2004-2005 Polaris ATP 500 OEM Service & Repair Manual

GENERAL INFORMATION 1.1 Model Identification 1.2 ....................... Serial Number Location 1.2 ................... Replacement Keys 1.3 ....................... 2004 ATP General Specifications 1.4 ........... Specifications - 2004 ATP 330 1.5 ............. Specifications - 2004 ATP 500 1.6 ............. 2005 ATP General Specifications 1.7 ........... Specifications - 2005 ATP 330 1.8 ............. Specifications - 2005 ATP 500 1.9 ............. Publication Numbers 1.10 ..................... Accessory Springs 1.10 ....................... Standard Torque Specifications 1.10 ............ Special Tools 1.11--1.15 ............................ Tap Drill Charts 1.16 .......................... Decimal Equivalent Chart 1.16 ................. Unit of Measure Conversion Table 1.17 .......... Glossary of Terms 1.18 ........................ Specs 2004-2005 330/500 ATP

GENERAL INFORMATION 1.2 MODEL IDENTIFICA TION The machine model number must be used with any correspondence regarding warranty or service. Machine Model Number Identification Year Designation Basic Chassis Designation Engine Designation A 05 JD 32 AA Emissions & Model Option ENGINE DESIGNATION NUMBERS ES320PFE101 Single, Oil/Air Cooled, SOHC 4 Stroke, Electric Start .............. EH500PLE201 Single, Water Cooled, SOHC 4 Stroke, Electric Start .............. VIN IDENTIFICA TION 1 2 3 4 5 6 7 8 9 10 1 1 12 13 14 15 16 17 4 X A J D 3 2 A * 5 P 0 0 0 0 0 0 Vehicle Descriptor Vehicle Identifier Powertrain Engine Emissions Model Year Plant No. Individual Serial No. Body Style Check Digit World Mfg. ID * This could be either a number or a letter ENGINE SERIAL NUMBER LOCA TION Be sure to refer to the engine model number and serial number whenever corresponding about an engine. This information can be found on the sticker applied to the recoil housing on the right side of engine.(A) An additional number is stamped on the center top of crankcase beneath the cylinder. UNIT MODEL NUMBER AND SERIAL NUMBER LOCA TION The machine model number and serial number are important for vehicle identification. The machine serial number is stamped on the lower left side of the frame tube.(B) A B Front

GENERAL INFORMATION 1.3 TRANSMISSION I.D. NUMBER- LOCA TION COLD WEATHER KITS FOR 4 CYCLE A TVS Engine Heater -- (PN 2871507) REPLACEMENT KEYS Replacement keys can be made from the original key. To identify which series the key is, take the first two digits on the original key and refer to the chart to the right for the proper part number. Series # Part Number 20 4010278 21 4010278 22 4010321 23 4010321 27 4010321 28 4010321 31 4110141 32 4110148 67 4010278 68 4010278 31XX Key Series Number The transmission I.D. number is located on the right side of machine. ACCESSORY ENGINE HEATER

GENERAL INFORMATION 1.4 MODEL: 2004 ATP 330 4x4 .......... MODEL NUMBER: A04JD32AA . ENGINE MODEL: ES32PFE101 .. Category Dimension / Capacity Length 91 in./231 cm Width 46 in./116.8 cm Height 46 in./116.8 cm Wheel Base 56 in./142 cm Dry Weight 719 lbs./326 kg Gross Vehicle Weight 1300 Lbs. / 590 kg Front Rack Capacity 90 lbs./40.8 kg Rear Box Capacity 250 lbs./113 kg Side Pocket Capacity 20 lbs./9 kg Towing Capacity 1000 lbs./454 kg Hitch Tongue Capacity 100 lbs./45.4 kg (Rear box capacity and tongue weight not to ex- ceed 250 lbs/113 kg) MODEL: 2004 ATP 500 4x4 .......... MODEL NUMBER: A04JD50AA, A04JD50CA . ENGINE MODEL: EH50PLE200, EH50PLE201 .. Category Dimension / Capacity Length 91 in./231 cm Width 46 in./116.8 cm Height 47 in./119.4 cm Wheel Base 56 in./142 cm Dry Weight 738 lbs./335 kg Gross Vehicle Weight 1500 Lbs. / 680 kg Front Rack Capacity 90 lbs./40.8 kg Rear Box Capacity 400 lbs./181 kg Side Pocket Capacity 20 lbs./9 kg Towing Capacity 1225 lbs./556 kg Hitch Tongue Capacity 120 lbs./54 kg (Rear box capacity and tongue weight not to ex- ceed 400 lbs/181 kg)

