Instruction/ maintenance manual of the product ATP 330 4x4 Polaris
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Part No. 9917747 Rev 03 PRINTED IN THE USA W ARNING Improper vehicle use can result in SEVERE INJUR Y or DEA TH. READ OWNER'S MANUAL. FOLLOW ALL INSTRUCTIONS AND W ARNINGS.
W ARNING The engine exhaust from this product contains chemicals known to cause cancer , birth defects or other reproductive harm. A card containing important A TV 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.
1 We’ve cr eat ed a web si t e j ust f or YOU! S T echni cal tips S New product introductions S Event schedules S Parts and Se rvice M anual information S Exciting details about The W ay Out Ch e ck it ou t.
2 Al l i nfor ma ti on i n thi s ma nua l i s ba se d on the l a te st pr oduct da ta a nd s pec if ic at ions a vai la ble a t the t ime of pr int ing. Pol ar is I ndust ri es I nc. r es er ve s the r i ght to make pr oduc t ch an g es an d imp ro vem en ts th at m ay af fect illu stratio n s o r exp lan ation s.
3 WELC O ME Thank you f or purc hasing a Polar is vehicle , and welc ome to our wor ld-wide fa mily of P olar is owner s. W e proudly produc e an exc iting line of utility an d rec re ationa l products.
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5 TABLE OF CONTENTS WELCO M E 3 ........................................ T ABL E OF CONTENT S 5 ............................. VEHICL E IDENT IF I CA T IO N NUM BERS 6 ............... SAF ET Y 7 .......................................... FEA T URES AND CONT ROLS 37 .
6 VE HICLE IDENTIFICATION NUMBERS The vehic le fra me vehic le identific ation number (VI N)(1) a nd engine ser ial number (2) a re importa nt for model identific ation whe n re gistering your vehicle , when obtaining insura nce, and w hen orde ring replacem ent p arts .
7 SA FETY Operator S afety Age Restr i ctions This vehi cle is an ADUL T VEHIC LE ONL Y . Operati on i s prohibi ted for anyone under 16 yea rs of age. Know Y our V ehi cle As the opera tor of the vehicle, you are r esponsible for your per sonal saf ety , the saf ety of others, and the prote ction of our e nvironment.
8 SA FETY Operator S afety The f ollowing signal words a nd symbols appea r throughout this manua l and on your A TV . Y our safe ty is involved whe n these wor ds and symbols ar e used. B ec ome fa miliar with the ir meanings bef ore re ading the manua l.
9 SA FETY Operator S afety S Rea d this manual a nd all labe ls car efully , and follow the oper ating proce dures de scribe d. S Neve r opera te an A TV without proper instruc tion. T ake a training course . Beginners s houl d receive trai ning from a certifi ed inst ructo r .
10 SA FETY Operator S afety S Alway s hav e the A TV in s pect ed by an au th ori zed P o lari s d eal er if it ’ s been i nvolved i n an accident . S Ne ver oper ate on hills too steep for the A TV or for your abilitie s. Pra ctic e on smalle r hills befor e atte mpting lar ger hills.
11 SA FETY Operator S afety S W et bra kes ma y have r educe d stopping ability . T est your bra kes a fter lea ving wa ter . If ne cessa ry , apply them lightly seve ra l times to allow frict i on t o dry o ut t h e pads . S Always che ck for obstac les or people behind the A TV befor e opera t- in g i n revers e.
12 SA FETY Operator S afety POTENTI AL HAZ A RD Oper at ing this A TV wit hout pr oper inst ruc t ion. WHA T CAN H APPEN The r isk of an accident is great ly inc reas ed if the oper at or does not know how t o oper ate t he A TV proper ly in diff erent sit uat ions and on diff erent t ypes of t er rain.
13 SA FETY Operator S afety POTENTI AL HAZ A RD Carr ying a pass enger on an A TV . WHA T CAN H APPEN Carr ying a pass enger gr eat ly reduc es the oper at or ’s ability to balanc e and cont rol t he A TV , whic h could c ause an accident and injur y t o t he operat or and/or pas senger .
14 SA FETY Operator S afety POTENTI AL HAZ A RD Oper at ing an A T V on pav ed sur f aces , inc luding sidewalk s, paths , park ing lots , and driv eways.
15 SA FETY Operator S afety POTENTI AL HAZ A RD Oper at ing this A TV on public st r eet s, r oads or highways . WHA T CAN H APPEN The A TV could c ollide wit h another vehic le. HOW T O A VOID THE HAZ ARD Never operat e t he A T V on any public str eet , r oad or highway , including dirt and gr avel r oads.
16 SA FETY Operator S afety POTENTI AL HAZ A RD Oper at ing t his A T V wit hout wear ing an approv ed helmet , eye prot ect ion and pr ot ect ive c lot hing. WHA T CAN H APPEN Oper at ing an A T V wit hout an appr oved helmet inc reas es t he ris k of a sev ere head injur y or deat h in t he ev ent of an accident .
17 SA FETY Operator S afety POTENTI AL HAZ A RD Oper at ing t he A T V af t er c onsum ing alcohol or drugs . WHA T CAN H APPEN Consumpt ion of alc ohol and/or drugs could ser iously affec t operat or judgm ent . React ion t ime m ay be s lower and operat or balance and perc ept ion could be aff ect ed.
18 SA FETY Operator S afety POTENTI AL HAZ A RD At t empt ing wheelies, jum ps and ot her s t unt s. WHA T CAN H APPEN At t empt ing s tunt s incr eases t he c hance of an acc ident , including an overt ur n. HOW T O A VOID THE HAZ ARD Never att em pt wheelies, jum ps, or ot her stunt s .
