Polaris Magnum 330 2x4 Owner's Manual
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Polaris Magnum 330 2x4 Owner's Manual

Polaris Magnum 330 2x4 Owner's Manual

Polaris 2005 atv owner's manual
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Summary of Contents for Polaris Magnum 330 2x4

  • 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 5 Copyright 2004 Polaris Sales Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this publication.

  • Page 6: Welcome

    S Watercraft S Victory motorcycles S RANGER utility vehicles We believe Polaris sets a standard of excellence for all utility and recreational vehicles manufactured in the world today. Many years of experience have gone 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 SPECIFICATIONS TROUBLESHOOTING WARRANTY .

  • Page 10: 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, so if both keys are lost, the ignition switch must be replaced.

  • Page 11: Safety

    Failure to follow the warnings contained in this manual can result in serious injury or death. A Polaris ATV is not a toy and can be hazardous to operate. This vehicle handles differently than other vehicles, such as motorcycles and cars. A collision or rollover can occur quickly, even during routine maneuvers like turning, or driving on hills or over obstacles, if you fail to take proper precautions.

  • Page 12: Operator 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 vehicle or in this manual, alerts you to the potential for personal injury.
  • Page 13 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 14 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 15: 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 16 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.
  • Page 17 SAFETY Operator Safety WARNING POTENTIAL HAZARD Carrying a passenger on an ATV. WHAT CAN HAPPEN Carrying a passenger greatly reduces the operator’s ability to balance and control the ATV, which could cause an accident and injury to the operator and/or passenger. HOW TO AVOID THE HAZARD Never carry a passenger.
  • 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 WARNING 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 20 SAFETY Operator Safety WARNING POTENTIAL HAZARD Attempting wheelies, jumps and other stunts. WHAT CAN HAPPEN Attempting stunts increases the chance of an accident, including an overturn. HOW TO AVOID THE HAZARD Never attempt wheelies, jumps, or other stunts. Avoid exhibition driving. WARNING POTENTIAL HAZARD Failure to inspect the ATV before operating.
  • Page 21 SAFETY Operator Safety WARNING POTENTIAL HAZARD Removing hands from the handlebars or feet from the footrests during operation. WHAT CAN HAPPEN Removing even one hand or foot can reduce ability to control the vehicle or could cause loss of balance and ejection from the ATV. If the operator’s foot is not firmly planted on the footrest, it could come into contact with the rear wheels and lead to accident or injury.
  • Page 22 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 23 SAFETY Operator Safety WARNING POTENTIAL HAZARD Operating on excessively steep hills. WHAT CAN HAPPEN The vehicle may overturn. HOW TO AVOID THE HAZARD Never operate on hills too steep for the ATV or for your abilities. Never operate the ATV on hills steeper than 25_. Practice on smaller hills before attempting large hills.
  • Page 24 SAFETY Operator Safety WARNING 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 25 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...
  • Page 26 SAFETY Operator Safety WARNING POTENTIAL HAZARD Stalling, rolling backwards or improperly dismounting while climbing a hill. WHAT CAN HAPPEN The vehicle could overturn. HOW TO AVOID THE HAZARD Maintain steady speed when climbing a hill. If all forward speed is lost: Keep your weight uphill.
  • Page 27 SAFETY Operator Safety WARNING 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 28 SAFETY Operator Safety WARNING POTENTIAL HAZARD Operating the ATV through deep or fast-flowing water. WHAT CAN HAPPEN Tires may float, causing loss of traction and loss of control, which could lead to an accident or overturn. HOW TO AVOID THE HAZARD Avoid operating the ATV through deep or fast-flowing water.
  • Page 29 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.
  • Page 30 SAFETY Operator Safety WARNING Leaving the keys in the ignition can lead to unauthorized use of the vehicle resulting in serious injury or death. Always remove the ignition key when the vehicle is not in use. WARNING After any overturn or accident, have a qualified service dealer inspect the entire vehicle for possible damage, including (but not limited to) brakes, throttle and steering systems.

