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!
STechnical tips
SNew product introductions
SEvent schedules
SParts and Service Manual information
SExciting details about The Way Out
Check it out...
www.polarisindustries.com/owner
1
Copyright 2003 Polaris Sales Inc. All information contained within this publication is
based on the latest product information at the time of publication. Due to constant
improvements in the design and quality of production components, some minor
discrepancies may result between the actual vehicle and the information presented in this
publication. Depictions and/or procedures in this publication are intended for reference
use only. No liability can be accepted for omissions or inaccuracies. Any reprinting or
reuse of the depictions and/or procedures contained within, whether whole or in part, is
expressly prohibited. Printed in U.S.A.
2
WELCOME
Thank you for purchasing a Polaris vehicle, and welcome to our
world-wide family of Polaris owners. We proudly produce an exciting
line of utility and recreational products.
Polaris Recreational and Utility Vehicles
S Snowmobiles
S All-terrain vehicles (ATVs)
S Watercraft
S Victory 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 manual. Your
manual contains instructions for minor maintenance, but information
about major repairs is outlined in the Polaris Service Manual and
should be performed only by a Factory Certified Master S ervice Dealer
(MSD) Technician.
Your Polaris dealer knows your vehicle best and is interested in your
total satisfaction. Be sure to return to your dealership for all of your
service needs during, and after, the warranty period.
We also take great pride i n 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.
3
4
TABLE OF CONTENTS
WELCOME3.................................
VEHICLE IDENTIFICATION NUMBERS6........
SAFETY7...................................
FEATURES A ND CONTROLS38...............
OPERATION59..............................
EMISSION CONTROL SYSTEMS76............
MAINTENANCE AND LUBRICATION77.........
POLARIS PRODUCTS130.....................
SPECIFICATIONS131........................
TROUBLESHOOTING140.....................
WARRANTY144..............................
INDEX147...................................
5
VEHICLE IDENTIFICATION NUMBERS
The vehicle frame vehicle identification number (VIN)(1) and engine
serial number 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 (2) in the
spaces provided.
31XX
1
Frame VIN:
Vehicle Model Number:
Engine Serial Number (right front side of engine crankcase):
Key Number:
6
2
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 ATV.
Age Restrictions
This vehicle is an ADULT VEHICLE ONLY. Operation is prohibited
for anyone under 16 years of age.
Know Your Vehicle
As the operator of the vehicle, you are responsible for your personal
safety, the safety of others, and the protection of our environment.
Read and understand your owner’s manual, which includes valuable
information about all aspects of your vehicle, including safe operating
procedures.
Safety Training
When you purchased your new ATV, your dealer offered a hands-on
safety training course that covers all aspects of vehicle safety. You were
also provided with printed materials that explain safe operating
procedures. You should review this information on a regular basis.
If you purchased a used Polaris ATV from a party other than a Polaris
dealer, you can request this free safety training from any authorized
Polaris dealer.
A Polaris ATV is an off-road vehicle. Familiarize yourself with all laws
and regulations concerning the operation of this vehicle in your area.
We strongly advise you to strictly follow the recommended
maintenance program outlined in your owner ’s manual. This
preventive maintenance program is designed to ensure that all critical
components on your vehicle are t horoughly inspected at specific
intervals.
7
SAFETY
Operator Safety
The following signal words and symbols appear throughout this
manual and on your ATV. Your safety is involved when these words
and symbols are used. Become familiar with their meanings before
reading the manual.
The safety alert symbol, on your ATV or in this manual, alerts you
to the potential for personal injury.
WARNING
The safety alert warning indicates a potential hazard that may result
in serious injury or death.
CAUTION
The safety alert caution indicates a potential hazard that may result
in minor personal injury or damage to the machine.
CAUTION
A caution indicates a situation that may result in damage to the
machine.
NOTE
A note will alert you to important information or instructions.
8
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 A TV 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 t urning at low speeds before attempting to turn at faster
speeds. Do not turn at excessive speeds.
9
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 t o 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 turn 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 t rees.
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 through deep or fast-flowing water. If it’s
unavoidable, travel slowly, balance your weight carefully, avoid sudden movements, and maintain a slow and steady forward motion. Do
not make sudden turns or stops, and do not make sudden throttle
changes.
10
SAFETY
Operator Safety
S Wet brakes may have reduced stopping ability. Test your brakes after
leaving water. If necessary, apply them lightly several times to allow
friction to dry out the pads.
S Always check for obstacles or people behind the ATV before operat-
ing in reverse. When it’s safe to proceed in reverse, move slowly and
avoid turning at sharp angles.
S Always use the size and type of tires specified for your ATV, and
always maintain tire pressure as recommended.
S Never modify an ATV through improper installation or use of acces-
sories.
S Never exceed the stated load capacity for your ATV. Cargo must be
properly distributed and securely attached. Reduce speed and follow
the instructions in this manual for carrying cargo or towing. Allow a
greater distance for braking.
S Always remove the ignition key when the vehicle is not in use to
prevent unauthorized use or accidental starting.
FOR MORE INFORMATION ABOUT ATV SAFETY ,call the Consumer Product Safety Commission at 1-800-638-2772, or call
Polaris at 1-800-342-3764.
Equipment Modifications
We are concerned for the safety of our customers and for the general
public. Therefore, we strongly recommend that consumers do not
install on a Polaris ATV any equipment that may increase the speed or
power of the vehicle, or make any other modifications to the vehicle
for these purposes. Any modifications to the original equipment of the
vehicle create a substantial safety hazard and increase the risk of bodily
injury.
The warranty on your Polaris ATV is terminated if any equipment has
been added to the vehicle, or if any modifications have been made to
the vehicle, that increase its speed or power.
NOTE: The addition of certain accessories, including (but not limited
to) mowers, blades, tires, sprayers, or large racks, may change the
handling characteristics of the vehicle. Use only Polaris-approved
accessories, and familiarize yourself with their function and effect on
the vehicle.
11
SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD
Operating this ATV without proper instruction.
WHAT CAN
The risk of an accident is greatly increased if the operator
does not know how to operate the ATV properly in different
situations and on different types of terrain.
HOW TO AVOID THE
Beginning and inexperienced operators should complete the
certified training course offered by Polaris. Operators should
regularly practice the skills learned in the course and the
operating techniques described in the owner’s manual.
For more information about the training course, contact an
authorized ATV dealer or call Polaris at 1-800-342-3764.
HAPPEN
HAZARD
WARNING
POTENTIAL
Failure to follow the age recommendations for this ATV.
WHAT CAN
Severe injury and/or death could occur if a child under the
minimum age recommendation operates an ATV.
Even though a child may be within the recommended age group
for operating some ATVs, he/she may not have the skills,
abilities, or judgment needed to operate an ATV safely and could
be susceptible to accident or injury.
HOW TO AVOID THE
No one under the age of 16 should operate a Polaris ATV.
12
HAZARD
HAPPEN
HAZARD
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
SAFETY
13
SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD
Operating an ATV on paved surfaces, including sidewalks,
paths, parking lots, and driveways.
WHAT CAN
ATV tires are designed for off-road use. Operating on paved
surfaces may seriously affect the handling and control of the
ATV and could result in loss of control, accident, and/or injury.
HOW TO AVOID THE
Avoid operating the ATV on pavement. If it’s unavoidable,
travel slowly and avoid sudden turns or stops.
HAPPEN
HAZARD
14
Operator Safety
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
15
SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD
Operating this ATV without wearing an approved helmet, eye
protection and protective clothing.
WHAT CAN
Operating an ATV without an approved helmet increases the
risk of a severe head injury or death in the event of an
accident.
Operating without eye protection could result in an accident
and could increase the chance of a severe injury in the event
of an accident.