19 SA FETY Operator S afety POTENTI AL HAZ A RD Failur e t o inspec t the A T V bef ore oper at ing. Failur e t o proper ly maint ain t he A T V . WHA T CAN H APPEN Poor m aint enance inc reas es t he poss ibilit y of an acc ident or equipment dam age.
20 SA FETY Operator S afety POTENTI AL HAZ A RD Failur e t o use ex t ra caut ion when oper at ing the A T V on unf amiliar terrai n. WHA T CAN H APPEN Unfamiliar t errain ma y c ont ain hidden rocks, bumps, o r holes that could caus e loss of cont rol or over tur n.
21 SA FETY Operator S afety POTENTI AL HAZ A RD Failur e t o use ex tr a caut ion when oper at ing on exces siv ely rough, s lippery or loos e ter rain. WHA T CAN H APPEN Oper at ing on exc essiv ely r ough, slipper y or loos e t err ain could cause los s of t rac t ion or los s of cont r ol, which could r esult in an accident or ov ert urn.
22 SA FETY Operator S afety POTENTI AL HAZ A RD T urning impr operly . WHA T CAN H APPEN Im proper t urns c ould caus e loss of c ont rol and lead t o a c ollision or overt ur n. HOW T O A VOID THE HAZ ARD Always f ollow proper pr ocedur es f or tur ning as descr ibed in the owner ’s manual.
23 SA FETY Operator S afety POTENTI AL HAZ A RD Climbing hills im proper ly . WHA T CAN H APPEN Im proper hill clim bing could caus e loss of cont rol or over tur n. HOW T O A VOID THE HAZ ARD Always f ollow proper pr ocedur es f or climbing hills as desc ribed in the owner ’ s m anual.
24 SA FETY Operator S afety POTENTI AL HAZ A RD T raveling downhill im proper ly . WHA T CAN H APPEN Im proper ly des cending a hill c ould cause los s of c ontr ol or overt ur n. HOW T O A VOID THE HAZ ARD Always f ollow proper pr ocedur es f or tr aveling down hills as descr ibed in t he owner ’s manual.
25 SA FETY Operator S afety POTENTI AL HAZ A RD Im proper ly c ross ing hills and t ur ning on hills. WHA T CAN H APPEN Im proper ly cr oss ing or turning as hills could caus e loss of c ontr ol or overt ur n.
26 SA FETY Operator S afety POTENTI AL HAZ A RD St alling, rolling bac kwards or impr operly dis mount ing while climbing a hill. WHA T CAN H APPEN The v ehicle c ould over t urn. HOW T O A VOID THE HAZ ARD Maint ain st eady speed when climbing a hill.
27 SA FETY Operator S afety POTENTI AL HAZ A RD Im proper ly operat ing over obs tac les. WHA T CAN H APPEN Oper at ing over obst acles could c ause loss of cont rol or over tur n. HOW T O A VOID THE HAZ ARD Bef ore oper at ing in a new area, chec k f or obst acles .
28 SA FETY Operator S afety POTENTI AL HAZ A RD Oper at ing t he A T V t hr ough deep or f ast - f lowing water . WHA T CAN H APPEN T ires may f loat , caus ing loss of t r act ion and loss of cont r ol, which could lead t o an ac cident or ov ert ur n.
29 SA FETY Operator S afety POTENTI AL HAZ A RD Oper at ing this A TV wit h impr oper t ires , or wit h improper or unev en tire pre ssure. WHA T CAN H APPEN Use of impr oper t ires , or oper ation of t he A TV wit h impr oper or uneven t ire pr ess ure, could c ause los s of cont r ol or ac cident .
30 SA FETY Operator S afety POTENTI AL HAZ A RD Ov erloading t he A T V or c arr ying/ t owing car go impr operly . WHA T CAN H APPEN Ov erloading and t owing c an cause c hanges in v ehicle handling, which could lead t o los s of cont r ol or an ac cident .
31 SA FETY Operator S afety Af t er any overt ur n or ac cident , have a qualif ied ser vic e dealer inspect t he ent ire v ehicle f or possible dam age, including ( but not limi ted to) brakes, throttle an d steering syste ms. Saf e operat ion of t his r ider- act ive v ehicle r equires good judgement and physic al sk ills.
32 SA FETY Safety D ecals and Locations W arning d ecals h ave been placed on th e A TV for your prot ecti on. Read an d fo ll o w th e ins t ruct i on s o n each decal carefu l ly . If a decal bec omes illegible or c omes of f, contac t your P olar is deale r to purcha se a repl acem ent .
33 SA FETY Safety D ecals and Locations D Never operate this vehi cl e on HILLS steeper than 25 degrees 25 ° . T o pr event flipove r o n hilly t er rain , w hen g oing up o r down , use thr ottle and brakes gradually . D REVERSE oper atio n can be dangerous, even at low s peeds.
34 SA FETY Safety D ecals and Locations IMPROPER TIR E PRESSU RE O R O VERLOADIN G c an c ause loss of control re s ultin g in SEVERE INJ URY OR D EA TH. TIRE PRESSUR E IN PSI (KPa): FRO N T 5 ( 34,5) R EA R 5 ( 34,5) M AXI MUM W EIGHT CAP ACITY (G ros s V ehic le Weight) INCL UDING MACHI NE, DRI VER AND CARGO IS 1500 LBS.
