2003-2006 Polaris Magnum 330 ATV OEM Service & Repair Manual

GENERAL MAINTENANCE ENGINE CARBURETION CLUTCHING FINAL DRIVE BODY AND STEERING TRANSMISSION BRAKES ELECTRICAL

GENERAL INFORMATION 1.1 Model Identification 1.2 ....................... Serial Number Location 1.2 ................... Machine Dimensions 1.3 ..................... Specifications - Magnum 330 1.3--1.7 .............. Publication Numbers 1.8 ..................... Replacement Keys 1.8 ....................... Special Tools 1.9--1.12 ............................ Standard Torque Specifications 1.13 ............ Tap Drill Charts 1.14 .......................... Decimal Equivalent Chart 1.14 ................. Unit of Measure Conversion Table 1.15 .......... Glossary of Terms 1.16 ........................ Specs

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 CD 32 AA Emissions & Model Option ENGINE DESIGNATION NUMBERS ES32PFE102 Single, Oil/Air 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 C 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 Whenever corresponding about an engine, be sure to refer to the engine model number and serial number. 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 coolant elbow. 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) TRANSMISSION I.D. NUMBER LOCA TION A B Front The transmission I.D. number is located on the right side of machine.

2005 Magnum 2x4 2005 Magnum 330 4x4 GENERAL INFORMATION 1.3 MODEL: 2003 --2005 Magnum 330 2x4 ..... 2004 MODEL NUMBER: A04CB32AA, FC ..... 2005 MODEL NUMBER: A05CB32AA .... ENGINE MODEL: ES32PFE .. Category Dimension / Capacity Length 81 in./206 cm Width 46 in./116.8 cm Height 46 in./116.8 cm Wheel Base 49.75 in./126.37 cm Dry Weight 590 lbs./267.6 kg Gross Vehicle Weight 1060 Lbs. / 590 kg Front Rack Capacity 90 lbs./40.8 kg Rear Rack Capacity 180 lbs./81.7 kg Towing Capacity 1000 lbs./454 kg Hitch Tongue Capacity 100 lbs./45 kg Body Style Gen IV MODEL: 2003 --2006 Magnum 330 4x4 ..... 2004 MODEL NUMBER: A04CD32AA, AB, AC, FB 2005 MODEL NUMBER: A05CD32AA, AB, AC ENGINE MODEL: ES32PFE .. Category Dimension / Capacity Length 81 in./206 cm Width 46 in./116.8 cm Height 46 in./116.8 cm Wheel Base 49.75 in./126.37 cm Dry Weight 637 lbs./288 kg Gross Vehicle Weight 1100 Lbs. / 499 kg Front Rack Capacity 90 lbs./40.8 kg Rear Rack Capacity 180 lbs./81.7 kg Towing Capacity 1000 lbs./454 kg Hitch Tongue Capacity 100 lbs./45 kg Front Cargo Box Std. Body Style Gen IV

GENERAL INFORMATION 1.4 MODEL: 2003-2004 Magnum 330 2x4 and HDS .......... MODEL NUMBER: A04CB32AA, AC, FC . ENGINE MODEL: ES32PFE102 .. Engine Platform Fuji 4 stroke, Single Cylinder Engine Model Number ES32PFE102 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  100 RPM Engine Max Operating Rpm 6900 RPM Cooling System Oil / Air w/ fan assist Overheat Warning 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) / After 1/1/2004 -- P--4 (829) --3rd Clip Position Pilot Screw 2 Turns Out (Initial starting point, settings may vary for each ATV) 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/26.9 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 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. / 400 ml Rear Gearcase Capacity 10 oz. / 295 ml Gear Ratio : Low Rev High Front Drive Rear Drive 10.49:1 6.20:1 4.0:1 3.7:1 3.1:1 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 6.75 in. / 17.14 cm Shock Preload Adjustment Front / Rear Front --Non Adjustable. Rear -- CamStyle-- Std. Turning Radius 72 in. / 183 cm Toe Out 1/8--1/4-- in / .0 -- .159 mm Wheels / Brakes Wheel Size / Pattern -- Front Steel 24x8--12 / 4--156 Wheel Size / Pattern -- Rear Steel 24x11--12 / 4--156 Front Tire Model / Size 24 x 8--12 Rear Tire Model / Size 24 x 11--12 Recommended Air Pressure Front -- 4 psi / Rear -- 3 psi 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 (5630279) (5631357) (7041157) (7041157) (7041782) (7041782) (5133701) (5133701) 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 16 20--38 41--35 41--35 Blu/Grn Blu/Grn Driven Spring Black Black

