Polaris ATP 330 4x4 Owner'S Manual Download

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SAFETY

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

charge. The part number is printed on the decal.

Summary of Contents for ATP 330 4x4

Page 1: ......

Page 2: ... ALCOHOL Operate without proper training or instruction Operate on public roads A collision can occur with another vehicle Operate at speeds too fast for your skills or the conditions Use ALCOHOL or DRUGS before or while operating this vehicle Carry Passengers ALWAYS Avoid paved surfaces which may adversely affect handling and control Use proper RIDING TECHNIQUES to avoid vehicle overturns on hill...

Page 3: ...own to cause cancer birth defects or other reproductive harm A card containing important ATV safety information should be attached to the owner s manual on the next page If you cannot locate this card or if it has been removed please call 1 800 342 3764 for assistance ...

Page 4: ...ated a web site just for YOU S Technical tips S New product introductions S Event schedules S Parts and Service Manual information S Exciting details about The Way Out Check it out www polarisindustries com owner ...

Page 5: ...ing Polaris Industries Inc reserves the right to make product changes and improvements that may affect illustrations or explanations No part of this manual shall be reproduced or used without the written permission of Polaris Industries Inc Copyright 2002 Polaris Industries Inc All Rights Reserved Printed in the U S A ...

Page 6: ...aking it the finest machine we ve ever produced For safe and 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 repairs is outlined in the Polaris Service Manual and should be performed only by a Factory Certified Master Service Dealer MSD Technician Yo...

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Page 8: ... OF CONTENTS 5 VEHICLE IDENTIFICATION NUMBERS 6 SAFETY 7 FEATURES AND CONTROLS 37 OPERATION 53 EMISSION CONTROL SYSTEMS 74 MAINTENANCE AND LUBRICATION 75 POLARIS PRODUCTS 121 TROUBLESHOOTING 122 SPECIFICATIONS 126 WARRANTY 130 INDEX 137 ...

Page 9: ...rs are essential to the recovery and identification of your vehicle Remove the spare key and store it in a safe place Your key can be duplicated only by mating a Polaris key blank with one of your existing keys If both keys are lost the ignition switch must be replaced See your Polaris dealer NOTE Record your vehicle s ID numbers and key number 3 in the spaces provided 2 1 31XX 3 Frame VIN Engine ...

Page 10: ...olaris dealer you can request this free safety training from any authorized Polaris dealer A Polaris ATV is an off road vehicle Familiarize yourself with all laws and regulations concerning the operation of this vehicle in your area We strongly advise you to strictly follow the recommended maintenance program outlined in your owner s manual This preventive maintenance program is designed to ensure...

Page 11: ...on your ATV or in this manual alerts you to the potential for personal injury The safety alert warning indicates a potential hazard that may result in serious injury or death The safety alert caution indicates a potential hazard that may result in minor personal injury or damage to the machine CAUTION NOTE A note will alert you to important information or instructions A caution indicates a situati...

Page 12: ...ves boots a long sleeved shirt or jacket and long pants S Never consume alcohol or drugs before or while operating an ATV S Never operate at excessive speeds Travel at speeds appropriate for the terrain visibility and operating conditions and your experience S Never attempt wheelies jumps or other stunts S Always inspect your ATV before each use to make sure it s in safe operating condition Always...

Page 13: ... 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 proper procedures if you stall or roll backwards while climbing a hill To avoid stalling maintain a steady speed when climbing a hill If you stall or roll backwards follow the special pro cedure for braki...

Page 14: ...e 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 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 veh...

Page 15: ...he 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 POTENTIAL HAZARD Failure to follow the age recommendations for this ATV WHAT CAN HAPPEN Severe injury and or death could occur if a child under the minimum age recommendation operates an ATV Even though a child may be within the r...

Page 16: ... carry a passenger The purpose of the long seat is to allow the operator to shift position as needed during operation It is not intended for carrying passengers WARNING POTENTIAL HAZARD Carrying a passenger in the cargo box WHAT CAN HAPPEN A passenger riding in the cargo box could be ejected from the vehicle unexpectedly or may contact moving components both of which can result in severe injury or...

Page 17: ...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 HOW TO AVOID THE HAZARD Avoid operating the ATV on pavement If it s unavoidable travel slowly and avoid sudden turns or stops WARNING ...

Page 18: ... 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 In many states it s illegal to operate ATVs on public streets roads and highways WARNING ...

Page 19: ...eases the risk of a severe head injury or death in the event of an accident Operating without eye protection could result in an accident and could increase the chance of a severe injury in the event of an accident HOW TO AVOID THE HAZARD Always wear an approved helmet that fits properly Always wear eye protection goggles or face shield gloves boots long sleeved shirt or jacket and long pants WARNI...

Page 20: ... 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 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...

Page 21: ...ARD Attempting wheelies jumps and other stunts WHAT CAN HAPPEN Attempting stunts increases the chance of an accident including an overturn HOW TO AVOID THE HAZARD Never attempt wheelies jumps or other stunts Avoid exhibition driving WARNING ...

Page 22: ...ocedures and schedules described in the owner s manual 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 w...

Page 23: ...V 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 Always be alert to changing terrain conditions WARNING ...

