2005 Polaris Magnum 330 2x4 Owners Manual

2005 Polaris Magnum 330 2x4 Manual

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  • 2005 Polaris Magnum 330 2x4 | Owners Manual - Page 1
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    contains chemicals known to cause cancer, birth defects or other reproductive harm. A card containing important ATV 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.
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    reuse of the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited. Printed in U.S.A. 2005 Magnum 330 2X4/4X4 Owner's Manual P/N 9919487 2
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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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    TABLE OF CONTENTS WELCOME ...3 VEHICLE IDENTIFICATION NUMBERS ...7 SAFETY ...8 FEATURES AND CONTROLS ...34 OPERATION ...50 EMISSION CONTROL SYSTEMS ...67 MAINTENANCE AND LUBRICATION ...68 POLARIS PRODUCTS ...108 SPECIFICATIONS ...109 TROUBLESHOOTING ...115 WARRANTY ...119 INDEX ...122 5
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    6
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    VEHICLE IDENTIFICATION NUMBERS Record your ATV's identification numbers and key number in the spaces provided. Remove the spare key and store it in a safe place. Your key can be duplicated only by mating a Polaris key blank with one of your existing keys, so if both keys are lost, the ignition
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    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 vehicle or in this manual, alerts you to the potential for personal injury. WARNING The damage to the vehicle. NOTE: A note will alert you to important information or instructions. 9
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    Operator 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
  • 2005 Polaris Magnum 330 2x4 | Owners Manual - Page 17
    SAFETY Operator 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 carry
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    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 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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    ATV before each 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. 17
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    SAFETY Operator Safety WARNING POTENTIAL HAZARD Removing hands from the handlebars or feet from the footrests during operation. WHAT CAN HAPPEN Removing even one hand or foot can reduce ability to control the vehicle or could cause loss of balance and ejection from the ATV. If the operator's foot
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    loss of control 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. 19
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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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    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 61. Always check the terrain carefully before descending a hill. Shift
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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 62. 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 62. 23
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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
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    Operator Safety 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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    and securely attached. Reduce speed when carrying cargo or pulling a 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 56. WARNING POTENTIAL HAZARD Operating on frozen bodies of water. WHAT CAN
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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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    the decals and other warnings on the ATV carefully. If any of the decals shown in this manual differ from the decals on your ATV, always read and follow the instructions of the decals on the ATV. If any decal becomes illegible or comes off, contact your Polaris dealer to purchase a replacement
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    Safety Decals and Locations WARNING SAFETY WARNING Operating this ATV if you are under the age of 16 increases your chance of severe injury or death. 7172561 NEVER operate this ATV if you are under age 16. 7172559 Location A Location B WARNING S S Moving parts hazard under belt-clutch guard. To
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    will severely damage and adjustments are required the engine. depending on temperature and altitude. See your Owner's S Clean pre-filter element often, Manual. more frequent cleaning Factory setting: required in dusty conditions. Do not operate vehicle without 40_ to 80_ F. at 0-3000 feet pre-filter
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    push switch to engage AWD if the rear wheels are spinning. This may cause severe drive shaft and clutch damage. See your Owner's Manual. 7172560 7079780 Applicable AWD Models Location H WARNING Pushing reverse override button may cause sudden increases in power and traction if too much throttle
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    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
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    Fuel Safety 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 well ventilated area. S Do not smoke or allow open flames or sparks in or near
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    FEATURES AND CONTROLS Electrical Switches 1 3 2 4 5 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
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    Electrical Switches FEATURES AND CONTROLS 3. Engine Stop Switch - The engine will not start or run when the switch is in the OFF position. Its purpose is to provide the operator with a quick means of engine shutdown in case of an emergency. 3 To stop the engine, slide the stop switch either right
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    to severe injury or death. Never start or operate an ATV with a sticking or improperly operating throttle. Always contact your dealer for service if throttle problems arise. Failure to check or maintain proper operation of the throttle system can result in an accident if the throttle lever sticks
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    Brakes Master Cylinder FEATURES AND CONTROLS 1 Check the brake fluid level in the master cylinder before each use of the ATV. The master cylinder (1) is located on the left handlebar. View the fluid level through the indicator window (2) on the top of the master cylinder. This eye will appear dark
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    FEATURES AND 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
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    Parking Brake FEATURES AND 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)
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    FEATURES AND CONTROLS Auxiliary Brake WARNING Aggressively applying the auxiliary 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.
