Polaris 2005 Magnum 330 2x4 Owner'S Manual Download Page 4

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Summary of Contents for 2005 Magnum 330 2x4

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Page 3: ...ed 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 The engine exhaust from this product contains chemicals kno...

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Page 5: ...or discrepancies may result between the actual vehicle and the information presented in this publication Depictions and or procedures in this publication are intended for reference use only No liabili...

Page 6: ...d enjoyable operation of your vehicle be sure to follow the instructions and recommendations in this owner s manual Your manual contains instructions for minor maintenance but information about major...

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Page 8: ...E 3 VEHICLE IDENTIFICATION NUMBERS 7 SAFETY 8 FEATURES AND CONTROLS 34 OPERATION 50 EMISSION CONTROL SYSTEMS 67 MAINTENANCE AND LUBRICATION 68 POLARIS PRODUCTS 108 SPECIFICATIONS 109 TROUBLESHOOTING 1...

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Page 10: ...ove 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 replace...

Page 11: ...ead and understand your owner s manual which includes valuable information about all aspects of your vehicle including safe operating procedures Safety Training When you purchased your new ATV your de...

Page 12: ...your vehicle or in this manual alerts you to the potential for personal injury WARNING The safety alert warning indicates a potential hazard that may result in serious injury or death CAUTION The safe...

Page 13: ...including a dirt or gravel road S Never operate an ATV without wearing an approved helmet that fits properly Always wear eye protection goggles or face shield gloves boots a long sleeved shirt or jack...

Page 14: ...attempt to turn the ATV around on any hill until you ve mastered on level ground the turn ing technique outlined in this manual Avoid crossing the side of a steep hill when possible S Always use prope...

Page 15: ...use or accidental starting FOR MORE INFORMATION ABOUT ATV SAFETY call the Con sumer Product Safety Commission at 1 800 638 2772 or call Polaris at 1 800 342 3764 Equipment Modifications We are concer...

Page 16: ...e and the operating techniques described in the owner s manual For more information about the training course contact an authorized ATV dealer or call Polaris at 1 800 342 3764 WARNING POTENTIAL HAZAR...

Page 17: ...allow the operator to shift position as needed during operation It is not intended for carrying passengers WARNING POTENTIAL HAZARD Operating an ATV on paved surfaces including sidewalks paths parking...

Page 18: ...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...

Page 19: ...fore or while operating an ATV could result in an accident causing severe injury or death HOW TO AVOID THE HAZARD Never consume alcohol or drugs before or while operating an ATV WARNING POTENTIAL HAZA...

Page 20: ...r stunts Avoid exhibition driving WARNING POTENTIAL HAZARD Failure to inspect the ATV before operating Failure to properly maintain the ATV WHAT CAN HAPPEN Poor maintenance increases the possibility o...

Page 21: ...into contact with the rear wheels and lead to accident or injury HOW TO AVOID THE HAZARD Always keep both hands on the handlebars and both feet on the footrests of the ATV during operation WARNING POT...

Page 22: ...e on excessively rough slippery or loose terrain until you ve learned and practiced the skills necessary to control the ATV on such terrain Always use extra caution on rough slippery or loose terrain...

Page 23: ...per 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 careful...

Page 24: ...res for traveling down hills as described in the owner s manual NOTE A special technique is required when braking while traveling downhill See page 61 Always check the terrain carefully before descend...

Page 25: ...t 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 See page 62 Use extra caution when turning on any hill Avoid crossin...

Page 26: ...en fully stopped apply the auxiliary rear brake as well then lock the parking brake If the ATV begins rolling backwards Keep weight uphill Never apply engine power Never apply the auxiliary rear brake...

Page 27: ...nual WARNING POTENTIAL HAZARD Skidding or sliding WHAT CAN HAPPEN Skidding or sliding can cause loss of control If the tires regain traction unexpectedly the ATV could overturn HOW TO AVOID THE HAZARD...

Page 28: ...nts and maintain a slow and steady forward motion Do not make sudden turns or stops and do not make sudden throttle changes Wet brakes may have reduced stopping ability Always test the brakes after le...

Page 29: ...re information WARNING 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...

Page 30: ...ntire vehicle for possible damage including but not limited to brakes throttle and steering systems WARNING Safe operation of this rider active vehicle requires good judgement and physical skills Pers...

Page 31: ...this manual differ from the decals on your 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 r...

Page 32: ...e with guard removed S 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 NO STEP 7172563 WARNING 71...

