubr ication R ecom m endations Oil an d Filter Chan ge 4 - Cyc le Engine s With Ex terna l O il T ank 1 1. Lubric ate the gaske t on the new filte r with a film of new engine oil. Make sure the ga sket is in good condition. Also make sure the gaske t from the old filter i s not still on the engine . 12. Insta ll the [...]

89 MAINTENANCE AND LUBRICATION Lubr ication R ecom m endations Oil an d Filter Chan ge Magnum 3 3 0 2x4, Ma gnum 33 0 4x4, T rail Boss 1. Position the vehicle on a leve l su rface. 2. Clean the ar ea around the dra in plug (1) . 3. Run the engine for two to thre e minutes until wa rm. Stop the engine . 4. Place a dr ain pan bene ath the engine cr a[...]

90 MAINTENANCE AND LUBRICATION Lubr ication R ecom m endations Oil an d Filter Chan ge Magnum 3 3 0 2x4, Ma gnum 33 0 4x4, T rail Boss 12. Remove the dipstick a nd fill the sump with 2 qua rts (1.9 l) of Polar i s P re mium 4 synthetic oil. 13. Place the ge ar sele ctor in neutra l and set t he park ing brake . 14. Start the engine and let it idle [...]

91 MAINTENANCE AND LUBRICATION Lubr ication R ecom m endations T ransm ission Oil Ch eck - Mo dels with F ill Plug Scramb ler 500 4x4, Ma gnums: 500, 330 4x4, 330 2x4 The tr ansmission lubr icant lev el s hould be c hecke d eve ry six months or 1000 miles ( 1600 km), whiche ver c omes fir st. T ra nsmission oil should be cha nged annua lly . 1. Pos[...]

92 MAINTENANCE AND LUBRICATION Lubr ication R ecom m endations T ransm ission Oil Ch ang e - Mo dels with F ill Plug Scramb ler 500 4x4, Ma gnums: 500, 330 4x4, 330 2x4 1. If equippe d, re move the propshaf t shield fr om t he right side of the veh icl e t o access th e fi ll p lu g. 2. Remove the fill plug. 3. Remove the t ra nsmission drain plug [...]

93 MAINTENANCE AND LUBRICATION Lubr ication R ecom m endations T ransm issio n Oil Check - Mo dels with Dipstick On most 2x4 models, the tra nsmission dipstick ( 1) is loca ted on the right side of the mac hine. On the S portsman, the di ps t i ck i s l ocat ed n ear th e rear brak e di s c. The tra nsmission lubrica nt level should be c hec ked mo[...]

94 MAINTENANCE AND LUBRICATION Lubr ication R ecom m endations T r ansmission Oil Change - 2x4 Mod els 7. T ighten the jam nut secur ely while holding the adjuster bolt. 8. Add the proper lubric ant through the dipstick hole until the oil leve l is betwe en the uppe r a nd lower limits. Do not overf ill. 9. Ch eck fo r l eaks . T r ansmission Oil C[...]

95 MAINTENANCE AND LUBRICATION Lubr ication R ecom m endations Front Gearcase Oil Check The f ront gear ca se oil le vel should be che cked e very six months or 1000 miles (1600 km), whiche ver come s first. The oil should be change d annua lly . Use Polaris Pre mium Synthetic Gea rc ase Lube (or G L5 80-90 weight gear lube ). NOTE: Se e page 141 f[...]

96 MAINTENANCE AND LUBRICATION Lubr ication R ecom m endations Rear Gear case Oil Check W i t h t h e A T V o n a l ev el s u rface, re move the fill plug and view the oil leve l through the fill hole (1) . Lubric ant should be kept e ven with the ce nter of the dr illpoint (2) , appr oximate ly 1 5/8 ″ be low the top of the fill hole. Use P olar[...]

97 MAINTENANCE AND LUBRICATION Lubr ication R ecom m endations Counte r B alance Oi l Check - 400 2 - Cyc le E ngines The c ounter bala nce oil should be c hec ked se mi-annually a nd oil should be a dded or c hanged as ne eded. The oil should be c hange d annua lly and be fore of f sea son storag e. If the mac hine is used in w et conditions, chec[...]

98 MAINTENANCE AND LUBRICATION Lubr ication R ecom m endations E ngine Oi l Chec k The oil tank is locate d either on the lef t side of t he vehic l e (e xter nal tank models) (1) or on the engine (2) . 1. Position the machine o n a level surf ace. 2. Start the engine and let it idle for 20-30 sec onds. S top the engine. 3. Remove the dipstick and [...]

