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

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WARNING

Improper vehicle 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 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.

We’ve created a web site just for YOU!

S Technical tips

S New product introductions

S Event schedules

S Parts and Service Manual information

S Exciting details about The Way Out

Check it out...

www .polarisindustries.com/owner

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.

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.

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

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.

31XX

Frame VIN:

Vehicle Model Number:

Engine Serial Number (right front side of engine crankcase):

Key Number:

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.

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.

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.

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.

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.

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.

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

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

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

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

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

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

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

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

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

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.

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

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

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:

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:

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

SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD Operating the ATV through deep or fast-flowing water. WHAT CAN Tires may float, causing loss of traction and loss of control,

which could lead to an accident or overturn. HOW TO AVOID THE 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 67), 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.

HAPPEN

HAZARD

WARNING

POTENTIAL Improperly operating in reverse. WHAT CAN The ATV could collide with an obstacle or person, resulting in

severe injury. HOW TO AVOID THE Before shifting into reverse gear, always check for obstacles or

people behind the ATV. When it’s safe to proceed, back slowly.

HAZARD

HAPPEN

HAZARD

SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD Operating this ATV with improper tires, or with improper or uneven

tire pressure. WHAT CAN 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 Always use the size and type of tires specified in the owner’s

manual for the ATV. Always maintain proper tire pressure.

HAPPEN

HAZARD

WARNING

POTENTIAL Operating the ATV with improper modifications. WHAT CAN Improper installation of accessories or modification of the ATV

may cause changes in handling which could lead to an accident.

HOW TO AVOID THE 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.

HAZARD

HAPPEN

HAZARD

SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD Overloading the ATV or carrying/towing cargo improperly. WHAT CAN Overloading and towing can cause changes in vehicle handling,

which could lead to loss of control or an accident. HOW TO AVOID THE 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 58.

HAPPEN

HAZARD

WARNING

POTENTIAL Operating on frozen bodies of water. WHAT CAN Severe injury or death can result if the ATV and/or the operator

fall through the ice. HOW TO AVOID THE Never operate the ATV on a frozen body of water. If you’re

confident that the ice is thick enough and sound enough to support the machine and its operator, as well as the force created by a moving vehicle, exercise extreme caution.

HAZARD

HAPPEN

HAZARD

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.

SAFETY

Safety Decals and Locations

Warning decals have been placed on the ATV for your protection. Read and follow the instructions on each decal carefully. If a decal becomes illegible or comes off, contact your Polaris dealer to purchase a replacement. Replacement safety decals are provided by Polaris at no charge. The part number is printed on the decal.

Safety Decals and Locations

WARNING

DNever operate this vehicle on HILLS steeper than 25 degrees 25°.

To preventflipover on hilly terrain,when goingup or down, use throttleand brakes gradually.

DREVERSE operation can be dangerous, even at low speeds. Steering be-

comes difficult. To prevent flipover, avoid sudden braking or sharp turns.

DUse OVERRIDE for reverse speed limiter with caution. Toprevent loss of

control, never activ ate override button with open throttle.

DWhen this ATV is not in operation or unattended, place shift in the park

position.

7171383

SAFETY

WARNING

IF OWNER’S MANUAL IS MISSING, CONTACT

A POLARI S DEALER FOR A REPLACEMENT.

E1997, 2000

7079083

WARNING

Operating this vehicle if you are under the age of 16 increases your chanc e of severe injury or death.

NEVER operate this vehicle if you are under age 16.

SAFETY

Safety Decals and Locations

WARNING

IMPROPER TIRE PRESSURE OR OVERLOADING can cause loss of control resulting in SEVERE INJURY OR DEATH.

TIRE PRESSURE IN PSI (KPa):

FRONT 5 (34,5) REAR 5 (34,5)

MAXIMUM WEIGHT CAPACITY (Gross Vehicle Weight)

INCLUDING MACHINE, DRIVER AND CARGO IS

1300 LBS. (590 kg)

MAXIMUM CARGO CAPACITY 350 LBS. (158 kg)

Reduce speed and allow greater distance for braking when carrying cargo. Overloading or carrying tall, off-center, or unsecured loads will increase your risk of losing control. Loads should be centered, carried as low as possible in box, and firmly secured to the rack. 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 or box.

Read Owner’s Manual for more detailed loading information.

WARNING

IMPROPER TIRE PRESSURE OR OVERLOADING can cause loss of control resulting in SEVERE INJURY OR DEATH.

7171463

ATP 330

TIRE PRESSURE IN PSI (KPa):

FRONT 5 (34,5) REAR 5 (34,5)

MAXIMUM WEIGHT CAPACITY (Gross Vehicle Weight)

INCLUDING MACHINE, DRIVER AND CARGO IS

Read Owner’s Manual for more detailed loading information.

1500 LBS. (680 kg)

7171464

ATP 500

WARNING

DO NOT TOW FROM RACK OR BUMPER. Vehicle damage or tipover may result causi ng severe injury or death. Tow only from tow hooks or hitch. Max. combined Front Rack and container Load 90 lbs. (41 kg) 7171465

Safety Decals and Locations

WARNING

Moving par ts hazar d under belt- c lutch guard. To prevent serious injury, do not operate vehicle with guard remov ed.

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.

SAFETY

7078689

NO STEP

WARNING

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.

7079604

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.

Under seat: ATP 330

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.

S Operation of this vehicle without

engine breather filter(s) can cause engine damage. Consult owner’s manual or dealer for details.