  • Page 31: Safety Decals And Locations

    ATV, always read and follow the instructions of the decals on the ATV. If any decal becomes illegible or comes off, contact your Polaris dealer to purchase a replacement. Replacement safety decals are provided by Polaris at no charge. The part number is printed on the decal.
  • Page 32 Safety Decals and Locations WARNING Location A WARNING Moving parts hazard under belt-clutch guard. To prevent serious injury, do not operate vehicle with guard removed. Do not modify engine or clutch. Doing so can cause part failure, possible imbalance, and excessive engine RPM, which can result in serious injury or death.
  • Page 33 SAFETY Safety Decals and Locations IMPROPER TIRE PRESSURE OR OVERLOADING can cause loss of control resulting in SEVERE INJURY OR DEATH. TIRE PRESSURE (PSI): FRONT ___ MAXIMUM WEIGHT CAPACITY (Gross Vehicle Weight) INCLUDING MACHINE, DRIVER AND CARGO IS ____ LBS. Reduce speed and allow greater distance for braking when carrying cargo.
  • Page 34 DRIVE SWITCH Do not push switch to engage AWD if the rear wheels are spinning. This may cause severe drive shaft and clutch damage. See your Owner’s Manual. 7079780 Applicable AWD Models MANUFACTURED BY: POLARIS IND. INC. DATE: VIN: 7171492...

  • Page 35: 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 36: Fuel Safety

    Fuel Safety WARNING Gasoline is highly flammable and explosive under certain conditions. S Always exercise extreme caution whenever handling gasoline. S Always refuel with the engine stopped, and outdoors or in a well ventilated area. S Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored.

  • Page 37: Features And Controls

    FEATURES AND CONTROLS Electrical Switches WARNING Operating the ATV on streets or roads, especially in darkness, could result in an accident and serious injury or death. Your ATV is not equipped with highway-approved lights. It’s designed for and must be used for off-road use only. Use caution and drive at reduced speeds in conditions of reduced visibility such as fog, rain and darkness.
  • Page 38 Electrical Switches 3. Engine Stop Switch - 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 39: 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 40: Master Cylinder

    If the fluid level is low, add DOT 3 brake fluid. DO NOT OVERFILL. See page 108 for the part numbers of Polaris products. WARNING An over-full master cylinder may cause brake drag or brake lock-up, which could result in serious injury or death.

  • Page 41: Brake Lever

    FEATURES AND CONTROLS Brake Lever The front and rear brakes are applied by squeezing the brake lever (1) toward the handlebar. The front and rear brakes are hydraulically activated disc type brakes that are activated by only one lever. Always test brake lever travel and master cylinder fluid level before riding.

  • Page 42: Parking Brake

    Parking Brake WARNING Operating the ATV while the parking brake is engaged could result in an accident and serious injury or death. Always check to be sure the parking brake is disengaged before operating. Setting the Parking Brake 1. Squeeze and release the brake lever (1) two or three times, then squeeze and hold.

  • Page 43: Auxiliary Brake

    FEATURES AND CONTROLS Auxiliary Brake WARNING Aggressively applying the auxiliary brake when backing down a hill may cause rear tipover, which could result in serious injury or death. Use caution when applying the auxiliary brake. Do not aggressively apply the auxiliary brake when going forward. The rear wheels may skid and slide sideways, causing loss of control and serious injury or death.

  • Page 44: Fuel Valve

    Choke The choke assists in starting a cold engine. Refer to the engine starting procedure on page 52 for correct choke and throttle settings during starting. Fuel Valve The fuel valve (1) is located on the left side of the vehicle on the side panel. It has three positions: OFF: For vehicle storage and when transporting.

  • Page 45: Belt Life

    FEATURES AND CONTROLS Automatic Transmission Gear Selector The transmission gear selector (1) is located on the right side of the vehicle. H: High Gear N: Neutral L: Low Gear R: Reverse P: Park To shift into HIGH or PARK, you must first apply the auxiliary brake to activate the high/park lock-out mechanism.

