Owners Manual
Page 14
... that may increase the speed or power of the vehicle, or make any modifications have reduced stopping ability. Any modifications to dry out the pads. Use only Polaris-approved accessories, and familiarize yourself with their function and effect on your brakes after leaving water. Operator Safety SAFETY S Wet brakes may change the handling characteristics of the vehicle. The warranty on the vehicle. 11 Cargo must be...
... that may increase the speed or power of the vehicle, or make any modifications have reduced stopping ability. Any modifications to dry out the pads. Use only Polaris-approved accessories, and familiarize yourself with their function and effect on your brakes after leaving water. Operator Safety SAFETY S Wet brakes may change the handling characteristics of the vehicle. The warranty on the vehicle. 11 Cargo must be...
Owners Manual
Page 38
... drive shaft and clutch damage. Under seat: ATP 500 35 Do not operate vehicle without 40_ to 80_ F. See your Owner's in dusty conditions. at 0-3000 feet pre-filter. (5_ to engage AWD if the rear wheels are required S Clean pre-filter element often, depending on temperature and altitude. Do not Manual. engine damage. DATE: VIN: D ALL WHEEL DRIVE SWITCH Do not push switch to 27_ C. operate vehicle without the air filter...
... drive shaft and clutch damage. Under seat: ATP 500 35 Do not operate vehicle without 40_ to 80_ F. See your Owner's in dusty conditions. at 0-3000 feet pre-filter. (5_ to engage AWD if the rear wheels are required S Clean pre-filter element often, depending on temperature and altitude. Do not Manual. engine damage. DATE: VIN: D ALL WHEEL DRIVE SWITCH Do not push switch to 27_ C. operate vehicle without the air filter...
Owners Manual
Page 46
...: For vehicle storage and when transporting. RES OFF ON 2 Fuel Tank The fuel tank filler cap (2) is exhausted. 1 NOTE: There's about a 7 to 10 mile (11.2 to clean the fuel filter. 43 Always refill the gas tank as soon as possible after refueling. Always return valve to the engine starting procedure on the left side panel. Choke FEATURES AND CONTROLS The choke assists in -line fuel filter should be replaced by your...
...: For vehicle storage and when transporting. RES OFF ON 2 Fuel Tank The fuel tank filler cap (2) is exhausted. 1 NOTE: There's about a 7 to 10 mile (11.2 to clean the fuel filter. 43 Always refill the gas tank as soon as possible after refueling. Always return valve to the engine starting procedure on the left side panel. Choke FEATURES AND CONTROLS The choke assists in -line fuel filter should be replaced by your...
Owners Manual
Page 48
... high/park lock-out mechanism. If towing the vehicle is necessary, shift the transmission into neutral for extended periods of HIGH or PARK, it's not necessary to the desired gear. When shifting out of time. H: High Gear L: Low Gear N: Neutral R: Reverse P: Park 1 H L N R P FEATURES AND CONTROLS To shift into high gear or park. Apply the auxiliary brake before attempting to the belt. 45 To change gears, stop the vehicle, and with the engine speed above idle or while the vehicle is...
... high/park lock-out mechanism. If towing the vehicle is necessary, shift the transmission into neutral for extended periods of HIGH or PARK, it's not necessary to the desired gear. When shifting out of time. H: High Gear L: Low Gear N: Neutral R: Reverse P: Park 1 H L N R P FEATURES AND CONTROLS To shift into high gear or park. Apply the auxiliary brake before attempting to the belt. 45 To change gears, stop the vehicle, and with the engine speed above idle or while the vehicle is...
Owners Manual
Page 50
... the length of Demand 4 Drive (AWD) in two wheel drive at rest. 47 All Wheel Drive (AWD) System FEATURES AND CONTROLS Polaris 4 wheel drive ATVs are spinning, release the throttle before getting into conditions where front wheel drive may be turned on or off while the vehicle is moving , it will not enable the AWD until the engine RPM is locked. See page 37. Initially, the vehicle's electronic system will not disengage until the rear wheels...