GENERAL INFORMATION 1.5 MODEL: 2004 ATP 330 4x4 .......... MODEL NUMBER: A04JD32AA . ENGINE MODEL: ES32PFE101 .. Engine Platform Fuji 4 stroke, Single Cylinder Engine Model Number ES32PFE101 Engine Displacement 329cc Number of Cylinders 1 Bore & Stroke (mm) 78.5 x 68 mm Compression Ratio 9.2:1 Compression Pressure 70--90 psi w/ decompressor Engine Idle Speed 1300 ± 200 RPM Engine Max Operating Rpm 6950 RPM Cooling System Oil / Air w/ fan assist Overheat Warning HOT on Instrument Cluster Lubrication Wet Sump Oil Requirements / Capacity Polaris 0W--40 1.9 qt. / 1.8 ltr Exhaust System USFS Approved Carburetion Carburetor model Mikuni BST 34mm Main Jet 122.5 Pilot Jet 42.5 Pilot Air Jet 160 Jet Needle -- Clip Position 4HB48--2 Needle Jet P--0 (829) Pilot Screw 2 Turns Out (Initial starting point, settings may vary for each ATP) Float Height 13 ± 1 mm / 0.51 ± 0.40“ Fuel Delivery Fuel Pump Fuel Capacity / Requirement 3.25 gal US / 12.3 ltr 87 Octane (minimum) 89 Oxygenated Electrical Alternator Output 200 w @ 5000 RPM Voltage Regulator 3--Phase -- LR--390 Lights : High Beam 30 watts Low Beam 30 watts Brake Two 12V/1.7 watts Tail Two 12V/8.26 watts Ignition System DC/CDI Ignition Ignition Timing 30°± 2° BTDC @ 5000 RPM Spark plug / Gap NGK BKR6E/ .036 in./ 0.9 mm Battery / Model / Amp Hr Low Maintenance Yuasa YTX12 14 Amp Hr Circuit Breakers Fan 10 amp / Harness 20 amp Starting Electric / Recoil Backup Instrument Cluster Analog Speedo w/ LCD Drivetrain Transmission Type Drumshift -- H/L/N/Rev/Park Transmission Capacity 13.5 oz. / 400ml Rear Gearcase Capacity 18 oz. / 532ml Front Gearcase Capacity 5 oz. / 150ml Gear Ratio : Low Rev High Front Drive Rear Drive 11.57:1 6.84:1 4.41:1 3.7:1 3.08:1 Clutch Type PVT Non--EBS Belt 3211077 Steering / Suspension Front Suspension / Shock A--arm / MacPherson Strut Front Travel 6.7 in. / 17.02 cm Rear Suspension / Shock Swing Arm w/ Sachs Shocks Rear Travel 7.1 in. / 18.03 cm Ground Clearance 6.5 in. / 11.43 cm Shock Preload Adjustment Front / Rear Front --Non Adjustable. Rear -- RatchetStyle-- Std. Turning Radius 75 in. / 190.5 cm unlocked Toe Out 1/8--1/4-- in/ .0 -- .159mm Wheels / Brakes Wheel Size / Pattern -- Front Steel 24x8--12 / 4--156 Wheel Size / Pattern -- Rear Steel 24x11--12 / 4--156 Front Tire Model / Size Titan 24x8--12 Rear Tire Model / Size Titan 24x11--12 Recommended Air Pressure Front & Rear -- 5psi Brake -- Front Dual Hydraulic Disc Brake -- Rear Dual Hydraulic Disc JETTING CHART Altitude Meters (Feet) AMBIENT TEMPERATURE 0--1800 (0--6000) above 1800 (above 6000) Below 40°F Below 5°C +40°F to +80°F +5°C to +28°C 127.5 122.5 120 115 CLUTCH CHART Standard helix spring position is 2 -- 2 Altitude Meters (Feet) 0--1800 (0--6000) 1800--3700 (6000--12000) Shift Drive Spring Driven Helix Weight 20--40 20--38 41--35 41--35 Blu/Grey Blu/Grey Driven Spring Black Black (5631356) (5631357) (7042202) (7042202) (7041782) (7041782) (5133701) (5133701) 2--2 2--2