35 SA FETY Safety D ecals and Locations ALL WHE EL DRIVE SWITCH Do not push s witc h to engage A WD if t he rear wheels are spinning. This m ay caus e sev ere drive s haf t and clutc h damage. See your Owner ’s Manual. 7079780 MANUFACTURED BY: POLARIS IND, INC.
36 SA FETY Safe Ridi ng Gear Always we ar c lothing suited to the t ype of riding. A TV riding requir es spec ial protec tive clothing for co mfort and to reduc e the chanc e of injury . 1. Helm et Y our he lmet is the most impor tant pie ce of prote ctive ge ar for sa fe r iding.
37 FEATURE S AND CO NTROLS Electr ical S witches While oper at ing in rev ers e, ac t ivat ing t he over ride s wit ch wit h t he thr ot t le open can caus e loss of cont rol, r esult ing in sev ere injur y or deat h. Do not ac t ivat e t he over ride s witc h while t he t hrot t le is open.
38 FEATURE S AND CO NTROLS Electr ical S witches Engine Stop Sw itc h (3 ) - The e ngine will not start or r un when the switc h is in t he OFF position. Its purpose is t o provide the oper ator with a quic k means of engine sh ut d own i n cas e of an emergency .
39 FEATURE S AND CO NTROLS Throttle Lever Eng i ne sp eed an d veh icl e moveme nt are c ontrolled by pre ssing the t hrottle le ver . The throttle le ver (1) is spring lo aded .
40 FEATURE S AND CO NTROLS Br ake Lever The fro nt an d rear b rak es are ap pl i ed b y s q ueezi ng t he b rake l ever ( 1) towar d the handleba r . The fr ont and rea r brake s are hydra ulica lly acti v at ed d is c t yp e br akes t hat are act iv at ed b y o nl y on e l ever .
41 FEATURE S AND CO NTROLS Park in g Brak e Locking th e Par king Brake 1. S qu eeze and rel ease t h e brak e leve r (1) two or thr ee time s, then sq ueeze and h ol d at f ul l s t rok e. 2. Push the par k brake lock ( 2) forw ard to engage the br ake.
42 FEATURE S AND CO NTROLS Auxiliary Brake The a uxiliary foot bra ke (1) is loca ted on the inside of t he right floor boa rd and is ope rate d by the right foot. The auxilia ry bra ke serve s as a backup to the main bra ke system if the main system be come s inopera tive.
43 FEATURE S AND CO NTROLS Choke The choke a ssists i n starting a cold engine . Refe r to the engine star ting proc edure on page 55 for c orre ct choke and throttle settings during star ting. Fuel V alve The fu el val ve (1 ) i s l o cated on th e l eft s i de pane l.
44 FEATURE S AND CO NTROLS Fuel Safety Gas oline is highly f lammable and ex plosiv e under c ert ain condit ions. S Always exer cis e ext rem e caut ion whenev er handling gasoline. S Always ref uel wit h t he engine st opped, and out doors or in a well vent ilat ed area.
45 FEATURE S AND CO NTROLS Autom atic T r ansmi ssion Gear Selector The tra nsmission gear se lector ( 1) is locate d on the right side of the vehic le. H: High Gear L: Low Gea r N: Neutral R: Rev er se P: Pa rk T o shift i nto HIGH or P ARK, you must first apply the auxilia ry bra ke to ac tivate the high/par k lock-out me cha nism.
46 FEATURE S AND CO NTROLS Recoil S tar ter If the batter y is weak a nd ca nnot star t the engine, use of the rec oil star ter ( 1) will allow ve hicle oper ation until re pairs c an be mad e. Th e recoi l st art er i s lo cat ed on the right side of the machine .
47 FEATURE S AND CO NTROLS All W heel Dr ive (A W D) S ystem Polar is 4 whee l drive A TVs ar e equipped with a unique, Polar is exclusive , Dema nd 4 Driv e (A WD) s ys t em acti v ated b y a swi tch (1 ) on the right handleba r .
48 FEATURE S AND CO NTROLS In stru men t Clu st er Y our A TV is e quipped with a n instrume nt cluster that se nses ve hicle spee d from the right fr ont wheel.
49 FEATURE S AND CO NTROLS In stru men t Clu st er Ri der Infor m ation Ce nter The ride r infor mation c ente r is loca ted in the instr ument c luster .
50 FEATURE S AND CO NTROLS In stru men t Clu st er Ri der Infor m ation Ce nter The r ider infor mation ce nter ha s 4 standar d modes: Mode 1 - Odometer Mode 2 - T ripmete r Mode 3 - T otal S er vice Hours Mode 4 - T achome ter The re verse ove rride button on the left handle bar is also the mode button .
51 FEATURE S AND CO NTROLS In stru men t Clu st er Ri der Infor m ation Ce nter Dia gnos tic Mode The diagnostic mode is for inf ormationa l purposes only . Please r eturn your A TV to your deale r for all major r epa irs. As long as the gauge is in the diagnostic mode, the wrenc h icon will re main lit.
52 FEATURE S AND CO NTROLS In stru men t Clu st er Ri der Infor m ation Ce nter Dia gnos tic Mode S cr een 5: Progr amma ble ser vice inter val The purpose of the progr amma ble servic e inter val is to provide the consume r and dea ler with a conve nient re minder for r outine mainte nanc e.
53 OPERATION Br eak -In Per iod The br eak -in per iod for your new Pola ris A TV is def ined a s the first te n hours of oper ation, or the time it takes to use the first two full tanks of gasoline . No single action o n your par t is as important a s following the proc edure s for a proper br eak- in.