99 MAINTENANCE AND LUBRICATION Engi ne C ooling S ystem Coolant Level The re covery bottle (1 ) is located on the lef t side of the machine . T o access th e recov ery b o ttle on Gen IV m achi nes , rem ov e t he l eft si d e pane l. S ee pa ge 1 1 1. The fluid leve l m ust be maintained betw ee n the minimum and maximum marks on the bottle (whe n[...]

100 MAINTENANCE AND LUBRICATION Engi ne C ooling S ystem Radiator Coolant Level NOTE: This pr oce dure is requir ed only if the c ooling system ha s been dra ined for ma intena nce a nd/or repa ir . Howe ver , if the rec overy bottle ha s run dry , t he leve l i n the radiator should be inspe cted a nd coolant add ed i f neces sary . 1. Loca te the[...]

101 MAINTENANCE AND LUBRICATION Engi ne C ooling S ystem NOTE: T o ensure that the c oolant mainta ins its ability to prote ct the eng in e, we reco m men d th at t h e sy s t em b e com p l etel y drai ned every tw o years an d a fresh mi x t ure of ant i freeze and wat er added . P o l aris recom m end s t h e us e of P o l aris P rem i um 60 /4 [...]

102 MAINTENANCE AND LUBRICATION Adju stment s Oil P ump - 2 50 Engine s 1. Befor e adjusting the oil pump, che ck the engine idle RPM and car buretor se ttings in the owner ’ s manual suppleme nt. 2. Loose n throttle ca ble jam nut and turn the adjuste r (1) in or out until ther e is 1/16 ″ -1 / 8 ″ (.16 - .32 cm) of throttle leve r trave l b[...]

103 MAINTENANCE AND LUBRICATION Adju stment s Oil P ump - 4 00 Engine s 1. Befor e adjusting the oil pump, che ck engine idle RPM and ca rbure tor adjustments in your owner ’ s m anua l supplement. 2. Loosen the throttle c able jam nut and turn the adjuster in or out until there is 1/16 ″ -1 / 8 ″ (.16 - . 32 cm) throttle leve r trave l befor[...]

104 MAINTENANCE AND LUBRICATION Adju stment s Fr ont Br ake The front bra kes ar e hydraulic disc br akes. They’r e activate d by moving the brake le ver towar d the handleba r . These br akes are self -a djusting. The fo l l owi ng check s are reco mm en ded to keep t h e brak e sy s tem i n good oper ating c ondition. Check mor e ofte n if brak[...]

105 MAINTENANCE AND LUBRICATION Adju stment s Rear Br ake The re ar bra ke is a hydraulic disc brak e. Th e rear brak e s ys t em is self -a djusting and r equire s no mainte nance othe r than per iodic check s o f th e pad s fo r wear . Pads should be c hanged w hen wor n to 3/64 ″ (.1 cm) , which is a bout the thickne ss of a U.S. dime. Inspe c[...]

106 MAINTENANCE AND LUBRICATION Adju stment s T oe Alignm ent Use the following proce dure to chec k the toe alignment of the vehicle. The re comme nded toe alignment is 1/8 ″ to 1/4 ″ toe out. 1. Set t he handle bars in a stra ight-a hea d position. NOTE: The st eeri ng fro g can be us ed as an i nd i cato r of whether the ha ndleba rs are str[...]

107 MAINTENANCE AND LUBRICATION Adju stment s Steer ing Assembly The ste er ing asse mbly 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 ler for se rvice be fore oper ating t he vehic le. Cam ber and Caster The ca mber and c aste r are non- adjusta ble. Rear S pring Th[...]

108 MAINTENANCE AND LUBRICATION Adju stment s Handlebars The h and l ebars can b e adj u st ed for rid er preferen ce. 1. Locat e han dl eb ar bo lt s (1). On models with a headlight pod, re move the upper he adlight pod. On other models, remove th e han d leb ar co ver . 2. Loosen the four bolts. 3. Adjust the handle bar to the desir ed height. Be[...]

109 MAINTENANCE AND LUBRICATION Adju stment s Ca r bure tor IMPOR T ANT : Y our Polar i s A TV is ca librate d at the f ac t ory f or optimal pe rfor m anc e at altitude s ra nging from z er o to 6,000 fee t (1800 m) and temper atur es of +40 degree s F . (4 degre es C .) or higher . Above 6000 fe et (1800 m) the e ngine a ir/fue l mixture be comes[...]

