Polaris 2X4 User Manual

7VEHICLE IDENTIFICATION NUMBERSRecord your ATV’s identification numbers and key number in thespaces provided. Remove the spare key and store it in a s

97MAINTENANCE AND LUBRICATIONAdjustmentsThrottle Cable FreeplayThe throttle cable adjuster is located at the right handlebar.1. Slide the boots (1) of

98MAINTENANCE AND LUBRICATIONAdjustmentsSide Panel RemovalNOTE: Side panel removal may be difficult until the locking tabs andreceivers have been snap

99MAINTENANCE AND LUBRICATIONAdjustmentsWARNINGOperating your ATV with worn tires, improperly inflated tires,non-standard tires or improperly installe

100MAINTENANCE AND LUBRICATIONAdjustmentsWARNINGImproperly installed wheels can adversely affect tire wear andvehicle handling, which can result in se

101MAINTENANCE AND LUBRICATIONAdjustmentsFront Wheel Hub TighteningFront wheel bearing tightness and spindle nut retention are criticalcomponent opera

102MAINTENANCE AND LUBRICATIONAdjustmentsAir Filter Service1. Remove the seat.2. Release the clips and remove the airbox cover (1).3. Loosen the clamp

103MAINTENANCE AND LUBRICATIONAccessoriesAuxiliary power outlets provide 12V power for operating accessoriessuch as hand held spot lights. See your Po

104MAINTENANCE AND LUBRICATIONCleaning and StorageStorage TipsSee page 108 for the part numbers of Polaris products.CAUTIONStarting the engine during

105MAINTENANCE AND LUBRICATIONCleaning and StorageStorage TipsSee page 108 for the part numbers of Polaris products.Fluid LevelsInspect the following

106MAINTENANCE AND LUBRICATIONCleaning and StorageChrome Wheel Care (if equipped)Proper maintenance will protect chrome wheels from corrosion,preserve

8SAFETYOperator SafetyWARNINGFailure to follow the warnings contained in this manual can resultin serious injury or death.A Polaris ATV is not a toy a

107MAINTENANCE AND LUBRICATIONCleaning and StorageTransporting an ATVFollow these procedures whentransporting an ATV.1. Turn off the engine andremove

108POLARIS PRODUCTSPart No. DescriptionEngine Lubricant2870791 Fogging Oil (12 oz. Aerosol)2871281 Premium 4 Synthetic 0W-40 (4-Cycle) Engine Oil (qt.

109SPECIFICATIONS2005 Magnum 330 2X4CapacitiesBody Style Gen IVGross Vehicle Weight 1060 lbs. (481 kg)Fuel Capacity 3.2 gal. (12.1 l)Engine Oil Capaci

110SPECIFICATIONS2005 Magnum 330 2X4Drive SystemDrive System Type PVTShift Type Side LeverFront Drive (ratio) 3.1/1Front Tires 24x8-12(4psi)Rear Tires

111SPECIFICATIONS2005 Magnum 330 2X4Jetting ChartAltitude AMBIENTTEMPERATUREBelow 40° F(Below 5° C)+40°F and above(+5°C and above)Meters(Feet)0-1800(0

112SPECIFICATIONS2005 Magnum 330 4X4CapacitiesBody Style Gen IVGross Vehicle Weight 1100 lbs. (499 kg)Fuel Capacity 3.25 gal. (12.3 l)Engine Oil Capac

113SPECIFICATIONS2005 Magnum 330 4X4Drive SystemDrive System Type PVTShift Type Side LeverFront Drive (ratio) 3.7/1Final Drive (ratio) 3.1/1Front Tire

114SPECIFICATIONS2005 Magnum 330 4X4Jetting ChartAltitude AMBIENTTEMPERATUREBelow 40° F(Below 5° C)+40°F and above(+5°C and above)Meters(Feet)0-1800(0

115TROUBLESHOOTINGDrive Belt and Cover ProblemsPossible Cause SolutionDriving the ATV onto apickup or tall trailer inhigh range.Shift transmission to

116TROUBLESHOOTINGContact your P olaris dealer for service if you’re unable to identifysolutions using the following charts.Engine Doesn’t Turn OverPo

