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Related Manuals for Polaris ATP 330 4x4 2005
Summary of Contents for Polaris ATP 330 4x4 2005
- Page 2 WARNING Improper vehicle use can result in SEVERE INJURY or DEATH. NEVER CARRY ALWAYS USE NEVER USE NEVER USE PASSENGERS AN APPROVED ON PUBLIC WITH DRUGS HELMET AND ROADS OR ALCOHOL PROTECTIVE GEAR NEVER: Operate without proper training or instruction. Operate on public roads.
- 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.
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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
....POLARIS PRODUCTS ...... -
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, so 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 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 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 vehicle 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.
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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.
- Page 16 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.
- Page 17 SAFETY Operator Safety WARNING 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 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 19 SAFETY Operator Safety WARNING POTENTIAL HAZARD Operating the ATV at excessive speeds. WHAT CAN HAPPEN Excessive speed increases the operator’s chance of losing control of the ATV, which can result in an accident. HOW TO AVOID THE HAZARD Always operate the ATV at a speed that’s proper for the terrain, visibility and operating conditions, and your experience.
- Page 20 SAFETY Operator Safety WARNING POTENTIAL HAZARD Failure to inspect the ATV before operating. Failure to properly maintain the ATV. WHAT CAN HAPPEN Poor maintenance increases the possibility of an accident or equipment damage. HOW TO AVOID THE HAZARD Always inspect your ATV before each use to make sure it’s in safe operating condition.
- Page 21 SAFETY Operator Safety WARNING POTENTIAL HAZARD Failure to use extra caution when operating the ATV on unfamiliar terrain. WHAT CAN HAPPEN Unfamiliar terrain may contain hidden rocks, bumps, or holes that could cause loss of control or overturn. HOW TO AVOID THE HAZARD Travel slowly and use extra caution when operating on unfamiliar terrain.
- Page 22 SAFETY Operator Safety WARNING POTENTIAL HAZARD Turning improperly. WHAT CAN HAPPEN Improper turns could cause loss of control and lead to a collision or overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for turning as described in the owner’s manual.
- Page 23 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 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.
- 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 manual.
- 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.
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Page 31: 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 32 SAFETY Safety Decals and Locations WARNING WARNING Operating this ATV if you are under the age of 16 increases your chance of severe injury or death. NEVER operate this ATV if you are 7172561 under age 16. 7172559 WARNING Improper ATV use can result in SEVERE INJURY or DEATH ALWAYS USE NEVER USE NEVER CARRY...
- Page 33 SAFETY Safety Decals and Locations WARNING 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 1300 LBS.
- Page 34 RPM, which can result in serious injury or death. NO STEP 7172563 WARNING MANUFACTURED ALL WHEEL BY: POLARIS IND, INC. DRIVE Pushing reverse DATE: override button SWITCH may cause VIN: sudden increases...
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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: Features And Controls
FEATURES AND CONTROLS Electrical Switches WARNING Activating the override switch while the throttle is open can cause loss of control, resulting in severe injury or death. Do not activate the override switch while the throttle is open. 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 37: 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 38: 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 39: 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. WARNING Operating the ATV with a spongy brake lever can result in loss of braking, which could cause an accident. -
Page 40: Brake Fluid
If the fluid level is low, add DOT 3 brake fluid only. DO NOT OVERFILL. See page 119 for the part numbers of Polaris products. WARNING Never store or use a partial bottle of brake fluid. Brake fluid is hygroscopic, meaning it rapidly absorbs moisture from the air. -
Page 41: Parking Brake
FEATURES AND CONTROLS 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. Locking the Parking Brake 1. -
Page 42: Auxiliary Brake
FEATURES AND CONTROLS Auxiliary Brake WARNING 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 43: Fuel Valve
FEATURES AND CONTROLS Choke The choke assists in starting a cold engine. Refer to the engine starting procedure on page 53 for correct choke and throttle settings during starting. Fuel Valve The fuel valve (1) is located on the left side panel. -
Page 44: Fuel Safety
FEATURES AND CONTROLS 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 Never fill a gas container while it’s in the cargo box. Static elec- tricity between the box and container could cause a spark. -
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 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 46: 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 47 When the switch is on TURF (right position), the differential is open, allowing the inside wheel to rotate independently from the outside wheel during turns. Operate your Polaris ATP in TURF mode only to protect smooth, level surfaces from tire damage. Otherwise, switch out of TURF mode.