Page 24: ...ly rough slippery or loose terrain could cause loss of traction or loss of control which could result in an accident or overturn HOW TO AVOID THE HAZARD Do not operate 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 WARNING ...

Page 25: ...bed in the owner s manual Practice turning at slow speeds before attempting to turn at faster speeds Never turn at excessive speed 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 at...

Page 26: ...er s manual Always check the terrain carefully before ascending any hill Never operate the ATV on hills steeper than 25_ Never climb hills with excessively slippery or loose surfaces Shift your weight forward Never open the throttle suddenly while traveling uphill The ATV could flip over backwards Never go over the top of any hill at high speed An obstacle a sharp drop or another vehicle or person...

Page 27: ...raveling down hills as described in the owner s manual NOTE A special technique is required when braking while traveling downhill See page 65 Always check the terrain carefully before you descending a hill Shift your weight backward Never travel down a hill at high speed Avoid traveling down a hill at an angle which would cause the vehicle to lean sharply to one side Travel straight down the hill ...

Page 28: ...rn 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 66 Use extra caution when turning on any hill Avoid crossing the side of a steep hill When crossing the side of a hill Always follow proper procedures as described in the owner s manual Avoid hills with excessively slippery or loose surfaces Shift your weight to the...

Page 29: ...adually When fully stopped apply the 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 rear brake while rolling backwards Apply the front brake or single lever brake gradually When fully stopped apply the rear brake as well and then lock the parking brake Dismount on uphill side or to either side if ATV is...

Page 30: ... as rocks and fallen trees when possible If unavoidable use extreme caution and always follow proper procedures as outlined in the owner s manual 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 On slippery surfaces such as ice travel slowly and use extra cauti...

Page 31: ...ight carefully avoid sudden movements 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 leaving water If necessary apply them several times to let friction dry out the pads POTENTIAL HAZARD Improperly operating in reverse WHAT CAN HAPPEN The ATV could coll...

Page 32: ...e pressure POTENTIAL HAZARD Operating the ATV with improper modifications WHAT CAN HAPPEN Improper installation of accessories or modification of the ATV may cause changes in handling which could lead to an accident HOW TO AVOID THE HAZARD 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 o...

Page 33: ...argo or pulling a trailer Allow a greater distance for braking Always follow the instructions in the owner s manual for carrying cargo or pulling a trailer See page 58 POTENTIAL HAZARD Operating on frozen bodies of water WHAT CAN HAPPEN Severe injury or death can result if the ATV and or the operator fall through the ice HOW TO AVOID THE HAZARD Never operate the ATV on a frozen body of water If yo...

Page 34: ...sons with cognitive or physical disabilities who operate this vehicle have an increased risk of overturn and loss of control which could result in severe injury or death CAUTION Always keep combustible materials away from the exhaust system Exposure to the hot components could result in a fire WARNING WARNING Leaving the keys in the ignition can lead to unauthorized use of the vehicle resulting in...

Page 35: ...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 charge The part number is printed on the decal A B C D E F G H ...

Page 36: ...ing or sharp turns DUse OVERRIDE for reverse speed limiter with caution To prevent loss of control never activate override button with open throttle DWhen this ATV is not in operation or unattended place shift in the park position 7079083 E1997 2000 IF OWNER S MANUAL IS MISSING CONTACT A POLARIS DEALER FOR A REPLACEMENT WARNING WARNING 7171383 A B Operating this vehicle if you are under the age of...

Page 37: ...E 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 590 kg MAXIMUM CARGO CAPACITY 350 LBS 158 kg Reduce speed and allow greater distance for braking when carrying cargo Overloading or carrying tall off center or unsecured ...

Page 38: ... filter ATTENTION Under seat ATP 330 S Specific carburetor jetting 7170007 and adjustments are required depending on temperature and altitude See your Owner s Manual Factory setting 40_ to 80_ F at 0 3000 feet 5_ to 27_ C at 0 900 meters S Operation of this vehicle without the air filter element will severely damage the engine S Clean pre filter element often more frequent cleaning required in dus...

Page 39: ...nstitute 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 protection for your eyes They should be kept clean and be of shatterproof design bearing the markings z2 1 or VESC 8 3 Gloves Off road style gloves with knuckle pads are the best for comfort and protection 4...

Page 40: ...l Drive in reverse if the Demand 4 Drive switch is on Main Switch 2 To start the engine slide the stop switch to the center RUN position and turn the main key switch clockwise past the ON position Release the key when the engine starts NOTE Turn off the main switch to end all electrical power to the vehicle including the cooling fan and lights 1 2 3 Leaving the keys in the ignition can lead to una...

Page 41: ...itch to shut off the power to the cooling fan Light Switches The light switch is located on the left handlebar 1 It s used to turn the lights on and off and to switch the lights from HI to LO on models equipped with HI LO beams NOTE The lights won t work unless the key is in the ON position and the shut off switch is in the RUN position RUN OFF OFF 3 1 Operating the ATV on streets or roads especia...

Page 42: ...onic Throttle Control ETC stops the engine in the event of a throttle system malfunction and is provided for your safety Do not attempt to modify the ETC system or replace it with any after market throttle mechanisms WARNING Do not start or operate an ATV with sticking or improperly operating throttle controls which could cause an accident and lead to severe injury or death Always contact your dea...

