Polaris ATP 500 4x4, ATP 330 4x4 User Manual

4 (1)
WARNING
Improper vehicle use can result in SEVERE INJURY or DEATH.
AN APPROVED
HELMET AND PROTECTIVE
GEAR
NEVER USE
ON PUBLIC
ROADS
NEVER CARRY
PASSENGERS
NEVER USE
WITH DRUGS
OR ALCOHOL
NEVER:
Operate without proper training or instruction. Operate on public roads. A collision can occur with another vehicle. Operate at speeds too fast for your skills or the conditions. Use ALCOHOL or DRUGS before or while operating this vehicle. Carry Passengers.
ALWAYS:
Avoid paved surfaces, which may adversely affect handling and control. Use proper RIDING TECHNIQUES to avoid vehicle overturns on hills
and rough terrain, and in turns. Wear eye protection, helmet and protective apparel.
READ OWNER'S MANUAL.
FOLLOW ALL INSTRUCTIONS AND WARNINGS.
Part No. 9917747 Rev 03 PRINTED IN THE USA
WARNING
The engine exhaust from this
product contains chemicals known
to cause cancer, birth defects or
other reproductive harm.
A card containing important ATV safety information should be attached to the owner’s manual on the next page. If you cannot locate this card, or if it has been removed, please call 1-800-342-3764 for assistance.
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All information in this manual is based on the latest product data and specifications available at the time of printing. Polaris Industries Inc. reserves the right to make product changes and improvements that may affect illustrations or explanations.
No part of this manual shall be reproduced or used without the written permission of Polaris Industries Inc.
Copyright 2002 Polaris Industries Inc. All Rights Reserved Printed in the U.S.A.
2
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 V ictory motorcycles S RANGER utility vehicles
Polaris Professional Series Workmobilest
S Utility Task Vehiclest (UTVs) S Personal Task Vehiclest (PTVs) S All-Surface Loaders (ASLs)
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 m anual. 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) T echnician.
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, Polaris The Way Out, and Workmobiles are registered trademarks of Polaris Industries Inc.
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4
TABLE OF CONTENTS
WELCOME 3........................................
TABLE OF CONTENTS 5.............................
VEHICLE IDENTIFICATION NUMBERS 6...............
SAFETY 7..........................................
FEATURES AND CONTROLS 37......................
OPERATION 53.....................................
EMISSION CONTROL SYSTEMS 74...................
MAINTENANCE AND LUBRICATION 75................
POLARIS PRODUCTS 121............................
TROUBLESHOOTING 122............................
SPECIFICATIONS 126................................
WARRANTY 130.....................................
INDEX 137..........................................
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VEHICLE IDENTIFICATION NUMBERS
The vehicle frame vehicle identification number (VIN)(1) and engine serial number (2) are important for model identification when registering your vehicle, when obtaining insurance, and when ordering replacement parts. If your vehicle is stolen, these numbers are essential to the recovery and identification of your vehicle.
Remove the spare key and store it in a safe place. Your key can be duplicated only by mating a Polaris key blank with one of your existing keys. If both keys are lost, the ignition switch must be replaced. See your Polaris dealer.
NOTE: Record your vehicle’s ID numbers and key number (3) in the spaces provided.
2
1
31XX
3
Frame VIN:
Vehicle Model Number:
Engine Serial Number (right front side of engine crankcase):
Key Number:
6
SAFETY
Operator Safety
WARNING
Failure to follow the warnings contained in this manual can result in severe 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 A TV.
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 t he 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.
7
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 ATV 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 machine.
CAUTION
A caution indicates a situation that may result in damage to the machine.
NOTE
A note will alert you to important information or instructions.
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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 safe­ty 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.
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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 excessive­ly 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 pos­sible.
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 t urn the ATV around on any hill until you’ve mastered (on level ground) the turn­ing 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 pro­cedure 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 de­scribed 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 skid­ding or sliding out of control.
S Avoid operating the ATV t hrough deep or fast-flowing water. If it’s
unavoidable, 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.
10
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 proper tire pressure.
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 Con­sumer 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.
11
SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD Operating this ATV without proper instruction. WHAT CAN 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 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.
HAPPEN
HAZARD
WARNING
POTENTIAL Failure to follow the age recommendations for this ATV. WHAT CAN 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 No one under the age of 16 should operate a Polaris ATV.
12
HAZARD
HAPPEN
HAZARD
SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD Carrying a passenger on an ATV. WHAT CAN 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 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.
HAPPEN
HAZARD
WARNING
POTENTIAL HAZARD Carrying a passenger in the cargo box. WHAT CAN A passenger riding in the cargo
box could be ejected from the vehicle unexpectedly or may contact moving components, both of which can result in severe injury or death.
HOW TO AVOID THE Never allow passengers to ride in the cargo box.
HAPPEN
HAZARD
13
SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD Operating an ATV on paved surfaces, including sidewalks,
paths, parking lots, and driveways. WHAT CAN 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 Avoid operating the ATV on pavement. If it’s unavoidable,
travel slowly and avoid sudden turns or stops.