Under seat: ATP 500

THIS VEHICLE IS AN ALL TERRAIN VEHICLE AND IS NOT INTENDEDFOR USE ON PUBLIC ROADS.

CE VÉHICULE EST UN VÉHICULE TOUT TERRAIN QUI NiEST PASDESTINÉ À ÊTRE UTILISÉ SUR LES CHEMINS PUBLICS.

Canadian Certification Decal

ATTENTION

MANUFACTURED BY: POLARIS IND, INC.

DATE:

VIN:

7078470

S Specific

carburetor jetting

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).

7170007

S Specific

carburetor jetting

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).

7079902

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

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.

FEATURES AND CONTROLS

Electrical Switches

WARNING

While operating in reverse, activating the override switch with the throttle open can cause loss of control, resulting in severe injury or death. Do not activate the override switch while the throttle is open.

Speedo Mode/Override Switch (1) (Reverse Speed Limiter) - This switch, if pressed while in any gear but reverse, will change the display mode of the speedometer (if equipped). To gain additional power while operating i n reverse, depress the override switch before opening the throttle. NOTE: The override switch also allows activation of Demand 4 Drive (All Wheel Drive) in reverse, if the Demand 4 Drive switch is on.

Main Switch (2) - To start the engine, slide the stop switch to the center RUN position and turn the main key switch clockwise past the ON position. Release the key when the engine starts. NOTE: Turn off the main switch to end all electrical power to the vehicle, including the cooling fan and lights.

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

A large key fob or key ring may contact the gas tank cap, causing an interruption to the electrical system and an unexpected engine shut-down during operation. This could result in serious injury or death. Do not attach a large key fob or key ring to the main switch.

FEATURES AND CONTROLS

Electrical Switches

Engine Stop Switch (3) - The engine will

OFFOFF

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. NOTE: Turning off the engine stop switch will shut off all electrical power to the vehicle, with the exception of the cooling fan on some models. On those models, use the main switch to shut off the power to the cooling fan.

Light Switches

The light switch is located on the left handlebar (1). It’s used to turn the lights on and off and to switch the lights from HI to LO on models equipped with HI/LO beams. NOTE: The lights won’t work unless the key is in the ON position and the shut-off switch is in the RUN position.

RUN

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.

FEATURES AND CONTROLS

WARNING

Do not start or operate an ATV with sticking or improperly operating throttle controls, which could cause an accident and lead to severe injury or death.

Always contact your dealer for service repairs 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.

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

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.

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 .

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.

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.

Brakes

Check the brake fluid level in the master cylinder before each use of the ATV. The master cylinder (2) is located on the left handlebar.

The fluid level can be seen through an indicator window (3) on the top of the master cylinder. This “eye” will appear dark when the fluid level is full. When fluid needs to be added, the eye will be clear.

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.

NOTE: When checking the fluid level, the ATV must be on level ground with the handlebars straight. If the fluid level is low, add DOT 3 brake fluid only. DO NOT OVERFILL. See page 121 for the part numbers of Polaris products.

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.

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.

Locking the Parking Brake

1. Squeeze and release the brake lever (1) two or three times, then squeeze and hold at full stroke.

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 Always place the gear shifter i n park before engaging the parking

brake.

S The parking brake m ay relax if left on for a long period of time. Al-

ways block the wheels to prevent rolling.

S Never depend on the parking brake alone if the ATV is parked on a

hill. Always block the wheels on the downhill side of the ATV to prevent rolling. Another option is to park the ATV in a sidehill position.

FEATURES AND CONTROLS

Auxiliary Brake

WARNING

Aggressively applying the rear brake when backing down a hill may cause rear tipover, which could result in serious injury or death. If the rear brake is applied aggressively while moving forward, the rear wheels may skid and slide sideways, causing loss of control and serious injury or death.

Always use caution when applying the auxiliary foot brake. Do not apply the auxiliary foot brake aggressively.

The auxiliary foot brake (1) is located on the inside of the right floor board and is operated by the right foot. The auxiliary brake serves as a backup to the main brake system if the main system becomes i noperative. It activates the rear brakes only.

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.

FEATURES AND CONTROLS

Choke

The choke assists in starting a cold engine. Refer to the engine starting procedure on page 55 for correct choke and throttle settings during starting.

Fuel Valve

The fuel valve (1) is located on the left 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.

OFF

Fuel Tank

The fuel tank filler cap (2) is located directly below the handlebar. Use either leaded or unleaded gasoline with a minimum pump octane number of 87=(R+ M/2) octane.

Fuel 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.

RES

FEATURES AND CONTROLS

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 Never fill a gas container while it’s in the cargo box. Static

electricity between the box and container could cause a spark.

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.

FEATURES AND CONTROLS

Automatic Transmission Gear Selector

The transmission gear selector (1) is located on the right side of the vehicle.

H: High Gear L: Low Gear N: Neutral R: Reverse P: Park

To shift into HIGH or PARK, you must first apply the auxiliary brake to activate t he high/park lock-out mechanism. When shifting out of HIGH or PAR K, 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. T o change gears, stop the vehicle, and with the engine idling, move the lever to the desired gear. Apply the auxiliary brake before attempting to shift into high gear or park.

Whenever the ATV is left unattended, always place the transmission in park and lock the parking brake.

Maintaining shift linkage adjustment is important to assure proper transmission function. See your dealer if you experience any shifting problems.

Belt Life

T o 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.

