Polaris Magnum 330 User Manual

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Polaris Magnum 330 User Manual

WARNING

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

A card containing important ATV safety information should be attached to the owner’s manual on the next page. If you cannot locate this card, or if it has been removed, please call 1-800-342-3764 for assistance.

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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.

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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 Service Dealer (MSD) Technician.

Your Polaris dealer knows your vehicle best and is interested in your total satisfaction. Be sure to return to your dealership for all of your service needs during, and after, the warranty period.

We also take great pride in our Parts Apparel and Accessories (PAA) products, available through our online store at www.purepolaris.com. Have your accessories and clothing delivered right to your door!

Polaris, Polaris The Way Out, and Workmobiles are registered trademarks of Polaris Industries Inc.

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TABLE OF CONTENTS

WELCOME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 VEHICLE IDENTIFICATION NUMBERS . . . . . . . . 6 SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 FEATURES AND CONTROLS . . . . . . . . . . . . . . . 38 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 EMISSION CONTROL SYSTEMS . . . . . . . . . . . . 76 MAINTENANCE AND LUBRICATION . . . . . . . . . 77 POLARIS PRODUCTS . . . . . . . . . . . . . . . . . . . . . 130 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . 131 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . 140 WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144 INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147

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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

2

Frame VIN:

Vehicle Model Number:

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

Key Number:

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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 thoroughly inspected at specific intervals.

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SAFETY

Operator Safety

The following signal words and symbols appear throughout this manual and on your ATV. Your safety is involved when these words and symbols are used. Become familiar with their meanings before reading the manual.

The safety alert symbol, on your ATV or in this manual, alerts you to the potential for personal injury.

WARNING

The safety alert warning indicates a potential hazard that may result in serious injury or death.

CAUTION

The safety alert caution indicates a potential hazard that may result in minor personal injury or damage to the machine.

CAUTION

A caution indicates a situation that may result in damage to the machine.

NOTE

A note will alert you to important information or instructions.

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SAFETY

Operator Safety

WARNING

Serious injury or death can result if you do not follow these instructions and procedures, which are outlined in further detail within your owner’s manual.

SRead this manual and all labels carefully, and follow the operating procedures described.

SNever operate an ATV without proper instruction. Take a training course. Beginners should receive training from a certified instructor. Contact an authorized Polaris ATV dealer or call Polaris at 1-800-342-3764 to find out about the training courses nearest you.

S Never allow anyone under 16 years of age to operate this ATV.

SNever 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.

SAlways avoid operating an ATV on paved surfaces, including sidewalks, driveways, parking lots, and streets.

SNever operate an ATV on a public street, road or highway, including a dirt or gravel road.

SNever 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.

SNever 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.

SAlways 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.

SAlways keep both hands on the handlebars and both feet on the footrests of the ATV during operation.

SAlways travel slowly and use extra caution when operating on unfamiliar terrain. Be alert to changing terrain conditions.

S Never operate on excessively rough, slippery, or loose terrain.

SAlways follow proper turning procedures as described in this manual. Practice turning at low speeds before attempting to turn at faster speeds. Do not turn at excessive speeds.

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SAFETY

Operator Safety

SAlways have the ATV inspected by an authorized Polaris dealer if it’s been involved in an accident.

SNever operate on hills too steep for the ATV or for your abilities. Practice on smaller hills before attempting larger hills.

SAlways follow proper procedures for climbing hills. Check the terrain 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.

SAlways follow proper procedures for going downhill and for braking on hills. Check the terrain carefully before you start down a hill. Shift your weight backward. Never go down a hill at high speed. Avoid going down a hill at an angle, which would cause the vehicle to lean sharply to one side. Travel straight down the hill when possible.

SAlways 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.

SAlways 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.

SAlways check for obstacles before operating in a new area. Never attempt to operate over large obstacles, such as rocks or fallen trees. Always follow proper procedures when operating over obstacles as described in this manual.

SAlways 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.

SAvoid 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.

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SAFETY

Operator Safety

SWet 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.

SAlways check for obstacles or people behind the ATV before operating in reverse. When it’s safe to proceed in reverse, move slowly and avoid turning at sharp angles.

SAlways use the size and type of tires specified for your ATV, and always maintain tire pressure as recommended.

SNever modify an ATV through improper installation or use of accessories.

SNever 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.

SAlways 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.

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SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD

Operating this ATV without proper instruction. WHAT CAN HAPPEN

The risk of an accident is greatly increased if the operator does not know how to operate the ATV properly in different situations and on different types of terrain.

