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.
The engine exhaust from this
product contains chemicals known
to cause cancer, birth defects or
other reproductive harm.
WARNING
2
Copyright 2004 Polaris Sales Inc. All information contained within this publication is
based on the latest product information at the time of publication. Due to constant
improvements in the design and quality of production components, some minor
discrepancies may result between the actual vehicle and the information presented in this
publication. Depictions and/or procedures in this publication are intended for reference
use only. No liability can be accepted for omissions or inaccuracies. Any reprinting or
reuse of the depictions and/or procedures contained within, whether whole or in part, is
expressly prohibited.
Printed in U.S.A.
2005 Magnum 330 2X4/4X4 Owner’s Manual P/N 9919487
3
WELCOME
Thank you for purchasing a Polaris vehicle, and welcome to our
world-wide family of Polaris owners. We proudly produce an exciting
line of utility and recreational products.
Polaris Recreational and Utility Vehicles
S Snowmobiles
S All-terrain vehicles (ATVs)
S Watercraft
S Victory motorcycles
S RANGER utility vehicles
We believe Polaris sets a standard of excellence for all utility and
recreational vehicles manufactured in the world today. Many years of
experience have gone into the engineering, design, and development of
your Polaris vehicle, making it the finest machine we’ve ever
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.
Your Polaris dealer knows your vehicle best and is interested in your
total satisfaction. Be sure to return to your dealership for all of your
service needs during, and after, the warranty period.
We also take great pride in our Parts Apparel and Accessories (PAA)
products, available through our online store at www.purepolaris.com.
Have your accessories and clothing delivered right to your door!
POLARIS and POLARIS THE WAY OUT are registered trademarks of
Polaris Industries Inc.
4
5
TABLE OF CONTENTS
WELCOME 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 115. . . . . . . . . . . . . . . . . . . . .
WARRANTY 119. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INDEX 122. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6
7
VEHICLE IDENTIFICATION NUMBERS
Record your ATV’s identification numbers and key number in the
spaces 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 switch
must be replaced.
Vehicle Model Number:
Frame VIN (1):
Engine Serial Number:
(right front side of engine crankcase)
Key Number (2):
1
31XX
2
8
SAFETY
Operator Safety
WARNING
Failure to follow the warnings contained in this manual can result
in serious injury or death.
A Polaris ATV is not a toy and can be hazardous to operate. This
vehicle handles differently than other vehicles, such as
motorcycles and cars. A collision or rollover can occur quickly,
even during routine maneuvers like turning, or driving on hills or
over obstacles, if you fail to take proper precautions.
Read and understand your owner’s manual and all warnings
before operating a Polaris ATV.
Age Restrictions
This vehicle is an ADULT VEHICLE ONLY. Operation is prohibited
for anyone under 16 years of age.
Know Your Vehicle
As the operator of the vehicle, you are responsible for your personal
safety, the safety of others, and the protection of our environment.
Read 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 dealer offered a hands-on
safety training course that covers all aspects of vehicle safety. You were
also provided with printed materials that explain safe operating
procedures. You should review this information on a regular basis.
If you purchased a used Polaris ATV from a party other than a Polaris
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 that all critical
components on your vehicle are thoroughly inspected at specific
intervals.
9
SAFETY
Operator Safety
The following signal words and symbols appear throughout this
manual and on your ATV. Your safety is involved when these words
and symbols are used. Become familiar with their meanings before
reading the manual.
The safety alert symbol, on your vehicle or in this manual, alerts
you to the potential for personal injury.
WARNING
The safety alert warning indicates a potential hazard that may
result in serious injury or death.
CAUTION
The safety alert caution indicates a potential hazard that may
result in minor personal injury or damage to the vehicle.
CAUTION
A caution indicates a situation that may result in damage to the
vehicle.
NOTE:
A note will alert you to important information or instructions.
10
SAFETY
Operator Safety
WARNING
Serious injury or death can result if you do not follow these
instructions and procedures, which are outlined in further detail
within your owner’s manual.
S Read this manual and all labels carefully, and follow the operating
procedures described.
S Never operate an ATV without proper instruction. Take a training
course. Beginners should receive training from a certified instructor.
Contact an authorized Polaris ATV dealer or call Polaris at
1-800-342-3764 to find out about the training courses nearest you.
S Never allow anyone under 16 years of age to operate this ATV.
S Never permit a guest to operate the ATV unless the guest has read
this manual and all product labels and has completed a certified safe-
ty training course.
S Always avoid operating an ATV on paved surfaces, including side-
walks, driveways, parking lots, and streets.
S Never operate an ATV on a public street, road or highway, 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 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 follow the inspection and maintenance
procedures and schedules outlined in your owner’s manual.
S Always keep both hands on the handlebars and both feet on the foot-
rests of the ATV during operation.
S Always travel slowly and use extra caution when operating on unfa-
miliar terrain. Be alert to changing terrain conditions.
S Never operate on excessively rough, slippery, or loose terrain.
S Always follow proper turning procedures as described in this manu-
al. Practice turning at low speeds before attempting to turn at faster
speeds. Do not turn at excessive speeds.
11
SAFETY
Operator Safety
S Always have the ATV inspected by an authorized Polaris dealer if
it’s been involved in an accident.
S Never operate on hills too steep for the ATV or for your abilities.
Practice on smaller hills before attempting larger hills.
S Always follow proper procedures for climbing hills. Check the ter-
rain carefully before ascend a hill. Never climb hills with excessive-
ly slippery or loose surfaces. Shift your weight forward. Never open
the throttle suddenly or make sudden gear changes. Never go over
the top of a hill at high speed.
S Always follow proper procedures for going downhill and for braking
on hills. Check the terrain carefully before you start down a hill.
Shift your weight backward. Never go down a hill at high speed.
Avoid going down a hill at an angle, which would cause the vehicle
to lean sharply to one side. Travel straight down the hill when pos-
sible.
S Always follow proper procedures for crossing the side of a hill.
Avoid hills with excessively slippery or loose surfaces. Shift your
weight to the uphill side of the ATV. Never 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 braking described in this manual. Always dismount on the
uphill side, or to either side if the ATV is pointed straight uphill.
Turn the ATV around and remount following the procedure de-
scribed in this manual.
S Always check for obstacles before operating in a new area. Never
attempt to operate over large obstacles, such as rocks or fallen trees.
Always follow proper procedures when operating over obstacles as
described in this manual.
S Always be careful of skidding or sliding. On slippery surfaces like
ice, travel slowly and use extra caution to reduce the chance of skid-
ding or sliding out of control.
S Avoid operating the ATV through deep or fast-flowing water. If it’s
unavoidable, travel slowly, balance your weight carefully, avoid sud-
den movements, and maintain a slow and steady forward motion. Do
not make sudden turns or stops, and do not make sudden throttle
changes.
12
SAFETY
Operator Safety
S Wet brakes may have reduced stopping ability. Test your brakes after
leaving water. If necessary, apply them lightly several times to allow
friction to dry out the pads.
S Always check for obstacles or people behind the ATV before operat-
ing in reverse. When it’s safe to proceed in reverse, move slowly and
avoid turning at sharp angles.
S Always use the size and type of tires specified for your ATV, and
always maintain tire pressure as recommended.
S Never modify an ATV through improper installation or use of acces-
sories.
S Never exceed the stated load capacity for your ATV. Cargo must be
properly distributed and securely attached. Reduce speed and follow
the instructions in this manual for carrying cargo or towing. Allow a
greater distance for braking.
S Always remove the ignition key when the vehicle is not in use to
prevent unauthorized 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 concerned for the safety of our customers and for the general
public. Therefore, we strongly recommend that consumers do not
install on a Polaris ATV any equipment that may increase the speed or
power of the vehicle, or make any other modifications to the vehicle
for these purposes. Any modifications to the original equipment of the
vehicle create a substantial safety hazard and increase the risk of bodily
injury.
The warranty on your Polaris ATV is terminated if any equipment has
been added to the vehicle, or if any modifications have been made to
the vehicle, that increase its speed or power.
NOTE: The addition of certain accessories, including (but not limited
to) mowers, blades, tires, sprayers, or large racks, may
change the handling characteristics of the vehicle. Use only
Polaris-approved accessories, and familiarize yourself with
their function and effect on the vehicle.
13
SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD
Operating this ATV without proper instruction.
WHAT CAN HAPPEN
The risk of an accident is greatly increased if the operator does
not know how to operate the ATV properly in different situations
and on different types of terrain.
HOW TO AVOID THE HAZARD
Beginning and inexperienced operators should complete the
certified training course offered by Polaris. Operators should
regularly practice the skills learned in the course 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 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 recommended age group
for operating some ATVs, he/she may not have the skills,
abilities, or judgment needed to operate an ATV safely and could
be susceptible to accident or injury.
HOW TO AVOID THE HAZARD
No one under the age of 16 should operate a Polaris ATV.
14
SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD
Carrying a passenger on an
ATV.
WHAT CAN HAPPEN
Carrying a passenger
greatly reduces the
operator’s ability to balance
and control the ATV, which
could cause an accident
and injury to the
operator and/or passenger.
HOW TO AVOID THE HAZARD
Never carry a passenger. 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
Operating an ATV
on paved
surfaces, including
sidewalks, paths,
parking lots, and
driveways.
WHAT CAN HAPPEN
ATV tires are designed for
off-road use. Operating on
paved surfaces may
seriously affect the handling and
control of the ATV and could result in loss of control, accident,
and/or injury.
HOW TO AVOID THE HAZARD
Avoid operating the ATV on pavement. If it’s unavoidable, travel
slowly and avoid sudden turns or stops.
15
SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD
Operating this ATV on
public streets, roads or
highways.
WHAT CAN HAPPEN
The ATV could collide
with another vehicle.
HOW TO AVOID THE HAZARD
Never operate the ATV on any
public street, road or highway,
including dirt and gravel roads. In many states
it’s illegal to operate ATVs on public streets, roads and highways.
WARNING
POTENTIAL HAZARD
Operating this ATV without
wearing an approved
helmet, eye protection and
protective clothing.
WHAT CAN HAPPEN
Operating an ATV without
an approved helmet
increases the risk of a
severe head injury or
death in the event of an
accident.
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.
16
SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD
Operating the ATV after consuming
alcohol or drugs.
WHAT CAN HAPPEN
Consumption of alcohol and/or drugs
could seriously affect operator
judgment. Reaction time may be slower
and operator balance and perception
could be affected.
Consuming alcohol and/or drugs before
or while operating an ATV could result in
an accident causing severe injury or death.
HOW TO AVOID THE HAZARD
Never consume alcohol or drugs before or while operating an
ATV.
WARNING
POTENTIAL HAZARD
Operating the ATV at excessive speeds.
WHAT CAN HAPPEN
Excessive speed increases the operator’s chance of losing
control of the ATV, which can result in an accident.
HOW TO AVOID THE HAZARD
Always operate the ATV at a speed that’s proper for the terrain,
visibility and operating conditions, and your experience.
17
SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD
Attempting wheelies, jumps
and other stunts.
WHAT CAN HAPPEN
Attempting stunts increases
the chance of an accident,
including an overturn.
HOW TO AVOID THE
HAZARD
Never attempt wheelies,
jumps, or other stunts. Avoid
exhibition driving.
WARNING
POTENTIAL HAZARD
Failure to inspect the ATV before operating.
Failure to properly maintain the ATV.
WHAT CAN HAPPEN
Poor maintenance increases the possibility of an accident or
equipment damage.
HOW TO AVOID THE HAZARD
Always inspect your ATV before each use to make sure it’s in
safe operating condition.
Always follow the inspection and maintenance procedures and
schedules described in the owner’s manual.
18
SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD
Removing hands from the handlebars or feet from the footrests
during operation.
WHAT CAN HAPPEN
Removing even one hand or foot can reduce ability to control the
vehicle or could cause loss of balance and ejection from the ATV.
If the operator’s foot is not firmly planted on the footrest, it could
come into contact with the rear wheels and lead to accident or
injury.
HOW TO AVOID THE HAZARD
Always keep both hands on the handlebars and both feet on the
footrests of the ATV during operation.
WARNING
POTENTIAL HAZARD
Failure to use extra
caution when operating
the ATV on unfamiliar
terrain.
WHAT CAN HAPPEN
Unfamiliar terrain may
contain hidden rocks,
bumps, or holes that could
cause loss of control or
overturn.
HOW TO AVOID THE HAZARD
Travel slowly and use extra caution when operating on unfamiliar
terrain. Always be alert to changing terrain conditions.
19
SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD
Failure to use extra
caution when operating on
excessively rough,
slippery or loose terrain.
WHAT CAN HAPPEN
Operating on excessively
rough, slippery or loose
terrain could cause loss of
traction or loss of control,
which could result in an
accident or overturn.
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
POTENTIAL HAZARD
Turning improperly.
WHAT CAN HAPPEN
Improper turns could cause loss of control and lead to a collision
or overturn.
HOW TO AVOID THE HAZARD
Always follow proper procedures for turning as described in the
owner’s manual.
Practice turning at slow speeds before attempting to turn at faster
speeds.
Never turn at excessive speed.
20
SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD
Operating on excessively steep hills.
WHAT CAN HAPPEN
The vehicle may overturn.
HOW TO AVOID THE HAZARD
Never operate on hills too steep for the ATV or for your abilities.