FEATURES AND CONTROLS

Recoil Starter

If the battery is weak 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 allowing compression to “leak” at cranking speeds. The decompressor senses when the engine is spinning fast enough to start and restores compression for starting.

1. Position the vehicle on a level surface, place the transmission in park and lock the parking brake (see page 41).

2. Grasp the recoil starter rope handle tightly and pull slightly until the starter mechanism engages.

3. Pull the rope abruptly to start the engine.

CAUTION

Extending the starter rope too far will 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.

FEATURES AND CONTROLS

All Wheel Drive (AWD) System

Polaris 4 wheel drive ATVs are equipped with a unique, Polaris exclusive, Demand 4 Drive (AWD) system activated by a switch (1) on the right handlebar. When the switch is on 2x4 (center position), the ATV is in two wheel drive at all times and the differential is locked. When the switch is on AWD (left position), the ATV is in Demand 4 Drive and the differential is locked. When the switch is on TURF (right position), the differential i s open, allowing the inside wheel to rotate independently from the outside wheel during turns. Use the TURF mode to help avoid causing damage to lawns and similar ground surfaces.

When in AWD, the front gearcase will automatically engage any time the rear wheels lose traction. When the rear wheels regain traction, the front gearcase will automatically disengage.

NOTE: The override switch allows activation of Demand 4 Drive (AWD) in reverse if the Demand 4 Drive switch is on. See page 37.

There is no limit to the length of time the vehicle may remain in Demand 4 Drive.

Engaging the Front Gearcase

The Demand 4 Drive switch may be turned on or off while the vehicle is moving. Initially, the vehicle’s electronic system will not enable the AWD until the engine 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 Demand 4 Drive switch before getting into conditions where front wheel drive may be needed. If the rear wheels are spinning, release the throttle before switching to Demand 4 Drive.

CAUTION

Switching to AWD (or from TURF to 2x4) while the rear wheels are spinning may cause severe drive shaft and gearcase damage. Always switch to AWD (or to TURF from 2x4) while the rear wheels have traction or are at rest.

FEATURES AND CONTROLS

Instrument Cluster

Your ATV i s 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. Refer to page 37 for additional information.

1. Rider Information Center

2. Speedometer needle - in addition to showing vehicle speed, the needle flashes when a warning condition exists.

3. Speedometer

CAUTION

To prevent damage, wash the ATV by hand or with a garden hose using mild soap. Do not use alcohol to clean the instrument cluster. Immediately clean off any gasoline that splashes on the instrument cluster.

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

The rider information center is located in the instrument cluster. All segments will light up for 2.5 seconds at start-up.

NOTE: If the instrument cluster fails to illuminate, a battery over-voltage may have occurred and the instrument cluster may have shut off to protect the electrical system. If this occurs, take the ATV to your Polaris dealer for proper diagnosis.

1. Gear Indicator - As the shift lever is moved, this indicator shows the gear the transmission is in:

H = High Range

L = Low R ange N = Neutral R = Reverse P = Park (if equipped)

2. AWD Indicator - This indicator illuminates when the electrical portion of the AWD system is enabled.

3. Engine Hour Display Indicator

4. Service Interval/Diagnostic Mode Indicator

5. Low Battery and Over Voltage - This warning usually indicates that the ATV is being operated at an RPM too low to keep the battery charged. A low battery warning may also occur under normal operation if the machine is at idle and high electrica l load (lights, cooling fan, accessories) is applied. Driving at a higher RPM or connecting a battery charger will usually clear the warning.

6. Odometer/Tachometer/Tripmeter/ Hour Meter

7. Check Engine Warning Indicator - The word HOT will display alphanumerically when the engine is overheating. Do not continue to operate the ATV is this warning appears or serious engine damage could result.

8. Mode Indicator

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

The rider information center has 4 standard modes: Mode 1 - Odometer Mode 2 - Tripmeter Mode 3 - Total Service Hours Mode 4 - Tachometer The reverse override button on t he 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.

Mode 4 - Tachometer

The engine RPM is displayed digitally. NOTE: Small fluctuations in the RPM from day to day may be normal because of changes in humidity, temperature and elevation.

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

Diagnostic Mode

The diagnostic mode is for informational purposes only. Please return your ATV to your dealer for all major repairs.

As long as the gauge 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.

To enter the diagnostics mode:

1. Turn the key switch off and wait 10 seconds.

2. Set the parking brake and shift the transmission into neutral.

3. Hold the mode/reverse override button and turn the key switch on.

4. Release the switch as soon as the display is activated.

The initial screen display refers to t he software version installed in your ATV. This information is displayed briefly.

Use the mode/reverse override button to toggle through the diagnostic screens.

Screen 1: Battery voltage

Screen 2: Tachometer

Screen 3: AWD diagnostic

This gauge indicates whether or not current is flowing through the AWD coil (only on models with switchable AWD).

Screen 4: Gear circuit diagnostic This screen displays the resistance value (in ohms) being read at the

gear switch input of the gauge.

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

Diagnostic Mode

Screen 5: 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 set at 50 hours. 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 t he 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.

Screen 6: Miles/Kilometers toggle The display in the tripmeter and odometer can be changed to display

either kilometers or miles. The current display mode will be shown as KM or MP. To change, hold in the mode button until the letters flash, then press and release the button once. When the display stops flashing, the mode has been set.

OPERATION

Break-In Period

The break-in period for your new Polaris 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. C areful 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.

