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136

INDEX

Accessories

. . . . . . . . . . . . . . . . . . . . . .

Adjustments

90-100

. . . . . . . . . . . . . . . . .

Age Restrictions

. . . . . . . . . . . . . . . . . . .

Air Filter

101

. . . . . . . . . . . . . . . . . . . . . . .

All Wheel Drive

44-45

. . . . . . . . . . . . . . .

Auxiliary Brake

39, 91

. . . . . . . . . . . . . . .

AWD

44-45

. . . . . . . . . . . . . . . . . . . . . . . .

Battery

110-112

. . . . . . . . . . . . . . . . . . . .

Battery Charging

111-112

. . . . . . . . . . . . .

Battery Installation

110

. . . . . . . . . . . . . . .

Battery Removal

110

. . . . . . . . . . . . . . . . .

Battery Storage

111, 116

. . . . . . . . . . . . . .

Belt Life

. . . . . . . . . . . . . . . . . . . . . . . .

Brake Fluid

. . . . . . . . . . . . . . . . . . . . . .

Brake Lever

. . . . . . . . . . . . . . . . . . . . .

Brakes

. . . . . . . . . . . . . . . . . . . . . . . . . .

Break-In Period

. . . . . . . . . . . . . . . . . .

Breather Filter/Hose (ATP 500)

101

. . . . .

Camber and Caster

. . . . . . . . . . . . . . . .

Carburetor

. . . . . . . . . . . . . . . . . . . . . .

Choke

. . . . . . . . . . . . . . . . . . . . . . . . . .

Chrome Wheel Care

117

. . . . . . . . . . . . . .

Cleaning and Storage

113-117

. . . . . . . . .

Cleaning the ATV

113

. . . . . . . . . . . . . . . .

Clutching (ATP 330)

125

. . . . . . . . . . . . .

Clutching (ATP 500)

127

. . . . . . . . . . . . .

Cold Weather Operation

. . . . . . . . . . . .

Coolant (ATP 500)

. . . . . . . . . . . . . . . .

Coolant Level (ATP 500)

. . . . . . . . . . .

Cooling System Operation (ATP 500)

Corrosion

117

. . . . . . . . . . . . . . . . . . . . . .

Crankcase Emission Control System

. .

Diagnostic Mode

49-50

. . . . . . . . . . . . . .

Driving Downhill

. . . . . . . . . . . . . . . . .

Driving in Reverse

. . . . . . . . . . . . . . . .

Driving on Slippery Surfaces

. . . . . . . .

Driving Over Obstacles

. . . . . . . . . . . .

Driving Procedures

. . . . . . . . . . . . . . . .

Driving Safely

58-69

. . . . . . . . . . . . . . . .

Driving Through Water

65-66

. . . . . . . . .

Driving Uphill

. . . . . . . . . . . . . . . . . . .

Dumping Cargo

. . . . . . . . . . . . . . . . . .

Electrical Switches

33-34

. . . . . . . . . . . . .

EMISSION CONTROL SYSTEMS

. . .

Engaging the Front Gearcase

. . . . . . . .

Engine Cooling System

88-89

. . . . . . . . .

Engine Fogging

115

. . . . . . . . . . . . . . . . .

Equipment Modifications

. . . . . . . . . . .

Exhaust Emission Control System

. . . .

FEATURES AND CONTROLS

33-50

. . .

Filter Systems

101

. . . . . . . . . . . . . . . . . . .

Front Gearcase Oil

. . . . . . . . . . . . . . . .

Front Wheel Hub Tightening

100

. . . . . . .

Fuel Filter

. . . . . . . . . . . . . . . . . . . . . . .

Fuel Safety

. . . . . . . . . . . . . . . . . . . . . .

Fuel Stabilizer

114

. . . . . . . . . . . . . . . . . .

Fuel Tank

. . . . . . . . . . . . . . . . . . . . . . .

Fuel Valve

. . . . . . . . . . . . . . . . . . . . . . .

Gear Selector

. . . . . . . . . . . . . . . . . . . .