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    Choke FEATURES AND CONTROLS The choke assists in starting a cold engine. Refer to the engine starting procedure on page 52 for correct choke and throttle settings during starting. Fuel Valve The fuel valve (1) is located on the left side of the vehicle on the side panel. It has three positions:
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    FEATURES AND CONTROLS Automatic Transmission Gear Selector The transmission gear selector (1) is located on the right side of the vehicle. 1 H: High Gear H N: Neutral L L: Low Gear R: Reverse N P: Park To shift into HIGH or PARK, you must first apply the P auxiliary brake to activate the high/park
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    Recoil Starter FEATURES AND CONTROLS 2 If the battery has been drained or 1 damaged and cannot 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
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    FEATURES AND CONTROLS All Wheel Drive System (Domestic Models) Polaris 4 wheel drive domestic model ATVs are equipped with a unique, Polaris exclusive, All Wheel Drive (AWD) System activated by a switch (1) on the right handlebar. Engage the AWD when the rear wheels lose traction. 1 When the AWD
  • 2005 Polaris Magnum 330 2x4 | Owners Manual - Page 48
    FEATURES AND CONTROLS Instrument Cluster (Magnum 330) 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
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    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
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    Information Center FEATURES AND CONTROLS 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
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    Instrument Cluster (Magnum 330) Rider Information Center FEATURES AND CONTROLS 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
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    OPERATION Break-In Period The break-in period for your new Polaris 4-cycle 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. Careful
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    Pre-Ride Inspection OPERATION 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. Pre-Ride Checklist Item Brake system / lever travel Brake fluid Auxiliary brake
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    OPERATION Starting the Engine Starting a Cold Engine 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. 1. Place the transmission in PARK and lock the parking brake. Make sure
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    Starting the Engine Starting a Warm Engine OPERATION Warm engines do not normally require the use of the choke. Excessive use of the choke can cause the spark plug to become wet fouled. 1. Position the vehicle on a level surface with the transmission in PARK. 2. Lock the parking brake, turn the
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    OPERATION Driving Safely Driving Procedures 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 brake
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    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
  • 2005 Polaris Magnum 330 2x4 | Owners Manual - Page 59
    OPERATION Driving Safely Hauling Cargo 1/3 2/3 Your ATV has been designed to carry or tow a certain amount of load. Always read and understand the load distribution warnings listed on the warning labels, and never exceed the specified weights. Cargo weight should be evenly distributed (1/3 on the
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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 USE EXTREME CAUTION when
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    OPERATION Driving Safely Driving on Slippery Surfaces 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 quick
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    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. 59
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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 the most dangerous type of driving encountered and should be avoided if at all possible. If you do enter into a situation
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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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    the maintenance chart. If your vehicle becomes immersed or is operated in water that exceeds the footrest level, take it to your dealer for service before starting the engine. NOTE: Avoid operating the vehicle through deep or fast-flowing water. If you cannot avoid water that exceeds the recommended
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    OPERATION Driving Safely Driving Over Obstacles 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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    Driving Safely Driving in Reverse OPERATION 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
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    OPERATION Driving Safely Parking on an Incline Avoid parking on an incline if possible. If it's unavoidable, follow these precautions: 1. Turn the engine off. 1. Place the transmission in PARK. 2. Set the parking brake. 3. Always block the rear wheels on the downhill side. See illustration. 4. Shut