Use of any oils other than those recommended by Polaris may cause serious engine damage. We recommend the use of Polaris Premium 4 Synthetic Oil for your 4-cycle engine.

1. Fill the fuel tank with gasoline. See page 43.

ADD 8 OZ. NORMAL FULL

2. Check the oil level on the dipstick. See page

82. 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 54.

6. Pull only light loads.

7. During the break-in period, change both the oil and the filter at 20 hours or 200 miles.

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.

Use the following checklist to verify that your vehicle is in proper working condition before each use.

Item/Inspection Procedure

1. Tires - Check condition and pressures.

2. Fuel and oil tanks - Fill both tanks to their proper levels.

3. All brakes - Check operation, adjustment and fluid level (includes auxiliary brake).

4. Throttle - Check for free operation and closing.

5. Headlight/Taillight/Brakelight - Check operation of all indicator lights and switches.

6. Engine stop switch - Check for proper function.

7. Wheels - Check for tightness of wheel nuts and axle nuts; check that axle nuts are secured by cotter pins.

8. Air cleaner element - Check for dirt; clean or replace.

9. Steering - Check for free operation, noting any unusual looseness in any area.

10. Loose parts - Visually inspect vehicle for any damaged components or loose nuts/bolts or fasteners.

11. Riding gear - Wear a helmet, goggles and protective clothing.

12. Engine coolant - Check for proper level at the recovery bottle if equipped.

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.

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. Place the transmission in park and lock the parking brake.

2. Turn the fuel tank valve on.

3. Sit on the vehicle.

4. Pull the choke knob out until it stops (1).

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.

5. Turn the engine stop switch to RUN.

NOTE: Do not press the throttle while starting the engine.

6. Turn the ignition key past the ON position to engage the starter. Activate the starter for a maximum of five seconds, releasing the key when the vehicle starts. If the engine does not start, release the starter and wait five seconds. Then activate the starter for another five seconds. Repeat this procedure until the engine starts.

7. If the engine slows or stops, position the choke knob half way in to allow proper engine warm up.

8. 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.

OPERATION

Starting the Engine

Starting a Warm Engine

Warm engines do not normally require the use of the choke. Using 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 sparkplugandtryagain.

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.

OPERATION

Hauling Cargo

WARNING

Overloading the vehicle or carrying or towing cargo improperly can alter vehicle handling and may cause loss of control or brake instability. Always follow these precautions when hauling cargo:

S Never exceed the stated load capacity for this vehicle. S Reduce speed and allow a greater distance for braking. S When operating over rough or hilly terrain, reduce speed and

cargo to maintain stable driving conditions.

S WEIGHT DISTRIBUTION in the cargo bed should be as far

forward and as low as possible. Carrying a high load raises the center of gravity and creates a less stable operating condition. Reduce load weight when cargo is high. When handling off-centered loads that cannot be centered, secure the load and operate with extra caution.

S ALL LOADS MUST BE SECURED BEFORE OPERATING.

Unsecured loads may shift and create unstable operating conditions, which could result in loss of control of the vehicle. Always be sure that the cargo bed is lowered and latched before moving the vehicle.

S EXTREME CAUTION MUST BE USED when operating with

loads extending beyond the rack or cargo bed. Stability and maneuverability may be adversely affected, causing the machinetooverturn.

S Carrying a load on only the front rack or cargo bed may cause

an imbalanced condition and increases the possibility of vehicle overturn. Balance loads proportionally between the front rack and cargo bed, but do not exceed the stated load capacity.

S Use extreme caution when applying brakes with a loaded ve-

hicle. Avoid terrain or situations that may require backing downhill.

S Always attach the tow load to the hitch point. S The vehicle should never exceed 10 mph (16 kph) while tow-

ing a load on a level 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.

S Do not obstruct the headlight when loading the front rack.

OPERATION

Hauling Cargo

Load Distribution

Your ATV has been designed to carry or tow a certain amount of load. Always read and understand the l oad distribution warnings listed on the warning labels, and never exceed the specified weights.

Cargo weight should be mounted as low as possible. When operating over rough or hilly terrain, reduce speed and cargo to maintain stable driving conditions.

1. Always load the cargo box with the l oad as far forward as possible.

2. Always operate the vehicle with extreme caution whenever hauling or towing loads. Balance, handling, and control may be affected.

3. Slow down.

4. The cargo box dump latch must be securely latched before loading and operating. Unintentional box tilting will result if weight is placed in the rear of the box and the latch is not secured.

Maximum Towing Capacities

Do not exceed the following maximum capacities when towing. Maximum grade while trailer towing is 15°. Do not tow any trailer on a grade steeper than 15°.

Towing Load

(Level Ground)

ATP 330 4x4 1000 lbs. ( 454 kg) 100 lbs. (45.4 kg) ATP 500 4x4 1225 lbs. ( 556 kg) 120 lbs. (54.4 kg)

Vertical Hitch

Weight

Belt Life

Use low forward gear when hauling or towing heavy cargo to extend belt life.

OPERATION

Hauling Cargo

Dumping Cargo

1. Select a level site to dump the cargo box. Do not attempt to dump or unload the vehicle while parked on an incline.

2. Place the transmission in park and set the parking brake.

3. Dismount the vehicle.

4. Lower the tailgate.

WARNING

If cargo weight is placed toward the rear of the cargo box, the load may dump unexpectedly and cause serious injury. When loading cargo, always position the weight as far forward and as low as possible.