Never operate the ATV on hills steeper than 25_.
Practice on smaller hills before attempting large hills.
WARNING
POTENTIAL HAZARD
Climbing hills improperly.
WHAT CAN HAPPEN
Improper hill climbing could
cause loss of control or
overturn.
HOW TO AVOID THE
HAZARD
Always follow proper
procedures for climbing
hills as described in the
owner’s manual.
Always check the terrain
carefully before ascending
any hill.
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 could be on the other
side of the hill.
21
SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD
Traveling downhill
improperly.
WHAT CAN HAPPEN
Improperly descending a hill
could cause loss of control
or overturn.
HOW TO AVOID THE
HAZARD
Always follow proper
procedures for traveling
down hills as described in
the owner’s manual. NOTE:
A special technique is
required when braking while
traveling downhill. See page 61.
Always check the terrain carefully before 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
when possible.
22
SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD
Improperly crossing hills and
turning on hills.
WHAT CAN HAPPEN
Improperly crossing or
turning as hills could cause
loss of control or overturn.
HOW TO AVOID THE
HAZARD
Never attempt to turn the
ATV around on any hill until
you’ve mastered the turning
technique (on level ground)
as described in the owner’s
manual. See page 62. 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 uphill side of the ATV.
23
SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD
Stalling, rolling backwards
or improperly dismounting
while climbing a hill.
WHAT CAN HAPPEN
The vehicle could overturn.
HOW TO AVOID THE
HAZARD
Maintain steady speed
when climbing a hill.
If all forward speed is lost:
Keep your weight uphill.
Apply the single lever brake gradually.
When 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 while rolling backwards.
Apply the single-lever brake gradually.
When fully stopped, apply the auxiliary 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 procedure
described in the owner’s manual. See page 62.
24
SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD
Improperly operating over obstacles.
WHAT CAN HAPPEN
Operating over obstacles could cause loss of control or overturn.
HOW TO AVOID THE HAZARD
Before operating in a new area, check for obstacles.
Avoid operating over large obstacles such as rocks and fallen
trees when possible. If unavoidable, use extreme caution and
always follow proper procedures as outlined in the owner’s
manual.
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
On slippery surfaces such as ice, travel slowly and use extra
caution to reduce the chance of skidding or sliding out of control.
WARNING
POTENTIAL HAZARD
Improperly operating in reverse.
WHAT CAN HAPPEN
The ATV could collide with an obstacle or person, resulting in
severe injury.
HOW TO AVOID THE HAZARD
Before shifting into reverse gear, always check for obstacles or
people behind the ATV. When it’s safe to proceed, back slowly.
25
SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD
Operating the ATV through deep or fast-flowing water.
WHAT CAN HAPPEN
Tires may float, causing loss of traction and loss of control, which
could lead to an accident or overturn.
HOW TO AVOID THE HAZARD
Avoid operating the ATV through deep or fast-flowing water. If it’s
unavoidable to enter water that exceeds the recommended
maximum depth (see page 63), travel slowly, balance 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 stopping ability. Always test the
brakes after leaving water. If necessary, apply them several
times to let friction dry out the pads.
WARNING
POTENTIAL HAZARD
Operating this ATV with improper tires, or with improper or
uneven tire pressure.
WHAT CAN HAPPEN
Use of improper tires, or operation of the ATV with improper or
uneven tire pressure, could cause loss of control or accident.
HOW TO AVOID THE HAZARD
Always use the size and type of tires specified for the ATV.
Always maintain proper tire pressure as specified.
26
SAFETY
Operator Safety
WARNING
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. or equivalent components
designed for use on this ATV and should be installed and used
according to approved instructions. See your authorized Polaris
ATV dealer for more 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 control or an accident.
HOW TO AVOID THE HAZARD
Never exceed the stated load capacity for this ATV.
Cargo should be properly distributed and securely attached.
Reduce speed when carrying cargo 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 56.
WARNING
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.
27
SAFETY
Operator Safety
WARNING
Leaving the keys in the ignition can lead to unauthorized use of
the vehicle resulting in serious injury or death. Always remove
the ignition key when the vehicle is not in use.
WARNING
After any overturn or accident, have a qualified service dealer
inspect the entire vehicle for possible damage, including (but not
limited to) brakes, throttle and steering systems.
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 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.
28
SAFETY
Safety Decals and Locations
Warning decals have been placed on the ATV for your protection. Read
and follow the instructions of the decals and other warnings on the
ATV carefully. If any of the decals shown in 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 replacement. Replacement safety decals are provided by
Polaris at no charge. The part number is printed on the decal.
NOTE: Your ATV may not have all of the decals shown. Decals vary
depending on the model.
A
B
C
D
E
F
G
E
H
29
SAFETY
Safety Decals and Locations
Location A
Location B
Location C
Location D
Location E (on models with racks)
Location E (on models with storage box)
Operating this ATV if you are under
the age of 16 increases your chance
of severe injury or death.
NEVER operate this ATV if you are
under age 16.
7172559
WARNING
WARNING
7172561
S Moving parts hazard under belt-clutch guard. To
prevent serious injury, do not operate vehicle
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
7172566
WARNING
S DO NOT TOW FROM RACK OR BUMPER.
Vehicle damage or tipover may result causing severe injury
or death. Tow only from tow hooks or hitch.
S Max Rack Loads: Front 90 lbs. (41 kg) Rear 180 lbs. (82 kg)
7172572
WARNING
DO NOT TOW FROM RACK OR BUMPER. Vehicle damage or tipover may result causing severe injury or
death. Tow only from tow hooks or hitch. Max. combined Front Rack and container Load 90 lbs. (41 kg)
7172569
WARNING
30
SAFETY
Safety Decals and Locations
IMPROPER TIRE PRESSURE OR OVERLOADING can cause loss of
control resulting in SEVERE INJURY OR DEATH.
TIRE PRESSURE (PSI): FRONT ___ REAR ___
MAXIMUM WEIGHT CAPACITY (Gross Vehicle Weight)
INCLUDING MACHINE, DRIVER AND CARGO IS ____ LBS.
Reduce speed and allow greater distance for braking when carrying
cargo. Overloading or carrying tall, off-center, or unsecured loads
will increase your risk of losing control. Loads should be centered,
carried as low as possible, and firmly secured to the racks. with
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.
Read Owner’s Manual for more detailed loading information
Location F
Location G
(Under Seat)
WARNING
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 operate vehicle without
pre-filter.
ATTENTION
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).
31
SAFETY
Safety Decals and Locations
Location H
ALL WHEEL
DRIVE
SWITCH
Do not push switch to
engage AWD if the rear
wheels are spinning.
This may cause severe
drive shaft and clutch
damage.
See your Owner’s
Manual.
7079780
Reverse Speed is
limited.
Reverse override is
controlled by the
override switch.
See your Owner’s
Manual.
OVERRIDE
SWITCH
7079906
2WD Models
MANUFACTURED
BY: POLARIS IND. INC.
DATE:
VIN:
THIS VEHICLE IS AN ALL TERRAIN VEHICLE AND IS NOT
INTENDED FOR USE ON PUBLIC ROADS.
7171492
CE VÉHICULE EST UN VÉHICULE TOUT TERRAIN QUI N EST
PAS DESTINÉ À ÊTRE UTILISÉ SUR LES CHEMINS PUBLICS.
Canadian Certification Decal
Applicable AWD Models
Improper ATV use can result in SEVERE INJURY or DEATH
ALWAYS USE
AN APPROVED
HELMET AND
PROTECTIVE
GEAR
NEVER USE
ON PUBLIC
ROADS
NEVER CARRY
PASSENGERS
NEVER USE
WITH DRUGS
OR ALCOHOL
NEVER operate:
ALWAYS:
7172560
WARNING
7172564
Pushing reverse
override button
may cause
sudden increases
in power and
traction if too
much throttle is
applied. Loss of
control or forward
flipover may
result, especially
in AWD. See
Owner’s Manual.
WARNING
AWD Models
32
SAFETY
Safe Riding Gear
Always wear clothing suited to the type of riding. ATV riding requires
special protective clothing for comfort and to reduce the chance of
injury.
1. Helmet
Your helmet is the most important piece
of protective gear for safe riding. A
helmet can prevent a severe head injury.
Select an approved helmet that meets or
exceeds your state’s safety standards
and bears either the Department of
Transportation (DOT) label, the
American National Standards Institute
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. Boots
The best footwear is a pair of strong over-the-calf boots with heels, like
moto-cross boots.
5. Clothing
Always wear long sleeves and long pants to protect arms and legs.
Riding pants with kneepads and a jersey with shoulder pads provide
the best protection.
1
2
3
4
5
33
SAFETY
Fuel Safety
WARNING
Gasoline is highly flammable and explosive under certain
conditions.
S Always exercise extreme caution whenever handling gasoline.
S Always refuel with the engine stopped, and outdoors or in a well
ventilated area.
S Do not smoke or allow open flames or sparks in or near the
area where refueling is performed or where gasoline is stored.
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
consciousness or death in a short time.
S Turn the fuel valve off whenever the ATV is stored or parked.
WARNING
The engine exhaust from this product contains chemicals known
to cause cancer, birth defects or other reproductive harm.
Operate this vehicle only outdoors or in well-ventilated areas.
34
FEATURES AND CONTROLS
Electrical Switches
WARNING
Operating the ATV on streets or roads, especially in darkness,
could result in an accident and serious injury or death.
Your ATV is not equipped with highway-approved lights. It’s
designed for and must be used for off-road use only. Use caution
and drive at reduced speeds in conditions of reduced visibility
such as fog, rain and darkness.
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, resulting in severe injury or death. Do not activate
the override switch while the throttle is open.
2. Override Switch (Reverse Speed Limiter) - This vehicle is
equipped with a reverse speed limiter system. To gain additional power
while backing, depress the override switch.
NOTE: The override switch also allows activation of AWD in reverse
if the AWD switch is on.
1
2
3
4
5
35
FEATURES AND CONTROLS
Electrical Switches
3. Engine Stop Switch - The engine will not start
or run when the switch is in the OFF position. Its
purpose is to provide the operator with a quick
means of engine shutdown in case of an emergency.
To stop the engine, slide the stop switch either right
or left to the OFF position.
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. 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.
5. All Wheel Drive Switch (AWD Models) Select AWD models do
not have an AWD switch. These models are continuously in AWD.
3
36
FEATURES AND CONTROLS
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 equipped with
Polaris Electronic Throttle Control
(ETC), which is designed to reduce the risk of a
frozen or stuck throttle. If the throttle cable should stick in an open
position when the operator releases the throttle lever, the engine will
stop, and power to the rear wheels will cease.
WARNING
Operating an ATV with sticking 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 your dealer for service if throttle
problems arise.
Failure to check or maintain proper operation of the throttle
system can result in an accident if the throttle lever sticks during
operation. Always check the lever for free movement and return
before starting the engine. Also check occasionally during
operation.
WARNING
The Electronic 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.
1
37
FEATURES AND CONTROLS
Brakes
Master Cylinder
Check the brake fluid level in
the master cylinder before each
use of the ATV. The master
cylinder (1) is located on the left
handlebar.
View the fluid level through the
indicator window (2) on the top of
the master cylinder. This eye will
appear dark when the fluid level is
full. When fluid is low, the eye will
be clear.
NOTE: When checking the fluid level, position the ATV on level
ground with the handlebars turned so the top of the 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 brake
lock-up, which could result in serious injury or death. Maintain
brake fluid at the recommended level. Do not overfill.
WARNING
After opening a bottle of brake fluid, always discard any unused
portion. Never store or use a partial bottle. Brake fluid is
hygroscopic, meaning it rapidly absorbs moisture from the air.
The moisture causes the boiling temperature of the brake fluid to
drop, which can lead to early brake fade and the possibility of
accident or severe injury.
1
2
38
FEATURES AND CONTROLS
Brake Lever
The front and rear brakes are applied
by squeezing the brake lever (1)
toward the handlebar. The front and
rear brakes are hydraulically activated
disc type brakes that are activated by
only one lever.
Always test brake lever travel and
master cylinder fluid level before
riding. When squeezed, the lever should feel firm. Any sponginess
would indicate a possible fluid leak or low master cylinder fluid level,
which must be corrected before riding. Contact your dealer for proper
diagnosis and repairs.
WARNING
Operating 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.
1
39
FEATURES AND CONTROLS
Parking Brake
WARNING
Operating the ATV while the parking brake is engaged could
result in an accident and serious injury or death. Always check to
be sure the parking brake is disengaged before operating.
Setting the Parking Brake
1. Squeeze and release the brake
lever (1) two or three times, then
squeeze and hold.
2. Push the park brake lock (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 brake may relax if left on for a long period of time. Al-
ways block the wheels to prevent rolling.
S Always block the wheels on the downhill side of the ATV if leaving
it parked on a hill. Another option is to park the ATV in a sidehill
position.
S Never depend on the parking brake alone if the ATV is parked on a
hill. Always block the wheels to prevent rolling.
1
2
40
FEATURES AND CONTROLS
Auxiliary Brake
WARNING
Aggressively applying the auxiliary brake when backing down a
hill may cause rear tipover, which could result in serious injury or
death.
Use caution when applying the auxiliary brake. Do not
aggressively apply the auxiliary brake when going forward. The
rear wheels may skid and slide sideways, causing loss of control
and serious injury or death.
