Polaris Magnum 330 manual

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A good user manual

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The term originates from the Latin word „instructio”, which means organizing. Therefore, in an instruction of Polaris Magnum 330 one could find a process description. An instruction's purpose is to teach, to ease the start-up and an item's use or performance of certain activities. An instruction is a compilation of information about an item/a service, it is a clue.

Unfortunately, only a few customers devote their time to read an instruction of Polaris Magnum 330. A good user manual introduces us to a number of additional functionalities of the purchased item, and also helps us to avoid the formation of most of the defects.

What should a perfect user manual contain?

First and foremost, an user manual of Polaris Magnum 330 should contain:
- informations concerning technical data of Polaris Magnum 330
- name of the manufacturer and a year of construction of the Polaris Magnum 330 item
- rules of operation, control and maintenance of the Polaris Magnum 330 item
- safety signs and mark certificates which confirm compatibility with appropriate standards

Why don't we read the manuals?

Usually it results from the lack of time and certainty about functionalities of purchased items. Unfortunately, networking and start-up of Polaris Magnum 330 alone are not enough. An instruction contains a number of clues concerning respective functionalities, safety rules, maintenance methods (what means should be used), eventual defects of Polaris Magnum 330, and methods of problem resolution. Eventually, when one still can't find the answer to his problems, he will be directed to the Polaris service. Lately animated manuals and instructional videos are quite popular among customers. These kinds of user manuals are effective; they assure that a customer will familiarize himself with the whole material, and won't skip complicated, technical information of Polaris Magnum 330.

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Table of contents for the manual

  • Page 1

    Universal Owner's Manual V ehicle Maintenance and Safety 2003 A TV for R ead this manual carefully . It contains impor tant safety infor mation. This is an adult vehicle only . Operation is prohibited for those under 16 years of age.[...]

  • Page 2

    W ARNING The engine exhaust from this product contains chemicals known to cause cancer , birth defects or other reproductive harm.[...]

  • Page 3

    1 We’ve cr eat ed a web si t e j ust f or YOU! S T echnical ti ps S New product introductions S Event schedules S Parts and Se rvice M anual information S Exciting details about The W ay Out Ch e c k it ou t... www .pol ar i sindust r i es. com/ owner[...]

  • Page 4

    2 Al l i nfor ma t i on i n t his m a nua l i s ba s e d on t he l a t es t pr oduc t da t a a nd s pe c if i c a t i ons a va il a bl e a t the t i me of pr i nt ing. Pol a r i s Indus t r i e s Inc . r e s e r ves t he r i ght to ma ke pr oduc t ch an g es an d imp ro vem en ts th at m ay af fect illu stratio n s o r ex plan atio n s. No par t of[...]

  • Page 5

    3 WELC O ME Thank you f or purc hasing a P olaris ve hicle , and welc ome to our wor ld-wide fa mily of P olar is owners. W e proudly produce a n exciting line of utility an d re cr ea tional pr oducts. Polar is Recr eational an d Utility V ehicles S Snowmobiles S All- ter ra in vehic les ( A TVs) S P erso nal wat ercraft S V ict or y mo t orcy cl [...]

  • Page 6

    4[...]

  • Page 7

    5 TABLE OF CONTENTS WELCO ME 3 ................................. T ABLE OF CONT ENT S 5 ...................... VEHICL E IDENTI FI CA TI ON NUM BERS 6 ........ SAFET Y 7 ................................... CONTROL S 37 ............................... FEA TURES 4 8 ............................... OPE RA TION 56 .............................. NOISE EM[...]

  • Page 8

    6 VE HICLE IDENTIFICATION NUMBERS The vehic le fr ame ve hicle identif ica tion number (VIN) (1) a nd engine ser ial numbe r (2) are important f or mode l identific ation when re gistering your vehic le, when obta ining insuranc e, and w hen orde ring replacem ent p arts . If your vehicl e is sto len, thes e numbers are essenti al to the r ec over [...]

  • Page 9

    7 SA FETY Operator S afety Age Restr i ctions This vehi cle is an ADUL T VEHIC LE ONL Y . Operati on is p rohibi ted for anyone under 16 years of age . Know Y our V ehi cle As the operator of the ve hicle, you are r esponsible for your pe rsonal saf ety , the safe ty of others, and the prote ction of our e nvironme nt. Read a nd under stand your ow[...]

  • Page 10

    8 SA FETY Operator S afety The f ollowing signal words a nd symbols appe ar thr oughout this manua l and on your A TV . Y our saf ety is involved w hen the se words and symbols ar e used. Become f amilia r with their me anings bef ore re ading the manua l. The s af et y aler t s ym bol, on your A T V or in t his m anual, alert s y ou to t he pot en[...]

  • Page 11

    9 SA FETY Operator S afety S Rea d this manua l and a ll labels c ar efully , and follow the ope ra ting proc edure s desc ribed. S Neve r opera te an A TV without proper instruc tion. T ake a training course . Beginners shoul d receive trai ning from a certifi ed inst ructo r . Co n tact an au t ho ri zed P o l aris A TV d ealer o r cal l P olari [...]

  • Page 12

    10 SA FETY Operator S afety S Alway s hav e th e A TV i ns pect ed b y an aut ho ri zed P ol ari s deal er i f it ’ s been invol ved i n an accident . S Ne ver ope ra te on hills too steep for the A TV or for your abilitie s. Pra ctic e on sma ller hills bef or e atte mpting lar ge r hills. S Alwa ys follow prope r proc edur es for c limbing hill[...]

  • Page 13

    11 SA FETY Operator S afety S W et bra kes ma y have re duce d stopping ability . T est your br ake s afte r lea ving wa ter . If n ec essa ry , apply them lightly se ver al times to a llow frict i on t o dry o ut t he pad s. S Always che ck for obstac les or people behind the A TV befor e oper at- in g i n revers e. Wh en i t’ s s afe to pro cee[...]

  • Page 14

    12 SA FETY Operator S afety POTENTI AL HAZ A RD Oper at ing t his A T V wit hout proper inst r uct ion. WHA T CAN H APPEN The r isk of an ac cident is gr eat ly inc reas ed if the oper at or does not know how t o oper ate t he A T V properly in differ ent sit uat ions and on diff erent t ypes of t er rain. HOW T O A VOID TH E HAZ ARD Beginning and [...]

  • Page 15

    13 SA FETY Operator S afety POTENTI AL HAZ A RD Carry ing a pass enger on an A T V . WHA T CAN H APPEN Carry ing a passenger great ly r educes t he operat or ’ s ability t o balance and cont r ol t he A T V , whic h could c ause an ac cident and injury t o t he oper at or and/ or passenger . HOW T O A VOID TH E HAZ ARD Never c arr y a pas senger [...]

  • Page 16

    14 SA FETY Operator S afety POTENTI AL HAZ A RD Oper at ing an A T V on paved s urf ac es, including s idewalks , paths , parki ng lots , and driveway s. WHA T CAN H APPEN A TV tir es ar e designed f or off-r oad use. O perat ing on pav ed surf ac es m ay s erious ly aff ect t he handling and cont rol of t he A TV and could result in loss of cont r[...]

  • Page 17

    15 SA FETY Operator S afety POTENTI AL HAZ A RD Oper at ing this A T V on public st reet s , r oads or highways . WHA T CAN H APPEN The A T V could collide wit h anot her vehicle. HOW T O A VOID TH E HAZ ARD Never oper at e t he A TV on any public st reet , road or highway , including dirt and gr avel r oads. In m any s t at es it ’s illegal to o[...]

  • Page 18

    16 SA FETY Operator S afety POTENTI AL HAZ A RD Oper at ing t his A T V wit hout wearing an appr oved helm et , eye prot ect ion and pr ot ect iv e clot hing. WHA T CAN H APPEN Oper at ing an A T V wit hout an approv ed helmet incr eases the risk of a sever e head injury or deat h in t he event of an accident . Oper at ing wit hout eye prot ec t io[...]