  • Page 46: Recoil Starter

    The recoil starter is located on the right side of the machine. Polaris 4-cycle engines are equipped with automatic decompressors. This makes recoil starting possible by reducing the amount of compression during starting. The decompressor senses when the engine is spinning fast enough to start and restores compression when running.

  • Page 47: Engaging Front Gearcase

    FEATURES AND CONTROLS All Wheel Drive System (Domestic Models) Polaris 4 wheel drive domestic model ATVs are equipped with a unique, Polaris exclusive, All Wheel Drive (AWD) System activated by a switch (1) on the right handlebar. Engage the AWD when the rear wheels lose traction.
  • Page 48 Instrument Cluster (Magnum 330) Your ATV is equipped with an instrument cluster that senses vehicle speed from the right front wheel. The instrument cluster measures distance in miles as well as hours of operation. It also includes a reverse speed limiter function that limits the ATV’s speed to approximately 7-9 mph (see page 34).

  • Page 49: Rider Information Center

    If the instrument cluster no longer illuminates, it’s possible that a battery over voltage occurred and the instrument cluster has shut off to protect the electrical system. If this occurs take the ATV to your Polaris dealer for proper diagnosis. NOTE: All segments of the rider information center will light up for 2.5 seconds at start-up.
  • Page 50 Instrument Cluster (Magnum 330) Rider Information Center The rider information center has 4 standard modes: Mode 1 - Odometer Mode 2 - Tripmeter Mode 3 - Total Service Hours Mode 4 - Programmable service interval The reverse override button on the left handlebar is also the mode button.
  • Page 51 FEATURES AND CONTROLS Instrument Cluster (Magnum 330) Rider Information Center Mode 4 - Programmable Service Interval The purpose of the programmable service interval is to provide the consumer and dealer with a convenient reminder for routine maintenance. When your vehicle leaves the factory, this feature is turned off.

  • Page 52: Diagnostic Mode

    Instrument Cluster (Magnum 330) Rider Information Center Diagnostic Mode The diagnostic mode is for informational purposes only. Please return your ATV to your dealer for all major repairs. To enter the diagnostics mode: 1. Turn the key switch off and wait 20 seconds. 2.

  • Page 53: Operation

    OPERATION Break-In Period The break-in period for your new Polaris 4-cycle ATV is defined as the first ten hours of operation, or the time it takes to use the first two full tanks of gasoline. No single action on your part is as important as following the procedures for a proper break-in.
  • Page 54 Pre-Ride Inspection WARNING If a proper inspection is not done before each use, severe injury or death could result. Always inspect the vehicle before each use to ensure it’s in proper operating condition. Item Brake system / lever travel Brake fluid Auxiliary brake Front suspension Rear suspension...

  • Page 55: Starting The Engine

    OPERATION Starting the Engine Starting a Cold Engine WARNING Engine exhaust contains poisonous carbon monoxide and can cause loss of consciousness resulting in severe injury or death. Never run an engine in an enclosed area. 1. Place the transmission in PARK and lock the parking brake.

  • Page 56: 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. OPERATION...

  • Page 57: 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 58: Making Turns

    Driving Safely Making Turns Your Polaris ATV is equipped with a solid rear axle that drives both rear wheels equally at all times. This means that the wheel on the outside of the turn must travel a greater distance than the inside wheel when turning and the inside tire must slip traction slightly.

  • Page 59: Hauling Cargo

    OPERATION Driving Safely Hauling Cargo Your ATV has been designed to carry or tow a certain amount of load. Always read and understand the load distribution warnings listed on the warning labels, and never exceed the specified weights. Cargo weight should be evenly distributed (1/3 on the front and 2/3 on the rear) and mounted as low as possible.
  • Page 60 Driving Safely Hauling Cargo WARNING S REDUCE SPEED AND ALLOW GREATER DISTANCES FOR BRAKING WHEN HAULING CARGO. S CARGO WEIGHT DISTRIBUTION should be 1/3 on the front rack and 2/3 on the rear rack. When operating over rough or hilly terrain, reduce speed and cargo to maintain stable driving conditions.