GENERAL INFORMATION 1.6 MODEL: 2004 ATP 500 4x4 .......... MODEL NUMBER: A04JD50AA, A04JD50CA . ENGINE MODEL: EH50PLE200, EH50PLE201 .. Engine Platform Fuji 4 stroke, Single Cylinder Engine Model Number EH50PLE200, EH50PLE201 Engine Displacement 499cc Number of Cylinders 1 Bore & Stroke (mm) 92 x 75 mm Compression Ratio 10.2:1 Compression Pressure 50--90 psi w/ decompressor Engine Idle Speed 1200 ± 200 RPM Engine Max Operating Rpm 7000 RPM Cooling System / Capacity Liquid -- 3.2 qt. / 3.02 ltr Overheat Warning HOT on Instrument Cluster Lubrication Pressurized Dry Sump Oil Requirements / Capacity Polaris 0W--40 2 qt. / 1.9 ltr Exhaust System USFS Approved Carburetion Carburetor model Mikuni BST 40 mm Main Jet 155 Pilot Jet 40 Pilot Air Jet 160 Jet Needle -- Clip Position 6H25--94--3 Needle Jet Y--0M (896) Pilot Screw 2 Turns Out (Initial starting point, settings may vary for each ATP) Float Height 14.7 ± 1 mm / 0.58 ± 0.40“ Fuel Delivery Fuel Pump Fuel Capacity / Requirement 3.25 gal US / 12.3 ltr 87 Octane (minimum) 89 Oxygenated Electrical Alternator Output 250 w @ 5000 RPM Voltage Regulator 3--Phase -- LR--390 Lights : Pod 60 watts Grill Two x 27 watts Brake Two 12V/1.7 watts Tail Two 12V/8.26 watts Ignition System DC/CDI Ignition Ignition Timing 30°± 2° BTDC @ 5000 RPM Spark plug / Gap NGK BKR6E/ .028 in./ 0.7 mm Battery / Model / Amp Hr Low Maintenance Yuasa YTX12 14 Amp Hr Circuit Breakers Fan 10 amp / Harness 20 amp Starting Electric / Recoil Backup Instrument Cluster Analog Speedo w/ LCD Drivetrain Transmission Type Drumshift -- H/L/N/Rev/Park Transmission Capacity 13.5 oz. / 400ml Rear Gearcase Capacity 18 oz. / 532ml Front Gearcase Capacity 5 oz. / 150ml Gear Ratio : Low Rev High Front Drive Rear Drive 8.66:1 3.52:1 5.12:1 3.7:1 3.08:1 Clutch Type PVT w/EBS Belt 3211069 Steering / Suspension Front Suspension / Shock A--arm / MacPherson Strut Front Travel 6.7 in. / 17.02 cm Rear Suspension / Shock Swing Arm w/ Sachs Shocks Rear Travel 7.1 in. / 18.03 cm Ground Clearance 7.0 in. / 17.8 cm Shock Preload Adjustment Front / Rear Front --Non Adjustable. Rear -- RatchetStyle-- Std. Turning Radius 75 in. / 190.5 cm unlocked Toe Out 0 -- 1/16 in / .0 -- .159 mm Wheels / Brakes Wheel Size / Pattern -- Front Steel 25x8--12 / 4--156 Wheel Size / Pattern -- Rear Steel 25x11--12 / 4--156 Front Tire Model / Size Titan 25x8--12 Rear Tire Model / Size Titan 25x11--12 Recommended Air Pressure Front & Rear -- 5psi Brake -- Front Dual Hydraulic Disc Brake -- Rear Dual Hydraulic Disc JETTING CHART Altitude Meters (Feet) AMBIENT TEMPERATURE 0--1800 (0--6000) above 1800 (above 6000) Below 40°F Below 5°C +40°F to +80°F +5°C to +28°C 160 155 152.5 147.5 CLUTCH CHART EBS models have no helix/spring adjustment Altitude Meters (Feet) 0--1800 (0--6000) 1800--3700 (6000--12000) Shift Drive Spring Driven Helix Weight 10 BH 10 RH EBS Blu/Grn Blu/Grn Driven Spring Wht/Yel (5630711) (5630709) (7041157) (7041157) Wht/Yel (7041635) (7041635) EBS (5132751) (5132751)