HOW TO AVOID THE
Always wear an approved helmet that fits properly.
Always wear eye protection (goggles or face shield), gloves,
boots, long-sleeved shirt or jacket, and long pants.
HAPPEN
HAZARD
16
Operator Safety
WARNING
POTENTIAL HAZARD
Operating the ATV after consuming alcohol or drugs.
WHAT CAN
Consumption of alcohol and/or drugs could seriously affect
operator judgment. Reaction time may be slower and operator
balance and perception could be affected.
Consuming alcohol and/or drugs before or while operating an
ATV could result in an accident causing severe injury or death.
HOW TO AVOID THE
Never consume alcohol or drugs before or while operating an
ATV.
HAPPEN
HAZARD
WARNING
SAFETY
POTENTIAL
Operating the ATV at excessive speeds.
WHAT CAN
Excessive speed increases the operator’s chance of losing
control of the ATV, which can result in an accident.
HOW TO AVOID THE
Always operate the ATV at a speed that’s appropriate for the
terrain, visibility and operating conditions, and your experience.
HAZARD
HAPPEN
HAZARD
17
SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD
Attempting wheelies, jumps and other stunts.
WHAT CAN
Attempting stunts increases the chance of an accident, including
an overturn.
HOW TO AVOID THE
Never attempt wheelies, jumps, or other stunts. Avoid exhibition
driving.
HAPPEN
HAZARD
18
Operator Safety
WARNING
POTENTIAL HAZARD
Failure to inspect the ATV before operating.
Failure to properly maintain the ATV.
WHAT CAN
Poor maintenance increases the possibility of an accident or
equipment damage.
HOW TO AVOID THE
Always inspect your ATV before each use to make sure it’s in
safe operating condition.
Always follow the inspection and maintenance procedures and
schedules described in the owner’s manual.
HAPPEN
HAZARD
WARNING
SAFETY
POTENTIAL
Removing hands from the handlebars or feet from the
footrests during operation.
WHAT CAN
Removing even one hand or foot can reduce ability to
control the vehicle or could cause loss of balance and
ejection from the ATV.
If the operator’s foot is not firmly planted on the footrest, it
could come into contact with the rear wheels and lead to
accident or injury.
HOW TO AVOID THE
Always keep both hands on the handlebars and both feet
on the footrests of the ATV during operation.
HAZARD
HAPPEN
HAZARD
19
SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD
Failure to use extra caution when operating the ATV on unfamiliar
terrain.
WHAT CAN
Unfamiliar terrain may contain hidden rocks, bumps, or holes that
could cause loss of control or overturn.
HOW TO AVOID THE
Travel slowly and use extra caution when operating on unfamiliar
terrain. Always be alert to changing terrain conditions.
HAPPEN
HAZARD
20
Operator Safety
WARNING
POTENTIAL HAZARD
Failure to use extra caution when operating on excessively
rough, slippery or loose terrain.
WHAT CAN
Operating on excessively rough, slippery or loose terrain could
cause loss of traction or loss of control, which could result in an
accident or overturn.
HOW TO AVOID THE
Do not operate on excessively rough, slippery or loose terrain
until you’ve learned and practiced the skills necessary to
control the ATV on such terrain.
Always use extra caution on rough, slippery or loose terrain.
HAPPEN
HAZARD
SAFETY
21
SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD
Turning improperly.
WHAT CAN
Improper turns could cause loss of control and lead to a collision
or overturn.
HOW TO AVOID THE
Always follow proper procedures for turning as described in the
owner’s manual.
Practice turning at slow speeds before attempting to turn at
faster speeds.
Never turn at excessive speed.
HAPPEN
HAZARD
WARNING
POTENTIAL
Operating on excessively steep hills.
WHAT CAN
The vehicle may overturn.
HOW TO AVOID THE
Never operate on hills too steep for the ATV or for your
abilities. Never operate the ATV on hills steeper than 25_.
Practice on smaller hills before attempting large hills.
22
HAZARD
HAPPEN
HAZARD
SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD
Climbing hills improperly.
WHAT CAN
Improper hill climbing could cause loss of control or overturn.
HOW TO AVOID THE
Always follow proper procedures for climbing hills as described
in the owner’s manual.
Always check the terrain carefully before ascending any hill.
Never operate the ATV on hills steeper than 25_.
Never climb hills with excessively slippery or loose surfaces.
Shift your weight forward.
Never open the throttle suddenly while traveling uphill. The ATV
could flip over backwards.
Never go over the top of any hill at high speed. An obstacle, a
sharp drop, or another vehicle or person could be on the other
side of the hill.
HAPPEN
HAZARD
23
SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD
Traveling downhill improperly.
WHAT CAN
Improperly descending a hill could cause loss of control or
overturn.
HOW TO AVOID THE
Always follow proper procedures for traveling down hills as
described in the owner’s manual. NOTE: A special technique
is required when braking while traveling downhill. See page
68.
Always check the terrain carefully before you descending a hill.
Shift your weight backward.
Never travel down a hill at high speed.
Avoid traveling down a hill at an angle, which would cause the
vehicle to lean sharply to one side. Travel straight down the
hill when possible.
HAPPEN
HAZARD
24
SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD
Improperly crossing hills and turning on hills.
WHAT CAN
Improperly crossing or turning as hills could cause loss of control
or overturn.
HOW TO AVOID THE
Never attempt to turn the ATV around on any hill until you’ve
mastered the turning technique (on level ground) as described in
the owner’s manual. See page 69. Use extra caution when
turning on any hill.
Avoid crossing the side of a steep hill.
When crossing the side of a
Always follow proper procedures as described in the owner’s
manual.
Avoid hills with excessively slippery or loose surfaces.
Shift your weight to the uphill side of the ATV.
HAPPEN
HAZARD
hill:
25
SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD
Stalling, rolling backwards or
improperly dismounting while
climbing a hill.
WHAT CAN
The vehicle could overturn.
HOW TO AVOID
HAZARD
Maintain steady speed when
climbing a hill.
If all forward speed is
Keep your weight uphill.
Apply the single lever brake gradually.
When fully stopped, apply the auxiliary rear brake as well, then
lock the parking brake.
If the ATV begins rolling
Keep weight uphill.
Never apply engine power.
Never apply the auxiliary rear brake while rolling backwards.
Apply the single-lever brake gradually.
When fully stopped, apply the auxiliary rear brake as well, and
then lock the parking brake.
Dismount on uphill side, or to either side if ATV is pointed
straight uphill.
Turn the ATV around and remount, following the procedure
described in the owner’s manual. See page 69.
HAPPEN
THE
lost:
backwards:
26
SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD
Improperly operating over obstacles.
WHAT CAN
Operating over obstacles could cause loss of control or overturn.
HOW TO AVOID THE
Before operating in a new area, check for obstacles.
Avoid operating over large obstacles such as rocks and fallen
trees when possible. If unavoidable, use extreme caution and
always follow proper procedures as outlined in the owner’s
manual.
HAPPEN
HAZARD
WARNING
POTENTIAL
Skidding or sliding.
WHAT CAN
Skidding or sliding can cause loss of control.
If the tires regain traction unexpectedly, the ATV 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
27
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 70), 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.
28
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.
Always maintain tire pressure as recommended in the owner’s
manual and on safety labels.
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
29
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 74.
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.
30
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.
31
SAFETY
Safety Decals and Locations
Warning decals have been placed on the ATV for your protection. Read
and follow the instructions of the decals and other warnings on the
ATV carefully. If any of the decals shown in this manual differ from
the decals on your ATV, always read and follow the instructions of the
decals on the ATV.
If any decal becomes illegible or comes off, contact your Polaris dealer
to purchase a replacement. Replacement safety decals are provided by
Polaris at no charge. The part number is printed on the decal.