  • Page 19

    17 SA FETY Operator S afety POTENTI AL HAZ A RD Oper at ing t he A TV af ter cons uming alc ohol or dr ugs. WHA T CAN H APPEN Consumpt ion of alcohol and/ or drugs could ser iously affect operat or judgm ent . React ion t ime m ay be s lower and oper at or balance and perc ept ion could be aff ect ed. Consuming alc ohol and/ or dr ugs bef or e or w[...]

  • Page 20

    18 SA FETY Operator S afety POTENTI AL HAZ A RD At t empt ing wheelies , jum ps and ot her st unt s. WHA T CAN H APPEN At t empt ing s t unts incr eases the c hance of an acc ident , including an overt ur n. HOW T O A VOID TH E HAZ ARD Never att em pt wheelies, jum ps, or ot her st unts . Avoid exhibition driving. W ARNING[...]

  • Page 21

    19 SA FETY Operator S afety POTENTI AL HAZ A RD Failur e t o inspec t the A T V bef or e operat ing. Failur e t o proper ly m aintain t he A T V . WHA T CAN H APPEN Poor m aint enance inc reas es t he pos sibilit y of an ac cident or equipment damage. HOW T O A VOID TH E HAZ ARD Always inspec t y our A T V befor e each us e t o make s ure it ’s i[...]

  • Page 22

    20 SA FETY Operator S afety POTENTI AL HAZ A RD Failur e t o use ex t ra c aution when oper at ing t he A T V on unf amiliar terrai n. WHA T CAN H APPEN Unfamiliar t errain ma y c ont ain hidden rocks, bumps, o r holes that could caus e loss of cont rol or overt ur n. HOW T O A VOID TH E HAZ ARD T ravel s lowly and use ex t ra c aut ion when operat[...]

  • Page 23

    21 SA FETY Operator S afety POTENTI AL HAZ A RD Failur e t o use ex t ra c aution when oper at ing on exc ess ively rough, slipper y or loose t err ain. WHA T CAN H APPEN Oper at ing on exc ess ively r ough, slipper y or l oose t err ain could cause los s of t rac t ion or los s of cont r ol, whic h could r esult in an accident or ov ert ur n. HOW [...]

  • Page 24

    22 SA FETY Operator S afety POTENTI AL HAZ A RD T urning impr operly . WHA T CAN H APPEN Im proper t urns c ould caus e loss of c ont rol and lead t o a c ollision or overt ur n. HOW T O A VOID TH E HAZ ARD Always f ollow proper procedur es f or tur ning as des cr ibed in t he owner ’s manual. Prac t ice t ur ning at slow speeds befor e at t empt[...]

  • Page 25

    23 SA FETY Operator S afety POTENTI AL HAZ A RD Climbing hills im proper ly . WHA T CAN H APPEN Im proper hill clim bing could c ause loss of cont rol or overt ur n. HOW T O A VOID TH E HAZ ARD Always f ollow proper pr ocedur es f or clim bing hills as described in the owner ’ s m anual. Always chec k t he t err ain car ef ully bef ore as cending[...]

  • Page 26

    24 SA FETY Operator S afety POTENTI AL HAZ A RD T raveling downhill im properly . WHA T CAN H APPEN Im proper ly des cending a hill c ould caus e loss of c ont rol or overt ur n. HOW T O A VOID TH E HAZ ARD Always f ollow proper pr ocedur es f or t raveling down hills as descr ibed in t he owner ’s manual. NOT E : A s pecial t echnique is requir [...]

  • Page 27

    25 SA FETY Operator S afety POTENTI AL HAZ A RD Im proper ly c ros sing hills and tur ning on hills. WHA T CAN H APPEN Im proper ly c ros sing or tur ning as hills could caus e loss of c ont rol or overt ur n. HOW T O A VOID TH E HAZ ARD Never at t em pt to t ur n the A T V around on any hill unt il y ou’ve mast er ed t he t urning t echnique ( o[...]

  • Page 28

    26 SA FETY Operator S afety POTENTI AL HAZ A RD St alling, rolling back wards or improper ly dis mount ing while climbing a hill. WHA T CAN H APPEN The v ehicle c ould over t urn. HOW T O A VOID TH E HAZ ARD Maint ain st eady speed when climbing a hill. If all f orwar d speed is lost: Keep your weight uphill. Apply t he s ingle lever brak e gradual[...]

  • Page 29

    27 SA FETY Operator S afety POTENTI AL HAZ A RD Im proper ly oper at ing over obst acles . WHA T CAN H APPEN Oper at ing over obst acles could c ause los s of cont r ol or ov ert urn. HOW T O A VOID TH E HAZ ARD Bef ore oper at ing in a new area, chec k f or obst acles . Avoid operating ov er lar ge obst ac les s uch as rock s and f allen tr ees wh[...]

  • Page 30

    28 SA FETY Operator S afety POTENTI AL HAZ A RD Oper at ing t he A TV t hrough deep or fas t -f lowing wat er . WHA T CAN H APPEN T ires may f loat , c ausing loss of t rac t ion and loss of cont rol, which could lead t o an ac cident or ov ert ur n. HOW T O A VOID TH E HAZ ARD Avoid operating t he A T V thr ough deep or f as t- f lowing wat er . I[...]

  • Page 31

    29 SA FETY Operator S afety POTENTI AL HAZ A RD Oper at ing this A T V wit h improper t ir es, or wit h improper or unev en tire pressu re. WHA T CAN H APPEN Use of impr oper t ir es, or oper at ion of t he A T V wit h im proper or uneven t ire pr ess ure, could c ause los s of c ontr ol or ac cident . HOW T O A VOID TH E HAZ ARD Always use t he si[...]

  • Page 32

    30 SA FETY Operator S afety POTENTI AL HAZ A RD Ov erloading t he A T V or car ry ing/t owing c argo im proper ly . WHA T CAN H APPEN Ov erloading and t owing c an caus e changes in vehicle handling, which could lead t o los s of cont r ol or an ac cident . HOW T O A VOID TH E HAZ ARD Never ex ceed t he s t ated load c apacit y for t his A T V . Ca[...]

  • Page 33

    31 SA FETY Operator S afety Af t er any overt ur n or ac cident , have a qualif ied s erv ice dealer inspect t he ent ire v ehicle f or possible dam age, including ( but not limi ted to) brake s, t hrottle an d steeri ng systems. Saf e operat ion of t his r ider- act iv e vehicle r equires good judgement and physic al sk ills. Per sons with c ognit[...]

  • Page 34

    32 SA FETY Safety D ecals and Locations W arning d ecals h ave been placed on th e A TV for your prot ecti on. Read an d fo ll o w th e in st ru cti o ns o n each decal carefu ll y . If a decal bec omes ille gible o r c omes of f, conta ct your Polar is dea ler to purc hase a repl acem ent . R ep l acemen t safety decals are pro vi ded b y P ol ari[...]

  • Page 35

    33 SA FETY Safety D ecals and Locations See your O wner ’s Manual Supplement f or s pecif ic ations . IMPROPER TIR E PRESSU RE O R O VERLOAD ING c an cause loss of control resulti ng in SEVERE INJU RY OR D EA TH . T IRE PRESSURE (PSI): FRO N T ___ RE AR ___ M AXI MUM W EIGHT CAP ACITY (G r os s V ehic le W eight) IN CLU D IN G MA CH IN E , DR IVE[...]

  • Page 36

    34 SA FETY Safety D ecals and Locations A TTEN TION D Oper ation of t his v ehic le wit hout the filter element will s ev er ely damage the engine. D Clean air filter of ten, more frequent c leaning r equired in dus ty c onditions Under Seat Mov ing parts haz ar d under belt -c lutc h guard. T o prev ent s er ious injury, do not operate v ehic le w[...]

  • Page 37

    35 SA FETY Safety D ecals and Locations ALL WHE EL DRIVE SWITCH Do not push s witc h to engage A WD if t he rear wheels are s pinning. This m ay caus e sev ere drive s haf t and clut c h damage. See your Owner ’s Manual. 7079780 MANUFACTURED BY : PO LARIS IN D DA TE: VIN: TH IS VEH IC L E IS AN AL L TERR AIN VEH IC LE AN D I S NO T I NTENDE D FOR[...]

