Table of Contents
Advertisement
Advertisement
Table of Contents
Related Manuals for Polaris ATP 330 4x4
Summary of Contents for Polaris ATP 330 4x4
- Page 2 WARNING Improper vehicle use can result in SEVERE INJURY or DEATH. ALWAYS USE NEVER USE AN APPROVED ON PUBLIC HELMET AND ROADS PROTECTIVE GEAR NEVER: 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.
- Page 3 WARNING The engine exhaust from this product contains chemicals known to cause cancer, birth defects or other reproductive harm. A card containing important ATV safety information should be attached to the owner’s manual on the next page. If you cannot locate this card, or if it has been removed, please call 1-800-342-3764 for assistance.
- Page 4 We’ve created a web site just for YOU! Check it out... www.polarisindustries.com/owner Technical tips New product introductions Event schedules Parts and Service Manual information Exciting details about The Way Out...
- Page 5 All information in this manual is based on the latest product data and specifications available at the time of printing. Polaris Industries Inc. reserves the right to make product changes and improvements that may affect illustrations or explanations. No part of this manual shall be reproduced or used without the written permission of Polaris Industries Inc.
-
Page 6: Welcome
S Personal Task Vehiclest (PTVs) S All-Surface Loaders (ASLs) We believe Polaris sets a standard of excellence for all utility and recreational vehicles manufactured in the world today. Many years of experience have gone into the engineering, design, and development of your Polaris vehicle, making it the finest machine we’ve ever... -
Page 8: Table Of Contents
........EMISSION CONTROL SYSTEMS MAINTENANCE AND LUBRICATION POLARIS PRODUCTS TROUBLESHOOTING SPECIFICATIONS WARRANTY . -
Page 9: Vehicle Identification Numbers
Remove the spare key and store it in a safe place. Your key can be duplicated only by mating a Polaris key blank with one of your existing keys. If both keys are lost, the ignition switch must be replaced. -
Page 10: Safety
Failure to follow the warnings contained in this manual can result in severe injury or death. A Polaris ATV is not a toy and can be hazardous to operate. This vehicle handles differently than other vehicles, such as motorcycles and cars. A collision or rollover can occur quickly, even during routine maneuvers like turning, or driving on hills or over obstacles, if you fail to take proper precautions. -
Page 11: Operator Safety
SAFETY Operator Safety The following signal words and symbols appear throughout this manual and on your ATV. Your safety is involved when these words and symbols are used. Become familiar with their meanings before reading the manual. The safety alert symbol, on your ATV or in this manual, alerts you to the potential for personal injury. - Page 12 S Never operate an ATV without proper instruction. Take a training course. Beginners should receive training from a certified instructor. Contact an authorized Polaris ATV dealer or call Polaris at 1-800-342-3764 to find out about the training courses nearest you.
- Page 13 SAFETY Operator Safety S Always have the ATV inspected by an authorized Polaris dealer if it’s been involved in an accident. S Never operate on hills too steep for the ATV or for your abilities. Practice on smaller hills before attempting larger hills.
-
Page 14: Equipment Modifications
We are concerned for the safety of our customers and for the general public. Therefore, we strongly recommend that consumers do not install on a Polaris ATV any equipment that may increase the speed or power of the vehicle, or make any other modifications to the vehicle for these purposes. - Page 15 ATVs, he/she may not have the skills, abilities, or judgment needed to operate an ATV safely and could be susceptible to accident or injury. HOW TO AVOID THE HAZARD No one under the age of 16 should operate a Polaris ATV. WARNING WARNING...
- Page 16 Operator Safety POTENTIAL HAZARD Carrying a passenger on an ATV. WHAT CAN HAPPEN Carrying a passenger greatly reduces the operator’s ability to balance and control the ATV, which could cause an accident and injury to the operator and/or passenger. HOW TO AVOID THE HAZARD Never carry a passenger.
- Page 17 SAFETY Operator Safety POTENTIAL HAZARD Operating an ATV on paved surfaces, including sidewalks, paths, parking lots, and driveways. WHAT CAN HAPPEN ATV tires are designed for off-road use. Operating on paved surfaces may seriously affect the handling and control of the ATV and could result in loss of control, accident, and/or injury.
- Page 18 SAFETY Operator Safety WARNING POTENTIAL HAZARD Operating this ATV on public streets, roads or highways. WHAT CAN HAPPEN The ATV could collide with another vehicle. HOW TO AVOID THE HAZARD Never operate the ATV on any public street, road or highway, including dirt and gravel roads.
- Page 19 SAFETY Operator Safety POTENTIAL HAZARD Operating this ATV without wearing an approved helmet, eye protection and protective clothing. WHAT CAN HAPPEN Operating an ATV without an approved helmet increases the risk of a severe head injury or death in the event of an accident.
- Page 20 Operator Safety POTENTIAL HAZARD Operating the ATV after consuming alcohol or drugs. WHAT CAN HAPPEN Consumption of alcohol and/or drugs could seriously affect operator judgment. Reaction time may be slower and operator balance and perception could be affected. Consuming alcohol and/or drugs before or while operating an ATV could result in an accident causing severe injury or death.