Page 43: ...d level is full When fluid needs to be added the eye will be clear NOTE When checking the fluid level the ATV must be on level ground with the handlebars straight If the fluid level is low add DOT 3 brake fluid only DO NOT OVERFILL See page 121 for the part numbers of Polaris products Operating the ATV with a spongy brake lever can result in loss of braking which could cause an accident Never oper...

Page 44: ...ways place the gear shifter in park before engaging the parking brake S The parking brake may relax if left on for a long period of time Al ways block the wheels to prevent rolling S Never depend on the parking brake alone if the ATV is parked on a hill Always block the wheels on the downhill side of the ATV to prevent rolling Another option is to park the ATV in a sidehill posi tion Operating the...

Page 45: ...idding Check the brake fluid level frequently for the auxiliary brake system The reservoir is located under the seat or near the foot brake Maintain the fluid level between the maximum and minimum marks 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...

Page 46: ...in supply is exhausted 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 refueling Fuel Tank The fuel tank filler cap 2 is located directly below the handlebar Use either leaded or unleaded gasoline with a minimum pump octane number of 87 R M 2 octane Fuel F...

Page 47: ...ea where refueling is performed or where gasoline is stored S Do 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 in an enclosed area Engine exhaust fumes are poisonous and can cause loss of con sciousness or death in a short time S Turn the fuel valve...

Page 48: ...justment is important to assure proper transmission function See your dealer if you experience any shifting problems Belt Life To extend belt life use low forward gear in heavy pulling situations and when operating at less than seven miles per hour for extended periods of time If towing the vehicle is necessary shift the transmission into neutral for better mobility and to prevent damage to the be...

Page 49: ...ugh to start and restores compression for starting 1 Position the vehicle on a level surface place the transmission in park and lock the parking brake see page 41 2 Grasp the recoil starter rope handle tightly and pull slightly until the starter mechanism engages 3 Pull the rope abruptly to start the engine 1 Extending the starter rope too far will cause damage to the recoil assembly Do not extend...

Page 50: ...engage NOTE The override switch allows activation of Demand 4 Drive AWD in reverse if the Demand 4 Drive switch is on See page 37 There is no limit to the length of time the vehicle may remain in Demand 4 Drive Engaging the Front Gearcase The Demand 4 Drive 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 ...

Page 51: ...nction that limits the ATV s speed to approximately 7 9 mph Refer to page 37 for additional information 1 Rider Information Center 2 Speedometer needle in addition to showing vehicle speed the needle flashes when a warning condition exists 3 Speedometer 2 3 1 CAUTION To prevent damage wash the ATV by hand or with a garden hose using mild soap Do not use alcohol to clean the instrument cluster Imme...

Page 52: ... indicator illuminates when the electrical portion of the AWD system is enabled 3 Engine Hour Display Indicator 4 Service Interval Diagnostic Mode Indicator 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 charged A low battery warning may also occur under normal operation if the machine is at idle and high electrica...

Page 53: ...traveled by the ATV Mode 2 Trip Meter The trip meter records the miles traveled by the ATV on each trip if it s reset before each trip To reset the trip meter select the trip meter mode Press and hold the mode button override button until the total changes to 0 NOTE In the Rider Information Center the trip meter display contains a decimal point but the odometer displays without a decimal point Mod...

Page 54: ... off and wait 10 seconds 2 Set the parking brake and shift the transmission into neutral 3 Hold the mode reverse override button and turn the key switch on 4 Release the switch as soon as the display is activated The initial screen display refers to the software version installed in your ATV This information is displayed briefly Use the mode reverse override button to toggle through the diagnostic...

Page 55: ...s to flash release the button The setting will increase by one hour each time the button is pressed Pressing and holding the button will allow the numbers to escalate much faster When the desired time increment is displayed release the button and wait for the wrench to stop flashing When the wrench stops blinking your service hours are set NOTE If you scroll past the intended number hold the butto...

Page 56: ...g range 1 3 Drive slowly at first Select an open area that allows room to familiarize yourself with vehicle operation and handling 4 Vary throttle positions Do not operate at sustained idle 5 Perform regular checks on fluid levels controls and areas outlined on the daily pre ride inspection checklist See page 54 6 Pull only light loads 7 During the break in period change both the oil and the filte...

Page 57: ... switch Check for proper function 7 Wheels Check for tightness of wheel nuts and axle nuts check that axle nuts are secured by cotter pins 8 Air cleaner element Check for dirt clean or replace 9 Steering Check for free operation noting any unusual looseness in any area 10 Loose parts Visually inspect vehicle for any damaged components or loose nuts bolts or fasteners 11 Riding gear Wear a helmet g...

Page 58: ... key past the ON position to engage the starter Activate the starter for a maximum of five seconds releasing the key when the vehicle starts If the engine does not start release the starter and wait five seconds Then activate the starter for another five seconds Repeat this procedure until the engine starts 7 If the engine slows or stops position the choke knob half way in to allow proper engine w...

Page 59: ...he 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 and all conditions are favorable change the spark plug and try again Cold Weather Operation for 4 Cycle Engines If the ATV is used year round check the oil level frequently A rising oil level could indica...