HOW TO AVOID THE HAZARD

Beginning and inexperienced operators should complete the certified training course offered by Polaris. Operators should regularly practice the skills learned in the course and the operating techniques described in the owner’s manual.

For more information about the training course, contact an authorized ATV dealer or call Polaris at 1-800-342-3764.

WARNING

POTENTIAL HAZARD

Failure to follow the age recommendations for this ATV. WHAT CAN HAPPEN

Severe injury and/or death could occur if a child under the minimum age recommendation operates an ATV.

Even though a child may be within the recommended age group for operating some ATVs, he/she may not have the skills, abilities, or judgment needed to operate an ATV safely and could be susceptible to accident or injury.

HOW TO AVOID THE HAZARD

No one under the age of 16 should operate a Polaris ATV.

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SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD

Carrying a passenger on an ATV. WHAT CAN HAPPEN

Carrying a passenger greatly reduces the operator’s ability to balance and control the ATV, which could cause an accident and injury to the operator and/or passenger.

HOW TO AVOID THE HAZARD

Never carry a passenger. The purpose of the long seat is to allow the operator to shift position as needed during operation. It is not intended for carrying passengers.

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SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD

Operating an ATV on paved surfaces, including sidewalks, paths, parking lots, and driveways.

WHAT CAN HAPPEN

ATV tires are designed for off-road use. Operating on paved surfaces may seriously affect the handling and control of the ATV and could result in loss of control, accident, and/or injury.

HOW TO AVOID THE HAZARD

Avoid operating the ATV on pavement. If it’s unavoidable, travel slowly and avoid sudden turns or stops.

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SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD

Operating this ATV on public streets, roads or highways. WHAT CAN HAPPEN

The ATV could collide with another vehicle. HOW TO AVOID THE HAZARD

Never operate the ATV on any public street, road or highway, including dirt and gravel roads. In many states it’s illegal to operate ATVs on public streets, roads and highways.

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SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD

Operating this ATV without wearing an approved helmet, eye protection and protective clothing.

WHAT CAN HAPPEN

Operating an ATV without an approved helmet increases the risk of a severe head injury or death in the event of an accident.

Operating without eye protection could result in an accident and could increase the chance of a severe injury in the event of an accident.

HOW TO AVOID THE HAZARD

Always wear an approved helmet that fits properly.

Always wear eye protection (goggles or face shield), gloves, boots, long-sleeved shirt or jacket, and long pants.

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SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD

Operating the ATV after consuming alcohol or drugs. WHAT CAN HAPPEN

Consumption of alcohol and/or drugs could seriously affect operator judgment. Reaction time may be slower and operator balance and perception could be affected.

Consuming alcohol and/or drugs before or while operating an ATV could result in an accident causing severe injury or death.

HOW TO AVOID THE HAZARD

Never consume alcohol or drugs before or while operating an ATV.

WARNING

POTENTIAL HAZARD

Operating the ATV at excessive speeds. WHAT CAN HAPPEN

Excessive speed increases the operator’s chance of losing control of the ATV, which can result in an accident.

HOW TO AVOID THE HAZARD

Always operate the ATV at a speed that’s appropriate for the terrain, visibility and operating conditions, and your experience.

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SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD

Attempting wheelies, jumps and other stunts. WHAT CAN HAPPEN

Attempting stunts increases the chance of an accident, including an overturn.

HOW TO AVOID THE HAZARD

Never attempt wheelies, jumps, or other stunts. Avoid exhibition driving.

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SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD

Failure to inspect the ATV before operating. Failure to properly maintain the ATV. WHAT CAN HAPPEN

Poor maintenance increases the possibility of an accident or equipment damage.

HOW TO AVOID THE HAZARD

Always inspect your ATV before each use to make sure it’s in safe operating condition.

Always follow the inspection and maintenance procedures and schedules described in the owner’s manual.

WARNING

POTENTIAL HAZARD

Removing hands from the handlebars or feet from the footrests during operation.

WHAT CAN HAPPEN

Removing even one hand or foot can reduce ability to control the vehicle or could cause loss of balance and ejection from the ATV.

If the operator’s foot is not firmly planted on the footrest, it could come into contact with the rear wheels and lead to accident or injury.

HOW TO AVOID THE HAZARD

Always keep both hands on the handlebars and both feet on the footrests of the ATV during operation.

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SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD

Failure to use extra caution when operating the ATV on unfamiliar terrain.

