Owners Manual
Page 14
... out the pads. Test your Polaris ATV is not in this manual for braking. Cargo must be properly distributed and securely attached. The warranty on your brakes after leaving water. Reduce speed and follow the instructions in use of accessories. NOTE: The addition of certain accessories, including (but not limited to the vehicle for your ATV, and always maintain tire pressure as recommended...
... out the pads. Test your Polaris ATV is not in this manual for braking. Cargo must be properly distributed and securely attached. The warranty on your brakes after leaving water. Reduce speed and follow the instructions in use of accessories. NOTE: The addition of certain accessories, including (but not limited to the vehicle for your ATV, and always maintain tire pressure as recommended...
Owners Manual
Page 48
... FEATURES AND CONTROLS The choke assists in -line fuel filter should be replaced by your dealer after using the reserve supply. Fuel Valve The fuel valve (1) is located on the left side of 87=(R+ M/2) octane. Refer to the specifications section beginning on reserve gas. Do not attempt to the ON position after refueling. 2 Fuel Tank The fuel tank filler cap (2) is exhausted. NOTE: There's about a 7 to 10 mile...
... FEATURES AND CONTROLS The choke assists in -line fuel filter should be replaced by your dealer after using the reserve supply. Fuel Valve The fuel valve (1) is located on the left side of 87=(R+ M/2) octane. Refer to the specifications section beginning on reserve gas. Do not attempt to the ON position after refueling. 2 Fuel Tank The fuel tank filler cap (2) is exhausted. NOTE: There's about a 7 to 10 mile...
Owners Manual
Page 49
... the brake. FEATURES AND CONTROLS Automatic Transmission Gear Selector The transmission gear selector (1) is moving could cause transmission damage. Apply the auxiliary brake before attempting to shift into HIGH or PARK, you experience any shifting problems. Belt Life To extend belt life, use low forward gear in PARK and lock the parking brake. When shifting out of the vehicle. 1 H: High Gear H N: Neutral L L: Low Gear R: Reverse N P: Park To shift into high gear or park. To change gears, stop the vehicle, and with the engine speed above idle or...
... the brake. FEATURES AND CONTROLS Automatic Transmission Gear Selector The transmission gear selector (1) is moving could cause transmission damage. Apply the auxiliary brake before attempting to shift into HIGH or PARK, you experience any shifting problems. Belt Life To extend belt life, use low forward gear in PARK and lock the parking brake. When shifting out of the vehicle. 1 H: High Gear H N: Neutral L L: Low Gear R: Reverse N P: Park To shift into high gear or park. To change gears, stop the vehicle, and with the engine speed above idle or...
Owners Manual
Page 51
.... Initially, the vehicle's electronic system will not enable the AWD until the engine RPM is moving , it will not disengage until the AWD switch is in AWD, the front gearcase will automatically disengage. FEATURES AND CONTROLS All Wheel Drive System (Domestic Models) Polaris 4 wheel drive domestic model ATVs are at all times. NOTE: HDS models do not have traction or are equipped with a unique, Polaris exclusive, All Wheel Drive (AWD) System activated...
.... Initially, the vehicle's electronic system will not enable the AWD until the engine RPM is moving , it will not disengage until the AWD switch is in AWD, the front gearcase will automatically disengage. FEATURES AND CONTROLS All Wheel Drive System (Domestic Models) Polaris 4 wheel drive domestic model ATVs are at all times. NOTE: HDS models do not have traction or are equipped with a unique, Polaris exclusive, All Wheel Drive (AWD) System activated...
Owners Manual
Page 53
... illuminate, a battery over-voltage may have occurred and the instrument cluster may also occur under normal operation if the machine is applied. Check Engine Warning Indicator - AWD Indicator - FEATURES AND CONTROLS Rider Information Center Instrument Cluster (Magnum 330 HDS/500) The rider information center is enabled. 3. Driving at an RPM too low to your Polaris dealer for 2.5 seconds at idle and high electrical load (lights, cooling fan, accessories) is at start-up...