B
C
A
D
E
F
H
E
NOTE: Your ATV may not have all of the decals shown. Decals vary
depending on the model.
32
G
Safety Decals and Locations
SAFETY
WARNING
DNever operate this vehicl e on HILLS steeper than 25 degrees
To prevent flipover on hilly terrain, when going up or down, use throttle
and brakes gradually.
DREVERSE operation can be dangerous, even at l ow speeds. Steering
becomes diffi c ult. To prevent flipover, avoid sudden braking or sharp
turns.
DUse OVERRIDE for reverse speed limiter with caution. To prevent loss
of control, never activate override button with open throttle.
DWhen this ATV i s not in operation, or unattended, place shi ft in park
position.
7171383
Location A
WARNING
Moving parts hazard under belt-clutch guard. To
prevent serious injury, do not operate v ehicl e with
guard removed.
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.
7078689
NO STEP
Location C
25°.
Operating this vehicle if y ou are under
the age of 16 increases your chance
of sev ere injury or death.
NEVER operate this vehicle if you are
under age 16.
Location B
WARNING
Location D
WARNING
7078253
7077920
WARNING
DO NOT TOW FROM RACK OR BUMPER.
Vehicle damage or tipover may result causing severe
injury or death. Tow only from t ow hooks or hitch.
Maximum Rack Loads: Front 90 lbs. Rear 180 Lbs
Location E (on models with racks)
WARNING
DO NOT TOW FROM RACK OR BUMPER. Vehicle damage or tipover may result causing severe injury or
death. Tow only from tow hooks or hi tch. Max. combined Front Rack and container Load 90 lbs. (41 kg) 7171465
Location E (on models with storage box)
7170021
33
SAFETY
Safety Decals and Locations
WARNING
IMPROPER TIRE PRESSURE OR OVERLOADING can cause loss of
control resulting in SEVERE INJURY OR DEATH.
TIRE PRESSURE (PSI): FRONT ___ REAR ___
MAXIMUM WEIGHT CAPACITY (Gross Vehicle Weight)
INCLUDING MACHINE, DRIVER AND CARGO IS ____ LBS.
Reduce speed and allow greater distance for braking when carrying
cargo. Overloading or carrying tall, off-center, or unsecured loads
will increase your risk of losing control. Loads should be centered,
carried as low as possible, and firmly secured to the racks. with
dual racks, load distribution 1/3 front 2/3 rear is best. For stability
on rough or hilly terrain, reduce speed and cargo. Do not block
headlight. Be careful if load extends over the side of the rack.
Read Owner’s Manual for more detailed loading information
Location F
Magnum 500
Magnum 330
34
Location G
(Under Seat)
Safety Decals and Locations
WARNING
IF OWNER’S MANUAL IS MISSING, CONTACT
A POLARIS DEALER FOR A REPLACEMENT.
E1997, 2000
Location H
7079083
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
Applicable AWD Models
SAFETY
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
AWD Models
OVERRIDE
SWITCH
Reverse Speed is
limited.
Reverse override is
controlled by the
override switch.
See your Owner’s
Manual.
7079906
2WD Models
MANUFACTURED
BY: POLARIS IND. INC.
DATE:
VIN:
THIS VEHICLE IS AN ALL TERRAIN VEHICLE AND IS NOT
INTENDEDFOR USE ON PUBLIC ROADS.
CE VÉHICUL E EST UN VÉHICUL E TOUT TERRAIN QUI NiEST
PAS DESTINÉ À ÊTRE UTILIS É SUR LES CHEMINS PUBLICS.
Canadian Certification Decal
7171492
35
SAFETY
Safe Riding Gear
Always wear clothing suited to the type of riding. ATV riding requires
special protective clothing for comfort and to reduce the chance of
injury.
1. Helmet
Your helmet is the most important piece
of protective gear for safe riding. A
helmet can prevent a severe head injury.
Select an approved helmet that meets or
exceeds your state’s safety standards
and bears either the Department of
Transportation (DOT) label, the
American National Standards Institute
label (ANSI z90.1), or the Snell
Memorial Foundation label.
2. Eye Protection
Do not depend on sunglasses for proper
eye protection. A pair of goggles or a
helmet face shield offer the best
protection for your eyes. They should
be kept clean and be of shatterproof
design (bearing the markings z2.1 or
VESC 8).
3. Gloves
Off-road style gloves with knuckle pads are the best for comfort and
protection.
4. Boots
The best footwear is a pair of strong over-the-calf boots with heels, like
moto-cross boots.
5. Clothing
Always wear long sleeves and long pants to protect arms and legs.
Riding pants with kneepads and a jersey with shoulder pads provide
the best protection.
1
2
3
5
4
36
SAFETY
Fuel Safety
WARNING
Gasoline is highly flammable and explosive under certain
conditions.
S Always exercise extreme caution whenever handling gasoline.
S Always refuel with the engine stopped, and outdoors or in a
well ventilated area.
S Do not smoke or allow open flames or sparks in or near the
area where refueling is performed or where gasoline is stored.
S Do not overfill the tank. Do not fill the tank neck.
S If gasoline spills on your skin or clothing, immediately wash it
off with soap and water and change clothing.
S Never start the engine or let it run in an enclosed area. Engine
exhaust fumes are poisonous and can cause loss of consciousness or death in a short time.
S Turn the fuel valve off whenever the ATV is stored or parked.
WARNING
The engine exhaust from this product contains chemicals known
to cause cancer, birth defects or other reproductive harm.
Operate this vehicle only outdoors or in well-ventilated areas.
37
FEATURES AND CONTROLS
Electrical Switches
1
3
2
5
4
WARNING
Operating the ATV on streets or roads, especially in darkness,
could result in an accident and serious injury or death.
Your ATV is not equipped with highway-approved lights. It’s
designed for and must be used for off-road use only. Use caution
and drive at reduced speeds in conditions of reduced visibility
such as fog, rain and darkness.
1. Light Switch/Hi-Lo Beam Control - The lights won’t turn on
unless the main switch is on.
WARNING
Activating the override switch while the throttle is open can cause
loss of control, resulting in severe injury or death. Do not activate
the override switch while the throttle is open.
2. Override Switch (Reverse Speed Limiter) - This vehicle is
equipped with a reverse speed limiter system. To gain additional power
while backing, depress the override switch. NOTE: The override
switch also allows activation of AWD in reverse if the AWD switch is
on.
38
FEATURES AND CONTROLS
Electrical Switches
3. Engine Stop Switch - The engine will not start
orrunwhentheswitchisintheOFF position. Its
purpose is to provide the operator with a quick
means of engine shutdown in case of an emergency.
To stop the engine, slide the stop switch either right
or left to the OFF position.
4. Main Switch - To start the engine, slide t he 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.
3
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.
5. All Wheel Drive Switch (AWD Models) Select AWD models do
not have an AWD switch. These models are continuously in AWD.
39
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.
1
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.
40
FEATURES AND CONTROLS
Brakes
Master Cylinder
Check the brake fluid level in
the master cylinder before each
use of the ATV. The master
cylinder (1) is located on the left
handlebar.
View the fluid level through the
indicator window (2) on the top of
the master cylinder. This eye will
appear dark when the fluid level is
full. When fluid is low, the eye will
be clear. NOTE: When checking the fluid level, position the ATV on
level ground with the handlebars turned so the top of the reservoir is
level. If the fluid level is low, add DOT 3 brake fluid. DO NOT
OVERFILL. See page 130 for the part numbers of Polaris products.
1
2
WARNING
An over-full master cylinder may cause brake drag or brake
lock-up, which could result in serious injury or death. Maintain
brake fluid at the recommended level. Do not overfill.
WARNING
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.
