Target Audience:
Recreational riders, utility users, farmers, hunters, and off-road enthusiasts requiring reliable and capable all-terrain vehicles.
Competitors:
Yamaha Big Bear, Honda FourTrax, Suzuki King Quad, Kawasaki Prairie (during the respective model years).
Key Selling Points:
Robust 330cc engine, comfortable ride, reliable drivetrain, user-friendly operation, value for money.
Vehicle Focus:
Designed for versatile off-road use, balancing trail capability with utility features.
Engine:
Complete overhaul, diagnostics, tuning, lubrication system, cooling system, fuel system, exhaust system, ignition system, starting system, charging system.
Transmission:
Automatic transmission (CVT) overhaul, diagnostics, fluid changes, belt inspection and replacement, clutch assembly.
Drivetrain:
Front and rear drive shafts, differentials, CV joints, wheel hubs, bearing replacement.
Suspension:
Front and rear suspension components, shock absorbers, springs, bushings, control arms, alignment procedures.
Brakes:
Hydraulic brake system, caliper overhaul, brake pad replacement, rotor inspection, bleeding procedure, parking brake adjustment.
Electrical System:
Wiring diagrams, battery maintenance, starter, alternator, lighting system, ignition switch, fuses, relays, troubleshooting electrical faults.
Body And Frame:
Frame inspection, body panel removal and installation, seat removal, handle bar assembly, rack systems.
Fuel System:
Carburetor disassembly, cleaning, and adjustment; fuel pump, fuel lines, fuel tank maintenance.
Cooling System:
Radiator, fan, hoses, thermostat inspection and replacement, coolant type and capacity.
Maintenance:
Scheduled maintenance intervals, oil changes, filter replacements, lubrication points, spark plug replacement, air filter cleaning/replacement, valve adjustments.
Troubleshooting:
Diagnostic charts for common symptoms, step-by-step troubleshooting guides for electrical and mechanical issues.
Repair:
Detailed step-by-step repair instructions for all major components and systems, including engine rebuilds, transmission overhauls, and suspension repairs.
Rebuild And Restoration:
Comprehensive instructions for complete engine and transmission rebuilding, component refurbishment, and restoration procedures.
Component Removal And Installation:
Detailed guides for removing and installing all major components, from engine and transmission to body panels and suspension parts.
Depth:
Comprehensive; suitable for DIY enthusiasts and professional technicians alike, covering everything from basic maintenance to advanced diagnostics and full rebuilds.
Type:
4-stroke, SOHC, 2-valve, air-cooled
Bore X Stroke:
Approximately 73mm x 75mm (specifics may vary slightly by model year or variant)
Compression Ratio:
Approximately 9.2:1
Horsepower:
Estimated 18-20 HP (at crankshaft, specific figures not always published by manufacturer)
Torque:
Estimated 19-21 lb-ft (at crankshaft, specific figures not always published by manufacturer)
Carburetor:
Mikuni VM32SS (or similar 32mm constant velocity carburetor)
Fuel Type:
Unleaded gasoline, minimum 87 octane
Ignition:
CDI (Capacitor Discharge Ignition)
Cooling Method:
Air-cooled
Type:
Automatic (CVT - Continuously Variable Transmission) with High/Low range and Reverse
Drive System:
Shaft Drive (2WD or 4WD depending on specific model/trim)
Clutch:
Automatic centrifugal clutch
Gear Reduction:
Integrated into transmission and differential units
Transmission Fluid:
Polaris ATV High-Performance Gearcase Lubricant (or equivalent API GL-5 gear oil with appropriate viscosity, e.g., SAE 80W-90)
Transmission Oil Capacity:
Approx. 1.5 L (1.6 US qt) for rear gearcase (refer to manual for exact capacity and fill level verification)
Length:
Approx. 77.5 inches (196.8 cm)
Width:
Approx. 46 inches (116.8 cm)
Height:
Approx. 47 inches (119.4 cm)
Wheelbase:
Approx. 50 inches (127 cm)
Ground Clearance:
Approx. 7.5 inches (19 cm)
Dry Weight:
Approx. 500-520 lbs (227-236 kg) depending on 2WD/4WD and specific model
Towing Capacity:
650 lbs (295 kg)
Rack Capacity Front:
50 lbs (22.7 kg)
Rack Capacity Rear:
100 lbs (45.4 kg)
Front Tire Size:
AT 25x8-12
Rear Tire Size:
AT 25x10-12
Wheel Bolt Pattern:
4x110mm (common for Polaris ATVs of this era)
Rollover Protection:
Not applicable to ATVs in the same way as cars; emphasis on rider skill and safe operation.
Braking System:
Hydraulic disc brakes front and rear.
Parking Brake:
Mechanical parking brake, often integrated into the transmission or rear caliper.
Handlebars:
Ergonomic handlebars with comfortable grips and controls.
Footwells:
Wide, non-slip footwells with heel guards for rider security.
Seat:
Comfortable, textured seat for grip and stability.
Engine Oil Change:
Every 100 hours or annually, whichever comes first. (Refer to manual for precise mileage/hour recommendations based on operating conditions).
Air Filter Cleaning:
Inspect every 20-40 hours, clean or replace as needed. More frequent cleaning in dusty conditions.
Spark Plug Replacement:
Replace every 100 hours or annually.
Transmission Oil Change:
Every 100 hours or annually.
Cvt Belt Inspection:
Inspect every 50 hours for wear, cracking, or damage. Replace as necessary.
Engine Oil:
Polaris 4-Stroke Synthetic SAE 0W-40 (or equivalent API SG, SH, SJ rated oil with the correct viscosity). Capacity: Approx. 2.1 L (2.2 US qt).
Brake Fluid:
DOT 3 or DOT 4 hydraulic brake fluid.
Coolant:
Polaris Premium All-Season Antifreeze/Coolant (or equivalent ethylene glycol-based coolant with corrosion inhibitors). Capacity: Approx. 1.5 L (1.6 US qt).
Common Wear Items:
CVT belt wear, suspension bushings, wheel bearings, starter solenoid (can be prone to failure if overloaded).
Carburetor Cleaning:
Carburetors can become fouled with ethanol fuels or debris, requiring periodic cleaning and adjustment for optimal performance.
Cooling System:
Overheating can occur if the radiator is clogged, fan is not operating, or coolant level is low. Regular cleaning and inspection are crucial.
Electrical Connections:
Corrosion or loose connections in the wiring harness can lead to intermittent electrical faults. Regular inspection and dielectric grease application are recommended.