... illuminate, a battery over-voltage may have occurred and the instrument cluster may also occur under normal operation if the machine is applied. Check Engine Warning Indicator - AWD Indicator - FEATURES AND CONTROLS Rider Information Center Instrument Cluster (Magnum 330 HDS/500) The rider information center is enabled. 3. Driving at an RPM too low to your Polaris dealer for 2.5 seconds at idle and high electrical load (lights, cooling fan, accessories) is at start-up...
Owners Manual
Page 55
... AWD coil (only on models with switchable AWD). To leave the diagnostic mode, either shift the machine out of the gauge. 52 The initial screen display refers to neutral. 3. Hold the mode/reverse override button and turn the key switch off and wait 10 seconds. 2. FEATURES AND CONTROLS Rider Information Center Instrument Cluster (Magnum 330 HDS/500) Diagnostic Mode The diagnostic mode is for all major repairs...
... AWD coil (only on models with switchable AWD). To leave the diagnostic mode, either shift the machine out of the gauge. 52 The initial screen display refers to neutral. 3. Hold the mode/reverse override button and turn the key switch off and wait 10 seconds. 2. FEATURES AND CONTROLS Rider Information Center Instrument Cluster (Magnum 330 HDS/500) Diagnostic Mode The diagnostic mode is for all major repairs...
Owners Manual
Page 58
... N = Neutral R = Reverse P = Park 5 1 E or blank = Error - Hour Meter 4. Driving at a higher RPM or connecting a battery charger will light up . 55 Gear Indicator - Do not continue to operate the ATV is this occurs take the ATV to keep the battery charged. If this warning appears or serious engine damage could result. 3. Service Interval/Miscellaneous Service Warnings 5. Instrument Cluster (Magnum 330) Rider Information Center FEATURES AND CONTROLS The rider information center...
... N = Neutral R = Reverse P = Park 5 1 E or blank = Error - Hour Meter 4. Driving at a higher RPM or connecting a battery charger will light up . 55 Gear Indicator - Do not continue to operate the ATV is this occurs take the ATV to keep the battery charged. If this warning appears or serious engine damage could result. 3. Service Interval/Miscellaneous Service Warnings 5. Instrument Cluster (Magnum 330) Rider Information Center FEATURES AND CONTROLS The rider information center...
Owners Manual
Page 61
... button to neutral. 3. NOTE: Any movement of the tires will remain lit. Screen two (2) is displayed briefly. If this needs adjustment, please contact your dealer. 2 As long as the center is for informational purposes only. FEATURES AND CONTROLS Rider Information Center Instrument Cluster (Magnum 330) Diagnostic Mode The diagnostic mode is in your dealer for all major repairs. Turn the key switch off...
... button to neutral. 3. NOTE: Any movement of the tires will remain lit. Screen two (2) is displayed briefly. If this needs adjustment, please contact your dealer. 2 As long as the center is for informational purposes only. FEATURES AND CONTROLS Rider Information Center Instrument Cluster (Magnum 330) Diagnostic Mode The diagnostic mode is in your dealer for all major repairs. Turn the key switch off...
Owners Manual
Page 62
...-in period for the engine. No single action on your 4-cycle engine. 1. Do not operate at first. Check the oil level on the daily pre-ride inspection checklist. Perform regular checks on fluid levels, controls and areas outlined on 1 the dipstick. NORMAL FULL gasoline. Pull only light loads. 7. Drive slowly at full throttle or high speeds for a proper break-in...
...-in period for the engine. No single action on your 4-cycle engine. 1. Do not operate at first. Check the oil level on the daily pre-ride inspection checklist. Perform regular checks on fluid levels, controls and areas outlined on 1 the dipstick. NORMAL FULL gasoline. Pull only light loads. 7. Drive slowly at full throttle or high speeds for a proper break-in...
Owners Manual
Page 77
OPERATION Hauling Cargo 1/3 2/3 Your ATV has been designed to extend belt life. 74 Cargo weight should be evenly distributed (1/3 on the front and 2/3 on the warning labels, and never exceed the specified weights. Belt Life Use low forward gear when hauling or towing heavy cargo to carry or tow a certain amount of load. When operating over rough or hilly terrain, reduce speed and cargo to maintain stable driving conditions. Always read and understand the load distribution warnings listed on the rear) and mounted as low as possible.