54 OPERATION Pr e - Ride Inspection Use the f ollowing che cklist to verif y that your vehic le is in proper wor king condition be fore each use. Item/Inspection Pr oced ure 1. T ire s - Chec k condition and pr essure s. 2. Fuel and oil tanks - Fill both tanks to their prope r levels.
55 OPERATION Star ting the Engi ne S tar ting a C old Engi ne 1. Place the tr ansmission in par k and lo ck t he park i ng b rake. 2. T urn the fuel tank valve on. 3. Sit on the vehicle. 4. Pull the c hoke knob out until it st op s (1). NOTE: The va ria ble choke is fully on when the knob is pulled comple tely out.
56 OPERATION Star ting the Engi ne S tar ting a W ar m Engi ne W ar m engines do not normally re quire the use of the choke . Using the choke c an cause the spa rk plug to become we t fouled. 1. Position the vehicle on a le vel surfa ce with the tra nsmission in park.
57 OPERATION Hauling Cargo Ov erloading t he v ehicle or c arr ying or t owing cargo im proper ly can alt er v ehicle handling and m ay caus e loss of cont rol or brake ins t abilit y . Always f ollow thes e prec aut ions when hauling cargo: S Never ex ceed t he s tat ed load c apacit y f or t his vehic le.
58 OPERATION Hauling Cargo Load D istr ibution Y our A TV ha s been de signed to ca rry or tow a c er tain amount of loa d. Always r ead a nd under stand the loa d distribution wa rnings liste d on th e warni ng l abel s , an d nev er exceed th e speci fi ed wei gh ts .
59 OPERATION Hauling Cargo Dumpin g Cargo 1. Selec t a leve l site to dump the c ar go box. Do not atte mpt to dump or unloa d the vehic le while pa rke d on an inc line. 2. Place the tra nsmission in par k and se t the par king brake . 3. Dismount the vehicle .
60 OPERATION Driving Safely Driving Pr ocedu res 1. Sit upright with both f eet on the footr ests and both hands on the handle bars. 2. Start the engine and a llow it to war m up, then shif t the tra nsmission into gea r . 3. Check your surr oundings and deter mine your path of trave l.
61 OPERATION Driving Safely Making T urns Y our Polar is A TV is equippe d with a r ea r dif fer ential tha t functions a s a solid r ea r axle , driving both re ar w hee ls equa lly when the A TP is in eithe r 2x4 or 4x4 mode.
62 OPERATION Driving Safely Dr iving o n Slippery S urfaces Whenev er rid i ng on s l i pp ery su rfaces su ch as wet t rai ls or l oo se grav el, or du rin g freezi ng weat her , fo l lo w th ese precau t io ns : 1. Slow down when e ntering slippe ry ar eas.
63 OPERATION Driving Safely Driving Uphill Whe nev er tra veling uphill, follow these precau t io ns : 1. Alwa ys tra vel stra ight uphill. 2. A void steep hills (25 _ maximum) . 3. Kee p both fee t on the footre sts. 4. T ransf er your weight forw ard.
64 OPERATION Driving Safely Sidehilling Sidehilling ca n be a da ngerous type of driving a nd should be a voided if at a ll possible. If you do ente r into a situa tion wher e side hilling is neces sary , fol l ow th ese p recau ti o ns : 1. Sl ow down.
65 OPERATION Driving Safely Driving Downh ill Whe neve r desc ending a hill, follow these pr ecauti o ns : 1. P roceed d i rectl y d ow nh ill. 2. T ra nsfer your we ight to the rea r of the vehic le. 3. Sl ow down. 4. Apply the brakes slightly t oa i di ns l o w i n g .
66 OPERATION Driving Safely T urning A r ound on a Hi ll If the ve hicle sta lls while climbing a hill, neve r back it down the hill! One mane uver that ca n be used whe n it’ s nec essar y to turn ar ound while c limbing a hill is the K-turn: 1. Stop and lock the pa rking br ake w hile kee ping body weight uphill.
67 OPERATION Driving Safely Dr iving Thr ough W ater Y our A TV c an ope rate through wa ter w ith a maximum r ecomme nded depth equa l to the bottom of the footre sts (1). F ollow these proc edure s when ope rating through wa ter: 1. Dete rmine wa ter depths and curr ent befor e crossing.
68 OPERATION Driving Safely Dr iving Thr ough W ater Afte r running the vehic le in water , it’ s critical to ha ve it se rvice d as outlined in the mainten anc e cha rt. See pa ge 75. The following ar ea s nee d spec ial atte ntion: engine oil, tra nsmission oil, front an d rea r gea rc ase s and all gre ase f ittings.
69 OPERATION Driving Safely Dr iving Over Obstacles Be al ert! Loo k ahead an d learn t o read t h e terrain . B e cons t ant l y alert for hazard s su ch as l og s , ro cks an d l ow h ang in g br anch es. Sever e injury or deat h can r esult if your vehic le com es in cont ac t with a hidden obs t acle.
70 OPERATION Driving Safely Dr iving in Reverse F ol l ow th ese precau t io ns when o perat i ng i n rev erse: 1. Always avoid ba cking downhill. 2. Bac k slowly . 3. When i n revers e, apply the brake s lightly for stopping. 4. A void turning at sharp angle s in reve rse .
71 OPERATION Driving Safely P a r k i n go na nI n c l i n e A void parking on a n incline if possible. If it’ s unavoidable , follow th es e precau ti o ns : 1. T urn the engine of f. 1. Place the tr ansmission in park. 2. Set t he park ing brake .
72 OPERATION PV T S ystem The basic ope ration of the Polaris PVT system is dependent on engine sp eed an d v ehi cl e to rqu e requ irem en ts . As engi n e sp eed i n creases , th e for ce exe rted on the movable drive shea ve by the flyweights also incr ease s.