HAPPEN
HAZARD
14
Operator Safety
WARNING
POTENTIAL HAZARD Operating this ATV on public streets, roads or highways. WHAT CAN The ATV could collide with another vehicle. HOW TO AVOID THE 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.
HAPPEN
HAZARD
SAFETY
15
SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD Operating this ATV without wearing an approved helmet, eye
protection and protective clothing. WHAT CAN 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 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.
HAPPEN
HAZARD
16
Operator Safety
WARNING
POTENTIAL HAZARD Operating the ATV after consuming alcohol or drugs. WHAT CAN 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 Never consume alcohol or drugs before or while operating an
ATV.
HAPPEN
HAZARD
WARNING
SAFETY
POTENTIAL Operating the ATV at excessive speeds. WHAT CAN Excessive speed increases the operator’s chance of losing
control of the ATV, which can result in an accident. HOW TO AVOID THE Always operate the ATV at a speed that’s proper for the terrain,
visibility and operating conditions, and your experience.
HAZARD
HAPPEN
HAZARD
17
SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD Attempting wheelies, jumps and other stunts. WHAT CAN Attempting stunts increases the chance of an accident, including
an overturn. HOW TO AVOID THE Never attempt wheelies, jumps, or other stunts. Avoid exhibition
driving.
HAPPEN
HAZARD
18
Operator Safety
WARNING
POTENTIAL HAZARD Failure to inspect the ATV before operating. Failure to properly maintain the ATV. WHAT CAN Poor maintenance increases the possibility of an accident or
equipment damage. HOW TO AVOID THE 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.
HAPPEN
HAZARD
WARNING
SAFETY
POTENTIAL Removing hands from the handlebars or feet from the
footrests during operation. WHAT CAN 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 Always keep both hands on the handlebars and both feet
on the footrests of the ATV during operation.
HAZARD
HAPPEN
HAZARD
19
SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD Failure to use extra caution when operating the ATV on unfamiliar
terrain. WHAT CAN Unfamiliar terrain may contain hidden rocks, bumps, or holes that
could cause loss of control or overturn. HOW TO AVOID THE Travel slowly and use extra caution when operating on unfamiliar
terrain. Always be alert to changing terrain conditions.
HAPPEN
HAZARD
20
Operator Safety
WARNING
POTENTIAL HAZARD Failure to use extra caution when operating on excessively
rough, slippery or loose terrain. WHAT CAN 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 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.
HAPPEN
HAZARD
SAFETY
21
SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD Turning improperly. WHAT CAN Improper turns could cause loss of control and lead to a collision
or overturn. HOW TO AVOID THE 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.
HAPPEN
HAZARD
WARNING
POTENTIAL Operating on excessively steep hills. WHAT CAN The vehicle may overturn. HOW TO AVOID THE 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.
22
HAZARD
HAPPEN
HAZARD
SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD Climbing hills improperly. WHAT CAN Improper hill climbing could cause loss of control or overturn. HOW TO AVOID THE 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.
HAPPEN
HAZARD
23
SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD Traveling downhill improperly. WHAT CAN Improperly descending a hill could cause loss of control or
overturn. HOW TO AVOID THE 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
65. Always check the terrain carefully before you descending a hill. Shift your weight backward. Never travel down a hill at high speed. Avoid traveling down a hill at an angle, which would cause the
vehicle to lean sharply to one side. Travel straight down the hill when possible.
HAPPEN
HAZARD
24
SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD Improperly crossing hills and turning on hills. WHAT CAN Improperly crossing or turning as hills could cause loss of control
or overturn. HOW TO AVOID THE 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 66. Use extra caution when turning on any hill.
Avoid crossing the side of a steep hill. When crossing the side of a 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.
HAPPEN
HAZARD
hill:
25
SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD Stalling, rolling backwards or
improperly dismounting while climbing a hill.
WHAT CAN The vehicle could overturn. HOW TO AVOID
HAZARD Maintain steady speed when
climbing a hill. If all forward speed is Keep your weight uphill. Apply the front brake (or the single lever brake, gradually). When fully stopped, apply the rear brake as well, then lock the
parking brake. If the ATV begins rolling Keep weight uphill. Never apply engine power. Never apply the rear brake while rolling backwards. Apply the front brake (or single-lever brake) gradually. When fully stopped, apply the rear brake as well, and then lock
the parking brake. Dismount on uphill side, or to either side if ATV is pointed
straight uphill. Turn the ATV around and remount, following the procedure
described in the owner’s manual. See page 66.
HAPPEN
THE
lost:
backwards:
26
SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD Improperly operating over obstacles. WHAT CAN Operating over obstacles could cause loss of control or overturn. HOW TO AVOID THE 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.
HAPPEN
HAZARD
WARNING
POTENTIAL Skidding or sliding. WHAT CAN Skidding or sliding can cause loss of control. If the tires regain traction unexpectedly, the A TV could overturn. HOW TO AVOID THE On slippery surfaces such as ice, travel slowly and use extra
caution to reduce the chance of skidding or sliding out of control.
HAZARD
HAPPEN
HAZARD
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