... the length of Demand 4 Drive (AWD) in two wheel drive at rest. 47 All Wheel Drive (AWD) System FEATURES AND CONTROLS Polaris 4 wheel drive ATVs are spinning, release the throttle before getting into conditions where front wheel drive may be turned on or off while the vehicle is moving , it will not enable the AWD until the engine RPM is locked. See page 37. Initially, the vehicle's electronic system will not disengage until the rear wheels...
Owners Manual
Page 52
.../Tripmeter/ Hour Meter 7. AWD Indicator - Driving at start-up for proper diagnosis. 1. Instrument Cluster FEATURES AND CONTROLS Rider Information Center The rider information center is located in : 4 H = High Range 6 5 3 L = Low Range N = Neutral 7 R = Reverse P = Park (if equipped) 2 2. Service Interval/Diagnostic Mode Indicator 5. If this indicator shows the gear the transmission is being operated at idle and high electrical load (lights, cooling fan, accessories) is overheating. Engine Hour Display Indicator 1 8 4. Gear Indicator - Check Engine Warning Indicator -
.../Tripmeter/ Hour Meter 7. AWD Indicator - Driving at start-up for proper diagnosis. 1. Instrument Cluster FEATURES AND CONTROLS Rider Information Center The rider information center is located in : 4 H = High Range 6 5 3 L = Low Range N = Neutral 7 R = Reverse P = Park (if equipped) 2 2. Service Interval/Diagnostic Mode Indicator 5. If this indicator shows the gear the transmission is being operated at idle and high electrical load (lights, cooling fan, accessories) is overheating. Engine Hour Display Indicator 1 8 4. Gear Indicator - Check Engine Warning Indicator -
Owners Manual
Page 56
... Oil for the engine. Careful treatment of gasoline. Fill the fuel tank with vehicle operation and handling. 4. Select an open area that allows room to familiarize yourself with ADD 8 OZ. Do not operate at 20 hours or 200 miles. 53 See page 43. 2. Drive slowly at full throttle or high speeds for a proper break-in. Perform regular checks on fluid levels, controls and...
... Oil for the engine. Careful treatment of gasoline. Fill the fuel tank with vehicle operation and handling. 4. Select an open area that allows room to familiarize yourself with ADD 8 OZ. Do not operate at 20 hours or 200 miles. 53 See page 43. 2. Drive slowly at full throttle or high speeds for a proper break-in. Perform regular checks on fluid levels, controls and...
Owners Manual
Page 60
... rack and cargo bed, but do not exceed the stated load capacity. S Always attach the tow load to maintain stable driving conditions. Hauling Cargo OPERATION WARNING Overloading the vehicle or carrying or towing cargo improperly can alter vehicle handling and may cause an imbalanced condition and increases the possibility of vehicle overturn. S Use extreme caution when applying brakes with loads extending beyond the rack or cargo bed. Vehicle speed...
... rack and cargo bed, but do not exceed the stated load capacity. S Always attach the tow load to maintain stable driving conditions. Hauling Cargo OPERATION WARNING Overloading the vehicle or carrying or towing cargo improperly can alter vehicle handling and may cause an imbalanced condition and increases the possibility of vehicle overturn. S Use extreme caution when applying brakes with loads extending beyond the rack or cargo bed. Vehicle speed...
Owners Manual
Page 61
... not tow any trailer on the warning labels, and never exceed the specified weights. When operating over rough or hilly terrain, reduce speed and cargo to extend belt life. 58 Unintentional box tilting will result if weight is placed in the rear of load. Always operate the vehicle with the load as far forward as possible. Towing Load (Level Ground) ATP 330 4x4 ATP 500 4x4 1000...
... not tow any trailer on the warning labels, and never exceed the specified weights. When operating over rough or hilly terrain, reduce speed and cargo to extend belt life. 58 Unintentional box tilting will result if weight is placed in the rear of load. Always operate the vehicle with the load as far forward as possible. Towing Load (Level Ground) ATP 330 4x4 ATP 500 4x4 1000...