11 0 MAINTENANCE AND LUBRICATION Adju stment s Ca r bure tor 4 - Cyc le E ngi nes If the e ngine idle spee d is not satisfa ctory , and all other c onditions are fa vorable , the carbu ret or can be ad ju s ted . 1. W arm up the engine by running the vehic le for appr oximately five minutes. 2. Plac e the transmission in gear w ith the par king bra[...]

111 MAINTENANCE AND LUBRICATION Adju stment s Side Panel Rem oval - Gen IV NOTE: Side panel r emoval may be diff icult until the loc king tabs a nd receiv ers hav e been sn app ed and u ns n app ed a few time s. 1. Remove the sea t . 2. Grasp the rea r of the side pan el n ear t he rear cab . W i t h a quic k and f irm motion, pull th e panel fo rw[...]

11 2 MAINTENANCE AND LUBRICATION Adju stment s Wheel Rem o val 1. Stop the engine , place the tra nsmission in gear a nd lock the par king brake . 2. Loosen the whe el nuts slightly . 3. Eleva t e the side of the vehic le by placing a suitable sta nd under the foot res t fram e. 4. Remove the whe el nuts and remove the whe el. Oper at ing your A TV[...]

11 3 MAINTENANCE AND LUBRICATION Adju stment s Wheel Installation 1. Place the tr ansmission in gear and lock the park ing brake . 2. P lace t h e wh eel o n th e wh eel hub with the valve stem towar d the outside and rota tion arr ows on the tire pointing toward for wa rd rota tion. 3. Install the wheel nuts and finge r tighten. 4. Lower the vehic[...]

11 4 MAINTENANCE AND LUBRICATION Adju stment s Fr ont Whee l Hub T ighteni ng Front whee l bear ing tightness and spindle nut r ete ntion ar e cr itical compone nt operations. All se rvic e must be per forme d by your aut ho ri zed P ol ari s d ealer . Ti re T read Depth Alway s repl ace ti res when t read depth is wor n to 1/8 ″ (.3 cm) or le ss[...]

11 5 MAINTENANCE AND LUBRICATION Adju stment s Drive Chain Polaris A TV drive cha ins are e quipped with o-ring- sea led, perma nently greas ed p i ns and rol l ers. Ho wev er , t h e ou t er su rfaces of t he ro l l er m us t be lubric ated. Always inspe ct the dr ive cha i n prior to ope ra ting the vehic le. Check f or dama ged or missing o-r in[...]

11 6 MAINTENANCE AND LUBRICATION Adju stment s Rear Dr ive Chain Slack - Con centric Dr ive Mo dels Chec k the a mount of cha i n slac k in thre e dif fe re nt locations by moving the ve hicle slightly f orwa rd to gain sla ck a t the top side of the r ear chai n. M eas ure t h e chai n sl ack at t h e ti g ht es t of t he t h ree po s it i o ns . [...]

11 7 MAINTENANCE AND LUBRICATION Adju stment s Rear Dr ive Chain Slack - Con centric Dr ive Mo dels 6. R o ll th e A TV forward o r back ward to adjust the cha in slack to the prope r tension. See the illustra tion for pr oper splice link clip ope ning position (1) . 7. T ig h ten t he eccen t ric l o cki n g b ol t s to 30 ft. lbs. (41 Nm) for ma [...]

11 8 MAINTENANCE AND LUBRICATION Filter System s Air Filter Rem oval and Service - 2 - Cycle Engines 1. Remove the A TV seat. 2. Rele ase the clips sec uring the cover a ssembly to the air box. 3. Loose n the clamp sec uring the filter , and remove the f ilter . 4. Remove the f oam pre- filte r fro m t he main filte r . 5. W ash the pre -filter i n[...]

11 9 MAINTENANCE AND LUBRICATION Filter System s Air Filter Service - 4 - Cycle 1. Rem o ve t h e seat , rel eas e t he cl i p s, and re move the air box cover . 2. Loosen the cla mp and r emove the filte r . 3. Remove the f abr i c type pre- filter (1) f rom the main filter ( 2). W ash the pr e- filte r in soa py wate r , then rinse a nd let dry .[...]