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 if the main
system becomes inoperative.
If the rear wheels slide while
using the auxiliary brake, reduce
brake pedal pressure to brake the
rear wheels without skidding.
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.
1
41
FEATURES AND CONTROLS
Choke
The choke assists in starting a cold engine. Refer to the engine starting
procedure on page 52 for correct choke and throttle settings during
starting.
Fuel Valve
The fuel valve (1) is located on the left side of
the vehicle on the side panel. It has three
positions:
OFF: For vehicle storage and when transporting.
ON: For normal operation.
RES: For reserve supply if 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 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. Refer to the
specifications section beginning on page 109 for tank capacity.
Fuel Filter
The in-line fuel filter should be replaced by your dealer after every 100
hours of operation, or annually. Do not attempt to clean the fuel filter.
2
1
42
FEATURES AND CONTROLS
Automatic Transmission Gear Selector
The transmission gear selector (1) is located on the right side of the
vehicle.
H: High Gear
N: Neutral
L: Low Gear
R: Reverse
P: Park
To shift into HIGH or PARK,
you must first apply the
auxiliary brake to activate the
high/park lock-out mechanism.
When shifting out of HIGH or PARK, it’s not necessary to apply the
brake.
CAUTION
Shifting gears with the engine speed above 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
shifting into HIGH or PARK.
Whenever the ATV is left unattended, always place the transmission in
PARK and lock the parking brake.
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 belt.
1
H
N
P
L
R
43
FEATURES AND CONTROLS
Recoil Starter
If the battery has been drained or
damaged and cannot start the
engine, use of the recoil starter (1)
will allow vehicle operation until
repairs can be made. The recoil
starter is located on the right side
of the machine.
Polaris 4-cycle engines are
equipped with automatic
decompressors. This makes
recoil starting possible by
reducing the amount of compression during starting. The
decompressor senses when the engine is spinning fast enough to start
and restores compression when running.
1. Position the vehicle on a level surface, place the transmission in
PARK and lock the parking brake (see page 39).
2. Make sure the engine stop switch is set to RUN and the main key
switch is in the 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 stroke will be a “compression stroke” and will
make the rope harder to pull. When a compression stroke is
found, continue pulling the rope just until the engine rolls past
the stroke, then stop pulling immediately.
4. Allow the recoil rope to rewind into the recoil assembly, then pull
the rope abruptly and forcefully to start the engine.
5. Repeat steps 3-4 if necessary.
CAUTION
Extending the recoil starter rope until it stops can cause damage
to the recoil assembly. Do not extend the starter rope so far that
it stops.
If the starter rope handle is not seated properly, water may enter
the recoil housing and damage components. Make sure the
handle is fully seated on the recoil housing, especially when
traveling in wet areas.
1
2
44
FEATURES AND CONTROLS
All Wheel Drive System (Domestic Models)
Polaris 4 wheel drive domestic
model ATVs are equipped with a
unique, Polaris exclusive, All Wheel
Drive (AWD) System activated by a
switch (1) on the right handlebar.
Engage the AWD when the rear
wheels lose traction.
When the AWD switch is off, the
ATV is in 2 wheel drive at all times.
When the switch is on, the ATV is in AWD.
When in AWD, the front gearcase will automatically engage when the
rear wheels lose traction. When the rear wheels regain traction, the
front gearcase will automatically disengage.
NOTE: The override switch allows activation of AWD in reverse if the
AWD 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 vehicle’s electronic system will not enable the AWD until
the engine RPM is below 3100. Once enabled, the AWD remains
enabled until the AWD switch is turned off. 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 drive may be needed. If the rear wheels are spinning, release the
throttle before switching to AWD.
CAUTION
Switching to AWD while the rear wheels are spinning may cause
severe drive shaft and gearcase damage. Always switch to AWD
while the rear wheels have traction or are at rest.
1
45
FEATURES AND CONTROLS
Instrument Cluster (Magnum 330)
Your ATV is equipped with an instrument cluster that senses vehicle
speed from the right front wheel. The instrument cluster measures
distance in miles as well as hours of operation. It also includes a
reverse speed limiter function that limits the ATV’s speed to
approximately 7-9 mph (see page 34).
1. Rider Information 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 cause water
to enter the instrument cluster and cause damage to the
electronic components. 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. Immediately clean off any
gasoline that splashes on the instrument cluster. Do not allow
insect sprays to come into contact with the lens.
2
3
1
46
FEATURES AND CONTROLS
Instrument Cluster (Magnum 330)
Rider Information Center
The rider information center is located in the lower portion of the
instrument cluster.
1. Gear Indicator - As the
shift lever is moved, this
will indicate the gear the
machine is in:
H = High Range
L = Low Range
N = Neutral
R = Reverse
P = Park
E or blank = Error - The
error message usually means
the gear selector is in between
gears. It can, however, also
indicate that the transmission
switch needs repair.
2. High Engine Coolant Temperature - Do not continue to operate the
ATV is this warning appears or serious engine damage could result.
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 charged. A low battery warning may also occur under normal
operation if the machine is at idle and high electrical load (lights,
cooling fan, accessories) is applied. Driving at a higher RPM or
connecting a battery charger will usually clear the warning.
NOTE: If the instrument cluster no longer illuminates, it’s possible
that a battery over voltage occurred and the instrument
cluster has shut off to protect the electrical system. If this
occurs take the ATV to your Polaris dealer for proper
diagnosis.
NOTE: All segments of the rider information center will light up for
2.5 seconds at start-up.
2
5
4
3
1
47
FEATURES AND CONTROLS
Instrument Cluster (Magnum 330)
Rider Information Center
The rider information center has 4 standard modes:
Mode 1 - Odometer
Mode 2 - Tripmeter
Mode 3 - Total Service Hours
Mode 4 - Programmable service interval
The reverse override button on the left handlebar is also the mode
button.
NOTE: If using the mode button to program the rider information
center, or to toggle 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 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.
Mode 3 - Hour Meter
This mode logs the total hours the engine has been in operation.
48
FEATURES AND CONTROLS
Instrument Cluster (Magnum 330)
Rider Information Center
Mode 4 - Programmable Service Interval
The purpose of the programmable service interval is to provide the
consumer and dealer with a convenient reminder for routine
maintenance. When your vehicle leaves the factory, this feature is
turned off. You must enable the programmable service interval before
it can be used.
Once the service interval mode is set with the hours when service is
due, the hours of actual engine operation are subtracted from the set
hours until 0 is reached. When the counter reaches 0, the wrench icon
will flash quickly for 5 seconds each time the vehicle is started 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 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 button down
until the count turns over to 0. You can then reset the
number.
If the service interval is enabled on your ATV and you wish to turn it
off, toggle to the service interval mode. Press and hold the mode
button for approximately 7 seconds until the word OFF appears in the
Rider Information Center.
49
FEATURES AND CONTROLS
Instrument Cluster (Magnum 330)
Rider Information Center
Diagnostic Mode
The diagnostic mode is for informational purposes only. Please return
your ATV to your dealer for all major repairs.
To enter the diagnostics mode:
1. Turn the key switch off and wait 20 seconds.
2. Set the park brake and shift the transmission to neutral.
3. Hold the mode/reverse
override button and turn the
key switch on.
The initial screen displayed 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
diagnostic screens. The first
screen (1) displays battery
voltage.
Screen two (2) is the tachometer
for setting idle speed. If this
needs adjustment, please contact
your dealer.
As long as the center is in the
diagnostic mode, the wrench icon
will remain lit.
To leave the diagnostic mode,
either shift the machine out of
neutral or turn the key switch off
and on.
NOTE: Any movement of the tires will also take the machine out of
the diagnostic mode.
1
2
50
OPERATION
Break-In Period
The break-in period for your new Polaris 4-cycle ATV is defined as the
first ten hours of operation, or the time it takes to use the first two full
tanks of gasoline. No single action on your part is as important as
following the procedures for a proper break-in. Careful treatment of a
new engine will result in more efficient performance and longer life for
the engine. Perform the following procedures carefully.
CAUTION
Excessive heat build-up during the first three hours of operation
will damage close-fitted engine parts. Do not operate at full
throttle or high speeds for extended periods during the first three
hours of use.
CAUTION
Mixing 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 brands.
1. Fill the fuel tank with gasoline. See page 41.
2. Check the oil level on the
dipstick. See page 75. Add
Polaris Premium 4 Synthetic
Oil if necessary to maintain the
oil level in the normal/safe
operating 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 51.
6. Pull only light loads.
7. During the break-in period, change both the oil and the filter at 20
hours, 200 miles, or one month, whichever comes first.
1
51
OPERATION
Pre-Ride Inspection
WARNING
If a proper inspection is not done before each use, severe injury
or death could result. Always inspect the vehicle before each use
to ensure it’s in proper operating condition.
Pre-Ride Checklist
Item Remarks See
Page
Brake system / lever travel Ensure proper operation 37, 38
Brake fluid Ensure proper level 37
Auxiliary brake Ensure proper operation 40
Front suspension Inspect, lubricate if necessary 72
Rear suspension Inspect, lubricate if necessary 72
Steering Ensure free operation --
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 level (if applicable) Ensure proper level --
Coolant hoses (if applicable) Inspect for leaks --
Throttle Ensure proper operation 36, 97
Indicator lights / switches Ensure operation 34
Engine stop switch Ensure proper operation 35
Air filter, pre-filter Inspect, clean 102
Air box sediment tube Drain deposits whenever visible --
Headlamp Check operation, apply dielectric
grease when lamp is replaced
80
Brake light / tail lamp Check operation, apply dielectric
grease when lamp is replaced
81
Riding gear Wear helmet, goggles, protective
clothing
32
52
OPERATION
Starting the Engine
Starting a Cold Engine
WARNING
Engine exhaust contains poisonous carbon monoxide and can
cause loss of consciousness resulting in severe injury or death.
Never run an engine in an enclosed area.
1. Place the transmission in PARK and
lock the parking brake. Make sure the
fuel valve is on.
2. Sit on the vehicle and pull the choke
knob (1) out until it stops. If the knob
doesn’t stay where positioned, increase
the tension by rotating the tension
adjusting nut (2) clockwise.
NOTE: The variable choke is fully on when
the knob is pulled completely out.
The choke is off when the knob is
pushed completely 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 engine
components.
3. Move the engine stop switch to RUN.
NOTE: Do not press the throttle while starting the engine.
4. Turn the ignition key past the ON position to engage the starter for
a maximum of five seconds. Release the key when the engine
starts. If it doesn’t start, release the key and wait five seconds.
Activate the starter for another five seconds. Repeat until the
engine starts.
5. If the engine slows or stops, position the choke knob half way in to
allow proper engine warm up.
6. Vary the engine RPM slightly with the throttle to aid in warm-up.
When the engine idles smoothly, push the choke all the way in.
CAUTION
Operating the vehicle immediately after starting could cause
engine damage. Allow the engine to warm up for several minutes
before operating the vehicle.
1
2
53
OPERATION
Starting the Engine
Starting a Warm Engine
Warm engines do not normally require the use of the choke. Excessive
use of the choke can cause the spark plug to become wet fouled.
1. Position the vehicle on a level surface with the transmission in
PARK.
2. Lock the parking brake, turn the fuel tank valve to ON, sit on the
vehicle, and turn the engine stop switch to RUN.
3. If the engine has cooled to a point where it does not readily start,
intermittent use of the choke button (pulled half way out) may be
necessary.
4. 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 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 indicate the accumulation of water in the bottom of the
oil tank. Water in the bottom of the tank can lead to engine damage
and must be drained. Water accumulation increases as outside
temperature decreases.
See your Polaris dealer for engine heater kits, which provide quicker
warm-ups and easier starting in colder weather.
54
OPERATION
Driving Safely
Driving Procedures
1. Sit upright with both feet on the footrests and both hands on the
handlebars.
2. Start the engine and allow it to warm up, then shift the transmission
into gear.
3. Check your surroundings and determine your path of travel.
4. 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.
55
OPERATION
Driving Safely
Making Turns
Your Polaris ATV is equipped with a solid rear axle that drives both
rear wheels equally at all times. This means that the wheel on the
outside of the turn must travel a greater distance than the inside wheel
when turning and the inside tire must slip traction slightly.
To make 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
rear 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.
WARNING
Turning at sharp angles or at excessive speeds can result in
vehicle overturn and lead to serious injury. Avoid turning at sharp
angles. Never turn at high speeds.
56
OPERATION
Driving Safely
Hauling Cargo
Your ATV has been designed to carry or tow a certain amount of load.
Always read and understand the load distribution warnings listed on
the warning labels, and never exceed the specified weights.
Cargo weight should be evenly distributed (1/3 on the front and 2/3 on
the rear) and mounted as low as possible. When operating over rough
or hilly terrain, reduce speed and cargo to maintain stable driving
conditions.
Belt Life
Use low forward gear when hauling or towing heavy cargo to extend
belt life.
2/3
1/3
57
OPERATION
Driving Safely
Hauling Cargo
WARNING
S REDUCE SPEED AND ALLOW GREATER DISTANCES FOR
BRAKING WHEN HAULING CARGO.