5. Pull the cargo box release lever upward.

6. Lift the front of the cargo box and dump the cargo.

7. Lower the cargo box and make sure the release latch is secured.

8. Secure the tailgate.

WARNING

Operating with the cargo box in the raised position can cause serious injury and damage to the vehicle. The cargo box could close unexpectedly and injure the driver. The rear tires will also catch the rear of the bed, damaging the vehicle and creating hazardous driving conditions.

Never operate this vehicle with the cargo box in the raised position.

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.

OPERATION

Driving Safely

Making Turns

Your Polaris ATV is equipped with a rear differential that functions as a solid rear axle, driving both rear wheels equally when the ATP is in either 2x4 or 4x4 mode. This means that the wheel on the outside of a turn must travel a greater distance than the inside wheel, causing the inside tire to 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 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 make turns at high speeds.

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. Drivingwith Demand 4 Drive (All Wheel Drive) engaged can assistin controlling the vehicle in slippery areas.

CAUTION

Severe damage to drive train may occur if the AWD is engaged while the wheels are spinning.

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.

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 front brake (or the single lever brake, gradually). When fully

stopped, apply rear 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 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 t o either side if ATV is pointed straight uphill. Turn the ATV around and remount, following the procedure described on page 66.

25_ Maximum

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.

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 a dangerous type of driving and should be avoided if at all possible. If you do enter into a situation where sidehilling is necessary, follow these precautions:

1. Slow down.

2. Lean into 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!

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 toaidinslowing. 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.

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 t hat 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

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.

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.

OPERATION

Driving Safely

Driving Through Water

After running the vehicle in water, it’s critical to have it serviced as outlined in the maintenance chart. See page 75. The following areas need special attention: engine oil, transmission oil, front and rear gearcases and all grease fittings. NOTE: If water has been ingested into the PVT, follow the procedure on page 73 for drying out the PVT.

If your vehicle becomes immersed, and it’s impossible to take it to a dealer before starting it, follow the steps described on page 110. Have the vehicle serviced by your dealer promptly.

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.

OPERATION

Driving Safely

Driving Over Obstacles

Be alert! Look ahead and learn to read the terrain. Be constantly alert for hazards such as logs, rocks and low hanging branches.

WARNING

Severe injury or death can result if your vehicle comes in contact with a hidden obstacle. Not all obstacles are immediately visible. Travel with caution in unfamiliar terrain.

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.

OPERATION

Driving Safely

ParkingonanIncline

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 as shown in illustration.

4. Shut off the fuel supply.

OPERATION

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

OPERATION

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.

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.

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.

Crankcase Emission Control System

This engine is equipped with a closed crankcase system. B l ow-by gases are forced back to the combustion chamber by the intake system. The system does not allow the blow-by gases to enter the atmosphere.

Exhaust Emission Control System

The emissions from the exhaust of this vehicle are controlled by engine design, including factory-set carburetion and ignition. The engine and related components must be 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.

MAINTENANCE AND LUBRICATION

Accessories

Polaris has a wide range of accessories available for your ATV. Auxiliary power outlets provide 12V power for operating accessories such as hand held spot lights. Accessory outlets are available for all models. See your Polaris dealer for more information about accessories.

Periodic Maintenance Schedule

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 schedule.

Some ATVs 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 52 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, such as operation in wet or dusty areas, should be inspected and serviced more frequently.

Inspect, clean, lubricate, adjust and replace parts as necessary. When inspection reveals the need for replacement parts, use genuine 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.

Maintenance Chart Key

" Perform these operations more often under severe use, such as in

dirty or wet conditions, to purge water or dirt contamination from grease fittings and other critical components.

L Emission Control System Service (California - 4-Cycle) NOTE: Some 4-Cycle models may have an additional California

-only emissions warranty.

J Dealer service item.

MAINTENANCE AND LUBRICATION

Periodic Maintenance Schedule

Hours of operation are based on a 10 mph average. If service is due at 20 hours, the equivalent odometer reading would be 200 miles. Perform all services at whichever reading is reached first.

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.

Item Hours/

Miles

Brake System Pre-Ride Pre-Ride Inspect Auxiliary Brake Pre-Ride Pre-Ride Inspect Tires Pre-Ride Pre-Ride Inspect Wheels Pre-Ride Pre-Ride Inspect Frame nuts, bolts,

fasteners Dump Box Latch Pre-Ride Pre-Ride Inspect; latch securely Air filter,

Pre-cleaner

Coolant level Pre-Ride Pre-Ride Replace coolant every two

Fuel and oil tanks Pre-Ride Pre-Ride Fill to proper levels Throttle Pre-Ride Pre-Ride Check operation Lights Pre-Ride Pre-Ride Check operation Engine stop switch Pre-Ride Pre-Ride Check operation Steering Pre-Ride Pre-Ride Check for free operation

" Air box sediment

tube Headlamp Pre-Ride Pre-Ride Check operation daily; ap-

Pre-Ride Pre-Ride Inspect

Pre-Ride Pre-Ride Inspect; clean

Pre-Ride Pre-Ride Drain deposits whenever

Frequency Remarks

years

visible

ply Polaris dielectric grease to connector when replaced

MAINTENANCE AND LUBRICATION

Periodic Maintenance Schedule

Item Hours/

Miles

Taillight/brakelight Pre-Ride Pre-Ride Check operation daily; ap-

Air filter,

main element

" Transmission oil

level Battery 20 hrs Monthly Check terminals; clean. Engine breather

filter

J Brake pad wear 10 hrs Monthly Inspect periodically " Front and rear

gearcase oil Engine cylinder

head and cylinder base fasteners

" General lubrication 50 hrs 3 months Lubricate all fittings, pivots,

Engine oil level/oil

change

Oil Filter 100 hrs./

Engine breather

hose

Weekly Weekly Inspect; replace as needed

20 hrs Monthly Inspect monthly; change

20 hrs Monthly Inspect; replace annually

100 hrs Monthly Check monthly; change

25 hrs 3 months Inspect (re-torque required

100 hrs / 1000 miles

1000 mi.

