2004–2005 Polaris ATP 330, ATP 500 Service & Repair Manual (P/N 9917747, 9919515)

• Covers the carbureted 2004–2005 Polaris ATP 330 and ATP 500 4x4 platforms with engine, PVT, final-drive, transmission, brake, steering/suspension, fuel-system, and electrical service data.
• Separates the Fuji four-stroke engine builds: ES32PFE101/103 329cc engines use fan-assisted oil/air cooling and wet-sump lubrication, while EH50PLE200/201 and EH50PLE203/204 499cc engines use liquid cooling, pressurized dry-sump lubrication, and EBS-equipped PVT.
• Model-identification data includes A04JD32AA and A05JD32AA for the 330. For the 500, the source tables use both CA and AC option-suffix ordering in different places, and the 2005 detailed/publication tables also list AB. Match the complete machine model/VIN rather than relying on a two-letter option suffix alone.
• The 375-page PDF runs from periodic maintenance through engine teardown, Mikuni BST carburetor work, PVT clutch repair, Centralized Hilliard front gearcase service, Versatrac rear carrier work, transmission overhaul, hydraulic brakes, and electrical fault diagnosis.
• The publication-number table identifies 9917747 for 2004 and 9919515 for 2005 as Owner’s Manual P/Ns and lists separate Parts Manual and microfiche numbers. Those two numbers are not identified in that table as the service manual’s own P/N.

Engine and Maintenance Walkthrough

The maintenance chapter covers severe-use scheduling, front and rear gearcase lubrication, transmission service, throttle/ETC adjustment, compression and cylinder-leakage testing, valve clearance, steering/toe alignment, brake inspection, ATP 500 cooling service, and oil-pump priming. Both engine sections specify .006 in. (.15 mm) valve clearance. Carburetion is model-specific: the 330 uses a Mikuni BST 34 mm and the 500 a BST 40 mm, with temperature/altitude jetting charts; PVT calibration has separate altitude charts.

Internal engine data includes cylinder taper and out-of-round limits, piston-to-cylinder clearance, piston-ring end gap and groove clearance, valve-guide and stem clearance, camshaft journal oil clearance, connecting-rod bearing clearance, crankshaft runout, and end-play measurements. The 330 piston-to-cylinder clearance is .0015–.0032 in. with a .004 in. service limit; the 500 is .0006–.0018 in. with a .0024 in. limit. Cylinder-head warpage is limited to .002 in. (.05 mm) in both engine sections.

Diagnostic values are similarly specific. The ES32PFE oil-pressure section gives 71–99 psi at 3000 RPM with the engine hot and a 20 psi minimum at idle. The EH500PLE section gives 20 psi at 5500 RPM hot with a 12 psi minimum. The 500 cooling-system pressure test uses 10 psi with a five-minute retention check, and the radiator-cap specification is 13 psi. The manual presents two coolant-capacity figures in different contexts: 3.2 qt (3.02 L) on the ATP 500 general specification sheet and 2.25 qt (2.13 L) in the detailed cooling-system table.

Service procedures include engine removal, top- and bottom-end disassembly, cylinder and piston measurement, valve-seat reconditioning, connecting-rod bearing clearance measurement, crankshaft end-play adjustment, 500 counterbalancer and oil-pump shaft end-play work, water-pump mechanical-seal replacement, carburetor float-height setting, and needle/seat leakage testing. Cylinder-head fasteners use model-specific multi-stage torque-angle patterns; the manual does not support a universal 14 ft-lb cylinder-head-bolt specification.

Drivetrain, Chassis, and Electrical Repair Coverage

The ATP 330 uses a non-EBS PVT with belt P/N 3211077; the ATP 500 uses EBS PVT with belt P/N 3211069. A production break matters on the 500: machines built before July 14, 2003 use the early-2004 EBS driven clutch, while units built on or after that date use the late-2004–2005 design. The front Centralized Hilliard gearcase likewise has early and late parts configurations around July 14, 2003, with separate disassembly, diagnosis, and exploded-view coverage.

The clutch chapter covers drive and driven clutch inspection, bushing service, belt deflection, center distance, and offset/alignment. Final-drive repair includes CV joints, hubs, prop shafts and U-joints, Centralized Hilliard front gearcase overhaul, and the rear carrier used for AWD, 2x4, and Turf modes. The drum-shift H/L/N/Reverse/Park transmission has its own removal, disassembly/reassembly, troubleshooting, and exploded-view sections. Brake coverage includes hydraulic bleeding, master-cylinder and caliper repair, pad/disc inspection, and troubleshooting.

Electrical diagnosis covers the gear-position switch, front-gearcase engagement limiter, rear differential solenoid, instrument cluster, wheel-speed input, coolant/fan controls, electronic throttle circuit, ignition and charging output, starter system, and battery service. Full wiring diagrams are supplied for 2004 ATP 330/500 and 2005 ATP 330/500, including a dedicated 2004 ATP 330 schematic for machines built after July 14, 2003. Representative named views include the ES320PFE Oil Flow Diagram, EH500PLE Oil Flow Diagram, Late 2004–2005 ATP Front Gearcase – Centralized Hilliard Exploded View, ATP Brake System Exploded View, Ignition System Testing Flowchart, and Charging System Testing Flowchart.

Special-service-tool references include PA-44689 Valve/Clutch Adjuster, 2870506 Drive Clutch Puller, 2872292 EBS Clutch Alignment Tool, 2872105 Water Pump Mechanical Seal Puller, 2872608 Roller Pin Removal Tool, and PV-43568 Fluke 77 Digital Multimeter.

Three repair cautions show the level of detail. On the 330 flywheel, puller bolts threaded too far can contact and damage the stator coils. Sealer on the 330 oil-pump mating surfaces can alter pump clearance and obstruct oil passages. During toe adjustment, incorrectly positioned tie-rod ends can bind, break, or wear prematurely.

Service work here includes pressurized cooling, hydraulic brakes, rotating PVT components, and electrical testing. Follow the manual’s warnings and test precautions for the specific repair.