120 MAINTENANCE AND LUBRICATION Lights Whe n servicing a halogen lamp, don’ t touch the lamp with ba re finger s. Oil fr om your skin leave s a re s idue, ca using a hot spot tha t will shorten the life of the la mp. Headlight Lamp Replacement - Scr ambler 1. Remove the wir e har ness conne ctor fr om the back of the hea dlight. 2. Gra sp the bul[...]

121 MAINTENANCE AND LUBRICATION Lights Headlight Lamp Replacement - T rail Blazer 1. Remove the fr ont cover and unplug the light harne ss. 2. Remove the rubbe r cap fr om the back of the head light to reve al the re tention scr ew . 3. Remove the sma ll phillips head scr ew , an d car ef ully remove the bulb from the housing. 4. Apply diele ctr ic[...]

122 MAINTENANCE AND LUBRICATION Lights Headlight L amp R eplacement - Gen IV 1. Remove the three sc rews on the headlight pod. 2. Using a sma ll flat- blade scr ew driver , push in on the lock ta bs through the two small ope nings at the front of the he adlight pod. 3. Lift the pod slightly while depre ssing the tabs. 4. Lift the pod cover and disc[...]

123 MAINTENANCE AND LUBRICATION Lights High Beam Adjustment - Gen IV The h ea dlight bea m can be adjusted to a ny position desire d by turning the adjusting knob on the bottom right side of the hea dlight pod. 1. Position the vehicle on a leve l surfac e with the headlight appr oximate ly 25 ft. (7.6 m.) fr om a wa ll. 2. Remove the two screws on [...]

124 MAINTENANCE AND LUBRICATION Lights Headlight Hou sing Replacement - Gen IV 1. Remove the three sc rews on the headlight pod. 2. Using a sma ll flat- blade scr ew driver , push in on the lock ta bs through the two small ope nings at the front of the he adlight pod. Lift the pod lightly while depr essing the tabs. 3. Lift the pod cove r . Disconn[...]

125 MAINTENANCE AND LUBRICATION Lights T aillight /Br akeligh t Lamp Replacement If the t aillight/br ake light does not work the lamp may nee d to be repl aced. 1. Remove the ta illight lens cover mounting scre ws. Re move the lens c over a nd gasket and se t aside f or re asse mbly . 2. Remove the lamp (1) and re place it with a new la mp. 3. T e[...]

126 MAINTENANCE AND LUBRICATION Spar k P l ugs Refe r to your owner ’ s manual supplement for re comme nded spar k plug and g ap sp eci ficat i o ns . Spar k plug condition is indica tive of engine operation. The spar k plug firing e nd condition should be re ad a fter t he e ngine has be en war med up an d th e veh icl e has b een dr iv en at h [...]

127 MAINTENANCE AND LUBRICATION V eh ic le Imme rsio n If it’ s impossible to take your A TV to a deale r befo re sta rting it, follow the steps outlined below . 1. Move the A TV to dry land or at the ver y lea st, to wate r below the foot re sts. 2. Check the air box for a ny water a nd dry it i f wat er i s p res ent . 3. T urn the fuel valve o[...]

128 MAINTENANCE AND LUBRICATION Spar k A r r estor W ARNING Failur e t o heed t he f ollowing warnings while serv icing t he s park arres t or c ould res ult in ser ious injur y or death. Do no t perform servi ce on the spa rk arrestor whi le the system is hot. Exhaust syst em tem perat ures ca n r each 1000 ° F . Allow component s to c ool suff i[...]

129 MAINTENANCE AND LUBRICATION Spar k A r r estor 1. Remove the ar restor cle an-out plug(s) (1) f rom the bottom of the muf fle r . 2. Place the tr ansmission in neutra l and start the engine . 3. Pur ge ca rbon fr om t he syste m by momentar ily re vving the e ngine seve ral time s. 4. If c arbon is expe lled, cover the exha ust outlet and ra p [...]

130 MAINTENANCE AND LUBRICATION Recoil Hou sing T o preve nt possible engine damage , alwa ys drain the re coil housing af ter ope rating the A TV in very w et conditions. This should also be done bef ore storing the A TV . W ate r will ente r the rec oil housing if the starte r handle is disengage d from the rope guide when under wa t er . NOTE: O[...]