Handlebars

. . . . . . . . . . . . . . . . . . . . . .

Hauling Cargo

55-57

. . . . . . . . . . . . . . . .

Headlight Adjustment, Lower

103

. . . . . .

Headlight Housing Replacement

104

. . . .

Headlight Lamp Replacement, Lower 103

Headlight Lamp Replacement, Pod

102

. .

Helmet

. . . . . . . . . . . . . . . . . . . . . . . . .

High Beam Adjustment

105

. . . . . . . . . . .

High Range

. . . . . . . . . . . . . . . . . . . . . .

Hour Meter

. . . . . . . . . . . . . . . . . . . . . .

Instrument Cluster

46-50

. . . . . . . . . . . . .

Jetting (ATP 330)

125

. . . . . . . . . . . . . . . .

Jetting (ATP 500)

127

. . . . . . . . . . . . . . . .

K-Turn

. . . . . . . . . . . . . . . . . . . . . . . . .

Light Switches

. . . . . . . . . . . . . . . . . . .

Lights

102-105

. . . . . . . . . . . . . . . . . . . . .

Load Distribution

. . . . . . . . . . . . . . . . .

Low Range

. . . . . . . . . . . . . . . . . . . . . .

Lubrication Recommendations

77-87

. . . .

Содержание ATP 330 4x4 2005

Страница 1: ......

Страница 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 DR...

Страница 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...

Страница 4: ......

Страница 5: ...some minor 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...

Страница 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...

Страница 7: ...4...

Страница 8: ...E 3 VEHICLE IDENTIFICATION NUMBERS 6 SAFETY 7 FEATURES AND CONTROLS 33 OPERATION 51 EMISSION CONTROL SYSTEMS 72 MAINTENANCE AND LUBRICATION 73 POLARIS PRODUCTS 119 TROUBLESHOOTING 120 SPECIFICATIONS 1...

Страница 9: ...aces provided 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 switc...

Страница 10: ...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...

Страница 11: ...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...

Страница 12: ...ncluding 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 jacke...

Страница 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 prope...

Страница 14: ...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...

Страница 15: ...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...

Страница 16: ...D Never 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 Carryin...

Страница 17: ...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 POTENTIAL HAZARD Operating...

Страница 18: ...ID 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 WARNING POTENTIAL HAZARD Oper...

Страница 19: ...ccident 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 WARNING POTENTIAL HAZARD Attempting wheelies jum...

Страница 20: ...ance procedures and schedules described in the owner s manual WARNING POTENTIAL HAZARD Removing hands from the handlebars or feet from the footrests during operation WHAT CAN HAPPEN Removing even one...

Страница 21: ...ert to changing terrain conditions WARNING POTENTIAL HAZARD Failure to use extra caution when operating on excessively rough slippery or loose terrain WHAT CAN HAPPEN Operating on excessively rough sl...

Страница 22: ...described in the owner s manual Practice turning at slow speeds before attempting to turn at faster speeds Never turn at excessive speed WARNING POTENTIAL HAZARD Operating on excessively steep hills...

Страница 23: ...the owner 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...

Страница 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 63 Always check the terrain carefully before descend...

Страница 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 64 Use extra caution when turning on any hill Avoid crossin...

Страница 26: ...rake gradually 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 wh...

Страница 27: ...res regain traction unexpectedly the ATV could overturn HOW TO AVOID THE HAZARD On slippery surfaces such as ice travel slowly and use extra caution to reduce the chance of skidding or sliding out of...

Страница 28: ...your weight 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 stoppin...

Страница 29: ...tallation 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 a...

Страница 30: ...ng systems WARNING Safe operation of this rider active vehicle requires good judgement and physical skills Persons with cognitive or physical disabilities who operate this vehicle have an increased ri...

Страница 31: ...our 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 pr...

Страница 32: ...your chance of severe injury or death NEVER operate this ATV if you are under age 16 7172559 Improper ATV use can result in SEVERE INJURY or DEATH ALWAYS USE AN APPROVED HELMET AND PROTECTIVE GEAR NE...

