2003 Polaris Universal ATV Owners Manual

2003 Polaris Universal ATV Manual

2003 Polaris Universal ATV manual content summary:

  • 2003 Polaris Universal ATV | Owners Manual - Page 1
    2003 ATV Universal Owner's Manual for Vehicle Maintenance and Safety Read this manual carefully. It contains important safety information. This is an adult vehicle only. Operation is prohibited for those under 16 years of age.
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    WARNING The engine exhaust from this product contains chemicals known to cause cancer, birth defects or other reproductive harm.
  • 2003 Polaris Universal ATV | Owners Manual - Page 3
    We've created a web site just for YOU! S S S S S Technical tips New product introductions Event schedules Parts and Service Manual information Exciting details about The Way Out Check it out...www.polarisindustries.com/owner 1
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    Industries Inc. reserves the right to make product changes and improvements that may affect illustrations or explanations. No part of this manual shall be reproduced or used without the written permission of Polaris Industries Inc. Copyright 2002 Polaris Industries Inc. All Rights Reserved Printed
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    operation of your vehicle, be sure to follow the instructions and recommendations in this owner's manual. Your manual contains instructions for minor maintenance, but information about major repairs is outlined in the Polaris Service Manual and should be performed only by a Factory Certified Master
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    4
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    ...48 OPERATION ...56 NOISE EMISSION CONTROL SYSTEM REGULATION ...74 MAINTENANCE AND LUBRICATION ...75 POLARIS RECOMMENDED PRODUCTS ...141 TROUBLESHOOTING ...142 WARRANTY ...146 INDEX ...149 NOTE: Illustrations used in this manual are for general representation only. Your model may differ. 5
  • 2003 Polaris Universal ATV | Owners Manual - Page 8
    VEHICLE IDENTIFICATION NUMBERS The vehicle frame vehicle identification number (VIN)(1) and engine serial number (2) are important for model identification when registering your vehicle, when obtaining insurance, and when ordering replacement parts. If your vehicle is stolen, these numbers are
  • 2003 Polaris Universal ATV | Owners Manual - Page 9
    routine maneuvers like turning, or driving on hills or over obstacles, if you fail to take proper precautions. Read and understand your owner's manual and all warnings before operating a Polaris ATV. Age Restrictions This vehicle is an ADULT VEHICLE ONLY. Operation is prohibited for anyone under 16
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    symbols are used. Become familiar with their meanings before reading the manual. The safety alert symbol, on your ATV or in this manual, alerts you to the potential for personal injury. WARNING The safety the machine. CAUTION NOTE A note will alert you to important information or instructions. 8
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    Safety SAFETY WARNING Serious injury or death can result if you do not follow these instructions and procedures, which are outlined in further detail within your owner's manual. S Read this manual and all labels carefully, and follow the operating procedures described. S Never operate an ATV
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    . To avoid stalling, maintain a steady speed when climbing a hill. If you stall or roll backwards, follow the special procedure for braking described in this manual. Always dismount on the uphill side, or to either side if the ATV is pointed straight uphill. Turn the ATV around and remount following
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    S Never exceed the stated load capacity for your ATV. Cargo must be properly distributed and securely attached. Reduce speed and follow the instructions in this manual for carrying cargo or towing. Allow a greater distance for braking. S Always remove the ignition key when the vehicle is not in use
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    Safety WARNING POTENTIAL HAZARD Operating this ATV without proper instruction. WHAT CAN HAPPEN The risk of an accident the skills learned in the course and the operating techniques described in the owner's manual. For more information about the training course, contact an authorized ATV dealer or
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    Operator Safety SAFETY WARNING POTENTIAL HAZARD Carrying a passenger on an ATV. WHAT CAN HAPPEN Carrying a passenger greatly reduces the operator's ability to balance and control the ATV, which could cause an accident and injury to the operator and/or passenger. HOW TO AVOID THE HAZARD Never
  • 2003 Polaris Universal ATV | Owners Manual - Page 16
    SAFETY Operator Safety WARNING POTENTIAL HAZARD Operating an ATV on paved surfaces, including sidewalks, paths, parking lots, and driveways. WHAT CAN HAPPEN ATV tires are designed for off-road use. Operating on paved surfaces may seriously affect the handling and control of the ATV and could
  • 2003 Polaris Universal ATV | Owners Manual - Page 17
    Operator Safety SAFETY WARNING POTENTIAL HAZARD Operating this ATV on public streets, roads or highways. WHAT CAN HAPPEN The ATV could collide with another vehicle. HOW TO AVOID THE HAZARD Never operate the ATV on any public street, road or highway, including dirt and gravel roads. In many states
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    SAFETY Operator Safety WARNING POTENTIAL HAZARD Operating this ATV without wearing an approved helmet, eye protection and protective clothing. WHAT CAN HAPPEN Operating an ATV without an approved helmet increases the risk of a severe head injury or death in the event of an accident. Operating
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    Operator Safety SAFETY WARNING POTENTIAL HAZARD Operating the ATV after consuming alcohol or drugs. WHAT CAN HAPPEN Consumption of alcohol and/or drugs could seriously affect operator judgment. Reaction time may be slower and operator balance and perception could be affected. Consuming alcohol and