- Page 21 SAFETY Operator Safety POTENTIAL HAZARD Attempting wheelies, jumps and other stunts. WHAT CAN HAPPEN Attempting stunts increases the chance of an accident, including an overturn. HOW TO AVOID THE HAZARD Never attempt wheelies, jumps, or other stunts. Avoid exhibition driving. WARNING...
- Page 22 Operator Safety POTENTIAL HAZARD Failure to inspect the ATV before operating. Failure to properly maintain the ATV. WHAT CAN HAPPEN Poor maintenance increases the possibility of an accident or equipment damage. HOW TO AVOID THE HAZARD Always inspect your ATV before each use to make sure it’s in safe operating condition.
- Page 23 SAFETY Operator Safety POTENTIAL HAZARD Failure to use extra caution when operating the ATV on unfamiliar terrain. WHAT CAN HAPPEN Unfamiliar terrain may contain hidden rocks, bumps, or holes that could cause loss of control or overturn. HOW TO AVOID THE HAZARD Travel slowly and use extra caution when operating on unfamiliar terrain.
- Page 24 SAFETY Operator Safety WARNING POTENTIAL HAZARD Failure to use extra caution when operating on excessively rough, slippery or loose terrain. WHAT CAN HAPPEN Operating on excessively rough, slippery or loose terrain could cause loss of traction or loss of control, which could result in an accident or overturn.
- Page 25 SAFETY Operator Safety POTENTIAL HAZARD Turning improperly. WHAT CAN HAPPEN Improper turns could cause loss of control and lead to a collision or overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for turning as described in the owner’s manual. Practice turning at slow speeds before attempting to turn at faster speeds.
- Page 26 SAFETY Operator Safety WARNING POTENTIAL HAZARD Climbing hills improperly. WHAT CAN HAPPEN Improper hill climbing could cause loss of control or overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for climbing hills as described in the owner’s manual. Always check the terrain carefully before ascending any hill.
- Page 27 SAFETY Operator Safety POTENTIAL HAZARD Traveling downhill improperly. WHAT CAN HAPPEN Improperly descending a hill could cause loss of control or overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for traveling down hills as described in the owner’s manual. NOTE: A special technique is required when braking while traveling downhill.
- Page 28 SAFETY Operator Safety WARNING POTENTIAL HAZARD Improperly crossing hills and turning on hills. WHAT CAN HAPPEN Improperly crossing or turning as hills could cause loss of control or overturn. HOW TO AVOID THE HAZARD Never attempt to turn the ATV around on any hill until you’ve mastered the turning technique (on level ground) as described in the owner’s manual.
- Page 29 SAFETY Operator Safety POTENTIAL HAZARD Stalling, rolling backwards or improperly dismounting while climbing a hill. WHAT CAN HAPPEN The vehicle could overturn. HOW TO AVOID THE HAZARD Maintain steady speed when climbing a hill. If all forward speed is lost: Keep your weight uphill.
- Page 30 Operator Safety POTENTIAL HAZARD Improperly operating over obstacles. WHAT CAN HAPPEN Operating over obstacles could cause loss of control or overturn. HOW TO AVOID THE HAZARD Before operating in a new area, check for obstacles. Avoid operating over large obstacles such as rocks and fallen trees when possible.
- Page 31 SAFETY Operator Safety POTENTIAL HAZARD Operating the ATV through deep or fast-flowing water. WHAT CAN HAPPEN Tires may float, causing loss of traction and loss of control, which could lead to an accident or overturn. HOW TO AVOID THE HAZARD Avoid operating the ATV through deep or fast-flowing water.
- Page 32 Never modify the ATV through improper installation or use of accessories. All parts and accessories added to the vehicle must be genuine Polaris Industries Inc. or equivalent components designed for use on this ATV and should be installed and used according to approved instructions. See your authorized Polaris ATV dealer for more information.
- Page 33 SAFETY Operator Safety POTENTIAL HAZARD Overloading the ATV or carrying/towing cargo improperly. WHAT CAN HAPPEN Overloading and towing can cause changes in vehicle handling, which could lead to loss of control or an accident. HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this ATV. Cargo should be properly distributed and securely attached.
- Page 34 Operator Safety Leaving the keys in the ignition can lead to unauthorized use of the vehicle resulting in serious injury or death. Always remove the ignition key when the vehicle is not in use. After any overturn or accident, have a qualified service dealer inspect the entire vehicle for possible damage, including (but not limited to) brakes, throttle and steering systems.
-
Page 35: Safety Decals And Locations
Warning decals have been placed on the ATV for your protection. Read and follow the instructions on each decal carefully. If a decal becomes illegible or comes off, contact your Polaris dealer to purchase a replacement. Replacement safety decals are provided by Polaris at no... - Page 36 DWhen this ATV is not in operation or unattended, place shift in the park position. WARNING IF OWNER’S MANUAL IS MISSING, CONTACT A POLARIS DEALER FOR A REPLACEMENT. E1997, 2000 25°. 7171383 WARNING...
- Page 37 SAFETY Safety Decals and Locations IMPROPER TIRE PRESSURE OR OVERLOADING can cause loss of control resulting in SEVERE INJURY OR DEATH. TIRE PRESSURE IN PSI (KPa): FRONT 5 (34,5) REAR 5 (34,5) MAXIMUM WEIGHT CAPACITY (Gross Vehicle Weight) INCLUDING MACHINE, DRIVER AND CARGO IS MAXIMUM CARGO CAPACITY 350 LBS.