Страница 33: ...E 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 A...

Страница 34: ...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 dusty conditions Do not o...

Страница 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...

Страница 36: ...erse if the AWD 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 eng...

Страница 37: ...tch 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...

Страница 38: ...Throttle Lever Engine speed and vehicle movement are controlled by pressing the throttle lever The throttle lever 1 is spring loaded Engine speed returns to idle when the lever is released This ATV is...

Страница 39: ...the ATV with a spongy brake lever can result in loss of braking which could cause an accident Never operate the ATV with a spongy feeling brake lever Always test brake lever travel and master cylinde...

Страница 40: ...erious injury or death Maintain brake fluid at the recommended level Do not overfill NOTE When checking the fluid level the ATV must be on level ground with the handlebars straight If the fluid level...

Страница 41: ...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 Always place...

Страница 42: ...the auxiliary foot brake aggressively The auxiliary foot 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...

Страница 43: ...f main 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...

Страница 44: ...the area 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...

Страница 45: ...ears stop the vehicle and with the engine idling move the lever to the desired gear Apply the auxiliary brake before attempting to shift into high gear or park Whenever the ATV is left unattended alwa...

Страница 46: ...gh 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 38 2 Grasp the recoil starter rope handle...

Страница 47: ...of AWD in reverse if the AWD switch is on See page 33 When the switch is on TURF right position the differential is open allowing the inside wheel to rotate independently from the outside wheel during...

Страница 48: ...off If the switch is turned off while the front gearcase is moving it will not disengage until the rear wheels regain traction Engage the AWD switch before getting into conditions where front wheel dr...

Страница 49: ...ction that limits the ATV s speed to approximately 7 9 mph Refer to page 33 for additional information 1 Rider Information Center 2 Speedometer needle in addition to showing vehicle speed the needle f...

Страница 50: ...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...

Страница 51: ...raveled 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...

Страница 52: ...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 i...

Страница 53: ...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...

Страница 54: ...ours of use Use of any oils other than those recommended by Polaris may cause serious engine damage We recommend the use of Polaris Premium 4 Synthetic Oil for your 4 cycle engine 1 Fill the fuel tank...

Страница 55: ...spect condition and pressure 30 100 125 Wheels fasteners Inspect ensure fastener tightness 99 Frame nuts bolts fasteners Inspect ensure tightness Fuel and oil Ensure proper levels 80 83 Coolant level...

Страница 56: ...in The choke can be adjusted gradually depending on how much choke is needed for starting Be sure the choke is off during operation as excess fuel washing into the engine oil will increase wear on en...

Страница 57: ...e 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 a...

Страница 58: ...table operating condi tions which could result in loss of control of the vehicle Always be sure that the cargo bed is lowered and latched before mov ing the vehicle S EXTREME CAUTION MUST BE USED when...

Страница 59: ...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 Unintentiona...

Страница 60: ...always position the weight as far forward and as low as possible 5 Pull the cargo box release lever upward 6 Lift the front of the cargo box and dump the cargo 7 Lower the cargo box and make sure the...

Страница 61: ...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...

Страница 62: ...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...

Страница 63: ...the skid and shifting your body weight forward 4 Driving with AWD engaged can assist in controlling the vehicle in slippery areas CAUTION Severe damage to drive train may occur if the AWD is engaged...

Страница 64: ...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...

Страница 65: ...dehilling can be a dangerous type of driving 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 Lean into t...

Страница 66: ...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 s...

Страница 67: ...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...

Страница 68: ...ve 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 operatin...

Страница 69: ...e procedure on page 71 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 107 Have the vehicle ser...

Страница 70: ...n 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 Not...

Страница 71: ...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...

Страница 72: ...king 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 downhil...

Страница 73: ...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...

Страница 74: ...ntenance 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 housi...

Страница 75: ...se 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...