131 MAINTENANCE AND LUBRICATION PV T S ystem The basic ope ra tion of t he Polaris PVT system is depende nt on engine sp eed an d v ehi cl e t orq ue req ui rem ent s . As en gi n e sp eed i n creases , t he forc e exerte d on the movable drive shea ve by the flyweights also incr ea ses. This, in turn, incre ase s the a mount of “pinc h” a ppli[...]

132 MAINTENANCE AND LUBRICATION PV T S ystem PVT Dryi n g There m ay be so m e ins t ances wh en wat er is acci den t ly i n ges t ed in t o the PVT system. Use the following instruc tions to dry it out bef ore oper ating: 1. Remove the dr ain plug and allow the wa ter to dra in. Repla ce the dra in plug. 2. Start the engine an d shift the transmis[...]

133 MAINTENANCE AND LUBRICATION Batter y (C onventional) Ke ep the batte ry termina l s and c onnec tions fre e of c orrosion. If cle aning is nec essa ry , remove the c orrosion with a stif f wire br ush. W ash with a solution of one ta blespoon baking soda a nd one cup wa ter . Ri n se wel l wi t h t ap wat er and dry o ff wi t h cl ean sh o p to[...]

134 MAINTENANCE AND LUBRICATION Batter y Re plenis hing Ba tter y Fluid (Conv entional Batte r y) A poorly ma intained ba ttery will dete riorate r apidly . Check the ba tter y fluid leve l often. The fluid le vel should be kept betwee n the upper and lower leve l marks ( 1). T o ref ill use only distilled w ate r . T ap wate r c ontains miner als [...]

135 MAINTENANCE AND LUBRICATION Batter y Battery Installation 1. Set the ba tter y in the ba tter y holder . 2. W ith conve ntional batte ries, install the batte ry vent tube . Seale d batte ries do not have a vent tube. NOTE: The ven t tube must be fr ee of obstr uctions a nd sec ure ly installed. If not, batte ry gase s could accum ul ate and cau[...]

136 MAINTENANCE AND LUBRICATION Batter y Batter y Charging (S ealed Battery ) For a re fr esh cha r ge, follow all instructions ca ref ully . 1. Chec k the batte ry voltage with a voltme ter or multimete r . A fully cha rge d batter y will registe r 12.8 V or higher . 2. If the volta ge is less than 12. 8 volts, re cha r ge the batte ry . NOTE: Whe[...]

137 MAINTENANCE AND LUBRICATION Cleaning a nd Stor age See page 141 for the pa rt numbers of Polaris-r ecomme nded produc ts. Cleaning th e A T V Kee ping your A TV c lean will not only improve its appe ara nce but it ca n also exte nd the life of var ious compone nts. W ith a fe w precauti ons, your A TV can be cleaned much l ik e an a utom obil e[...]

138 MAINTENANCE AND LUBRICATION Cleaning a nd Stor age Sto ra g e Tip s See page 141 for the pa rt numbers of Polaris-r ecomme nded produc ts. Clean t he Exterio r Make nec essary r epairs a nd then cle an the A TV thoroughly with mild soap a nd wa rm wa ter to r emove all dir t and grime . Don’ t use har sh dete r gents or high pressur e washe r[...]

139 MAINTENANCE AND LUBRICATION Cleaning a nd Stor age Sto ra g e Tip s See page 141 for the pa rt numbers of Polaris-r ecomme nded produc ts. Fog the E ngine 2C y c l e - Use Pola ris F ogging Oil and follow the direc tions on the can. 4-Cycle - Re move the spa rk plug a nd add 2-3 ta blespoons of Premium 4 S yn t het i c 0W4 0 en gi n e oi l . T [...]

140 MAINTENANCE AND LUBRICATION Cleaning a nd Stor age Sto ra g e Tip s Batte r y Stor ag e Con ven ti o n al B attery : Remove the batter y and add distille d wate r to th e pro per l ev el . Do not use tap water , wh i ch m ay con tai n m i neral s that re duce ba ttery life . Apply P olar is di-ele ctric gre ase to the termina l bolts and te rmi[...]

141 POLARIS RECOMMENDE D PRODUCTS Part No. Descr ipt ion Engine Lubr icant 2870791 Fogging O il (12 oz. Aerosol ) 2871098 Prem ium 2-C ycle Engi ne Oil (qt .) 2871721 Prem ium Gold S ynthet ic 2- Cycle Oi l ( qt. ) 2871281 Prem ium 4 Synthet ic 0W -40 Engi ne Oil (4- Cycle) (qt .) Gear case / T ransmi ssion Lubri cants 2873602 Prem ium Synt heti c [...]