9SAFETYOperator SafetyThe following signal words and s ymbols appear throughout thismanual and on your ATV. Your safety is involved when these wordsan

117TROUBLESHOOTINGEngine BackfiresPossible Cause SolutionWeak spark from spark plugs Inspect, clean and/or replace spark plugsIncorrect spark plug gap

118TROUBLESHOOTINGEngine Stops or Loses PowerPossible Cause SolutionOut o f fuel Turn fuel valve to reserve, refuelKinked or plugged fuel vent line In

119WARRANTYLIMITED WARRANTYPolaris Sales Inc., 2100 Highway 55, Medina, MN 55340, gives a SIX MONTH LIMITEDWARRANTY o n all components of the Polaris

120WARRANTYWARRANTY COVERAGE AND EXCLUSIONS:LIMITATIONS OF WARRANTIES AND REMEDIESALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE IMPLIEDWARR

121WARRANTYExported Veh iclesEXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE IS NO WAR-RANTY OR SERVICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SO

122INDEXAAccessories 103...Adjustments 91-102...Age Restrictions 8...Air Filter 102...All Whe

123INDEXLLight Switch 34...Lights 80-81...Low Range 86...Lubrication Guide 72...MMain Swit

10SAFETYOperator SafetyWARNINGSerious injury or death can result if you do not follow theseinstructions and procedures, which are outlined in further

11SAFETYOperator SafetyS Always have the ATV inspected by an authorized Polaris dealer ifit’s been involved in an accident.S Never operate on hills to

12SAFETYOperator SafetyS Wet brakes may have reduced stopping ability. Test your brakes afterleaving water. If necessary, apply them lightly several t

13SAFETYOperator SafetyWARNINGPOTENTIAL HAZARDOperating this ATV without proper instruction.WHAT CANHAPPENThe risk of an accident is greatly increased

14SAFETYOperator SafetyWARNINGPOTENTIAL HAZARDCarrying a passenger on anATV.WHAT CANHAPPENCarrying a passengergreatly reduces theoperator’s ability to

15SAFETYOperator SafetyWARNINGPOTENTIAL HAZARDOperating this ATV onpublic streets, roads orhighways.WHAT CANHAPPENThe ATV could collidewith another ve

16SAFETYOperator SafetyWARNINGPOTENTIAL HAZARDOperating the ATV after consumingalcohol or drugs.WHAT CANHAPPENConsumption of alcohol and/or drugscould

17SAFETYOperator SafetyWARNINGPOTENTIAL HAZARDAttempting wheelies, jumpsand other stunts.WHAT CANHAPPENAttempting stunts increasesthe chance of an acc

18SAFETYOperator SafetyWARNINGPOTENTIAL HAZARDRemoving hands from the handlebars or feet from the footrestsduring operation.WHAT CANHAPPENRemoving eve

19SAFETYOperator SafetyWARNINGPOTENTIAL HAZARDFailure to use extracaution when operating onexcessively rough,slippery or loose terrain.WHAT CANHAPPENO

20SAFETYOperator SafetyWARNINGPOTENTIAL HAZARDOperating on excessively steep hills.WHAT CANHAPPENThe vehicle may overturn.HOW TO AVOID THEHAZARDNever

21SAFETYOperator SafetyWARNINGPOTENTIAL HAZARDT raveling downhillimproperly.WHAT CANHAPPENImproperly descending a hillcould cause loss of controlor ov

22SAFETYOperator SafetyWARNINGPOTENTIAL HAZARDImproperly crossing hills andturning on hills.WHAT CANHAPPENImproperly crossing orturning as hills could

23SAFETYOperator SafetyWARNINGPOTENTIAL HAZARDStalling, rolling backwardsor improperly dismountingwhile climbing a hill.WHAT CANHAPPENThe vehicle coul

24SAFETYOperator SafetyWARNINGPOTENTIAL HAZARDImproperly operating over obstacles.WHAT CANHAPPENOperating over obstacles could cause loss of control o