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    SAFETY Operator Safety WARNING POTENTIAL HAZARD Attempting wheelies, jumps and other stunts. WHAT CAN HAPPEN Attempting stunts increases the chance of an accident, including an overturn. HOW TO AVOID THE HAZARD Never attempt wheelies, jumps, or other stunts. Avoid exhibition driving. 18
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    use to make sure it's in safe operating condition. Always follow the inspection and maintenance procedures and schedules described in the owner's manual. WARNING POTENTIAL HAZARD Removing hands from the handlebars or feet from the footrests during operation. WHAT CAN HAPPEN Removing even one hand
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    SAFETY Operator Safety WARNING POTENTIAL HAZARD Failure to use extra caution when operating the ATV on unfamiliar terrain. WHAT CAN HAPPEN Unfamiliar terrain may contain hidden rocks, bumps, or holes that could cause loss of control or overturn. HOW TO AVOID THE HAZARD Travel slowly and use extra
  • 2003 Polaris Universal ATV | Owners Manual - Page 23
    Operator Safety SAFETY WARNING POTENTIAL HAZARD Failure to use extra caution when operating on excessively rough, slippery or loose terrain. WHAT CAN HAPPEN Operating on excessively rough, slippery or loose terrain could cause loss of traction or loss of control, which could result in an accident
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    and lead to a collision or overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for turning as described in the owner's manual. Practice turning at slow speeds before attempting to turn at faster speeds. Never turn at excessive speed. WARNING POTENTIAL HAZARD Operating on excessively
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    could cause loss of control or overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for climbing hills as described in the owner's manual. Always check the terrain carefully before ascending any hill. Never operate the ATV on hills steeper than 25_. Never climb hills with excessively
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    loss of control or overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for traveling down hills as described in the owner's manual. NOTE: A special technique is required when braking while traveling downhill. See page 68. Always check the terrain carefully before you descending a hill
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    Never attempt to turn the ATV around on any hill until you've mastered the turning technique (on level ground) as described in the owner's manual. See page 69. Use extra caution when turning on any hill. Avoid crossing the side of a steep hill. When crossing the side of a hill: Always
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    uphill side, or to either side if ATV is pointed straight uphill. Turn the ATV around and remount, following the procedure described in the owner's manual. See page 69. 26
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    such as rocks and fallen trees when possible. If unavoidable, use extreme caution and always follow proper procedures as outlined in the owner's manual. WARNING POTENTIAL HAZARD Skidding or sliding. WHAT CAN HAPPEN Skidding or sliding can cause loss of control. If the tires regain traction
  • 2003 Polaris Universal ATV | Owners Manual - Page 30
    SAFETY Operator Safety WARNING POTENTIAL HAZARD Operating the ATV through deep or fast-flowing water. WHAT CAN HAPPEN Tires may float, causing loss of traction and loss of control, which could lead to an accident or overturn. HOW TO AVOID THE HAZARD Avoid operating the ATV through deep or fast-
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    tires specified in the owner's manual supplement for the ATV. Always maintain proper tire pressure as described in the owner's manual supplement. WARNING POTENTIAL HAZARD Operating installed and used according to approved instructions. See your authorized Polaris ATV dealer for more information. 29
  • 2003 Polaris Universal ATV | Owners Manual - Page 32
    trailer. Allow a greater distance for braking. Always follow the instructions in the owner's manual for carrying cargo or pulling a trailer. See page 61. the ice is thick enough and sound enough to support the machine and its operator, as well as the force created by a moving vehicle,
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    injury or death. Always remove the ignition key when the vehicle is not in use. WARNING After any overturn or accident, have a qualified service dealer inspect the entire vehicle for possible damage, including (but not limited to) brakes, throttle and steering systems. WARNING Safe operation of
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    been placed on the ATV for your protection. Read and follow the instructions on each decal carefully. If a decal becomes illegible or comes operation, or unattended, place shift in park position. 7171383 IF OWNER'S MANUAL IS MISSING, CONTACT A POLARIS DEALER FOR A REPLACEMENT. E1997, 2000 7079083
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    rough or hilly terrain, reduce speed and cargo. Do not block headlight. Be careful if load extends over the side of the rack. Read Owner's Manual for more detailed loading information See your Owner
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    filter often, more frequent cleaning required in dusty conditions DSpecific carburetor jetting and adjustments are required depending on temperature and altitude. See your Owner's Manual. Factory setting: DClean 40_ to 80_ F. at 0-3000 feet (5_ to 27_ C. at 0-900 meters). 7079901 Under Seat 34
  • 2003 Polaris Universal ATV | Owners Manual - Page 37
    . Reverse override is controlled by the override switch. See your Owner's Manual. 7079906 2WD Models ALL WHEEL DRIVE SWITCH Do not push switch to engage This may cause severe drive shaft and clutch damage. See your Owner's Manual. 7079780 MANUFACTURED BY: POLARIS IND DATE: VIN: THIS VEHICLE IS AN
  • 2003 Polaris Universal ATV | Owners Manual - Page 38
    SAFETY Safe Riding Gear Always wear clothing suited to the type of riding. ATV riding requires special protective clothing for comfort and to reduce the chance of injury. 1. Helmet Your helmet is the most important piece of protective gear for safe riding. A helmet can prevent a severe head injury.