100 hrs. 6 months Inspect

Frequency Remarks

ply Polaris dielectric grease to socket when replaced

annually

and as needed

annually

at first service only)

cables, etc.

6 months Check level daily; break-in

service at one month; change oil more often in cold weather

6 months Replace with oil change

" More often under severe use, such as dirty or wet conditions

L Emission Control System Service (California)

J Dealer service item

MAINTENANCE AND LUBRICATION

Periodic Maintenance Schedule

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.

Item Hours/

Miles

Carburetor float bowl

J Throttle Cable/ETC

Switch Choke (enricher)

cable Coolant strength/

pressure test system

Shift linkage 50 hrs. 6 months Inspect; adjust

J Drive belt 50 hrs. 6 months Inspect; replace as needed " Steering 50 hrs. 6 months Inspect daily; lubricate " Front suspension 50 hrs. 6 months Inspect; lubricate; tighten

" Rear suspension 50 hrs. 6 months Inspect; tighten fasteners

Spark plug 100 hrs. 12 months Inspect; replace as needed

Ignition Timing 100 hrs. 12 months Inspect; adjust as needed

50 hrs. 6 months Drain bowl periodically and

50 hrs. 6 months Inspect; adjust; lubricate;

100 hrs. 6 months Inspect strength seasonal-

Frequency Remarks

prior to storage

replace if necessary

ly; pressure test system annually

fasteners

MAINTENANCE AND LUBRICATION

Periodic Maintenance Schedule

Item Hours/

Miles

Fuel system 100 hrs. 12 months Check for leaks at tank

J Fuel filter 100 hrs. 12 months Replace annually

Radiator (500) 100 hrs. 12 months Inspect; clean external sur-

Cooling system hoses (500)

" Front gearcase 100 hrs. 12 months Change fluid annually J Clutches

(drive and driven) Engine mounts 100 hrs. 12 months Inspect Valve clearance 100 hrs. 12 months Inspect; adjust

100 hrs. 12 months Inspect

100 hrs. 12 months Inspect; clean

J Brake fluid 200 hrs. 24 months Change every two years

Spark arrestor 300 hrs. 36 months Clean out

" Rear axle As required Inspect bearings if axle has

Idle speed As required Adjust as needed

Recoil housing As required Drain moisture after

J Toe adjustment As required Periodic inspection; adjust

Headlight aim As required Adjust as needed

Frequency Remarks

cap, lines, fuel valve, filter, pump and carburetor; replace lines every two years

face

ingested water or if unusual noises are present

operating in water

when parts are replaced

" More often under severe use, such as dirty or wet conditions

L Emission Control System Service (California)

J Dealer service item

MAINTENANCE AND LUBRICATION

Lubrication Recommendations

NOTE: Hours are based on 10 mph average. If service is due at 20 hours, the equivalent odometer reading would be 200 miles. Perform all services at whichever reading is reached first.

Lubrication Chart Key

" More often under severe use, such as wet or dusty conditions

L Polaris Premium All Season Grease or grease conforming to NLG

No. 2, such as Conoco Superlube M or Mobilegrease Special

F Use Polaris Premium U-Joint Lube every 500 miles, before long

periods of storage, or after pressure washing or submerging

Item Lube Method Frequency

Engine Polaris Premium 4

Brakes DOT 3 fluid only Maintain level between fill

Transmission Polaris Premium

Front Gearcase

Front Prop Shaft U-joints

Front Prop Shaft Yoke

Front Drive Axle (U Joint)

Ball Joint

Synthetic 0W40

Synthetic gear case lube

Polaris Premium Synthetic gear case lube

FGrease Grease fittings. Every 3 months or

FGrease Grease fittings

FGrease Locate grease fitting and

"LGrease

Add to proper level on dipstick.

lines. See page 40.

See Page 88. Check every 6

See Page 89. Change annually or

(3 pumps maximum)

grease with grease gun. Locate fitting on back side of

struts and grease with grease gun.

Check level daily.

As required; change every two years or 200 hours

months/1000 miles. Change annually or at 100 hours

at 100 hours

50 hours Every 3 months or

50 hours

Every 3 months or 50 hours

MAINTENANCE AND LUBRICATION

Periodic Maintenance Record

Use the following chart to record periodic maintenance.

Maintenance

Interval

Performed

10 hrs. 20 hrs. 50 hrs.

100 hrs.

Servicing

Date

Servicing

Dealer

or Person

Remarks

MAINTENANCE AND LUBRICATION

Lubrication Recommendations

Premium 4 Synth etic Oil

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 121 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. 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 m ay 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 All Season synthetic oil or API certified “SH” oil, 0W-40. Never substitute or mix oil brands. Use only 0W-40.

Engine Oil Check

The oil tank is located on the left side of the vehicle.