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    and operation of this vehicle. Spark Arrestor Your Polaris vehicle has a spark arrestor that was tested and approved in accordance with the USDA Forest Service Standard 5100-1C. Federal law requires that this spark arrestor be installed and functional when the vehicle is operated on public lands
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    these operations. Some models are equipped with a speedometer that has a programmable service interval mode. This important feature will help you determine when maintenance service is due. See page 48 for instructions. Maintenance intervals in the following charts are based upon average riding
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    Periodic Maintenance Chart Item MAINTENANCE AND LUBRICATION Maintenance Interval Remarks Perform all services at whichever maintenance interval is reached first. (whichever comes first) Hours Calendar Miles (Km) 10 H 20 H 25 H 25 H 25 H 25 H Pre-Ride Pre-Ride Pre-
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    ) " Cooling hoses " Engine mounts Exhaust muffler/ pipe J Spark plug E E " J Ignition Timing Perform these procedures more often for vehicles subjected to severe use. E Emission Control System Service (California) J Have an authorized Polaris dealer perform these
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    wheel J Brake fluid Spark arrestor E Idle speed J Toe adjustment Headlight aim " Perform these procedures more often for vehicles subjected to severe use. E Emission Control System Service (California) J Have an authorized Polaris dealer perform these
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    MAINTENANCE AND LUBRICATION Lubrication Guide Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart beginning on page 68. Items not listed in the chart should
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    Periodic Maintenance Record Maintenance Interval Performed MAINTENANCE AND LUBRICATION Servicing Servicing Date Dealer or Person Remarks Use the following chart to record periodic maintenance. 73
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    MAINTENANCE AND LUBRICATION Premium 4 Synthetic Lubricant Polaris Premium 4 All Season synthetic engine oil has been specially formulated for use in Polaris 4-cycle engines. It's a fully synthetic, high performance, multi-viscosity oil designed to provide the ultimate in lubrication performance and
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    Engine Oil Check NOTE: MAINTENANCE AND LUBRICATION 1 The oil dipstick (1) is located on the left side of the engine. A rising oil level between checks in cool weather driving can indicate contaminants such as gas or moisture collecting in the crankcase. If the oil level is over the full/safe mark,
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    MAINTENANCE AND LUBRICATION Oil and Filter Change 5. Place a drain pan beneath the engine crankcase and remove the drain plug. 6. Allow the oil to drain completely. 7. Install a new sealing washer on the drain plug. NOTE: The sealing surfaces on the drain plug and crankcase should be clean and free
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    Transmission Oil MAINTENANCE AND LUBRICATION Always check and change the transmission oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 68. Maintain the oil level 1 5/8" from the top of the fill hole. We recommend the use of Premium AGL Synthetic Gearcase Lubricant.
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    . 4. Reinstall the fill plug. Torque to specification. Oil Change 3 1. Check the vent hose (3) to be sure it's unobstructed and routed properly. 2. Support the vehicle securely with a jackstand and remove the front tire on the driver's side. 2 3. Remove the drain plug (4) located on the bottom of
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    Rear Gearcase Oil Oil Check MAINTENANCE AND LUBRICATION Always check and change the rear gearcase oil at the intervals outlined in 2 the Periodic Maintenance Chart beginning on page 68. Maintain the rear gearcase oil level at the bottom of the fill hole threads (1). We recommend the use of Polaris
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    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 1. Turn the back of the headlight harness in a counter-clockwise direction
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    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). 3. Apply
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    will be few combustion deposits. The electrodes are not 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 by use of an improper spark plug or incorrect carburetion
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    (1). 9. Turn the fuel valve on. 10. Attempt to start the engine. If necessary, repeat the drying procedure. 11. 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
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    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
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    . This should also be done before storing the ATV. NOTE: Water will enter the recoil housing if the starter handle is disengaged from the rope guide when under water. The drain screw is located at the bottom of the recoil housing. Use a wrench to remove the screw. Be sure to reinstall