Page 33: ...th dual racks load distribution 1 3 front 2 3 rear is best For stability on rough or hilly terrain reduce speed and cargo Do not block headlight Be careful if load extends over the side of the rack Re...

Page 34: ...IS NOT INTENDED FOR USE ON PUBLIC ROADS 7171492 CE V HICULE EST UN V HICULE TOUT TERRAIN QUI NiEST PAS DESTIN TRE UTILIS SUR LES CHEMINS PUBLICS Canadian Certification Decal Applicable AWD Models Imp...

Page 35: ...stitute label ANSI z90 1 or the Snell Memorial Foundation label 2 Eye Protection Do not depend on sunglasses for proper eye protection A pair of goggles or a helmet face shield offer the best protecti...

Page 36: ...o not overfill the tank Do not fill the tank neck S If gasoline spills on your skin or clothing immediately wash it off with soap and water and change clothing S Never start the engine or let it run i...

Page 37: ...g rain and darkness 1 Light Switch Hi Lo Beam Control The lights won t turn on unless the main switch is on WARNING Activating the override switch while the throttle is open can cause loss of control...

Page 38: ...e stop switch either right or left to the OFF position 4 Main Switch To start the engine slide the stop switch to the center RUN position and turn the main key switch clockwise past the ON position Re...

Page 39: ...g or improperly operating throttle controls could cause an accident and lead to severe injury or death Never start or operate an ATV with a sticking or improperly operating throttle Always contact you...

Page 40: ...e reservoir is level 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...

Page 41: ...ke lever travel and master cylinder fluid level before riding When squeezed the lever should feel firm Any sponginess would indicate a possible fluid leak or low master cylinder fluid level which must...

Page 42: ...2 forward to engage the brake Release the brake lever 3 To release the parking brake lock squeeze and release the brake lever It will return to its unlocked position Important Safeguards S The parking...

Page 43: ...and serious injury or death The auxiliary brake 1 is located on the inside of the right floor board and is operated by the right foot The auxiliary brake serves as a backup to the main brake system i...

Page 44: ...ed NOTE There s about a 7 to 10 mile 11 2 to 16 km range on reserve gas Always refill the gas tank as soon as possible after using the reserve supply Always return valve to the ON position after refue...

Page 45: ...ove idle or while the vehicle is moving could cause transmission damage To change gears stop the vehicle and with the engine idling move the lever to the desired gear Apply the auxiliary brake if shif...

Page 46: ...he ON position NOTE If the engine is cold use the choke as outlined on page 52 3 Grasp the recoil starter rope handle 2 firmly and pull slowly so you can feel the engine strokes NOTE Every other strok...

Page 47: ...switch is on See page 34 There is no limit to the length of time the vehicle may remain in AWD Engaging Front Gearcase The AWD switch may be turned on or off while the vehicle is moving Initially the...

Page 48: ...nformation Center 2 Speedometer needle in addition to depicting vehicle speed this needle will flash to signal a fault condition 3 Speedometer CAUTION Washing the ATV with a high pressure washer may c...

Page 49: ...lt 3 Hour Meter 4 Service Interval Miscellaneous Service Warnings 5 Low Battery and Over Voltage This warning usually indicates that the ATV is being operated at an RPM too low to keep the battery cha...

Page 50: ...le through the options the machine cannot be in reverse Mode 1 Odometer The odometer records the miles traveled by the ATV Mode 2 Trip Meter The trip meter records the miles traveled by the ATV on eac...

Page 51: ...tarted as a reminder that the periodic maintenance is due To set the hours press and hold the mode override button until the wrench icon flashes When it begins to flash release the button The setting...

Page 52: ...ayed looks similar to the top illustration and refers to the software version installed in your ATV This information is displayed briefly Use the mode reverse override button to toggle through the dia...

Page 53: ...ixing brands or using a non recommended oil may cause serious engine damage We recommend the use of Polaris Premium 4 synthetic Oil or another 0W 40 API certified SH oil Never substitute or mix oil br...

Page 54: ...Tires Inspect condition and pressure 30 101 Wheels fasteners Inspect ensure fastener tightness 100 Frame nuts bolts fasteners Inspect ensure tightness Fuel and oil Ensure proper levels 75 Coolant leve...

Page 55: ...ded for starting Be sure the choke is off during operation as excess fuel washing into the engine oil will increase wear on engine components 3 Move the engine stop switch to RUN NOTE Do not press the...