S CARGO WEIGHT DISTRIBUTION should be 1/3 on the front
rack and 2/3 on the rear rack. When operating over rough or
hilly terrain, reduce speed and cargo to maintain stable driving
conditions. Carrying loads on one rack only increases the
possibility of vehicle overturn.
S CARRY LOADS AS LOW ON THE RACKS AS POSSIBLE.
Carrying loads high on the racks raises the center of gravity of
the vehicle and creates a less stable operating condition.
S SECURE ALL LOADS BEFORE OPERATING. Unsecured
loads can create unstable operating conditions, which could
result in loss of control of the vehicle.
S OPERATE ONLY WITH 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
designated for your vehicle.
S HEAVY LOADS CAN CAUSE BRAKING AND CONTROL
PROBLEMS. Use extreme caution when applying brakes with a
loaded vehicle. Avoid terrain or situations that may require
backing downhill.
S USE EXTREME CAUTION when operating with loads that
extend over the rack sides. Stability and maneuverability may
be adversely affected, causing the vehicle to overturn.
S DO NOT BLOCK THE FRONT HEADLIGHT BEAM when
carrying loads on the front rack.
S DO NOT TRAVEL FASTER THAN THE RECOMMENDED
SPEEDS. Vehicle should never exceed 10 mph (16 kph) while
towing a load on a level grass surface. Vehicle speed should
never exceed 5 mph (8 kph) when towing loads in rough terrain,
while cornering, or while ascending or descending a hill.
58
OPERATION
Driving Safely
Driving on Slippery Surfaces
Whenever riding on slippery surfaces such as wet trails or loose gravel,
or during freezing weather, follow these precautions:
1. Slow down when entering slippery areas.
2. Maintain a high level of alertness, reading the trail and avoiding
quick, sharp turns which can cause skids.
3. Correct a skid by turning the handlebars in the direction of the skid
and shifting your body 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 spinning. Always allow the rear wheels to
stop spinning before engaging AWD, or engage AWD before
wheels begin to lose traction.
WARNING
Failure to exercise care when operating on slippery surfaces can
result in loss of tire traction and cause loss of control, accident,
and serious injury or death.
Never apply the brakes during a skid. Do not operate on
excessively slippery surfaces. Always reduce speed and use
additional caution.
59
OPERATION
Driving Safely
Driving Uphill
Whenever traveling uphill, follow these
precautions:
1. Always travel straight uphill.
2. Avoid steep hills (25_ maximum).
3. Keep both feet on the footrests.
4. Transfer your weight forward.
5. Proceed at a steady rate of speed
and throttle opening.
6. Remain alert and be prepared to
take emergency action. This
may include quick dismounting
of the vehicle.
If all forward speed is lost:
Keep your weight uphill.
Apply the single lever brake, gradually. When fully stopped, apply the
auxiliary brake as well, then lock the park brake.
If the ATV 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, apply the
auxiliary 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 procedure
described on page 62.
WARNING
Braking and handling are greatly affected when operating in hilly
terrain. Improper procedure could cause loss of control or
overturn and result in serious injury or death.
Avoid climbing steep hills (25_ maximum).
Use extreme caution when operating on hills, and follow proper
operating procedures outlined in the owner’s manual.
25_ Maximum
60
OPERATION
Driving Safely
Sidehilling
WARNING
Improperly crossing hills or turning on hills can result in loss of
control or vehicle overturn, resulting in severe injury or death.
Avoid crossing the side of a hill when possible. Follow proper
procedures as outlined in the owner’s manual.
Sidehilling can be the most dangerous type of driving encountered and
should be avoided if at all possible. If you do enter into a situation
where sidehilling is necessary, follow these precautions:
1. Slow down.
2. Lean into the hill, transferring your upper body weight toward 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!
61
OPERATION
Driving Safely
Driving Downhill
Whenever descending a hill, follow these precautions:
1. Proceed directly downhill.
2. Transfer your weight to the rear of the vehicle.
3. Slow down.
4. Apply the brakes slightly to aid in slowing, using the single brake
lever.
NOTE: Familiarize yourself with operation of the auxiliary rear brake
pedal for additional braking in the event of normal service
brake loss.
WARNING
Excessive speed can cause loss of control and lead to serious
injury or death. Always operate slowly when traveling downhill.
62
OPERATION
Driving Safely
Turning Around on a Hill
WARNING
Improper hill climbing procedures could cause loss of control or
overturn and result in serious injury or death.
Avoid climbing steep hills (25_ maximum).
Use extreme caution when operating on hills, and follow proper
operating procedures outlined in the owner’s manual.
If the vehicle stalls while climbing a hill, never back it down the hill!
One maneuver that can be used when it’s necessary to turn around
while climbing a hill is the K-turn:
1. Stop and lock the parking 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. Staying uphill of the vehicle, turn the handlebars full left.
5. While holding 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 brake, until the vehicle is on more level ground.
8’
Uphill
63
OPERATION
Driving Safely
Driving Through Water
Your ATV can operate through
water with a maximum
recommended depth equal to
the bottom of the footrests (1).
Follow these procedures when
operating through water:
1. Determine water depths
and current before
crossing.
2. Choose a crossing where
both banks have 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.
After running the vehicle in water, it’s critical to have it serviced as
outlined in the maintenance chart. See page 68. The following areas
need special attention: engine oil, transmission oil, front 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 chart.
If your vehicle becomes immersed or is operated in water that
exceeds the footrest level, take it to your dealer for service before
starting the engine.
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
slow and steady forward motion. Do not make sudden turns
or stops, and do not make sudden throttle changes.
If your vehicle becomes immersed, and it’s impossible to take it to a
dealer before starting it, follow the steps described on page 83. Have
the vehicle serviced by your dealer at the first opportunity.
1
64
OPERATION
Driving Safely
Driving Over Obstacles
Be alert! Look ahead and learn to read the terrain you’re traveling on.
Be constantly alert for hazards such as logs, rocks and low hanging
branches.
WARNING
Severe injury or death can result if your vehicle comes in contact
with a hidden obstacle. Not all obstacles are immediately visible.
Travel with caution in unfamiliar terrain.
65
OPERATION
Driving Safely
Driving in Reverse
Follow these precautions when operating in reverse:
1. Always avoid backing downhill.
2. Back slowly.
3. When in reverse, apply the brakes lightly for stopping.
4. Avoid turning at sharp angles in reverse.
5. Never open the throttle suddenly while backing.
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 vehicle movement. Use with caution.
Avoid backing on inclines, and avoid turning at sharp angles.
NOTE: Most Polaris ATVs are equipped with a reverse speed limiter.
The override button should be used with caution as rearward
vehicle speed is greatly increased. Do not operate at wide
open throttle. Open the throttle just enough to maintain a
desired speed.
CAUTION
Excessive throttle operation while in the speed limit mode may
cause fuel to build in the exhaust, resulting in engine popping
and/or engine damage.
66
OPERATION
Driving Safely
Parking on an Incline
Avoid parking on an incline if possible. If it’s unavoidable, follow
these precautions:
1. Turn the engine off.
1. Place the transmission in PARK.
2. Set the parking brake.
3. Always block the rear wheels on the downhill side. See
illustration.
4. Shut off the fuel supply.
67
EMISSION CONTROL SYSTEMS
Noise Emission Control System
Do not modify the engine, intake or exhaust components, as doing so
may affect compliance with state and local noise level requirements.
Crankcase Emission Control System
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 fuel delivery and ignition. The engine
and related components must be maintained at Polaris 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
authorized Polaris dealer.
The emissions label (1) is located
on the recoil cover.
WARNING
The installation of devices that effectively increase exhaust
emissions beyond their legal limits will void all manufacturer
warranties and may violate laws governing the registration and
operation of this vehicle.
Spark Arrestor
Your Polaris vehicle has a spark arrestor that was tested and approved
in accordance with the USDA Forest Service Standard 5100-1C.
Federal law requires that this spark arrestor be installed and functional
when the vehicle is operated on public lands.
Electromagnetic Interference
This spark ignition system complies with Canadian ICES--002.
1
68
MAINTENANCE AND LUBRICATION
Periodic Maintenance Chart
Careful periodic maintenance will help keep your vehicle in the safest,
most reliable condition. Inspection, adjustment and lubrication of
important components are explained in the periodic maintenance chart.
Inspect, clean, lubricate, adjust and replace parts as necessary. When
inspection reveals the need for replacement parts, use genuine Polaris
parts available from your Polaris dealer.
NOTE: Service and adjustments are critical. If you’re not familiar
with safe service and adjustment procedures, have a
qualified dealer perform these operations.
Some models are equipped with a speedometer that has a
programmable service interval mode. This important feature 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 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 Racing or race-style high RPM use
S Prolonged low speed, heavy load operation
S Extended idle
S Short trip cold weather operation
Maintenance Chart Key
"
Perform these procedures more frequently for vehicles subjected to
severe use.
E
Emission Control System Service (California)
J
Have an authorized Polaris dealer perform these services.
WARNING
Improperly performing the procedures marked with a
J
could
result in component failure and lead to serious injury or death.
Have an authorized Polaris dealer perform these services.
69
MAINTENANCE AND LUBRICATION
Periodic Maintenance Chart
Perform all services at whichever maintenance interval is reached first.
Item Maintenance Interval
(whichever comes first)
Remarks
Hours Calendar Miles
(Km)
J
Steering -- Pre-Ride --
Make adjustments as need-
e
d
S
e
e
P
r
e
R
i
d
e
C
h
e
c
k
l
i
s
t
"
Front suspension -- Pre-Ride --
j
ed. See Pre-Ride Checklist
on pa
g
e 51.
"
Rear suspension -- Pre-Ride --
o
n
p
a
g
e
5
1
.
Tires -- Pre-Ride --
"
Brake fluid level -- Pre-Ride --
"
Brake lever travel -- Pre-Ride --
Brake system -- Pre-Ride --
Wheels/fasteners -- Pre-Ride --
Frame fasteners -- Pre-Ride --
"
E
Engine oil level -- Pre-Ride --
"
E
Air filter, pre-filter -- Daily -- Inspect; clean often
"
E
Air box sediment
tube
-- Daily -- Drain deposits when visible
Coolant
(if applicable)
-- 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 housing -- Weekly -- Drain water as needed,
check often if operating in
wet conditions
"
J
Brake pad wear 10 H Monthly 100 (160) Inspect periodically
Battery 20 H Monthly 200 (320) Check terminals; clean; test
"
Front gearcase oil
(if equipped)
25 H Monthly 250 (400) Inspect level; change yearly
"
Rear gearcase oil
(if equipped)
25 H Monthly 250 (400) Inspect level; change yearly
"
Transmission oil 25 H Monthly 250 (400) Inspect level; change yearly
"
E
Engine breather
filter (if equipped)
25 H Monthly 250 (400) Inspect; clean if needed
"
Perform these procedures more often for vehicles subjected to severe use.
E Emission Control System Service (California)
J
Have an authorized Polaris dealer perform these services.
70
MAINTENANCE AND LUBRICATION
Periodic Maintenance Chart
Item Maintenance Interval
(whichever comes first)
Remarks
Hours Calendar Miles
(Km)
"
General
lubrication
50 H 3 M 500 (800) Lubricate all fittings, pivots,
cables, etc.
Carburetor float
bowl
50 H 6 M 500 (800) Drain bowl periodically and
prior to storage
J
E
Throttle Cable/
ETC Switch
50 H 6 M 500 (800) Inspect; adjust; lubricate;
replace if necessary
J
E
Choke cable 50 H 6 M 500 (800) Inspect; adjust; lubricate;
replace if necessary
E
Carburetor air
intake ducts/
flange
50 H 6 M 500 (800) Inspect ducts for proper
sealing/air leaks
Drive belt 50 H 6 M 500 (800) Inspect; adjust; replace as
needed
Cooling system
(if applicable)
50 H 6 M 1000 (1600) Inspect coolant strength
seasonally; 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 clearance 100 H 12 M 1000 (1600) Inspect; adjust
J
E
Fuel system/filter 100 H 12 M 1000 (1600) Check for leaks at tank cap,
lines, fuel valve, filter, pump,
carburetor; replace lines
every two years
"
Radiator
(if applicable)
100 H 12 M 1000 (1600) Inspect; clean external
surfaces
"
Cooling hoses
(if applicable)
100 H 12 M 1000 (1600) Inspect for leaks
"
Engine mounts 100 H 12 M 1000 (1600) Inspect
Exhaust muffler/
pipe
100 H 12 M 1000 (1600) Inspect
J
E
Spark plug 100 H 12 M 1000 (1600) Inspect; replace as needed
J
E
Ignition Timing 100 H 12 M 1000 (1600) Inspect
"
Perform these procedures more often for vehicles subjected to severe use.
E Emission Control System Service (California)
J
Have an authorized Polaris dealer perform these services.
71
MAINTENANCE AND LUBRICATION
Periodic Maintenance Chart
Item Maintenance Interval
(whichever comes first)
Remarks
Hours Calendar Miles
(Km)
"
Wiring 100 H 12 M 1000 (1600) Inspect for wear, routing,
security; apply dielectric
grease to connectors
subjected to water, mud, etc.
J
Clutches (drive
and driven)
100 H 12 M 1000 (1600) 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) Clean out
E
Idle speed -- Adjust as needed
J
Toe adjustment -- Inspect periodically; adjust
when parts are replaced
Headlight aim -- Adjust as needed
"
Perform these procedures more often for vehicles subjected to severe use.