  • Page 61: 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 62: 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 63 OPERATION Driving Safely Sidehilling WARNING Improperly crossing hills or turning on hills can result in loss of control or vehicle overturn, resulting in severe injury or death. Avoid crossing the side of a hill when possible. Follow proper procedures as outlined in the owner’s manual. Sidehilling can be the most dangerous type of driving encountered and should be avoided if at all possible.

  • Page 64: 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, using the single brake lever.

  • Page 65: Turning Around On A Hill

    OPERATION Driving Safely Turning Around on a Hill WARNING Improper hill climbing procedures could cause loss of control or overturn and result in serious injury or death. Avoid climbing steep hills (25_ maximum). Use extreme caution when operating on hills, and follow proper operating procedures outlined in the owner’s manual.

  • Page 66: Driving Through Water

    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. Choose a crossing where both banks have gradual inclines.

  • Page 67: Driving Over Obstacles

    OPERATION Driving Safely Driving Over Obstacles Be alert! Look ahead and learn to read the terrain you’re traveling on. Be constantly alert for hazards such as logs, rocks and low hanging branches. WARNING Severe injury or death can result if your vehicle comes in contact with a hidden obstacle.

  • Page 68: Driving In Reverse

    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.

  • Page 69: 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. See illustration.

  • Page 70: 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 71: Maintenance And Lubrication

    Inspection, adjustment and lubrication of important components are explained in the periodic maintenance chart. Inspect, clean, lubricate, adjust and replace parts as necessary. When inspection reveals the need for replacement parts, use genuine Polaris parts available from your Polaris dealer. NOTE: Service and adjustments are critical.

  • Page 72: Periodic Maintenance Chart

    25 H " filter (if equipped) Perform these procedures more often for vehicles subjected to severe use. " E Emission Control System Service (California) Have an authorized Polaris dealer perform these services. Maintenance Interval (whichever comes first) Miles (Km) Pre-Ride...
  • Page 73 100 H Ignition Timing 100 H Perform these procedures more often for vehicles subjected to severe use. " E Emission Control System Service (California) Have an authorized Polaris dealer perform these services. Maintenance Interval (whichever comes first) Miles (Km) 50 H...
  • Page 74 Idle speed Toe adjustment Headlight aim Perform these procedures more often for vehicles subjected to severe use. " E Emission Control System Service (California) Have an authorized Polaris dealer perform these services. Maintenance Interval (whichever comes first) Miles (Km) 12 M...

  • Page 75: Lubrication Guide

    MAINTENANCE AND LUBRICATION Lubrication Guide Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart beginning on page 68. Items not listed in the chart should be lubricated at the General Lubrication interval. Item Engine Oil Brakes (1) Transmission (2) Front Gearcase...
  • Page 76 MAINTENANCE AND LUBRICATION Periodic Maintenance Record Use the following chart to record periodic maintenance. Maintenance Servicing Servicing Remarks Interval Date Dealer Performed or Person...

  • Page 77: Premium 4 Synthetic Lubricant

    +49° C.) Its exceptional frictional properties result in more efficient operation, more power output and lower fuel consumption. Although Polaris Premium 4 is the only oil recommended for use in this engine, use of any API certified SH oil is allowable as long as it’s 0W-40.

  • Page 78: Engine Oil Check

    MAINTENANCE AND LUBRICATION Engine Oil Check The oil dipstick (1) is located on the left side of the engine. A rising oil level between NOTE: checks in cool weather driving can indicate contaminants such as gas or moisture collecting in the crankcase. If the oil level is over the full/safe mark, change the oil immediately.