Page 60: ...erating conditions which could result in loss of control of the vehicle Always be sure that the cargo bed is lowered and latched be fore moving the vehicle S EXTREME CAUTION MUST BE USED when operating with loads extending beyond the rack or cargo bed Stability and maneuverability may be adversely affected causing the ma chine to overturn S Carrying a load on only the front rack or cargo bed may c...

Page 61: ...h extreme caution whenever hauling or towing loads Balance handling and control may be affected 3 Slow down 4 The cargo box dump latch must be securely latched before loading and operating Unintentional box tilting will result if weight is placed in the rear of the box and the latch is not secured Maximum Towing Capacities Do not exceed the following maximum capacities when towing Maximum grade wh...

Page 62: ...e latch is secured 8 Secure the tailgate WARNING If cargo weight is placed toward the rear of the cargo box the load may dump unexpectedly and cause serious injury When loading cargo always position the weight as far forward and as low as possible WARNING Operating with the cargo box in the raised position can cause serious injury and damage to the vehicle The cargo box could close unexpectedly an...

Page 63: ...t 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 driving Vehicle speed is controlled by the amount of throttle opening 6 Drive slowly Practice maneuvering and using the throttle and brakes on level surfaces ...

Page 64: ...a turn steer in the direction 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 wheels allowing the turn to be made smoothly The same leaning technique should be used for turning in reverse NOTE Practice making turns at slow speeds before attempting to turn at faster speeds WARN...

Page 65: ... in the direction of the skid and shifting your body weight forward 4 Driving with Demand 4 Drive All Wheel Drive engagedcan assistin controlling the vehicle in slippery areas Severe damage to drive train may occur if the AWD is engaged while the wheels are spinning CAUTION WARNING Failure to exercise care when operating on slippery surfaces can result in loss of tire traction and cause loss of co...

Page 66: ... If the ATV begins rolling backwards Keep your weight uphill Never apply engine power Never apply the rear brake while rolling backwards Apply the front brake or single lever brake gradually When fully stopped apply the rear brake as well and then lock the parking brake Dismount on uphill side or to either side if ATV is pointed straight uphill Turn the ATV around and remount following the procedu...

Page 67: ...ward the hill while keeping your feet on the footrests 3 Steer slightly into the hill to maintain vehicle directions NOTE If the vehicle begins to tip quickly turn the front wheel downhill if possible or dismount on the uphill side immediately 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 ...

Page 68: ...o 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 Excessive speed can cause loss of control and lead to serious injury or death Always operate slowly when traveling downhill WARNING ...

Page 69: ...ding the brake lever release the parking brake lock and slowly allow the vehicle to roll around to your right until it s pointing across the hill or slightly downward 6 Lock the parking brake and remount the vehicle from the uphill side keeping body weight uphill 7 Restart the engine with the transmission still in forward 8 Release the parking brake and proceed slowly controlling speed with the br...

Page 70: ...ave gradual inclines 3 Proceed slowly avoiding rocks and obstacles if possible 4 After crossing dry the brakes by applying light pressure to the lever until braking action is normal NOTE Avoid operating the vehicle through deep or fast flowing water If you cannot avoid water that exceeds the recommended maximum depth go slowly balance your weight carefully avoid sudden movements and maintain a slo...

Page 71: ...he procedure on page 73 for drying out the PVT If your vehicle becomes immersed and it s impossible to take it to a dealer before starting it follow the steps described on page 110 Have the vehicle serviced by your dealer promptly Major engine damage can result if the vehicle is not thoroughly inspected after operation in water Perform the services outlined in the maintenance chart If your vehicle...

Page 72: ...rn to read the terrain Be constantly alert for hazards such as logs rocks and low hanging branches Severe injury or death can result if your vehicle comes in contact with a hidden obstacle Not all obstacles are immediately visible Travel with caution in unfamiliar terrain WARNING ...

Page 73: ... increased Do not operate at wide open throttle Open the throttle just enough to maintain a desired speed WARNING Failure to use caution when operating in reverse can result in serious injury or death Before shifting into reverse always check for obstacles 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 vehic...

Page 74: ...rking 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 4 Shut off the fuel supply ...

Page 75: ...e 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 running at a speed too low to provide the pinch needed to prevent belt slip Belt slip is responsible for creating the excessive heat that destroys belts and causes outer clutch covers to fail By switching to low ...

Page 76: ...to comply with the instructions in this warning can result in severe injury or death Do not modify any component of the PVT system Doing so may reduce its strength so that a failure may occur at a high speed The PVT system has been precision balanced Any modification will cause the system to be out of balance creating vibration and additional loads on components The PVT system rotates at high spee...

Page 77: ... This engine is equipped with a closed crankcase system Blow by gases are forced back to the combustion chamber by the intake system The system does not allow the blow by gases to enter the atmosphere Exhaust Emission Control System The emissions from the exhaust of this vehicle are controlled by engine design including factory set carburetion and ignition The engine and related components must be...

Page 78: ...ance intervals in the following charts are based upon average riding conditions and an average vehicle speed of approximately 10 miles per hour Vehicles subjected to severe use such as operation in wet or dusty areas should be inspected and serviced more frequently Inspect clean lubricate adjust and replace parts as necessary When inspection reveals the need for replacement parts use genuine Polar...