- Page 38 S Operation of this vehicle without engine breather filter(s) can cause engine damage. Consult owner’s manual or dealer for details. Under seat: ATP 500 7078689 MANUFACTURED BY: POLARIS IND, INC. DATE: VIN: ATTENTION S Specific carburetor jetting and adjustments are required depending on temperature and altitude.
-
Page 39: Safe Riding Gear
SAFETY Safe Riding Gear Always wear clothing suited to the type of riding. ATV riding requires special protective clothing for comfort and to reduce the chance of injury. 1. Helmet Your helmet is the most important piece of protective gear for safe riding. A helmet can prevent a severe head injury. -
Page 40: Features And Controls
Electrical Switches While operating in reverse, activating the override switch with the throttle open can cause loss of control, resulting in severe injury or death. Do not activate the override switch while the throttle is open. Speedo Mode/Override Switch (1) (Reverse Speed Limiter) - This switch, if pressed while in any gear but reverse, will change the display mode of the speedometer (if equipped). -
Page 41: Light Switches
FEATURES AND CONTROLS Electrical Switches Engine Stop Switch (3) - The engine will not start or run when the switch is in the OFF position. Its purpose is to provide the operator with a quick means of engine shutdown in case of an emergency. To stop the engine, slide the stop switch either right or left to the OFF position. -
Page 42: Throttle Lever
This ATV is equipped with Polaris Electronic Throttle Control (ETC), which is designed to reduce the risk of a frozen or stuck throttle. If the throttle cable should stick in an open position when the operator releases the throttle lever, the engine will stop, and power to the rear wheels will cease. -
Page 43: Brake Lever
If the fluid level is low, add DOT 3 brake fluid only. DO NOT OVERFILL. See page 121 for the part numbers of Polaris products. Never store or use a partial bottle of brake fluid. Brake fluid is hygroscopic, meaning it rapidly absorbs moisture from the air. -
Page 44: Parking Brake
Parking Brake Operating the ATV while the parking brake is engaged could result in an accident and serious injury or death. Always check to be sure the parking brake is disengaged before operating. Locking the Parking Brake 1. Squeeze and release the brake lever (1) two or three times, then squeeze and hold at full stroke. -
Page 45: Auxiliary Brake
FEATURES AND CONTROLS Auxiliary Brake Aggressively applying the rear brake when backing down a hill may cause rear tipover, which could result in serious injury or death. If the rear brake is applied aggressively while moving forward, the rear wheels may skid and slide sideways, causing loss of control and serious injury or death. -
Page 46: Fuel Valve
FEATURES AND CONTROLS Choke The choke assists in starting a cold engine. Refer to the engine starting procedure on page 55 for correct choke and throttle settings during starting. Fuel Valve The fuel valve (1) is located on the left side panel. -
Page 47: Fuel Safety
FEATURES AND CONTROLS Fuel Safety Gasoline is highly flammable and explosive under certain conditions. Always exercise extreme caution whenever handling gasoline. Always refuel with the engine stopped, and outdoors or in a well ventilated area. S Never fill a gas container while it’s in the cargo box. Static electricity between the box and container could cause a spark. -
Page 48: Belt Life
Automatic Transmission Gear Selector The transmission gear selector (1) is located on the right side of the vehicle. H: High Gear L: Low Gear N: Neutral R: Reverse P: Park To shift into HIGH or PARK, you must first apply the auxiliary brake to activate the high/park lock-out mechanism. -
Page 49: Recoil Starter
(1) will allow vehicle operation until repairs can be made. The recoil starter is located on the right side of the machine. Polaris 4-cycle engines are equipped with automatic decompressors. This makes recoil starting possible by allowing compression to “leak” at cranking speeds. -
Page 50: Engaging The Front Gearcase
All Wheel Drive (AWD) System Polaris 4 wheel drive ATVs are equipped with a unique, Polaris exclusive, Demand 4 Drive (AWD) system activated by a switch (1) on the right handlebar. When the switch is on 2x4 (center position), the ATV is in two wheel drive at all times and the differential is locked. -
Page 51: Instrument Cluster
FEATURES AND CONTROLS Instrument Cluster Your ATV is equipped with an instrument cluster that senses vehicle speed from the right front wheel. The instrument cluster measures distance in miles as well as hours of operation. It also includes a reverse speed limiter function that limits the ATV’s speed to approximately 7-9 mph. -
Page 52: Rider Information Center
If this occurs, take the ATV to your Polaris dealer for proper diagnosis. 1. Gear Indicator - As the shift lever is moved, this indicator shows... - Page 53 FEATURES AND CONTROLS Instrument Cluster Rider Information Center The rider information center has 4 standard modes: Mode 1 - Odometer Mode 2 - Tripmeter Mode 3 - Total Service Hours Mode 4 - Tachometer The reverse override button on the left handlebar is also the mode button.
-
Page 54: Diagnostic Mode
FEATURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode The diagnostic mode is for informational purposes only. Please return your ATV to your dealer for all major repairs. As long as the gauge is in the diagnostic mode, the wrench icon will remain lit. - Page 55 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode Screen 5: Programmable service interval The purpose of the programmable service interval is to provide the consumer and dealer with a convenient reminder for routine maintenance. When your vehicle leaves the factory, this feature is set at 50 hours.