  • Page 38

    36 SA FETY Safe Riding Gear Always we ar c l othing suited to the t ype of riding. A TV riding requir es spec ial protec tive clothing for comfor t and to reduc e t he cha nce of injury . 1. Helm et Y our he lmet is the most importa nt piec e of prote ctive ge ar for saf e riding. A hel m et can prev ent a s evere head i nj ury . S elect an ap pro [...]

  • Page 39

    37 CONTROLS Electr i cal Switches Act iv at ing t he overr ide swit c h while t he t hrot t le is open c an caus e loss of c ontr ol, res ulting in s ever e injury or deat h. Do not ac t ivat e the ov err ide swit c h while the t hr ot t le is open. W ARNING Ov erri d e S wi tch (1) (Reve rse Spee d Limiter ) - This vehic l e is equipped with a re [...]

  • Page 40

    38 CONTROLS Throttle Lever Eng i ne s peed an d veh i cle moveme nt ar e controlle d by pre ssing the throttle leve r . The throttle le ver (1) is spring lo aded . En gi n e sp eed ret u rns to idle when the le ver is releas ed . This A TV is e quipped w ith Polar i s Elec tronic Thr ottle Control (ETC), which is designe d to reduc e the r isk of a[...]

  • Page 41

    39 CONTROLS Light S witches The light sw itch is loca t ed on the left h and l ebar (1). It ’ s us ed t o tu rn the lights on a nd of f and to switc h the lights fr om HI to LO on mode ls equippe d with HI- LO beams. NOTE: The lights won’ t work unless the key is i n the “on” position and the shut-of f switch is in the “run” position. B[...]

  • Page 42

    40 CONTROLS Br ake Lever The fro nt an d rear b rakes are app l i ed by sq ueezi ng t he b rake l ever ( 1) towar d the handlebar . The fr ont and re ar br ake s are hydr aulic ally activa ted di s c ty pe b rak es t h at are act i v ated by only one lever . Alway s tes t b rake lev er travel an d maste r cylinder f luid level be fore ridi ng. When[...]

  • Page 43

    41 CONTROLS Park in g Brak e Setting the P arking B rake 1. S qu eeze and rel ease t h e brak e leve r (1) two or three times, then sq ueeze an d h ol d . 2. Push the par k brake loc k (2) forw ard to engage the br ake . Rel eas e t he b rak e lev er . 3. T o rele ase the par king brake loc k, sq ueeze an d r eleas e t he b rak e leve r . It will r[...]

  • Page 44

    42 CONTROLS Auxiliary Brake The a uxiliary bra ke (1), is loca ted on the i nside of the right floor boa rd a nd is opera ted by the right foot. The auxilia ry bra ke serve s as a backup to the main bra ke system if the main system be come s i noper ative . If the r ea r whe els slide while using the a uxiliary br ake, r educe brak e ped al pres su[...]

  • Page 45

    43 CONTROLS Choke The choke a ssists i n starting a cold e ngine. Refe r to the engine star ting proc edure o n page 59 for cor rec t choke and throttle settings during star ting. Fuel V alve The f uel val ve (1 ) i s l o cat ed o n t he l eft s id e of the vehic le, either be low the fende r or on t he side pane l. It has three positions: OFF: For[...]

  • Page 46

    44 CONTROLS Fuel Safety Gas oline is highly flam mable and ex plosiv e under c ert ain condit ions. S Always exer cis e ext rem e caut ion whenev er handling gas oline. S Always ref uel wit h t he engine st opped, and out doors or in a well vent ilat ed area. S Do not s mok e or allow open f lam es or spark s in or near t he area where r ef ueling [...]

  • Page 47

    45 CONTROLS Oil Injection T ank - 2 - Cycle Mod els Models with 2- cyc l e e ngines ha ve oil injec tion. The oil inje ction tan k fille r c ap (1 ) is loca ted on the f ront of the v ehic le. T ank ca pac ity is two quarts (1.9 l.). Mixi ng brands or using a non- rec omm ended oil may c ause s erious engine damage. We recom mend t he use of Polar [...]

  • Page 48

    46 CONTROLS Autom atic T ransm ission Gear Selector The tra nsmission gear se lec tor (1) is locate d on the right side of the vehi cl e. S hi ft p at t erns v ary , depe nding on your model. H: High Gear N: Neutral L: Low G ear R: Rev ers e P: Pa rk Whe never the A TV is left unatte nded, always place the tr ansmission in gea r with the parking br[...]

  • Page 49

    47 CONTROLS Recoil S tar ter If the batter y is wea k and c annot star t t he engine , use of the rec oil star ter (1) w ill allow vehic le oper ation until re pairs ca n be mad e. Th e recoi l st art er i s l o cat ed on the right side of the machine . Polaris 4- cycle engine s ar e equippe d with automa tic deco mp ress o rs. Th i s m akes reco i[...]

  • Page 50

    48 FEATURE S All W heel Dr ive (A W D) S ystem Polar is 4 whe el drive A TVs ar e equippe d with a unique, Polaris excl us i ve, Dem and 4 Dri v e (A WD) sy st em t h at ’ s acti vat ed b y a swi tch (1) on the right handleba r . When the s w i t c hi so f f ,t h eA T Vi si n2w h e e l drive a t all times. W hen the switc h is on, the A TV is in [...]

  • Page 51

    49 FEATURE S All W heel Dr ive (A W D) S ystem Di sengagi ng Whe el Hubs Although the hubs norma lly disengage when ope rating in r eve rse, one or both hubs may o ccasional ly rem ain engaged. If th e handlebars pull to one side , it’ s likely tha t one fr ont hub is engage d . If both hubs ar e eng aged, s t eeri ng effort in creases b ut rem a[...]

  • Page 52

    50 FEATURE S Indicator Li ghts The conf iguration of the indica t or li ghts dif fers with individual models. Not eve ry model is equippe d with all of the lights, and the lights on some models appe ar in the spee domete r . The inf orma tion i n your owner ’ s m anua l supplement and on this pa ge will help you identif y the lights and their fun[...]

  • Page 53

    51 FEATURE S In st rume nt C lus te r Y our A TV is e quipped w ith an instr ument c luster tha t sense s vehic le spee d fr om the r ight front whe el. The instr ument c luster me asure s distanc e in miles a s we ll as hours of oper ation. It a lso includes a re ver se spee d limiter f unction that limits the A TV’ s speed to appr oximate ly 7-[...]

  • Page 54

    52 FEATURE S In st rume nt C lus te r Ri der Infor mati on C enter The r ider infor mation ce nter is locate d in the lowe r portion of the instrume nt cluster . 1. Gea r Indica tor - As the shift leve r is moved, this will indicate the gea r the mach i ne i s in : H = High R ange L = Low Range N = Neutral R = Reverse P=P a r k Eo rb l a n k =E r r[...]

  • Page 55

    53 FEATURE S In st rume nt C lus te r Ri der Infor mati on C enter The r ider info rmation c enter has 4 sta ndard mode s: Mode 1 - Odometer Mode 2 - T ripme ter Mode 3 - T otal Servic e Hours Mode 4 - P rogr amma ble ser vice inte rva l The re ver se overr i de button on the left handleb ar is also the mode button . NOTE: I f using t he mode butto[...]

  • Page 56

    54 FEATURE S In st rume nt C lus te r Ri der Infor mati on C enter Mo de 4 - Prog rammable S ervice Int erval The purpose of the progr ammable ser vice interv al is to provide the consume r and de aler with a c onvenie nt reminde r for routine mainte nanc e. When your vehic le leave s the fac tory , this fea ture is turne d of f. Y ou must ena ble [...]

  • Page 57

    55 FEATURE S In st rume nt C lus te r Ri der Infor mati on C enter Dia gnos tic Mode The diagnostic mode is for infor mational purposes only . Please r eturn your A TV to your deale r for a ll major repa irs. T o enter the dia gnostics mode: 1. T urn the ke y switch of f and wa i t 20 seconds. 2. Set the pa rk bra ke and shift the tra nsmission to [...]