Страница 76: ...rage vehicle speed of approximately 10 miles per hour Vehicles subjected to severe use must be inspected and serviced more frequently Severe Use Definition S Frequent immersion in mud water or sand S...

Страница 77: ...able 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 Recoi...

Страница 78: ...ETC Switch 50 H 6 M 310 500 Inspect adjust lubricate replace if necessary J E Choke cable 50 H 6 M 310 500 Inspect adjust lubricate replace if necessary E Carburetor air intake ducts flange 50 H 6 M...

Страница 79: ...place as needed J E Ignition Timing 100 H 12 M 620 1000 Inspect Wiring 100 H 12 M 620 1000 Inspect for wear routing security apply dielectric grease to connectors subjected to water mud etc J Clutches...

Страница 80: ...F Use Polaris Premium U Joint Lube every 500 miles before long periods of storage or after pressure washing or submerging Item Lube Method Engine Polaris Premium 4 Synthetic 0W40 Add to proper level...

Страница 81: ...78 MAINTENANCE AND LUBRICATION Periodic Maintenance Record Use the following chart to record periodic maintenance Maintenance Interval Performed Servicing Date Servicing Dealer or Person Remarks...

Страница 82: ...sed film strength over the widest possible temperature range It resists viscosity and frictional breakdown in ambient temperatures from 40 F to 120 F Its exceptional frictional properties result in mo...

Страница 83: ...rfill Oil and Filter Change ATP 500 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 Always replace the oil...

Страница 84: ...screen fitting 3 from the oil tank Clean and reinstall the fitting torquing to 25 ft lbs 34 Nm Reattach the oil line NOTE The fitting threads must be sealed with Loctitet PST 505 or PTFE seal tape The...

Страница 85: ...p using the procedure below Then stop the engine and inspect for leaks 16 Re check the oil level on the dipstick and add oil as necessary to bring the level to the upper full mark on the dipstick 17 D...

Страница 86: ...ult in engine damage Always replace the oil and filter within a few hours of draining the oil Do not allow the vehicle to be without oil overnight 1 Obtain the correct oil filter and an adequate suppl...

Страница 87: ...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 R...

Страница 88: ...e of the machine behind the footwell 1 Position the ATV on a level surface 2 Remove the fill plug 3 Check the oil level 4 Add the recommended oil as needed 5 Reinstall the fill plug Torque to 14 ft lb...

Страница 89: ...ris products Oil Check 1 Position the vehicle on a level surface 2 Remove the fill plug 1 3 View the oil level and add the recommended oil as needed 4 Reinstall the fill plug Torque to 8 10 ft lbs 11...

Страница 90: ...3 View the oil level through the fill hole 4 Add the recommended oil as needed 5 Reinstall the fill plug Torque to 40 ft lbs 54 Nm Oil Change 1 Place a drain pan under the drain plug 2 2 Remove the dr...

Страница 91: ...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 bottle Coolant ATP 500...

Страница 92: ...e radiator coolant level is required only if the cooling system has been drained for maintenance and or repair However if the recovery bottle has run dry the level in the radiator should also be inspe...

Страница 93: ...operation 1 Always keep brake fluid at an adequate level see page 37 NOTE Under normal operation the diaphragm extends into the reservoir as fluid level drops If the fluid level is low and the diaphra...

Страница 94: ...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...

Страница 95: ...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...

Страница 96: ...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...

Страница 97: ...possible serious personal injury or death Follow the adjustment procedures exactly or see your Polaris dealer for service 1 Remove the instrument panel and locate the handlebar bolts 1 2 Loosen the fo...

Страница 98: ...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 performan...

Страница 99: ...nline 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 NOTE While adjusting freeplay be sure to flip the thr...

Страница 100: ...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...

Страница 101: ...ur ATV and in the specifications section of the owner s manual beginning on page 124 Always use original equipment size and type when replacing tires Make sure the wheels are installed properly Always...

Страница 102: ...on 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 rotatio...

Страница 103: ...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...

Страница 104: ...filter damage could occur Breather Filter Hose ATP 500 CAUTION Operation of your vehicle without a breather filter can cause engine damage Always reinstall the breather filter after removing for servi...