Owners Manual
Page 79
... Pre-Ride Pre-Ride Pre-Ride Pre-Ride Pre-Ride L Pre-cleaner Coolant level Fuel and oil tanks Throttle Lights Engine stop switch Steering " Air box sediment tube Headlamp 76 Item Brake System Auxiliary Brake Tires Wheels Frame nuts, bolts, fasteners Dump Box Latch " Air filter, Hours/ Miles Frequency Remarks Inspect Inspect Inspect Inspect Inspect Inspect; Perform all services at whichever reading is due at 20 hours, the equivalent odometer reading...
... Pre-Ride Pre-Ride Pre-Ride Pre-Ride Pre-Ride L Pre-cleaner Coolant level Fuel and oil tanks Throttle Lights Engine stop switch Steering " Air box sediment tube Headlamp 76 Item Brake System Auxiliary Brake Tires Wheels Frame nuts, bolts, fasteners Dump Box Latch " Air filter, Hours/ Miles Frequency Remarks Inspect Inspect Inspect Inspect Inspect Inspect; Perform all services at whichever reading is due at 20 hours, the equivalent odometer reading...
Owners Manual
Page 82
... months 12 months 12 months 12 months 24 months 36 months Radiator (500) Cooling system hoses (500) " Front gearcase J Clutches (drive and driven) Engine mounts J Valve clearance L J Brake fluid Spark arrestor " Rear axle As required Inspect bearings if axle has ingested water or if unusual noises are replaced As required Adjust as needed L Idle speed Recoil housing J Toe adjustment Headlight aim " More often under severe use, such as needed As required...
... months 12 months 12 months 12 months 24 months 36 months Radiator (500) Cooling system hoses (500) " Front gearcase J Clutches (drive and driven) Engine mounts J Valve clearance L J Brake fluid Spark arrestor " Rear axle As required Inspect bearings if axle has ingested water or if unusual noises are replaced As required Adjust as needed L Idle speed Recoil housing J Toe adjustment Headlight aim " More often under severe use, such as needed As required...
Owners Manual
Page 87
... the rear side of burrs, nicks or scratches. 6. Reattach the oil line. ATP 500 4x4 4. NOTE: The sealing surfaces on the drain plug and the oil tank should be sealed with the mark (4) on the oil drain plug. NOTE...oil tank and remove the drain plug (1). Disconnect the lower oil delivery hose and remove 2 the screen fitting (3) from 1 the oil tank. Clean and reinstall the fitting, 3 4 torquing to 14-17 ft. The fitting must be clean and free of the oil tank. 84 Allow the oil to drain completely. 5. lbs. MAINTENANCE AND LUBRICATION Lubrication Recommendations Oil and Filter Change...
... the rear side of burrs, nicks or scratches. 6. Reattach the oil line. ATP 500 4x4 4. NOTE: The sealing surfaces on the drain plug and the oil tank should be sealed with the mark (4) on the oil drain plug. NOTE...oil tank and remove the drain plug (1). Disconnect the lower oil delivery hose and remove 2 the screen fitting (3) from 1 the oil tank. Clean and reinstall the fitting, 3 4 torquing to 14-17 ft. The fitting must be clean and free of the oil tank. 84 Allow the oil to drain completely. 5. lbs. MAINTENANCE AND LUBRICATION Lubrication Recommendations Oil and Filter Change...
Owners Manual
Page 89
... burns. CAUTION 1. Stop the engine. ATP 330 4x4 If the ATV is left without interruption. 2. MAINTENANCE AND LUBRICATION Lubrication Recommendations Oil and Filter Change - Obtain the correct oil filter and an adequate supply of draining the oil. Clean the area around the drain plug on a level surface. 3. Run the engine for extended periods, the oil pump may result in engine damage. Do not allow the vehicle to drain completely. 7.
... burns. CAUTION 1. Stop the engine. ATP 330 4x4 If the ATV is left without interruption. 2. MAINTENANCE AND LUBRICATION Lubrication Recommendations Oil and Filter Change - Obtain the correct oil filter and an adequate supply of draining the oil. Clean the area around the drain plug on a level surface. 3. Run the engine for extended periods, the oil pump may result in engine damage. Do not allow the vehicle to drain completely. 7.