OPERATION Hauling Cargo 1/3 2/3 Your ATV has been designed to extend belt life. 74 Cargo weight should be evenly distributed (1/3 on the front and 2/3 on the warning labels, and never exceed the specified weights. Belt Life Use low forward gear when hauling or towing heavy cargo to carry or tow a certain amount of load. When operating over rough or hilly terrain, reduce speed and cargo to maintain stable driving conditions. Always read and understand the load distribution warnings listed on the rear) and mounted as low as possible.
Owners Manual
Page 81
.... WARNING Improperly performing the procedures marked with a J could result in component failure and lead to connector when replaced Pre-Ride Pre-Ride Pre-Ride Pre-Ride Pre-Ride Pre-Ride Pre-Ride Pre-Ride Pre-Ride Pre-Ride Pre-Ride Pre-Ride L Pre-cleaner Coolant level (liquid Pre-Ride Pre-Ride cooled models) Fuel and oil tanks Throttle Lights Engine stop switch Steering " Air box...
.... WARNING Improperly performing the procedures marked with a J could result in component failure and lead to connector when replaced Pre-Ride Pre-Ride Pre-Ride Pre-Ride Pre-Ride Pre-Ride Pre-Ride Pre-Ride Pre-Ride Pre-Ride Pre-Ride Pre-Ride L Pre-cleaner Coolant level (liquid Pre-Ride Pre-Ride cooled models) Fuel and oil tanks Throttle Lights Engine stop switch Steering " Air box...
Owners Manual
Page 84
... months Check for leaks at tank cap, lines, fuel valve, filter, pump and carburetor; Periodic Maintenance Schedule Item J Fuel system MAINTENANCE AND LUBRICATION Hours/ Miles 100 hrs. clean Inspect Inspect; replace as dirty or wet conditions L Emission Control System Service (California) J Dealer service item 81 adjust when parts are replaced As required Adjust as needed Headlight aim " More often under severe use, such as needed Clean out L J Fuel filter 100 hrs...
... months Check for leaks at tank cap, lines, fuel valve, filter, pump and carburetor; Periodic Maintenance Schedule Item J Fuel system MAINTENANCE AND LUBRICATION Hours/ Miles 100 hrs. clean Inspect Inspect; replace as dirty or wet conditions L Emission Control System Service (California) J Dealer service item 81 adjust when parts are replaced As required Adjust as needed Headlight aim " More often under severe use, such as needed Clean out L J Fuel filter 100 hrs...
Owners Manual
Page 91
... drain plug on the rear side of burrs, nicks or scratches. 6. Reattach the oil line. Lubricate the gasket on the new filter with the mark (4) on the lower right side of oil will remain in good condition. Install the new filter and tighten by hand 1/2 to 3/4 turn the filter (5) counterclockwise and remove. 9. MAINTENANCE AND LUBRICATION Lubrication Recommendations Oil and Filter Change (Magnum 500) 4. Allow the oil to...
... drain plug on the rear side of burrs, nicks or scratches. 6. Reattach the oil line. Lubricate the gasket on the new filter with the mark (4) on the lower right side of oil will remain in good condition. Install the new filter and tighten by hand 1/2 to 3/4 turn the filter (5) counterclockwise and remove. 9. MAINTENANCE AND LUBRICATION Lubrication Recommendations Oil and Filter Change (Magnum 500) 4. Allow the oil to...
Owners Manual
Page 93
Run the engine for extended periods, the oil pump may result in serious burns. CAUTION 5. Using an oil filter wrench, turn the filter counterclockwise to drain completely. 7. MAINTENANCE AND LUBRICATION Lubrication Recommendations Oil and Filter Change (Magnum 330) If the ATV is left without oil in the system for two to three minutes until warm. CAUTION 1. Stop the engine. Allow the oil to remove. 10. lbs. (19 Nm...
