2003-2006 Polaris Magnum 330 2×4 4×4 HDS Service Manual

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  • 2003, 2004, 2005 Polaris Magnum 330 2×4 and HDS
  • 2003, 2004, 2005, 2006 Polaris Magnum 330 4×4 and HDS

Pages: 246
Format: PDF
Compatibility: Windows/Mac/Tablet

This service manual contains all the necessary instructions needed for any repair your 2003-2006 Polaris Magnum 330 may require. This is the same manual technicians use to diagnose and repair your 2003-2006 Magnum 330. Whether it’s routine maintenance, such as tune-ups and brake service, or more extensive repairs involving engine and transmission disassembly, this manual provides the most accurate information to perform the job.

The following is a list of topics contained in the 2003-2006 Magnum 330 Service Manual:

Model Identification
Serial Number Location
Machine Dimensions
Specifications – Magnum 330
Publication Numbers
Replacement Keys
Special Tools
Standard Torque Specifications
Tap Drill Charts
Decimal Equivalent Chart
Unit of Measure Conversion Table
Glossary of Terms

Periodic Maintenance Chart
Pre-Ride Inspection
Lubricant and Maintenance
ATV Component Locations
Lubrication Charts
Front Gearcase Lubrication
Rear Gearcase Lubrication
Transmission Lubrication
Carburetor Adjustments
Fuel System
Compression Test
Battery Maintenance
Air Filter Service
Air Box Sediment Tube Service
Recoil Housing
Oil Change/Filter
Valve Clearance
Steering and Toe Alignment
Exhaust System Service
Brake System Service
Suspension Service
Wheel Removal/Installation
Tire Inspection

Engine Service Data
Special Tools and Torque Specifications
Torque Patterns
Piston Identification
Engine Removal
Engine Installation Notes
Cylinder Honing
Engine Lubrication
Oil Pressure Test
Lubrication/Oil Flow
Engine Exploded Views
Engine Top End Disassembly
Valve/ Valve Seat Service
Engine Bottom End Disassembly
Crankcase & Bearing Assembly
Crankshaft End Play Inspection
Engine Assembly/Inspection
Valve Clearance Adjustments
Recoil Disassembly/Inspection/Reassembly
Spark Plug Fouling Checklist

Exploded View, Mikuni BST 34 Carburetor
Fuel Tank Asm
Fuel Flow Diagram
Special Tool & Jetting Guidelines
Carburetor Jetting
Main Jet / Pilot Jet Part Numbers
CV Carburetor System Function (4 Cycle)
CV Carburetor Vent System (4 Cycle)
CV Carburetor Operation
Disassembly Notes, CV Carburetor
Cleaning, CV Carburetor
Inspection, CV Carburetor
Assembly, CV Carburetor
Float Adjustment, CV Carburetor
Needle & Seat Leakage Test
Fuel Level
Fuel Pump Service
Fuel Pump Exploded View

Torque Specifications and Special Tools
Body Assembly, Exploded View
Cab & Cover / Side Panel Removal
Front Box/Rack Removal
Magnum 330 Pod Exploded View
Handlebar Block Installation
Steering Assembly, Exploded View 2×4
Steering Assembly, Exploded View 4×4
A-Arm Replacement
Shaft Ride Assembly Exploded View
Shaft Ride Swingarm Removal/Installation
Strut Assembly Exploded View 2×4
Strut Assembly Exploded View 4×4
Front Strut Weldment Replacement
Front Strut Ball Joint Replacement
Decal Replacement
Steering Post Assembly

Service Tools, Supplies & Torques
PVT System Operation
PVT Maintenance/Inspection
PVT Disassembly
PVT Assembly
PVT Sealing and Ducting Components
Drive Clutch Exploded View
Drive Clutch Spring Specifications
Shift Weights
Drive Clutch Inspection
Drive Clutch Disassembly
Drive Clutch Assembly
Drive Belt Tension
Drive Belt Removal/Inspection
Drive Belt Installation
Clutch Alignment /Offset
Drive Clutch Bushing Service
Driven Clutch Disassembly/Inspection
Driven Clutch Assembly
Driven Clutch Bushing Service
EBS Exploded View
EBS Drive Clutch Disassembly/Inspection
EBS Driven Clutch Disassembly/Inspection
EBS Drive Clutch Bushing Service
EBS Driven Clutch Bushing Service

Final Drive Torque Specifications
2×4 Front Hub Disassembly/Inspection
2×4 Front Hub Assembly
2×4 Front Hub Installation
AWD Front Drive Axle Removal
AWD Front Drive Axle Installation
CV Boot Handling Tips / Inspection
2004 Front CV Joint Boot Replacement
2005 Front CV Joint Boot Replacement
AWD Front Hub Disass
U-Joint Disassembly
U-Joint Assembly
Drive Axle / Propshaft Exploded Views
Front Gearcase Removal
Front Gearcase Operation (Cent
Front Gearcase Disassembly (Cent Hill)
Front Gearcase Assembly (Cent Hill)
Front Gearcase Diagnosis (Cent Hill)
Front Gearcase Installation
Front Gearcase Exploded Veiw (Cent Hill)
HDS Front Gearcase Operation (Visko Lokt)
HDS Front Gearcase Disassembly (Visko Lokt)
HDS Front Gearcase Assembly (Visko Lokt)
Front Gearcase Installation
HDS Front Gearcase (Visko Lokt) Exp
Rear Axle Removal
Rear Axle Installation
Rear Axle Bearing Removal
Rear Axle Bearing Installation
Rear Gearcase Removal
Rear Gearcase Disassembly
Rear Gearcase Assembly
Rear Gearcase Installation
Rear Gearcase Exploded View

Transmission Specifications
Shift Linkage Inspection
Gear Shift Selector Removal
Transmission Removal
Transmission Installation
2x4Transmission Disassembly
2x4Transmission Reassembly
Troubleshooting Checklist
2×4 Transmission Exploded View
4x4Transmission Disassembly
4x4Transmission Reassembly
Troubleshooting Checklist
4×4 Transmission Exploded View

Special Tools/Specifications/Torques
Brake System View
Brake Line Identification
Brake System Service Notes
Brake Noise Troubleshooting
Hydraulic Brake System Overview
Hydraulic Caliper Bleeding
Brake Bleeding / Fluid Change
Master Cylinder Removal
Master Cylinder Installation
Front Pad Removal
Front Pad Assembly
Brake Burnishing
Front Disc Inspection
Front Disc Removal/Replacement
Front Caliper Removal
Front Caliper Disassembly
Front Caliper Inspection
Front Caliper Reassembly
Front Caliper Installation
Front Caliper Exploded View
Brake Burnishing
Rear Pad Removal
Rear Pad Installation
Rear Caliper Removal/Inspection
Rear Caliper Reassembly
Rear Disc Inspection
Rear Caliper Exploded View

Special Tools/Service Notes
330 (Domestic) Instrument Cluster
330 HDS (International) Instrument Cluster
Instrument Cluster Removal/Install
Timing Check Procedure
Electronic Throttle Circuit System Operation
ECM Operation
Oil Thermistor Diagnosis
330 Oil Cooler Fan Control Test
330 Fan Motor Current Draw Test
Ignition System Troubleshooting
CDI Output Tests/Stator Output Tests
Flywheel Identification
ES32PF 200 Watt Alternator, Exploded View
Ignition System Testing
Charging System Testing
Battery Activation/Service
Head Light/Brake Light Lamp Service
Starter System Troubleshooting
Starter Motor Service
Starter Drive
Starter Assembly Exploded View
Starter System Testing Flow Chart


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