Polaris ATP 500 4x4 - Manuals

3 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 motorcy...

5 TABLE OF CONTENTS WELCOME 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TABLE OF CONTENTS 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VEHICLE IDENTIFICATION NUMBERS 6 . . . . . . . . . . . . . . . SAFETY 7 . . . . . . . . . . . . . . . . . . . . ...

6 VEHICLE IDENTIFICATION NUMBERS The vehicle frame vehicle identification number (VIN)(1) and engine serial number (2) are important for model identification when registering your vehicle, when obtaining insurance, and when ordering replacement parts. If your vehicle is stolen, these numbers are ess...

7 SAFETY Operator Safety 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...

8 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 ...

9 SAFETY Operator Safety S Read this manual and all labels carefully, and follow the operating procedures described. S Never operate an ATV without proper instruction. Take a training course . Beginners should receive training from a certified instructor. Contact an authorized Polaris ATV dealer or ...

11 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...

12 SAFETY Operator Safety POTENTIAL HAZARDOperating this ATV without proper instruction.WHAT CAN HAPPENThe 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 HAZARDBeginning...

14 SAFETY Operator Safety POTENTIAL HAZARDOperating an ATV on paved surfaces, including sidewalks, paths, parking lots, and driveways.WHAT CAN HAPPENATV 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 ...

15 SAFETY Operator Safety POTENTIAL HAZARDOperating this ATV on public streets, roads or highways.WHAT CAN HAPPENThe ATV could collide with another vehicle.HOW TO AVOID THE HAZARDNever operate the ATV on any public street, road or highway, including dirt and gravel roads. In many states it’s illegal...

16 SAFETY Operator Safety POTENTIAL HAZARDOperating this ATV without wearing an approved helmet, eye protection and protective clothing.WHAT CAN HAPPENOperating 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 pro...

17 SAFETY Operator Safety POTENTIAL HAZARDOperating the ATV after consuming alcohol or drugs.WHAT CAN HAPPENConsumption 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 b...

19 SAFETY Operator Safety POTENTIAL HAZARDFailure to inspect the ATV before operating.Failure to properly maintain the ATV.WHAT CAN HAPPENPoor maintenance increases the possibility of an accident or equipment damage.HOW TO AVOID THE HAZARDAlways inspect your ATV before each use to make sure it’s in ...

20 SAFETY Operator Safety POTENTIAL HAZARDFailure to use extra caution when operating the ATV on unfamiliar terrain.WHAT CAN HAPPENUnfamiliar terrain may contain hidden rocks, bumps, or holes that could cause loss of control or overturn.HOW TO AVOID THE HAZARDTravel slowly and use extra caution when...

21 SAFETY Operator Safety POTENTIAL HAZARDFailure to use extra caution when operating on excessively rough, slippery or loose terrain.WHAT CAN HAPPENOperating on excessively rough, slippery or loose terrain could cause loss of traction or loss of control, which could result in an accident or overtur...

22 SAFETY Operator Safety POTENTIAL HAZARDTurning improperly.WHAT CAN HAPPENImproper turns could cause loss of control and lead to a collision or overturn.HOW TO AVOID THE HAZARDAlways follow proper procedures for turning as described in the owner’s manual.Practice turning at slow speeds before atte...

23 SAFETY Operator Safety POTENTIAL HAZARDClimbing hills improperly.WHAT CAN HAPPENImproper hill climbing could cause loss of control or overturn.HOW TO AVOID THE HAZARDAlways follow proper procedures for climbing hills as described in the owner’s manual.Always check the terrain carefully before asc...

24 SAFETY Operator Safety POTENTIAL HAZARDTraveling downhill improperly.WHAT CAN HAPPENImproperly descending a hill could cause loss of control or overturn.HOW TO AVOID THE HAZARDAlways follow proper procedures for traveling down hills as described in the owner’s manual. NOTE: A special technique is...

25 SAFETY Operator Safety POTENTIAL HAZARDImproperly crossing hills and turning on hills.WHAT CAN HAPPENImproperly crossing or turning as hills could cause loss of control or overturn.HOW TO AVOID THE HAZARDNever attempt to turn the ATV around on any hill until you’ve mastered the turning technique ...

26 SAFETY Operator Safety POTENTIAL HAZARDStalling, rolling backwards or improperly dismounting while climbing a hill.WHAT CAN HAPPENThe vehicle could overturn.HOW TO AVOID THE HAZARDMaintain steady speed when climbing a hill.If all forward speed is lost:Keep your weight uphill.Apply the front brake...

27 SAFETY Operator Safety POTENTIAL HAZARDImproperly operating over obstacles.WHAT CAN HAPPENOperating over obstacles could cause loss of control or overturn.HOW TO AVOID THE HAZARDBefore operating in a new area, check for obstacles.Avoid operating over large obstacles such as rocks and fallen trees...

30 SAFETY Operator Safety POTENTIAL HAZARDOverloading the ATV or carrying/towing cargo improperly.WHAT CAN HAPPENOverloading and towing can cause changes in vehicle handling, which could lead to loss of control or an accident.HOW TO AVOID THE HAZARDNever exceed the stated load capacity for this ATV....

32 SAFETY Safety Decals and Locations Warning decals have been placed on the ATV for your protection. Read and follow the instructions on each decal carefully. If a decal becomes illegible or comes off, contact your Polaris dealer to purchase a replacement. Replacement safety decals are provided by ...

35 SAFETY Safety Decals and Locations 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 MANUFACTURED BY: POLARIS IND, INC. DATE: VIN: THIS VEHICLE IS AN ALL TERRAIN VEHICLE A...

36 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 injur...

37 FEATURES AND CONTROLS Electrical Switches While operating in reverse, activating the override switch with the throttle open can cause loss of control, resulting in severe injury or death. Do not activate the override switch while the throttle is open. WARNING Speedo Mode/Override Switch (1) (Reve...

38 FEATURES AND CONTROLS Electrical Switches Engine Stop Switch (3) - The engine will not start or run when the switch is in the OFF position. Its purpose is to provide the operator with a quick means of engine shutdown in case of an emergency. To stop the engine, slide the stop switch either right ...

39 FEATURES AND CONTROLS 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 desi...

40 FEATURES AND CONTROLS Brake Lever The front and rear brakes are applied by squeezing the brake lever (1) toward the handlebar. The front and rear brakes are hydraulically activated disc type brakes that are activated by only one lever. Always test brake lever travel and master cylinder fluid leve...

41 FEATURES AND CONTROLS Parking Brake Locking the Parking Brake 1. Squeeze and release the brake lever (1) two or three times, then squeeze and hold at full stroke. 2. Push the park brake lock (2) forward to engage the brake. Release the brake lever. 3. To release the parking brake lock, squeeze an...

42 FEATURES AND CONTROLS Auxiliary Brake The auxiliary foot brake (1) is located on the inside of the right floor board and is operated by the right foot. The auxiliary brake serves as a backup to the main brake system if the main system becomes inoperative. It activates the rear brakes only.If the ...

43 FEATURES AND CONTROLS Choke The choke assists in starting a cold engine. Refer to the engine starting procedure on page 55 for correct choke and throttle settings during starting. Fuel Valve The fuel valve (1) is located on the left side panel. It has three positions:OFF: For vehicle storage and ...