Run the engine for extended periods, the oil pump may result in serious burns. CAUTION 5. Using an oil filter wrench, turn the filter counterclockwise to drain completely. 7. MAINTENANCE AND LUBRICATION Lubrication Recommendations Oil and Filter Change (Magnum 330) If the ATV is left without oil in the system for two to three minutes until warm. CAUTION 1. Stop the engine. Allow the oil to remove. 10. lbs. (19 Nm...
Owners Manual
Page 129
... the engine or exhaust system. Use a professional type washing mitten, cleaning the upper body first and the lower parts last. Avoid the use of a high pressure type car wash system for the part numbers of Polaris products. CAUTION 126 See page 130 for washing the ATV. If a high pressure system is with a chamois to the wheel bearings, transmission seals, body panels, brakes and warning labels...
... the engine or exhaust system. Use a professional type washing mitten, cleaning the upper body first and the lower parts last. Avoid the use of a high pressure type car wash system for the part numbers of Polaris products. CAUTION 126 See page 130 for washing the ATV. If a high pressure system is with a chamois to the wheel bearings, transmission seals, body panels, brakes and warning labels...
Owners Manual
Page 134
2004 Magnum 330 2x4 Body Style Gross Vehicle Weight Fuel Capacity Engine Oil Capacity Transmission Oil Rear Gearcase Oil Front Rack Rear Rack Tongue Weight Tow Capacity Turn Radius Ground Clearance Height Length Width Seat Height Dry Weight Wheel Base Engine Model Number / Type Lubrication Bore x Stroke Displacement Compression Ratio Engine Cooling Alternator Output (watts) Carburetion Main Jet Pilot Jet Needle Jet Pilot Air Jet Jet Needle Ignition Timing Spark Plug Type / Gap SPECIFICATIONS Capacities Gen IV 1060 lbs. (481 kg) 3.2 gal. (12.1 l) 1.9 qts. (1.8 l) 13.5 oz. (400 ml) 10 oz...
2004 Magnum 330 2x4 Body Style Gross Vehicle Weight Fuel Capacity Engine Oil Capacity Transmission Oil Rear Gearcase Oil Front Rack Rear Rack Tongue Weight Tow Capacity Turn Radius Ground Clearance Height Length Width Seat Height Dry Weight Wheel Base Engine Model Number / Type Lubrication Bore x Stroke Displacement Compression Ratio Engine Cooling Alternator Output (watts) Carburetion Main Jet Pilot Jet Needle Jet Pilot Air Jet Jet Needle Ignition Timing Spark Plug Type / Gap SPECIFICATIONS Capacities Gen IV 1060 lbs. (481 kg) 3.2 gal. (12.1 l) 1.9 qts. (1.8 l) 13.5 oz. (400 ml) 10 oz...
Owners Manual
Page 137
SPECIFICATIONS Body Style Gross Vehicle Weight Fuel Capacity Engine Oil Capacity Transmission Oil Front Gearcase Oil Rear Gearcase Oil Front Rack Rear Rack Tongue Weight Tow Capacity Turn Radius Ground Clearance Height Length Width Seat Height Dry Weight Wheel Base Engine Model Number / Type Lubrication Bore x Stroke Displacement Compression Ratio Engine Cooling Alternator Output (watts) Carburetion Main Jet Pilot Jet Needle Jet Pilot Air Jet Jet Needle Ignition Timing Spark Plug Type / Gap 2004 Magnum 330 4x4 Capacities Gen IV 1100 lbs. (499 kg) 3.25 gal. (12.3 l) 1.9 qts. (1.8 l) 13.5 oz. (...
SPECIFICATIONS Body Style Gross Vehicle Weight Fuel Capacity Engine Oil Capacity Transmission Oil Front Gearcase Oil Rear Gearcase Oil Front Rack Rear Rack Tongue Weight Tow Capacity Turn Radius Ground Clearance Height Length Width Seat Height Dry Weight Wheel Base Engine Model Number / Type Lubrication Bore x Stroke Displacement Compression Ratio Engine Cooling Alternator Output (watts) Carburetion Main Jet Pilot Jet Needle Jet Pilot Air Jet Jet Needle Ignition Timing Spark Plug Type / Gap 2004 Magnum 330 4x4 Capacities Gen IV 1100 lbs. (499 kg) 3.25 gal. (12.3 l) 1.9 qts. (1.8 l) 13.5 oz. (...