Page 56: ...If the engine is over choked when warm depress the throttle lever fully while cranking to aid in starting 5 Release the throttle lever immediately after the engine starts If the engine does not start...

Page 57: ...to warm up then shift the transmission into gear 3 Check your surroundings and determine your path of travel 4 Release the parking brake 5 Slowly depress the throttle with your right thumb and begin...

Page 58: ...ion of the turn leaning your upper body to the inside of the turn while supporting your weight on the outer footrest This technique alters the balance of traction between the rear wheels allowing the...

Page 59: ...ed 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 When operating over rough...

Page 60: ...ITH STABLE AND SAFELY ARRANGED LOADS When handling off centered loads that cannot be centered securely fasten the load and operate with extra caution Always attach the tow load to the hitch point desi...

Page 61: ...y weight forward 4 Drive with AWD engaged AWD models to assist in controlling the vehicle in slippery areas CAUTION Severe damage to drive train may occur if the AWD is engaged while the wheels are sp...

Page 62: ...TV begins rolling backwards Keep your weight uphill Never apply engine power Never apply the auxiliary rear brake while rolling backwards Apply the single lever brake gradually When fully stopped appl...

Page 63: ...can be the most dangerous type of driving encountered and should be avoided if at all possible If you do enter into a situation where sidehilling is necessary follow these precautions 1 Slow down 2 Le...

Page 64: ...vehicle 3 Slow down 4 Apply the brakes slightly to aid in slowing using the single brake lever NOTE Familiarize yourself with operation of the auxiliary rear brake pedal for additional braking in the...

Page 65: ...brake while keeping body weight uphill 2 Leave transmission in forward and shut off the engine 3 Dismount on the uphill side of the vehicle or on the left if the vehicle is pointing straight uphill 4...

Page 66: ...and rear gearcases and all grease fittings CAUTION Major engine damage can result if the vehicle is not thoroughly inspected after operation in water Perform the services outlined in the maintenance...

Page 67: ...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 obs...

Page 68: ...or people behind the vehicle When it s safe to proceed back slowly Do not use the override switch unless additional power is required for vehicle movement Use with caution Avoid backing on inclines a...

Page 69: ...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 dow...

Page 70: ...is specifications to achieve optimal performance Adjustment to engine idle is the only adjustment Polaris recommends that the operator perform Any other adjustments should be performed by an authorize...

Page 71: ...ture will help you determine when maintenance service is due See page 48 for instructions Maintenance intervals in the following charts are based upon average riding conditions and an average vehicle...

Page 72: ...ble Daily Check level daily change coolant every 2 years Headlamp tail lamp Daily Check operation apply dielectric grease if replacing E Air filter main element Weekly Inspect replace as needed Recoil...

Page 73: ...asonally pressure test system yearly E Engine oil change 100 H 6 M 1000 1600 Perform a break in oil change at one month E Oil filter change 100 H 6 M 1000 1600 Replace with oil change J E Valve cleara...

Page 74: ...Inspect clean replace worn parts J Front wheel bearings 100 H 12 M 1000 1600 Inspect replace as needed J Brake fluid 200 H 24 M 2000 3200 Change every two years Spark arrestor 300 H 36 M 3000 4800 Cle...

Page 75: ...Oil Premium 4 Synthetic 0W40 See page 75 Brakes DOT 3 fluid only See page 37 1 Transmission Premium AGL Synthetic Gearcase Lube See page 77 2 Front Gearcase Premium Demand Drive Hub Fluid See page 78...

Page 76: ...73 MAINTENANCE AND LUBRICATION Periodic Maintenance Record Use the following chart to record periodic maintenance Maintenance Interval Performed Servicing Date Servicing Dealer or Person Remarks...

Page 77: ...breakdown in ambient temperatures from 40 F to 120 F 40 to 49 C Its exceptional frictional properties result in more efficient operation more power output and lower fuel consumption Although Polaris...

Page 78: ...ck and read the oil level Maintain the oil level in the normal safe operating range 2 Do not overfill Oil and Filter Change CAUTION If the ATV is left without oil in the system for extended periods th...

Page 79: ...turn by hand until the filter gasket contacts the sealing surface then turn and additional 1 2 turn 13 Remove the dipstick and fill the sump with the recommended oil Refer to the specifications sectio...

Page 80: ...Position the ATV on a level surface 2 Remove the fill plug 1 and check the oil level 3 Add the recommended oil as needed 4 Reinstall the fill plug Torque to specification Oil Change The transmission d...