73 OPERATION PV T S ystem PVT Dryi n g There m ay be so me i ns tan ces when wat er i s accid ent l y i ng est ed i nt o the PVT system. Use the following instruc tions to dry it out befor e oper ating: 1. Remove the dr ain plug and allow the wa ter to dra in.
74 EMISSION C O NT RO L SYSTEMS Noise E m ission C ontrol S ystem Do not modify the engine, i ntake o r exha ust components, as doing so may af fe ct complia nce with sta te and loca l noise level re quire ments.
75 MAINTENANCE AND LUBRICATION Accessor ies Po laris has a wi de range of acces sori es avai labl e for your A TV . Auxilia ry power outle ts provide 12V power f or oper ating acces so ri es such a s hand held spot lights. Acc essory outle ts ar e ava ilable for a ll models.
76 MAINTENANCE AND LUBRICATION Per i odic Maintenance S chedul e Hours of ope ration a re based o n a 10 mph ave rage . If ser vice is due a t 20 hours, the e quivalent odome ter r eading w ould be 200 mile s. P erform al l serv i ces at whi chever readi ng i s reached fi rst .
77 MAINTENANCE AND LUBRICATION Per i odic Maintenance S chedul e Item Hours/ Mile s Fr equency Remarks T a illig h t/b rak e lig h t Pre- Ride Pr e-Ri de Check operat ion daily; ap- ply P olar is di e.
78 MAINTENANCE AND LUBRICATION Per i odic Maintenance S chedul e Item Hours/ Mile s Fr equency Remarks Carbur etor f loat bowl 50 hr s. 6 m onths Drai n bowl periodi call y and pri or to stor age J Throt tle C able/ ETC Swit ch 50 hr s. 6 mont hs Inspect; adj ust; lubr icate; r eplace if necessar y L Choke (enr icher) cable 50 hr s.
79 MAINTENANCE AND LUBRICATION Per i odic Maintenance S chedul e Item Hours/ Mile s Fr equency Remarks J L Fuel system 100 hr s. 12 mont hs Check f or l eaks at t ank cap, li nes, f uel valve, f il ter , pump and car buret or ; r e- place l ines ever y t wo years J Fuel fi l ter 100 hr s.
80 MAINTENANCE AND LUBRICATION Lubr icati on Rec omm endations NOTE: Hour s are base d on 10 mph aver age. If serv ice is due a t 20 hours, the e quivalent odome ter r eading w ould be 200 mile s. Per form all s ervi ces at wh ich ever readi n g is r eached fi rst .
81 MAINTENANCE AND LUBRICATION Per iodic Maint enance Record Use t he fo l lo wi ng chart to record peri od i c mai n ten ance. Maintenance In t erval Perfo rmed Se rv icing Date Se rv icing Dealer or Pe rs on Remarks 10 hrs.
82 MAINTENANCE AND LUBRICATION Lubr ication R ecom m endations Pr emium 4 Synthetic Oil Polaris Pre mium 4 All S ea son Synthetic e ngine oil has be en spec ially for mulate d for use in Polar is 4-cyc le engine s.
83 MAINTENANCE AND LUBRICATION Lubr ication R ecom m endations Oil and F ilter Change - A T P 500 4x4 The r ecomme nded oil c hange inte rva l is 100 hours, 1000 miles, or eve ry six months, whic heve r c omes fir st. S uggeste d bre ak- in oil cha nge is at 20 hours, 200 mile s, or one month, whic heve r c omes first.
84 MAINTENANCE AND LUBRICATION Lubr ication R ecom m endations Oil and F ilter Change - A T P 500 4x4 4. Place a dr ain pa n bene ath the oil tank a nd remove the dr ain plug (1) . Allow the oil to dra in co mplete ly . 5. Insta ll a new se aling wa sher ( 2) on the oil dra in plug.
85 MAINTENANCE AND LUBRICATION Lubr ication R ecom m endations Oil and F ilter Change - A T P 500 4x4 8. Place shop towels benea th the oil f ilter . Using an o il filte r wre nch, turn the filter (1) c ounterc lockwise and re move. 9. Lubric ate the gasket on the new f ilter with a film of new e ngine oil.
86 MAINTENANCE AND LUBRICATION Lubr ication R ecom m endations Oil and F ilter Change - A T P 330 4x4 1. Obta in the c orre ct oil filte r and a n ade quate supply of oil so the oil and f ilter c hange ca n be c ompleted w ithout interr uption. 2. Position the vehicle on a leve l surf ace.
87 MAINTENANCE AND LUBRICATION Lubr ication R ecom m endations Oil and F ilter Change - A T P 330 4x4 8. Reinstall the dr ain plug and tor que to 14 ft. lbs. (19 Nm). 9. Plac e shop towe ls bene ath the oil f ilter . Using an oil filte r wr enc h, turn the filte r counter clockw ise to remove.
88 MAINTENANCE AND LUBRICATION Lubr ication R ecom m endations T ransmission Oil Check The tra nsmission lubrica nt l eve l should be chec ked eve ry six months or 1000 mile s (1600 km), whiche ver c omes f irst. T ransmission oil should be cha nged a nnually .
89 MAINTENANCE AND LUBRICATION Lubr ication R ecom m endations Front Gearcase Oil Check The f ront gea rc ase oil level should be che cke d eve ry six months or 1000 miles (1600 km), whiche ver c omes first. The oil should be cha nged annua lly . W e rec ommend the use of Polar is Premium Hub Drive Fluid.