E Emission Control System Service (California)
J
Have an authorized Polaris dealer perform these services.
72
MAINTENANCE AND LUBRICATION
Lubrication Guide
Check and lubricate all components at the intervals outlined in the
Periodic Maintenance Chart beginning on page 68. Items not listed in
the chart should be lubricated at the General Lubrication interval.
Item Lube Method
Engine 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.
(3) Rear Gearcase Premium ATV Angle Drive
Fluid
See page 79.
(4) Rear Prop Shaft
F
Grease Grease fitting (3 pumps
maximum).
(5) Front Prop Shaft Yoke
F
Grease Grease fitting (3 pumps
maximum).
(6) Ball Joint
"
L
Grease
Locate fitting on back side of
struts and grease with
grease gun.
(1)
(2)
(3)
(5)
(6)
(4)
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
74
MAINTENANCE AND LUBRICATION
Premium 4 Synthetic Lubricant
Polaris Premium 4 All Season synthetic engine oil has been specially
formulated for use in Polaris 4-cycle engines. It’s a fully synthetic,
high performance, multi-viscosity oil designed to provide the ultimate
in lubrication performance and protection.
NOTE: See page 108 for the part numbers of Polaris products.
Premium 4 possesses unsurpassed film strength over the widest
possible temperature range. It resists viscosity and frictional
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 Premium 4 is the only oil recommended for use in
this engine, use of any API certified SH oil is allowable as long as it’s
0W-40. Oil may need to be changed more frequently if Polaris
Premium 4 is not used. Follow the manufacturer’s recommendations
for ambient temperature operation.
CAUTION
Mixing 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 brands.
75
MAINTENANCE AND LUBRICATION
Engine Oil Check
The oil dipstick (1) is located on the
left side of the engine.
NOTE: A rising oil level between
checks in cool weather driving
can indicate contaminants
such as gas or moisture
collecting in the crankcase.
If the oil level is over the
full/safe mark, change the oil immediately.
1. Position the ATV on a level surface.
2. Start the engine and let it idle for 20-30 seconds. Stop the engine.
3. Remove the dipstick and wipe it dry with a clean cloth.
4. Screw the dipstick completely in.
The dipstick must be screwed
completely in to ensure an accurate
reading.
5. Remove the dipstick 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,
the oil pump may lose its prime, which could result 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 supply of oil so the oil
and filter change can be completed without interruption.
2. Position the vehicle on a level surface.
3. Clean the area around the drain plug on the bottom of the engine
crankcase.
4. Run the engine for two to three minutes until warm. Stop the
engine.
CAUTION
Hot oil can cause serious burns to skin. Do not allow hot oil to
come into contact with skin.
1
2
76
MAINTENANCE AND LUBRICATION
Oil and Filter Change
5. Place a drain pan beneath the engine crankcase and remove the
drain plug.
6. Allow the oil to drain completely.
7. Install a new sealing washer on the drain plug.
NOTE: The sealing surfaces on the drain plug and crankcase should
be clean and free of burrs, nicks or scratches.
8. Reinstall the drain plug and torque to 14 ft. lbs. (19 Nm).
9. Place shop towels beneath the oil filter. Using an oil filter wrench,
turn the filter counterclockwise to remove.
10. Using a clean, dry cloth, clean the filter sealing surface on the
crankcase.
11. Lubricate the gasket on the new filter with a film 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 the recommended oil.
Refer to the specifications section beginning on page 109 for
capacities.
14. Place the gear selector in PARK and lock the parking brake.
15. Start the engine and let it idle for one to two minutes. Stop the
engine and inspect for leaks.
16. Recheck the oil level and add oil as necessary to bring the level to
the upper mark on the dipstick.
17. Dispose of used filter and oil properly.
Gearcase Specification Chart
Gearcase Lubricant Capacity Fill Plug
Torque
Drain Plug
Torque
Transmission Premium AGL Synthetic
Gearcase Lubricant
13.5 oz.
(400 ml)
14 ft. lbs.
(19 Nm)
14 ft. lbs.
(19 Nm)
Front Gearcase Premium Demand Drive
Hub Fluid
5 oz.
(148 ml)
8-10 ft. lbs.
(11-13 Nm)
11 ft. lbs.
(15 Nm)
Rear Gearcase Premium ATV Angle
Drive Fluid
10 oz.
(300 ml)
14 ft. lbs.
(19 Nm)
14 ft. lbs.
(19 Nm)
77
MAINTENANCE AND LUBRICATION
Transmission Oil
Always check and change the transmission
oil at the intervals outlined in the Periodic
Maintenance Chart beginning on page 68.
Maintain the oil level 1 5/8” from the top
of the fill hole. We recommend the use of
Premium AGL Synthetic Gearcase
Lubricant. Refer to the gearcase
specifications chart on page 76. See page
108 for the part numbers of Polaris products.
Oil Check
The transmission fill plug is located on
the right side of the machine, behind the
footwell.
1. 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 drain plug is located on the bottom left hand side of
the machine.
1. Remove the propshaft shield (if equipped) from the right side of
the vehicle to access the fill plug.
2. Remove the fill plug.
3. Remove the transmission drain plug and drain the oil into an
appropriate container. Discard used oil properly.
4. Clean and reinstall the drain plug. Torque to specification.
5. Add the recommended fluid.
6. Reinstall the fill plug. Torque to specification.
7. Check for leaks.
8. Reinstall the propshaft shield (if equipped).
1 5/8″
1
78
MAINTENANCE AND LUBRICATION
Front Gearcase Oil
Always check and change the front gearcase oil at the intervals
outlined in the Periodic Maintenance Chart beginning on page 68.
Refer to the gearcase specifications chart on page 76. See page 108 for
the part numbers of Polaris products.
Oil Check
We recommend the use of Polaris Premium Demand Drive Hub Fluid
in models with centralized Hilliard gearcases (domestic models).
Maintain the level at the bottom of the fill plug threads (1).
1. Position the ATV on a level surface.
2. Remove the fill plug (2) and check
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 vehicle securely with
a jackstand and remove the front
tire on the driver’s side.
3. Remove the drain plug (4) located
on the bottom of the gearcase and
drain the oil into a suitable
container. The drain plug is
accessible through the skid plate.
Discard used oil properly.
4. Clean and reinstall drain plug using a new sealing washer. Torque
to specification.
5. Remove the fill plug (3) and add the recommended fluid. DO NOT
OVERFILL. Overfilling may cause excess drag, which can lead to
unwanted engagement.
6. Reinstall the fill plug. Torque to specification.
1
3
4
2
79
MAINTENANCE AND LUBRICATION
Rear Gearcase Oil
Oil Check
Always check and change the rear
gearcase oil at the intervals outlined in
the Periodic Maintenance Chart
beginning on page 68. Maintain the rear
gearcase oil level at the bottom of the
fill hole threads (1). We recommend the
use of Polaris Premium ATV Angle
Drive Fluid. Refer to the gearcase
specifications chart on page 76. See
page 108 for the part numbers of Polaris
products.
1. Position the ATV on a level surface.
2. Remove the gearcase fill plug (2)
and check the oil level.
3. Add the recommended oil as needed.
4. Reinstall the fill plug. Torque to
specification.
5. Check for leaks.
Oil Change
1. Remove the drain plug (3) located on the bottom of the gearcase.
Catch and discard the used oil properly.
2. Clean and reinstall the drain plug with a new sealing washer.
Torque to specification.
3. Remove the fill plug and add the recommended gearcase oil.
4. Reinstall the fill plug. Torque to specification.
5. Check for leaks.
1
3
2
80
MAINTENANCE AND LUBRICATION
Lights
When servicing a halogen lamp, don’t touch the lamp with bare
fingers. Oil from your skin leaves a residue, causing a hot spot that
will shorten the life of the lamp.
WARNING
Poor lighting while driving can result in severe injury or death.
Headlight and taillight lenses become dirty during normal
operation. Wash the headlights frequently to maintain lighting
quality.
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-clockwise
direction to loosen (A).
2. Pull the harness assembly
out from the headlight
assembly.
3. Remove the headlamp and
replace with a new
headlamp.
4. Install the new headlamp
and harness assembly into
the headlight assembly. Turn the headlight harness clockwise (B)
to secure.
Headlight Adjustment
1. Loosen the nuts (C) that secure the lower headlamps. Adjust the
headlamps as needed.
2. Tighten the nuts.
A
B
C
81
MAINTENANCE AND LUBRICATION
Lights
Taillight/Brakelight Lamp Replacement
If the taillight/brakelight does not work the lamp may need to be
replaced.
1. Remove the taillight lens cover
mounting screws. Remove the
lens cover and gasket and set
aside for reassembly.
2. Remove the lamp (1).
3. Apply dielectric grease to the
socket and install a new bulb.
4. Test the taillight/brakelight for
proper operation.
5. Reinstall the gasket and lens cover.
1
82
MAINTENANCE AND LUBRICATION
Spark Plugs
Refer to the specifications section beginning on page 109 for spark plug
and gap specifications.
CAUTION
Using non-recommended spark plugs can result in serious engine
damage. Always use Polaris-recommended spark plugs.
Spark plug condition is indicative of engine operation. The spark plug
firing end condition should be read after the engine has been warmed
up and the vehicle has been driven at higher speeds. Immediately
check the spark plug for correct color.
WARNING
A hot exhaust system and engine can cause serious burns. Wear
protective gloves when removing a spark plug for inspection.
1. 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 and the service.
NOTE: The tip should not be white. 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 the choke, or
incorrect carburetion adjustments.
Spark Plug Removal and Replacement
1. Remove the spark plug cap.
2. Using the special wrench
provided in the tool pouch, rotate
the spark plug counterclockwise
to remove.
3. Reverse the procedure for spark
plug installation. Torque to 14
ft. lbs. (19 Nm).
83
MAINTENANCE AND LUBRICATION
Vehicle Immersion
CAUTION
If your vehicle becomes immersed, major engine damage can
result if the machine is not thoroughly inspected. Take the
vehicle to your dealer before starting the engine.
If it’s impossible to take your ATV to a dealer before starting it, follow
the steps outlined below.
1. Move the ATV to dry land or at the
very least, to water below the footrests.
2. Check the 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 start.
7. Dry the spark plug and reinstall, or
replace it with a new plug.
8. Tighten the carburetor drain screw (1).
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 page 87 for drying out the PVT.
1
84
MAINTENANCE AND LUBRICATION
Spark Arrestor
WARNING
Failure to heed the following warnings while servicing the spark
arrestor could result in serious injury or death.
Do not perform service on the spark arrestor while the system is
hot. Exhaust system temperatures can reach 1000° F. Allow
components to cool sufficiently before proceeding.
Remove any combustible materials from the area. Wear eye
protection and leather work gloves. Do not stand behind or in
front of the vehicle while purging. Never run the engine in an
enclosed area. Exhaust contains poisonous carbon monoxide
gas. Never go under 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
momentarily revving the engine
several times.
4. If carbon is expelled, cover or plug the
exhaust outlet (2) and rap on the pipe around
the cleanout plug while revving the engine several more times.
5. If particles are still suspected to be in the muffler, elevate the rear
of the vehicle one foot higher than the front. Set the parking brake
and block the wheels. Make sure the 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.
1
2
1
85
MAINTENANCE AND LUBRICATION
Recoil Housing
To prevent possible engine
damage, always drain the recoil
housing (1) after operating the
ATV in very wet conditions.
This should also be done before
storing the ATV.
NOTE: Water will enter the recoil
housing if the starter
handle is disengaged from
the rope guide when under
water.
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 crankcase
drain is opened.
86
MAINTENANCE AND LUBRICATION
PVT System
The basic operation of the Polaris PVT system is dependent on engine
speed and vehicle torque requirements. As engine speed increases, the
force exerted on the movable drive sheave by the flyweights also
increases. This, in turn, increases the amount of “pinch” applied to the
drive belt. Similarly, if the engine speed decreases, the amount of
centrifugal force decreases, reducing the amount of belt “pinch.”
On Polaris ATVs, the approximate gear ratio difference between high
and low range is 1:2.25. This difference in gearing affects the operation
of the PVT, especially at speeds less than 7 MPH, due to the system’s
dependence on engine speed.
For example, when operating at a ground speed of 3 MPH in low
range, the engine speed would be around 3000 RPM. This is well
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 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 range while operating at low ground speeds, the
air temperature in the clutch cover is reduced by almost 160 degrees.
Reducing the temperature inside the clutch cover extends the life of the
PVT components (belt, cover, etc.).
When To Use Low Range vs. High Range
Following is a guideline for when to use low range and high range.
Low Range
S When basic operation is at speeds less than 7 MPH
S For heavy pulling
S When operating in rough terrain (swamps, mountains, etc.) at low
ground speeds
High Range
S When basic operation is at speeds greater than 7 MPH
S When operating at high ground speeds
87
MAINTENANCE AND LUBRICATION
PVT System
WARNING
Failure 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 speeds, creating large amounts
of force on clutch components. Extensive engineering and
testing has been conducted to ensure the safety of this product.
However, as the owner, you have the following responsibilities to
make sure this system remains safe:
Always follow all recommended maintenance procedures. See
your dealer as outlined in the owner’s manual.