Owners Manual
Page 90
ATP 330 4x4 MAINTENANCE AND LUBRICATION 8. Remove the dipstick and fill the sump with a film of Polaris Premium 4 synthetic oil. 14. Start the engine and let it idle for leaks. 16. Using an oil filter wrench, turn . 13. Place the gear selector in good condition. 12. Stop the engine and inspect for one to remove. 10. Using a clean, dry cloth, clean the filter sealing surface on the new...
ATP 330 4x4 MAINTENANCE AND LUBRICATION 8. Remove the dipstick and fill the sump with a film of Polaris Premium 4 synthetic oil. 14. Start the engine and let it idle for leaks. 16. Using an oil filter wrench, turn . 13. Place the gear selector in good condition. 12. Stop the engine and inspect for one to remove. 10. Using a clean, dry cloth, clean the filter sealing surface on the new...
Owners Manual
Page 91
.... 3. Check for the part numbers of Polaris products. Transmission oil should be changed annually. 1 1. Use the gearcase oil fill chart and the following illustration to 14 ft. NOTE: When adding oil, use Polaris Premium Synthetic Gearcase Lubricant. Gearcase Oil Fill Chart Model ATP 500 4x4 ATP 330 4x4 Oil Level "A" 1 5/8″ 1 5/8″ Capacity 13.5 oz. (400 ml) 13.5 oz. (400 ml) 1. Position the ATV on the...
.... 3. Check for the part numbers of Polaris products. Transmission oil should be changed annually. 1 1. Use the gearcase oil fill chart and the following illustration to 14 ft. NOTE: When adding oil, use Polaris Premium Synthetic Gearcase Lubricant. Gearcase Oil Fill Chart Model ATP 500 4x4 ATP 330 4x4 Oil Level "A" 1 5/8″ 1 5/8″ Capacity 13.5 oz. (400 ml) 13.5 oz. (400 ml) 1. Position the ATV on the...
Owners Manual
Page 129
SPECIFICATIONS ATP 330 4x4 Gross Vehicle Weight Fuel Capacity Hitch Towing Rating Unbraked Trailer Towing Capacity* Hitch Tongue Capacity Front Rack & Compartment Capacity Rear Box Capacity Overall Length Overall Width Overall Height Wheelbase Ground Clearance Dry Weight Minimum Turning Radius Engine Oil Capacity Engine Displacement Bore x Stroke Pilot Jet Main Jet Needle Jet Jet Needle Pilot Screw Alternator Output Compression Ratio Starting System Carburetor Ignition System Ignition Timing Spark Plug / Gap Lubrication System Driving System Type * Based on EU Directive 76/432/EC 1300 lbs./590...
SPECIFICATIONS ATP 330 4x4 Gross Vehicle Weight Fuel Capacity Hitch Towing Rating Unbraked Trailer Towing Capacity* Hitch Tongue Capacity Front Rack & Compartment Capacity Rear Box Capacity Overall Length Overall Width Overall Height Wheelbase Ground Clearance Dry Weight Minimum Turning Radius Engine Oil Capacity Engine Displacement Bore x Stroke Pilot Jet Main Jet Needle Jet Jet Needle Pilot Screw Alternator Output Compression Ratio Starting System Carburetor Ignition System Ignition Timing Spark Plug / Gap Lubrication System Driving System Type * Based on EU Directive 76/432/EC 1300 lbs./590...
Owners Manual
Page 130
Rear Tire Pressure- Rear Front/Rear Brakes Auxiliary Brake Parking Brake Headlight Taillights Brake Light Instrument Cluster Side Lever (High, Low, Neutral, Reverse, Park) 11.57:1 6.84:1 4.41:1 3.7:1 3.08:1 24 x 8 - 12 24 x 11 - 12 5 psi 5 psi Hydraulic Disc Hydraulic Disc Hydraulic lock, all wheel Hi/Low 30 watt Two 12v/2.88 watt Two 12v/16.8 watt LCD Clutching and Jetting Charts Altitude Meters (Feet) AMBIENT TEMPERATURE Below 40° F Below...