  • 2003 Polaris Universal ATV | Owners Manual - Page 39
    Electrical Switches CONTROLS 3 1 2 WARNING Activating the override switch while the throttle is open can cause loss of control, resulting in severe injury or death. Do not activate the override switch while the throttle is open. Override Switch (1) (Reverse Speed Limiter) - This OFF RUN OFF
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    or improperly operating throttle controls, which could cause an accident and lead to severe injury or death. Always contact your dealer for service repairs if throttle problems arise. Failure to check or maintain proper operation of the throttle system can result in an accident if the throttle lever
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    CONTROLS WARNING Operating the ATV on streets or roads, especially in darkness, could result in an accident and serious injury or death. Your ATV is not equipped with highway-approved lights. It's designed for and must be used for off-road use only. Use caution and drive at reduced speeds in
  • 2003 Polaris Universal ATV | Owners Manual - Page 42
    CONTROLS Brake Lever 1 The front and rear brakes are applied by squeezing the brake lever (1) toward the handlebar. The front and rear brakes are hydraulically activated disc type brakes that are activated by only one lever. Always test brake lever travel and master cylinder fluid level before
  • 2003 Polaris Universal ATV | Owners Manual - Page 43
    Parking Brake CONTROLS WARNING Operating the ATV while the parking brake is engaged could result in an accident and serious injury or death. Always check to be sure the parking brake is disengaged before operating. Setting the Parking Brake 1. Squeeze and release the brake lever (1) two or three
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    CONTROLS Auxiliary Brake WARNING Aggressively applying the rear brake when backing down a hill may cause rear tipover, which could result in serious injury or death. Use caution when applying the auxiliary brake. Do not aggressively apply the auxiliary brake when going forward. The rear wheels may
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    located directly below the handlebar. Use either leaded or unleaded gasoline with a minimum pump octane number of 87=(R+ M/2) octane. Refer to your owner's manual supplement for tank capacity. Fuel Filter The in-line fuel filter should be replaced by your dealer after every 100 hours of operation
  • 2003 Polaris Universal ATV | Owners Manual - Page 46
    CONTROLS Fuel Safety WARNING Gasoline is highly flammable and explosive under certain conditions. S Always exercise extreme caution whenever handling gasoline. S Always refuel with the engine stopped, and outdoors or in a S S S S S well ventilated area. Do not smoke or allow open flames or sparks
  • 2003 Polaris Universal ATV | Owners Manual - Page 47
    Oil Injection Tank - 2-Cycle Models CONTROLS CAUTION Mixing brands or using a non-recommended oil may cause serious engine damage. We recommend the use of Polaris Premium Synthetic 2-cycle oil for your 2-cycle Polaris ATV. Never substitute or mix oil brands. To avoid serious engine damage, always
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    the parking brake locked. Maintaining shift linkage adjustment is important to assure proper transmission function. See your dealer if you experience any shifting problems. Belt Life To extend belt life, use low forward gear in heavy pulling situations and when operating at less than seven miles
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    Recoil Starter CONTROLS If the battery is weak and cannot 1 start the engine, use of the recoil starter (1) will allow vehicle operation until repairs can be made. The recoil starter is located on the right side of the machine. Polaris 4-cycle engines are equipped with automatic decompressors.
  • 2003 Polaris Universal ATV | Owners Manual - Page 50
    FEATURES All Wheel Drive (AWD) System Polaris 4 wheel drive ATVs are equipped with a unique, Polaris exclusive, Demand 4 Drive (AWD) system that's activated by a switch (1) on the right handlebar. When the switch is off, the ATV is in 2 wheel drive at all times. When the switch is on, the ATV is in
  • 2003 Polaris Universal ATV | Owners Manual - Page 51
    short distance. Then proceed in forward again. NOTE: If the hubs remain engaged after following this procedure, return the ATV to your dealer for service. To continue using AWD in reverse, activate the override switch and the Demand 4 Drive switch. See page 37. WARNING Operating with only one front
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    . Not every model is equipped with all of the lights, and the lights on some models appear in the speedometer. The information in your owner's manual supplement and on this page will help you identify the lights and their function. With the engine running, verify the function of all indicator lights
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    Instrument Cluster FEATURES Your ATV is equipped with an instrument cluster that senses vehicle speed from the right front wheel. The instrument cluster measures distance in miles as well as hours of operation. It also includes a reverse speed limiter function that limits the ATV's speed to
  • 2003 Polaris Universal ATV | Owners Manual - Page 54
    Coolant Temperature - Do not continue to operate the ATV is this warning appears or serious engine damage could result. 3. Hour Meter 4. Service Interval/Miscellaneous Service Warnings 5. Low Battery and Over Voltage - This warning usually indicates that the ATV is being operated at an RPM too low
  • 2003 Polaris Universal ATV | Owners Manual - Page 55
    Cluster Rider Information Center FEATURES The rider information center has 4 standard modes: Mode 1 - Odometer Mode 2 - Tripmeter Mode 3 - Total Service Hours Mode 4 - Programmable service interval The reverse override button on the left handlebar is also the mode button. NOTE: If using the mode
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    faster. When the desired time increment is displayed, release the button and wait for the wrench to stop flashing. When the wrench stops blinking, your service hours are set. NOTE: If you scroll past the intended number, hold the button down until the count turns over to 0. You can then reset
  • 2003 Polaris Universal ATV | Owners Manual - Page 57
    Instrument Cluster Rider Information Center FEATURES Diagnostic Mode The diagnostic mode is for informational purposes only. Please return your ATV to your dealer for all major repairs. To enter the diagnostics mode: 1. Turn the key switch off and wait 20 seconds. 2. Set the park brake and shift
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    engine damage. Always fill the oil tank when refueling the ATV. The first tank of fuel must be pre-mixed according to the following instructions. After the break-in period, the oil injection system will provide the necessary engine lubrication without pre-mixing. 1. Mix 12.8 ounces of Polaris
  • 2003 Polaris Universal ATV | Owners Manual - Page 59
    Break-In Period 4-Cycle Engines OPERATION The break-in period for your new Polaris ATV is defined as the first ten hours of operation, or the time it takes to use the first two full tanks of gasoline. No single action on your part is as important as following the procedures for a proper break-in.