  • Page 79: Gearcase Specification Chart

    MAINTENANCE AND LUBRICATION Oil and Filter Change 5. Place a drain pan beneath the engine crankcase and remove the drain plug. 6. Allow the oil to drain completely. 7. Install a new sealing washer on the drain plug. NOTE: The sealing surfaces on the drain plug and crankcase should be clean and free of burrs, nicks or scratches.

  • Page 80: Transmission Oil

    Premium AGL Synthetic Gearcase Lubricant. Refer to the gearcase specifications chart on page 76. See page 108 for the part numbers of Polaris products. Oil Check The transmission fill plug is located on the right side of the machine, behind the footwell.

  • Page 81: Front Gearcase Oil

    Refer to the gearcase specifications chart on page 76. See page 108 for the part numbers of Polaris products. Oil Check We recommend the use of Polaris Premium Demand Drive Hub Fluid in models with centralized Hilliard gearcases (domestic models). Maintain the level at the bottom of the fill plug threads (1).

  • Page 82: Rear Gearcase Oil

    Polaris Premium ATV Angle Drive Fluid. Refer to the gearcase specifications chart on page 76. See page 108 for the part numbers of Polaris products. 1. Position the ATV on a level surface. 2. Remove the gearcase fill plug (2) and check the oil level.

  • Page 83: 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. WARNING Poor lighting while driving can result in severe injury or death. Headlight and taillight lenses become dirty during normal operation.
  • Page 84 MAINTENANCE AND LUBRICATION Lights Taillight/Brakelight Lamp Replacement If the taillight/brakelight does not work the lamp may need to be replaced. 1. Remove the taillight lens cover mounting screws. Remove the lens cover and gasket and set aside for reassembly. 2. Remove the lamp (1). 3.

  • Page 85: Spark Plugs

    CAUTION Using non-recommended spark plugs can result in serious engine damage. Always use Polaris-recommended spark plugs. Spark plug condition is indicative of engine operation. The spark plug firing end condition should be read after the engine has been warmed up and the vehicle has been driven at higher speeds.

  • Page 86: Vehicle Immersion

    MAINTENANCE AND LUBRICATION Vehicle Immersion CAUTION If your vehicle becomes immersed, major engine damage can result if the machine is not thoroughly inspected. Take the vehicle to your dealer before starting the engine. If it’s impossible to take your ATV to a dealer before starting it, follow the steps outlined below.

  • Page 87: Spark Arrestor

    MAINTENANCE AND LUBRICATION Spark Arrestor WARNING Failure to heed the following warnings while servicing the spark arrestor could result in serious injury or death. Do not perform service on the spark arrestor while the system is hot. Exhaust system temperatures can reach 1000° F. Allow components to cool sufficiently before proceeding.

  • Page 88: 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 89: Pvt System

    MAINTENANCE AND LUBRICATION PVT System The basic operation of the Polaris PVT system is dependent on engine speed and vehicle torque requirements. As engine speed increases, the force exerted on the movable drive sheave by the flyweights also increases. This, in turn, increases the amount of “pinch” applied to the drive belt.

  • Page 90: 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 91: Battery Removal

    MAINTENANCE AND LUBRICATION Battery WARNING Improperly connecting or disconnecting battery cables can result in an explosion and cause serious injury or death. When removing the battery, always disconnect the negative (black) cable first. When reinstalling the battery, always connect the negative (black) cable last.

  • Page 92: Battery Charging

    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. Battery...
  • Page 93 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 charger @ standard amps specified on top of battery)
  • Page 94 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. 2. Check the brake system for fluid leaks.
  • Page 95 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. Change the brake pads when they’re worn to 3/64″ (.1 cm). Inspect the brake disc spline and pad wear surface for excessive wear.

  • Page 96: Toe Alignment

    Severe injury or death can result from improper toe alignment and adjustment. Do not attempt to adjust tie rod alignment. All tie rod adjustments should be performed by an authorized Polaris dealer. Toe Alignment Use the following procedure to check the toe alignment of the vehicle.