Rear Tire Pressure- Rear Front/Rear Brakes Auxiliary Brake Parking Brake Headlight Taillights Brake Light Instrument Cluster Side Lever (High, Low, Neutral, Reverse, Park) 11.57:1 6.84:1 4.41:1 3.7:1 3.08:1 24 x 8 - 12 24 x 11 - 12 5 psi 5 psi Hydraulic Disc Hydraulic Disc Hydraulic lock, all wheel Hi/Low 30 watt Two 12v/2.88 watt Two 12v/16.8 watt LCD Clutching and Jetting Charts Altitude Meters (Feet) AMBIENT TEMPERATURE Below 40° F Below...
Owners Manual
Page 131
SPECIFICATIONS ATP 500 4x4 Gross Vehicle Weight Fuel Capacity Towing Rating Unbraked Trailer Towing Capacity* Hitch Tongue Capacity Front Rack & Compartment Capacity Rear Box Capacity Overall Length Overall Width Overall Height Wheelbase Ground Clearance Dry Weight Minimum Turning Radius Engine Oil Capacity Coolant Capacity Engine Displacement Bore x Stroke Pilot Jet Main Jet Needle Jet Jet Needle Pilot Screw Alternator Output Compression Ratio Starting System Carburetor Ignition System Ignition Timing Spark Plug / Gap Lubrication System Driving System Type * Based on EU Directive 76/432/EC ...
SPECIFICATIONS ATP 500 4x4 Gross Vehicle Weight Fuel Capacity Towing Rating Unbraked Trailer Towing Capacity* Hitch Tongue Capacity Front Rack & Compartment Capacity Rear Box Capacity Overall Length Overall Width Overall Height Wheelbase Ground Clearance Dry Weight Minimum Turning Radius Engine Oil Capacity Coolant Capacity Engine Displacement Bore x Stroke Pilot Jet Main Jet Needle Jet Jet Needle Pilot Screw Alternator Output Compression Ratio Starting System Carburetor Ignition System Ignition Timing Spark Plug / Gap Lubrication System Driving System Type * Based on EU Directive 76/432/EC ...
Owners Manual
Page 136
... no cost to conform with those regulations as the carburetor and the ignition system. The warranty repairs should contact the Polaris Warranty Department at the time of manufacture so as to you retain all receipts covering maintenance on your 2004 and later Large Spark Ignition Engine (herein "LSI engine"). Owner's Warranty Responsibilities: S As the LSI engine owner, you warranty coverage if your LSI engine or a part has failed due to...
... no cost to conform with those regulations as the carburetor and the ignition system. The warranty repairs should contact the Polaris Warranty Department at the time of manufacture so as to you retain all receipts covering maintenance on your 2004 and later Large Spark Ignition Engine (herein "LSI engine"). Owner's Warranty Responsibilities: S As the LSI engine owner, you warranty coverage if your LSI engine or a part has failed due to...
Owners Manual
Page 141
... Towing Capacities ...58 Transmission Gear Selector ...45 Transmission Oil Check ...88 Transporting the ATV ...119 Trip Meter ...50 TROUBLESHOOTING ...122-125 Turning Around on a Hill ...66 P Parking Brake ...41 Parking on an Incline ...71 Periodic Maintenance Schedule ...75-79 POLARIS PRODUCTS ...121 Pre Ride Inspection ...54 Premium 4 Synthetic Oil ...82 PVT Drying ...73 PVT System ...72-73 R Radiator Coolant Level (ATP 500) ...92 Rear Gearcase Oil Change ...90 Rear Gearcase Oil Check ...90 Rear Spring...
... Towing Capacities ...58 Transmission Gear Selector ...45 Transmission Oil Check ...88 Transporting the ATV ...119 Trip Meter ...50 TROUBLESHOOTING ...122-125 Turning Around on a Hill ...66 P Parking Brake ...41 Parking on an Incline ...71 Periodic Maintenance Schedule ...75-79 POLARIS PRODUCTS ...121 Pre Ride Inspection ...54 Premium 4 Synthetic Oil ...82 PVT Drying ...73 PVT System ...72-73 R Radiator Coolant Level (ATP 500) ...92 Rear Gearcase Oil Change ...90 Rear Gearcase Oil Check ...90 Rear Spring...