44 FEATURES AND CONTROLS Fuel Safety Gasoline is highly flammable and explosive under certain conditions. S Always exercise extreme caution whenever handling gasoline. S Always refuel with the engine stopped, and outdoors or in a well ventilated area. S Never fill a gas container while it’s in the c...

45 FEATURES AND CONTROLS Automatic Transmission Gear Selector The transmission gear selector (1) is located on the right side of the vehicle.H: High GearL: Low GearN: NeutralR: Reverse P: ParkTo shift into HIGH or PARK, you must first apply the auxiliary brake to activate the high/park lock-out mech...

46 FEATURES AND CONTROLS Recoil Starter If the battery is weak and cannot start the engine, use of the recoil starter (1) will allow vehicle operation until repairs can be made. The recoil starter is located on the right side of the machine.Polaris 4-cycle engines are equipped with automatic decompr...

47 FEATURES AND CONTROLS All Wheel Drive (AWD) System Polaris 4 wheel drive ATVs are equipped with a unique, Polaris exclusive, Demand 4 Drive (AWD) system activated by a switch (1) on the right handlebar. When the switch is on 2x4 (center position), the ATV is in two wheel drive at all times and th...

48 FEATURES AND CONTROLS Instrument Cluster Your ATV is equipped with an instrument cluster that senses vehicle speed from the right front wheel. The instrument cluster measures distance in miles as well as hours of operation. It also includes a reverse speed limiter function that limits the ATV’s s...

49 FEATURES AND CONTROLS Instrument Cluster Rider Information Center The rider information center is located in the instrument cluster. All segments will light up for 2.5 seconds at start-up. NOTE: If the instrument cluster fails to illuminate, a battery over-voltage may have occurred and the instru...

50 FEATURES AND CONTROLS Instrument Cluster Rider Information Center The rider information center has 4 standard modes:Mode 1 - OdometerMode 2 - TripmeterMode 3 - Total Service HoursMode 4 - TachometerThe reverse override button on the left handlebar is also the mode button . NOTE: If using the mode...

51 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode The diagnostic mode is for informational purposes only. Please return your ATV to your dealer for all major repairs.As long as the gauge is in the diagnostic mode, the wrench icon will remain lit.To leave the diagno...

52 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode Screen 5: Programmable service interval The purpose of the programmable service interval is to provide the consumer and dealer with a convenient reminder for routine maintenance. When your vehicle leaves the factory...

53 OPERATION Break-In Period The break-in period for your new Polaris ATV is defined as the first ten hours of operation, or the time it takes to use the first two full tanks of gasoline. No single action on your part is as important as following the procedures for a proper break-in. Careful treatme...

54 OPERATION Pre-Ride Inspection Use the following checklist to verify that your vehicle is in proper working condition before each use. Item/Inspection Procedure 1. Tires - Check condition and pressures.2. Fuel and oil tanks - Fill both tanks to their proper levels.3. All brakes - Check operation, ...

55 OPERATION Starting the Engine Starting a Cold Engine 1. Place the transmission in park and lock the parking brake. 2. Turn the fuel tank valve on.3. Sit on the vehicle.4. Pull the choke knob out until it stops (1). NOTE: The variable choke is fully on when the knob is pulled completely out. The c...

56 OPERATION Starting the Engine Starting a Warm Engine Warm engines do not normally require the use of the choke. Using the choke can cause the spark plug to become wet fouled.1. Position the vehicle on a level surface with the transmission in park. 2. Lock the parking brake, turn the fuel tank val...

57 OPERATION Hauling Cargo Overloading the vehicle or carrying or towing cargo improperly can alter vehicle handling and may cause loss of control or brake instability. Always follow these precautions when hauling cargo: S Never exceed the stated load capacity for this vehicle. S Reduce speed and al...

58 OPERATION Hauling Cargo Load Distribution 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 mounted as low as possible. When ope...

59 OPERATION Hauling Cargo Dumping Cargo 1. Select a level site to dump the cargo box. Do not attempt to dump or unload the vehicle while parked on an incline. 2. Place the transmission in park and set the parking brake.3. Dismount the vehicle.4. Lower the tailgate. 5. Pull the cargo box release lev...

60 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 brak...

61 OPERATION Driving Safely Making Turns Your Polaris ATV is equipped with a rear differential that functions as a solid rear axle, driving both rear wheels equally when the ATP is in either 2x4 or 4x4 mode. This means that the wheel on the outside of a turn must travel a greater distance than the i...

62 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...

63 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...

64 OPERATION Driving Safely Sidehilling 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 th...

65 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. Familiarize yourself with operation of the auxiliary rear bra...

66 OPERATION Driving Safely Turning Around on a Hill 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. L...

67 OPERATION Driving Safely Driving Through Water Your ATV can operate through water with a maximum recommended depth equal to the bottom of the footrests (1). Follow these procedures when operating through water:1. Determine water depths and current before crossing.2. Choose a crossing where both b...

68 OPERATION Driving Safely Driving Through Water After running the vehicle in water, it’s critical to have it serviced as outlined in the maintenance chart. See page 75. The following areas need special attention: engine oil, transmission oil, front and rear gearcases and all grease fittings. NOTE:...

69 OPERATION Driving Safely Driving Over Obstacles Be alert! Look ahead and learn to read the terrain. Be constantly alert for hazards such as logs, rocks and low hanging branches. Severe injury or death can result if your vehicle comes in contact with a hidden obstacle. Not all obstacles are immedi...

70 OPERATION Driving Safely Driving in Reverse Follow these precautions when operating in reverse:1. Always avoid backing downhill. 2. Back slowly.3. When in reverse, apply the brakes lightly for stopping. 4. Avoid turning at sharp angles in reverse. 5. Never open the throttle suddenly while backing...

71 OPERATION Driving Safely Parking on an Incline Avoid parking on an incline if possible. If it’s unavoidable, follow these precautions:1. Turn the engine off.1. Place the transmission in park.2. Set the parking brake.3. Always block the rear wheels on the downhill side as shown in illustration. 4....

72 OPERATION PVT System The basic operation of the Polaris PVT system is dependent on engine speed and vehicle torque requirements. As engine speed increases, the force exerted on the movable drive sheave by the flyweights also increases. This, in turn, increases the amount of “pinch” applied to the...

73 OPERATION PVT System PVT Drying There may be some instances when water is accidently ingested into the PVT system. Use the following instructions to dry it out before operating: 1. Remove the drain plug and allow the water to drain. Replace the drain plug. 2. Start the engine and shift the transm...

74 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 ...

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

76 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. Item Hours/ Miles Frequency Remarks Brake Syst...

80 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, ...

81 MAINTENANCE AND LUBRICATION Periodic Maintenance Record Use the following chart to record periodic maintenance. Maintenance Interval Performed Servicing Date Servicing Dealer or Person Remarks 10 hrs.20 hrs.50 hrs. 100 hrs.

82 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 lub...

83 MAINTENANCE AND LUBRICATION Lubrication Recommendations Oil and Filter Change - ATP 500 4x4 The recommended oil change interval is 100 hours, 1000 miles, or every six months, whichever comes first. Suggested break-in oil change is at 20 hours, 200 miles, or one month, whichever comes first. Sever...