This PVT system is intended for use on Polaris products only. Do
not install it in any other product.
Always make sure the PVT housing is securely in place during
operation.
PVT Drying
There may be some instances when water is accidently ingested into
the PVT system. Use the following instructions to dry it out before
operating:
1. Remove the drain plug and allow the water to drain. Replace the
drain plug.
2. Start the engine and shift the transmission into PARK. Apply
varying throttle for 10-15 seconds to expel the moisture and air-dry
the belt and clutches. Do not hold the throttle wide open for more
than 10 seconds.
3. Allow the engine RPM to settle to idle speed, then shift the
transmission to the lowest available range.
4. Test for belt slippage. If the belt slips, repeat the process.
5. Take the vehicle to your dealer for service as soon as possible.
88
MAINTENANCE AND LUBRICATION
Battery
WARNING
Improperly connecting or disconnecting battery cables can result
in an explosion and cause serious injury or death. When
removing the battery, always disconnect the negative (black)
cable first. When reinstalling the battery, always connect the
negative (black) cable last.
Battery Removal
1. Disconnect the battery hold-down strap and remove the battery cover.
2. Disconnect the black (negative) battery cable first.
3. Disconnect the red (positive) 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 fully charged can
damage the battery and result in a shorter life. It can also hinder
vehicle performance. Follow the battery charging instructions on page
89 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 routed.
89
MAINTENANCE AND LUBRICATION
Battery
Battery Storage
Whenever the vehicle is not used for a period of three months or more,
remove the battery from the vehicle, ensure that it’s fully charged, and
store it out of the sun in a cool, dry place. Check battery voltage each
month during storage and recharge as needed to maintain a full charge.
NOTE: Battery charge can be maintained by using a Polaris Battery
Tendert charger (PN 2871076) or by charging about once a
month to make up for normal self-discharge. Battery
Tendert can be left connected during the storage period,
and will automatically charge the battery if the voltage drops
below a pre-determined point.
Battery Charging
The following battery charging instructions apply only to the
installation of a sealed battery. Read all instructions before proceeding
with the installation of this battery.
The sealed battery is already 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 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.
For a refresh charge, follow all instructions carefully.
1. Check the battery voltage with a voltmeter or multimeter. A fully
charged battery will register 12.8 V or higher.
2. If the voltage is less than 12.8 volts, recharge the battery at 1.2
amps or less until the battery voltage is 12.8 or greater.
NOTE: When using an automatic charger, refer to the charger
manufacturer’s instructions for recharging. When using a
constant current charger, use the following guidelines for
recharging.
WARNING
An overheated battery may explode, causing severe injury or
death. Always watch charging times carefully. Stop charging if the
battery becomes very warm to the touch. Allow it to cool before
resuming charging.
90
MAINTENANCE AND LUBRICATION
Battery
Battery Charging
NOTE: Always verify battery condition before and 1-2 hours after the
end of charging.
State of
Charge
Voltage Action Charge Time*
(Using constant current
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 with
desulfating charger
At least 20 hours
91
MAINTENANCE AND LUBRICATION
Adjustments
Brakes
The front and rear brakes are hydraulic disc brakes, activated by
moving the single brake lever toward the handlebar. These brakes are
self-adjusting.
The following checks are recommended to keep the brake system in
good operating condition. Check more often if brakes are used heavily
under normal operation.
WARNING
Never store or use a partial bottle of brake fluid. Brake fluid is
hygroscopic, meaning it rapidly absorbs moisture from the air.
The moisture causes the boiling temperature of the brake fluid to
drop, which can lead to early brake fade and the possibility of
accident or severe injury. After opening a bottle of brake fluid,
always discard any 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.
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
diaphragm is not extended, a leak is likely and the diaphragm
should be replaced. Always fill the reservoir as needed
whenever the cover is loosened or removed to ensure proper
diaphragm operation. Use Polaris DOT 3 brake fluid. Do not
overfill.
2. Check the brake system for fluid leaks.
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: Change the brake pads when
they’re worn to 3/64″ (.1 cm).
3/64″ (.1 cm)
92
MAINTENANCE AND LUBRICATION
Adjustments
Auxiliary Brake
The auxiliary brake is a hydraulic disc brake. The rear brake system is
self-adjusting and requires no maintenance other than periodic checks
of the pads for wear.
Change the brake pads when they’re worn to 3/64″ (.1 cm).
Inspect the brake disc spline and pad wear surface for excessive wear.
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 not be as
effective for braking as the all-wheel single lever system.
93
MAINTENANCE AND LUBRICATION
Adjustments
WARNING
Severe injury or death can result from improper toe alignment and
adjustment. Do not attempt to adjust tie rod alignment. All tie rod
adjustments should be performed by an authorized Polaris dealer.
Toe Alignment
Use the following procedure to check the toe alignment of the vehicle.
The recommended toe alignment is 1/8″ to 1/4″ toe out.
1. Set the handlebars in a
straight-ahead position.
NOTE: The steering frog can be
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. See
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 improper alignment, see your Polaris dealer
for service.
1
2
3
94
MAINTENANCE AND LUBRICATION
Adjustments
Steering Assembly
The steering assembly of the ATV should be checked periodically for
loose nuts and bolts. If loose nuts and bolts are found, see your Polaris
dealer for service before operating the vehicle.
Camber and Caster
The camber and caster are non-adjustable.
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
95
MAINTENANCE AND LUBRICATION
Adjustments
WARNING
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 personal injury or death. Follow the adjustment
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. Adjust the handlebar to the desired
height. Be sure the handlebars do not
contact the gas tank or any other part
of the machine when turned fully to
the left or right.
4. 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.
1
96
MAINTENANCE AND LUBRICATION
Adjustments
Carburetor
IMPORTANT: Your Polaris ATV is calibrated at the factory for
optimal performance at altitudes ranging from zero to 6,000 feet (1800
m) and temperatures of +40 degrees F. (4 degrees C.) or higher. Above
6000 feet (1800 m) the engine air/fuel mixture becomes overly rich and
the engine loses approximately 3% of its power for each 1000-foot
(304.8 m) increase in elevation. Although this power cannot be
regained, adjustments to the carburetor and drive system can be made
to allow more efficient operation. Optional jets, available from your
Polaris 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 conditions are favorable, the
carburetor can be adjusted.
1. Warm up the engine by running the
vehicle for approximately five
minutes.
2. Place the transmission in PARK and
lock the parking brake.
3. Adjust the carburetor idle screw (1)
either in or out until the desired idle
RPM is reached. Turning the screw
in (clockwise) will raise RPM.
Turning the screw out (counterclockwise) will lower RPM.
1
97
MAINTENANCE AND LUBRICATION
Adjustments
Throttle Cable Freeplay
The throttle cable adjuster is located at the right handlebar.
1. Slide the boots (1) off the inline cable adjuster sleeve (2). Loosen
the adjuster locknut (3).
2. Turn the adjuster until 1/16″ to 1/8″ freeplay is achieved at the
thumb lever.
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
98
MAINTENANCE AND LUBRICATION
Adjustments
Side Panel Removal
NOTE: Side panel removal may be difficult until the locking tabs and
receivers have been snapped and unsnapped a few times.
1. Remove the seat.
2. Grasp the rear of the side
panel near the rear cab. With
a quick and firm motion, pull
the panel forward and outward
to disengage the two rear tabs.
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 the tabs lock. Bend the
rear of the side panel and
insert the two tabs into the rear
cab.
Step 2
Step 3
Step 4
99
MAINTENANCE AND LUBRICATION
Adjustments
WARNING
Operating your ATV with worn tires, improperly inflated tires,
non-standard tires or improperly installed tires will affect vehicle
handling and could cause an accident resulting in serious injury or
death.
Maintain proper tire pressure as described on the decal on your
ATV and in the specifications section of the owner’s manual
beginning on page 109.
Always use original equipment size and type when replacing tires.
Make sure the wheels are installed properly.
Always replace tires when the tread depth measures 1/8″ (.3 cm)
or less.
Wheel Removal
1. Stop the engine, place the transmission in PARK and lock the
parking brake.
2. Loosen the wheel nuts slightly.
3. Elevate the side of the vehicle by placing a suitable stand under the
footrest frame.
4. Remove the wheel nuts and remove the wheel.
100
MAINTENANCE AND LUBRICATION
Adjustments
WARNING
Improperly installed wheels can adversely affect tire wear and
vehicle handling, which can result in serious injury or death.
Always ensure that all nuts are torqued to specification. Do not
service axle nuts that have a cotter pin installed. See your
Polaris dealer.
Wheel Installation
1. Place the transmission in PARK
and lock the parking brake.
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. Install the wheel nuts and finger
tighten.
4. Lower the vehicle to the ground.
5. Torque the wheel nuts to specification.
Wheel Nut Torque Specifications
Check the wheel nut torques occasionally and when they’ve been
loosened for maintenance service.
Location Specification
Front Wheel Nuts 27 ft. lbs. (37 Nm)
Rear Wheel Nuts 27 ft. lbs. (37 Nm)
101
MAINTENANCE AND LUBRICATION
Adjustments
Front Wheel Hub Tightening
Front wheel bearing tightness and spindle nut retention are critical
component operations. All service must be performed by your
authorized Polaris dealer.
Tire Tread Depth
Always replace tires when tread
depth is worn to 1/8″ (.3 cm) or less.
See illustration.
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.
WARNING
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. Maintain proper tire
pressure as outlined in this owner’s manual. When replacing a
tire always use original equipment size and type.
1/8I (.3 cm)
102
MAINTENANCE AND LUBRICATION
Adjustments
Air Filter Service
1. Remove the seat.
2. Release the clips and remove the air
box cover (1).
3. Loosen the clamp and remove the
filter.
4. Remove the fabric type pre-filter
(2) from the main filter (3). Wash
the pre-filter in soapy water, then
rinse and let dry.
5. Reinstall the pre-filter over the
main filter. (Replace the main filter
if needed.)
6. Reinstall the filter into the air box
and tighten the clamp. Do not over
tighten the clamp, as filter damage
could occur.
3
2
1
103
MAINTENANCE AND LUBRICATION
Accessories
Auxiliary power outlets provide 12V power for operating accessories
such as hand held spot lights. See your Polaris dealer.
Cleaning and Storage
See page 108 for the part numbers of Polaris products.
Cleaning the ATV
Keeping your ATV clean will not only improve its appearance but it
can also extend the life of various components. With a few
precautions, your ATV can be cleaned much like an automobile.
Washing the ATV
The best and safest way to clean your ATV is with a garden hose and a
pail of mild soap and water. Use a professional type washing mitten,
cleaning the upper body first and the lower parts last. Rinse with water
frequently 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 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
the vehicle to run for a while to evaporate any water that may
have entered the engine or exhaust system.
Waxing the ATV
Your ATV can be waxed with any non-abrasive automotive paste wax.
Avoid the use of harsh cleaners since they can scratch the body finish.
CAUTION
Certain products, including insect repellants and chemicals, will
damage plastic surfaces. Use caution when using these products
near plastic surfaces.
104
MAINTENANCE AND LUBRICATION
Cleaning and Storage
Storage Tips
See page 108 for the part numbers of Polaris products.
CAUTION
Starting the engine during the storage period will disturb the
protective film created by fogging and damage could occur. Never
start the engine during the storage period.
Exterior
Make necessary repairs and then clean the ATV thoroughly with mild
soap and warm water to remove all dirt and grime. Don’t use harsh
detergents or high pressure washers. Some detergents deteriorate rubber
parts. Use dish soap type cleaners only. High pressure washers may
force water past seals.
Fuel Stabilizer
Polaris Carbon Clean is a fuel stabilizer and fuel system dryer. It
cleans 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 Polaris Carbon Clean or Fuel
Stabilizer. Follow the instructions on the container for the
recommended amounts.
2. Start the engine and allow it to run for 15-20 minutes so the stabilizer
can disperse through the fuel in the tank and carburetor.
3. Stop the engine, 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.
Recoil Housing
Remove the recoil housing drain plug and drain any moisture.
Engine Anti-Freeze
Test engine coolant strength and change if necessary. Coolant should
be replaced every two years.
105
MAINTENANCE AND LUBRICATION
Cleaning and Storage
Storage Tips
See page 108 for the part numbers of Polaris products.
Fluid Levels
Inspect the following fluid levels and change if necessary: engine oil;
transmission oil; brake fluid (change every two years or as needed if
fluid looks dark or contaminated).
Engine
1. Remove the spark plug and pour 2-3 tablespoons of Premium 4
Synthetic 0W40 engine oil into the hole. Use a section of clear 1/4”
hose and a small plastic squeeze bottle filled with the pre-measured
amount of oil.
NOTE: Do this carefully! If you miss the plug hole, oil will drain from
the spark plug cavity into the hole at the front of the cylinder
head and appear to be an oil leak.
2. Reinstall the spark plug.
3. With the ignition off, turn the engine over several times using the
recoil starter. This will 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 Polaris Carbon Clean.
6. If Polaris fuel system additive is not used, drain all fuel from the
fuel tank, fuel lines, and carburetor. Eliminate any fuel remaining
in the carburetor by running the engine until it stops.
Lubricate
Inspect all cables and lubricate with Polaris Cable Lubricant. Follow
lubrication guidelines in the maintenance section of the service or
owner’s manual to completely grease and lubricate the entire vehicle
with Polaris Premium All Season Grease.