GENERAL INFORMATION 1.5 MODEL: 2005 Magnum 330 2x4 .......... MODEL NUMBER: A05CB32AA . 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  100 RPM Engine Max Operating Rpm 7250 RPM Cooling System Oil / Air w/ fan assist Overheat Warning 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--3 Needle Jet P--4M (829) Pilot Screw 2.25 Turns Out (Initial starting point, settings may vary for each ATV) 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/26.9 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 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. / 400 ml Rear Gearcase Capacity 10 oz. / 295 ml Gear Ratio : Low Rev High Front Drive Rear Drive 10.49:1 6.20:1 4.0:1 3.7:1 3.1:1 Clutch Type PVT Non--EBS Belt 3211077 Steering / Suspension Front Suspension / Shock A--arm / MacPherson Strut Front Travel 6.75 in. / 17.1 cm Rear Suspension / Shock Swing Arm w/ Sachs Shocks Rear Travel 7.1 in. / 18.03 cm Ground Clearance 6.75 in. / 17.14 cm Shock Preload Adjustment Front / Rear Front --Non Adjustable. Rear -- CamStyle-- Std. Turning Radius 70 in. / 178 cm Toe Out 1/8--1/4-- in / .0 -- .159 mm Wheels / Brakes Wheel Size / Pattern -- Front Steel 24x8--12 / 4--156 Wheel Size / Pattern -- Rear Steel 24x11--12 / 4--156 Front Tire Model / Size 24 x 8--12 Rear Tire Model / Size 24 x 11--12 Recommended Air Pressure Front -- 4 psi / Rear -- 3 psi 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 16 20--38 41--35 41--35 Blu/Grn Blu/Grn Driven Spring Black Black (5630279) (5631357) (7041157) (7041157) (7041782) (7041782) (5133701) (5133701)

GENERAL INFORMATION 1.6 MODEL: 2003-2004 Magnum 330 4x4 and HDS .......... MODEL NUMBER: A04CD32AA, AC, AB, FB . ENGINE MODEL: ES32PFE102 .. Engine Platform Fuji 4 stroke, Single Cylinder Engine Model Number ES32PFE102 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  100 RPM Engine Max Operating Rpm 6900 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) / After 1/1/04 -- P--4 (829) -- 3rd Clip Position Pilot Screw 2 Turns Out (Initial starting point, settings may vary for each ATV) 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/26.9 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 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 16 oz. / 473ml Front Gearcase Capacity 5 oz. / 150ml Front Gearcase (HDS) 13.5 oz. / 400ml Gear Ratio : Low Rev High Front Drive Rear Drive 10.49:1 6.20:1 4.0:1 3.7:1 3.1:1 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 6.75 in. / 17.14 cm Shock Preload Adjustment Front / Rear Front --Non Adjustable. Rear -- CamStyle-- Std. Turning Radius 71 in. / 180 cm Toe Out 1/8--1/4-- in / .0 -- .159 mm 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 -- 4 psi / Rear -- 3 psi 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 16 20--38 41--35 41--35 Blu/Grn Blu/Grn Driven Spring Black Black (5631357) (7041157) (7041157) (7041782) (7041782) (5133701) (5133701) (5630279)