  • 2003 Polaris Universal ATV | Owners Manual - Page 60
    OPERATION Pre-Ride Inspection WARNING If a proper inspection is not done before each use, severe injury or death could result. Always inspect the vehicle before each use to ensure it's in proper operating condition. Use the following checklist to verify that your vehicle is in proper working
  • 2003 Polaris Universal ATV | Owners Manual - Page 61
    Starting the Engine Starting a Cold Engine OPERATION WARNING Engine exhaust contains poisonous carbon monoxide and can cause loss of consciousness resulting in severe injury or death. Never run an engine in an enclosed area. CAUTION Operating the vehicle immediately after starting could cause
  • 2003 Polaris Universal ATV | Owners Manual - Page 62
    OPERATION Starting the Engine Starting a Warm Engine Warm engines do not normally require the use of the choke. Using the choke can cause the spark plug to become wet fouled. 1. Position the vehicle on a level surface with the transmission in neutral. 2. Lock the parking brake, turn the fuel tank
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    load. Always read and understand the load distribution warnings listed on the warning labels, and never exceed the weights specified in your owner's manual supplement. Cargo weight should be evenly distributed (1/3 on the front and 2/3 on the rear) and mounted as low as possible. When operating over
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    extra caution. Always attach the tow load to the hitch point designated for your vehicle. S HEAVY LOADS CAN CAUSE BRAKING AND CONTROL PROBLEMS. Use extreme caution when applying brakes with a loaded vehicle. Avoid terrain or situations that may require backing downhill. S EXTREME CAUTION MUST BE
  • 2003 Polaris Universal ATV | Owners Manual - Page 65
    Driving Safely Driving Procedures OPERATION 1. Sit upright with both feet on the footrests and both hands on the handlebars. 2. Start the engine and allow it to warm up, then shift the transmission into gear. 3. Check your surroundings and determine your path of travel. 4. Release the parking
  • 2003 Polaris Universal ATV | Owners Manual - Page 66
    must slip traction slightly. To make a turn, steer in the direction of the turn, leaning your upper body to the inside of the turn while supporting your weight on the outer footrest. This technique alters the balance of traction between the rear wheels, allowing the turn to be made smoothly. The
  • 2003 Polaris Universal ATV | Owners Manual - Page 67
    Driving Safely Driving on Slippery Surfaces OPERATION Whenever riding on slippery surfaces such as wet trails or loose gravel, or during freezing weather, follow these precautions: 1. Slow down when entering slippery areas. 2. Maintain a high level of alertness, reading the trail and avoiding
  • 2003 Polaris Universal ATV | Owners Manual - Page 68
    injury or death. Avoid climbing steep hills (25_ maximum). Use extreme caution when operating on hills, and follow proper operating procedures outlined in the owner's manual. 66
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    overturn, resulting in severe injury or death. Avoid crossing the side of a hill when possible. Follow proper procedures as outlined in the owner's manual. Sidehilling can be a dangerous type of driving and should be avoided if at all possible. If you do enter into a situation where sidehilling
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    the single brake lever. NOTE: Familiarize yourself with operation of the auxiliary rear brake pedal for additional braking in the event of normal service brake loss. WARNING Excessive speed can cause loss of control and lead to serious injury or death. Always operate slowly when traveling downhill
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    or death. Avoid climbing steep hills (25_ maximum). Use extreme caution when operating on hills, and follow proper operating procedures outlined in the owner's manual. If the vehicle stalls while climbing a hill, never back it down the hill! One maneuver that can be used when it's necessary to turn
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    brakes by applying light pressure to the lever until braking action is normal. After running the vehicle in water, it's critical to have it serviced as outlined in the maintenance chart. See page 75. The following areas need special attention: engine oil, transmission oil, front and rear gearcases
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    Driving Safely Driving Over Obstacles OPERATION Be alert! Look ahead and learn to read the terrain you're traveling on. Be constantly alert for hazards such as logs, rocks and low hanging branches. WARNING Severe injury or death can result if your vehicle comes in contact with a hidden obstacle.
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    OPERATION Driving Safely Driving in Reverse Follow these precautions when operating in reverse: 1. Always avoid backing downhill. 2. Back slowly. 3. When in reverse, apply the brakes lightly for stopping. 4. Avoid turning at sharp angles in reverse. 5. Never open the throttle suddenly while backing.
  • 2003 Polaris Universal ATV | Owners Manual - Page 75
    Driving Safely Parking on an Incline OPERATION Avoid parking on an incline if possible. If it's unavoidable, follow these precautions: 1. Turn the engine off. 1. Place the transmission in gear. 2. Set the parking brake. 3. Always block the rear wheels on the downhill side. See illustration. 4.
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    tall grass, especially dry grass. USFS Approved Spark Arrestor Most Polaris ATVs have mufflers that were tested and approved in accordance with the USFS Forest Service Standard 5100-1A. Refer to your owner's manual supplement for model specific information. 74
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    service interval mode. This important feature will help you determine when maintenance service is due. See page 54 for instructions Service and adjustments are critical. If you're not familiar with safe service critical components. L Emission Control System Service (California - 4-Cycle) NOTE: Some
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    marked with a J could result in component failure and lead to serious injury or death. Have an authorized Polaris dealer perform these services. Item Brake System Auxiliary Brake Tires Wheels Frame nuts, bolts, fasteners Oil level (2-Cycle) " Air filter, Hours/ Miles Frequency Remarks Inspect
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    annually and as needed Inspect periodically Check monthly; change annually Inspect (re-torque required at first service only) Lubricate all fittings, pivots, cables, etc. Check level daily; break-in service at one month; change oil more often in cold weather Replace with oil change Inspect, adjust