86 MAINTENANCE AND LUBRICATION Lubrication Recommendations Oil and Filter Change - ATP 330 4x4 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 dr...

88 MAINTENANCE AND LUBRICATION Lubrication Recommendations Transmission Oil Check The transmission lubricant level should be checked every six months or 1000 miles (1600 km), whichever comes first. Transmission oil should be changed annually.1. Position the ATV on a level surface, remove the fill pl...

89 MAINTENANCE AND LUBRICATION Lubrication Recommendations Front Gearcase Oil Check The front gearcase oil level should be checked every six months or 1000 miles (1600 km), whichever comes first. The oil should be changed annually. We recommend the use of Polaris Premium Hub Drive Fluid. See page 12...

90 MAINTENANCE AND LUBRICATION Lubrication Recommendations Rear Gearcase Oil Check With the ATV on a level surface, remove the fill plug and view the oil level through the fill hole (1). Lubricant should be kept even with the bottom of the fill hole. Use Polaris Premium Synthetic Gearcase Lube (or G...

91 MAINTENANCE AND LUBRICATION Engine Cooling System Oil Cooler (ATP 330) The oil cooling system requires little maintenance other than to make sure the cooler is kept free of mud and debris. Change the engine oil as recommended in the maintenance schedule. Coolant Level (ATP 500) The recovery bottl...

92 MAINTENANCE AND LUBRICATION Engine Cooling System Radiator Coolant Level (ATP 500) NOTE: This procedure is required only if the cooling system has been drained for maintenance and/or repair. However, if the recovery bottle has run dry, the level in the radiator should be inspected and coolant add...

93 MAINTENANCE AND LUBRICATION Adjustments Brakes The front brakes are hydraulic disc brakes, activated by moving the brake lever toward the handlebar. These brakes are self-adjusting. The following checks are recommended to keep the brake system in good operating condition. Check more often if brak...

94 MAINTENANCE AND LUBRICATION Adjustments Auxiliary Brake The auxiliary brake is a hydraulic disc brake. The rear brake system is self-adjusting and requires no maintenance other than periodic checks of the pads for wear.Pads should be changed when worn to 3/64 ″ (.1 cm), which is about the thickne...

95 MAINTENANCE AND LUBRICATION Adjustments Toe Alignment Use the following procedure to check the toe alignment of the vehicle. The recommended toe alignment is 1/8 ″ to 1/4 ″ toe out. 1. Set the handlebars in a straight-ahead position. NOTE: The steering frog can be used as an indicator of whether ...

96 MAINTENANCE AND LUBRICATION Adjustments Steering Assembly The steering assembly of the ATV should be checked periodically for loose nuts and bolts. If loose nuts and bolts are found, see your Polaris dealer for service before operating the vehicle. Camber and Caster The camber and caster are non-...

97 MAINTENANCE AND LUBRICATION Adjustments Handlebars If desired, the handlebars can be adjusted for rider preference. 1. Remove the instrument panel and locate the handlebar bolts (1). 2. Loosen the four bolts and adjust the handlebar to the desired height. Be sure the handlebars do not contact the...

98 MAINTENANCE AND LUBRICATION Adjustments Carburetor IMPORTANT: Your Polaris ATV is calibrated at the factory for optimal performance at altitudes ranging from zero to 6,000 feet (1800 m) and temperatures of +40 degrees F. (4 degrees C.) or higher. Above 6000 feet (1800 m) the engine air/fuel mixtu...

99 MAINTENANCE AND LUBRICATION Adjustments Throttle Cable Freeplay Throttle cable freeplay is adjusted at the handlebar.1. Slide the boots (1) off the inline cable adjuster sleeve (2). Loosen the adjuster locknut (3). 2. Turn the adjuster until 1/16 ″ to 1/8 ″ freeplay is achieved at the thumb lever...

100 MAINTENANCE AND LUBRICATION Adjustments Side Panel Removal NOTE: Side panel removal may be difficult until the locking tabs and receivers have been snapped and unsnapped a few times.1. Remove the seat.2. Grasp the rear of the side panel near the rear cab. With a quick and firm motion, pull the p...

101 MAINTENANCE AND LUBRICATION Adjustments Wheel Removal 1. Stop the engine, place the transmission in park and lock the parking brake. 2. Loosen the wheel nuts slightly.3. Elevate the side of the vehicle by placing a suitable stand under the footrest frame. 4. Remove the wheel nuts and remove the ...

102 MAINTENANCE AND LUBRICATION Adjustments Wheel Installation 1. With the transmission in park and the parking brake locked, place the wheel on the wheel hub with the valve stem toward the outside and rotation arrows on the tire pointing toward forward rotation. 2. Install the wheel nuts and finger...

103 MAINTENANCE AND LUBRICATION Adjustments Front Wheel Hub Tightening Front wheel bearing tightness and spindle nut retention are critical component operations. All service must be performed by your authorized Polaris dealer. Tire Tread Depth Always replace tires when tread depth is worn to 1/8 ″ (...

104 MAINTENANCE AND LUBRICATION Filter Systems Air Filter Service 1. Remove the seat, release the clips, and remove the air box cover. 2. Loosen the clamp and remove the filter. 3. Remove the fabric type pre-filter (1) from the main filter (2). Wash the pre-filter in soapy water, then rinse and let ...

105 MAINTENANCE AND LUBRICATION Lights When servicing a halogen lamp, don’t touch the lamp with bare fingers. Oil from your skin leaves a residue, causing a hot spot that will shorten the life of the lamp. Headlight Lamp Replacement 1. Remove the three screws on the headlight pod.2. Using a small fl...

106 MAINTENANCE AND LUBRICATION Lights High Beam Adjustment The headlight beam can be adjusted to any position desired by turning the adjusting knob on the bottom right side of the headlight pod.1. Position the vehicle on a level surface with the headlight approximately 25 ft. (7.6 m.) from a wall. ...

107 MAINTENANCE AND LUBRICATION Lights Headlight Housing Replacement 1. Remove the three screws on the headlight pod.2. Using a small flat-blade screwdriver, push in on the lock tabs through the two small openings at the front of the headlight pod. Lift the pod lightly while depressing the tabs. 3. ...

108 MAINTENANCE AND LUBRICATION Lights Taillight/Brakelight Lamp Replacement If the taillight/brakelight does not work, the lamp may need to be replaced.1. Remove the two screws securing the lens assembly.2. Pivot the assembly outward.3. Turn the housing clockwise and remove the bulb.4. Install a ne...

109 MAINTENANCE AND LUBRICATION Spark Plugs S Use the recommended spark plugs for your model (see SPECIFICATIONS beginning on page 126). S Make sure the electrode gap meets specifications for your model. S Torque spark plugs to 14 ft. lbs. (19 Nm). Spark plug condition is indicative of engine operat...

110 MAINTENANCE AND LUBRICATION Vehicle Immersion If it’s impossible to take your ATV to a dealer before starting it, follow the steps outlined below.1. Move the ATV to dry land or at the very least, to water below the foot rests. 2. Turn the fuel valve off.3. Remove the spark plug.4. Check the air ...

111 MAINTENANCE AND LUBRICATION Spark Arrestor 1. Remove the arrestor clean-out plug(s) (1) from the bottom of the muffler. 2. Place the transmission in PARK and start the engine. 3. Purge carbon from the system by momentarily revving the engine several times. 4. If carbon is expelled, cover or plug...