Page 79: ...y L Air filter Pre cleaner Pre Ride Pre Ride Inspect clean Coolant level Pre Ride Pre Ride Replace coolant every two years Fuel and oil tanks Pre Ride Pre Ride Fill to proper levels Throttle Pre Ride Pre Ride Check operation Lights Pre Ride Pre Ride Check operation Engine stop switch Pre Ride Pre Ride Check operation Steering Pre Ride Pre Ride Check for free operation Air box sediment tube Pre Rid...

Page 80: ... wear 10 hrs Monthly Inspect periodically Front and rear gearcase oil 100 hrs Monthly Check monthly change annually Engine cylinder head and cylinder base fasteners 25 hrs 3 months Inspect re torque required at first service only General lubrication 50 hrs 3 months Lubricate all fittings pivots cables etc L Engine oil level oil change 100 hrs 1000 miles 6 months Check level daily break in service ...

Page 81: ...h seasonal ly pressure test system annually Shift linkage 50 hrs 6 months Inspect adjust J Drive belt 50 hrs 6 months Inspect replace as needed Steering 50 hrs 6 months Inspect daily lubricate Front suspension 50 hrs 6 months Inspect lubricate tighten fasteners Rear suspension 50 hrs 6 months Inspect tighten fasteners L Spark plug 100 hrs 12 months Inspect replace as needed J L Ignition Timing 100...

Page 82: ...100 hrs 12 months Inspect clean Engine mounts 100 hrs 12 months Inspect J L Valve clearance 100 hrs 12 months Inspect adjust J Brake fluid 200 hrs 24 months Change every two years Spark arrestor 300 hrs 36 months Clean out Rear axle As required Inspect bearings if axle has ingested water or if unusual noises are present L Idle speed As required Adjust as needed Recoil housing As required Drain moi...

Page 83: ...emium 4 Synthetic 0W40 Add to proper level on dip stick Check level daily Brakes DOT 3 fluid only Maintain level between fill lines See page 40 As required change every two years or 200 hours Transmission Polaris Premium Synthetic gear case lube See Page 88 Check every 6 months 1000 miles Change annually or at 100 hours Front Gear case Polaris Premium Synthetic gear case lube See Page 89 Change an...

Page 84: ...NCE AND LUBRICATION Periodic Maintenance Record Use the following chart to record periodic maintenance Maintenance Interval Performed Servicing Date Servicing Dealer or Person Remarks 10 hrs 20 hrs 50 hrs 100 hrs ...

Page 85: ...se of any API certified SH oil is allowable as long as it s 0W 40 Oil may need to be changed more frequently if Polaris Premium 4 is not used Follow the manufacturer s recommendations for ambient temperature operation Engine Oil Check The oil tank is located on the left side of the vehicle 1 Position the machine on a level surface 2 Start the engine and let it idle for 20 30 seconds Stop the engin...

Page 86: ...eed Always change the oil filter whenever changing oil 1 Obtain the correct oil filter and an adequate supply of oil so the oil and filter change can be completed without interruption 2 Position the vehicle on a level surface Clean the area around the drain plug at the bottom of the oil tank and the bottom of the engine 3 Run the engine for two to three minutes then turn it off CAUTION If the ATV ...

Page 87: ... drain plug and the oil tank should be clean and free of burrs nicks or scratches 6 Reinstall the drain plug and torque to 14 17 ft lbs 1 93 2 35 kg m 7 Disconnect the lower oil delivery hose and remove the screen fitting 3 from the oil tank Clean and reinstall the fitting torquing to 25 ft lbs Reattach the oil line NOTE The fitting threads must be sealed with Loctitet PST 505 or PTFE seal tape Th...

Page 88: ...ain in the crankcase To drain remove the drain plug on the lower right side of the crankcase NOTE 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 If the sump is not drained add about 1 3...

Page 89: ...n 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 CAUTION If the ATV is left without oil in the system for extended periods the oil pump may lose its prime which could result in engine damage Alway...

Page 90: ... of engine oil Check to make sure the gasket is in good condition 12 Install the new filter and 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 2 quarts 1 9 l of Polaris Premium 4 synthetic oil 14 Place the gear selector in park and set the parking brake 15 Start the engine and let it idle for one to ...

Page 91: ...owing illustration to determine correct fluid levels NOTE When adding oil use Polaris Premium Synthetic Gearcase Lubricant See page 121 for the part numbers of Polaris products Gearcase Oil Fill Chart Model Oil Level A Capacity ATP 500 4x4 1 5 8 13 5 oz 400 ml ATP 330 4x4 1 5 8 13 5 oz 400 ml 1 Remove the fill plug 2 Remove the transmission drain plug 2 located on the bottom left hand side and dra...

Page 92: ...mbers of Polaris products With the ATV on a level surface remove the fill plug and check the oil level The level should be maintained 3 4 below the fill plug opening Front Gearcase Oil Change 1 Position the vehicle on a level surface and remove the fill plug 1 2 Place a drain pan beneath the gearcase remove the gearcase drain plug 2 and drain the oil 3 Clean and reinstall the drain plug Torque to ...