142 TROUB LES HOOTIN G Dr ive Belt and Cover Pr oblems Po ssi b l e Cau se Solu tio n Dr ivi ng the A TV onto a p ick u p o r tall trailer in hi gh ra nge. Shi ft tr ans mis si on to l ow ra nge dur ing l oadi ng of t he A TV t o pre vent be lt bur ning. St ar ti ng out goi ng up a steep in clin e. Whe n st ar ti ng out on a n inc li ne, use low ra[...]

143 TROUB LES HOOTIN G Contac t your P olar is deale r for ser vice if you’ re unable to identif y solutions using the follow ing cha rts. Engine Doesn’t T urn Over Po ssi bl e Cause Sol uti o n Trip p ed circu it b reak er Reset th e b reak er Lo w battery v o ltage Re c har ge ba tt er y to 12. 5 VDC Loos e ba tt er y conne ct ions Ch eck all[...]

144 TROUB LES HOOTIN G Engine Backfir es Po ssi bl e Cause Sol uti o n W ea k spa rk f rom s pa rk pl ugs In sp ect, clean and /o r repl ace sp ark p lu g s In co rrect spark p lu g g ap o r h eat rang e Se t ga p to s pec s or re pla ce plugs Ol d or non- re c omme nded f uel Re pla ce w it h new fue l In co rrectly in stalled sp ark p lu g w ires[...]

145 TROUB LES HOOTIN G E ngine S tops or Loses P ower Po ssi bl e Cause Sol uti o n Out of fuel Tu rn fu el valv e to reserve, refu el Ki nke d or plugge d fue l ve nt li ne Insp ect and rep lace W ater p resen t in fuel Re pla ce w it h new fue l Ove rus e of choke In sp ect, clean and /o r repl ace sp ark p lu g s Foul ed or de fe ct ive spa rk p[...]

146 WARRANTY LI MIT ED W ARRANTY Polaris I ndustries I nc., 2100 Highwa y 55, Me dina, MN 55340, gives a SIX MONTH LIMITED W ARRANTY on all components of the P ol ari s All T errai n V eh icl e (A T V) again st d efects i n m ateri al o r wor kmanship. Polar is also gives a one ye ar limited w ar ra nty on the final drive ch ain for failur e due to[...]

147 WARRANTY W ARRANT Y COVERAGE AND EXCL USIONS: LI MIT A T IONS OF W ARRANTIES AND REMEDIES The Pola ris limite d war ranty exc ludes any f ailur es that a re not cau sed by a de fe ct in mate rial or workma nship. This warra nty does not cover accid ent al dam ag e, no rm al w ear and tear , ab us e or i m p rop er han dl i n g. This warr anty a[...]

148 WARRANTY ALL IMP LIED W ARR ANTIES (INCLUDING B UT NOT LIMITED T O THE IMP LIED W AR RANTIES OF MERC HANT ABILITY AND FITNES S FOR A P AR TIC ULAR P UR P OSE) AR E LIMITED IN DURA TION TO THE ABOVE S IX MONTH W AR RANTY P ER IOD. POLAR IS FUR THER DIS C LAIMS ALL EXPRES S W AR RANTIES NOT ST A TED IN THIS W ARR ANTY . S om e stat es do not al l[...]

149 INDEX A Access or ies 75 ............................. Adj ust ments 102-1 17 ........................ Age Restrictio n s 7 .......................... Air Filter 118- 119 ........................... Al l W heel D rive 48-49 ....................... Aux iliar y Brak e 42 , 1 05 ..................... A W D 48-49 ............................... B B[...]

150 INDEX O Oil Injection T ank 45 ........................ Oi l Pump Adj ustme nt - 250 Engi nes 102 ......... Oi l Pump Adj ustme nt - 400 Engi nes 103 ......... Oi l P ump Bl eedi ng - 2-Cyc le E ngine s 101 ....... OPE RA TI ON 56-73 ....................... Ope rat or Sa fet y 7-31 ........................ Override S witch 37 ..................[...]

Operate without proper training or instruction. Operate on public roads. A collision can occur with another vehicle. Operate at speeds too fast for your skills or the conditions. Use ALCOHOL or DR UGS before or while operating this vehicle. Carry Passengers. P art No. 9917492 Rev . 05 PRINTED IN THE USA W ARNING Improper vehicle use can result in S[...]