Piston Identification; Engine Removal; Accessible Components - Polaris 2009 Trail Boss 330 Service Manual

PISTON IDENTIFICATION

The piston may have an identification mark or the
piston may not have an identification mark for
piston placement. If the piston has an identification
mark, follow the directions for piston placement
below. If the piston does not have an identification
mark, the direction for placement of the piston does
not matter.
Note the directional and identification marks when
viewing the pistons from the top. The letter "F", " !
", " "" or : must always be toward the flywheel side
of the engine. The other numbers are used for
identification as to diameter, length and design. Four
stroke engine rings are rectangular profile.
numbers or letters on all rings (except oil control rings)
must be positioned upward. See text for oil control
ring upper rail installation. Use the information below
to identify pistons and rings.
Engine Oversize
Model No. Available*
(mm)
ES32PFE .25
.50
*
Pistons and rings marked 25 are .25mm (.010I)
oversized. Pistons and rings marked 50 are .50mm
(.020I) oversized

ACCESSIBLE COMPONENTS

The following components can be serviced or
removed with the engine installed in the frame:
G
Flywheel
G Alternator/Stator
G
Starter Motor/Starter Drive
G
Cylinder Head
G
Cylinder
G
Piston/RIngs
G Oil pump
G
Rocker Arms
G
Cam Chain and Sprockets
The following components require engine
removal for service:

ENGINE REMOVAL

1. Clean work area.
2. Thoroughly clean the ATV engine and chassis.
The
3. Disconnect battery negative (-) cable.
4. Remove the following parts as required.
Standard
Piston
Identification
None
5. Disconnect spark plug high tension lead.
6. Disconnect all electrical wires from the engine.
7. Remove springs from exhaust pipe and remove
8. Drain engine oil.
9. Remove airbox.
10. Remove carburetor. Insert a shop towel into the
11. Loosen auxiliary brake master cylinder mount if
12. Refer to PVT System Chapter 6 to remove outer
13. Starter motor. Note ground cable location. Mark
14. Remove transmission linkage rod(s) from gear
15. Remove engine to chassis ground cable.
16. Remove all engine mount nuts and / or engine
17. Remove engine through right side of frame.
G
Camshaft
G
Connecting Rod
G
Crankshaft
G Crankshaft Main Bearings
G
Crankcase
G Seat
G Left and Right Side Covers (Refer to
Chapter 5)
G Fuel Tank Cover / Front Cab (Refer to
Chapter 5)
G
Fuel Tank (Refer to Chapter 4)
pipe.
carburetor flange to prevent dirt from entering the
intake port.
necessary for clearance.
clutch cover, drive belt, drive clutch, driven clutch,
and inner cover.
positive (+) cable mounting angle and remove
cable.
selector and secure out of the way.
mount plates.
ENGINE
3.5