1. Position the machine on a level surface.

2. Start the engine and let it idle for 20-30 seconds. Stop the engine.

3. Remove the dipstick (1) and wipe it dry with a clean cloth.

4. Screw the dipstick completely in. NOTE: The dipstick must be screwed completely in to keep the angle and depth of the stick consistent.

5. Remove the dipstick and read the oil level. Maintain the oil level in the normal operating range (2). Do not overfill.

ADD 8 OZ . NORMAL FULL

MAINTENANCE AND LUBRICATION

Lubrication Recommendations

Oil and Filter Change - ATP 500 4x4

The recommended oil change interval is 100 hours, 1000 miles, or every six months, whichever comes first. Suggested break-in oil change is at 20 hours, 200 miles, or one month, whichever comes first. Severe use requires more frequent service. Severe use includes continuous duty in dusty or wet conditions and cold weather operation. Severe use cold weather operation is all operation below 10° F. and operation between 10° F. and 3 0° F. when most trips are at a slow speed. Always change the oil filter whenever changing oil.

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. Clean the area around the drain plug at the bottom of the oil tank and the bottom of the engine.

3. Run the engine for two to three minutes, then turn it off.

CAUTION

Hot oil can cause serious burns to skin. Do not allow hot oil to come into contact with skin.

MAINTENANCE AND LUBRICATION

Lubrication Recommendations

Oil and Filter Change - ATP 500 4x4

4. Place a drain pan beneath the oil tank and remove the drain plug (1). Allow the oil to drain completely.

5. Install a new sealing washer (2) on the oil drain plug. NOTE: The sealing surfaces on the drain plug and the oil tank should be clean and free of burrs, nicks or scratches.

6. Reinstall the drain plug and torque to 14-17 ft. lbs. (1.93-2.35 kg/m)

7. Disconnect the lower oil delivery hose and remove the screen fitting (3) from the oil tank. Clean and reinstall the fitting, torquing to 25 ft. lbs. Reattach the oil line. NOTE: The fitting threads must be sealed with Loctitet PST 505 or PTFE seal tape. The fitting must also line up with the mark (4) on the rear side of the oil tank.

MAINTENANCE AND LUBRICATION

Lubrication Recommendations

Oil and Filter Change - ATP 500 4x4

8. Place shop towels beneath the oil filter. Using an oil filter wrench, turn the filter (1) counterclockwise and remove.

9. Lubricate the gasket on the new filter with a film of new engine oil. Check to make sure the gasket is in good condition. Also make sure the gasket from the old filter is not still on the engine.

10. Install the new filter and tighten by hand 1/2 to 3/4 turn after gasket contacts the engine.

11. Approximately one cup of engine oil will remain in the crankcase. To drain, remove the drain plug on the lower right side of the crankcase. NOTE: The sealing surfaces on the drain plug and crankcase should be clean and free of burrs, nicks or scratches.

12. After draining, reinstall the drain plug.

13. Remove the dipstick (2) and add two quarts (1.9 l.) of Polaris Premium 4 synthetic oil. Reinstall the dipstick. NOTE: If the sump is not drained, add about 1 3/4 quarts initially.

14. Place the gear selector in park and set 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 on the dipstick and add oil as necessary to bring the level to the upper (full) mark on the dipstick.

17. Dispose of used filter and oil properly.

MAINTENANCE AND LUBRICATION

Lubrication Recommendations

Oil and Filter Change - ATP 330 4x4

CAUTION

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

Contact with hot oil may result in serious burns. Do not allow hot oil to come into contact with skin.

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.

MAINTENANCE AND LUBRICATION

Lubrication Recommendations

Oil and Filter Change - ATP 330 4x4

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 2 quarts (1.9 l) of Polaris Premium 4 synthetic oil.

14. Place the gear selector in park and set the parking brake.

15. Start the engine and let it idle for one to 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 t he dipstick.

17. Dispose of used filter and oil properly.

MAINTENANCE AND LUBRICATION

Lubrication Recommendations

Transmission Oil Check

The transmission lubricant level should be checked every six months or 1000 miles (1600 km), whichever comes first. Transmission oil should be changed annually.

1. Position the ATV on a level surface, remove the fill plug (1), and check the oil level. NOTE: The transmission fill plug is located on the right side of the machine, behind the footwell.

2. Use the gearcase oil fill chart and the following illustration to determine correct fluid levels. NOTE: When adding oil, use Polaris Premium Synthetic Gearcase Lubricant. See page 121 for the part numbers of Polaris products.

Gearcase Oil Fill Chart

Model

ATP 500 4x4 15/8″ 13.5 oz. (400 ml) ATP 330 4x4 15/8″ 13.5 oz. (400 ml)

1. Remove the fill plug.

2. Remove the transmission drain plug (2) located on the bottom left hand side and drain the oil. Catch and discard used oil properly.

3. Clean and reinstall the drain plug torque to 14 ft. lbs. (19 Nm).

4. Add the correct amount of Polaris Premium Synthetic Gearcase Lubricant. Refer the the gearcase oil fill chart for proper oil levels.

5. Check for leaks.

Oil Level “A” Capacity

MAINTENANCE AND LUBRICATION

Lubrication Recommendations

Front Gearcase Oil Check

The front gearcase oil level should be checked every six months or 1000 miles (1600 km), whichever comes first. The oil should be changed annually. We recommend the use of Polaris Premium Hub Drive Fluid. See page 121 for the part numbers of Polaris products.

With the A TV on a level surface, remove the fill plug and check the oil level. The level should be maintained 3/4” below the fill plug opening.