90 MAINTENANCE AND LUBRICATION Lubr ication R ecom m endations Rear Gear case Oil Check W it h th e A TV o n a l ev el s u rface, re move the fill plug and view the oil leve l through the fill hole (1). Lubric ant should be ke pt eve n with the bottom of the fill hole.
91 MAINTENANCE AND LUBRICATION Engi ne C ooling S ystem Oil Cooler (A TP 330) The oil cooling system re quire s little maintena nce o ther than to make sure the c ooler is kept free of mud and deb ris. C hange the e ngine oil as re comme nded in the maintena nce sc hedule .
92 MAINTENANCE AND LUBRICATION Engi ne C ooling S ystem Radiator Coolant Level (A TP 500) NOTE: This pr ocedur e is re quired only if the c ooling system has be en dra ined for mainte nanc e and/or re pair . Howe ver , if the rec overy bottle has run dry , the leve l in t he radia tor should be inspe cted a nd coolant added i f neces sary .
93 MAINTENANCE AND LUBRICATION Adju stments Br akes The front bra kes are hydr aulic disc bra kes, activa ted by moving the brak e lev er t oward th e han dl ebar . T hes e brak es are s el f-adj us t i ng . The fo l lo wi ng checks are recom m end ed t o keep t h e brak e sy st em in good oper ating condition.
94 MAINTENANCE AND LUBRICATION Adju stments Auxiliary Brake The auxilia ry brak e is a hydraulic disc br ake . The re ar br ake system is self -adjusting a nd re quires no ma int en ance o t her t h an p eri od i c check s of t he p ads for wear . Pads should be c hanged w hen wor n to 3/64 ″ (.
95 MAINTENANCE AND LUBRICATION Adju stments T oe Alignm ent Use the following proce dure to chec k the toe alignment of the vehicle. The re comme nded toe alignment is 1/8 ″ to 1/4 ″ toe out. 1. Set t he handle bars in a stra ight-ahe ad position.
96 MAINTENANCE AND LUBRICATION Adju stments Steer ing Assembly The ste ering a ssembly of the A TV should be che cke d periodic ally fo r loose nuts and bolts. If loose nuts and bolts are found, see your Polar is dea ler for ser vice bef ore ope rating the vehicle .
97 MAINTENANCE AND LUBRICATION Adju stments Handlebars If des ired , t he han dl eb ars can be adj u st ed fo r ri der p reference. 1. Rem o ve t h e i ns t rum en t p anel an d l o cate th e han dl ebar b ol t s (1). 2. Loosen the four bolts a nd adjust the handle bar to the desire d height.
98 MAINTENANCE AND LUBRICATION Adju stments Ca rbur etor IMPOR T ANT : Y our Polar is A TV is calibr ate d at the f ac tory for optimal pe rfor manc e at a ltitudes ra nging from z ero to 6,000 fe et (1800 m) and temper ature s of +40 degree s F . (4 degree s C .
99 MAINTENANCE AND LUBRICATION Adju stments Thr ottle Ca ble Fre eplay Thr ottle ca ble fre ep lay is adjuste d at the handleb ar . 1. Slide the boots (1) of f the inline ca ble adjuste r sleeve ( 2). Loosen the adjuste r locknut (3). 2. T urn the adjuster until 1/16 ″ to 1/8 ″ freepl ay is ach i eved at t h e th um b l ev er .
100 MAINTENANCE AND LUBRICATION Adju stments S ide Pa nel Rem oval NOTE: Side panel r emova l may be dif fic ult until the locking tabs a nd receiv ers hav e been sn app ed and un s napp ed a few times. 1. Remove the sea t. 2. Grasp the rea r of the side pan el n ear t he rear cab .
101 MAINTENANCE AND LUBRICATION Adju stments Wheel Rem oval 1. Stop the engine , place the tra nsmission in par k and lock the par king brake . 2. Loosen the whe el nuts slightly . 3. Eleva te the side of the vehicle by pla cing a suitable stand under the foot res t frame.
102 MAINTENANCE AND LUBRICATION Adju stments Wheel Installation 1. W ith the tra nsmission in par k and the pa rking bra ke locked, place the wheel on t he wheel h ub with the valve ste m towar d the outside and rota tion ar rows on the tire pointing toward f orward rota tion.
103 MAINTENANCE AND LUBRICATION Adju stments Fr ont Wheel H ub Ti ghtening Front whee l bear ing tightness and spindle nut re tention ar e c ritica l compone nt opera tions. All servic e must be per forme d by your aut ho ri zed P ol ari s d ealer . Ti re T r ead Dept h Alway s repl ace ti res when t read depth is wor n to 1/8 ″ (.
104 MAINTENANCE AND LUBRICATION Filter System s Air Filter Service 1. Rem o ve t h e seat , rel eas e t he clips, and re move the air box cove r . 2. Loose n the cla mp and re move the filte r . 3. Remove the f abr ic type pre-f ilter (1) f rom the main filte r (2) .
105 MAINTENANCE AND LUBRICATION Lights Whe n ser vicing a ha logen la mp, don’ t touch the la mp with bare finger s. Oil from your skin lea ves a re sidue, ca using a hot spot tha t will shorten the life o f the lamp. Headlight L amp Replacem ent 1.
106 MAINTENANCE AND LUBRICATION Lights High Beam Adju st ment The h eadlight be am ca n be a djusted to a ny position desir ed by turning the adjusting knob on the bottom right side of the headlight pod. 1. Position the vehicle on a leve l surfa ce with the he adlight appr oximate ly 25 ft.