-
Page 56: Operation
Break-In Period The break-in period for your new Polaris ATV is defined as the first ten hours of operation, or the time it takes to use the first two full tanks of gasoline. No single action on your part is as important as following the procedures for a proper break-in. - Page 57 OPERATION Pre-Ride Inspection If a proper inspection is not done before each use, severe injury or death could result. Always inspect the vehicle before each use to ensure it’s in proper operating condition. Use the following checklist to verify that your vehicle is in proper working condition before each use.
-
Page 58: Starting The Engine
Starting the Engine Starting a Cold Engine Engine exhaust contains poisonous carbon monoxide and can cause loss of consciousness resulting in severe injury or death. Never run an engine in an enclosed area. Operating the vehicle immediately after starting could cause engine damage. -
Page 59: Starting A Warm Engine
Water in the bottom of the tank can lead to engine damage and must be drained. Water accumulation increases as outside temperature decreases. See your Polaris dealer for engine heater kits, which provide quicker warm-ups and easier starting in colder weather. -
Page 60: Hauling Cargo
Hauling Cargo Overloading the vehicle or carrying or towing cargo improperly can alter vehicle handling and may cause loss of control or brake instability. Always follow these precautions when hauling cargo: S Never exceed the stated load capacity for this vehicle. S Reduce speed and allow a greater distance for braking. -
Page 61: Load Distribution
Maximum grade while trailer towing is 15°. Do not tow any trailer on a grade steeper than 15°. Towing Load (Level Ground) ATP 330 4x4 1000 lbs. ( 454 kg) ATP 500 4x4 1225 lbs. ( 556 kg) Belt Life Use low forward gear when hauling or towing heavy cargo to extend belt life. -
Page 62: Dumping Cargo
Hauling Cargo Dumping Cargo 1. Select a level site to dump the cargo box. Do not attempt to dump or unload the vehicle while parked on an incline. 2. Place the transmission in park and set the parking brake. 3. Dismount the vehicle. 4. -
Page 63: Driving Safely
OPERATION Driving Safely Driving Procedures 1. Sit upright with both feet on the footrests and both hands on the handlebars. 2. Start the engine and allow it to warm up, then shift the transmission into gear. 3. Check your surroundings and determine your path of travel. 4. -
Page 64: Making Turns
Driving Safely Making Turns Your Polaris ATV is equipped with a rear differential that functions as a solid rear axle, driving both rear wheels equally when the ATP is in either 2x4 or 4x4 mode. This means that the wheel on the outside of a turn must travel a greater distance than the inside wheel, causing the inside tire to slip traction slightly. -
Page 65: Driving On Slippery Surfaces
OPERATION Driving Safely Driving on Slippery Surfaces Whenever riding on slippery surfaces such as wet trails or loose gravel, or during freezing weather, follow these precautions: 1. Slow down when entering slippery areas. 2. Maintain a high level of alertness, reading the trail and avoiding quick, sharp turns which can cause skids. -
Page 66: Driving Uphill
Driving Safely Driving Uphill Whenever traveling uphill, follow these precautions: 1. Always travel straight uphill. 2. Avoid steep hills (25_ maximum). 3. Keep both feet on the footrests. 4. Transfer your weight forward. 5. Proceed at a steady rate of speed and throttle opening. - Page 67 OPERATION Driving Safely Sidehilling Improperly crossing hills or turning on hills can result in loss of control or vehicle overturn, resulting in severe injury or death. Avoid crossing the side of a hill when possible. Follow proper procedures as outlined in the owner’s manual. Sidehilling can be a dangerous type of driving and should be avoided if at all possible.
-
Page 68: Driving Downhill
Driving Safely Driving Downhill Whenever descending a hill, follow these precautions: 1. Proceed directly downhill. 2. Transfer your weight to the rear of the vehicle. 3. Slow down. 4. Apply the brakes slightly to aid in slowing. Familiarize yourself with operation of the auxiliary rear brake pedal for additional braking in the event of normal service brake loss. -
Page 69: Turning Around On A Hill
OPERATION Driving Safely Turning Around on a Hill Improper hill climbing procedures could cause loss of control or overturn and result in serious injury or death. Avoid climbing steep hills (25_ maximum). Use extreme caution when operating on hills, and follow proper operating procedures outlined in the owner’s manual. -
Page 70: Driving Through Water
OPERATION Driving Safely Driving Through Water Your ATV can operate through water with a maximum recommended depth equal to the bottom of the footrests (1). Follow these procedures when operating through water: 1. Determine water depths and current before crossing. 2. - Page 71 OPERATION Driving Safely Driving Through Water After running the vehicle in water, it’s critical to have it serviced as outlined in the maintenance chart. See page 75. The following areas need special attention: engine oil, transmission oil, front and rear gearcases and all grease fittings.