  • Page 58

    56 OPERATION Br eak -In Per iod 2 - Cyc le E ngines The bre ak-in per iod for your new Polaris A TV is define d as the time it take s t o use the fir st tank of f uel. No single a ction on your pa rt is as importa nt as following the proce dures for a prope r brea k-in. Car eful treat m ent of a n ew en gi n e wil l resu l t i n mo re ef fi cien t [...]

  • Page 59

    57 OPERATION Br eak -In Per iod 4 - Cyc le E ngines The br ea k-in pe riod for your new Polar is A TV is def ined a s the fir st ten hours of oper ation, or the time it take s to use the first two full tanks of gasoline . No single ac tion on your par t is as impor tant as f ollowing the proc edur es for a prope r brea k-in. Care ful trea tment of [...]

  • Page 60

    58 OPERATION Pr e - R ide Inspection Use the f ollowing chec klist to verify tha t your vehic l e is in prope r wor king condition be fore each u s e. Item/Inspection Pr ocedu re 1. T ires - Che ck condition and pr essures. 2. Fuel and o il tanks - Fill both tanks to their prope r lev els. 3. All bra kes - Che ck ope ration, ad justment and f luid [...]

  • Page 61

    59 OPERATION Star ting the Engi ne S tar ting a Cold E ngine 1. Place the tr ansmission in neutra l and lock the park ing brake . 2. T urn the fuel tank valve on. 3. Sit on the vehicle. 4. Pull the c hoke knob out until it st op s (1). NOTE: The va riable c hoke is fully on when the knob is pulled comple tely out. The c hoke is of f when the knob i[...]

  • Page 62

    60 OPERATION Star ting the Engi ne S tar ting a W arm E ngine W ar m engines do not normally re quire the use of the c hoke. Using the choke c an ca use the spar k plug to become we t foule d. 1. Position the vehicle on a leve l surfa ce with the tra nsmission in neutr al. 2. Lock the par king brak e, turn the f uel tank va l ve to “ on”, sit o[...]

  • Page 63

    61 OPERATION Hauling Cargo Y our A TV ha s been designe d to carr y or tow a ce rta in amount of load . Always r ea d and unde rstand the l oad distr ibution war nings listed on the warning l abels , and never exceed the weight s speci fied i n your owner ’ s manua l supplement. Car go we ight should be eve nly distribute d (1/3 on the fr ont and[...]

  • Page 64

    62 OPERATION Hauling Cargo Hauling cargo im proper ly c an alt er v ehicle handling and m ay caus e loss of c ont rol or brak e inst ability and res ult in ser ious injury or death. Alway s f ollow t hes e prec autions when hauling car go: S REDUCE SPEED AN D ALLO W G REA TER DI ST ANCE FO R BRAKING WHEN HAULING C ARGO. S CARG O WE I G HT DIS T RIB[...]

  • Page 65

    63 OPERATION Driving Safely Driving Pr o cedu res 1. Sit upright with both fee t on the footrests a nd both hands on the handle bar s. 2. Start the engine and allow it t o wa rm up, then shift t he tra nsmission into gea r . 3. Check your surroundings and de termine your path of tra vel. 4. Relea se t he parking bra ke. 5. Slowly depre ss t he thro[...]

  • Page 66

    64 OPERATION Driving Safely Making T urns Some Pola ris A TV s ar e e quipped with a solid rea r axle , which dr ives both re ar w hee ls equa lly at all time s. This mea ns that the w hee l on the outside of the turn must travel a gre ater dista nce than the inside whee l whe n turning and the inside tir e must slip tra ction slightly . T o make a[...]

  • Page 67

    65 OPERATION Driving Safely Dr iving on Slipp ery S u rfaces When ever rid i ng o n sl i pp ery su rfaces s uch as wet t rail s o r lo os e gravel , or du rin g freezi ng weat h er , fo l lo w th ese precau t i on s: 1. Slow down when e ntering slippe ry are as. 2. Mai nt ai n a h i gh l evel of alert nes s , readin g t he t rai l an d av oi d in g[...]

  • Page 68

    66 OPERATION Driving Safely Driving Uphill Whe neve r tra veling uphill, follow these precau t io n s: 1. Alwa ys trave l stra ight uphill. 2. A void stee p hills (25 _ ma ximum). 3. Kee p both fe et on the f ootrests. 4. T ransfe r your weight forwa rd. 5. P roceed at a s t eady rat e of speed and throttle ope ning. 6. Rem ai n alert an d be p rep[...]

  • Page 69

    67 OPERATION Driving Safely Sidehilling Sidehilling ca n be a d ange rous type of driving and should be avoided if at a ll possible. If you do e nter into a situation wher e sidehilling is neces sary , fo l lo w t h ese p recaut i on s : 1. Sl ow down. 2. Lea n into the hill, transfe rring your uppe r body we ight toward the hill while kee ping you[...]

  • Page 70

    68 OPERATION Driving Safely Driving Downh ill Whe never de sce nding a hill, follow the se pr ecaut i on s: 1. P roceed d i rectl y d own h ill. 2. T ransf er your we ight to the rea r of the vehic le. 3. Sl ow down. 4. Apply the brakes slightly to aid in slowing, using the single bra ke leve r . NOTE: Fa miliar ize your self with ope ra tion of th[...]

  • Page 71

    69 OPERATION Driving Safely T urning A round on a H ill If the ve hicle stalls while c limbing a hill, neve r back it down the hill! One mane uver that c an be use d when it’ s nece ssary to tur n around while c limbing a hill is the K-turn: 1. Stop and lock the pa rking brake while kee ping body weight uphill. 2. Lea ve tra nsmission in forwa rd[...]

  • Page 72

    70 OPERATION Driving Safely Dr iving Thr ough W ater Y our A TV c an ope rate through water with a maximum re comme nded depth e qual to the bottom of the footr ests (1). Follow th ese p roced ures when oper ating through water: 1. De ter mine wa ter depths a nd curr ent bef ore cr ossing. 2. Choose a crossing where both banks have gra dual incline[...]

  • Page 73

    71 OPERATION Driving Safely Dr iving Over Obstacles Be al ert! Loo k ahead an d learn t o read t h e terrai n yo u’re tr avel i ng o n. Be con s tan t l y alert fo r hazards s u ch as l og s, ro cks and l o w hang i ng bran ches . Sever e injury or deat h can r esult if your vehicle c omes in cont act with a hidden obs t acle. Not all obst acles [...]

  • Page 74

    72 OPERATION Driving Safely Dr iving in Reverse F ol l ow t hes e precaut i on s when o perat i ng i n rev erse: 1. Always avoid ba cking downhill. 2. Back slowly . 3. When i n revers e, apply the brake s lightly for stopping. 4. A void turning at shar p angle s in rever se. 5. Ne ver open the throttle suddenly while ba cking. NOTE: Most Polar is A[...]

  • Page 75

    73 OPERATION Driving Safely P a r k i n go na nI n c l i n e A void parking on a n incline if possible . If it’ s unavoida ble, follow th es e precau ti o ns : 1. T urn the engine of f. 1. Place the tr ansmission in gear . 2. Set t he parking bra ke. 3. Always block the rea r wheels on the downhill side. See illustra tion. 4. Shut of f the fuel s[...]

  • Page 76

    74 NOISE EMIS SION CO NTROL SYSTEM R EG U LA T IO N T AM P ERING WITH NOIS E C ONTROL S YS TEM P R OHIBITED! U.S . F ede ral law prohibits the following ac ts or t he ca using there of: (1) T he re moval or rende ring inopera tive by any pe rson other than f or pu rpo ses of m ai n t enan ce, repai r , or rep l acem ent of an y d evi ce o r ele men[...]

  • Page 77

    75 MAINTENANCE AND LUBRICATION Accessor ies Auxilia ry power outle ts provide 12V power f or oper ating access ori es such a s hand he ld spot lights. Ac ce ssory outle ts are availa ble for all models. Contact your Polar is deale r for more informa tion. Po laris has a wi de range of addit i onal acces sori es avai labl e for your A TV . S ee your[...]