GENERAL INFORMATION 1.7 MODEL: 2005 ATP 330 4x4 .......... MODEL NUMBER: A05JD32AA . ENGINE MODEL: ES32PFE .. Category Dimension / Capacity Length 91 in./231 cm Width 46 in./116.8 cm Height 46 in./116.8 cm Wheel Base 56 in./142 cm Dry Weight 719 lbs./326 kg Gross Vehicle Weight 1300 Lbs. / 590 kg Front Rack Capacity 90 lbs./40.8 kg Rear Box Capacity 250 lbs./113 kg Side Pocket Capacity 20 lbs./9 kg Towing Capacity 1000 lbs./454 kg Hitch Tongue Capacity 100 lbs./45.4 kg (Rear box capacity and tongue weight not to ex- ceed 250 lbs/113 kg) MODEL: 2005 ATP 500 4x4 .......... MODEL NUMBER: A05JD50AA, A05JD50CA . ENGINE MODEL: EH50PLE .. Category Dimension / Capacity Length 91 in./231 cm Width 46 in./116.8 cm Height 47 in./119.4 cm Wheel Base 56 in./142 cm Dry Weight 738 lbs./335 kg Gross Vehicle Weight 1500 Lbs. / 680 kg Front Rack Capacity 90 lbs./40.8 kg Rear Box Capacity 400 lbs./181 kg Side Pocket Capacity 20 lbs./9 kg Towing Capacity 1225 lbs./556 kg Hitch Tongue Capacity 120 lbs./54 kg (Rear box capacity and tongue weight not to ex- ceed 400 lbs/181 kg)

GENERAL INFORMATION 1.8 MODEL: 2005 ATP 330 4x4 .......... MODEL NUMBER: A05JD32AA . ENGINE MODEL: ES32PFE .. Engine Platform Fuji 4 stroke, Single Cylinder Engine Model Number ES32PFE103 Engine Displacement 329cc Number of Cylinders 1 Bore & Stroke (mm) 78.5 x 68 mm Compression Ratio 9.2:1 Compression Pressure 70--90 psi w/ decompressor Engine Idle Speed 1300 ± 200 RPM Engine Max Operating Rpm 7250 RPM Cooling System Oil / Air w/ fan assist Overheat Warning HOT on Instrument Cluster Lubrication Wet Sump Oil Requirements / Capacity Polaris 0W--40 1.9 qt. / 1.8 ltr Exhaust System USFS Approved Carburetion Carburetor model Mikuni BST 34mm Main Jet 122.5 Pilot Jet 42.5 Pilot Air Jet 160 Jet Needle -- Clip Position 48B48--3 (3rd clip position) Needle Jet P--4M (829) Pilot Screw 2.25 Turns Out (Initial starting point, settings may vary for each ATP) Float Height 13 ± 1 mm / 0.51 ± 0.40“ Fuel Delivery Fuel Pump Fuel Capacity / Requirement 3.25 gal US / 12.3 ltr 87 Octane (minimum) 89 Oxygenated Electrical Alternator Output 200 w @ 5000 RPM Voltage Regulator 3--Phase -- LR--390 Lights : High Beam 30 watts Low Beam 30 watts Brake Two 12V/1.7 watts Tail Two 12V/8.26 watts Ignition System DC/CDI Ignition Ignition Timing 30°± 2° BTDC @ 5000 RPM Spark plug / Gap NGK BKR6E/ .036 in./ 0.9 mm Battery / Model / Amp Hr Low Maintenance --14 Amp Hr Starting Electric / Recoil Backup Instrument Cluster Analog Speedo w/ LCD Drivetrain Transmission Type Drumshift -- H/L/N/Rev/Park Transmission Capacity 13.5 oz. / 400ml Rear Gearcase Capacity 18 oz. / 532ml Front Gearcase Capacity 5 oz. / 150ml Gear Ratio : Low Rev High Front Drive Rear Drive 11.57:1 6.84:1 4.41:1 3.7:1 3.08:1 Clutch Type PVT Non--EBS Belt 3211077 Steering / Suspension Front Suspension / Shock A--arm / MacPherson Strut Front Travel 6.7 in. / 17.02 cm Rear Suspension / Shock Swing Arm w/ Sachs Shocks Rear Travel 7.1 in. / 18.03 cm Ground Clearance 6.5 in. / 11.43 cm Shock Preload Adjustment Front / Rear Front --Non Adjustable. Rear -- RatchetStyle-- Std. Turning Radius 75 in. / 190.5 cm unlocked Toe Out 1/8--1/4-- in/ .0 -- .159mm Wheels / Brakes Wheel Size / Pattern -- Front Steel 24x8--12 / 4--156 Wheel Size / Pattern -- Rear Steel 24x11--12 / 4--156 Front Tire Model / Size Titan 24x8--12 Rear Tire Model / Size Titan 24x11--12 Recommended Air Pressure Front & Rear -- 5psi Brake -- Front Dual Hydraulic Disc Brake -- Rear Dual Hydraulic Disc JETTING CHART Altitude Meters (Feet) AMBIENT TEMPERATURE 0--1800 (0--6000) above 1800 (above 6000) Below 40°F Below 5°C +40°F to +80°F +5°C to +28°C 127.5 122.5 120 115 CLUTCH CHART Standard helix spring position is 2 -- 2 Altitude Meters (Feet) 0--1800 (0--6000) 1800--3700 (6000--12000) Shift Drive Spring Driven Helix Weight 20--40 20--38 41--35 41--35 Blu/Grey Blu/Grey Driven Spring Black Black (5631356) (5631357) (7042202) (7042202) (7041782) (7041782) (5133701) (5133701) 2--2 2--2