41
FEATURES AND CONTROLS
Brake 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.
The front and rear brakes are applied
by squeezing the brake lever (1)
toward the handlebar. The front and
rear brakes are hydraulically activated
disc type brakes that are activated by
only one lever.
Always test brake lever travel and
master cylinder fluid level before
riding. When squeezed, the lever should feel firm. Any sponginess
would indicate a possible fluid leak or low master cylinder fluid level,
which must be corrected before riding. Contact your dealer for proper
diagnosis and repairs.
1
42
FEATURES AND CONTROLS
Parking Brake
WARNING
Operating the ATV while the parking brake is engaged could
result in an accident and serious injury or death.
Always check to be sure the parking brake is disengaged
before operating.
Setting the Parking Brake
1. Squeeze and release the brake
lever (1) two or three times, then
squeeze and hold.
2. Push the park brake lock (2)
forward to engage the brake.
Release the brake lever.
3. To release the parking brake lock,
squeeze and release the brake
lever. It will return to its unlocked
position.
Important Safeguards
S The parking brake m ay relax if left on for a long period of time. Al-
ways block the wheels to prevent rolling.
S Always block the wheels on the downhill side of the ATV if leaving
it parked on a hill. Another option is to park the ATV in a sidehill
position.
S Never depend on the parking brake alone if the ATV is parked on a
hill. Always block the wheels to prevent rolling.
1
2
43
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.
Use caution when applying the auxiliary brake. Do not
aggressively apply the auxiliary brake when going forward. The
rear wheels may skid and slide sideways, causing loss of control
and serious injury or death.
The auxiliary brake (1), is
located on the inside of the right
floor board and i s operated by
the right foot. The auxiliary
brake serves as a backup to the
main brake system if the main
system becomes inoperative.
If the rear wheels slide while
using the auxiliary brake, reduce
brake pedal pressure to brake the
rear wheels without skidding.
Check the brake fluid level frequently for the auxiliary brake system.
The reservoir is located under the seat or near the foot brake. Maintain
the fluid level between the maximum and minimum marks.
1
44
FEATURES AND CONTROLS
Choke
The choke assists in starting a cold engine. Refer to the engine starting
procedure on page 61 for correct choke and throttle settings during
starting.
Fuel Valve
The fuel valve (1) is located on the left side of
the vehicle on the side panel. It has three
positions:
OFF: For vehicle storage and when transporting.
ON: For normal operation.
RES: For reserve supply if main
supply is exhausted.
NOTE: There’s about a 7 to 10 mile
(11.2 to 16 km) range on reserve gas.
Always refill the gas tank as soon as
possible after using the reserve supply.
Always return valve to the ON
position after refueling.
Fuel T ank
The fuel tank filler cap (2) is located
directly below t he handlebar. Use
either leaded or unleaded gasoline with
a minimum pump octane number of
87=(R+ M/2) octane. Refer to the
specifications section beginning on
page 131 for tank capacity.
1
2
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.
45
FEATURES AND CONTROLS
Automatic Transmission Gear Selector
The transmission gear selector (1) is located on the right side of the
vehicle.
H: High Gear
N: Neutral
L: Low Gear
R: Reverse
P: Park
To shift into HIGH or PARK,
you must first apply the
auxiliary brake to activate the
high/park lock-out mechanism.
When shifting out of HIGH or PARK, it’s not necessary to apply the
brake.
H
L
N
R
P
1
CAUTION
Shifting gears with the engine speed above idle or while the
vehicle is moving could cause transmission damage. To change
gears, stop the vehicle, and with the engine idling, move the lever
to the desired gear. Apply the auxiliary brake 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.
46
FEATURES AND CONTROLS
Recoil Starter
If the battery has been drained or
damaged and cannot start the
engine, use of the recoil starter (1)
will allow vehicle operation until
repairs can be made. The recoil
starter is located on the right side
of the machine.
Polaris 4-cycle engines are
equipped with automatic
decompressors. This makes
recoil starting possible by
reducing the amount of compression during starting. The
decompressor senses when the engine is spinning fast enough to start
and restores compression when running.
1. Position the vehicle on a level surface, place the transmission in
PARK and lock the parking brake (see page 43).
2. Make sure the engine stop switch is set to RUN and the main key
switch is in the ON position. NOTE: If the engine is cold, use the
choke as outlined on page 61.
3. Grasp the recoil starter rope handle (2) firmly and pull slowly so
you can feel the engine strokes. NOTE: Every other stroke will
be a “compression stroke” and will make the rope harder to pull.
When a compression stroke is found, continue pulling the rope just
until the engine rolls past the stroke, t hen stop pulling immediately.
4. Allow the recoil rope to rewind into the recoil assembly, t hen pull
the rope abruptly and forcefully to start the engine.
5. Repeat steps 3-4 if necessary.
2
1
CAUTION
Extending the recoil starter rope until it stops can cause damage
to the recoil assembly. Do not extend the starter rope so far that
it stops.
If the starter rope handle is not seated properly, water may enter
the recoil housing and damage components. Make sure the
handle is fully seated on the recoil housing, especially when
traveling in wet areas.
47
FEATURES AND CONTROLS
All Wheel Drive System (Domestic Models)
Polaris 4 wheel drive domestic
model ATVs are equipped with a
unique, Polaris exclusive, All Wheel
Drive (AWD) System activated by a
switch (1) on the right handlebar.
NOTE: HDS models do not have
an AWD switch. These models are
continuously in AWD.
When the AWD switch is off, the
ATV i s in 2 wheel drive at all times.
When the switch is on, the ATV is in
AWD.
When in AWD, the front gearcase will automatically engage 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 AWD in reverse if
the AWD switch is on. See page 38.
There is no limit to the length of time the vehicle may remain in AWD.
Engaging Front Gearcase
The AWD switch may be turned on or off while the vehicle is moving.
Initially, the vehicle’s electronic system will not enable the AWD until
the engine RPM is below 3100. Once enabled, the AWD remains
enabled until the AWD switch is turned off. If the switch is t urned off
while the front gearcase i s moving, it will not disengage until the rear
wheels regain traction.
Engage the AWD switch before getting i nto conditions where front
wheel drive may be needed. If the rear wheels are spinning, release the
throttle before switching to AWD.
1
CAUTION
Switching to AWD while the rear wheels are spinning may
cause severe drive shaft and gearcase damage. Always
switch to AWD while the rear wheels have traction or are at
rest.
48
FEATURES AND CONTROLS
Instrument Cluster (Magnum 330 HDS/500)
Your ATV is equipped with an instrument cluster that senses vehicle
speed from the right front wheel. The instrument cluster m easures
distance in miles as well as hours of operation. It also includes a
reverse speed limiter function that limits the ATV’s speed to
approximately 7-9 mph (see page 38).
3
2
1
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.
49
FEATURES AND CONTROLS
Instrument Cluster (Magnum 330 HDS/500)
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 i nstrument cluster may have
shut off to protect the electrical system. If this occurs, take the A TV to
your Polaris dealer for proper diagnosis.
1. Gear Indicator - As the shift lever is moved, this indicates the
gear the transmission is in:
4
5
H = High Range
3
L = Low Range
N = Neutral
R = Reverse
P = Park (if equipped)
2
2. AWD Indicator - This
indicator illuminates
when the electrical
portion of the AWD
system is enabled.
3. Engine Hour Display Indicator
1
6
8
2
4. Service Interval/Diagnostic Mode Indicator
5. Low B attery and Over Voltage - This warning usually indicates
that the ATV is being operated at an RPM too low to keep the
battery charged. A low battery warning may also occur under normal
operation if the machine is at idle and high electrical load (lights,
cooling fan, accessories) is applied. Driving at a higher RPM or
connecting a battery charger will usually clear the warning.