  • Page 78

    76 MAINTENANCE AND LUBRICATION Pe r iodic Mai ntenance Sc hedule Hours of ope ration ar e ba sed on a 10 mph ave rage . If se rvic e is due a t 20 hours, the e quivale nt odometer re ading would be 200 miles. P erform al l serv i ces at whi chev er readin g is reached fi rs t. Item Hours/ Mile s Fr equency Remarks Brake S ystem Pre- Ride Pr e-Ri de[...]

  • Page 79

    77 MAINTENANCE AND LUBRICATION Pe r iodic Mai ntenance Sc hedule Item Hours/ Mile s Fr equency Remarks T a illig h t/bra k e lig h t Pre- Ride Pr e-Ride Check operati on dail y; ap- ply P olar is diel ectr ic grease to socket when repl aced " L Air filte r , mai n elem ent W eekly W eekly Inspect ; repl ace as needed " T ransmi ssion oi l[...]

  • Page 80

    78 MAINTENANCE AND LUBRICATION Pe r iodic Mai ntenance Sc hedule Item Hours/ Mile s Fr equency Remarks Carbur etor f loat bowl 50 hr s. 6 mont hs Drain bowl peri odical ly and pri or to stor age J Throt tl e Cable/ ETC Swit ch 50 hrs. 6 months Inspect ; adjust ; lubr icat e; r eplace if necessar y L Choke (enr icher ) cable 50 hr s. 6 mont hs I nsp[...]

  • Page 81

    79 MAINTENANCE AND LUBRICATION Pe r iodic Mai ntenance Sc hedule Item Hours/ Mile s Fr equency Remarks J L Fuel system 100 hours 12 months Check f or l eaks at t ank cap, li nes, fuel val ve, fi lt er , pump and car bur etor ; r e- place l ines ever y two year s J Fuel fi lt er 100 hr s. 12 mont hs Replace annual ly Radiat or 100 hrs. 12 m onths I [...]

  • Page 82

    80 MAINTENANCE AND LUBRICATION Lubr icat ion Re com mendati ons NOTE: Hour s are based on 10 mph ave ra ge. If se rvice i s due at 20 hours, the e quivale nt odometer re ading would be 200 miles. P erf orm all serv i ces at wh ich ever read in g i s reached fi rs t . Lubr ica tion C har t Ke y " More often unde r seve re use , such a s wet or [...]

  • Page 83

    81 MAINTENANCE AND LUBRICATION Lubr icat ion Re com mendati ons (4) (1) (5) (2) (2) (3)[...]

  • Page 84

    82 MAINTENANCE AND LUBRICATION Lubr icat ion Re com mendati ons Item Lube M ethod Fr equency (6) Demand 4 Hubs - All Wheel Dr iv e A TV s Prem ium Hub Lube Remov e set s c rew in hubs . R otate wheels to 4 O ’c loc k pos ition. If lubr i- c ant is not v is ible add mor e. Reins tall se t scre w . Annually or at 100 hrs . (7) Fro nt Drive Ax le (U[...]

  • Page 85

    83 MAINTENANCE AND LUBRICATION Lubr icat ion Re com mendati ons (7) (9) (8) (6) 4 O’clock posit ion (6) (1 1) (10) (12) (14) (15) (13) (13)[...]

  • Page 86

    84 MAINTENANCE AND LUBRICATION Per io dic Maint enance Record Use t he fo l lo wi ng ch art to record p eri od ic m ai nt en ance. Maintenance In t erval Perfo rmed Se rvic ing Date Se rvic ing Dealer or Pe rson Remarks 10 hrs. 20 hrs. 50 hrs. 100 hrs.[...]

  • Page 87

    85 MAINTENANCE AND LUBRICATION Lubr ication R ecom m endations P olar is 2 - Cycl e Lubri cants Polar is P remium 2-c ycle lubric ants ar e the most advanc ed for mulation of oils, specific ally designed for toda y’ s 2-cyc le engine s. Our ongoing lab a nd field tests ha ve re sulted in a ne w gen era tion of 2-c ycle lubric ants. Polar is Premi[...]

  • Page 88

    86 MAINTENANCE AND LUBRICATION Lubr ication R ecom m endations Pr emium 4 S ynth etic Oil Polaris Pre mium 4 All Sea son Synthetic e ngine oil ha s been spe cially for mulate d for use in Polaris 4-c ycle e ngines. It’ s a fully synthetic, high per for manc e, multi-viscosity oil de signed to pr ovide the u ltimate in lu bri cat i on p erform an [...]

  • Page 89

    87 MAINTENANCE AND LUBRICATION Lubr ication R ecom m endations Oil an d Filter Chan ge 4 - Cyc le Engine s With Ex terna l O il T ank 1. Position the vehicle on a leve l surf ace. 2. Clean the ar ea ar ound the dra in plug, which is loca ted on e ither the bottom of t he oil t ank or on the bottom of t he engine . 3. Run the engine for two to thr e[...]

  • Page 90

    88 MAINTENANCE AND LUBRICATION Lubr ication R ecom m endations Oil an d Filter Chan ge 4 - Cyc le Engine s With Ex terna l O il T ank 1 1. Lubric ate the gaske t on the new filte r with a film of new engine oil. Make sure the ga sket is in good condition. Also make sure the gaske t from the old filter i s not still on the engine . 12. Insta ll the [...]

  • Page 91

    89 MAINTENANCE AND LUBRICATION Lubr ication R ecom m endations Oil an d Filter Chan ge Magnum 3 3 0 2x4, Ma gnum 33 0 4x4, T rail Boss 1. Position the vehicle on a leve l su rface. 2. Clean the ar ea around the dra in plug (1) . 3. Run the engine for two to thre e minutes until wa rm. Stop the engine . 4. Place a dr ain pan bene ath the engine cr a[...]

  • Page 92

    90 MAINTENANCE AND LUBRICATION Lubr ication R ecom m endations Oil an d Filter Chan ge Magnum 3 3 0 2x4, Ma gnum 33 0 4x4, T rail Boss 12. Remove the dipstick a nd fill the sump with 2 qua rts (1.9 l) of Polar i s P re mium 4 synthetic oil. 13. Place the ge ar sele ctor in neutra l and set t he park ing brake . 14. Start the engine and let it idle [...]

  • Page 93

    91 MAINTENANCE AND LUBRICATION Lubr ication R ecom m endations T ransm ission Oil Ch eck - Mo dels with F ill Plug Scramb ler 500 4x4, Ma gnums: 500, 330 4x4, 330 2x4 The tr ansmission lubr icant lev el s hould be c hecke d eve ry six months or 1000 miles ( 1600 km), whiche ver c omes fir st. T ra nsmission oil should be cha nged annua lly . 1. Pos[...]

  • Page 94

    92 MAINTENANCE AND LUBRICATION Lubr ication R ecom m endations T ransm ission Oil Ch ang e - Mo dels with F ill Plug Scramb ler 500 4x4, Ma gnums: 500, 330 4x4, 330 2x4 1. If equippe d, re move the propshaf t shield fr om t he right side of the veh icl e t o access th e fi ll p lu g. 2. Remove the fill plug. 3. Remove the t ra nsmission drain plug [...]

  • Page 95

    93 MAINTENANCE AND LUBRICATION Lubr ication R ecom m endations T ransm issio n Oil Check - Mo dels with Dipstick On most 2x4 models, the tra nsmission dipstick ( 1) is loca ted on the right side of the mac hine. On the S portsman, the di ps t i ck i s l ocat ed n ear th e rear brak e di s c. The tra nsmission lubrica nt level should be c hec ked mo[...]

  • Page 96

    94 MAINTENANCE AND LUBRICATION Lubr ication R ecom m endations T r ansmission Oil Change - 2x4 Mod els 7. T ighten the jam nut secur ely while holding the adjuster bolt. 8. Add the proper lubric ant through the dipstick hole until the oil leve l is betwe en the uppe r a nd lower limits. Do not overf ill. 9. Ch eck fo r l eaks . T r ansmission Oil C[...]