107 MAINTENANCE AND LUBRICATION Lights Headlight Hou sing Replacement 1. Remove the thre e scre ws on the headlight pod. 2. Using a sma ll flat-bla de sc re wdrive r , push in on t he loc k tabs through the two small ope nings at the front of the he adlight pod.
108 MAINTENANCE AND LUBRICATION Lights T ailligh t/Brakelight Lamp Replacement If the t aillight/br akelight doe s not work, the la mp may ne ed to be repl aced. 1. Remove the tw o scre ws secu ring the lens assembly . 2. Pivot the assembly outward. 3.
109 MAINTENANCE AND LUBRICATION Spar k P l ugs S Use the rec ommende d s par k plugs for your model (see SPECIFICA TIONS beginning on page 126). S Make sur e the elec trode gap mee ts specific ations for your model. S T orque spar k plugs to 14 ft. l bs.
11 0 MAINTENANCE AND LUBRICATION V eh ic le Imme rsio n If it’ s impossible to take your A TV to a deale r bef ore star ting it, follow the steps outlined below . 1. Move the A TV to dry land or at t he very lea st, to wate r below the f oot rests. 2.
111 MAINTENANCE AND LUBRICATION Spar k A r r estor 1. Remove the ar restor c lean- out plug(s) (1 ) from the bottom of t he muf fler . 2. Place the tr ansmission in P ARK and star t the engine. 3. Pur ge car bon from the system by momenta rily re vving the e ngine seve ra l times.
11 2 MAINTENANCE AND LUBRICATION Recoil Hou sing T o preve nt possible engine dama ge, always dr ain the re coil housing (1) af ter oper ating the A TV in very w et conditions.
11 3 MAINTENANCE AND LUBRICATION Batter y Batt ery Remo val 1. Disconne ct the ba tter y hold-down stra p and re move the ba tter y cover . 2. Dis con nect t he b lack (neg ati v e) bat t ery cab le fi rs t . 3. Disconne ct the re d (positive) ba tter y cab le next.
11 4 MAINTENANCE AND LUBRICATION Batter y Batter y Stor age Whe neve r the vehic le is not used for a pe riod of three months or more, remo ve t he b at tery from t he v ehi cl e, ens ure t hat i t ’ s fu l ly charged, and st or e it o ut o f th e sun i n a cool , d ry pl ace.
11 5 MAINTENANCE AND LUBRICATION Batter y Batt ery Ch argi ng NOTE: A lways ver ify batte ry condition be fore and 1- 2 hours af ter the end of cha r ging. Stat e of Char ge Vo l t a g e Action Char ge Ti me* (Us ing c onstant c ur rent char ger @ s tandar d amps spec ified on top of battery ) 100% 12.
11 6 MAINTENANCE AND LUBRICATION Cleaning a nd Stor age See page 121 for the pa rt numbers of P olar is products. Cleaning th e A T V Kee ping your A TV c lea n will not only improve its appe ara nce but it ca n also e xtend the life o f var ious compone nts.
11 7 MAINTENANCE AND LUBRICATION Cleaning a nd Stor age Sto ra g e Tip s See page 121 for the pa rt numbers of P olar is products. Clean t he Exterio r Make nec essa ry re pairs a nd then c lean the A TV thoroughly w ith mild soap a nd war m wate r to re move all dir t and grime .
11 8 MAINTENANCE AND LUBRICATION Cleaning a nd Stor age Sto ra g e Tip s See page 121 for the pa rt numbers of P olar is products. Fog the E ngine Remove the spar k plug and a dd 2-3 table spoons of Pre mium 4 S ynthetic 0W4 0 en gi n e oi l .
11 9 MAINTENANCE AND LUBRICATION Cleaning a nd Stor age Sto ra g e Tip s Batte r y Stor ag e Remove the ba ttery fr om t he vehic le and ensure tha t it’ s fully char ged bef ore plac ing it in storage . S ee pa ge 1 14 for instructions. Engi ne Anti -Freeze T est engine coola nt strength and c hange if ne cessa ry .
120 -N O T E S -.
121 POLARIS PRODUCTS Part No. Descr ipt ion Engine Lubr icant 2870791 Fogging O il ( 12 oz. Aer osol) 2871098 Prem ium 2- Cycle Engi ne Oil (qt .) 2871721 Prem ium G old Synt heti c 2-Cycl e Oi l ( qt. ) 2871281 Prem ium 4 Synt hetic 0W -40 Engi ne Oi l ( 4-Cycl e)( qt.
122 TROUB LES HOOTI NG Dr ive Belt and Cover Pr o blems Po ssi b l e Cause Solution Dr ivi ng the A TV ont o a p ick u p o r tall trailer in hi gh ra nge . Shi ft tr a nsm is s ion t o l ow ra nge dur i ng loa di ng of t he A TV t o pre vent be lt bur ning.
123 TROUB LES HOOTI NG Contac t your P olar is deale r for se rvice if you’ re una ble to i dentif y solutions using the follow ing cha rts. Engine Doesn’t T u rn Over Po ssi bl e Cause Sol uti o n Trip p ed circu it b reak er Reset th e b reak er Lo w battery v o ltage Re cha r ge ba tt e ry t o 12.
124 TROUB LES HOOTI NG Engine Backfir es Po ssi bl e Cause Sol uti o n W ea k spa r k fr om s pa rk pl ugs In sp ect, clean and /o r repl ace sp ark p lu g s In co rrect spark p lu g g ap o r h eat ra.