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    the procedures marked with a J could result in component failure and lead to serious injury or death. Have an authorized Polaris dealer perform these services. Item Carburetor float bowl J Throttle Cable/ETC Hours/ Miles 50 hrs. 50 hrs. 50 hrs. 100 hrs. Frequency Remarks 6 months 6 months 6 months
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    when parts are replaced As required Adjust as needed Headlight aim " More often under severe use, such as dirty or wet conditions L Emission Control System Service (California) J Dealer service item 79
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    MAINTENANCE AND LUBRICATION Lubrication Recommendations NOTE: Hours are based on 10 mph average. If service is due at 20 hours, the equivalent odometer reading would be 200 miles. Perform all services at whichever reading is reached first. Lubrication Chart Key " L Polaris Premium All Season
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    MAINTENANCE AND LUBRICATION Lubrication Recommendations (1) (2) (3) (2) (4) (5) 81
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    MAINTENANCE AND LUBRICATION Lubrication Recommendations Item (6) Demand 4 Hubs - All Wheel Drive ATVs (7) Front Drive Axle (U Joint) (AWD Models) (8) Ball Joint Lube Premium Hub Lube Method Remove set screw in hubs. Rotate wheels to 4 O'clock position. If lubricant is not visible add more. Reinstall
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    MAINTENANCE AND LUBRICATION Lubrication Recommendations (7) (6) (8) (6) 4 O'clock position (9) (12) (11) (10) (14) (15) (13) (13) 83
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    MAINTENANCE AND LUBRICATION Periodic Maintenance Record Use the following chart to record periodic maintenance. Maintenance Interval Performed 10 hrs. 20 hrs. 50 hrs. 100 hrs. Servicing Servicing Date Dealer or Person Remarks 84
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    Lubrication Recommendations Polaris 2-Cycle Lubricants MAINTENANCE AND LUBRICATION Polaris Premium 2-cycle lubricants are the most advanced formulation of oils, specifically designed for today's 2-cycle engines. Our ongoing lab and field tests have resulted in a new generation of 2-cycle
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    first. Suggested break-in oil change is at 20 hours, 200 miles, or one month, whichever comes first. Severe use operation requires more frequent service. Severe use includes continuous duty in dusty or wet conditions and cold weather riding. NOTE: Severe use cold weather riding is all riding below
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    Lubrication Recommendations Oil and Filter Change MAINTENANCE AND LUBRICATION 4-Cycle Engines With External Oil Tank 1. Position the vehicle on a level surface. 2. Clean the area around the drain plug, which is located on either the bottom of the oil tank or on the bottom of the engine. 3. Run the
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    should be clean and free of burrs, nicks or scratches. 15. Remove the dipstick (2) and add the amount of oil indicated in your owner's manual supplement. Reinstall the dipstick. NOTE: If the sump is not drained, add about 1 3/4 quarts initially. 16. Place the gear selector in neutral and set
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    Lubrication Recommendations Oil and Filter Change MAINTENANCE AND LUBRICATION Magnum 330 2x4, Magnum 330 4x4, Trail Boss 1. Position the vehicle on a level 1 surface. 2. Clean the area around the drain plug (1). 3. Run the engine for two to three minutes until warm. Stop the engine. Contact with
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    MAINTENANCE AND LUBRICATION Lubrication Recommendations Oil and Filter Change Magnum 330 2x4, Magnum 330 4x4, Trail Boss 12. Remove the dipstick and fill the sump with 2 quarts (1.9 l) of Polaris Premium 4 synthetic oil. 13. Place the gear selector in neutral and set the parking brake. 14. Start the
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    Lubrication Recommendations MAINTENANCE AND LUBRICATION Transmission Oil Check - Models with Fill Plug Scrambler 500 4x4, Magnums: 500, 330 4x4, 330 2x4 The transmission lubricant level should be checked every six months or 1000 miles (1600 km), whichever comes first. Transmission oil should be
  • 2003 Polaris Universal ATV | Owners Manual - Page 94
    MAINTENANCE AND LUBRICATION Lubrication Recommendations Transmission Oil Change - Models with Fill Plug Scrambler 500 4x4, Magnums: 500, 330 4x4, 330 2x4 1. If equipped, remove the propshaft shield from the right side of the vehicle to access the fill plug. 2. Remove the fill plug. 3. Remove the
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    Lubrication Recommendations MAINTENANCE AND LUBRICATION Transmission Oil Check - Models with Dipstick On most 2x4 models, the 1 transmission dipstick (1) is located on the right side of the machine. On the Sportsman, the dipstick is located near the rear brake disc. The transmission lubricant
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    MAINTENANCE AND LUBRICATION Lubrication Recommendations Transmission Oil Change - 2x4 Models 7. Tighten the jam nut securely while holding the adjuster bolt. 8. Add the proper lubricant through the dipstick hole until the oil level is between the upper and lower limits. Do not overfill. 9. Check for
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    Lubrication Recommendations Front Gearcase Oil Check The front gearcase oil level should be checked every six months or 1000 miles (1600 km), whichever comes first. The oil should be changed annually. Use Polaris Premium Synthetic Gearcase Lube (or GL5 80-90 weight gear lube). NOTE: See page 141 for
  • 2003 Polaris Universal ATV | Owners Manual - Page 98
    MAINTENANCE AND LUBRICATION Lubrication Recommendations Rear Gearcase Oil Check With the ATV on a level surface, remove the fill plug and view the oil level through the fill hole (1). Lubricant should be kept even with the center of the drillpoint (2), approximately 1 5/8″ below the top of the fill
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    Lubrication Recommendations MAINTENANCE AND LUBRICATION Counter Balance Oil Check - 400 2-Cycle Engines The counter balance oil should be checked semi-annually and oil should be added or changed as needed. The oil should be changed annually and before off season storage. If the machine is used in
  • 2003 Polaris Universal ATV | Owners Manual - Page 100
    MAINTENANCE AND LUBRICATION Lubrication Recommendations Engine Oil Check The oil tank is located either on the left side of the vehicle (external tank models)(1) or on the engine (2). 1. Position the machine on a level surface. 2. Start the engine and let it idle for 20-30 seconds. Stop the engine.