  • Page 97

    95 MAINTENANCE AND LUBRICATION Lubr ication R ecom m endations Front Gearcase Oil Check The f ront gear ca se oil le vel should be che cked e very six months or 1000 miles (1600 km), whiche ver come s first. The oil should be change d annua lly . Use Polaris Pre mium Synthetic Gea rc ase Lube (or G L5 80-90 weight gear lube ). NOTE: Se e page 141 f[...]

  • Page 98

    96 MAINTENANCE AND LUBRICATION Lubr ication R ecom m endations Rear Gear case Oil Check W i t h t h e A T V o n a l ev el s u rface, re move the fill plug and view the oil leve l through the fill hole (1) . Lubric ant should be kept e ven with the ce nter of the dr illpoint (2) , appr oximate ly 1 5/8 ″ be low the top of the fill hole. Use P olar[...]

  • Page 99

    97 MAINTENANCE AND LUBRICATION Lubr ication R ecom m endations Counte r B alance Oi l Check - 400 2 - Cyc le E ngines The c ounter bala nce oil should be c hec ked se mi-annually a nd oil should be a dded or c hanged as ne eded. The oil should be c hange d annua lly and be fore of f sea son storag e. If the mac hine is used in w et conditions, chec[...]

  • Page 100

    98 MAINTENANCE AND LUBRICATION Lubr ication R ecom m endations E ngine Oi l Chec k The oil tank is locate d either on the lef t side of t he vehic l e (e xter nal tank models) (1) or on the engine (2) . 1. Position the machine o n a level surf ace. 2. Start the engine and let it idle for 20-30 sec onds. S top the engine. 3. Remove the dipstick and [...]

  • Page 101

    99 MAINTENANCE AND LUBRICATION Engi ne C ooling S ystem Coolant Level The re covery bottle (1 ) is located on the lef t side of the machine . T o access th e recov ery b o ttle on Gen IV m achi nes , rem ov e t he l eft si d e pane l. S ee pa ge 1 1 1. The fluid leve l m ust be maintained betw ee n the minimum and maximum marks on the bottle (whe n[...]

  • Page 102

    100 MAINTENANCE AND LUBRICATION Engi ne C ooling S ystem Radiator Coolant Level NOTE: This pr oce dure is requir ed only if the c ooling system ha s been dra ined for ma intena nce a nd/or repa ir . Howe ver , if the rec overy bottle ha s run dry , t he leve l i n the radiator should be inspe cted a nd coolant add ed i f neces sary . 1. Loca te the[...]

  • Page 103

    101 MAINTENANCE AND LUBRICATION Engi ne C ooling S ystem NOTE: T o ensure that the c oolant mainta ins its ability to prote ct the eng in e, we reco m men d th at t h e sy s t em b e com p l etel y drai ned every tw o years an d a fresh mi x t ure of ant i freeze and wat er added . P o l aris recom m end s t h e us e of P o l aris P rem i um 60 /4 [...]

  • Page 104

    102 MAINTENANCE AND LUBRICATION Adju stment s Oil P ump - 2 50 Engine s 1. Befor e adjusting the oil pump, che ck the engine idle RPM and car buretor se ttings in the owner ’ s manual suppleme nt. 2. Loose n throttle ca ble jam nut and turn the adjuste r (1) in or out until ther e is 1/16 ″ -1 / 8 ″ (.16 - .32 cm) of throttle leve r trave l b[...]

  • Page 105

    103 MAINTENANCE AND LUBRICATION Adju stment s Oil P ump - 4 00 Engine s 1. Befor e adjusting the oil pump, che ck engine idle RPM and ca rbure tor adjustments in your owner ’ s m anua l supplement. 2. Loosen the throttle c able jam nut and turn the adjuster in or out until there is 1/16 ″ -1 / 8 ″ (.16 - . 32 cm) throttle leve r trave l befor[...]

  • Page 106

    104 MAINTENANCE AND LUBRICATION Adju stment s Fr ont Br ake The front bra kes ar e hydraulic disc br akes. They’r e activate d by moving the brake le ver towar d the handleba r . These br akes are self -a djusting. The fo l l owi ng check s are reco mm en ded to keep t h e brak e sy s tem i n good oper ating c ondition. Check mor e ofte n if brak[...]

  • Page 107

    105 MAINTENANCE AND LUBRICATION Adju stment s Rear Br ake The re ar bra ke is a hydraulic disc brak e. Th e rear brak e s ys t em is self -a djusting and r equire s no mainte nance othe r than per iodic check s o f th e pad s fo r wear . Pads should be c hanged w hen wor n to 3/64 ″ (.1 cm) , which is a bout the thickne ss of a U.S. dime. Inspe c[...]

  • Page 108

    106 MAINTENANCE AND LUBRICATION Adju stment s T oe Alignm ent Use the following proce dure to chec k the toe alignment of the vehicle. The re comme nded toe alignment is 1/8 ″ to 1/4 ″ toe out. 1. Set t he handle bars in a stra ight-a hea d position. NOTE: The st eeri ng fro g can be us ed as an i nd i cato r of whether the ha ndleba rs are str[...]

  • Page 109

    107 MAINTENANCE AND LUBRICATION Adju stment s Steer ing Assembly The ste er ing asse mbly of the A TV should be che cked pe riodica lly for loose nuts and bolts. If loose nuts and bolts are found, see your Polaris dea ler for se rvice be fore oper ating t he vehic le. Cam ber and Caster The ca mber and c aste r are non- adjusta ble. Rear S pring Th[...]

  • Page 110

    108 MAINTENANCE AND LUBRICATION Adju stment s Handlebars The h and l ebars can b e adj u st ed for rid er preferen ce. 1. Locat e han dl eb ar bo lt s (1). On models with a headlight pod, re move the upper he adlight pod. On other models, remove th e han d leb ar co ver . 2. Loosen the four bolts. 3. Adjust the handle bar to the desir ed height. Be[...]

  • Page 111

    109 MAINTENANCE AND LUBRICATION Adju stment s Ca r bure tor IMPOR T ANT : Y our Polar i s A TV is ca librate d at the f ac t ory f or optimal pe rfor m anc e at altitude s ra nging from z er o to 6,000 fee t (1800 m) and temper atur es of +40 degree s F . (4 degre es C .) or higher . Above 6000 fe et (1800 m) the e ngine a ir/fue l mixture be comes[...]

  • Page 112

    11 0 MAINTENANCE AND LUBRICATION Adju stment s Ca r bure tor 4 - Cyc le E ngi nes If the e ngine idle spee d is not satisfa ctory , and all other c onditions are fa vorable , the carbu ret or can be ad ju s ted . 1. W arm up the engine by running the vehic le for appr oximately five minutes. 2. Plac e the transmission in gear w ith the par king bra[...]

  • Page 113

    111 MAINTENANCE AND LUBRICATION Adju stment s Side Panel Rem oval - Gen IV NOTE: Side panel r emoval may be diff icult until the loc king tabs a nd receiv ers hav e been sn app ed and u ns n app ed a few time s. 1. Remove the sea t . 2. Grasp the rea r of the side pan el n ear t he rear cab . W i t h a quic k and f irm motion, pull th e panel fo rw[...]

  • Page 114

    11 2 MAINTENANCE AND LUBRICATION Adju stment s Wheel Rem o val 1. Stop the engine , place the tra nsmission in gear a nd lock the par king brake . 2. Loosen the whe el nuts slightly . 3. Eleva t e the side of the vehic le by placing a suitable sta nd under the foot res t fram e. 4. Remove the whe el nuts and remove the whe el. Oper at ing your A TV[...]

  • Page 115

    11 3 MAINTENANCE AND LUBRICATION Adju stment s Wheel Installation 1. Place the tr ansmission in gear and lock the park ing brake . 2. P lace t h e wh eel o n th e wh eel hub with the valve stem towar d the outside and rota tion arr ows on the tire pointing toward for wa rd rota tion. 3. Install the wheel nuts and finge r tighten. 4. Lower the vehic[...]