Page 81: ...k the oil level 3 Add the recommended oil as needed 4 Reinstall the fill plug Torque to specification Oil Change 1 Check the vent hose 3 to be sure it s unobstructed and routed properly 2 Support the...

Page 82: ...age 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 3 Add the recommended oil as needed 4 Reinstall the fil...

Page 83: ...ality Hot components can cause serious burns to skin Do not service the headlamps until they ve cooled sufficiently Headlight Lamp Replacement 1 Turn the back of the headlight harness in a counter clo...

Page 84: ...he 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 Apply dielectric grease to the soc...

Page 85: ...ght brown There will be few combustion deposits The electrodes are not burned or eroded This indicates the proper type and heat range for the engine and the service NOTE The tip should not be white A...

Page 86: ...airbox for any water and dry it if water is present 3 Turn the fuel valve off 4 Remove the spark plug 5 Loosen the carburetor drain screw 1 6 Turn the engine over several times using the electric sta...

Page 87: ...nder the vehicle while it s inclined 1 Remove the arrestor clean out plug 1 from the bottom of the muffler 2 Place the transmission in PARK and start the engine 3 Purge carbon from the system by momen...

Page 88: ...e ATV NOTE Water will enter the recoil housing if the starter handle is disengaged from the rope guide when under water The drain screw is located at the bottom of the recoil housing Use a wrench to r...

Page 89: ...ell above the engagement speed of 1200 1400 RPM However in high range at 3 MPH the engine would be running at only 1500 RPM Whenever operating this close to the engagement speed the engine may be runn...

Page 90: ...ended 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...

Page 91: ...tive battery cable next 4 Lift the battery out of the ATV Battery Installation When installing a new battery make sure it s fully charged prior to its initial use Using a new battery that has not been...

Page 92: ...ready filled with electrolyte and has been sealed and fully charged at the factory Never pry the sealing strip off or add any other fluid to this battery The single most important thing about maintain...

Page 93: ...tandard amps specified on top of battery 100 12 8 13 0 volts None check at 3 mos from date of manufacture None required 75 100 12 5 12 8 volts May need slight charge if no charge given check in 3 mont...

Page 94: ...ny unused portion WARNING An over full master cylinder may cause brake drag or brake lock up which could result in serious injury or death Maintain brake fluid at the recommended level Do not overfill...

Page 95: ...they re worn to 3 64 1 cm Inspect the brake disc spline and pad wear surface for excessive wear Your vehicle s auxiliary brake system is intended to be used as a backup for the main brake system Shoul...

Page 96: ...used as an indicator of whether the handlebars are straight The frog should always point straight back from the steering post 2 Place stands 1 in front of the vehicle perpendicular to the rear tires...

Page 97: ...d bolts are found see your Polaris dealer for service before operating the vehicle Camber and Caster The camber and caster are non adjustable Rear Spring The rear shock absorber spring is adjusted by...

Page 98: ...ustment procedures exactly or see your Polaris dealer for service Handlebars The handlebars can be adjusted for rider preference 1 Remove the handlebar cover 2 Loosen the four handlebar bolts 1 3 Adju...

Page 99: ...olaris dealer are required for operation above 6 000 feet and temperatures below 40 degrees F 4 degrees C NOTE Continuous operation of the engine without proper jetting when required can cause poor pe...

Page 100: ...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 NOTE While adjusting freeplay be sure to flip the thr...

Page 101: ...and outward to disengage the two rear tabs 3 Place your hand on top of the side panel behind the fuel tank With a quick and firm motion push down on the side panel to disengage the top rear two tabs...

Page 102: ...ur ATV and in the specifications section of the owner s manual beginning on page 109 Always use original equipment size and type when replacing tires Make sure the wheels are installed properly Always...

Page 103: ...1 Place the transmission in PARK and lock the parking brake 2 Place the wheel on the wheel hub with the valve stem toward the outside and rotation arrows on the tire pointing toward forward rotation 3...

Page 104: ...erating the vehicle with worn tires will increase the possibility of skidding which could lead to loss of control and serious injury or death Always replace tires when the tread depth measures 1 8 3 c...

Page 105: ...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 5 Reinstall the pre filter over the main filter Replace th...

Page 106: ...ly and dry with a chamois to prevent water spots NOTE 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...

Page 107: ...leans the fuel system the combustion chamber and the exhaust ports It also prevents bacterial growth and promotes better starting after the storage period 1 Fill the fuel tank with fuel and add Polari...

