Drive Chain Inspection; Sprocket Inspection - Polaris Trail Boss 330 2003 Service Manual

If less than one inch, two things must be examined:
Free Play:
Free play of the brake pedal should be 1/8 - 1/4
inch (3.2 - 6.35 mm).
If free play is excessive, inspect pedal, linkage, and
master cylinder for wear or damage and replace any
parts as needed.
Bleeding:
If free play is correct and brake pedal travel is still
excessive, air may be trapped somewhere in the
system. Bleed the hydraulic auxiliary brake system in
a conventional manner, following the procedure
outlined in Brake Chapter 9.
DRIVE CHAIN AND

SPROCKET INSPECTION

Polaris ATV drive chains are equipped with O-ring
sealed permanently greased pins and rollers. The
sprockets and outer
lubrication. Lubricate the chain with Polaris O-Ring
Chain Lubricant (PN 2872073).
Inspect the drive chain for missing or damaged
O-Rings, link plates, or rollers. Do not wash the chain
with a high pressure washer, gasoline or solvents; do
not use a wire brush to clean the chain as damage to
the O-Rings may occur. Clean chain with hot soapy
water and a soft bristled nylon brush.
Never allow battery acid to contact the drive chain.
Service Limit:
1/4² (6mm)
Drive Chain Lubricant:
Polaris O-Ring Chain Lubricant
(PN 2872073)
SPROCKET INSPECTION
Inspect the sprocket for worn, broken or bent teeth.
2.24
rollers require periodic
To check for wear, pull outward on the chain as
shown. Replace sprocket if chain movement exceeds
1/4² (.6 cm).

DRIVE CHAIN INSPECTION

The chain must be replaced when it reaches 3%
elongation.
1. Stretch the chain tightly in a straight line.
2. Measure a length of twenty pitches (pins) from pin
center to pin center, and compare to the
specification. Replace the chain if the length
exceeds the wear limit.
3. When replacing or reinstalling drive chain, install
the closed end of the splice link clip as shown, with
the closed end leading in forward operation.
Drive Chain Wear Limit- -20 Pitch Length:
Std: 12.5² (32 cm)
Wear Limit: 12.875² (32.7 cm)
DRIVE CHAIN ADJUSTMENT,
CONCENTRIC SWINGARM
CAUTION: Never adjust or operate the vehicle
with the rear drive chain too loose or too tight as
severe damage to the transmission and drive
components can result.
Break-In: It is extremely important to maintain proper
chain tension to ensure the best possible chain life.
There is a chain break-in period of approximately 100
miles or two (2) tanks of fuel. During this time chain
tension should be watched very closely and loads to
the chain should be kept light.
Checking Deflection: Inspect chain deflection by
slowly moving the ATV forward so any slack that may
have previously been on the under part of the chain
is now on the top side of the chain. The bottom part
of the chain should be taught during inspection.
Measure the chain deflection as shown in the
diagram. Deflection should be approximately 3/8
in. (10 mm).
MAINTENANCE
Proper
Splicelink Clip
Opening
Position