25SAFETYOperator SafetyWARNINGPOTENTIAL HAZARDOperating the ATV through deep or fast-flowing water.WHAT CANHAPPENT ires may float, causing loss of tra

26SAFETYOperator SafetyWARNINGPOTENTIAL HAZARDOperating the ATV with improper modifications.WHAT CANHAPPENImproper installation of accessories or modi

A card containing important ATV safety information should be attachedto the owner’s manual on the next page. If you cannot locate this card,or if it h

27SAFETYOperator SafetyWARNINGLeaving the keys in the ignition can lead to unauthorized use ofthe vehicle resulting in serious injury or death. Always

28SAFETYSafety Decals and LocationsWarning decals have been placed on the ATV for your protection. Readand follow the instructions of the decals and o

29SAFETYSafety Decals and LocationsLocation ALocation BLocation CLocation DLocation E (on models with racks)Location E (on models with storage box)Ope

30SAFETYSafety Decals and LocationsIMPROPER TIRE PRESSURE OR OVERLOADING can cause loss ofcontrol resulting in SEVERE INJURY OR DEATH.TIRE PRESSURE (P

31SAFETYSafety Decals and LocationsLocation HALL WHEELDRIVESWITCHDo not push switch toengage AWD if the rearwheels are spinning.This may cause severed

32SAFETYSafe Riding GearAlways wear clothing suited to the type of riding. ATV riding requiresspecial protective clothing for comfort and to reduce th

33SAFETYFuel SafetyWARNINGGasoline is highly flammable and explosive under certainconditions.S Always exercise extreme caution whenever handling gasol

34FEATURES AND CONTROLSElectrical SwitchesWARNINGOperating the ATV on streets or roads, especially in darkness,could result in an accident and serious

35FEATURES AND CONTROLSElectrical Switches3. Engine Stop Switch - The engine will not startorrunwhentheswitchisintheOFF position. Itspurpose is to pro

36FEATURES AND CONTROLSThrottle LeverEngine speed and vehiclemovement are controlled bypressing the throttle lever.The throttle lever (1) is springloa

37FEATURES AND CONTROLSBrakesMaster Cylind erCheck the brake fluid level inthe master cylinder before eachuse of t he ATV. The mastercylinder (1) is l

38FEATURES AND CONTROLSBrake LeverThe front and rear brakes are appliedby squeezing the brake lever (1)toward the handlebar. The front andrear brakes

39FEATURES AND CONTROLSParking BrakeWARNINGOperating the ATV while the parking brake is engaged couldresult in an accident and serious injury or death

40FEATURES AND CONTROLSAuxiliary BrakeWARNINGAggressively applying the auxiliary brake when backing down ahill may cause rear tipover , which could re

41FEATURES AND CONTROLSChokeThe choke assists in starting a cold engine. Refer to the engine startingprocedure on page 52 for correct choke and thrott

42FEATURES AND CONTROLSAutomatic Transmission Gear SelectorThe transmission gear selector (1) is located on the right side of thevehicle.H: High GearN

43FEATURES AND CONTROLSRecoil StarterIf the battery has been drained ordamaged and cannot start theengine, use of the recoil starter (1)will allow veh

44FEATURES AND CONTROLSAll Wheel Drive System (Domestic Models)Polaris 4 wheel drive domesticmodel ATVs are equipped with aunique, Polaris exclusive,

45FEATURES AND CONTROLSInstrument Cluster (Magnum 330)Your ATV is equipped with an instrument cluster that senses vehiclespeed from the right front wh

46FEATURES AND CONTROLSInstrument Cluster (Magnum 330)Rider Information CenterThe rider information center is located in the lower portion of theinstr

2Copyright 2004 Polaris Sales Inc. All information contained within this publication isbased on the latest product information at the time of publicat

47FEATURES AND CONTROLSInstrument Cluster (Magnum 330)Rider Information CenterThe rider information center has 4 standard modes:Mode 1 - OdometerMode

48FEATURES AND CONTROLSInstrument Cluster (Magnum 330)Rider Information CenterMode 4 - Programmable Service IntervalThe purpose of t he programmable s