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Page 48: Engaging The Front Gearcase
FEATURES AND CONTROLS All Wheel Drive (AWD) System Engaging the Front Gearcase The AWD switch may be turned on or off while the vehicle is moving. Initially, the vehicle’s electronic system will not enable the AWD until the engine RPM is below 3100. Once enabled, the AWD remains enabled until the AWD switch is turned off. -
Page 49: 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 50: 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 51 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.
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Page 52: 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 53 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.
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Page 54: Operation
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 55 Air filter, pre-filter Inspect, clean Air box sediment tube Drain deposits whenever visible Headlamp Check operation, apply Polaris dielec- tric grease when lamp is replaced Brake light / tail lamp Check operation, apply Polaris dielec- tric grease when lamp is replaced...
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Page 56: 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. CAUTION Operating the vehicle immediately after starting could cause engine damage. -
Page 57: 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 58: Hauling Cargo
OPERATION Hauling Cargo WARNING 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 59: Load Distribution
OPERATION Hauling Cargo Load Distribution 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 mounted as low as possible. When operating over rough or hilly terrain, reduce speed and cargo to maintain stable driving conditions. -
Page 60: Dumping Cargo
OPERATION 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. -
Page 61: 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 62: 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 63: 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 64: Driving Uphill
OPERATION Driving Safely Driving Uphill Whenever traveling uphill, follow these precautions: 1. Always travel straight uphill. 2. Avoid steep hills (25_ maximum). 3. Keep both feet on the footrests. 4. Transfer your weight forward. 5. Proceed at a steady rate of speed and throttle opening. - Page 65 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 a dangerous type of driving and should be avoided if at all possible.
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Page 66: Driving Downhill
OPERATION Driving Safely Driving Downhill Whenever descending a hill, follow these precautions: 1. Proceed directly downhill. 2. Transfer your weight to the rear of the vehicle. 3. Slow down. 4. Apply the brakes slightly to aid in slowing. Familiarize yourself with operation of the auxiliary rear brake pedal for additional braking in the event of normal service brake loss. -
Page 67: 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 68: 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 69 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 73. The following areas need special attention: engine oil, transmission oil, front and rear gearcases and all grease fittings.
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Page 70: Driving Over Obstacles
OPERATION 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. WARNING Severe injury or death can result if your vehicle comes in contact with a hidden obstacle. -
Page 71: 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 72: 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 73: 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 74: 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 75: 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 76: Maintenance And Lubrication
MAINTENANCE AND LUBRICATION Accessories Auxiliary power outlets provide 12V power for operating accessories such as hand held spot lights. See your Polaris dealer. Periodic Maintenance Chart Careful periodic maintenance will help keep your vehicle in the safest, most reliable condition. Inspection, adjustment and lubrication of important components are explained in the periodic maintenance chart. -
Page 77: Periodic Maintenance Chart
(if equipped) Transmission oil 25 H Monthly 155 (250) Inspect level; change yearly " 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. - Page 78 Inspect routing, condition " Valve clearance 100 H 12 M 620 (1000) Inspect; adjust 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.
- Page 79 Auxiliary brake Inspect daily; adjust as " needed Headlight aim Adjust as needed 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.
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Page 80: 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 81 MAINTENANCE AND LUBRICATION Periodic Maintenance Record Use the following chart to record periodic maintenance. Maintenance Servicing Servicing Remarks Interval Date Dealer Performed or Person...
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Page 82: Engine 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 83 MAINTENANCE AND LUBRICATION Lubrication Recommendations Engine Oil Oil Check (ATP 500) The oil tank is located on the left side of the vehicle. 1. Position the ATV on a level surface. 2. Start the engine and let it idle for 20-30 seconds.