  • Page 116

    11 4 MAINTENANCE AND LUBRICATION Adju stment s Fr ont Whee l Hub T ighteni ng Front whee l bear ing tightness and spindle nut r ete ntion ar e cr itical compone nt operations. All se rvic e must be per forme d by your aut ho ri zed P ol ari s d ealer . Ti re T read Depth Alway s repl ace ti res when t read depth is wor n to 1/8 ″ (.3 cm) or le ss[...]

  • Page 117

    11 5 MAINTENANCE AND LUBRICATION Adju stment s Drive Chain Polaris A TV drive cha ins are e quipped with o-ring- sea led, perma nently greas ed p i ns and rol l ers. Ho wev er , t h e ou t er su rfaces of t he ro l l er m us t be lubric ated. Always inspe ct the dr ive cha i n prior to ope ra ting the vehic le. Check f or dama ged or missing o-r in[...]

  • Page 118

    11 6 MAINTENANCE AND LUBRICATION Adju stment s Rear Dr ive Chain Slack - Con centric Dr ive Mo dels Chec k the a mount of cha i n slac k in thre e dif fe re nt locations by moving the ve hicle slightly f orwa rd to gain sla ck a t the top side of the r ear chai n. M eas ure t h e chai n sl ack at t h e ti g ht es t of t he t h ree po s it i o ns . [...]

  • Page 119

    11 7 MAINTENANCE AND LUBRICATION Adju stment s Rear Dr ive Chain Slack - Con centric Dr ive Mo dels 6. R o ll th e A TV forward o r back ward to adjust the cha in slack to the prope r tension. See the illustra tion for pr oper splice link clip ope ning position (1) . 7. T ig h ten t he eccen t ric l o cki n g b ol t s to 30 ft. lbs. (41 Nm) for ma [...]

  • Page 120

    11 8 MAINTENANCE AND LUBRICATION Filter System s Air Filter Rem oval and Service - 2 - Cycle Engines 1. Remove the A TV seat. 2. Rele ase the clips sec uring the cover a ssembly to the air box. 3. Loose n the clamp sec uring the filter , and remove the f ilter . 4. Remove the f oam pre- filte r fro m t he main filte r . 5. W ash the pre -filter i n[...]

  • Page 121

    11 9 MAINTENANCE AND LUBRICATION Filter System s Air Filter Service - 4 - Cycle 1. Rem o ve t h e seat , rel eas e t he cl i p s, and re move the air box cover . 2. Loosen the cla mp and r emove the filte r . 3. Remove the f abr i c type pre- filter (1) f rom the main filter ( 2). W ash the pr e- filte r in soa py wate r , then rinse a nd let dry .[...]

  • Page 122

    120 MAINTENANCE AND LUBRICATION Lights Whe n servicing a halogen lamp, don’ t touch the lamp with ba re finger s. Oil fr om your skin leave s a re s idue, ca using a hot spot tha t will shorten the life of the la mp. Headlight Lamp Replacement - Scr ambler 1. Remove the wir e har ness conne ctor fr om the back of the hea dlight. 2. Gra sp the bul[...]

  • Page 123

    121 MAINTENANCE AND LUBRICATION Lights Headlight Lamp Replacement - T rail Blazer 1. Remove the fr ont cover and unplug the light harne ss. 2. Remove the rubbe r cap fr om the back of the head light to reve al the re tention scr ew . 3. Remove the sma ll phillips head scr ew , an d car ef ully remove the bulb from the housing. 4. Apply diele ctr ic[...]

  • Page 124

    122 MAINTENANCE AND LUBRICATION Lights Headlight L amp R eplacement - Gen IV 1. Remove the three sc rews on the headlight pod. 2. Using a sma ll flat- blade scr ew driver , push in on the lock ta bs through the two small ope nings at the front of the he adlight pod. 3. Lift the pod slightly while depre ssing the tabs. 4. Lift the pod cover and disc[...]

  • Page 125

    123 MAINTENANCE AND LUBRICATION Lights High Beam Adjustment - Gen IV The h ea dlight bea m can be adjusted to a ny position desire d by turning the adjusting knob on the bottom right side of the hea dlight pod. 1. Position the vehicle on a leve l surfac e with the headlight appr oximate ly 25 ft. (7.6 m.) fr om a wa ll. 2. Remove the two screws on [...]

  • Page 126

    124 MAINTENANCE AND LUBRICATION Lights Headlight Hou sing Replacement - Gen IV 1. Remove the three sc rews on the headlight pod. 2. Using a sma ll flat- blade scr ew driver , push in on the lock ta bs through the two small ope nings at the front of the he adlight pod. Lift the pod lightly while depr essing the tabs. 3. Lift the pod cove r . Disconn[...]

  • Page 127

    125 MAINTENANCE AND LUBRICATION Lights T aillight /Br akeligh t Lamp Replacement If the t aillight/br ake light does not work the lamp may nee d to be repl aced. 1. Remove the ta illight lens cover mounting scre ws. Re move the lens c over a nd gasket and se t aside f or re asse mbly . 2. Remove the lamp (1) and re place it with a new la mp. 3. T e[...]

  • Page 128

    126 MAINTENANCE AND LUBRICATION Spar k P l ugs Refe r to your owner ’ s manual supplement for re comme nded spar k plug and g ap sp eci ficat i o ns . Spar k plug condition is indica tive of engine operation. The spar k plug firing e nd condition should be re ad a fter t he e ngine has be en war med up an d th e veh icl e has b een dr iv en at h [...]

  • Page 129

    127 MAINTENANCE AND LUBRICATION V eh ic le Imme rsio n If it’ s impossible to take your A TV to a deale r befo re sta rting it, follow the steps outlined below . 1. Move the A TV to dry land or at the ver y lea st, to wate r below the foot re sts. 2. Check the air box for a ny water a nd dry it i f wat er i s p res ent . 3. T urn the fuel valve o[...]

  • Page 130

    128 MAINTENANCE AND LUBRICATION Spar k A r r estor W ARNING Failur e t o heed t he f ollowing warnings while serv icing t he s park arres t or c ould res ult in ser ious injur y or death. Do no t perform servi ce on the spa rk arrestor whi le the system is hot. Exhaust syst em tem perat ures ca n r each 1000 ° F . Allow component s to c ool suff i[...]

  • Page 131

    129 MAINTENANCE AND LUBRICATION Spar k A r r estor 1. Remove the ar restor cle an-out plug(s) (1) f rom the bottom of the muf fle r . 2. Place the tr ansmission in neutra l and start the engine . 3. Pur ge ca rbon fr om t he syste m by momentar ily re vving the e ngine seve ral time s. 4. If c arbon is expe lled, cover the exha ust outlet and ra p [...]

  • Page 132

    130 MAINTENANCE AND LUBRICATION Recoil Hou sing T o preve nt possible engine damage , alwa ys drain the re coil housing af ter ope rating the A TV in very w et conditions. This should also be done bef ore storing the A TV . W ate r will ente r the rec oil housing if the starte r handle is disengage d from the rope guide when under wa t er . NOTE: O[...]

  • Page 133

    131 MAINTENANCE AND LUBRICATION PV T S ystem The basic ope ra tion of t he Polaris PVT system is depende nt on engine sp eed an d v ehi cl e t orq ue req ui rem ent s . As en gi n e sp eed i n creases , t he forc e exerte d on the movable drive shea ve by the flyweights also incr ea ses. This, in turn, incre ase s the a mount of “pinc h” a ppli[...]

  • Page 134

    132 MAINTENANCE AND LUBRICATION PV T S ystem PVT Dryi n g There m ay be so m e ins t ances wh en wat er is acci den t ly i n ges t ed in t o the PVT system. Use the following instruc tions to dry it out bef ore oper ating: 1. Remove the dr ain plug and allow the wa ter to dra in. Repla ce the dra in plug. 2. Start the engine an d shift the transmis[...]

  • Page 135

    133 MAINTENANCE AND LUBRICATION Batter y (C onventional) Ke ep the batte ry termina l s and c onnec tions fre e of c orrosion. If cle aning is nec essa ry , remove the c orrosion with a stif f wire br ush. W ash with a solution of one ta blespoon baking soda a nd one cup wa ter . Ri n se wel l wi t h t ap wat er and dry o ff wi t h cl ean sh o p to[...]