Page 108: ...ensure coverage of the piston rings cylinder walls and crankshaft bearings 4 Apply dielectric grease to the inside of the spark plug cap and install the cap onto the plug 5 Treat the fuel system with...

Page 109: ...h 3 Routinely and liberally apply a weather resistant wax to each polished chrome wheel Choose a product suitable for chrome finishes Read and follow the product labels and instructions 4 Chrome wheel...

Page 110: ...ng transporting 2 Turn the fuel valve off 3 Be sure the fuel cap oil cap and seat are installed correctly and securely 4 Always tie the frame of the ATV to the transporting unit securely using suitabl...

Page 111: ...Hub Fluid 8 oz 2872277 Premium Demand Drive Hub Fluid 2 5 gal Grease Specialized Lubricants 2871322 Premium All Season Grease 3 oz cartridge 2871423 Premium All Season Grease 14 oz cartridge 2871460...

Page 112: ...Ground Clearance 6 75 in 17 1 cm Length 81 in 205 7 cm Width 46 in 116 8 cm Height 46 in 116 8 cm Seat Height 34 in 86 4 cm Dry Weight 590 lbs 268 kg Wheel Base 49 75 in 126 4 cm Engine Cooling Engin...

Page 113: ...cm travel Shock Adjustment CAM Front Brake Single Control Hydraulic Disc Rear Brake Single Control Hydraulic Disc Auxiliary Brake Hydraulic Disc Park Brake Hydraulic Lock All Wheel Features Headlight...

Page 114: ...rs Feet 0 1800 0 6000 127 5 122 5 1800 3700 6000 12000 120 115 Clutching Chart Altitude Shift Weight Drive Clutch Spring Driven Clutch Spring Helix Spring Setting Meters Feet 0 1800 0 6000 16 5630279...

Page 115: ...dius 71 in 180 cm unloaded Ground Clearance 6 75 in 17 1 cm Length 81 in 205 7 cm Width 46 in 116 8 cm Height 46 in 116 8 cm Seat Height 34 in 86 4 cm Wheel Base 49 75 in 126 4 cm Dry Weight 637 lbs 2...

Page 116: ...m travel Shock Adjustment 2 in Gas Charged Monotube Cam Front Brake Single Control Hydraulic Disc Rear Brake Single Control Hydraulic Disc Auxiliary Brake Hydraulic Disc Park Brake Hydraulic Lock All...

Page 117: ...rs Feet 0 1800 0 6000 127 5 122 5 1800 3700 6000 12000 120 115 Clutching Chart Altitude Shift Weight Drive Clutch Spring Driven Clutch Spring Helix Spring Setting Meters Feet 0 1800 0 6000 16 5630279...

Page 118: ...for efficient enga gement Towing pushing at low RPM low ground speed Use low range only Utility use plowing snow dirt etc Use low range only Stuck in mud or snow Shift the transmission to low range an...

Page 119: ...in fuel Drain the fuel system and refuel Fuel valve is turned off Turn the fuel valve on Old or non recommended fuel Replace with new fuel Fouled or defective spark plug s Inspect plug s replace if n...

Page 120: ...e ignition connections Check all connections and tighten Water present in fuel Replace with new fuel Low battery voltage Recharge battery to 12 8 VDC Kinked or plugged fuel vent line Inspect and repla...

Page 121: ...s See your Polaris dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs Loose ignition connections Check all connections and tighten Low battery voltage Recharge battery to...

Page 122: ...ANTY COVERAGE AND EXCLUSIONS 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...

Page 123: ...u must present your copy of the Warranty Registration form to the dealer THE COST OF TRANSPORTATION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY Polaris suggests that you use your original selling de...

Page 124: ...ized Polaris dealer You must show the dealer photo identification from the country of the selling dealer s authorized location as proof of residence Upon residence verification the servicing dealer wi...

Page 125: ...61 Driving in Reverse 65 Driving on Slippery Surfaces 58 Driving Over Obstacles 64 Driving Procedures 54 Driving Safely 54 66 Driving Through Water 63 Driving Uphill 59 E Electrical Switches 34 35 Ele...

Page 126: ...Center 46 49 S Safe Riding Gear 32 SAFETY 8 33 Safety Decals and Locations 28 31 Safety Training 8 Severe Use 68 Side Panel Removal 98 Sidehilling 60 Spark Arrestor 67 84 Spark Plugs 82 SPECIFICATIONS...

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Polaris 2005 Magnum 330 2x4, Owner'S Manual

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