Page 93: ...f Polaris products Rear Gearcase Oil Change 1 Remove the drain plug 2 Catch and discard used oil properly 2 Clean the drain plug and inspect the o ring Replace with a new o ring if signs of tearing or fretting exist Reinstall the drain plug and torque to 40 in lbs 4 5 Nm 3 Remove the fill plug and add 18 oz 532 ml of recommended gear lube Maintain the oil level at the bottom of the fill hole 4 Cle...

Page 94: ...the radiator past the pressure cap and into the recovery bottle As engine coolant temperature decreases the contracting cooled coolant is drawn back up from the tank past the pressure cap and into the radiator NOTE Some coolant level drop on new machines is normal as the system is purging itself of trapped air Observe coolant levels and maintain as recommended by adding coolant to the recovery bot...

Page 95: ...nt 1 Remove the front cover 2 by placing your fingers under the front of the cover and pulling upward 2 Remove the pressure cap 3 Using a funnel slowly add coolant as necessary through the radiator filler neck 4 Replace the pressure cap and secure the front cover NOTE Use of a non standard pressure cap will not allow the recovery system to function properly Contact your dealer for the correct repl...

Page 96: ...m operation Use Polaris DOT 3 brake fluid Do not overfill 2 Check the brake system for fluid leaks 3 Check the brakes for excessive travel or spongy feel 4 Check the friction pads for wear damage and looseness 5 Check the security and surface condition of the disc NOTE Pads should be changed when worn to 3 64 1 cm or about the thickness of a U S dime Never store or use a partial bottle of brake fl...

Page 97: ...m which is about the thickness of a U S dime 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 Should the main system fail the rear brake can be activated by depressing the foot pedal on the inside of the right footrest NOTE Since the auxiliary brake is a rear brake only it will n...

Page 98: ... illustration 3 Tie an elastic string around the stands making sure the string just touches the side surface of the rear tires on each side of the vehicle and goes around the stands in front of the vehicle 2 4 Measure the distance from the string to the rim at the front and rear of the front rim 3 Rear measurement should be 1 16 1 8 2 to 3 cm more than the front measurement NOTE If you discover im...

Page 99: ...nd 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 rotating the adjuster 1 either clockwise or counterclockwise to increase or decrease spring tension NOTE Accessory springs are available through your Polaris dealer 1 ...

Page 100: ... part of the machine when turned fully to the left or right 3 Torque the front two bolts to 10 12 ft lbs 14 17 Nm then torque the rear two bolts A gap of up to 1 8 will remain at the rear bolts Improper adjustment of the handlebars or incorrect torquing of the adjuster block tightening bolts can cause limited steering or loosening of the handlebars resulting in loss of control and possible serious...

Page 101: ...laris 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 performance overheating or engine damage See your Polaris dealer for more information about jetting the ATV for conditions in your area If the engine idle speed is not satisfactory and all other conditio...

Page 102: ...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 throttle lever back and forth 3 Tighten the locknut and slide the boots over the cable adjuster until they touch at the midpoint of the adjuster 1 2 1 3 ...

Page 103: ...d 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 Then pull up on the side panel to disengage the front upper and lower tabs 4 To reinstall the side panel align the panel tabs with the slots on the front cab Push the panel upward and forward until t...

Page 104: ...V with worn tires improperly inflated tires non standard tires or improperly installed tires will affect vehicle handling and could cause an accident resulting in serious injury or death Maintain proper tire pressure as described on the decal on your ATV and in the specifications section of the owner s manual beginning on page 126 Always use original equipment size and type when replacing tires Ma...

Page 105: ...ion 2 Install the wheel nuts and finger tighten 3 Lower the vehicle to the ground 4 Torque the wheel nuts according to the wheel nut torque specifications chart NOTE All nuts that have a cotter pin installed must be serviced by an authorized Polaris dealer Wheel Nut Torque Specifications Check the wheel nut torques occasionally and when they ve been loosened for maintenance service Bolt Size Speci...

Page 106: ... WARNING Operating 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 cm or less Use of non standard size or type of tires or improper tire inflation may adversely affect vehicle maneuverability and cause loss of control resulting in serious injury or death Ma...

Page 107: ...tighten the clamp as filter damage could occur Breather Filter Hose ATP 500 4x4 1 Remove the clamps and pull the filter 1 out of the hoses NOTE It s not necessary to remove the lower hose from the engine 2 Inspect the filter for debris Blow gently through the filter in the direction of the arrow to check for clogging Replace if needed 3 Check the hoses for cracks deterioration abrasion or leaks Re...

Page 108: ...sses from the speedometer Unplug the indicator light harness and remove the pod cover 5 Unplug the headlamp from the wiring harness Be sure to pull on the connector not on the wiring 6 Grasp the bulb housing and turn counterclockwise to remove lamp 7 Apply dielectric grease to the light bulb socket before installing the new bulb 8 Reverse the previous steps to replace the lamp and reassemble the p...

Page 109: ...e depressing the tabs 5 Remove the screw in the back of the headlight pod 6 Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height 7 Start the engine and turn the headlight switch to high beam 8 Observe the headlight aim on the wall The most intense part of the headlight beam should be aimed two inches 5 1 cm below the mark placed on the w...

Page 110: ... indicator light harness and remove the pod cover 4 Unplug the headlamp from the wiring harness 5 Remove the o ring 1 from the headlight pivot pins 6 Pull the headlight housing up to release from the locking tabs 7 Lift the adjusting knob up to remove from the locking tabs 8 Carefully pull the assembly up and out of pod 9 Reverse the steps to install the new housing and reassemble the pod NOTE The...