Storage Area/Covers
Set the tire pressure and safely support the ATV with the tires 1-2” off
the ground. Be sure the storage area is well ventilated, and cover the
machine with a genuine Polaris ATV cover.
NOTE: Do not use plastic or coated materials. They do not allow
enough ventilation to prevent condensation, and may promote
corrosion and oxidation.
106
MAINTENANCE AND LUBRICATION
Cleaning and Storage
Chrome Wheel Care (if equipped)
Proper maintenance will protect chrome wheels from corrosion,
preserve wheel life and ensure a “like new” appearance for many years.
1. Wash chrome rims frequently. Use a mild detergent to remove any
salt, dirt, mud or grime. Never use abrasive cleaners on plated or
painted surfaces.
2. Polish the clean chrome wheels periodically. Use an automotive
grade chrome polish.
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 wheels exposed to road salt (or salt in the air in coastal
areas) are more susceptible to corrosion if not properly cleaned.
Clean chrome wheels more often if they’re exposed to salt or other
corrosive elements.
Removing Corrosion
If light rust is found on the chrome finish, use steel wool (#0000-OTT
grade) to remove it. Gently rub the affected areas with the steel wool
until the corrosion has been removed. Clean and polish the wheel as
outlined above.
107
MAINTENANCE AND LUBRICATION
Cleaning and Storage
Transporting an ATV
Follow these procedures when
transporting an ATV.
1. Turn off the engine and
remove the key to prevent
loss during transporting.
2. Turn the fuel valve off.
3. Be sure the fuel cap, oil cap
and seat are installed
correctly and securely.
4. Always tie the frame of the
ATV to the transporting unit
securely using suitable
straps or rope. The rack,
bumper or handlebars do not
offer enough support for
tie-down while transporting
the unit.
5. Always place the
transmission in PARK and
lock the parking brake.
108
POLARIS PRODUCTS
Part No. Description
Engine Lubricant
2870791 Fogging Oil (12 oz. Aerosol)
2871281 Premium 4 Synthetic 0W-40 (4-Cycle) Engine Oil (qt.)
2871844 Premium 4 Synthetic 0W-40 (4-Cycle) Engine Oil (gal.)
Gearcase / Transmission Lubricants
2873602 Premium AGL Synthetic Gearcase Lube (qt.)
2873603 Premium AGL Synthetic Gearcase Lube (gal.)
2871653 Premium ATV Angle Drive Fluid (8 oz.)
2872276 Premium ATV Angle Drive Fluid (2.5 gal.)
2870465 Pump for Gallon Jug
2871654 Premium Demand Drive 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 Starter Drive Grease
2871515 Premium U-Joint Lube (3 oz.)
2871551 Premium U-Joint Lube (14 oz.)
2871312 Grease Gun Kit
2871329 Dielectric Grease (Nyogelt)
2872073 Chain Lube (6.25 oz. aerosol)
2872348 Chain Lube (16 oz. aerosol)
Coolant
2871323 60/40 Coolant (gal.)
2871534 60/40 Coolant (qt.)
Additives / Miscellaneous
2872889 Brake and Clutch Cleaner
2871326 Carbon Clean Plus (12 oz.)
2870652 Fuel Stabilizer (16 oz.)
2870990 DOT3 Brake Fluid
2872893 Engine Degreaser
2871956 LOCTITE 565 Thread Sealant
109
SPECIFICATIONS
2005 Magnum 330 2X4
Capacities
Body Style Gen IV
Gross Vehicle Weight 1060 lbs. (481 kg)
Fuel Capacity 3.2 gal. (12.1 l)
Engine Oil Capacity 1.9 qts. (1.8 l)
Transmission Oil 13.5 oz. (400 ml)
Rear Gearcase Oil 10 oz. (300 ml)
Front Rack 90 lbs. (40.8 kg)
Rear Rack 180 lbs. (81.6 kg)
Tongue Weight 100 lbs. (45.4 kg)(Rear rack weight and tongue
weight not to exceed 180 lbs.)
Tow Capacity 1000 lbs.(454 kg)
Turn Radius 70 in. (178 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)
Dry Weight 590 lbs. (268 kg)
Wheel Base 49.75 in. (126.4 cm)
Engine & Cooling
Engine Model Number / Type ES32PFE103 / 4 Cycle, Single Cylinder
Lubrication Wet Sump
Bore x Stroke 78.5 x 68
Displacement 329cc
Compression Ratio 9.2:1 Full Stroke
Engine Cooling Air with fan assisted oil cooler
Alternator Output (watts) 200w @5000 rpm
Carburetion 1 / BST34 (CV Type)
Main Jet 122.5
Pilot Jet 42.5
Needle Jet 4HB48-3
Pilot Air Jet 160
Jet Needle -2 Clip
Ignition DC CDI
Timing 30° ± 2° @ 5000 RPM
Spark Plug Type / Gap NGK BKR6E / .036 in. (.9 mm)
110
SPECIFICATIONS
2005 Magnum 330 2X4
Drive System
Drive System Type PVT
Shift Type Side Lever
Front Drive (ratio) 3.1/1
Front Tires 24 x 8-12 (4 psi)
Rear Tires 24 x 11-12 (3 psi)
Suspension and Brakes
Front Suspension: Mac Strut 6.7 in. (17 cm) travel
Rear Suspension: Progressive Rate
Swing Arm
7.1 in. (18 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 Grill, Hi/Lo 30W
Taillight 12V 8.26W
Brake Light 12V 26.9W
Battery 12V 14 AH
DC Plug-In (Rear) Accessory
Electric Start Standard
High Beam Indicator Standard
High Temp Indicator Standard
Windshield Accessory
Neutral Indicator Standard
Reverse Indicator Standard
Speedometer Standard
Tool Kit Standard
111
SPECIFICATIONS
2005 Magnum 330 2X4
Jetting Chart
Altitude AMBIENT
TEMPERATURE
Below 40° F
(Below 5° C)
+40°F and above
(+5°C and above)
Meters
(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
Blue/Green
7041157
Black
7041782
41-35
°
5133701
2+2
1800-3700
(6000-12000)
20-38
5631357
Blue/Green
7041157
Black
7041782
41-35
°
5133701
2+2
112
SPECIFICATIONS
2005 Magnum 330 4X4
Capacities
Body Style Gen IV
Gross Vehicle Weight 1100 lbs. (499 kg)
Fuel Capacity 3.25 gal. (12.3 l)
Engine Oil Capacity 1.9 qts. (1.8 l)
Transmission Oil 13.5 oz. (400 ml)
Front Gearcase Oil (Centralized Hilliard) 5 oz. (148 ml)
Rear Gearcase Oil 10 oz. (300 ml)
Front Rack 90 lbs. (40.8 kg)
Rear Rack 180 lbs. (81.6 kg)
Tongue Weight 100 lbs. (45.4 kg)(Rear rack weight and
tongue weight not to exceed 180 lbs.)
Tow Capacity 1000 lbs.(454 kg)
Turn Radius 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. (289 kg)
Engine & Cooling
Engine Model Number / Type ES32PFE103 / 4 Cycle, Single Cylinder
Lubrication Wet Sump
Bore x Stroke 78.5 x 68
Displacement 329cc
Compression Ratio 9.2:1 Full Stroke
Engine Cooling Air with fan assisted oil cooler
Alternator Output (watts) 200w @5000 rpm
Carburetion 1 / BST34 (CV Type)
Main Jet 122.5
Pilot Jet 42.5
Needle Jet 4HB48-3
Pilot Air Jet 160
Jet Needle -2 Clip
Ignition DC CDI
Timing 30° ± 2° @ 5000 RPM
Spark Plug Type / Gap NGK BKR6E / .036 in. (.9 mm)
113
SPECIFICATIONS
2005 Magnum 330 4X4
Drive System
Drive System Type PVT
Shift Type Side Lever
Front Drive (ratio) 3.7/1
Final Drive (ratio) 3.1/1
Front Tires 24 x 8-12 (4 psi)
Rear Tires 24 x 11-12 (3 psi)
Suspension and Brakes
Front Suspension: Mac Strut 6.7 in. (17 cm) travel
Rear Suspension: Progressive Rate
Swing Arm
7.1 in. (18 cm) 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 Wheel
Features
Headlight Grill, Hi/Lo 30W
Taillight 12V 8.26W
Brake Light 12V 26.9W
Battery 12V 14 AH
DC Plug-In (Rear) Accessory
Electric Start Standard
High Beam Indicator Standard
High Temp Indicator Standard
Windshield Accessory
Neutral Indicator Standard
Reverse Indicator Standard
Speedometer Standard
Tool Kit Standard
114
SPECIFICATIONS
2005 Magnum 330 4X4
Jetting Chart
Altitude AMBIENT
TEMPERATURE
Below 40° F
(Below 5° C)
+40°F and above
(+5°C and above)
Meters
(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
Blue/Green
7041157
Black
7041782
41-35
°
5133701
2+2
1800-3700
(6000-12000)
20-38
5631357
Blue/Green
7041157
Black
7041782
41-35
°
5133701
2+2
115
TROUBLESHOOTING
Drive Belt and Cover Problems
Possible Cause Solution
Driving the ATV onto a
pickup or tall trailer in
high range.
Shift transmission to low range during loading of the ATV
to prevent belt burning.
Starting out going up a
steep incline.
When starting out on an incline, use low range or dis-
mount the ATV (after first applying the park brake) and
perform the K-turn as described on page 62.
Driving at low RPM or
low ground speed (at
approximately 3-7 MPH).
Drive at a higher speed or use low range more frequently.
The use of low range is highly recommended for cooler
PVT operating temperatures and longer component life.
Insufficient warm-up of
ATVs exposed to low am-
bient temperatures.
Warm the engine at least 5 minutes. With the transmission
in PARK, advance the throttle to about 1/8 throttle in short
bursts, 5 to 7 times. The belt will become more flexible
and prevent belt burning.
Slow and easy clutch en-
gagement.
Use the throttle quickly and effectively 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.
Shift the transmission to low range, and carefully use fast,
brief, aggressive throttle application to engage clutch.
WARNING: Excessive throttle may cause loss of control
and vehicle overturn.
Belt slippage from water
or snow ingestion into the
PVT system.
Shift the transmission to PARK. Using the throttle, vary
the engine RPM from idle to full throttle. Repeat several
times as required. During this procedure, the throttle
should not be held at the full position for more than 10
seconds. Clutch seals should be inspected for damage if
repeated leaking occurs.
Clutch malfunction. Contact your Polaris dealer for inspection of clutch com-
ponents.
Poor engine performance. Check for fouled plugs or foreign material in gas tank,
fuel lines, or carburetor. Contact your dealer for service.
116
TROUBLESHOOTING
Contact your Polaris dealer for service if you’re unable to identify
solutions using the following charts.
Engine Doesn’t Turn Over
Possible Cause Solution
Tripped circuit breaker Reset the breaker
Low battery voltage Recharge battery to 12.8 VDC
Loose battery connections Check all connections and tighten
Loose solenoid connections Check all connections and tighten
Engine Turns Over, Fails to Start
Possible Cause Solution
Out of fuel Turn fuel valve to reserve, refuel
Clogged fuel valve or filter Inspect and clean or replace
Water is present 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 plugs
Clogged fuel filter Replace the filter
Low battery voltage Recharge battery to 12.8 VDC
Mechanical failure See your Polaris dealer
Engine Pings or Knocks
Possible Cause Solution
Poor quality or low octane fuel Replace with recommended fuel
Incorrect ignition timing See your Polaris dealer
Incorrect spark plug gap or heat range Set gap to specs or replace plugs
117
TROUBLESHOOTING
Engine Backfires
Possible Cause Solution
Weak spark from spark plugs Inspect, clean and/or replace spark plugs
Incorrect spark plug gap or heat range Set gap to specs or replace plugs
Old or non-recommended fuel Replace with new fuel
Incorrectly installed spark plug wires See your Polaris dealer
Incorrect ignition timing See your Polaris dealer
Mechanical failure See your Polaris dealer
Engine Runs Irregularly, Stalls or Misfires
Possible Weak Spark Cause Solution
Fouled or defective spark plugs Inspect, clean and/or replace spark plugs
Worn or defective spark plug wires See your Polaris dealer
Incorrect spark plug gap or heat range Set gap to specs or replace plugs
Loose ignition connections 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 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 your Polaris dealer
Other mechanical failure See your Polaris dealer
Possible Lean Fuel Mixture Cause Solution
Low or contaminated fuel Add or change fuel, clean the fuel system
Low octane fuel Replace with recommended fuel
Clogged fuel filter Replace filter
Incorrect jetting See your Polaris dealer
Possible Rich Fuel Mixture Cause Solution
Overuse of choke Inspect, clean and/or replace spark plugs
Fuel is very high octane Replace with lower octane fuel
Incorrect jetting See your Polaris dealer
118
TROUBLESHOOTING
Engine Stops or Loses Power
Possible Cause Solution
Out of fuel Turn fuel valve to reserve, refuel
Kinked or plugged fuel vent line Inspect and replace
Water present in fuel Replace with new fuel
Overuse of choke Inspect, clean and/or replace spark plugs
Fouled or defective spark plugs Inspect, clean and/or replace spark plugs
Worn or defective spark plug wires See your Polaris dealer
Incorrect spark plug gap or heat range Set gap to specs or replace plugs
Loose ignition connections Check all connections and tighten
Low battery voltage Recharge battery to 12.8 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 See your Polaris dealer
Other mechanical failure See your Polaris dealer
Overheated engine Clean radiator screen and core if equipped
Clean engine exterior
See your Polaris dealer
119
WARRANTY
LIMITED WARRANTY
Polaris Sales Inc., 2100 Highway 55, Medina, MN 55340, gives a SIX MONTH LIMITED
WARRANTY on all components of the Polaris All Terrain Vehicle (ATV) against defects
in material or workmanship. Polaris also gives a one year limited warranty on the final drive
chain for failure due to defects. This warranty covers the parts and labor charges for repair
or replacement of defective parts which are covered by this warranty. This warranty begins
on the date of purchase. This warranty is transferrable to another consumer during the war-
ranty period through a Polaris dealer.
