Polaris TRAIL BOSS 325 2001 Manuals

Manuals and User Guides for Polaris TRAIL BOSS 325 2001. We have 1 Polaris TRAIL BOSS 325 2001 manual available for free PDF download: Manual

Polaris TRAIL BOSS 325 2001 Manual

Polaris TRAIL BOSS 325 2001 Manual (296 pages)

Brand: Polaris | Category: Offroad Vehicle | Size: 3.79 MB

Table of Contents

Chapter 1 General Information

1
- Table of Contents
  1
- General Information
  3
- Model Identification
  3
- Serial Number Location
  3
- Machine Dimensions
  4
- Paint Codes
  8
- Publication Numbers
  8
- Replacement Keys
  8
- Standard Torque Specifications
  9
- Conversion Table
  13
- Glossary of Terms
  15
Chapter 2 Maintenance

17
- Periodic Maintenance Chart
  19
- Pre-Ride Inspection
  20
- Recommended Lubricants
  21
- Transmission Lubrication
  25
- Fuel System
  30
- Compression Test
  32
- Battery Maintenance
  33
- Air Box Sediment Tube Service
  35
- Air Filter Service
  35
- Recoil Housing
  36
- Oil Change/Filter
  37
- Valve Clearance
  39
- Wheel Removal/Installation
  52
- Tire Inspection
  53
Chapter 3 Engine

55
- Torque Specifications
  57
- Piston Identification
  58
- Torque Patterns
  58
- Engine Removal
  61
- Engine Installation Notes
  62
- Engine Lubrication
  64
- Oil Pressure Test
  64
- Engine Bottom End Disassembly
  87
Chapter 4 Fuel System/Carburetion

125
- Jetting Guidelines
  127
- Fuel Flow Diagram
  129
- Mikuni Jet Part Numbers
  129
- Mikuni BST Carburetor, Exploded View
  134
- Fuel Pump Exploded View
  143
- Troubleshooting
  144
Chapter 5 Body and Steering

147
- Body Assembly Exploded View
  150
- Steering Assembly, Exploded View
  152
- A-Arm Replacement
  153
- Concentric Swingarm Assembly/Installation
  155
- Strut Assembly Exploded View
  156
- Front Strut Weldment Replacement
  157
- Front Strut Ball Joint Replacement
  158
- Decal Replacement
  159
Chapter 6 Clutches

161
- Steering Post Assembly
  159
- PVT Maintenance/Inspection
  165
- PVT Disassembly
  167
- PVT Assembly
  169
- PVT Sealing and Ducting Components
  170
- Drive Clutch Spring Specifications
  172
- Shift Weights
  173
- Drive Clutch Exploded View
  175
- Drive Clutch Assembly
  179
- Drive Belt Tension
  180
- Drive Belt Removal/Inspection
  181
- Drive Belt Installation
  182
- Clutch Alignment /Offset
  183
- Drive Clutch Bushing Service
  184
- Driven Clutch Disassembly/Inspection
  188
- Driven Clutch Assembly
  191
- Troubleshooting
  196
Chapter 7 Final Drive 7

199
Chapter 8 Transmission Service

217
- Torque Specifications
  219
- Transmission Disassembly
  221
- Transmission Assembly
  227
- Transmission Exploded View
  229
Chapter 9 Brakes

231
- Troubleshooting
  231
- Brake Pad Kits
  234
- Brake System Service Notes
  234
- Brake Noise Troubleshooting
  235
- Hydraulic Brake System Operation
  236
- Dual Hydraulic Caliper Bleeding
  237
- Fluid Replacement/Bleeding Procedure
  238
- Master Cylinder Removal
  240
- Master Cylinder Disassembly
  241
- Master Cylinder Assembly
  242
- Master Cylinder Inspection
  242
- Master Cylinder Installation
  244
- Front Pad Removal
  245
- Front Pad Assembly
  246
- Front Disc Inspection
  247
- Front Caliper Disassembly
  249
- Front Caliper Removal
  249
- Front Caliper Inspection
  250
- Front Caliper Assembly
  251
- Front Caliper Installation
  252
- Troubleshooting
  261
Chapter 10 Electrical

263
- Special Tools
  265
- Timing Check Procedure
  268
- Typical Ignition Timing Curve
  269
- Flywheel Identification
  270
- Ignition System Troubleshooting
  274
- Battery Service
  275
- Charging System Testing
  279
- Starter System Troubleshooting
  282
- Starter Drive
  289

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