-
Page 72: Driving Over Obstacles
Driving Safely Driving Over Obstacles Be alert! Look ahead and learn to read the terrain. Be constantly alert for hazards such as logs, rocks and low hanging branches. Severe injury or death can result if your vehicle comes in contact with a hidden obstacle. -
Page 73: Driving In Reverse
Use with caution. Avoid backing on inclines, and avoid turning at sharp angles. NOTE: Most Polaris ATVs are equipped with a reverse speed limiter. The override button should be used with caution as rearward vehicle speed is greatly increased. Do not operate at wide open throttle. Open the throttle just enough to maintain a desired speed. -
Page 74: Parking On An Incline
OPERATION Driving Safely Parking on an Incline Avoid parking on an incline if possible. If it’s unavoidable, follow these precautions: 1. Turn the engine off. 1. Place the transmission in park. 2. Set the parking brake. 3. Always block the rear wheels on the downhill side as shown in illustration. -
Page 75: Pvt System
OPERATION PVT System The basic operation of the Polaris PVT system is dependent on engine speed and vehicle torque requirements. As engine speed increases, the force exerted on the movable drive sheave by the flyweights also increases. This, in turn, increases the amount of “pinch” applied to the drive belt. -
Page 76: Pvt Drying
Always follow all recommended maintenance procedures. See your dealer as outlined in the owner’s manual. This PVT system is intended for use on Polaris products only. Do not install it in any other product. Always make sure the PVT housing is securely in place during operation. -
Page 77: Emission Control Systems
Spark Arrestor Your Polaris vehicle has a spark arrestor that was tested and approved in accordance with the USDA Forest Service Standard 5100-1C. Federal law requires that this spark arrestor be installed and functional when the vehicle is operated on public lands. -
Page 78: Maintenance And Lubrication
MAINTENANCE AND LUBRICATION Accessories Polaris has a wide range of accessories available for your ATV. Auxiliary power outlets provide 12V power for operating accessories such as hand held spot lights. Accessory outlets are available for all models. See your Polaris dealer for more information about accessories. -
Page 79: Periodic Maintenance Schedule
Perform all services at whichever reading is reached first. Improperly performing the procedures marked with a result in component failure and lead to serious injury or death. Have an authorized Polaris dealer perform these services. Item Brake System Auxiliary Brake... - Page 80 100 hrs./ 6 months 1000 mi. 100 hrs. 6 months Check operation daily; ap- ply Polaris dielectric grease to socket when replaced Inspect; replace as needed Inspect monthly; change annually Check terminals; clean. Inspect; replace annually and as needed Inspect periodically Check monthly;...
- Page 81 MAINTENANCE AND LUBRICATION Periodic Maintenance Schedule Improperly performing the procedures marked with a result in component failure and lead to serious injury or death. Have an authorized Polaris dealer perform these services. Item Carburetor float bowl Throttle Cable/ETC Switch Choke (enricher)
- Page 82 MAINTENANCE AND LUBRICATION Periodic Maintenance Schedule Item Fuel system Fuel filter Radiator (500) Cooling system hoses (500) Front gearcase " Clutches (drive and driven) Engine mounts Valve clearance Brake fluid Spark arrestor Rear axle " Idle speed Recoil housing Toe adjustment Headlight aim More often under severe use, such as dirty or wet conditions "...
-
Page 83: Lubrication Recommendations
More often under severe use, such as wet or dusty conditions " Polaris Premium All Season Grease or grease conforming to NLG No. 2, such as Conoco Superlube M or Mobilegrease Special Use Polaris Premium U-Joint Lube every 500 miles, before long... - Page 84 MAINTENANCE AND LUBRICATION Periodic Maintenance Record Use the following chart to record periodic maintenance. Maintenance Servicing Interval Performed 10 hrs. 20 hrs. 50 hrs. 100 hrs. Servicing Date Dealer or Person Remarks...
-
Page 85: Premium 4 Synthetic Oil
Although Polaris Premium 4 is the only oil recommended for use in this engine, use of any API certified “SH” oil is allowable as long as it’s 0W-40. - Page 86 MAINTENANCE AND LUBRICATION Lubrication Recommendations Oil and Filter Change - ATP 500 4x4 The recommended oil change interval is 100 hours, 1000 miles, or every six months, whichever comes first. Suggested break-in oil change is at 20 hours, 200 miles, or one month, whichever comes first. Severe use requires more frequent service.
- Page 87 MAINTENANCE AND LUBRICATION Lubrication Recommendations Oil and Filter Change - ATP 500 4x4 4. Place a drain pan beneath the oil tank and remove the drain plug (1). Allow the oil to drain completely. 5. Install a new sealing washer (2) on the oil drain plug. NOTE: The sealing surfaces on the drain plug and the oil tank should be clean and free of burrs, nicks or scratches.
- Page 88 12. After draining, reinstall the drain plug. 13. Remove the dipstick (2) and add two quarts (1.9 l.) of Polaris Premium 4 synthetic oil. Reinstall the dipstick. NOTE: If the sump is not drained, add about 1 3/4 quarts initially.
- Page 89 MAINTENANCE AND LUBRICATION Lubrication Recommendations Oil and Filter Change - ATP 330 4x4 If the ATV is left without oil in the system for extended periods, the oil pump may lose its prime, which could result in engine damage. Always replace the oil and filter within a few hours of draining the oil.