112 MAINTENANCE AND LUBRICATION Recoil Housing To prevent possible engine damage, always drain the recoil housing (1) after operating the ATV in very wet conditions. This should also be done before storing the ATV. NOTE: Water will enter the recoil housing if the starter handle is disengaged from th...

113 MAINTENANCE AND LUBRICATION Battery Battery Removal 1. Disconnect the battery hold-down strap and remove the battery cover.2. Disconnect the black (negative) battery cable first.3. Disconnect the red (positive) battery cable next.4. Lift the battery out of the ATV. Battery Installation When inst...

114 MAINTENANCE AND LUBRICATION Battery Battery Storage Whenever the vehicle is not used for a period of three months or more, remove the battery from the vehicle, ensure that it’s fully charged, and store it out of the sun in a cool, dry place. Check battery voltage each month during storage and re...

115 MAINTENANCE AND LUBRICATION Battery Battery Charging NOTE: Always verify battery condition before and 1-2 hours after the end of charging. State of Charge Voltage Action Charge Time* (Using constant current charger @ standard amps specified on top of battery) 100% 12.8-13.0 volts None, check at ...

116 MAINTENANCE AND LUBRICATION Cleaning and Storage See page 121 for the part numbers of Polaris products. Cleaning the ATV Keeping your ATV clean will not only improve its appearance but it can also extend the life of various components. With a few precautions, your ATV can be cleaned much like an...

117 MAINTENANCE AND LUBRICATION Cleaning and Storage Storage Tips See page 121 for the part numbers of Polaris products. Clean the Exterior Make necessary repairs and then clean the ATV thoroughly with mild soap and warm water to remove all dirt and grime. Don’t use harsh detergents or high pressure...

118 MAINTENANCE AND LUBRICATION Cleaning and Storage Storage Tips See page 121 for the part numbers of Polaris products. Fog the Engine Remove the spark plug and add 2-3 tablespoons of Premium 4 Synthetic 0W40 engine oil. To access the plug hole, use a section of clear 1/4” hose and a small plastic ...

119 MAINTENANCE AND LUBRICATION Cleaning and Storage Storage Tips Battery Storage Remove the battery from the vehicle and ensure that it’s fully charged before placing it in storage. See page 114 for instructions. Engine Anti-Freeze Test engine coolant strength and change if necessary. Coolant shoul...

121 POLARIS PRODUCTS Part No. Description Engine Lubricant 2870791 Fogging Oil (12 oz. Aerosol) 2871098 Premium 2-Cycle Engine Oil (qt.) 2871721 Premium Gold Synthetic 2-Cycle Oil (qt.) 2871281 Premium 4 Synthetic 0W-40 Engine Oil (4-Cycle)(qt.) Gearcase / Transmission Lubricants 2873602 Premium Syn...

122 TROUBLESHOOTING Drive Belt and Cover Problems Possible Cause Solution Driving the ATV onto a pickup or tall trailer in high range. Shift transmission to low range during loading of the ATV to prevent belt burning. Starting out going up a steep incline. When starting out on an incline, use low ra...

123 TROUBLESHOOTING Contact your Polaris dealer for service if you’re unable to identify solutions using the following charts. Engine Doesn’t Turn Over Possible Cause Solution Tripped circuit breaker Reset the breaker Low battery voltage Recharge battery to 12.5 VDC Loose battery connections Check a...

124 TROUBLESHOOTING Engine Backfires Possible Cause Solution Weak spark from spark plugs Inspect, clean and/or replace spark plugs Incorrect spark plug gap or heat range Set gap to specs or replace plugs Old or non-recommended fuel Replace with new fuel Incorrectly installed spark plug wires See you...

125 TROUBLESHOOTING Engine Stops or Loses Power Possible Cause Solution Out of fuel Turn fuel valve to reserve, refuel Kinked or plugged fuel vent line Inspect and replace Water present in fuel Replace with new fuel Overuse of choke Inspect, clean and/or replace spark plugs Fouled or defective spark...

126 SPECIFICATIONS ATP 330 4x4 Gross Vehicle Weight 1300 lbs./590 kg Fuel Capacity 3.25 gal./12.3 l Hitch Towing Rating 1 000 l bs./454 k g Unbraked Trailer Towing Capacity* 1585 lbs./719 kg Hitch Tongue Capacity 100 lbs./45.4 kg (rear box capacity and tongue weight not to exceed 250 lbs./113 kg) Fr...

127 SPECIFICATIONS ATP 330 4x4 Shift Type Side Lever (High, Low, Neutral, Reverse, Park) Gear Reduction - Low 11.57:1 Gear Reduction - Reverse 6.84:1 Gear Reduction - High 4.41:1 Drive Ratio - Front: 3.7:1 Drive Ratio - Final 3.08:1 Tire Size - Front 24 x 8 - 12 Tire Size - Rear 24 x 11 - 12 Tire Pr...

130 WARRANTY LIMITED WARRANTY Polaris Industries Inc., 2100 Highway 55, Medina, MN 55340, gives a SIX MONTH LIM- ITED WARRANTY on all components of the Polaris All Terrain Vehicle (ATV) against de- fects in material or workmanship. This warranty covers the parts and labor charges for repair or repla...

131 WARRANTY LIMITATIONS OF WARRANTIES AND REMEDIES ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE) ARE LIMITED IN DURATION TO THE ABOVE SIX MONTH WARRAN- TY PERIOD. POLARIS FURTHER DISCLAIMS ALL EXPRESS WARRANTIES ...

132 WARRANTY Exported Vehicles EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE IS NO WARRANTY OR SERVICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD OUTSIDE THE COUNTRY OF THE SELLING DEALER’S AUTHORIZED LOCATION.This policy does not apply to vehicles that have received authorization for export...

133 WARRANTY California Emission Control Warranty Statement Your Warranty Rights and Obligations The California Air Resources Board and Polaris Industries Inc., 2100 Highway 55, Medina, Minnesota 55340 (herein “POLARIS”) are pleased to explain the emission control system warranty on your 2004 and la...

134 WARRANTY California Emission Control Warranty Statement Warranty Period This warranty period begins on the date, which the LSI engine is delivered, to the origi- nal retail purchaser and ends two years after that date. During this two year period POLARIS warrants to the original retail purchaser...

135 WARRANTY California Emission Control Warranty Statement What is Not Covered Under This Warranty This warranty does not cover any emission-related part, which malfunctions, fails, or is damaged due to alterations and/or modifications such as changing, adding, or removing parts. When the LSI engin...

136 WARRANTY California Emission Control Warranty Statement Maintenance Schedule Item Hrs/Miles When Remarks b Air filter pre-cleaner Daily Daily Inspect, clean b Air filter main element Weekly Weekly Inspect, replace if necessary b Engine breather filter 20 hrs. Monthly I nspect, replace annually a...

137 INDEX A Accessories 75 . . . . . . . . . . . . . . . . . . . . . . Adjustments 93-103 . . . . . . . . . . . . . . . . . Age Restrictions 7 . . . . . . . . . . . . . . . . . . . Air Filter 104 . . . . . . . . . . . . . . . . . . . . . . . All Wheel Drive 47 . . . . . . . . . . . . . . . . . . Aux...