- Page 84 MAINTENANCE AND LUBRICATION Lubrication Recommendations Engine Oil Oil and Filter Change (ATP 500) 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.
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Page 85: Oil Pump Priming
The sealing surfaces on the drain plug and crankcase should be clean and free of burrs, nicks or scratches. 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:... - Page 86 MAINTENANCE AND LUBRICATION Lubrication Recommendations Engine Oil Oil Check (ATP 330) The oil fill is located on the left side of the engine (1). Maintain the oil level in the safe operating range (2). Do not overfill. 1. Position the machine on a level surface.
- Page 87 1/2 turn. 13. Remove the dipstick and fill the sump with 2 quarts (1.9 l) of Polaris Premium 4 synthetic oil. 14. Place the gear selector in park and set the parking brake.
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Page 88: Transmission Oil
We recommend the use of Premium AGL Synthetic Gearcase Lubricant. See page 119 for the part numbers 1 5/8″ of Polaris products. Oil Check The transmission fill plug (1) is located on the right side of the machine, behind the footwell. -
Page 89: Oil Change
Periodic Maintenance Chart beginning on page 73. Maintain the oil level 3/4” below the fill plug opening. We recommend the use of Polaris Premium Demand Drive Hub Fluid. See page 119 for the part numbers of Polaris products. -
Page 90: Rear Gearcase Oil
Periodic Maintenance Chart beginning on page 73. Maintain the oil level at the bottom of the fill hole. We recommend the use of Polaris ATV Angle Drive Fluid. See page 119 for the part numbers of Polaris products. -
Page 91: Engine Cooling System
Polaris Premium 60/40 anti-freeze/coolant or a 50/50 mixture of high quality aluminum compatible anti-freeze/coolant and distilled water. Polaris Premium 60/40 is already premixed and ready to use. Do not dilute with water. See page 119 for the part numbers of Polaris products. NOTE: Always follow the manufacturer’s mixing recommendations... -
Page 92: Coolant Level (Atp)
MAINTENANCE AND LUBRICATION Engine Cooling System Coolant Level (ATP 500) The recovery bottle (1) is located on the left side of the machine. To access the recovery bottle, remove the left side panel. See page 97. Maintain the coolant level between the minimum and maximum marks on the bottle (when the fluid is cool). - Page 93 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. WARNING An over-full master cylinder may cause brake drag or brake lock-up, which could result in serious injury or death.
- Page 94 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.
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Page 95: 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 96: 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 97 Follow the adjustment procedures exactly, or see your Polaris dealer for service. 1. Remove the instrument panel and locate the handlebar bolts (1).
- Page 98 MAINTENANCE AND LUBRICATION Adjustments Carburetor 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...
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Page 99: 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″ (.16-.32 cm) freeplay is achieved at the thumb lever. -
Page 100: 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. Step 2 2. Grasp the rear of the side panel near the rear cab. -
Page 101: 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 124. -
Page 102: 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 103: Front Wheel Hub Tightening
Adjustments Front Wheel Hub Tightening Front wheel bearing tightness and spindle nut retention are critical component operations. All service must be performed by your authorized Polaris dealer. Tire Tread Depth 1/8I (.3 cm) Always replace tires when tread depth is worn to 1/8″ (.3 cm) or less. -
Page 104: Filter Systems
MAINTENANCE AND LUBRICATION Filter Systems Air Filter 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 105 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 106 MAINTENANCE AND LUBRICATION Lights Lower Headlight Lamp Replacement 1. Turn the back of the headlight harness in a counter-clockwise direction to loosen (A). 2. Pull the harness assembly out from the headlight assembly. 3. Remove the headlamp and replace with a new headlamp.
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Page 107: 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 108: 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 109: Spark Plugs
S Torque spark plugs to 14 ft. lbs. (19 Nm). 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 110: 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 111: 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 112: 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 113: 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 114: 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 115 MAINTENANCE AND LUBRICATION Battery Battery Charging NOTE: Always verify battery condition before and 1-2 hours after the end of charging. State of Voltage Action Charge Time* Charge (Using constant current charger @ standard amps specified on top of battery) 100% 12.8-13.0 volts None, check at None required...