- Page 90 MAINTENANCE AND LUBRICATION Lubrication Recommendations Oil and Filter Change - ATP 330 4x4 8. Reinstall the drain plug and torque to 14 ft. lbs. (19 Nm). 9. Place shop towels beneath the oil filter. Using an oil filter wrench, turn the filter counterclockwise to remove.
-
Page 91: Transmission Oil Check
Catch and discard used oil properly. 3. Clean and reinstall the drain plug torque to 14 ft. lbs. (19 Nm). 4. Add the correct amount of Polaris Premium Synthetic Gearcase Lubricant. Refer the the gearcase oil fill chart for proper oil levels. -
Page 92: Front Gearcase Oil Check
1000 miles (1600 km), whichever comes first. The oil should be changed annually. We recommend the use of Polaris Premium Hub Drive Fluid. See page 121 for the part numbers of Polaris products. With the ATV on a level surface, remove the fill plug and check the oil level. -
Page 93: Rear Gearcase Oil Check
Use Polaris Premium Synthetic Gearcase Lube (or GL5 80-90 weight gear lube). NOTE: See page 121 for the part numbers of Polaris products. Rear Gearcase Oil Change 1. Remove the drain plug (2). Catch and discard used oil properly. -
Page 94: Engine Cooling System
Polaris Premium 60/40 is already premixed and ready to use. Do not dilute with water. See page 121 for the part numbers of Polaris products. NOTE: To ensure that the coolant maintains its ability to protect the engine, we recommend that the system be completely drained every two years and a fresh mixture of antifreeze and water added. -
Page 95: Radiator Coolant Level (Atp)
MAINTENANCE AND LUBRICATION Engine Cooling System Escaping steam can cause severe burns. Never remove the pressure cap while the engine is warm or hot. Always allow the engine to cool before removing the pressure cap. Radiator Coolant Level (ATP 500) NOTE: This procedure is required only if the cooling system has been drained for maintenance and/or repair. - Page 96 Always fill the reservoir as needed whenever the cover is loosened or removed to ensure proper diaphragm operation. Use Polaris DOT 3 brake fluid. Do not overfill. An over-full master cylinder may cause brake drag or brake lock-up, which could result in serious injury or death.
- Page 97 MAINTENANCE AND LUBRICATION Adjustments Auxiliary Brake The auxiliary brake is a hydraulic disc brake. The rear brake system is self-adjusting and requires no maintenance other than periodic checks of the pads for wear. Pads should be changed when worn to 3/64″ (.1 cm), which is about the thickness of a U.S.
-
Page 98: Toe Alignment
(3). Rear measurement should be 1/16″ - 1/8″ (.2 to .3 cm) more than the front measurement. NOTE: If you discover improper alignment, see your Polaris dealer for service. WARNING... -
Page 99: Steering Assembly
Adjustments Steering Assembly The steering assembly of the ATV should be checked periodically for loose nuts and bolts. If loose nuts and bolts are found, see your Polaris dealer for service before operating the vehicle. Camber and Caster The camber and caster are non-adjustable. - Page 100 Follow the adjustment procedures exactly, or see your Polaris dealer for service. 1. Remove the instrument panel and locate the handlebar bolts (1).
- Page 101 NOTE: Continuous operation of the engine without proper jetting when required can cause poor performance, overheating or engine damage. See your Polaris dealer for more information about jetting the ATV for conditions in your area. If the engine idle speed is not satisfactory, and all other conditions are favorable, the carburetor can be adjusted.
-
Page 102: Throttle Cable Freeplay
MAINTENANCE AND LUBRICATION Adjustments Throttle Cable Freeplay Throttle cable freeplay is adjusted at the handlebar. 1. Slide the boots (1) off the inline cable adjuster sleeve (2). Loosen the adjuster locknut (3). 2. Turn the adjuster until 1/16″ to 1/8″ freeplay is achieved at the thumb lever. -
Page 103: Side Panel Removal
MAINTENANCE AND LUBRICATION Adjustments Side Panel Removal NOTE: Side panel removal may be difficult until the locking tabs and receivers have been snapped and unsnapped a few times. 1. Remove the seat. 2. Grasp the rear of the side panel near the rear cab. With a quick and firm motion, pull the panel forward and outward to disengage the two rear tabs. -
Page 104: Wheel Removal
MAINTENANCE AND LUBRICATION Adjustments Operating your ATV with worn tires, improperly inflated tires, non-standard tires or improperly installed tires will affect vehicle handling and could cause an accident resulting in serious injury or death. Maintain proper tire pressure as described on the decal on your ATV and in the specifications section of the owner’s manual beginning on page 126. -
Page 105: Wheel Installation
4. Torque the wheel nuts according to the wheel nut torque specifications chart. NOTE: All nuts that have a cotter pin installed must be serviced by an authorized Polaris dealer. Wheel Nut Torque Specifications Check the wheel nut torques occasionally and when they’ve been loosened for maintenance service. -
Page 106: Front Wheel Hub Tightening
Front Wheel Hub Tightening Front wheel bearing tightness and spindle nut retention are critical component operations. All service must be performed by your authorized Polaris dealer. Tire Tread Depth Always replace tires when tread depth is worn to 1/8″ (.3 cm) or less. -
Page 107: Filter Systems
MAINTENANCE AND LUBRICATION Filter Systems Air Filter Service 1. Remove the seat, release the clips, and remove the air box cover. 2. Loosen the clamp and remove the filter. 3. Remove the fabric type pre-filter (1) from the main filter (2). Wash the pre-filter in soapy water, then rinse and let dry. -
Page 108: Headlight Lamp Replacement
MAINTENANCE AND LUBRICATION Lights When servicing a halogen lamp, don’t touch the lamp with bare fingers. Oil from your skin leaves a residue, causing a hot spot that will shorten the life of the lamp. Poor lighting while driving can result in severe injury or death. Headlight and taillight lenses become dirty during normal operation. -
Page 109: High Beam Adjustment
MAINTENANCE AND LUBRICATION Lights High Beam Adjustment The headlight beam can be adjusted to any position desired by turning the adjusting knob on the bottom right side of the headlight pod. 1. Position the vehicle on a level surface with the headlight approximately 25 ft. -
Page 110: Headlight Housing Replacement
MAINTENANCE AND LUBRICATION Lights Headlight Housing Replacement 1. Remove the three screws on the headlight pod. 2. Using a small flat-blade screwdriver, push in on the lock tabs through the two small openings at the front of the headlight pod. Lift the pod lightly while depressing the tabs. - Page 111 MAINTENANCE AND LUBRICATION Lights Taillight/Brakelight Lamp Replacement If the taillight/brakelight does not work, the lamp may need to be replaced. 1. Remove the two screws securing the lens assembly. 2. Pivot the assembly outward. 3. Turn the housing clockwise and remove the bulb. 4.