3 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 motorcy...

5 TABLE OF CONTENTS WELCOME 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TABLE OF CONTENTS 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VEHICLE IDENTIFICATION NUMBERS 6 . . . . . . . . . . . . . . . SAFETY 7 . . . . . . . . . . . . . . . . . . . . ...

6 VEHICLE IDENTIFICATION NUMBERS The vehicle frame vehicle identification number (VIN)(1) and engine serial number (2) are important for model identification when registering your vehicle, when obtaining insurance, and when ordering replacement parts. If your vehicle is stolen, these numbers are ess...

7 SAFETY Operator Safety 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...

8 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 ...

9 SAFETY Operator Safety S Read this manual and all labels carefully, and follow the operating procedures described. S Never operate an ATV without proper instruction. Take a training course . Beginners should receive training from a certified instructor. Contact an authorized Polaris ATV dealer or ...

11 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...

12 SAFETY Operator Safety POTENTIAL HAZARDOperating this ATV without proper instruction.WHAT CAN HAPPENThe 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 HAZARDBeginning...

14 SAFETY Operator Safety POTENTIAL HAZARDOperating an ATV on paved surfaces, including sidewalks, paths, parking lots, and driveways.WHAT CAN HAPPENATV 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 ...

15 SAFETY Operator Safety POTENTIAL HAZARDOperating this ATV on public streets, roads or highways.WHAT CAN HAPPENThe ATV could collide with another vehicle.HOW TO AVOID THE HAZARDNever operate the ATV on any public street, road or highway, including dirt and gravel roads. In many states it’s illegal...

16 SAFETY Operator Safety POTENTIAL HAZARDOperating this ATV without wearing an approved helmet, eye protection and protective clothing.WHAT CAN HAPPENOperating 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 pro...

17 SAFETY Operator Safety POTENTIAL HAZARDOperating the ATV after consuming alcohol or drugs.WHAT CAN HAPPENConsumption 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 b...

19 SAFETY Operator Safety POTENTIAL HAZARDFailure to inspect the ATV before operating.Failure to properly maintain the ATV.WHAT CAN HAPPENPoor maintenance increases the possibility of an accident or equipment damage.HOW TO AVOID THE HAZARDAlways inspect your ATV before each use to make sure it’s in ...

20 SAFETY Operator Safety POTENTIAL HAZARDFailure to use extra caution when operating the ATV on unfamiliar terrain.WHAT CAN HAPPENUnfamiliar terrain may contain hidden rocks, bumps, or holes that could cause loss of control or overturn.HOW TO AVOID THE HAZARDTravel slowly and use extra caution when...

21 SAFETY Operator Safety POTENTIAL HAZARDFailure to use extra caution when operating on excessively rough, slippery or loose terrain.WHAT CAN HAPPENOperating on excessively rough, slippery or loose terrain could cause loss of traction or loss of control, which could result in an accident or overtur...

22 SAFETY Operator Safety POTENTIAL HAZARDTurning improperly.WHAT CAN HAPPENImproper turns could cause loss of control and lead to a collision or overturn.HOW TO AVOID THE HAZARDAlways follow proper procedures for turning as described in the owner’s manual.Practice turning at slow speeds before atte...

23 SAFETY Operator Safety POTENTIAL HAZARDClimbing hills improperly.WHAT CAN HAPPENImproper hill climbing could cause loss of control or overturn.HOW TO AVOID THE HAZARDAlways follow proper procedures for climbing hills as described in the owner’s manual.Always check the terrain carefully before asc...

24 SAFETY Operator Safety POTENTIAL HAZARDTraveling downhill improperly.WHAT CAN HAPPENImproperly descending a hill could cause loss of control or overturn.HOW TO AVOID THE HAZARDAlways follow proper procedures for traveling down hills as described in the owner’s manual. NOTE: A special technique is...

25 SAFETY Operator Safety POTENTIAL HAZARDImproperly crossing hills and turning on hills.WHAT CAN HAPPENImproperly crossing or turning as hills could cause loss of control or overturn.HOW TO AVOID THE HAZARDNever attempt to turn the ATV around on any hill until you’ve mastered the turning technique ...

26 SAFETY Operator Safety POTENTIAL HAZARDStalling, rolling backwards or improperly dismounting while climbing a hill.WHAT CAN HAPPENThe vehicle could overturn.HOW TO AVOID THE HAZARDMaintain steady speed when climbing a hill.If all forward speed is lost:Keep your weight uphill.Apply the front brake...

27 SAFETY Operator Safety POTENTIAL HAZARDImproperly operating over obstacles.WHAT CAN HAPPENOperating over obstacles could cause loss of control or overturn.HOW TO AVOID THE HAZARDBefore operating in a new area, check for obstacles.Avoid operating over large obstacles such as rocks and fallen trees...

30 SAFETY Operator Safety POTENTIAL HAZARDOverloading the ATV or carrying/towing cargo improperly.WHAT CAN HAPPENOverloading and towing can cause changes in vehicle handling, which could lead to loss of control or an accident.HOW TO AVOID THE HAZARDNever exceed the stated load capacity for this ATV....

32 SAFETY Safety Decals and Locations Warning decals have been placed on the ATV for your protection. Read and follow the instructions on each decal carefully. If a decal becomes illegible or comes off, contact your Polaris dealer to purchase a replacement. Replacement safety decals are provided by ...

35 SAFETY Safety Decals and Locations 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 MANUFACTURED BY: POLARIS IND, INC. DATE: VIN: THIS VEHICLE IS AN ALL TERRAIN VEHICLE A...

36 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 injur...

37 FEATURES AND CONTROLS Electrical Switches While operating in reverse, activating the override switch with the throttle open can cause loss of control, resulting in severe injury or death. Do not activate the override switch while the throttle is open. WARNING Speedo Mode/Override Switch (1) (Reve...

38 FEATURES AND CONTROLS Electrical Switches Engine Stop Switch (3) - The engine will not start or run when the switch is in the OFF position. Its purpose is to provide the operator with a quick means of engine shutdown in case of an emergency. To stop the engine, slide the stop switch either right ...

39 FEATURES AND CONTROLS 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 desi...

40 FEATURES AND CONTROLS Brake Lever The front and rear brakes are applied by squeezing the brake lever (1) toward the handlebar. The front and rear brakes are hydraulically activated disc type brakes that are activated by only one lever. Always test brake lever travel and master cylinder fluid leve...

41 FEATURES AND CONTROLS Parking Brake Locking the Parking Brake 1. Squeeze and release the brake lever (1) two or three times, then squeeze and hold at full stroke. 2. Push the park brake lock (2) forward to engage the brake. Release the brake lever. 3. To release the parking brake lock, squeeze an...

42 FEATURES AND CONTROLS Auxiliary Brake The auxiliary foot brake (1) is located on the inside of the right floor board and is operated by the right foot. The auxiliary brake serves as a backup to the main brake system if the main system becomes inoperative. It activates the rear brakes only.If the ...

43 FEATURES AND CONTROLS Choke The choke assists in starting a cold engine. Refer to the engine starting procedure on page 55 for correct choke and throttle settings during starting. Fuel Valve The fuel valve (1) is located on the left side panel. It has three positions:OFF: For vehicle storage and ...