GENERAL INFORMATION 1.9 MODEL: 2005 ATP 500 4x4 .......... MODEL NUMBER: A05JD50AA, AB, AC . ENGINE MODEL: EH50PLE .. Engine Platform Fuji 4 stroke, Single Cylinder Engine Model Number EH50PLE203,204 Engine Displacement 499cc Number of Cylinders 1 Bore & Stroke (mm) 92 x 75 mm Compression Ratio 10.2:1 Compression Pressure 50--90 psi w/ decompressor Engine Idle Speed 1200 ± 200 RPM Engine Max Operating Rpm 7000 RPM Cooling System / Capacity Liquid -- 3.2 qt. / 3.02 ltr Overheat Warning HOT on Instrument Cluster Lubrication Pressurized Dry Sump Oil Requirements / Capacity Polaris 0W--40 2 qt. / 1.9 ltr Exhaust System USFS Approved Carburetion Carburetor model Mikuni BST 40 mm Main Jet 155 Pilot Jet 40 Pilot Air Jet 160 Jet Needle -- Clip Position 6H25--94--3 Needle Jet Y--0M (896) Pilot Screw 2 Turns Out (Initial starting point, settings may vary for each ATP) Float Height 14.7 ± 1 mm / 0.58 ± 0.40“ Fuel Delivery Fuel Pump Fuel Capacity / Requirement 3.25 gal US / 12.3 ltr 87 Octane (minimum) 89 Oxygenated Electrical Alternator Output 250 w @ 5000 RPM Voltage Regulator 3--Phase -- LR--390 Lights : Pod 60 watts Grill Two x 27 watts Brake Two 12V/1.7 watts Tail Two 12V/8.26 watts Ignition System DC/CDI Ignition Ignition Timing 30°± 1.5° BTDC @ 3500 RPM Spark plug / Gap NGK BKR6E/ .028 in./ 0.7 mm Battery / Model / Amp Hr Low Maintenance -- 14 Amp Hr Starting Electric / Recoil Backup Instrument Cluster Analog Speedo w/ LCD Drivetrain Transmission Type Drumshift -- H/L/N/Rev/Park Transmission Capacity 13.5 oz. / 400ml Rear Gearcase Capacity 18 oz. / 532 ml Front Gearcase Capacity 5 oz. / 150ml Gear Ratio : Low Rev High Front Drive Rear Drive 8.66:1 3.52:1 5.12:1 3.7:1 3.08:1 Clutch Type PVT w/EBS Belt 3211069 Steering / Suspension Front Suspension / Shock A--arm / MacPherson Strut Front Travel 6.7 in. / 17.02 cm Rear Suspension / Shock Swing Arm w/ Sachs Shocks Rear Travel 7.1 in. / 18.03 cm Ground Clearance 7.0 in. / 17.8 cm Shock Preload Adjustment Front / Rear Front --Non Adjustable. Rear -- RatchetStyle-- Std. Turning Radius 75 in. / 190.5 cm unlocked Toe Out 0 -- 1/16 in / .0 -- .159 mm Wheels / Brakes Wheel Size / Pattern -- Front 25x8--12 / 4--156 Wheel Size / Pattern -- Rear 25x11--12 / 4--156 Front Tire Model / Size Titan 25x8--12 Rear Tire Model / Size Titan 25x11--12 Recommended Air Pressure Front & Rear -- 5psi Brake -- Front Dual Hydraulic Disc Brake -- Rear Dual Hydraulic Disc JETTING CHART Altitude Meters (Feet) AMBIENT TEMPERATURE 0--1800 (0--6000) above 1800 (above 6000) Below 40°F Below 5°C +40°F to +80°F +5°C to +28°C 160 155 152.5 147.5 CLUTCH CHART EBS models have no helix/spring adjustment Altitude Meters (Feet) 0--1800 (0--6000) 1800--3700 (6000--12000) Shift Drive Spring Driven Helix Weight 10 BH 10 RH EBS Blu/Grn Blu/Grn Driven Spring Wht/Yel (5630711) (5630709) (7041157) (7041157) Wht/Yel (7041635) (7041635) EBS (5132751) (5132751)