-
Page 112: Spark Plugs
S Torque spark plugs to 14 ft. lbs. (19 Nm). Using non-recommended spark plugs can result in serious engine damage. Always use Polaris spark plugs. Spark plug condition is indicative of engine operation. The spark plug firing end condition should be read after the engine has been warmed up and the vehicle has been driven at higher speeds. -
Page 113: Vehicle Immersion
MAINTENANCE AND LUBRICATION Vehicle Immersion If your vehicle becomes immersed, major engine damage can result if the machine is not thoroughly inspected. Take the vehicle to your dealer before starting the engine. If it’s impossible to take your ATV to a dealer before starting it, follow the steps outlined below. -
Page 114: Spark Arrestor
MAINTENANCE AND LUBRICATION Spark Arrestor Failure to heed the following warnings while servicing the spark arrestor could result in serious injury or death. Do not perform service on the spark arrestor while the system is hot. Exhaust system temperatures can reach 1000° F. Allow components to cool sufficiently before proceeding. -
Page 115: Recoil Housing
MAINTENANCE AND LUBRICATION Recoil Housing To prevent possible engine damage, always drain the recoil housing (1) after operating the ATV in very wet conditions. This should also be done before storing the ATV. NOTE: Water will enter the recoil housing if the starter handle is disengaged from the rope guide when under water. -
Page 116: Battery Removal
MAINTENANCE AND LUBRICATION Battery Improperly connecting or disconnecting battery cables can result in an explosion and cause serious injury or death. When removing the battery, always disconnect the negative (black) cable first. When reinstalling the battery, always connect the negative (black) cable last. -
Page 117: Battery Charging
Check battery voltage each month during storage and recharge as needed to maintain a full charge. NOTE: Battery charge can be maintained by using a Polaris Battery Tendert charger (PN 2871076) or by charging about once a month to make up for normal self-discharge. - Page 118 MAINTENANCE AND LUBRICATION Battery Battery Charging NOTE: Always verify battery condition before and 1-2 hours after the end of charging. State of Voltage Charge 100% 12.8-13.0 volts 75%-100% 12.5-12.8 volts 50%-75% 12.0-12.5 volts 25%-50% 11.5-12.0 volts 0%-25% 11.5 volts or less Action (Using constant current charger @ standard amps...
-
Page 119: Cleaning And Storage
Polaris dealer for free replacement. Polaris does not recommend the use of a high pressure type car wash system for washing the ATV. If a high pressure system is used, exercise extreme care to avoid water damage to the wheel bearings, transmission seals, body panels, brakes and warning labels. -
Page 120: Fluid Levels
Use dish soap type cleaners only. High pressure washers may force water past seals. Stabilize the Fuel Fill the fuel tank. Add Polaris Carbon Clean Fuel Treatment or Polaris Fuel Stabilizer. Follow the instructions on the container for the recommended amount. (Carbon clean will also reduce the possibility of bacterial growth in the fuel system.) Allow 15-20 minutes of operation... -
Page 121: Storage Tips
5. Treat the fuel system with Polaris Carbon Clean. 6. If Polaris fuel system additive is not used, fuel tank, fuel lines, and carburetor should be completely drained of gasoline. To eliminate any fuel remaining in the carburetor, run the engine until it stops. -
Page 122: Transporting The Atv
Set the tire pressure and safely support the ATV with the tires 1-2” off the ground. Be sure the storage area is well ventilated, and cover the machine with a genuine Polaris ATV cover. NOTE: Do not use plastic or coated materials. They do not allow enough ventilation to prevent condensation, and may promote corrosion and oxidation. - Page 123 - NOTES -...