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Page 116: 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 117: 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 118: 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 119: 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 120 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.
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Page 122: 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.) 2873603 Premium AGL Synthetic Gearcase Lube (gal.) -
Page 123: Troubleshooting
Clutch seals should be inspected for damage if repeated leaking occurs. Clutch malfunction. Contact your Polaris dealer for inspection of clutch com- ponents. Poor engine performance. Check for fouled plugs or foreign material in gas tank, fuel lines, or carburetor. Contact your dealer for service. - Page 124 TROUBLESHOOTING Contact your Polaris dealer for service if you’re unable to identify solutions using the following charts. Engine Doesn’t Turn Over Possible Cause Solution Tripped circuit breaker Reset the breaker Low battery voltage Recharge battery to 12.5 VDC Loose battery connections...
- Page 125 Incorrect spark plug gap or heat range Set gap to specs or replace plugs Old or non-recommended fuel Replace with new fuel Incorrectly installed spark plug wires See your Polaris dealer Incorrect ignition timing See your Polaris dealer Mechanical failure See your Polaris dealer...
- Page 126 Inspect, clean and/or replace spark plugs Fouled or defective spark plugs Inspect, clean and/or replace spark plugs Worn or defective spark plug wires See your Polaris dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs Loose ignition connections...
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Page 127: Specifications
SPECIFICATIONS ATP 330 4X4 Gross Vehicle Weight 1300 lbs./590 kg Fuel Capacity 3.25 gal./12.3 l Towing Rating 1000 lbs./454 kg Unbraked Trailer Towing Capacity* 1585 lbs./719 kg Hitch Tongue Capacity 100 lbs./45.4 kg (rear box capacity and tongue weight not to exceed 250 lbs./113 kg) Front Rack &... - Page 128 SPECIFICATIONS ATP 330 4X4 Driving System Type Shift Type Side Lever (H/L/N/R/P) Gear Reduction - Low 11.57:1 Gear Reduction - Reverse 6.84:1 Gear Reduction - High 4.41:1 Drive Ratio - Front 3.7:1 Drive Ratio - Final 3.08:1 Tire Size - Front 24 x 8 - 12 Tire Size - Rear 24 x 11 - 12...
- Page 129 SPECIFICATIONS ATP 500 4X4 Gross Vehicle Weight 1500 lbs./680 kg Fuel Capacity 3.25 gal./12.3 l Towing Rating 1225 lbs./556 kg Unbraked Trailer Towing Capacity* . 1847 lbs./838 kg Hitch Tongue Capacity 120 lbs./54.4 kg (Rear box capacity and tongue weight not to exceed 400 lbs./181 kg) Front Rack &...
- Page 130 SPECIFICATIONS ATP 500 4X4 Lubrication System Dry Sump Driving System Type Shift Type Side Lever (H/L/N/R/P) Gear Reduction - Low 8.66:1 Gear Reduction - Reverse 5.12:1 Gear Reduction - High 3.52:1 Drive Ratio - Front 3.7:1 Drive Ratio - Final 3.08:1 Tire Size - Front 25 x 8 - 12...
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Page 131: 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 132 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 133 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...
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Page 134: 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 135 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.
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Page 136: 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 137 WARRANTY California Emission Control Warranty Statement Maintenance Schedule Item Maintenance Interval Remarks (whichever comes first) Hours Calendar Miles (Km) Engine oil level Pre-Ride Make adjustments as need- " ed. See Pre-Ride Checklist on page 52. Air filter, pre-filter Daily Inspect; clean often "...
- Page 138 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.
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Page 139: Index
INDEX Accessories ..... . Electrical Switches ... . . 33-34 Adjustments . - Page 140 73-76 Trip Meter ..... . POLARIS PRODUCTS ... . TROUBLESHOOTING .