Page 111: ...lacement If the taillight brakelight does not work the lamp may need to be replaced 1 Remove the two screws securing the lens assembly 2 Pivot the assembly outward 3 Turn the housing clockwise and remove the bulb 4 Install a new bulb and reinstall the taillight assembly ...

Page 112: ...hite A white insulator tip indicates overheating caused by use of an improper spark plug or incorrect carburetion adjustments 2 Wet Fouled The wet fouled insulator tip is black A damp oil film covers the firing end There may be a carbon layer over the entire nose Generally the electrodes are not worn General causes of fouling are excessive oil use of non recommended injection oil improper use of t...

Page 113: ...using the electric start 7 Dry the spark plug and reinstall or replace it with a new plug 8 Tighten the carburetor drain screw 9 Turn the fuel valve on 10 Attempt to start the engine If necessary repeat the drying procedure 11 Take the ATV to your dealer for service as soon as possible whether you succeed in starting it or not NOTE If water has been ingested into the PVT follow the procedure on pa...

Page 114: ...he vehicle is in PARK and repeat steps 3 and 4 until no more particles are expelled when the engine is revved 6 Stop the engine and allow the arrestor to cool Reinstall the arrestor plug and remove the outlet cover or plug 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 ...

Page 115: ...TV 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 remove the screw Be sure to reinstall the screw after draining the housing NOTE Do not open the crankcase drain unless the engine has ingested water Some engine oil will be lost if the crankcase drain is ...

Page 116: ...n also hinder vehicle performance Follow the battery charging instructions on page 114 before installing the battery 1 Ensure that the battery is fully charged 2 Set the battery in the battery holder 3 Connect and tighten the red positive cable first 4 Connect and tighten the black negative cable last 5 Reinstall the battery cover and attach the hold down strap 6 Verify that cables are properly ro...

Page 117: ...d battery is already filled with electrolyte and has been sealed and fully charged at the factory Do not ever pry the sealing strip off or add any other fluid to this battery The single most important thing about maintaining a sealed battery is to keep it fully charged Since the battery is sealed and the sealing strip cannot be removed you must use a voltmeter or multimeter to measure DC voltage F...

Page 118: ...rent charger standard 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 months 3 6 hours 50 75 12 0 12 5 volts Needs Charge 5 11 hours 25 50 11 5 12 0 volts Needs Charge At least 13 hours verify state of charge 0 25 11 5 volts or less Needs Charge At least 20 ho...

Page 119: ...nd 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 NOTE Grease all zerk fittings immediately after washing and allow th...

Page 120: ...e fuel system Allow 15 20 minutes of operation for the stabilizer to disperse through the fuel in the tank and carburetor Turn the fuel valve off and drain the carburetor bowl Oil and Filter Warm the engine and change the oil and filter Air Filter Air Box Inspect and clean or replace the pre cleaner and air filter Clean the air box and drain the sediment tube Breather Filter Inspect and clean or r...

Page 121: ...ing Oil perform the following procedure 1 Support the front end of the machine so the engine is level or tilted slightly rearward 2 Remove the spark plug s Rotate the piston to BDC and pour approximately two ounces of Polaris oil into the cylinder 3 Apply dielectric grease to the inside of the spark plug cap and install the cap onto the plug 4 Turn the engine over several times to ensure coverage ...

Page 122: ...he 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 Transporting the ATV Follow these procedures when transporting the vehicle 1 Turn off the engine and remove the key to prevent loss during transporting 2 Always plac...

Page 123: ...120 NOTES ...

Page 124: ...id 2 5 gal 2871654 Premium Drive Hub Fluid 8 oz Grease Specialized Lubricants 2871312 Grease Gun Kit Premium All Season 3 oz 2871322 Premium All Season Grease 3 oz cartridge 2871423 Premium All Season Grease 14 oz cartridge 2871460 Starter Drive Grease 2 oz 2871515 Premium U Joint Lube 3 oz 2871551 Premium U Joint Lube 14 oz 2871329 Dielectric Grease Nyogelt Coolant 2871323 60 40 Coolant gal 28715...

Page 125: ... 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 and carefully use fast aggressive throttle application to engage clutch WARNING Excessive throttle may cause loss of control and vehicle overturn Climbing over large ob jects from a stopped posi tion S...

Page 126: ...t 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 necessary No spark to spark plug Inspect plug s verify stop switch is on Crankcase filled with water or fuel Immediately see your Polaris dealer Overuse of choke Inspect clean and or replace spark plu...

Page 127: ...se ignition connections Check all connections and tighten Water present in fuel Replace with new fuel Low battery voltage Recharge battery to 12 5 VDC Kinked or plugged fuel vent line Inspect and replace Incorrect fuel Replace with recommended fuel Clogged air filter Inspect and clean or replace Reverse speed limiter malfunction See your Polaris dealer Electronic throttle control malfunction See y...

Page 128: ...es 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 12 5 VDC Incorrect fuel Replace with recommended fuel Clogged air filter Inspect and clean or replace Reverse speed limiter malfunction See your Polaris dealer Electronic throttle control malfunction...