  • Page 136

    134 MAINTENANCE AND LUBRICATION Batter y Re plenis hing Ba tter y Fluid (Conv entional Batte r y) A poorly ma intained ba ttery will dete riorate r apidly . Check the ba tter y fluid leve l often. The fluid le vel should be kept betwee n the upper and lower leve l marks ( 1). T o ref ill use only distilled w ate r . T ap wate r c ontains miner als [...]

  • Page 137

    135 MAINTENANCE AND LUBRICATION Batter y Battery Installation 1. Set the ba tter y in the ba tter y holder . 2. W ith conve ntional batte ries, install the batte ry vent tube . Seale d batte ries do not have a vent tube. NOTE: The ven t tube must be fr ee of obstr uctions a nd sec ure ly installed. If not, batte ry gase s could accum ul ate and cau[...]

  • Page 138

    136 MAINTENANCE AND LUBRICATION Batter y Batter y Charging (S ealed Battery ) For a re fr esh cha r ge, follow all instructions ca ref ully . 1. Chec k the batte ry voltage with a voltme ter or multimete r . A fully cha rge d batter y will registe r 12.8 V or higher . 2. If the volta ge is less than 12. 8 volts, re cha r ge the batte ry . NOTE: Whe[...]

  • Page 139

    137 MAINTENANCE AND LUBRICATION Cleaning a nd Stor age See page 141 for the pa rt numbers of Polaris-r ecomme nded produc ts. Cleaning th e A T V Kee ping your A TV c lean will not only improve its appe ara nce but it ca n also exte nd the life of var ious compone nts. W ith a fe w precauti ons, your A TV can be cleaned much l ik e an a utom obil e[...]

  • Page 140

    138 MAINTENANCE AND LUBRICATION Cleaning a nd Stor age Sto ra g e Tip s See page 141 for the pa rt numbers of Polaris-r ecomme nded produc ts. Clean t he Exterio r Make nec essary r epairs a nd then cle an the A TV thoroughly with mild soap a nd wa rm wa ter to r emove all dir t and grime . Don’ t use har sh dete r gents or high pressur e washe r[...]

  • Page 141

    139 MAINTENANCE AND LUBRICATION Cleaning a nd Stor age Sto ra g e Tip s See page 141 for the pa rt numbers of Polaris-r ecomme nded produc ts. Fog the E ngine 2C y c l e - Use Pola ris F ogging Oil and follow the direc tions on the can. 4-Cycle - Re move the spa rk plug a nd add 2-3 ta blespoons of Premium 4 S yn t het i c 0W4 0 en gi n e oi l . T [...]

  • Page 142

    140 MAINTENANCE AND LUBRICATION Cleaning a nd Stor age Sto ra g e Tip s Batte r y Stor ag e Con ven ti o n al B attery : Remove the batter y and add distille d wate r to th e pro per l ev el . Do not use tap water , wh i ch m ay con tai n m i neral s that re duce ba ttery life . Apply P olar is di-ele ctric gre ase to the termina l bolts and te rmi[...]

  • Page 143

    141 POLARIS RECOMMENDE D PRODUCTS Part No. Descr ipt ion Engine Lubr icant 2870791 Fogging O il (12 oz. Aerosol ) 2871098 Prem ium 2-C ycle Engi ne Oil (qt .) 2871721 Prem ium Gold S ynthet ic 2- Cycle Oi l ( qt. ) 2871281 Prem ium 4 Synthet ic 0W -40 Engi ne Oil (4- Cycle) (qt .) Gear case / T ransmi ssion Lubri cants 2873602 Prem ium Synt heti c [...]

  • Page 144

    142 TROUB LES HOOTIN G Dr ive Belt and Cover Pr oblems Po ssi b l e Cau se Solu tio n Dr ivi ng the A TV onto a p ick u p o r tall trailer in hi gh ra nge. Shi ft tr ans mis si on to l ow ra nge dur ing l oadi ng of t he A TV t o pre vent be lt bur ning. St ar ti ng out goi ng up a steep in clin e. Whe n st ar ti ng out on a n inc li ne, use low ra[...]

  • Page 145

    143 TROUB LES HOOTIN G Contac t your P olar is deale r for ser vice if you’ re unable to identif y solutions using the follow ing cha rts. Engine Doesn’t T urn Over Po ssi bl e Cause Sol uti o n Trip p ed circu it b reak er Reset th e b reak er Lo w battery v o ltage Re c har ge ba tt er y to 12. 5 VDC Loos e ba tt er y conne ct ions Ch eck all[...]

  • Page 146

    144 TROUB LES HOOTIN G Engine Backfir es Po ssi bl e Cause Sol uti o n W ea k spa rk f rom s pa rk pl ugs In sp ect, clean and /o r repl ace sp ark p lu g s In co rrect spark p lu g g ap o r h eat rang e Se t ga p to s pec s or re pla ce plugs Ol d or non- re c omme nded f uel Re pla ce w it h new fue l In co rrectly in stalled sp ark p lu g w ires[...]

  • Page 147

    145 TROUB LES HOOTIN G E ngine S tops or Loses P ower Po ssi bl e Cause Sol uti o n Out of fuel Tu rn fu el valv e to reserve, refu el Ki nke d or plugge d fue l ve nt li ne Insp ect and rep lace W ater p resen t in fuel Re pla ce w it h new fue l Ove rus e of choke In sp ect, clean and /o r repl ace sp ark p lu g s Foul ed or de fe ct ive spa rk p[...]

  • Page 148

    146 WARRANTY LI MIT ED W ARRANTY Polaris I ndustries I nc., 2100 Highwa y 55, Me dina, MN 55340, gives a SIX MONTH LIMITED W ARRANTY on all components of the P ol ari s All T errai n V eh icl e (A T V) again st d efects i n m ateri al o r wor kmanship. Polar is also gives a one ye ar limited w ar ra nty on the final drive ch ain for failur e due to[...]

  • Page 149

    147 WARRANTY W ARRANT Y COVERAGE AND EXCL USIONS: LI MIT A T IONS OF W ARRANTIES AND REMEDIES The Pola ris limite d war ranty exc ludes any f ailur es that a re not cau sed by a de fe ct in mate rial or workma nship. This warra nty does not cover accid ent al dam ag e, no rm al w ear and tear , ab us e or i m p rop er han dl i n g. This warr anty a[...]

  • Page 150

    148 WARRANTY ALL IMP LIED W ARR ANTIES (INCLUDING B UT NOT LIMITED T O THE IMP LIED W AR RANTIES OF MERC HANT ABILITY AND FITNES S FOR A P AR TIC ULAR P UR P OSE) AR E LIMITED IN DURA TION TO THE ABOVE S IX MONTH W AR RANTY P ER IOD. POLAR IS FUR THER DIS C LAIMS ALL EXPRES S W AR RANTIES NOT ST A TED IN THIS W ARR ANTY . S om e stat es do not al l[...]

  • Page 151

    149 INDEX A Access or ies 75 ............................. Adj ust ments 102-1 17 ........................ Age Restrictio n s 7 .......................... Air Filter 118- 119 ........................... Al l W heel D rive 48-49 ....................... Aux iliar y Brak e 42 , 1 05 ..................... A W D 48-49 ............................... B B[...]

  • Page 152

    150 INDEX O Oil Injection T ank 45 ........................ Oi l Pump Adj ustme nt - 250 Engi nes 102 ......... Oi l Pump Adj ustme nt - 400 Engi nes 103 ......... Oi l P ump Bl eedi ng - 2-Cyc le E ngine s 101 ....... OPE RA TI ON 56-73 ....................... Ope rat or Sa fet y 7-31 ........................ Override S witch 37 ..................[...]

  • Page 153

    Operate without proper training or instruction. Operate on public roads. A collision can occur with another vehicle. Operate at speeds too fast for your skills or the conditions. Use ALCOHOL or DR UGS before or while operating this vehicle. Carry Passengers. P art No. 9917492 Rev . 05 PRINTED IN THE USA W ARNING Improper vehicle use can result in S[...]