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 if this warning appears or serious engine
damage could result.
8. Mode Indicator
50
FEATURES AND CONTROLS
Instrument Cluster (Magnum 330 HDS/500)
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 the left handlebar is also the mode
button. NOTE: If using the mode button to program the rider
information center, or to toggle through the options, the machine
cannot be in reverse.
Mode 1 - Odometer
The odometer records the miles traveled by the ATV.
Mode 2 -Trip Meter
The trip meter records the miles traveled by the ATV on each trip if it’s
reset before each trip. To reset the trip meter, select the trip meter
mode. Press and hold the mode button (override button) until the t otal
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.
51
FEATURES AND CONTROLS
Instrument Cluster (Magnum 330 HDS/500)
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 park brake and shift the transmission to 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.
52
FEATURES AND CONTROLS
Instrument Cluster (Magnum 330 HDS/500)
Rider Information Center
Diagnostic Mode
Screen 5: Programmable service interval
The purpose of t he 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 t he programmable service interval before it
can be used.
Once the service interval mode is set with the hours when service is
due, the hours of actual engine operation are subtracted from the set
hours until 0 is reached. When the counter reaches 0, the wrench icon
will flash quickly for 5 seconds each time the vehicle is started as a
reminder that the periodic maintenance is due.
To set the hours, press and hold the mode/override button until the
wrench icon flashes. When it begins to flash, release the button. The
setting will increase by one hour each time the button i s 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 t he mode button until the letters flash,
then press and release the button once. When the display stops
flashing, the mode has been set.
53
FEATURES AND CONTROLS
Instrument Cluster (Magnum 330)
Your ATV is equipped with an instrument cluster that senses vehicle
speed from the right front wheel. The instrument cluster m easures
distance in miles as well as hours of operation. It also includes a
reverse speed limiter function that limits the ATV’s speed to
approximately 7-9 mph (see page 38).
3
2
1
1. Rider Information Center
2. Speedometer needle - in addition to depicting vehicle speed, this
needle will flash to signal a fault condition.
3. Speedometer
CAUTION
Washing the ATV with a high pressure washer may cause water to
enter the instrument cluster and cause damage to the electronic
components. 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.
54
FEATURES AND CONTROLS
Instrument Cluster (Magnum 330)
Rider Information Center
The rider information center is located in the lower portion of the
instrument cluster.
1. Gear Indicator - As the
shift lever is moved, this
will indicate the gear the
machine is in:
H = High Range
L = Low Range
N = Neutral
R = Reverse
P=Park
Eorblank=Error-The
error message usually means
the gear selector is in between
gears. It can, however, also
indicate that the transmission
switch needs repair.
2. High Engine Coolant Temperature - Do not continue to operate the
ATV is this warning appears or serious engine damage could result.
3. Hour Meter
4. Service Interval/Miscellaneous Service Warnings
5. Low Battery and Over Voltage - This warning usually indicates
that the ATV is being operated at an RPM too low to keep the
battery charged. A low battery warning may also occur under normal
operation if the machine is at idle and high electrical load (lights,
cooling fan, accessories) is applied. Driving at a higher RPM or
connecting a battery charger will usually clear the warning.
NOTE: If the instrument cluster no longer illuminates, it’s possible
that a battery over voltage occurred and the instrument cluster has shut
off to protect the electrical system. If this occurs take the ATV to your
Polaris dealer for proper diagnosis.
NOTE: All segments of the rider information center will light up for
2.5 seconds at start-up.
2
1
3
4
5
55
FEATURES AND CONTROLS
Instrument Cluster (Magnum 330)
Rider Information Center
The rider information center has 4 standard modes:
Mode 1 - Odometer
Mode 2 - Tripmeter
Mode 3 - Total Service Hours
Mode 4 - Programmable service interval
The reverse override button on the left handlebar is also the mode
button. NOTE: If using the mode button to program the rider
information center, or to toggle through the options, the machine
cannot be in reverse.
Mode 1 - Odometer
The odometer records the miles traveled by the ATV.
Mode 2 -Trip Meter
The trip meter records the miles traveled by the ATV on each trip if it’s
reset before each trip. To reset the trip meter, select the trip meter
mode. Press and hold the mode button (override button) until the t otal
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.
56
FEATURES AND CONTROLS
Instrument Cluster (Magnum 330)
Rider Information Center
Mode 4 - Programmable Service Interval
The purpose of t he programmable service interval is to provide the
consumer and dealer with a convenient reminder for routine
maintenance. When your vehicle leaves the factory, this feature is
turned off. You m ust enable the programmable service interval before
it can be used.
Once the service interval mode is set with the hours when service is
due, the hours of actual engine operation are subtracted from the set
hours until 0 is reached. When the counter reaches 0, the wrench icon
will flash quickly for 5 seconds each time the vehicle is started as a
reminder that the periodic maintenance is due.
To set the hours, press and hold the mode/override button until the
wrench icon flashes. When it begins to flash, release the button. The
setting will increase by one hour each time the button i s 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.
57
FEATURES AND CONTROLS
Instrument Cluster (Magnum 330)
Rider Information Center
Diagnostic Mode
The diagnostic mode is for informational purposes only. Please return
your ATV to your dealer for all major repairs.
To enter the diagnostics mode:
1. Turn the key switch off and wait 20 seconds.
2. Set the park brake and shift the transmission to neutral.
3. Hold the mode/reverse
override button and turn the
key switch on.
The initial screen displayed looks
similar to the top illustration and
refers to the software version
installed in your ATV. This
information is displayed briefly.
Use the mode/reverse override
button to toggle through the
diagnostic screens. The first
screen (1) displays battery
voltage.
Screen two (2) is the tachometer
for setting idle speed. If this
needs adjustment, please contact
your dealer.
As long as the center is in the
diagnostic mode, the wrench icon
will remain lit.
To leave the diagnostic mode,
either shift the machine out of
neutral or turn the key switch off
and on. NOTE: Any movement
of the tires will also take the
machine out of the diagnostic
mode.
1
2
58
OPERATION
Break-In Period
The break-in period for your new Polaris 4-cycle ATV is defined as the
first ten hours of operation, or the time it takes to use the first two full
tanks of gasoline. No single action on your part is as important as
following the procedures for a proper break-in. Careful treatment of a
new engine will result in more efficient performance and longer life for
the engine. Perform the following procedures carefully.
CAUTION
Excessive heat build-up during the first three hours of
operation will damage close-fitted engine parts. Do not operate
at full throttle or high speeds for extended periods during the
first three hours of use.
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 45.
2. Check the oil level on
the dipstick. See page
ADD 8 OZ.NORMALFULL
500
1
86. Add Polaris
Premium 4 Synthetic Oil if
necessary to maintain the oil
level in the normal/safe operating
range (1).
1
330
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 60.
6. Pull only light loads.
7. During the break-in period, change both the oil and the filter at 20
hours or 200 miles.
59
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 t hat your vehicle i s 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 (liquid cooled models) - Check for proper level at
the recovery bottle.
60
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. Make sure the
fuel valve is on.
2. Sit on the vehicle and pull the choke
knob (1) out until it stops. NOTE: If
the knob doesn’t stay where positioned,
increase the tension by rotating the tension
adjusting nut (2) clockwise.
NOTE: The variable choke is fully on when the
knob is pulled completely out. The choke is
off when the knob is pushed completely in.
The choke can be adjusted gradually, depending
on how much choke is needed for starting. Be
sure the choke is off during operation, as excess fuel
washing into the engine oil will increase wear on engine components.
3. Move the engine stop switch to RUN.
NOTE: Do not press the throttle while starting the engine.