Page 129: ... 46 in 116 8 cm Wheelbase 56 in 142 cm Ground Clearance 6 5 in 16 5 cm Dry Weight 719 lbs 326 kg Minimum Turning Radius 75 in 190 5 cm unloaded Engine Oil Capacity 1 9 qts 1 8 l Engine ES320PFE101 Displacement 329 cc Bore x Stroke 78 5 x 68 Pilot Jet 42 5 Main Jet 122 5 Needle Jet P 0M Jet Needle 4HB48 2 2nd clip Pilot Screw 2 Turns Out Alternator Output 200 w 5000 rpm Compression Ratio 9 2 1 Full...

Page 130: ...c Parking Brake Hydraulic lock all wheel Headlight Hi Low 30 watt Taillights Two 12v 2 88 watt Brake Light Two 12v 16 8 watt Instrument Cluster LCD Clutching and Jetting Charts Altitude AMBIENT TEMPERATURE Below 40 F Below 5 C 40 Fand above 5 C to above Meters Feet 0 1800 0 6000 127 5 122 5 1800 3700 6000 12000 120 115 Altitude Shift Weight Drive Clutch Spring Driven Clutch Spring Helix Meters Fee...

Page 131: ...47 in 119 4 cm Wheelbase 56 in 142 2 cm Ground Clearance 7 0 in 17 8 cm Dry Weight 738 lbs 335 kg Minimum Turning Radius 75 in 190 5 cm unloaded Engine Oil Capacity 2 qts 1 9 l Coolant Capacity 3 2 qts 3 02 l Engine EH500PLE200 Displacement 499 cc Bore x Stroke 92 x 75 Pilot Jet 40 Main Jet 155 Needle Jet Y 0 Jet Needle 6H25 94 3 Pilot Screw 2 Turns Out Alternator Output 250 w Compression Ratio 10...

Page 132: ...eadlight Single beam 60 watt Grill 2 single beam 27 watt Taillights Two 12v 2 88 watt Brake Light Two 12v 16 8 watt Instrument Cluster LCD Clutching and Jetting Charts Altitude AMBIENT TEMPERATURE Below 40 F Below 5 C 40 Fand above 5 C to above Meters Feet 0 1800 0 6000 160 155 1800 3700 6000 12000 152 5 147 5 Altitude Shift Weight Drive Clutch Spring Driven Clutch Spring Helix Meters Feet 0 1800 ...

Page 133: ...ES 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 tered structurally modified neglected improperly maintained used for racing or used for purposes other than for which it was manufact...

Page 134: ...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 dealer however you may use any Polaris Servicing Dealer to perform war ranty service Please work with your dealer to resolve any warranty issues Should your dealer require any additional assistance they will contact t...

Page 135: ...rized 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 will be authorized to per form the warranty repair If You Move If you move to another country be sure to contact Polaris Customer Assistance and the customs department of the destination country before...

Page 136: ...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 er s Manual POLARIS recommends that you retain all receipts covering mainten ance on your LSI engine but POLARIS cannot deny warranty solely for t...

Page 137: ...arranty period Any warranted part which is scheduled for replacement as required maintenance shall be warranted for the period of time up to the first scheduled replacement of that part This warranty shall apply only towards the repair replacement and or adjustment of the component parts listed below Emission Related Parts Covered Under This Warranty 1 Fuel Metering System i Carburetor and interna...

Page 138: ...ecified in the 2004 and later Owner s Manual d Repairs and diagnosis performed outside of an authorized dealer e Use of parts which are not authorized by POLARIS Maintenance Schedule The LSI engine owner is responsible for having all scheduled inspection and maintenance services performed at the intervals specified in the 2004 and later Owner s Manual and to retain records of these services as hav...

Page 139: ...or leaks at tank cap lines fuel filter pump and carburetor Replace lines every two years a Valve clearance 100 hrs 12 mos Inspect adjust Idle speed As Required 100 hrs Adjust Repair and Replacement of Emission Related Parts It is recommended that only LSI engine replacement parts which have been authorized and approved by POLARIS should be used in the performance of any warranty maintenance or rep...

Page 140: ...ough Water 67 68 Driving Uphill 63 Dumping Cargo 59 E Electrical Switches 37 38 EMISSION CONTROL SYSTEMS 74 Engaging the Front Gearcase 47 Engine Cooling System 91 92 Engine Fogging 118 E Engine Oil Check 82 Equipment Modifications 11 Exhaust Emission Control System 74 F FEATURES AND CONTROLS 37 52 Filter Systems 104 Front Gearcase Oil Change 89 Front Gearcase Oil Check 89 Front Wheel Hub Tighteni...

Page 141: ...ng 7 Side Panel Removal 100 Sidehilling 64 Spark Arrestor 111 Spark Plug Removal Replacement 109 Spark Plugs 109 SPECIFICATIONS 126 129 S Speedo Mode Switch 37 Starting a Cold Engine 55 Starting a Warm Engine 56 Starting the Engine 55 56 Steering Assembly 96 Stop Switch 38 Storage Tips 117 119 T TABLE OF CONTENTS 5 Tachometer 50 Taillight Brakelight Lamp 108 Throttle Cable Freeplay 99 Throttle Lev...

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