44 FEATURES AND CONTROLS Fuel Safety Gasoline is highly flammable and explosive under certain conditions. S Always exercise extreme caution whenever handling gasoline. S Always refuel with the engine stopped, and outdoors or in a well ventilated area. S Never fill a gas container while it’s in the c...

45 FEATURES AND CONTROLS Automatic Transmission Gear Selector The transmission gear selector (1) is located on the right side of the vehicle.H: High GearL: Low GearN: NeutralR: Reverse P: ParkTo shift into HIGH or PARK, you must first apply the auxiliary brake to activate the high/park lock-out mech...

46 FEATURES AND CONTROLS Recoil Starter If the battery is weak and cannot start the engine, use of the recoil starter (1) will allow vehicle operation until repairs can be made. The recoil starter is located on the right side of the machine.Polaris 4-cycle engines are equipped with automatic decompr...

47 FEATURES AND CONTROLS All Wheel Drive (AWD) System Polaris 4 wheel drive ATVs are equipped with a unique, Polaris exclusive, Demand 4 Drive (AWD) system activated by a switch (1) on the right handlebar. When the switch is on 2x4 (center position), the ATV is in two wheel drive at all times and th...

48 FEATURES AND CONTROLS Instrument Cluster Your ATV is equipped with an instrument cluster that senses vehicle speed from the right front wheel. The instrument cluster measures distance in miles as well as hours of operation. It also includes a reverse speed limiter function that limits the ATV’s s...

49 FEATURES AND CONTROLS Instrument Cluster Rider Information Center The rider information center is located in the instrument cluster. All segments will light up for 2.5 seconds at start-up. NOTE: If the instrument cluster fails to illuminate, a battery over-voltage may have occurred and the instru...

50 FEATURES AND CONTROLS Instrument Cluster Rider Information Center The rider information center has 4 standard modes:Mode 1 - OdometerMode 2 - TripmeterMode 3 - Total Service HoursMode 4 - TachometerThe reverse override button on the left handlebar is also the mode button . NOTE: If using the mode...

51 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode The diagnostic mode is for informational purposes only. Please return your ATV to your dealer for all major repairs.As long as the gauge is in the diagnostic mode, the wrench icon will remain lit.To leave the diagno...

52 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode Screen 5: Programmable service interval The purpose of the programmable service interval is to provide the consumer and dealer with a convenient reminder for routine maintenance. When your vehicle leaves the factory...

53 OPERATION Break-In Period The break-in period for your new Polaris ATV is defined as the first ten hours of operation, or the time it takes to use the first two full tanks of gasoline. No single action on your part is as important as following the procedures for a proper break-in. Careful treatme...

54 OPERATION Pre-Ride Inspection Use the following checklist to verify that your vehicle is in proper working condition before each use. Item/Inspection Procedure 1. Tires - Check condition and pressures.2. Fuel and oil tanks - Fill both tanks to their proper levels.3. All brakes - Check operation, ...

55 OPERATION Starting the Engine Starting a Cold Engine 1. Place the transmission in park and lock the parking brake. 2. Turn the fuel tank valve on.3. Sit on the vehicle.4. Pull the choke knob out until it stops (1). NOTE: The variable choke is fully on when the knob is pulled completely out. The c...

56 OPERATION Starting the Engine Starting a Warm Engine Warm engines do not normally require the use of the choke. Using the choke can cause the spark plug to become wet fouled.1. Position the vehicle on a level surface with the transmission in park. 2. Lock the parking brake, turn the fuel tank val...

57 OPERATION Hauling Cargo Overloading the vehicle or carrying or towing cargo improperly can alter vehicle handling and may cause loss of control or brake instability. Always follow these precautions when hauling cargo: S Never exceed the stated load capacity for this vehicle. S Reduce speed and al...

58 OPERATION Hauling Cargo Load Distribution 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 mounted as low as possible. When ope...

59 OPERATION Hauling Cargo Dumping Cargo 1. Select a level site to dump the cargo box. Do not attempt to dump or unload the vehicle while parked on an incline. 2. Place the transmission in park and set the parking brake.3. Dismount the vehicle.4. Lower the tailgate. 5. Pull the cargo box release lev...

60 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 brak...

61 OPERATION Driving Safely Making Turns Your Polaris ATV is equipped with a rear differential that functions as a solid rear axle, driving both rear wheels equally when the ATP is in either 2x4 or 4x4 mode. This means that the wheel on the outside of a turn must travel a greater distance than the i...

62 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...

63 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...

64 OPERATION Driving Safely Sidehilling 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 th...

65 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. Familiarize yourself with operation of the auxiliary rear bra...

66 OPERATION Driving Safely Turning Around on a Hill 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. L...

67 OPERATION Driving Safely Driving Through Water Your ATV can operate through water with a maximum recommended depth equal to the bottom of the footrests (1). Follow these procedures when operating through water:1. Determine water depths and current before crossing.2. Choose a crossing where both b...

68 OPERATION Driving Safely Driving Through Water After running the vehicle in water, it’s critical to have it serviced as outlined in the maintenance chart. See page 75. The following areas need special attention: engine oil, transmission oil, front and rear gearcases and all grease fittings. NOTE:...

69 OPERATION Driving Safely Driving Over Obstacles Be alert! Look ahead and learn to read the terrain. Be constantly alert for hazards such as logs, rocks and low hanging branches. Severe injury or death can result if your vehicle comes in contact with a hidden obstacle. Not all obstacles are immedi...

70 OPERATION Driving Safely Driving in Reverse Follow these precautions when operating in reverse:1. Always avoid backing downhill. 2. Back slowly.3. When in reverse, apply the brakes lightly for stopping. 4. Avoid turning at sharp angles in reverse. 5. Never open the throttle suddenly while backing...

71 OPERATION Driving Safely Parking on an Incline Avoid parking on an incline if possible. If it’s unavoidable, follow these precautions:1. Turn the engine off.1. Place the transmission in park.2. Set the parking brake.3. Always block the rear wheels on the downhill side as shown in illustration. 4....

72 OPERATION PVT System The basic operation of the Polaris PVT system is dependent on engine speed and vehicle torque requirements. As engine speed increases, the force exerted on the movable drive sheave by the flyweights also increases. This, in turn, increases the amount of “pinch” applied to the...

73 OPERATION PVT System PVT Drying There may be some instances when water is accidently ingested into the PVT system. Use the following instructions to dry it out before operating: 1. Remove the drain plug and allow the water to drain. Replace the drain plug. 2. Start the engine and shift the transm...

74 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 ...

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

76 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. Item Hours/ Miles Frequency Remarks Brake Syst...

80 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, ...

81 MAINTENANCE AND LUBRICATION Periodic Maintenance Record Use the following chart to record periodic maintenance. Maintenance Interval Performed Servicing Date Servicing Dealer or Person Remarks 10 hrs.20 hrs.50 hrs. 100 hrs.

82 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 lub...

83 MAINTENANCE AND LUBRICATION Lubrication Recommendations Oil and Filter Change - ATP 500 4x4 The recommended oil change interval is 100 hours, 1000 miles, or every six months, whichever comes first. Suggested break-in oil change is at 20 hours, 200 miles, or one month, whichever comes first. Sever...