49FEATURES AND CONTROLSInstrument Cluster (Magnum 330)Rider Information CenterDiagnostic ModeThe diagnostic mode is for informational purposes only. P

50OPERATIONBreak-In PeriodThe break-in period for your new Polaris 4-cycle ATV is defined as thefirst ten hours of operation, or the time it takes to

51OPERATIONPre-Ride InspectionWARNINGIf a proper inspection is not done before each use, severe injuryor death could result. Always inspect the vehicl

52OPERATIONStarting the EngineStarting a Cold EngineWARNINGEngine exhaust contains poisonous carbon monoxide and cancause loss of consciousness result

53OPERATIONStarting the EngineStarting a Warm EngineWarm engines do not normally require the use of the choke. Excessiveuse of t he choke can cause th

54OPERATIONDriving SafelyDriving Procedures1. Sit upright with both feet on the footrests and both hands on thehandlebars.2. Start the engine and allo

55OPERATIONDriving SafelyMaking TurnsYour Polaris ATV is equipped with a solid rear axle that drives bothrear wheels equally at all times. This means

56OPERATIONDriving SafelyHauling CargoYour ATV has been designed to carry or tow a certain amount of load.Always read and understand the load distribu

3WELCOMEThank you for purchasing a Polaris vehicle, and welcome to ourworld-wide family of Polaris owners. We proudly produce an excitingline of utili

57OPERATIONDriving SafelyHauling CargoWARNINGS REDUCE SPEED AND ALLOW GREATER DISTANCES FORBRAKING WHEN HAULING CARGO.S CARGO WEIGHT DISTRIBUTION shou

58OPERATIONDriving SafelyDriving on Slippery SurfacesWhenever riding on slippery surfaces such as wet trails or loose gravel,or during freezing weathe

59OPERATIONDriving SafelyDriving UphillWhenever traveling uphill, follow theseprecautions:1. Always travel straight uphill.2. Avoid steep hills (25_ m

60OPERATIONDriving SafelySidehillingWARNINGImproperly crossing hills or turning on hills can result in loss ofcontrol or vehicle overturn, resulting i

61OPERATIONDriving SafelyDriving DownhillWhenever descending a hill, follow these precautions:1. Proceed directly downhill.2. Transfer your weight to

62OPERATIONDriving SafelyTurning Around on a HillWARNINGImproper hill climbing procedures could cause loss of control oroverturn and result in serious

63OPERATIONDriving SafelyDriving Through WaterYour ATV can operate throughwater with a maximumrecommended depth equal tothe bottom of the footrests (1

64OPERATIONDriving SafelyDriving Over ObstaclesBe alert! Look ahead and learn to read the terrain you’re traveling on.Be constantly alert for hazards

65OPERATIONDriving SafelyDriving in ReverseFollow these precautions when operating in reverse:1. Always avoid backing downhill.2. Back slowly.3. When

66OPERATIONDriving SafelyParkingonanInclineAvoid parking on an incline if possible. If it’s unavoidable, followthese precautions:1. Turn the engine of

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67EMISSION CONTROL SYSTEMSNoise Emission Control SystemDo not modify the engine, intake or exhaust components, as doing somay affect compliance with s

68MAINTENANCE AND LUBRICATIONPeriodic Maintenance ChartCareful periodic maintenance will help keep your vehicle in the safest,most reliable condition.

69MAINTENANCE AND LUBRICATIONPeriodic Maintenance ChartPerform all services at whichever maintenance interval is reached first.Item Maintenance Interv

70MAINTENANCE AND LUBRICATIONPeriodic Maintenance ChartItem Maintenance Interval(whichever comes first)RemarksHours Calendar Miles(Km)"Generallub

71MAINTENANCE AND LUBRICATIONPeriodic Maintenance ChartItem Maintenance Interval(whichever comes first)RemarksHours Calendar Miles(Km)"Wiring 100

72MAINTENANCE AND LUBRICATIONLubrication GuideCheck and lubricate all components at the intervals outlined in thePeriodic Maintenance Chart beginning

73MAINTENANCE AND LUBRICATIONPeriodic Maintenan ce RecordUse the following chart to record periodic maintenance.MaintenanceIntervalPerformedServicingD