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    MAINTENANCE AND LUBRICATION PVT System 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 "pinch"
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    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. 87
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    not been fully charged can damage the battery and result in a shorter life. It can also hinder vehicle performance. Follow the battery charging instructions on page 89 before installing the battery. 1. Ensure that the battery is fully charged. 2. Set the battery in the battery holder. 3. Connect and
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    or less until the battery voltage is 12.8 or greater. 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 may explode, causing severe
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    MAINTENANCE AND LUBRICATION Battery NOTE: Battery Charging Always verify battery condition before and 1-2 hours after the end of charging. Voltage Action Charge Time* (Using constant current charger @ standard amps specified on top of battery) State of Charge 100% 12.8-13.0 volts None, check at
  • 2005 Polaris Magnum 330 2x4 | Owners Manual - Page 94
    Adjustments Brakes MAINTENANCE AND LUBRICATION The front and rear brakes are hydraulic disc brakes, activated by moving the single brake lever toward the handlebar. These brakes are self-adjusting. The following checks are recommended to keep the brake system in good operating condition. Check
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    MAINTENANCE AND LUBRICATION Adjustments Auxiliary Brake The auxiliary 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. Change the brake pads when they're worn to 3/64″ (.1 cm). Inspect the brake disc
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    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. 93
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    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
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    in loss of control and possible serious personal injury or death. Follow the adjustment procedures exactly, or see your Polaris dealer for service. Handlebars 1 The handlebars can be adjusted for rider preference. 1. Remove the handlebar cover. 2. Loosen the four handlebar bolts (1). 3. Adjust the
  • 2005 Polaris Magnum 330 2x4 | Owners Manual - Page 99
    MAINTENANCE AND LUBRICATION Adjustments Carburetor 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 mixture
  • 2005 Polaris Magnum 330 2x4 | Owners Manual - Page 100
    Adjustments MAINTENANCE AND LUBRICATION Throttle Cable Freeplay The throttle cable adjuster is located at the right handlebar. 1. Slide the boots (1) off the inline cable adjuster sleeve (2). Loosen the adjuster locknut (3). 2. Turn the adjuster until 1/16″ to 1/8″ freeplay is achieved at the
  • 2005 Polaris Magnum 330 2x4 | Owners Manual - Page 101
    MAINTENANCE AND LUBRICATION Adjustments NOTE: Side Panel Removal Side panel removal may be difficult until the locking tabs and receivers have been snapped and unsnapped a few times. Step 2 1. Remove the seat. 2. Grasp the rear of the side panel near the rear cab. With a quick and firm motion,
  • 2005 Polaris Magnum 330 2x4 | Owners Manual - Page 102
    in serious injury or death. Maintain proper tire pressure as described on the decal on your ATV and in the specifications section of the owner's manual beginning on page 109. Always use original equipment size and type when replacing tires. Make sure the wheels are installed properly. Always replace
  • 2005 Polaris Magnum 330 2x4 | Owners Manual - Page 103
    tire wear and vehicle handling, which can result in serious injury or death. Always ensure that all nuts are torqued to specification. Do not service axle nuts that have a cotter pin installed. See your Polaris dealer. Wheel Installation 1. Place the transmission in PARK and lock the parking brake
  • 2005 Polaris Magnum 330 2x4 | Owners Manual - Page 104
    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. 101
  • 2005 Polaris Magnum 330 2x4 | Owners Manual - Page 105
    MAINTENANCE AND LUBRICATION Adjustments Air Filter Service 1. Remove the seat. 2. Release the clips and remove the air box cover (1). 3. Loosen the clamp and remove the filter. 4. Remove the fabric type pre-filter (2)
  • 2005 Polaris Magnum 330 2x4 | Owners Manual - Page 106
    Accessories MAINTENANCE AND LUBRICATION Auxiliary power outlets provide 12V power for operating accessories such as hand held spot lights. See your Polaris dealer. Cleaning and Storage See page 108 for the part numbers of Polaris products. Cleaning the ATV Keeping your ATV clean will not only
  • 2005 Polaris Magnum 330 2x4 | Owners Manual - Page 107
    and promotes better starting after the storage period. 1. Fill the fuel tank with fuel and add Polaris Carbon Clean or Fuel Stabilizer. Follow the instructions on the container for the recommended amounts. 2. Start the engine and allow it to run for 15-20 minutes so the stabilizer can disperse
  • 2005 Polaris Magnum 330 2x4 | Owners Manual - Page 108
    lubrication guidelines in the maintenance section of the service or owner's manual to completely grease and lubricate the entire vehicle with Polaris Premium All Season Grease. Storage Area/Covers Set the tire pressure and safely support