125 TROUB LES HOOTI NG E ngine St ops or Lose s Powe r Po ssi bl e Cause Sol uti o n Out of fuel Tu rn fu el valv e to reserve, refuel Ki nked or pl ugged fue l vent l ine In sp ect an d rep lace W at.
126 SPECIFIC AT ION S A TP 330 4x4 Gro ss V eh icle W eigh t 1300 lbs ./ 590 kg Fu el Cap acity 3.25 ga l. /12. 3 l Hitch T o w in g R atin g 1 000 l bs ./ 454 k g Un b raked Trailer T o w in g C ap acity * 1585 lbs ./ 719 kg Hi tc h T ongue Capa c it y 1 0 0 lb s.
127 SPECIFIC AT IO NS A TP 330 4x4 Shi ft T ype Side Le ver (Hig h , Lo w , N eu tral, R ev erse, Park ) Gear R ed u ctio n - L o w 1 1.57: 1 Ge ar Re duct ion - Reve r se 6.84: 1 Ge a r Reduc t ion - High 4.41: 1 Driv e R atio - F ro n t: 3.7: 1 Driv e R atio - F in al 3.
128 SPECIFIC AT IO NS A TP 500 4x4 Gro ss V eh icle W eig h t 1500 l bs. / 680 kg F u el Cap acity 3. 25 ga l. / 12.3 l T o w in g R atin g 1225 l bs. /556 kg Un brak ed Trailer T o w in g C ap acity * 1847 lbs ./ 838 kg Hi tc h T ongue Capa c it y 1 2 0 lb s.
129 SPECIFIC AT IO NS A TP 500 4x4 Shi ft T ype Side Le ver (Hig h , Lo w , N eu tral, R ev erse, Park ) Gear R ed u ctio n - L o w 8.66: 1 Ge ar Re duct ion - Reve r se 5.12: 1 Ge a r Reduc t ion - High 3.52: 1 Driv e R atio - F ro n t: 3.7: 1 Driv e R atio - F in al 3.
130 WARRANTY LIM IT ED W ARRANTY Pol ar i s Indus tr ie s Inc . , 2100 Highwa y 55, Me dina , MN 55340, give s a SI X MONTH LI M- I TED W ARRANTY on a ll c ompone nts of the Pol ar is All T er ra in V ehi cl e (A TV) a ga ins t d e - f ec ts i n ma te ri al or wor kma ns hip.
131 WARRANTY LIM IT A T IONS OF W ARRANTIES AND REM EDIES ALL IM PLIED W ARRANTIES ( IN CLUDING BUT NOT LIMI TED T O THE IMPLI ED W ARRANTIES OF MERCHANT ABILI TY AND FITNESS FOR A P AR TICULAR PURPOSE) ARE LI MI TED IN DURA TION TO THE ABOVE SIX MONTH W ARRAN- TY PERI OD.
132 WARRANTY Exported V ehicles EXCEPT WHERE SPECI FICALL Y REQUIRED BY LA W , THERE I S NO W ARRANTY OR SER VICE BULLETI N COVERAGE ON THI S VEHICLE I F IT I S SOLD OUTSI DE THE COUNTR Y OF THE SELLING DEALER’ S AUTHORIZED LOCA TION.
133 WARRANTY Ca lifor nia E mi ssion C ontrol W arr anty State ment Y our W a rra nty Rights a nd Obliga tions The Ca li for nia Air Res ourc e s Boa rd a nd Pola ri s I ndust ri es Inc .
134 WARRANTY Ca lifor nia E mi ssion C ontrol W arr anty State ment W a rranty Per iod Thi s war ra nt y per iod be gins on the da te , whic h the LSI e ngi ne is de l ive re d, to the or igi - n al retail p u rch aser an d en d s two y ears after th at d ate.
135 WARRANTY Ca lifor nia E mi ssion C ontrol W arr anty State ment What is Not Cove re d Unde r Thi s W a rranty Thi s wa rr a nty doe s not cove r a ny em is s ion- r el at ed pa rt , w hic h mal f unct ions , f a il s, or i s da ma ged due to al te ra ti ons and/ or modif i ca ti ons suc h as c hangi ng, addi ng, or re moving pa rt s .
136 WARRANTY Ca lifor nia E mi ssion C ontrol W arr anty State ment Mai nte nanc e S c he dule Item H rs /M iles Wh en Remarks b Air filte r pr e-cl eaner Da ily Da ily Inspect , clean b Air filte r m ain elem ent W eekly W eekly I nspect, r eplace if necessar y b Engine br eather filter 20 hrs.
137 INDEX A Accessori es 75 ...................... Adj ustments 93-103 ................. Age R estrictio ns 7 ................... Air F ilter 104 ....................... All W h ee l Dr i v e 4 7 .................. Auxiliary Brake 42, 94 .............
138 INDEX N Noi se Em ission Cont rol Syst em 74 ...... O O dometer 50 ....................... Oi l and F ilter Change (A TP 330) 86-87 .. Oi l and F ilter Change (A TP 500) 83-85 .. Oi l C ooler (A TP 330) 91 .............. OP ER A T ION 53-73 ......
An important point after buying a device Polaris ATP 330 4x4 (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Polaris ATP 330 4x4 yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Polaris ATP 330 4x4 - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Polaris ATP 330 4x4 you will learn all the available features of the product, as well as information on its operation. The information that you get Polaris ATP 330 4x4 will certainly help you make a decision on the purchase.
If you already are a holder of Polaris ATP 330 4x4, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Polaris ATP 330 4x4.
However, one of the most important roles played by the user manual is to help in solving problems with Polaris ATP 330 4x4. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Polaris ATP 330 4x4 along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