86 MAINTENANCE AND LUBRICATION Lubrication Recommendations Oil and Filter Change - ATP 330 4x4 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 dr...

88 MAINTENANCE AND LUBRICATION Lubrication Recommendations Transmission Oil Check The transmission lubricant level should be checked every six months or 1000 miles (1600 km), whichever comes first. Transmission oil should be changed annually.1. Position the ATV on a level surface, remove the fill pl...

89 MAINTENANCE AND LUBRICATION Lubrication Recommendations Front Gearcase Oil Check The front gearcase oil level should be checked every six months or 1000 miles (1600 km), whichever comes first. The oil should be changed annually. We recommend the use of Polaris Premium Hub Drive Fluid. See page 12...

90 MAINTENANCE AND LUBRICATION Lubrication Recommendations Rear Gearcase Oil Check With the ATV on a level surface, remove the fill plug and view the oil level through the fill hole (1). Lubricant should be kept even with the bottom of the fill hole. Use Polaris Premium Synthetic Gearcase Lube (or G...

91 MAINTENANCE AND LUBRICATION Engine Cooling System Oil Cooler (ATP 330) The oil cooling system requires little maintenance other than to make sure the cooler is kept free of mud and debris. Change the engine oil as recommended in the maintenance schedule. Coolant Level (ATP 500) The recovery bottl...

92 MAINTENANCE AND LUBRICATION Engine Cooling System Radiator Coolant Level (ATP 500) NOTE: This procedure is required only if the cooling system has been drained for maintenance and/or repair. However, if the recovery bottle has run dry, the level in the radiator should be inspected and coolant add...

93 MAINTENANCE AND LUBRICATION Adjustments Brakes The front brakes are hydraulic disc brakes, activated by moving the brake lever toward the handlebar. These brakes are self-adjusting. The following checks are recommended to keep the brake system in good operating condition. Check more often if brak...

94 MAINTENANCE AND LUBRICATION Adjustments Auxiliary Brake The auxiliary brake is a hydraulic disc brake. The rear brake system is self-adjusting and requires no maintenance other than periodic checks of the pads for wear.Pads should be changed when worn to 3/64 ″ (.1 cm), which is about the thickne...

95 MAINTENANCE AND LUBRICATION Adjustments Toe Alignment Use the following procedure to check the toe alignment of the vehicle. The recommended toe alignment is 1/8 ″ to 1/4 ″ toe out. 1. Set the handlebars in a straight-ahead position. NOTE: The steering frog can be used as an indicator of whether ...

96 MAINTENANCE AND LUBRICATION Adjustments Steering Assembly The steering assembly of the ATV should be checked periodically for loose nuts and bolts. If loose nuts and bolts are found, see your Polaris dealer for service before operating the vehicle. Camber and Caster The camber and caster are non-...

97 MAINTENANCE AND LUBRICATION Adjustments Handlebars If desired, the handlebars can be adjusted for rider preference. 1. Remove the instrument panel and locate the handlebar bolts (1). 2. Loosen the four bolts and adjust the handlebar to the desired height. Be sure the handlebars do not contact the...

98 MAINTENANCE AND LUBRICATION Adjustments Carburetor IMPORTANT: Your Polaris ATV is calibrated at the factory for optimal performance at altitudes ranging from zero to 6,000 feet (1800 m) and temperatures of +40 degrees F. (4 degrees C.) or higher. Above 6000 feet (1800 m) the engine air/fuel mixtu...

99 MAINTENANCE AND LUBRICATION Adjustments Throttle Cable Freeplay Throttle cable freeplay is adjusted at the handlebar.1. Slide the boots (1) off the inline cable adjuster sleeve (2). Loosen the adjuster locknut (3). 2. Turn the adjuster until 1/16 ″ to 1/8 ″ freeplay is achieved at the thumb lever...

100 MAINTENANCE AND LUBRICATION Adjustments Side Panel Removal NOTE: Side panel removal may be difficult until the locking tabs and receivers have been snapped and unsnapped a few times.1. Remove the seat.2. Grasp the rear of the side panel near the rear cab. With a quick and firm motion, pull the p...

101 MAINTENANCE AND LUBRICATION Adjustments Wheel Removal 1. Stop the engine, place the transmission in park and lock the parking brake. 2. Loosen the wheel nuts slightly.3. Elevate the side of the vehicle by placing a suitable stand under the footrest frame. 4. Remove the wheel nuts and remove the ...

102 MAINTENANCE AND LUBRICATION Adjustments Wheel Installation 1. With the transmission in park and the parking brake locked, place the wheel on the wheel hub with the valve stem toward the outside and rotation arrows on the tire pointing toward forward rotation. 2. Install the wheel nuts and finger...

103 MAINTENANCE AND LUBRICATION Adjustments Front Wheel Hub Tightening Front wheel bearing tightness and spindle nut retention are critical component operations. All service must be performed by your authorized Polaris dealer. Tire Tread Depth Always replace tires when tread depth is worn to 1/8 ″ (...

104 MAINTENANCE AND LUBRICATION Filter Systems Air Filter Service 1. Remove the seat, release the clips, and remove the air box cover. 2. Loosen the clamp and remove the filter. 3. Remove the fabric type pre-filter (1) from the main filter (2). Wash the pre-filter in soapy water, then rinse and let ...

105 MAINTENANCE AND LUBRICATION Lights When servicing a halogen lamp, don’t touch the lamp with bare fingers. Oil from your skin leaves a residue, causing a hot spot that will shorten the life of the lamp. Headlight Lamp Replacement 1. Remove the three screws on the headlight pod.2. Using a small fl...

106 MAINTENANCE AND LUBRICATION Lights High Beam Adjustment The headlight beam can be adjusted to any position desired by turning the adjusting knob on the bottom right side of the headlight pod.1. Position the vehicle on a level surface with the headlight approximately 25 ft. (7.6 m.) from a wall. ...

107 MAINTENANCE AND LUBRICATION Lights Headlight Housing Replacement 1. Remove the three screws on the headlight pod.2. Using a small flat-blade screwdriver, push in on the lock tabs through the two small openings at the front of the headlight pod. Lift the pod lightly while depressing the tabs. 3. ...

108 MAINTENANCE AND LUBRICATION Lights Taillight/Brakelight Lamp Replacement If the taillight/brakelight does not work, the lamp may need to be replaced.1. Remove the two screws securing the lens assembly.2. Pivot the assembly outward.3. Turn the housing clockwise and remove the bulb.4. Install a ne...

109 MAINTENANCE AND LUBRICATION Spark Plugs S Use the recommended spark plugs for your model (see SPECIFICATIONS beginning on page 126). S Make sure the electrode gap meets specifications for your model. S Torque spark plugs to 14 ft. lbs. (19 Nm). Spark plug condition is indicative of engine operat...

110 MAINTENANCE AND LUBRICATION Vehicle Immersion If it’s impossible to take your ATV to a dealer before starting it, follow the steps outlined below.1. Move the ATV to dry land or at the very least, to water below the foot rests. 2. Turn the fuel valve off.3. Remove the spark plug.4. Check the air ...

111 MAINTENANCE AND LUBRICATION Spark Arrestor 1. Remove the arrestor clean-out plug(s) (1) from the bottom of the muffler. 2. Place the transmission in PARK and start the engine. 3. Purge carbon from the system by momentarily revving the engine several times. 4. If carbon is expelled, cover or plug...