  • Page 97: 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 98 Follow the adjustment procedures exactly, or see your Polaris dealer for service. Handlebars The handlebars can be adjusted for rider preference.
  • Page 99 MAINTENANCE AND LUBRICATION Adjustments Carburetor IMPORTANT: Your Polaris ATV is calibrated at the factory for optimal performance at altitudes ranging from zero to 6,000 feet (1800 m) and temperatures of +40 degrees F. (4 degrees C.) or higher. Above 6000 feet (1800 m) the engine air/fuel mixture becomes overly rich and the engine loses approximately 3% of its power for each 1000-foot (304.8 m) increase in elevation.

  • Page 100: Throttle Cable Freeplay

    MAINTENANCE AND LUBRICATION Adjustments Throttle Cable Freeplay The throttle cable adjuster is located at the right handlebar. 1. Slide the boots (1) off the inline cable adjuster sleeve (2). Loosen the adjuster locknut (3). 2. Turn the adjuster until 1/16″ to 1/8″ freeplay is achieved at the thumb lever.

  • Page 101: 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 102: Wheel Removal

    MAINTENANCE AND LUBRICATION Adjustments WARNING Operating your ATV with worn tires, improperly inflated tires, non-standard tires or improperly installed tires will affect vehicle handling and could cause an accident resulting in serious injury or death. Maintain proper tire pressure as described on the decal on your ATV and in the specifications section of the owner’s manual beginning on page 109.

  • Page 103: Wheel Installation

    Always ensure that all nuts are torqued to specification. Do not service axle nuts that have a cotter pin installed. See your Polaris dealer. Wheel Installation 1. Place the transmission in PARK and lock the parking brake.

  • Page 104: 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 105: Air Filter Service

    MAINTENANCE AND LUBRICATION Adjustments Air Filter Service 1. Remove the seat. 2. Release the clips and remove the air box cover (1). 3. Loosen the clamp and remove the filter. 4. Remove the fabric type pre-filter (2) from the main filter (3). Wash the pre-filter in soapy water, then rinse and let dry.

  • Page 106: Cleaning And Storage

    If warning and safety labels are damaged, contact your a Polaris dealer for free replacement. Polaris does not recommend the use of a high pressure type car wash system for washing the ATV. If a high pressure system is used, exercise extreme care to avoid water damage to the wheel bearings, transmission seals, body panels, brakes and warning labels.

  • Page 107: Storage Tips

    It also prevents bacterial growth and promotes better starting after the storage period. 1. Fill the fuel tank with fuel and add Polaris Carbon Clean or Fuel Stabilizer. Follow the instructions on the container for the recommended amounts.

  • Page 108: Fluid Levels

    5. Treat the fuel system with Polaris Carbon Clean. 6. If Polaris fuel system additive is not used, drain all fuel from the fuel tank, fuel lines, and carburetor. Eliminate any fuel remaining in the carburetor by running the engine until it stops.
  • Page 109 MAINTENANCE AND LUBRICATION Cleaning and Storage Chrome Wheel Care (if equipped) Proper maintenance will protect chrome wheels from corrosion, preserve wheel life and ensure a “like new” appearance for many years. 1. Wash chrome rims frequently. Use a mild detergent to remove any salt, dirt, mud or grime.

  • Page 110: Transporting An Atv

    MAINTENANCE AND LUBRICATION Cleaning and Storage Transporting an ATV Follow these procedures when transporting an ATV. 1. Turn off the engine and remove the key to prevent loss during transporting. 2. Turn the fuel valve off. 3. Be sure the fuel cap, oil cap and seat are installed correctly and securely.