WHAT CAN HAPPEN

Unfamiliar terrain may contain hidden rocks, bumps, or holes that could cause loss of control or overturn.

HOW TO AVOID THE HAZARD

Travel slowly and use extra caution when operating on unfamiliar terrain. Always be alert to changing terrain conditions.

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SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD

Failure to use extra caution when operating on excessively rough, slippery or loose terrain.

WHAT CAN HAPPEN

Operating on excessively rough, slippery or loose terrain could cause loss of traction or loss of control, which could result in an accident or overturn.

HOW TO AVOID THE HAZARD

Do not operate on excessively rough, slippery or loose terrain until you’ve learned and practiced the skills necessary to control the ATV on such terrain.

Always use extra caution on rough, slippery or loose terrain.

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SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD Turning improperly. WHAT CAN HAPPEN

Improper turns could cause loss of control and lead to a collision or overturn.

HOW TO AVOID THE HAZARD

Always follow proper procedures for turning as described in the owner’s manual.

Practice turning at slow speeds before attempting to turn at faster speeds.

Never turn at excessive speed.

WARNING

POTENTIAL HAZARD

Operating on excessively steep hills. WHAT CAN HAPPEN

The vehicle may overturn. HOW TO AVOID THE HAZARD

Never operate on hills too steep for the ATV or for your abilities. Never operate the ATV on hills steeper than 25_.

Practice on smaller hills before attempting large hills.

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SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD Climbing hills improperly. WHAT CAN HAPPEN

Improper hill climbing could cause loss of control or overturn. HOW TO AVOID THE HAZARD

Always follow proper procedures for climbing hills as described in the owner’s manual.

Always check the terrain carefully before ascending any hill. Never operate the ATV on hills steeper than 25_.

Never climb hills with excessively slippery or loose surfaces. Shift your weight forward.

Never open the throttle suddenly while traveling uphill. The ATV could flip over backwards.

Never go over the top of any hill at high speed. An obstacle, a sharp drop, or another vehicle or person could be on the other side of the hill.

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SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD Traveling downhill improperly. WHAT CAN HAPPEN

Improperly descending a hill could cause loss of control or overturn.

HOW TO AVOID THE HAZARD

Always follow proper procedures for traveling down hills as described in the owner’s manual. NOTE: A special technique is required when braking while traveling downhill. See page 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.

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SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD

Improperly crossing hills and turning on hills. WHAT CAN HAPPEN

Improperly crossing or turning as hills could cause loss of control or overturn.

HOW TO AVOID THE HAZARD

Never attempt to turn the ATV around on any hill until you’ve mastered the turning technique (on level ground) as described in the owner’s manual. See page 69. Use extra caution when turning on any hill.

Avoid crossing the side of a steep hill. When crossing the side of a hill:

Always follow proper procedures as described in the owner’s manual.

Avoid hills with excessively slippery or loose surfaces. Shift your weight to the uphill side of the ATV.

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SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD

Stalling, rolling backwards or improperly dismounting while climbing a hill.

WHAT CAN HAPPEN The vehicle could overturn.

HOW TO AVOID THE HAZARD

Maintain steady speed when climbing a hill.

If all forward speed is lost: Keep your weight uphill.

Apply the single lever brake gradually.

When fully stopped, apply the auxiliary rear brake as well, then lock the parking brake.

If the ATV begins rolling backwards: Keep weight uphill.

Never apply engine power.

Never apply the auxiliary rear brake while rolling backwards. Apply the single-lever brake gradually.

When fully stopped, apply the auxiliary rear brake as well, and then lock the parking brake.

Dismount on uphill side, or to either side if ATV is pointed straight uphill.

Turn the ATV around and remount, following the procedure described in the owner’s manual. See page 69.

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SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD

Improperly operating over obstacles. WHAT CAN HAPPEN

Operating over obstacles could cause loss of control or overturn. HOW TO AVOID THE HAZARD

Before operating in a new area, check for obstacles.

Avoid operating over large obstacles such as rocks and fallen trees when possible. If unavoidable, use extreme caution and always follow proper procedures as outlined in the owner’s manual.

WARNING

POTENTIAL HAZARD Skidding or sliding. WHAT CAN HAPPEN

Skidding or sliding can cause loss of control.

If the tires regain traction unexpectedly, the ATV could overturn. HOW TO AVOID THE HAZARD

On slippery surfaces such as ice, travel slowly and use extra caution to reduce the chance of skidding or sliding out of control.

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