74MAINTENANCE AND LUBRICATIONPremium 4 Synthetic LubricantPolaris Premium 4 All Season synthetic engine oil has been speciallyformulated for use in Po

75MAINTENANCE AND LUBRICATIONEngine Oil CheckThe oil dipstick (1) is located on theleft side of the engine.NOTE: A rising oil level betweenchecks in c

76MAINTENANCE AND LUBRICATIONOil and Filter Change5. Place a drain pan beneath the engine crankcase and remove thedrain plug.6. Allow the oil to drain

5TABLE OF CO NTENTSWELCOME 3...VEHICLE IDENTIFICATION NUMBERS 7...SAFETY 8...FEATUR

77MAINTENANCE AND LUBRICATIONTransmission OilAlways check and change the transmissionoil at the intervals outlined in the PeriodicMaintenance Chart be

78MAINTENANCE AND LUBRICATIONFront Gearcase OilAlways check and change the front gearcase oil at the intervalsoutlined in the Periodic Maintenance Cha

79MAINTENANCE AND LUBRICATIONRear Gearcase OilOil CheckAlways check and change the reargearcase oil at the intervals outlined inthe Periodic Maintenan

80MAINTENANCE AND LUBRICATIONLightsWhen servicing a halogen lamp, don’t touch the lamp with barefingers. Oil from your skin leaves a residue, causing

81MAINTENANCE AND LUBRICATIONLightsTaillight/Brakelight Lamp ReplacementIf the taillight/brakelight does not work the lamp m ay need to bereplaced.1.

82MAINTENANCE AND LUBRICATIONSpark PlugsRefer to the specifications section beginning on page 109 for spark plugand gap specifications.CAUTIONUsing no

83MAINTENANCE AND LUBRICATIONVehicle ImmersionCAUTIONIf your vehicle becomes immersed, major engine damage canresult if the machine is not thoroughly

84MAINTENANCE AND LUBRICATIONSpark ArrestorWARNINGFailure to heed the following warnings while servicing the sparkarrestor could result in serious inj

185MAINTENANCE AND LUBRICATIONRecoil HousingTo prevent possible enginedamage, always drain the recoilhousing (1) after operating theATV in very wet co

86MAINTENANCE AND LUBRICATIONPVT SystemThe basic operation of the Polaris PVT system is dependent on enginespeed and vehicle torque requirements. As e

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87MAINTENANCE AND LUBRICATIONPVT SystemWARNINGFailure to comply with the instructions in this warning can result insevere injury or death.Do not modif

88MAINTENANCE AND LUBRICATIONBatteryWARNINGImproperly connecting or disconnecting battery cables can resultin an explosion and cause serious injury or

89MAINTENANCE AND LUBRICATIONBatteryBattery StorageWhenever the vehicle is not used for a period of three months or more,remove the battery from the v

90MAINTENANCE AND LUBRICATIONBatteryBattery ChargingNOTE: Always verify battery condition before and 1-2 hours after theend of charging.State ofCharge

91MAINTENANCE AND LUBRICATIONAdjustmentsBrakesThe front and rear brakes are hydraulic disc brakes, activated bymoving the single brake lever toward th

92MAINTENANCE AND LUBRICATIONAdjustmentsAuxiliary BrakeThe auxiliary brake is a hydraulic disc brake. The rear brake system isself-adjusting and requi

93MAINTENANCE AND LUBRICATIONAdjustmentsWARNINGSevere injury or death can result from improper toe alignment andadjustment. Do not attempt to adjust t

94MAINTENANCE AND LUBRICATIONAdjustmentsSteering AssemblyThe steering assembly of the ATV should be checked periodically forloose nuts and bolts. If l

95MAINTENANCE AND LUBRICATIONAdjustmentsWARNINGImproper adjustment of the handlebars or incorrect torquing ofthe adjuster block tightening bolts can c

96MAINTENANCE AND LUBRICATIONAdjustmentsCarburetorIMPORTANT: Your Polaris ATV is calibrated at the factory foroptimal performance at altitudes ranging