4. Turn the ignition key past the ON position to engage the starter for
a maximum of five seconds. Release the key when the engine
starts. If it doesn’t start, release the key and wait five seconds.
Activate the starter for another five seconds. Repeat until the
engine starts.
5. If the engine slows or stops, position the choke knob half way in to
allow proper engine warm up.
6. Vary the engine RPM slightly with the throttle to aid in warm-up.
When the engine idles smoothly, push the choke all the way in.
1
2
61
OPERATION
Starting the Engine
Starting a Warm Engine
Warm engines do not normally require the use of the choke. Excessive
use of the choke can cause the spark plug to become wet fouled.
1. Position the vehicle on a level surface with the transmission in
PARK.
2. Lock the parking brake, turn the fuel tank valve to ON, sit on the
vehicle, and turn the engine stop switch to RUN.
3. If the engine has cooled to a point where i t 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.
62
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.
63
OPERATION
Driving Safely
Making Turns
Your Polaris ATV is equipped with a solid rear axle that drives both
rear wheels equally at all times. This means that the wheel on the
outside of the turn must travel a greater distance than the inside wheel
when turning and the inside tire must slip traction slightly.
To make a turn, steer in the direction of the turn, leaning your upper
body to the inside of t he turn while supporting your weight on the
outer footrest. This technique alters the balance of traction between the
rear wheels, allowing the turn to be made smoothly. The same leaning
technique should be used for turning in reverse.
NOTE: Practice making turns at slow speeds before attempting to turn
at faster speeds.
WARNING
Turning at sharp angles or at excessive speeds can result in vehicle
overturn and lead to serious injury. Avoid turning at sharp angles.
Never turn at high speeds.
64
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 t he skid
and shifting your body weight forward.
4. Drive with AWD engaged (AWD models) to assist in controlling the
vehicle in slippery areas.
CAUTION
Severe damage to drive train may occur if the AWD is engaged
while the wheels are spinning. Always engage the AWD when the
tires have traction or are at rest.
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.
65
OPERATION
Driving Safely
Driving Uphill
Whenever traveling uphill, follow these
precautions:
1. Always travel straight uphill.
2. Avoid steep hills (25_ maximum).
3. Keep both feet on the footrests.
4. Transfer your weight forward.
5. Proceed at a steady rate of speed
and throttle opening.
6. Remain alert and be prepared to
take emergency action.This
may include quick dismounting
of the vehicle.
If all forward speed is lost:
Keep your weight uphill.
Apply the single lever brake, gradually. When fully stopped, apply the
auxiliary brake as well, then lock the park brake.
If the ATV begins rolling backwards:
Keep your weight uphill. Never apply engine power. Never apply the
auxiliary rear brake while rolling backwards.
Apply the single-lever brake, gradually. When fully stopped, apply the
auxiliary rear brake as well, and then lock the parking brake.
Dismount on uphill side, or to either side if ATV is pointed straight
uphill. Turn the ATV around and remount, following the procedure
described on page 69.
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.
66
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 the
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!
67
OPERATION
Driving Safely
Driving Downhill
Whenever descending a hill, follow these precautions:
1. Proceed directly downhill.
2. Transfer your weight to the rear of the vehicle.
3. Slow down.
4. Apply the brakes slightly to aid in slowing, using the single brake
lever.
NOTE: F amiliarize 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.
68
OPERATION
Driving Safely
Turning Around on a Hill
WARNING
Improper hill climbing procedures could cause loss of control or
overturn and result in serious injury or death.
Avoid climbing steep hills (25_ maximum).
Use extreme caution when operating on hills, and follow proper
operating procedures outlined in the owner’s manual.
If the vehicle stalls while climbing a hill, never back it down the hill!
One maneuver that can be used when it’s necessary to turn around
while climbing a hill is the K-turn:
1. Stop and lock the parking brake while keeping body weight uphill.
2. Leave transmission in forward and shut off the engine.
3. Dismount on the uphill side of the vehicle, or on the left if the
vehicle is pointing straight uphill.
4. Staying uphill of the vehicle, turn the handlebars full l eft.
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
69
OPERATION
Driving Safely
Driving Through Water
1
Your ATV can operate through water with a maximum recommended
depth equal to the bottom of the footrests (1). Follow these procedures
when operating through water:
1. Determine water depths and current before crossing.
2. Choose a crossing where both banks have gradual inclines.
3. Proceed slowly, avoiding rocks and obstacles if possible.
4. After crossing, dry the brakes by applying light pressure to the
lever until braking action is normal.
After running the vehicle in water, it’s critical to have it serviced as
outlined in the maintenance chart. See page 77. The following areas
need special attention: engine oil, transmission oil, front and rear
gearcases, and all grease fittings.
CAUTION
Major engine damage can result if the vehicle is not thoroughly
inspected after operation in water. Perform the services outlined
in the maintenance chart.
If your vehicle becomes immersed or is operated in water that
exceeds the footrest level, take it to your dealer for service
before starting the engine.
70
OPERATION
Driving Safely
Driving Through Water
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 t urns or stops, and do not make sudden throttle
changes.
If your vehicle becomes immersed, and it’s impossible to take it to a
dealer before starting it, follow the steps described on page 105. Have
the vehicle serviced by your dealer at the first opportunity.
Driving Over Obstacles
Be alert! Look ahead and learn to read the terrain you’re traveling on.
Be constantly alert for hazards such as logs, rocks and low hanging
branches.
WARNING
Severe injury or death can result if your vehicle comes in contact
with a hidden obstacle. Not all obstacles are immediately visible.
Travel with caution in unfamiliar terrain.
71
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 t he 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.
72
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 t he parking brake.
3. Always block the rear wheels on the downhill side. See
illustration.
4. Shut off the fuel supply.
73
OPERATION
Hauling Cargo
1/3
Your ATV has been designed to carry or tow a certain amount of load.
Always read and understand the load distribution warnings listed on
the warning labels, and never exceed the specified weights.
Cargo weight should be evenly distributed (1/3 on the front and 2/3 on
the rear) and mounted as low as possible. When operating over rough
or hilly terrain, reduce speed and cargo to maintain stable driving
conditions.
Belt Life
Use low forward gear when hauling or towing heavy cargo to extend
belt life.
2/3
74
OPERATION
Hauling Cargo
WARNING
Hauling cargo improperly can alter vehicle handling and may
cause loss of control or brake instability and result in serious injury
or death. Always follow these precautions when hauling cargo:
S REDUCE SPEED AND ALLOW GREATER DISTANCE FOR
BRAKING WHEN HAULING CARGO.
S CARGO WEIGHT DISTRIBUTION should be 1/3 on the front
rack and 2/3 on the rear rack. When operating over rough or
hilly terrain, reduce speed and cargo to maintain stable driving
conditions. Carrying loads on one rack only increases the possibility of vehicle overturn.
S LOADS MUST BE CARRIED AS LOW ON THE RACKS AS
POSSIBLE. Carrying loads high on the racks raises the center
of gravity of the vehicle and creates a less stable operating
condition. When cargo loads are carried high on the racks, the
weight of the loads must be reduced to maintain stable operating conditions.
S ALL LOADS MUST BE SECURED BEFORE OPERATING.
Unsecured loads can create unstable operating conditions,
which could result in loss of control of the vehicle.
S OPERATE ONLY WITH STABLE AND SAFELY ARRANGED
LOADS. When handling off-centered loads that cannot be centered, securely fasten load and operate with extra caution. Always attach the tow load to the hitch point designated for your
vehicle.
S HEAVY LOADS CAN CAUSE BRAKING AND CONTROL
PROBLEMS. Use extreme caution when applying brakes with
a loaded vehicle. Avoid terrain or situations that may require
backing downhill.