  • 2005 Polaris Magnum 330 2x4 | Owners Manual - Page 109
    apply a weather resistant wax to each polished chrome wheel. Choose a product suitable for chrome finishes. Read and follow the product labels and instructions. 4. Chrome wheels exposed to road salt (or salt in the air in coastal areas) are more susceptible to corrosion if not properly cleaned
  • 2005 Polaris Magnum 330 2x4 | Owners Manual - Page 110
    tie the frame of the ATV to the transporting unit securely using suitable straps or rope. The rack, bumper or handlebars do not offer enough support for tie-down while transporting the unit. 5. Always place the transmission in PARK and lock the parking brake. 107
  • 2005 Polaris Magnum 330 2x4 | Owners Manual - Page 111
    POLARIS PRODUCTS Part No. 2870791 2871281 2871844 2873602 2873603 2871653 2872276 2870465 2871654 2872277 2871322 2871423 2871460 2871515 2871551 2871312 2871329 2872073 2872348 2871323 2871534 2872889 2871326 2870652 2870990 2872893 2871956 Description Engine Lubricant Fogging Oil (12 oz. Aerosol)
  • 2005 Polaris Magnum 330 2x4 | Owners Manual - Page 112
    2005 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 Length Width Height Seat Height Dry Weight Wheel Base Engine Model Number / Type Lubrication Bore x
  • 2005 Polaris Magnum 330 2x4 | Owners Manual - Page 113
    SPECIFICATIONS Drive System Type Shift Type Front Drive (ratio) Front Tires Rear Tires 2005 Magnum 330 2X4 Drive System PVT Side Lever 3.1/1 24 x 8-12 (4 psi) 24 x 11-12 (3 psi) Suspension and Brakes Front Suspension: Mac Strut 6.7 in. (17 cm) travel Rear Suspension: Progressive Rate 7.1 in. (18
  • 2005 Polaris Magnum 330 2x4 | Owners Manual - Page 114
    2005 Magnum 330 2X4 Jetting Chart Altitude Meters (Feet) AMBIENT TEMPERATURE 0-1800 (0-6000) 1800-3700 (6000-12000) SPECIFICATIONS Below 40° F (Below 5° C) 127.5 120 +40°F and above (+5°C and above) 122.5 115 Clutching Chart Altitude Meters (Feet) 0-1800 (0-6000) 1800-3700 (6000-12000) Shift
  • 2005 Polaris Magnum 330 2x4 | Owners Manual - Page 115
    SPECIFICATIONS 2005 Magnum 330 4X4 Capacities Body Style Gen IV Gross Vehicle Weight 1100 lbs. (499 kg) Fuel Capacity 3.25 gal. (12.3 l) Engine Oil Capacity 1.9 qts. (1.8 l) Transmission Oil 13.5 oz. (400 ml) Front Gearcase Oil (Centralized Hilliard) 5 oz. (148 ml) Rear Gearcase Oil 10 oz. (300 ml)
  • 2005 Polaris Magnum 330 2x4 | Owners Manual - Page 116
    2005 Magnum 330 4X4 Drive System Type Shift Type Front Drive (ratio) Final Drive (ratio) Front Tires Rear Tires SPECIFICATIONS Drive System PVT Side Lever 3.7/1 3.1/1 24 x 8-12 (4 psi) 24 x 11-12 (3 psi) Suspension and Brakes Front Suspension: Mac Strut 6.7 in. (17 cm) travel Rear Suspension:
  • 2005 Polaris Magnum 330 2x4 | Owners Manual - Page 117
    SPECIFICATIONS Jetting Chart Altitude Meters (Feet) AMBIENT TEMPERATURE 0-1800 (0-6000) 1800-3700 (6000-12000) 2005 Magnum 330 4X4 Below 40° F (Below 5° C) 127.5 120 +40°F and above (+5°C and above) 122.5 115 Clutching Chart Altitude Meters (Feet) 0-1800 (0-6000) 1800-3700 (6000-12000) Shift
  • 2005 Polaris Magnum 330 2x4 | Owners Manual - Page 118
    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. 115
  • 2005 Polaris Magnum 330 2x4 | Owners Manual - Page 119
    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
  • 2005 Polaris Magnum 330 2x4 | Owners Manual - Page 120
    plugs Incorrect spark plug gap or heat range Old or non-recommended fuel Incorrectly installed spark plug wires Incorrect ignition timing Mechanical failure TROUBLESHOOTING Solution Inspect, clean and/or replace spark plugs Set gap to specs or replace plugs Replace with new fuel See your Polaris
  • 2005 Polaris Magnum 330 2x4 | Owners Manual - Page 121
    TROUBLESHOOTING Possible Cause Out of fuel Kinked or plugged fuel vent line Water present in fuel Overuse of choke Fouled or defective spark plugs Worn or
  • 2005 Polaris Magnum 330 2x4 | Owners Manual - Page 122
    preparation and set-up of your ATV is very important in ensuring trouble-free operation. Purchasing a machine in the crate or without proper 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
  • 2005 Polaris Magnum 330 2x4 | Owners Manual - Page 123
    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
  • 2005 Polaris Magnum 330 2x4 | Owners Manual - Page 124
    must be done by an authorized Polaris dealer. If you move or are traveling within the country where your vehicle was purchased, Warranty or Service Bulletin repairs may be requested from any authorized Polaris dealer who sells the same line as your vehicle. Outside the Country where your vehicle
  • 2005 Polaris Magnum 330 2x4 | Owners Manual - Page 125
    INDEX A Accessories ...103 Adjustments ...91-102 Age Restrictions ...8 Air Filter ...102 All Wheel Drive ...44 All Wheel Drive Switch ...35 Auxiliary Brake ...40, 92 AWD Switch ...35 E Electrical Switches ...34-35 Electromagnetic Interference ...67 EMISSION CONTROL SYSTEMS 67 Engaging Front
  • 2005 Polaris Magnum 330 2x4 | Owners Manual - Page 126
    ...80-81 Low Range ...86 Lubrication Guide ...72 S Safe Riding Gear ...32 Oil ...77 Transporting an ATV ...107 Trip Meter ...47 TROUBLESHOOTING ...115-118 Turning Around on a Hill ...62 P ...51 Premium 4 Synthetic Lubricant ...74 Programmable Service Interval ...48 PVT Drying ...87 PVT System
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