GENERAL INFORMATION 1.7 MODEL: 2005-2006 Magnum 330 4x4 .......... MODEL NUMBER: A05CD32AA, AC, AB . ENGINE MODEL: ES32PFE103 .. 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  100 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 4HB48--3 Needle Jet P--4M (829) Pilot Screw 2.25 Turns Out (Initial starting point, settings may vary for each ATV) 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/26.9 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 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 16 oz. / 473ml Front Gearcase Capacity 5 oz. / 400ml Gear Ratio : Low Rev High Front Drive Rear Drive 10.49:1 6.20:1 4.0:1 3.7:1 3.1:1 Clutch Type PVT 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 6.75 in. / 17.14 cm Shock Preload Adjustment Front / Rear Front --Non Adjustable. Rear -- CamStyle-- Std. Turning Radius 71 in. / 180 cm Toe Out 1/8--1/4-- in / .0 -- .159 mm 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 -- 4 psi / Rear -- 3 psi 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 16 20--38 Blu/Grn Blu/Grn Driven Spring Black Black (5631357) (7041157) (7041157) (7041782) (7041782) (5133701) (5133701) (5630279) 41--35 41--35 2--2 2--2

GENERAL INFORMATION 1.8 NOTE: When ordering service parts be sure to use the correct parts manual. ATV PAINT INFORMA TION FRAME COLOR - (All) P067 Medium Gloss Black 9440 / 8520147. Order direct from Midwest Industrial Coatings (952-942-1840). Mix as directed. COLD WEATHER KITS FOR 4 CYCLE A TVS Oil Tank Cover -- (PN 2871874) 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 ACCESSORY ENGINE HEATER

GENERAL INFORMATION 1.9 SPECIAL T OOLS PART NUMBER TOOL DESCRIPTION CHAPTER TOOL USED IN 2870872 Shock Spanner Wrench 2, 7 2871043 Flywheel Puller 3 2870773 C--Clip Installation Tool 3 2870569 Crankshaft Truing Tool 3 8700229 Flywheel Holding Wrench 3 2870386 Piston Pin Puller 3 2871445 Piston Pin Puller Adapter 3 2870967 Slotted Nut Socket 3 2870968 Counter Balance Puller 3 2872314 Carburetor Float Adjustment Tool 4 2870975 Mity Vact 3, 4, 9 2870506 Clutch Puller 6 9314177 Clutch Holding Wrench 6 2871358 Clutch Holding Fixture 6 2870341 Drive Clutch Spider Removal and Install Tool 6 2870654 Clutch Offset Alignment Tool 6 2870913 Driven Clutch Puller 6 2870910 Roller Pin Tool 6 2871226 Clutch Bushing Replacement Tool Kit 6 2870386 Piston Pin Puller 6 8700220 Clutch Compression Tool 6 2870871 Ball Joint Replacement Tool 7 2870623 Shock Absorber Spring Compression Tool 5, 7 2871572 Strut Rod Wrench 5, 7 2871573 LH Strut Spring Compressor 5, 7 2871574 RH Strut Spring Compressor 5, 7 2871710 10” Center Distance Tool 8 PV--43568 Fluket77 Digital Multimeter 10 2870836 Battery Hydrometer 10 2870630 Timing Light 10 8712100 or 8712500 Tachometer 10 NOTE: Polaris dealers can order the tools listed above through their Polaris Special Service Tools catalog. SPECIAL T OOLS Special Tools maybe required while servicing your machine. Some of the tools listed are mandatory and other tools maybe substituted with a similar tool, if available. Polaris recommends the use of Polaris special tools when servicing any Polaris product. Standard Tools and Engine T ools PU--45432 -- Caliper or A Basic Caliper Basic Micrometer 2871043 -- Flywheel Puller 2870773 -- C--Clip Install Tool 2870967 -- Slotted Nut Socket 8700229 -- Flywheel Holder & Adapter

2003-2006 Polaris Magnum 330 ATV OEM Service & Repair Manual

You're Reading a Preview

Recently Viewed