S EXTREME CAUTION MUST BE USED when operating with
loads extending over the rack sides. Stability and maneuverability may be adversely affected, causing the machine to overturn.
S DO NOT BLOCK THE FRONT HEADLIGHT BEAM when car-
rying loads on the front rack.
S DO NOT TRAVEL FASTER THAN THE RECOMMENDED
SPEEDS. Vehicle should never exceed 10 mph (16 kph) while
towing a load on a level grass surface. Vehicle speed should
never exceed 5 mph (8 kph) when towing loads in rough terrain,
while cornering, or while ascending or descending a hill.
75
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. Blow-by
gases are forced back to the combustion chamber by the intake system.
The system does not allow the blow-by gases to enter t he 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.
1
76
MAINTENANCE AND LUBRICATION
Accessories
Auxiliary power outlets provide 12V power for operating accessories
such as hand held spot lights. Accessory outlets are available for all
models. Contact your Polaris dealer for more information.
Polaris has a wide range of additional accessories available for your
ATV. See your Polaris dealer.
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 models are equipped with a speedometer that has a
programmable service interval mode. This important feature will help
you determine when maintenance service i s due. See page 57 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, t o purge water or dirt contamination from
grease fittings and other critical components.
LEmission Control System Service (California - 4-Cycle)
NOTE: Some 4-Cycle models may have an additional California
-only emissions warranty. Refer to the specifications section beginning
on page 131 for model specific information.
JDealer service item.
77
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.
ItemHours/
Miles
Brake SystemPre-Ride Pre-RideInspect
Auxiliary BrakePre-Ride Pre-RideInspect
TiresPre-Ride Pre-RideInspect
WheelsPre-Ride Pre-RideInspect
Frame nuts, bolts,
fasteners
"
Air filter,
Pre-cleaner
L
Coolant level (liquid
cooled models)
Fuel and oil tanksPre-Ride Pre-RideFill to proper levels
" General lubrication50 hrs3 monthsLubricate all fittings, pivots,
"
Engine oil level/oil
change
L
"
Oil Filter100 hrs./
L
Engine breather
L
hose
WeeklyWeeklyInspect; replace as needed
20 hrsMonthlyInspect monthly; change
20 hrsMonthlyInspect; replace annually
100 hrsMonthlyCheck monthly; change
25 hrs3 monthsInspect (re-torque required
100 hrs /
1000
miles
1000 mi.
100 hrs.6 monthsInspect
Frequency Remarks
ply Polaris dielectric grease
to socket when replaced
annually
and as needed
annually
at first service only)
cables, etc.
6 monthsCheck level daily; break-in
service at one month;
change oil more often in
cold weather
6 monthsReplace with oil change
" More often under severe use, such as dirty or wet conditions
L Emission Control System Service (California)
J Dealer service item
79
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.
ItemHours/
Miles
Carburetor float
bowl
J Throttle Cable/ETC
Switch
Choke (enricher)
L
cable
Coolant strength/
pressure test system (if applicable)
Shift linkage50 hrs.6 monthsInspect; adjust
J Drive belt50 hrs.6 monthsInspect; replace as needed
" Steering50 hrs.6 monthsInspect daily; lubricate
" Front suspension50 hrs.6 monthsInspect; lubricate; tighten
cap, lines, fuel valve, filter,
pump and carburetor; replace lines every two years
face
L
J Brake fluid200 hrs.24 monthsChange every two years
J Front wheel bear-
ings (2WD)
Spark arrestor300 hrs.36 monthsClean out
Idle speedAs required Adjust
L
Recoil housingAs required Drain moisture out after rid-
J Toe adjustmentAs required Periodic inspection; adjust
Headlight aimAs required Adjust as needed
300 hrs.36 monthsInspect; replace as needed
inginwater
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
81
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
FUse Polaris Premium U-Joint Lube every 500 miles, before long
periods of storage, or after pressure washing or submerging
∆When suspension action becomes stiff, or after washing
ItemLubeMethodFrequency
4-Cycle
Engine
BrakesDOT 3 fluid onlyMaintain level between fill
(1) Transmission
(2) Front
Gearcase
(Domestic
Models)
(3) Visco
Drive (HDS
Models)
(4) Rear
Gearcase
Polaris Premium 4
Synthetic 0W40
AGL Synthetic
Gearcase Lube
Polaris Premium
Hub Drive Fluid
Polaris ATV Angle
Drive Fluid
Polaris ATV Angle
Drive Fluid
Add to proper level on dipstick.
lines. See page 41.
See page 92.Check every 6
See page 94.Change annually or
See page 94.Change annually or
See page 96.Change annually or
Check level daily.
As required; change
every two years or
200 hours
months/1000 miles.
Change annually or
at 100 hours
at 100 hours
at 100 hours
at 100 hours
82
MAINTENANCE AND LUBRICATION
Lubrication Recommendations
(1)
(2)
(3)
(4)
83
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
84
MAINTENANCE AND LUBRICATION
Lubrication Recommendations
Premium 4 Synthetic 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 130 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. It s
exceptional frictional properties result in more efficient operation, more
power output and lower fuel consumption.
Although Polaris Premium 4 is the only oil recommended for use in
this engine, use of any API certified “SH” oil is allowable as long as
it’s 0W-40. Oil may need to be changed more frequently if Polaris
Premium 4 is not used. Follow the manufacturer’s recommendations
for ambient temperature operation.
CAUTION
Mixing brands or using a non-recommended oil may cause serious
engine damage. We recommend the use of Polaris Premium 4 All
Season synthetic oil or API certified “SH” oil, 0W-40. Never
substitute or mix oil brands.
85
MAINTENANCE AND LUBRICATION
Lubrication Recommendations
Engine Oil Check
The oil dipstick (1) is located on the
left side of the ATV (Magnum 500) or
on the left side of the engine (Magnum
330).
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 and wipe it
dry with a clean cloth.
4. Screw the dipstick completely in.
NOTE: The dipstick must be
screwed completely in to ensure
an accurate reading.
5. Remove the dipstick
and read the oil level.
Maintain the oil level
in the normal/safe
ADD 8 OZ.NORMALFULL
operating range (2).
Do not overfill.
NOTE: A rising oil level between
checks in cool weather driving can
indicate moisture collecting in the oil
reservoir. If the oil level is over the
full mark, change the oil.
1
500
330
2
2
1
500
330
86
MAINTENANCE AND LUBRICATION
Lubrication Recommendations
Oil and Filter Change (Magnum 500)
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 i ncludes
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.
CAUTION
Hot oil can cause serious burns to skin. Do not allow hot oil to
come into contact with skin.
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 t he engine for two to three minutes, t hen turn it off.
87
MAINTENANCE AND LUBRICATION
Lubrication Recommendations
Oil and Filter Change (Magnum 500)
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.
(19-23 Nm).
7. Disconnect the lower oil
delivery hose and remove the
screen fitting (3) from the oil tank. Clean and reinstall the fitting,
then torque to 25 ft. lbs. (34 Nm). Reattach the oil line. NOTE:
The fitting threads must be sealed with Loctitet PST 505 or PTFE
seal tape. The fitting must also line up with the m ark (4) on the
rear side of the oil tank.
8. Place shop towels beneath the
oil filter. Using an oil filter
wrench, turn the filter (5)
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 oil will remain in the crankcase. To
drain, remove the drain plug on the lower right side of the
crankcase.
2
1
4
5
3
88
MAINTENANCE AND LUBRICATION
Lubrication Recommendations
Oil and Filter Change (Magnum 500)
12. After draining, reinstall the drain plug and torque to 14 ft. lbs. (19
Nm). NOTE: The sealing surfaces on the drain plug and
crankcase should be clean and free of burrs, nicks or scratches.
13. Remove the dipstick 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. Pl ace the gear selector in PARK and lock the parking brake.