  • 2003 Polaris Universal ATV | Owners Manual - Page 101
    Engine Cooling System Coolant Level MAINTENANCE AND LUBRICATION The recovery bottle (1) is located on GEN III the left side of the machine. To 1 access the recovery bottle on Gen IV machines, remove the left side panel. See page 111. The fluid level must be maintained between the minimum and
  • 2003 Polaris Universal ATV | Owners Manual - Page 102
    MAINTENANCE AND LUBRICATION Engine Cooling System WARNING Escaping steam can cause severe burns. Never remove the pressure cap while the engine is warm or hot. Always allow the engine to cool before removing the pressure cap. Radiator Coolant Level NOTE: This procedure is required only if the
  • 2003 Polaris Universal ATV | Owners Manual - Page 103
    screw is loose will result in loss of oil, which will cause serious engine damage. Always retighten the bleed screw if it's been loosened for service. 3. Start the engine and rotate the oil pump lever to its full open position. With the engine at idle, hold the lever up for thirty
  • 2003 Polaris Universal ATV | Owners Manual - Page 104
    in or out until there is 1/16″ - 1/8″ (.16 - .32 cm) of throttle lever travel before the throttle slide starts to open. See your owner's manual supplement. 3. Place very slight pressure on the throttle lever (2) until all freeplay is removed from the throttle cable (to the point where the carb slide
  • 2003 Polaris Universal ATV | Owners Manual - Page 105
    the adjuster in or out until there is 1/16″ - 1/8″ (.16 - .32 cm) throttle lever travel before the throttle slide starts to open. See your owner's manual supplement. 3. Place very slight pressure on the throttle lever until all freeplay is removed from the throttle cable (to the point where the carb
  • 2003 Polaris Universal ATV | Owners Manual - Page 106
    MAINTENANCE AND LUBRICATION Adjustments Front Brake WARNING After opening a bottle of brake fluid, always discard any unused portion. Never store or use a partial bottle. Brake fluid is hygroscopic, meaning it rapidly absorbs moisture from the air. The moisture causes the boiling temperature of the
  • 2003 Polaris Universal ATV | Owners Manual - Page 107
    Adjustments Rear Brake MAINTENANCE AND LUBRICATION The rear brake is a hydraulic disc brake. The rear brake system is self-adjusting and requires no maintenance other than periodic checks of the pads for wear. Pads should be changed when worn to 3/64″ (.1 cm), which is about the thickness of a
  • 2003 Polaris Universal ATV | Owners Manual - Page 108
    front rim (3). Rear measurement should be 1/16″ - 1/8″ (.2 to .3 cm) more than the front measurement. NOTE: If you discover improper alignment, see your Polaris dealer for service. 106
  • 2003 Polaris Universal ATV | Owners Manual - Page 109
    assembly of the ATV should be checked periodically for loose nuts and bolts. If loose nuts and bolts are found, see your Polaris dealer for service before operating the vehicle. Camber and Caster The camber and caster are non-adjustable. Rear Spring The rear shock absorber spring is adjusted by
  • 2003 Polaris Universal ATV | Owners Manual - Page 110
    loss of control and possible serious personal injury or death. Follow the adjustment procedures exactly, or see your Polaris dealer for service. Handlebars The handlebars can be adjusted for rider preference. 1. Locate handlebar bolts (1). On models with a headlight pod, remove the upper headlight
  • 2003 Polaris Universal ATV | Owners Manual - Page 111
    Adjustments Carburetor MAINTENANCE AND LUBRICATION IMPORTANT: Your Polaris ATV is calibrated at the factory for optimal performance at altitudes ranging from zero to 6,000 feet (1800 m) and temperatures of +40 degrees F. (4 degrees C.) or higher. Above 6000 feet (1800 m) the engine air/fuel
  • 2003 Polaris Universal ATV | Owners Manual - Page 112
    MAINTENANCE AND LUBRICATION Adjustments Carburetor 4-Cycle Engines If the engine idle speed is not satisfactory, and all other conditions are favorable, the carburetor can be adjusted. 1. Warm up the engine by running the vehicle for approximately five minutes. 2. Place the transmission in gear with
  • 2003 Polaris Universal ATV | Owners Manual - Page 113
    Adjustments MAINTENANCE AND LUBRICATION Side Panel Removal - Gen IV NOTE: Side panel removal may be difficult until the locking tabs and receivers have been snapped and unsnapped a few times. 1. Remove the seat. Step 2 2. Grasp the rear of the side panel near the rear cab. With a quick and firm
  • 2003 Polaris Universal ATV | Owners Manual - Page 114
    an accident resulting in serious injury or death. Maintain proper tire pressure as described on the decal on your ATV and in your owner's manual supplement. Always use original equipment size and type when replacing tires. Make sure the wheels are installed properly. Always replace tires when the
  • 2003 Polaris Universal ATV | Owners Manual - Page 115
    5. Torque the wheel nuts according to the wheel nut torque specifications chart. NOTE: All nuts that have a cotter pin installed must be serviced by an authorized Polaris dealer. Wheel Nut Torque Specifications Check the wheel nut torques occasionally and when they've been loosened for maintenance
  • 2003 Polaris Universal ATV | Owners Manual - Page 116
    wheel bearing tightness and spindle nut retention are critical component operations. All service must be performed by your authorized Polaris dealer. Tire Tread Depth Always tire pressure as outlined in this owner's manual. When replacing a tire always use original equipment size and type. 114
  • 2003 Polaris Universal ATV | Owners Manual - Page 117
    chain. Cylinder Head/Cylinder Base Fastener - 2-Cycle Have your dealer check the ATV cylinder head and cylinder base fasteners for proper torque at the first service or after 25 hours. 115
  • 2003 Polaris Universal ATV | Owners Manual - Page 118
    following procedure if adjustment is required. 1 3/16″-3/8″ (.48 cm - .95 cm) 1. Remove the chain guard if applicable. 2. Loosen the chain guide. 3. Loosen the two eccentric locking bolts (1). 1 4. Loosen the caliper mounting bracket bolts located under the axle. 5. Insert a pin punch (2) through