112 MAINTENANCE AND LUBRICATION Recoil Housing To prevent possible engine damage, always drain the recoil housing (1) after operating the ATV in very wet conditions. This should also be done before storing the ATV. NOTE: Water will enter the recoil housing if the starter handle is disengaged from th...

113 MAINTENANCE AND LUBRICATION Battery Battery Removal 1. Disconnect the battery hold-down strap and remove the battery cover.2. Disconnect the black (negative) battery cable first.3. Disconnect the red (positive) battery cable next.4. Lift the battery out of the ATV. Battery Installation When inst...

114 MAINTENANCE AND LUBRICATION Battery Battery Storage Whenever the vehicle is not used for a period of three months or more, remove the battery from the vehicle, ensure that it’s fully charged, and store it out of the sun in a cool, dry place. Check battery voltage each month during storage and re...

115 MAINTENANCE AND LUBRICATION Battery Battery Charging NOTE: Always verify battery condition before and 1-2 hours after the end of charging. State of Charge Voltage Action Charge Time* (Using constant current charger @ standard amps specified on top of battery) 100% 12.8-13.0 volts None, check at ...

116 MAINTENANCE AND LUBRICATION Cleaning and Storage See page 121 for the part numbers of Polaris products. Cleaning the ATV Keeping your ATV clean will not only improve its appearance but it can also extend the life of various components. With a few precautions, your ATV can be cleaned much like an...

117 MAINTENANCE AND LUBRICATION Cleaning and Storage Storage Tips See page 121 for the part numbers of Polaris products. Clean the Exterior Make necessary repairs and then clean the ATV thoroughly with mild soap and warm water to remove all dirt and grime. Don’t use harsh detergents or high pressure...

118 MAINTENANCE AND LUBRICATION Cleaning and Storage Storage Tips See page 121 for the part numbers of Polaris products. Fog the Engine Remove the spark plug and add 2-3 tablespoons of Premium 4 Synthetic 0W40 engine oil. To access the plug hole, use a section of clear 1/4” hose and a small plastic ...

119 MAINTENANCE AND LUBRICATION Cleaning and Storage Storage Tips Battery Storage Remove the battery from the vehicle and ensure that it’s fully charged before placing it in storage. See page 114 for instructions. Engine Anti-Freeze Test engine coolant strength and change if necessary. Coolant shoul...

121 POLARIS PRODUCTS Part No. Description Engine Lubricant 2870791 Fogging Oil (12 oz. Aerosol) 2871098 Premium 2-Cycle Engine Oil (qt.) 2871721 Premium Gold Synthetic 2-Cycle Oil (qt.) 2871281 Premium 4 Synthetic 0W-40 Engine Oil (4-Cycle)(qt.) Gearcase / Transmission Lubricants 2873602 Premium Syn...

122 TROUBLESHOOTING Drive Belt and Cover Problems Possible Cause Solution Driving the ATV onto a pickup or tall trailer in high range. Shift transmission to low range during loading of the ATV to prevent belt burning. Starting out going up a steep incline. When starting out on an incline, use low ra...

123 TROUBLESHOOTING Contact your Polaris dealer for service if you’re unable to identify solutions using the following charts. Engine Doesn’t Turn Over Possible Cause Solution Tripped circuit breaker Reset the breaker Low battery voltage Recharge battery to 12.5 VDC Loose battery connections Check a...

124 TROUBLESHOOTING Engine Backfires Possible Cause Solution Weak spark from spark plugs Inspect, clean and/or replace spark plugs Incorrect spark plug gap or heat range Set gap to specs or replace plugs Old or non-recommended fuel Replace with new fuel Incorrectly installed spark plug wires See you...

125 TROUBLESHOOTING Engine Stops or Loses Power Possible Cause Solution Out of fuel Turn fuel valve to reserve, refuel Kinked or plugged fuel vent line Inspect and replace Water present in fuel Replace with new fuel Overuse of choke Inspect, clean and/or replace spark plugs Fouled or defective spark...

126 SPECIFICATIONS ATP 330 4x4 Gross Vehicle Weight 1300 lbs./590 kg Fuel Capacity 3.25 gal./12.3 l Hitch Towing Rating 1 000 l bs./454 k g Unbraked Trailer Towing Capacity* 1585 lbs./719 kg Hitch Tongue Capacity 100 lbs./45.4 kg (rear box capacity and tongue weight not to exceed 250 lbs./113 kg) Fr...

127 SPECIFICATIONS ATP 330 4x4 Shift Type Side Lever (High, Low, Neutral, Reverse, Park) Gear Reduction - Low 11.57:1 Gear Reduction - Reverse 6.84:1 Gear Reduction - High 4.41:1 Drive Ratio - Front: 3.7:1 Drive Ratio - Final 3.08:1 Tire Size - Front 24 x 8 - 12 Tire Size - Rear 24 x 11 - 12 Tire Pr...

130 WARRANTY LIMITED WARRANTY Polaris Industries Inc., 2100 Highway 55, Medina, MN 55340, gives a SIX MONTH LIM- ITED WARRANTY on all components of the Polaris All Terrain Vehicle (ATV) against de- fects in material or workmanship. This warranty covers the parts and labor charges for repair or repla...

131 WARRANTY LIMITATIONS OF WARRANTIES AND REMEDIES ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE) ARE LIMITED IN DURATION TO THE ABOVE SIX MONTH WARRAN- TY PERIOD. POLARIS FURTHER DISCLAIMS ALL EXPRESS WARRANTIES ...

132 WARRANTY Exported Vehicles EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE IS NO WARRANTY OR SERVICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD OUTSIDE THE COUNTRY OF THE SELLING DEALER’S AUTHORIZED LOCATION.This policy does not apply to vehicles that have received authorization for export...

133 WARRANTY California Emission Control Warranty Statement Your Warranty Rights and Obligations The California Air Resources Board and Polaris Industries Inc., 2100 Highway 55, Medina, Minnesota 55340 (herein “POLARIS”) are pleased to explain the emission control system warranty on your 2004 and la...

134 WARRANTY California Emission Control Warranty Statement Warranty Period This warranty period begins on the date, which the LSI engine is delivered, to the origi- nal retail purchaser and ends two years after that date. During this two year period POLARIS warrants to the original retail purchaser...

135 WARRANTY California Emission Control Warranty Statement What is Not Covered Under This Warranty This warranty does not cover any emission-related part, which malfunctions, fails, or is damaged due to alterations and/or modifications such as changing, adding, or removing parts. When the LSI engin...

136 WARRANTY California Emission Control Warranty Statement Maintenance Schedule Item Hrs/Miles When Remarks b Air filter pre-cleaner Daily Daily Inspect, clean b Air filter main element Weekly Weekly Inspect, replace if necessary b Engine breather filter 20 hrs. Monthly I nspect, replace annually a...

137 INDEX A Accessories 75 . . . . . . . . . . . . . . . . . . . . . . Adjustments 93-103 . . . . . . . . . . . . . . . . . Age Restrictions 7 . . . . . . . . . . . . . . . . . . . Air Filter 104 . . . . . . . . . . . . . . . . . . . . . . . All Wheel Drive 47 . . . . . . . . . . . . . . . . . . Aux...