-
Page 124: Polaris Products
2871329 Dielectric Grease (Nyogelt) Coolant 2871323 60/40 Coolant (gal.) 2871534 60/40 Coolant (qt.) Additives / Miscellaneous 2871326 Carbon Clean Plus (12 oz.) 2870652 Fuel Stabilizer (16 oz.) 2870990 DOT3 Brake Fluid (12 oz.) 2872893 Engine Degreaser (12 oz.) POLARIS PRODUCTS... -
Page 125: Troubleshooting
10 seconds. Clutch seals should be inspected for damage if repeated leaking occurs. Contact your Polaris dealer for inspection of clutch com- ponents. fuel lines, or carburetor. Contact your dealer for service. - Page 126 Contact your Polaris dealer for service if you’re unable to identify solutions using the following charts. Engine Doesn’t Turn Over Possible Cause Tripped circuit breaker Low battery voltage Loose battery connections Loose solenoid connections Engine Turns Over, Fails to Start...
- Page 127 Incorrect jetting Solution Inspect, clean and/or replace spark plugs Set gap to specs or replace plugs Replace with new fuel See your Polaris dealer See your Polaris dealer See your Polaris dealer Solution Inspect, clean and/or replace spark plugs See your Polaris dealer...
- Page 128 Inspect and replace Replace with new fuel Inspect, clean and/or replace spark plugs Inspect, clean and/or replace spark plugs See your Polaris dealer Set gap to specs or replace plugs Check all connections and tighten Recharge battery to 12.5 VDC...
-
Page 129: Specifications
Ignition System Ignition Timing Spark Plug / Gap Lubrication System Driving System Type * Based on EU Directive 76/432/EC ATP 330 4x4 1300 lbs./590 kg 3.25 gal./12.3 l 1000 lbs./454 kg 1585 lbs./719 kg 100 lbs./45.4 kg (rear box capacity and tongue weight not to exceed 250 lbs./113 kg) -
Page 130: Clutching And Jetting Charts
(0-6000) 1800-3700 (6000-12000) Altitude Meters 0-1800 (Feet) (0-6000) 1800-3700 (6000-12000) SPECIFICATIONS ATP 330 4x4 Side Lever (High, Low, Neutral, Reverse, Park) 11.57:1 6.84:1 4.41:1 3.7:1 3.08:1 24 x 8 - 12 24 x 11 - 12 5 psi 5 psi... - Page 131 SPECIFICATIONS Gross Vehicle Weight Fuel Capacity Towing Rating Unbraked Trailer Towing Capacity* Hitch Tongue Capacity Front Rack & Compartment Capacity Rear Box Capacity Overall Length Overall Width Overall Height Wheelbase Ground Clearance Dry Weight Minimum Turning Radius Engine Oil Capacity Coolant Capacity Engine Displacement...
- Page 132 Shift Type Gear Reduction - Low Gear Reduction - Reverse Gear Reduction - High Drive Ratio - Front: Drive Ratio - Final Tire Size - Front Tire Size - Rear Tire Pressure- Front Tire Pressure- Rear Front/Rear Brakes Auxiliary Brake Parking Brake Headlight Taillights...
-
Page 133: Warranty
LIMITATIONS OF WARRANTIES AND REMEDIES The Polaris limited warranty excludes any failures that are not caused by a defect in material or workmanship. This warranty does not cover accidental damage, normal wear and tear, abuse or improper handling. This warranty also does not cover any ATV that has been al-... - Page 134 HOW TO OBTAIN WARRANTY SERVICE If your ATV requires warranty service, you must take it to a Polaris dealer authorized to re- pair Polaris ATVs. When requesting warranty service you must present your copy of the Warranty Registration form to the dealer. (THE COST OF TRANSPORTATION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY).
- Page 135 How to Get Service If Purchased From A Private Party: If you purchase a Polaris product from a private citizen outside of the country in which the vehicle was originally purchased, all warranty coverage will be denied. Notice...
-
Page 136: Limited Warranty
Manufacturer’s Warranty Coverage: The 2004 and later LSI engines are warranted for two (2) years. If any emission related part on your LSI engine is defective, the part will be repaired or replaced by POLARIS. Owner’s Warranty Responsibilities: S As the LSI engine owner, you are responsible for the performance of the required maintenance listed in your Owner’s Safety and Maintenance Manual (herein “Own-... - Page 137 During this two year period POLARIS warrants to the original retail purchaser and each subsequent purchaser that the LSI engine is free from defect in material and workmanship that can cause the failure of a warranted emission-related part.
-
Page 138: Maintenance Schedule
When the LSI engine is being serviced under warranty, POLARIS and any of its authorized dealers shall not be liable for any loss of use of the LSI engine, for any damage to goods, or loss of time or inconvenience. - Page 139 All repairs qualifying under this Limited Warranty must be performed by a dealer who sold you the LSI engine or a dealer authorized by POLARIS. In the event that any emission-related part is found to be defective during the warranty period, you must notify the Polaris Warranty Department at 1-763-417-8650 and you will be advised of the appropriate dealer where the warranty repair is to be performed.
-
Page 140: Index
Accessories ..... . Adjustments ....Age Restrictions . - Page 141 Parking on an Incline ....Periodic Maintenance Schedule POLARIS PRODUCTS ... . Pre Ride Inspection ....