Front Gearcase Oil Change

1. Position the vehicle on a level surface and remove the fill plug (1).

2. Place a drain pan beneath the gearcase, remove the gearcase drain plug (2) and drain t he oil.

3. Clean and reinstall the drain plug. Torque to 14 ft. lbs. (19 Nm).

4. Add 5 oz. (148 ml) of the recommended gear lube.

5. Reinstall the fill plug and check for leaks.

MAINTENANCE AND LUBRICATION

Lubrication Recommendations

Rear Gearcase Oil Check

With the A TV on a level surface, remove the fill plug and view the oil level through the fill hole (1). Lubricant should be kept even with the bottom of the fill hole. Use Polaris Premium Synthetic Gearcase Lube (or GL5 80-90 weight gear lube). NOTE: See page 121 for the part numbers of Polaris products.

Rear Gearcase Oil Change

1. Remove the drain plug (2). Catch anddiscardusedoilproperly.

2. Clean the drain plug and inspect the o-ring. Replace with a new o-ring if signs of tearing or fretting exist. Reinstall the drain plug and torque to 40 in. lbs. (4.5 Nm).

3. Remove the fill plug and add 18 oz. (532 ml) of recommended gear lube. Maintain the oil level at the bottom of the fill hole.

4. Clean the fill plug and inspect the o-ring. Replace the o-ring if it’s worn or damaged.

5. Reinstall the fill plug and torque to 40 ft. lbs. (54 Nm).

6. Check for leaks.

MAINTENANCE AND LUBRICATION

Engine Cooling System

Oil Cooler (ATP 330)

The oil cooling system requires little maintenance other than to make sure the cooler is kept free of mud and debris. Change the engine oil as recommended in the maintenance schedule.

Coolant Level (ATP 500)

The recovery bottle (1) is located on the left side of the machine. To access the recovery bottle, remove the left side panel. See page 100.

The fluid level must be maintained between the minimum and maximum marks on the bottle (when the fluid is cool).

The engine coolant level is controlled or maintained by the recovery system. The recovery system components are the recovery bottle, radiator filler neck, radiator pressure cap and connecting hose.

As coolant operating temperature increases, the expanding (heated) excess coolant is forced out of the radiator, past the pressure cap, and into the recovery bottle. As engine coolant temperature decreases, the contracting (cooled) coolant is drawn back up from the tank, past the pressure cap, and into the radiator.

NOTE: Some coolant level drop on new machines is normal, as the system is purging itself of trapped air. Observe coolant levels and maintain as recommended by adding coolant to the recovery bottle.

Polaris recommends the use of Polaris Premium 60/40 anti-freeze/coolant or a 50/50 mixture of high quality aluminum compatible anti-freeze/coolant and distilled water. Polaris Premium 60/40 is already premixed and ready t o use. Do not dilute with water. See page 121 for the part numbers of P olaris products.

NOTE: To ensure that the coolant maintains its ability to protect the engine, we recommend that the system be completely drained every two years and a fresh mixture of antifreeze and water added.

NOTE: Always follow the manufacturer’s mixing recommendations for the freeze protection required in your area.

MAINTENANCE AND LUBRICATION

Engine Cooling System

WARNING

Escaping steam can cause severe burns. Never remove the pressure cap while the engine is warm or hot. Always allow the engine to cool before removing the pressure cap.

Radiator Coolant Level (AT P 500)

NOTE: This procedure i s required only if the cooling system has been drained for maintenance and/or repair. However, if the recovery bottle has run dry, the level in the radiator should be inspected and coolant added if necessary.

1. Using the tool provided, remove the four screws securing the front compartment (1). Remove the front cover (2) by placing your fingers under the front of the cover and pulling upward.

2. Remove the pressure cap.

3. Using a funnel, slowly add coolant as necessary through the radiator filler neck.

4. Replace the pressure cap and secure the front cover.

NOTE: Use of a non-standard pressure cap will not allow the recovery system to function properly. Contact your dealer for the correct replacement part.

MAINTENANCE AND LUBRICATION

Adjustments

Brakes

The front brakes are hydraulic disc brakes, activated by moving the brake lever toward the handlebar. These brakes are self-adjusting.

WARNING

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.

1. Always keep brake fluid at an adequate level (see page 40). 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.

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.

2. Check the brake system for fluid leaks.

3. Check the brakes for excessive travel or spongy feel.

4. Check the friction pads for wear, damage and looseness.

5. Check the security and surface condition of the disc.

NOTE: Pads should be changed when worn to 3/64″ (.1 cm), or about the thickness of a U.S. dime.

3/64″ (.1 cm)

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.

Pads should be changed when worn to 3/64″ (.1 cm), which is about the thickness of a U.S. dime.

Inspect the brake disc spline and pad wear surface for excessive wear.

Your vehicle’s auxiliary brake system is intended to be used as a backup for the main brake system. Should t he 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.

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″ (.2to.3cm) more than the front measurement.

NOTE: If you discover improper alignment, see your Polaris dealer for service.

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.

MAINTENANCE AND LUBRICATION

Adjustments

Handlebars

If desired, the handlebars can be adjusted for rider preference.

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.

1. Remove the instrument panel and locate the handlebar bolts (1).

2. Loosen the four bolts and 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.

3. Torque the front two bolts to 10-12 ft. lbs. (14-17 Nm), then torque the rear two bolts. A gap of up to 1/8” will remain at the rear bolts.

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

Specifications and Main Features

Frequently Asked Questions

User Manual