15. IMPORTANT: Prime the oil pump using the procedure outlined
below. Then 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.
Oil Pump Priming
This priming procedure must be performed whenever the oil hose
connection between the oil tank and pump inlet has been disconnected.
1. Clamp or pinch off the vent
line (1) approximately 2I
from the oil tank (2), between
the end of the oil tank vent
fitting and the vent line’s
pressure relief slit (3).
2. Run the engine for 45-60
seconds.
3. Remove the vent line clamp.
The oil pump will now be
properly primed and ready for
operation.
2I
2
1
3
89
MAINTENANCE AND LUBRICATION
Lubrication Recommendations
Oil and Filter Change (Magnum 330)
CAUTION
If the ATV is left without oil in the system for extended periods, the
oil pump may lose its prime, which could result in engine damage.
Always replace the oil and filter within a few hours of draining the
oil. Do not allow the vehicle to be without oil overnight.
1. Obtain the correct oil filter and an adequate supply of oil so the oil
and filter change can be completed without interruption.
2. Position the vehicle on a level surface.
3. Clean the area around the drain plug on the bottom of the engine
crankcase.
4. Run the engine for two to three minutes until warm. Stop the
engine.
CAUTION
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 t he engine crankcase and remove the
drain plug.
6. Allow the oil to drain completely.
7. Install a new sealing washer on the drain plug. NOTE: The
sealing surfaces on the drain plug and crankcase should be clean
and free of burrs, nicks or scratches.
8. Reinstall the drain plug and torque to 14 ft. l bs. (19 Nm).
9. Place shop towels beneath t he 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.
90
MAINTENANCE AND LUBRICATION
Lubrication Recommendations
Oil and Filter Change (Magnum 330)
11. Lubricate the gasket on the new filter with a film of engine oil.
Check to make sure the gasket is in good condition.
12. Install the new filter and turn by hand until the filter gasket
contacts the sealing surface, then turn and additional 1/2 turn.
13. Remove the dipstick and fill the sump with the recommended oil.
Refer to the specifications section beginning on page 131 for
capacities.
14. Pl ace the gear selector in PARK and lock the parking brake.
15. Start the engine and let it idle for one to two minutes. Stop the
engine and inspect for leaks.
16. Recheck the oil level and add oil as necessary to bring the level to
the upper mark on the dipstick.
17. Dispose of used filter and oil properly.
91
MAINTENANCE AND LUBRICATION
Lubrication Recommendations
Transmission Oil Check
The transmission fill plug is located on
the right side of the machine, behind
the footwell. The transmission oil level
should be checked every six months or
1000 miles (1600 km), whichever
comes first. Change transmission oil
annually.
We recommend the use of AGL
Synthetic Gearcase Lubricant. Refer to
the specifications section beginning on
page 131 for capacities. See page 130 for
the part numbers of Polaris products.
1. Position the ATV on a level
surface.
2. Remove the fill plug (1), and check
the oil level.
3. Add the recommended oil as needed
to maintain the oil level 1 5/8″ from
the top of the fill hole.
4. Reinstall the fill plug.
1
4x4 Shown
15/8″
92
MAINTENANCE AND LUBRICATION
Lubrication Recommendations
Transmission Oil Change
1. Remove the propshaft shield (if equipped) from the right side of
the vehicle to access the fill plug.
2. Remove the fill plug.
3. Remove the transmission drain plug located on the bottom left
hand side and drain the oil. Catch and discard used oil properly.
4. Clean and reinstall the drain plug torque to 14 ft. l bs. (19 Nm).
5. Add the correct amount of AGL Synthetic Gearcase Lubricant.
Refer to the specifications section beginning on page 131 for
capacities.
6. Reinstall the fill plug and check for leaks.
7. Reinstall the propshaft shield (if equipped).
93
MAINTENANCE AND LUBRICATION
Lubrication Recommendations
Front Gearcase Oil Check
Maintain gearcase oil levels as indicated in the chart below. Change
the front gearcase oil annually.
Gearcase Capacities
ModelFluidCapacity
Magnum 330
w/Centralized Hilliard
Magnum 330 HDSAngle Drive Fluid13.5 oz. (400 ml)
Magnum 500 HDSAngle Drive Fluid13.5 oz. (400 ml)
Centralized Hilliard
We recommend the use of Polaris P remium Hub Drive Fluid in models
with centralized Hilliard gearcases (domestic models). Since this fluid
level cannot be checked, change the fluid annually as recommended.
Visco-Lok
We recommend the use of Polaris ATV
Angle Drive Fluid in HDS models with
V isco-Lok gearcases. Check the oil
level every six months or 1000 miles
(1600 km), whichever comes first.
With the ATV on a level surface,
remove the fill plug (2) and check the
oil level. Maintain the level at the
bottom of the fill plug threads.
Premium Hub
Drive Fluid
5 oz. (148 ml)
2
94
MAINTENANCE AND LUBRICATION
Lubrication Recommendations
Front Gearcase Oil Change
Centralized Hilliard
1. Check the vent hose (1) to be sure
it’s unobstructed and routed
properly.
2. Support the vehicle securely with
a jackstand and remove the front
tire on the driver’s side.
3. Remove the drain plug (2) located
on the bottom of the gearcase and
drain the oil into a suitable
container. The drain plug is
accessible through the skid plate.
Discard used oil properly.
4. Clean and reinstall drain plug using a new sealing washer. Torque
to 14 ft. lbs. (19 Nm).
5. Remove the fill plug (3) and add 5oz. (148 ml) of the
recommended fluid. DO NOT OVERFILL. Overfilling may cause
excess drag, which can lead to unwanted engagement.
6. Reinstall the fill plug and torque to 14 ft. lbs. (19 Nm).
2
1
3
Visco-Lok
1. Position the vehicle on a level surface and remove the fill plug.
2. Place a drain pan beneath the gearcase, remove the gearcase drain
plug, and drain the oil.
3. Clean and reinstall the drain plug. Torque to 14 ft. lbs. (19 Nm).
4. Add 13. 5 oz. (140 ml) of the recommended fluid.
5. Reinstall the fill plug and check for leaks.
95
MAINTENANCE AND LUBRICATION
Lubrication Recommendations
Rear Gearcase Oil Check
Check the rear gearcase oil level
monthly, and change the oil annually.
Maintain the rear gearcase oil level at
the bottom of the fill hole threads. We
recommend the use of Polaris ATV
Angle Drive Fluid. See page 130 for
the part numbers of Polaris products.
1. With machine on level ground,
remove the gearcase fill plug (1)
and inspect the oil level. Maintain
the oil level at the bottom of the
fill hole threads (2).
2. If the oil level is low, add the
recommended lubricant as needed.
3. Reinstall the fill plug and torque to
14 ft. lbs. (19 Nm).
4. Check for leaks.
Rear Gearcase Oil Change
1. Remove the drain plug (3) located on the bottom of t he gearcase.
Catch and discard the used oil properly.
2. Clean and reinstall the drain plug with a new sealing washer.
Torque to 14 ft. lbs. (19 Nm).
3. Remove the fill plug and add 10 oz. (300 ml) of the
recommended gearcase oil.
4. Reinstall the fill plug. Torque to 14 ft. lbs. (19 Nm).
5. Check for leaks.
1
3
2
96
MAINTENANCE AND LUBRICATION
Engine Cooling System (Magnum 500)
Coolant Level
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 120.
The fluid level m ust 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 t emperature 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. S ee page 130 for the
part numbers of Polaris products.
NOTE: Polaris Premium 60/40 is already premixed and ready to use.
Do not dilute with water.
NOTE: Always follow the manufacturer’s mixing recommendations
for the freeze protection required in your area.
1
97
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