  • 2003 Polaris Universal ATV | Owners Manual - Page 119
    around the chain. NOTE: The chain is adjusted correctly when the tightest portion of the chain has approximately 3/8" (10mm) deflection. 11. Position the chain guide to allow 1/8" (3mm) clearance and tighten the retaining bolt to 5 ft. lbs. (7 Nm). 12. Reinstall the chain guard if applicable. 117
  • 2003 Polaris Universal ATV | Owners Manual - Page 120
    MAINTENANCE AND LUBRICATION Filter Systems Air Filter Removal and Service - 2-Cycle Engines 1. 2. 3. 4. 5. 6. Remove the ATV seat. Release the clips securing the cover assembly to the air box. Loosen the clamp securing the filter, and remove
  • 2003 Polaris Universal ATV | Owners Manual - Page 121
    - 4-Cycle Engines with Dry Sump NOTE: Refer to your owner's manual supplement to determine if your machine has a dry sump. CAUTION Operation filter can cause engine damage. Always reinstall the breather filter after removing for service. 1. Remove the clamps and pull the filter (1) out of the
  • 2003 Polaris Universal ATV | Owners Manual - Page 122
    during normal operation. Wash the headlights frequently to maintain lighting quality. Hot components can cause serious burns to skin. Do not service the headlamps until they've cooled sufficiently. Headlight Lamp Replacement - Scrambler 1. Remove the wire harness connector from the back of the
  • 2003 Polaris Universal ATV | Owners Manual - Page 123
    Lights MAINTENANCE AND LUBRICATION Headlight Lamp Replacement - Trail Blazer 1. Remove the front cover and unplug the light harness. 2. Remove the rubber cap from the back of the headlight to reveal the retention screw. 3. Remove the small phillips head screw, and carefully remove the bulb from
  • 2003 Polaris Universal ATV | Owners Manual - Page 124
    MAINTENANCE AND LUBRICATION Lights Headlight Lamp Replacement - Gen IV 1. Remove the three screws on the headlight pod. 2. Using a small flat-blade screwdriver, push in on the lock tabs through the two small openings at the front of the headlight pod. 3. Lift the pod slightly while depressing the
  • 2003 Polaris Universal ATV | Owners Manual - Page 125
    Lights MAINTENANCE AND LUBRICATION High Beam Adjustment - Gen IV The headlight beam can be adjusted to any position desired by turning the adjusting knob on the bottom right side of the headlight pod. 1. Position the vehicle on a level surface with the headlight approximately 25 ft. (7.6 m.) from
  • 2003 Polaris Universal ATV | Owners Manual - Page 126
    MAINTENANCE AND LUBRICATION Lights Headlight Housing Replacement - Gen IV 1. Remove the three screws on the headlight pod. 2. Using a small flat-blade screwdriver, push in on the lock tabs through the two small openings at the front of the headlight pod. Lift the pod lightly while depressing the
  • 2003 Polaris Universal ATV | Owners Manual - Page 127
    Lights MAINTENANCE AND LUBRICATION Taillight/Brakelight Lamp Replacement If the taillight/brakelight does not work the lamp may need to be replaced. 1. Remove the taillight lens cover mounting screws. Remove the lens cover and gasket and set aside for reassembly. 2. Remove the lamp (1) and replace
  • 2003 Polaris Universal ATV | Owners Manual - Page 128
    AND LUBRICATION Spark Plugs Refer to your owner's manual supplement for recommended spark plug and gap specifications burned or eroded. This indicates the proper type and heat range for the engine and the service. NOTE: The tip should not be white. A white insulator tip indicates overheating, caused
  • 2003 Polaris Universal ATV | Owners Manual - Page 129
    . Turn the fuel valve on. 2 12. Attempt to start the engine. If necessary, repeat the drying procedure. 13. Take the ATV to your dealer for service as soon as possible, whether you succeed in starting it or not. NOTE: If water has been ingested into the PVT, follow the procedure on
  • 2003 Polaris Universal ATV | Owners Manual - Page 130
    MAINTENANCE AND LUBRICATION Spark Arrestor WARNING Failure to heed the following warnings while servicing the spark arrestor could result in serious injury or death. Do not perform service on the spark arrestor while the system is hot. Exhaust system temperatures can reach 1000° F. Allow components
  • 2003 Polaris Universal ATV | Owners Manual - Page 131
    Spark Arrestor MAINTENANCE AND LUBRICATION 1 1 1 1. Remove the arrestor clean-out plug(s) (1) from the bottom of the muffler. 2. Place the transmission in neutral and start the engine. 3. Purge carbon from the system by momentarily revving the engine several times. 4. If carbon is expelled,
  • 2003 Polaris Universal ATV | Owners Manual - Page 132
    conditions. This should also be done before storing the ATV. Water will enter the recoil housing if the starter handle is disengaged from the rope guide when under water. NOTE: On the Trail Blazer 250, the recoil handle must be behind the heat shield for it to seal properly. The drain
  • 2003 Polaris Universal ATV | Owners Manual - Page 133
    PVT System MAINTENANCE AND LUBRICATION The basic operation of the Polaris PVT system is dependent on engine speed and vehicle torque requirements. As engine speed increases, the force exerted on the movable drive sheave by the flyweights also increases. This, in turn, increases the amount of "
  • 2003 Polaris Universal ATV | Owners Manual - Page 134
    procedures. See your dealer as outlined in the owner's manual. This PVT system is intended for use on Polaris products when water is accidently ingested into the PVT system. Use the following instructions to dry it out before operating: 1. Remove the drain plug and service as soon as possible. 132
  • 2003 Polaris Universal ATV | Owners Manual - Page 135
    Battery (Conventional) MAINTENANCE AND LUBRICATION Keep the battery terminals and connections free of corrosion. If cleaning is necessary, remove the corrosion with a stiff wire brush. Wash with a solution of one tablespoon baking soda and one cup water. Rinse well with tap water and dry off with
  • 2003 Polaris Universal ATV | Owners Manual - Page 136
