2004-2005 Polaris Magnum 330 Service Manual

 High definition, bookmarked, searchable, printable PDF  Instant download

Covers:

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

Pages: 246
Format: PDF
File size: 14mb
Compatibility: Windows/Mac/Tablet

This downloadable PDF service manual contains instructions and technical information to maintain and repair your 2004 or 2005 Polaris Magnum 330 ATV. This is the same manual technicians use to diagnose and repair your ATV. 2×4 and 4×4 models are covered. Whether it’s routine maintenance, such as tune-ups and brake service, or more extensive repairs involving engine and transmission disassembly, the service manual provides the most accurate information to perform the job. The bookmarks panel in this manual makes it easy to quickly navigate chapters and sub-chapters.

Topics:

General Information

• 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

Maintenance

• 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
• Electrical
• 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
• Troubleshooting

Fuel System/Carburetion

• Mikuni BST 34 Carburetor Exploded View
• Fuel Tank Assembly Exploded View
• 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
• Troubleshooting

Body and Steering

• 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
• A-Arm Replacement
• Shaft Ride Assembly Exploded View
• Shaft Ride Swingarm Removal/Installation
• Strut Assembly Exploded View
• Front Strut Weldment Replacement
• Front Strut Ball Joint Replacement
• Decal Replacement
• Steering Post Assembly

Clutching

• 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
• Troubleshooting

Final Drive

• 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

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

Brakes

• 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
• Troubleshooting

Electrical

• Special Tools/Service Notes
• 330 (Domestic) Instrument Cluster
• 330 HDS (International) Instrument Cluster
• Instrument Cluster Removal/Install
• Timing Check Procedure
• Trans
• 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