Страница 105: ...light Lamp Replacement ATP 500 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 headlig...

Страница 106: ...headlight harness clockwise B to secure Lower Headlight Adjustment 1 Loosen the nuts C that secure the lower headlamps Adjust the headlamps as needed 2 Tighten the nuts on the headlamps after adjustme...

Страница 107: ...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 l...

Страница 108: ...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...

Страница 109: ...Normal The normal insulator tip is gray tan or light 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 a...

Страница 110: ...Turn the fuel valve off 3 Remove the spark plug 4 Check the air box and drain if water is present 5 Loosen the carburetor drain screw 1 6 Turn the engine over several times using the electric start 7...

Страница 111: ...while it s inclined 1 Remove the arrestor clean out plug s 1 from the bottom of the muffler 2 Place the transmission in PARK and start the engine 3 Purge carbon from the system by momentarily revving...

Страница 112: ...V 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 remov...

Страница 113: ...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...

Страница 114: ...ady 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 main...

Страница 115: ...ent 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 ch...

Страница 116: ...d 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...

Страница 117: ...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...

Страница 118: ...ng 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 approximate...

Страница 119: ...e 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 ma...

Страница 120: ...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...

Страница 121: ...118 NOTES...

Страница 122: ...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...

Страница 123: ...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...

Страница 124: ...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...

Страница 125: ...e 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 repla...

Страница 126: ...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...

Страница 127: ...t 719 lbs 326 kg Minimum Turning Radius 75 in 190 5 cm unloaded Transmission Oil Capacity 13 5 oz 400 ml Front Gearcase Oil Capacity 5 oz 148 ml Rear Gearcase Oil Capacity 16 oz 473 ml Engine Oil Capa...

Страница 128: ...Parking Brake Hydraulic lock all wheel Headlight Hi Low 30 watt Taillights Two 12v 3 8 watt Brake Light Two 12 8v 37 watt Instrument Cluster LCD Jetting ATP 330 Altitude AMBIENT TEMPERATURE Below 40...

Страница 129: ...17 8 cm Dry Weight 738 lbs 335 kg Minimum Turning Radius 75 in 190 5 cm unloaded Transmission Oil Capacity 13 5 oz 400 ml Front Gearcase Oil Capacity 5 oz 148 ml Rear Gearcase Oil Capacity 16 oz 473...

Страница 130: ...k all wheel Headlight Single beam 60 watt Grill 2 single beam 27 watt Taillights Two 12v 3 8 watt Brake Light Two 12 8v 37 watt Instrument Cluster LCD Jetting ATP 500 Altitude AMBIENT TEMPERATURE Belo...

Страница 131: ...S 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 ha...

Страница 132: ...our 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...

Страница 133: ...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...

Страница 134: ...s 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 y...

Страница 135: ...rranty 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 s...

Страница 136: ...ecommended fuel as specified 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 Sched...

Страница 137: ...Switch 50 H 6 M 310 500 Inspect adjust lubricate replace if necessary J E Choke cable 50 H 6 M 310 500 Inspect adjust lubricate replace if necessary E Carburetor air intake ducts flange 50 H 6 M 310...

Страница 138: ...t parts will be provided at no charge if the part is still under warranty How to File a Warranty Claim Where to Get Warranty Service All repairs qualifying under this Limited Warranty must be performe...

Страница 139: ...urfaces 60 Driving Over Obstacles 67 Driving Procedures 58 Driving Safely 58 69 Driving Through Water 65 66 Driving Uphill 61 Dumping Cargo 57 E Electrical Switches 33 34 EMISSION CONTROL SYSTEMS 72 E...

Страница 140: ...ion Center 47 50 S Safe Riding Gear 32 SAFETY 7 32 Safety Decals and Locations 28 31 S Safety Training 7 Side Panel Removal 97 Sidehilling 62 Spark Arrestor 72 108 Spark Plug Removal and Replacement 1...

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