  • Page 111: Polaris Products

    POLARIS PRODUCTS Part No. Description Engine Lubricant 2870791 Fogging Oil (12 oz. Aerosol) 2871281 Premium 4 Synthetic 0W-40 (4-Cycle) Engine Oil (qt.) 2871844 Premium 4 Synthetic 0W-40 (4-Cycle) Engine Oil (gal.) Gearcase / Transmission Lubricants 2873602 Premium AGL Synthetic Gearcase Lube (qt.) Premium AGL Synthetic Gearcase Lube (gal.)

  • Page 112: Specifications

    2005 Magnum 330 2X4 Body Style Gross Vehicle Weight Fuel Capacity Engine Oil Capacity Transmission Oil Rear Gearcase Oil Front Rack Rear Rack Tongue Weight Tow Capacity Turn Radius Ground Clearance Length Width Height Seat Height Dry Weight Wheel Base...
  • Page 113 SPECIFICATIONS 2005 Magnum 330 2X4 Drive System Type Shift Type Front Drive (ratio) Front Tires Rear Tires Front Suspension: Mac Strut Rear Suspension: Progressive Rate Swing Arm Shock Adjustment Front Brake Rear Brake Auxiliary Brake Park Brake Headlight Taillight Brake Light...

  • Page 114: Jetting Chart

    2005 Magnum 330 2X4 Jetting Chart Altitude AMBIENT TEMPERATURE Meters 0-1800 (Feet) (0-6000) 1800-3700 (6000-12000) Clutching Chart Altitude Meters 0-1800 (Feet) (0-6000) 1800-3700 (6000-12000) SPECIFICATIONS Below 40° F (Below 5° C) 127.5 Shift Drive Clutch Weight Spring Blue/Green 5630279 7041157...
  • Page 115 SPECIFICATIONS 2005 Magnum 330 4X4 Body Style Gross Vehicle Weight Fuel Capacity Engine Oil Capacity Transmission Oil Front Gearcase Oil (Centralized Hilliard) Rear Gearcase Oil Front Rack Rear Rack Tongue Weight Tow Capacity Turn Radius Ground Clearance Length Width Height Seat Height Wheel Base Dry Weight...
  • Page 116 2005 Magnum 330 4X4 Drive System Type Shift Type Front Drive (ratio) Final Drive (ratio) Front Tires Rear Tires Front Suspension: Mac Strut Rear Suspension: Progressive Rate Swing Arm Shock Adjustment Front Brake Rear Brake Auxiliary Brake Park Brake Headlight Taillight Brake Light Battery...
  • Page 117 SPECIFICATIONS 2005 Magnum 330 4X4 Jetting Chart Altitude AMBIENT TEMPERATURE Meters 0-1800 (Feet) (0-6000) 1800-3700 (6000-12000) Clutching Chart Altitude Meters 0-1800 (Feet) (0-6000) 1800-3700 (6000-12000) Below 40° F (Below 5° C) 127.5 Shift Drive Clutch Weight Spring Blue/Green 5630279 7041157 20-38 Blue/Green 5631357...

  • Page 118: 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 119 TROUBLESHOOTING Contact your Polaris dealer for service if you’re unable to identify solutions using the following charts. Engine Doesn’t Turn Over Possible Cause Tripped circuit breaker Low battery voltage Loose battery connections Loose solenoid connections Engine Turns Over, Fails to Start...
  • Page 120 TROUBLESHOOTING 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 121 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 12.8 VDC...

  • Page 122: Warranty

    WARRANTY on all components of the Polaris All Terrain Vehicle (ATV) against defects in material or workmanship. Polaris also gives a one year limited warranty on the final drive chain for failure due to defects. This warranty covers the parts and labor charges for repair or replacement of defective parts which are covered by this warranty.

  • Page 123: Engine Oil

    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 124 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 125: Index

    INDEX Accessories ....Adjustments ....Age Restrictions ....Air Filter .
  • Page 126 Parking on an Incline ... Periodic Maintenance Chart POLARIS PRODUCTS ..Pre Ride Inspection ... . .

This manual is also suitable for:

Magnum 330 4x42005 magnum 330 2x42005 magnum 330 4x4

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