REGISTRATION
At the time of sale, the Warranty Registration Form must be completed by your dealer and
submitted to Polaris within ten days. Upon receipt of this registration, Polaris will record
the registration for warranty. THE PURCHASER MUST COMPLETE AN ATV SAFETY
TRAINING COURSE PROVIDED BY THE DEALER IN ORDER TO HAVE VALID
WARRANTY ON THE ATV. No verification of registration will be sent to the purchaser
as the copy of the Warranty Registration Form will be the warranty entitlement. If you have
not signed the original registration and received the “customer copy”, please contact your
dealer immediately. NO WARRANTY COVERAGE WILL BE ALLOWED UNLESS
YOUR ATV IS REGISTERED WITH POLARIS.
Initial dealer preparation and set-up of your ATV is very important in ensuring trouble-free
operation. Purchasing a machine in the crate or without proper dealer set-up will void your
warranty coverage.
WARRANTY 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 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 manufactured, or for any damages which occur during
trailer transit or as a result of unauthorized service or the use of unauthorized parts. In addi-
tion, this warranty does not cover physical damage to paint or finish, stress cracks, tearing
or puncturing of upholstery material, corrosion, or defects in parts, components or the ATV
due to fire, explosions or any other cause beyond Polaris’ control.
This warranty does not cover the use of unauthorized lubricants, chemicals, or fuels that are
not compatible with the ATV. The exclusive remedy for breach of this warranty shall be, at
Polaris’ exclusive option, repair or replacement of any defective materials, or components
or products. THE REMEDIES SET FORTH IN THIS WARRANTY ARE THE ONLY
REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY.
POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL,
CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION, WHETHER
ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CON-
TRACT, NEGLIGENCE, OR OTHER TORT OR OTHERWISE. Some states do not per-
mit the exclusion or limitation ofincidental or consequential damages or implied warranties,
so the above limitations or exclusions may not apply to you if inconsistent with controlling
state law.
120
WARRANTY
WARRANTY COVERAGE AND EXCLUSIONS:
LIMITATIONS OF WARRANTIES AND REMEDIES
ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE IMPLIED
WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR
PURPOSE) ARE LIMITED IN DURATION TO THE ABOVE SIX MONTH WARRAN-
TY PERIOD. POLARIS FURTHER DISCLAIMS ALL EXPRESS WARRANTIES NOT
STATED IN THIS WARRANTY. Some states do not allow limitations on how long an im-
plied warranty lasts, so the above limitation may not apply to you if inconsistent with con-
trolling state law.
HOW TO OBTAIN WARRANTY SERVICE
If your ATV requires warranty service, you must take it to a Polaris dealer authorized to re-
pair Polaris ATVs. When requesting warranty service you must present your copy of the
Warranty Registration form to the dealer. (THE COST OF TRANSPORTATION TO AND
FROM THE DEALER IS YOUR RESPONSIBILITY). 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 the appropriate personnel at Polaris.
This warranty gives you specific legal rights, and you may also have other rights which vary
from state to state.
If any of the above terms are void because of state or federal law, all other warranty terms
will remain in effect.
Engine Oil
1. Mixing oil brands or using non-recommended oil may cause engine damage. We recom-
mend the use of Polaris engine oil.
2. Damage resulting from the use of non-recommended lubricants may not be covered by
warranty.
121
WARRANTY
Exported Vehicles
EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE IS NO WAR-
RANTY OR SERVICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD
OUTSIDE THE COUNTRY OF THE SELLING DEALER’S AUTHORIZED LOCA-
TION.
This policy does not apply to vehicles that have received authorization for export from
Polaris Industries. Dealers may not give authorization for export. You should consult an
authorized dealer to determine this vehicle’s warranty or service bulletin coverage if you
have any questions.
This policy does not apply to vehicles registered to government officials or military per-
sonnel on assignment outside the country of the selling dealer’s authorized location.
This policy does not apply to Safety Recalls.
How to Get Service
In the Country where your vehicle was purchased:
Warranty or Service Bulletin repairs must be done by an authorized Polaris dealer. If you
move or are traveling within the country where your vehicle was purchased, Warranty or
Service Bulletin repairs may be requested from any authorized Polaris dealer who sells
the same line as your vehicle.
Outside the Country where your vehicle was purchased:
If you are traveling temporarily outside the country where your vehicle was purchased,
you should take your vehicle to an authorized 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 you move. Vehicles importation
rules vary considerably from country to country. You may be required to present docu-
mentation of your move to Polaris Industries in order to continue your warranty cover-
age. You may also be required to obtain documentation from Polaris Industries in order
to register your vehicle in your new country.
How to Get Service
If Purchased From A Private Party:
If you purchase a Polaris product from a private citizen outside of the country in which
the vehicle was originally purchased, all warranty coverage will be denied.
Notice
If your vehicle is registered outside of the country where it was purchased, and you have
not followed the procedure set out above, your vehicle will no longer be eligible for war-
ranty or service bulletin coverage of any kind. (Vehicles registered to Government offi-
cials or military personnel on assignment outside of the country where the vehicle was
purchased will continue to be covered by the basic warranty.)
For questions call Polaris Customer Assistance:
United States: 1-763-417-8650
Canada: 1-204-925-7100
122
INDEX
A
Accessories 103. . . . . . . . . . . . . . . . . .
Adjustments 91-102. . . . . . . . . . . . . . .
Age Restrictions 8. . . . . . . . . . . . . . . .
Air Filter 102. . . . . . . . . . . . . . . . . . . .
All Wheel Drive 44. . . . . . . . . . . . . . .
All Wheel Drive Switch 35. . . . . . . . .
Auxiliary Brake 40, 92. . . . . . . . . . . .
AWD Switch 35. . . . . . . . . . . . . . . . . .
B
Battery 88-90. . . . . . . . . . . . . . . . . . . .
Battery Charging 89-90. . . . . . . . . . . . .
Battery Installation 88. . . . . . . . . . . . .
Battery Removal 88. . . . . . . . . . . . . . .
Battery Storage 89. . . . . . . . . . . . . . . .
Belt Life 42. . . . . . . . . . . . . . . . . . . . .
Brake Lever 38. . . . . . . . . . . . . . . . . .
Brakes 37, 91. . . . . . . . . . . . . . . . . . . .
Break-In Period 50. . . . . . . . . . . . . . . .
C
Camber and Caster 94. . . . . . . . . . . . .
Carburetor 96. . . . . . . . . . . . . . . . . . . .
Choke 41. . . . . . . . . . . . . . . . . . . . . . .
Chrome Wheel Care 106. . . . . . . . . . .
Cleaning and Storage 103-107. . . . . . .
Cleaning the ATV 103. . . . . . . . . . . . .
Clutching Chart, 2X4 111. . . . . . . . . .
Clutching Chart, 4X4 114. . . . . . . . . .
Cold Weather Operation 53. . . . . . . . .
CONTROLS 34-49. . . . . . . . . . . . . . . .
Corrosion 106. . . . . . . . . . . . . . . . . . .
Crankcase Emission Control System 67
D
Diagnostic Mode 49. . . . . . . . . . . . . . .
Driving Downhill 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. . . . . . . . . . .
Electromagnetic Interference 67. . . . . .
EMISSION CONTROL SYSTEMS 67
Engaging Front Gearcase 44. . . . . . . .
Engine Fogging 105. . . . . . . . . . . . . .
Equipment Modifications 12. . . . . . . .
Exhaust Emission Control System 67.
F
FEATURES 34-49. . . . . . . . . . . . . . . .
Front Gearcase Oil 78. . . . . . . . . . . . .
Front Wheel Hub Tightening 101. . . .
Fuel Filter 41. . . . . . . . . . . . . . . . . . . .
Fuel Safety 33. . . . . . . . . . . . . . . . . . .
Fuel Stabilizer 104. . . . . . . . . . . . . . . .
Fuel Tank 41. . . . . . . . . . . . . . . . . . . .
Fuel Valve 41. . . . . . . . . . . . . . . . . . . .
G
Gear Selector 42. . . . . . . . . . . . . . . . . .
Gearcase Oil, Front 78. . . . . . . . . . . . .
Gearcase Oil, Rear 79. . . . . . . . . . . . . .
Gearcase Specification Chart 76. . . . . .
H
Handlebars 95. . . . . . . . . . . . . . . . . . .
Hauling Cargo 56-57. . . . . . . . . . . . . . .
Headlight Adjustment 80. . . . . . . . . . .
Headlight Lamp Replacement 80. . . . .
Helmet 32. . . . . . . . . . . . . . . . . . . . . .
High Range 86. . . . . . . . . . . . . . . . . . .
Hour Meter 47. . . . . . . . . . . . . . . . . . .
I
Instrument Cluster 45-49. . . . . . . . . . . .
J
Jetting Chart, 2X4 111. . . . . . . . . . . . .
Jetting Chart, 4X4 114. . . . . . . . . . . . .
K
K-Turn 62. . . . . . . . . . . . . . . . . . . . . .
123
INDEX
L
Light Switch 34. . . . . . . . . . . . . . . . . .
Lights 80-81. . . . . . . . . . . . . . . . . . . . .
Low Range 86. . . . . . . . . . . . . . . . . . .
Lubrication Guide 72. . . . . . . . . . . . . .
M
Main Switch 35. . . . . . . . . . . . . . . . . .
MAINTENANCE AND
LUBRICATION 68-107. . . . . . . .
Maintenance Record 73. . . . . . . . . . . .
Making Turns 55. . . . . . . . . . . . . . . . .
Master Cylinder 37. . . . . . . . . . . . . . .
N
Noise Emission Control System 67. . .
O
Odometer 47. . . . . . . . . . . . . . . . . . . .
Oil Change 75-76. . . . . . . . . . . . . . . . .
Oil Check 75. . . . . . . . . . . . . . . . . . . .
OPERATION 50-66. . . . . . . . . . . . . . .
Operator Safety 8-27. . . . . . . . . . . . . . .
Override Switch 34. . . . . . . . . . . . . . .
P
Parking Brake 39. . . . . . . . . . . . . . . . .
Parking on an Incline 66. . . . . . . . . . .
Periodic Maintenance Chart 68-71. . . .
POLARIS PRODUCTS 108. . . . . . . .
Pre Ride Inspection 51. . . . . . . . . . . . .
Premium 4 Synthetic Lubricant 74. . . .
Programmable Service Interval 48. . . .
PVT Drying 87. . . . . . . . . . . . . . . . . .
PVT System 86-87. . . . . . . . . . . . . . . .
R
Rear Gearcase Oil 79. . . . . . . . . . . . . .
Rear Spring 94. . . . . . . . . . . . . . . . . . .
Recoil Housing 85. . . . . . . . . . . . . . . .
Recoil Starter 43. . . . . . . . . . . . . . . . .
Rider Information 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 109-114. . . . . . . . .
Starting a Cold Engine 52. . . . . . . . . .
Starting a Warm Engine 53. . . . . . . . .
Starting the Engine 52-53. . . . . . . . . . .
Steering Assembly 94. . . . . . . . . . . . .
Stop Switch 35. . . . . . . . . . . . . . . . . . .
Storage Tips 104-105. . . . . . . . . . . . . .
T
TABLE OF CONTENTS 5. . . . . . . . .
Taillight/Brakelight
Lamp Replacement 81. . . . . . . . .
Throttle Cable Freeplay 97. . . . . . . . . .
Throttle Lever 36. . . . . . . . . . . . . . . . .
Tire Tread Depth 101. . . . . . . . . . . . . .
Toe Alignment 93. . . . . . . . . . . . . . . .
Transmission Gear Selector 42. . . . . . .
Transmission Oil 77. . . . . . . . . . . . . . .
Transporting an ATV 107. . . . . . . . . .
Trip Meter 47. . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING 115-118. . . . .
Turning Around on a Hill 62. . . . . . . .
V
VEHICLE IDENTIFICATION
NUMBERS 7. . . . . . . . . . . . . . . .
Vehicle Immersion 83. . . . . . . . . . . . .
W
WARRANTY 119-121. . . . . . . . . . . . .
Washing the ATV 103. . . . . . . . . . . . .
Waxing the ATV 103. . . . . . . . . . . . . .
WELCOME 3. . . . . . . . . . . . . . . . . . .
Wheel Installation 100. . . . . . . . . . . . .
Wheel Nut Torque Specifications 100.
Wheel Removal 99. . . . . . . . . . . . . . .