    MAINTENANCE AND LUBRICATION Battery Replenishing Battery Fluid (Conventional Battery) A poorly maintained battery will deteriorate rapidly. Check the battery fluid level often. The fluid level should be kept between the upper and lower level marks (1). To refill use only distilled water. Tap water
  • 2003 Polaris Universal ATV | Owners Manual - Page 137
    battery cover can be installed. Battery Charging (Sealed Battery) The following battery charging instructions apply only to the installation of a YUASA activated, sealed battery. Read all instructions before proceeding with the installation of this battery. The YUASA activated, sealed battery is
  • 2003 Polaris Universal ATV | Owners Manual - Page 138
    the voltage is less than 12.8 volts, recharge the battery. NOTE: When using an automatic charger, refer to the charger manufacturer's instructions for recharging. When using a constant current charger, use the following guidelines for recharging. WARNING An overheated battery could explode, causing
  • 2003 Polaris Universal ATV | Owners Manual - Page 139
    Cleaning and Storage Cleaning the ATV MAINTENANCE AND LUBRICATION See page 141 for the part numbers of Polaris-recommended products. Keeping your ATV clean will not only improve its appearance but it can also extend the life of various components. With a few precautions, your ATV can be cleaned
  • 2003 Polaris Universal ATV | Owners Manual - Page 140
    may force water past seals. Stabilize the Fuel Fill the fuel tank. Add Polaris Carbon Clean Fuel Treatment or Polaris Fuel Stabilizer. Follow the instructions on the container for the recommended amount. (Carbon clean will also reduce the possibility of bacterial growth in the fuel system.) Allow 15
  • 2003 Polaris Universal ATV | Owners Manual - Page 141
    If you choose not to use Polaris Fogging Oil, perform the following procedure. 1. Support the front end of the machine so the engine is level or tilted slightly lubrication guidelines in the maintenance section of the service or owner's manual to completely grease and lubricate the entire vehicle
  • 2003 Polaris Universal ATV | Owners Manual - Page 142
    Remove the battery and ensure that it's fully charged. See page 135 for instructions. Both battery types should be stored in a cool, dry place. Battery replaced every two years. Storage Area/Covers Set the tire pressure and safely support the ATV with the tires 1-2" off the ground. Be sure the
  • 2003 Polaris Universal ATV | Owners Manual - Page 143
    POLARIS RECOMMENDED PRODUCTS Part No. 2870791 2871098 2871721 2871281 2873602 2871653 2871654 2871312 2871322 2871423 2871460 2871515 2871551 2871329 2871323 2871534 2871326 2870652 2870990 2872893 Description Engine Lubricant Fogging Oil (12 oz. Aerosol) Premium 2-Cycle Engine Oil (qt.) Premium
  • 2003 Polaris Universal ATV | Owners Manual - Page 144
    TROUBLESHOOTING Drive Belt and Cover Problems Possible Cause Driving the ATV onto a pickup or tall trailer in high range. Starting out going up a steep incline. performance. Check for fouled plugs or foreign material in gas tank, fuel lines, or carburetor. Contact your dealer for service. 142
  • 2003 Polaris Universal ATV | Owners Manual - Page 145
    TROUBLESHOOTING Contact your Polaris dealer for service if you're unable to identify solutions using the following charts. Engine Doesn't Turn Over Possible Cause Tripped circuit breaker Low battery voltage Loose battery
  • 2003 Polaris Universal ATV | Owners Manual - Page 146
    TROUBLESHOOTING Engine Backfires Possible Cause Weak spark from spark plugs Incorrect spark plug gap or heat range Old or non-recommended fuel Incorrectly installed spark plug
  • 2003 Polaris Universal ATV | Owners Manual - Page 147
    TROUBLESHOOTING Engine Stops or Loses Power Possible Cause Out of fuel Kinked or plugged fuel vent line Water present in fuel Overuse of choke Fouled or
  • 2003 Polaris Universal ATV | Owners Manual - Page 148
    COVERAGE WILL BE ALLOWED UNLESS YOUR ATV IS REGISTERED WITH POLARIS. Initial dealer preparation and set-up of your ATV is very important in ensuring trouble-free operation. Purchasing a machine in the crate or without proper dealer set-up will void your warranty coverage. 146
  • 2003 Polaris Universal ATV | Owners Manual - Page 149
    for purposes other than for which it was manufactured, or for any damages which occur during trailer transit or as a result of unauthorized service or the use of unauthorized parts. In addition, this warranty does not cover physical damage to paint or finish, stress cracks, tearing or puncturing
  • 2003 Polaris Universal ATV | Owners Manual - Page 150
    THE DEALER IS YOUR RESPONSIBILITY). Polaris suggests that you use your original selling dealer; however, you may use any Polaris Servicing Dealer to perform warranty service. Please work with your dealer to resolve any warranty issues. Should your dealer require any additional assistance they will
  • 2003 Polaris Universal ATV | Owners Manual - Page 151
    INDEX A Accessories ...75 Adjustments ...102-117 Age Restrictions ...7 Air Filter ...118-119 All Wheel Drive ...48-49 Auxiliary Brake ...42, 105 AWD ...48-49 F FEATURES ...48-55 Filter Systems ...118-119 Front Brake ...104 Front Gearcase Oil Change ...95 Front Gearcase Oil Check ...95 Front Wheel
  • 2003 Polaris Universal ATV | Owners Manual - Page 152
    Transporting the ATV ...140 Trip Meter ...53 TROUBLESHOOTING ...142-145 Turning Around on a Hill 86 Premium Gold Synthetic 2-Cycle Oil ...85 Programmable Service Interval ...54 PVT Drying ...132 PVT System ...59 W Warning, Read Your Owner's Manual ...7 WARRANTY ...148 Warranty ...146-147 Washing
  • 2003 Polaris Universal ATV | Owners Manual - Page 153
    NEVER USE WITH DRUGS OR ALCOHOL NEVER: Operate without proper training or instruction. Operate on public roads. A collision can occur with another vehicle. Operate and protective apparel. READ OWNER'S MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS. Part No. 9917492 Rev. 05 PRINTED IN THE USA
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Universal
Owner's Manual
Vehicle Maintenance and Safety
2003
ATV
for
Read this manual carefully. It contains important safety information.
This is an adult vehicle only.
Operation is prohibited for those under 16 years of age.