GENERAL INFORMATION 1.10 PUBLICATION NUMBERS Year Model Model No. Owner’s Manual PN Parts Manual PN Parts Micro Fiche PN 2004 ATP 330 4x4 A04JD32AA 9917747 9917748 9917749 2004 ATP 500 4x4 A04JD50AA, A04JD50AC 9917747 9918593 9918594 2005 ATP 330 4x4 A05JD32AA 9919515 9919516 9919517 2005 ATP 500 4x4 A05JD50AA, A05JD50AB, A05JD50AC 9919515 9919518 9919519 NOTE: When ordering service parts be sure to use the correct parts manual. NOTE: Other publications can be downloaded from www.polarisindustries.com or ordered from www.pure- polaris.com. ACCESSORY HEAVY DUTY SPRINGS STANDARD TORQUE SPECIFICA TIONS The following torque specifications are to be used as a general guideline. FOR SPECIFIC TORQUE VALUES OF FASTENERS Refer to exploded views in the appropriate section. There are exceptions in the steering, suspension, and engine sections. Bolt Size Threads/In Grade 2 Grade 5 Grade 8 Torque in. lbs. (Nm) #10 - 24 27 (3.1) 43 (5.0) 60 (6.9) .............. ................ .............. #10 - 32 31 (3.6) 49 (5.6) 68 (7.8) .............. ................ .............. Torque ft. lbs. (Nm) * 1/4 - 20 5 (7) 8 (11) 12 (16) .............. .................. ................ 1/4 - 28 6 (8) 10 (14) 14 (19) .............. .................. .............. 5/16 - 18 11 (15) 17 (23) 25 (35) .............. ................ .............. 5/16 - 24 12 (16) 19 (26) 29 (40) .............. ................ .............. 3/8 - 16 20 (27) 30 (40) 45 (62) .............. ................ .............. 3/8 - 24 23 (32) 35 (48) 50 (69) .............. ................ .............. 7/16 - 14 30 (40) 50 (69) 70 (97) .............. ................ .............. 7/16 - 20 35 (48) 55 (76) 80 (110) .............. ................ .............. 1/2 - 13 50 (69) 75 (104) 110 (152) .............. ................ ............. 1/2 - 20 55 (76) 90 (124) 120 (166) .............. ................ ............. Metric / Torque 6 x 1.0. 72-78 In. lbs. 8 x 1.25 14-18 ft. lbs 10 x 1.25 26-30 ft. lbs. 7042324--385 Heavy Duty Spring *Available Grey Only *Order Through Your Polaris Dealer ATP 330 & 500

2004-2005 Polaris ATP 500 OEM Service & Repair Manual

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