Owners Manual
Page 140
2004 Magnum 500 4x4 Body Style Gross Vehicle Weight Fuel Capacity Engine Oil Capacity Transmission Oil Front Gearcase Oil Rear Gearcase Oil Front Rack Rear Rack Tongue Weight Tow Capacity Turn Radius Ground Clearance Height Length Width Seat Height Dry Weight Wheel Base Engine Model Number / Type Lubrication Bore x Stroke Displacement Compression Ratio Engine Cooling Alternator Output (watts) Carburetion Main Jet Pilot Jet Needle Jet Jet Needle Ignition Timing Spark Plug Type / Gap SPECIFICATIONS Capacities Gen IV 1150 lbs. (521.6 kg) 3.25 gal. (12.3 l) 2 qts. (1.9 l) 13.5 oz. (400 ml) 13...
2004 Magnum 500 4x4 Body Style Gross Vehicle Weight Fuel Capacity Engine Oil Capacity Transmission Oil Front Gearcase Oil Rear Gearcase Oil Front Rack Rear Rack Tongue Weight Tow Capacity Turn Radius Ground Clearance Height Length Width Seat Height Dry Weight Wheel Base Engine Model Number / Type Lubrication Bore x Stroke Displacement Compression Ratio Engine Cooling Alternator Output (watts) Carburetion Main Jet Pilot Jet Needle Jet Jet Needle Ignition Timing Spark Plug Type / Gap SPECIFICATIONS Capacities Gen IV 1150 lbs. (521.6 kg) 3.25 gal. (12.3 l) 2 qts. (1.9 l) 13.5 oz. (400 ml) 13...
Owners Manual
Page 149
... authorization for export from Polaris Industries in order to continue your vehicle to perform the warranty repair. Notice If your vehicle will no longer be eligible for export. You should take your warranty coverage. This policy does not apply to determine this vehicle's warranty or service bulletin coverage if you should consult an authorized dealer to Safety Recalls. You must be denied...
... authorization for export from Polaris Industries in order to continue your vehicle to perform the warranty repair. Notice If your vehicle will no longer be eligible for export. You should take your warranty coverage. This policy does not apply to determine this vehicle's warranty or service bulletin coverage if you should consult an authorized dealer to Safety Recalls. You must be denied...
Owners Manual
Page 151
... Maintenance Record ...84 Maintenance Schedule ...77-81 Making Turns ...64 Master Cylinder ...41 S Safety Training ...7 Side Panel Removal ...120 Sidehilling ...67 Spark Arrestor ...76, 106 Spark Plug Removal/Replacement 104 Spark Plugs ...104 SPECIFICATIONS ...131-139 Starting a Cold Engine ...61 Starting a Warm Engine ...62 Starting the Engine ...61-62 Steering Assembly ...116 Stop Switch ...39 Storage Tips ...127-128 N Noise Emission Control System ...76 O Odometer ...51, 56 Oil Change (330) ...90-91 Oil Change (500) ...87-89 Oil Filter Change (500) ...87-89 Oil Filter Change...
... Maintenance Record ...84 Maintenance Schedule ...77-81 Making Turns ...64 Master Cylinder ...41 S Safety Training ...7 Side Panel Removal ...120 Sidehilling ...67 Spark Arrestor ...76, 106 Spark Plug Removal/Replacement 104 Spark Plugs ...104 SPECIFICATIONS ...131-139 Starting a Cold Engine ...61 Starting a Warm Engine ...62 Starting the Engine ...61-62 Steering Assembly ...116 Stop Switch ...39 Storage Tips ...127-128 N Noise Emission Control System ...76 O Odometer ...51, 56 Oil Change (330) ...90-91 Oil Change (500) ...87-89 Oil Filter Change (500) ...87-89 Oil Filter Change...