Polaris Trail Boss 330 2003 Manuals

Polaris Trail Boss 330 2003 Manuals

Manuals and User Guides for Polaris Trail Boss 330 2003. We have 1 Polaris Trail Boss 330 2003 manual available for free PDF download: Service Manual

Polaris Trail Boss 330 2003 Service Manual

Polaris Trail Boss 330 2003 Service Manual (213 pages)

Brand: Polaris | Category: Offroad Vehicle | Size: 5 MB

Table of Contents

Chapter 1 General Information/ 1

6
- Table of Contents
  6
- Engine Serial Number Location
  7
- Model Identification
  7
- 2003 Trailboss Model
  8
- Replacement Keys
  9
- Machine Dimensions
  10
  - General Information
    11
- Paint Codes
  13
  - Standard Torque Specifications
    13
  - Conversion Table
    15
- Publication Numbers
  13
- Glossary of Terms
  16
Maintenance Chapter 2 Maintenance

18
- Chapter 2 Maintenance
  19
- Periodic Maintenance Chart
  19
- Pre-Ride Inspection
  20
- Recommended Maintenance Products
  22
  - Maintenance Quick Reference
    22
- Special Tools
  24
- Transmission Lubrication
  25
- Throttle Operation / Choke Adjustment
  28
  - Idle Speed Adjustment
    28
  - Throttle Cable
    28
- Fuel System
  29
  - Fuel Filter
    29
- Battery Maintenance
  30
  - Spark Plug
    31
  - Ignition Timing
    31
- Compression Test
  30
  - Engine Mounts
    30
- Air Box Sediment Tube Service
  33
- Recoil Housing/Pvt Drying
  33
  - Engine Oil Level
    34
  - Oil and Filter Change
    35
- Valve Clearance
  36
  - Steering
    37
  - Camber and Caster
    38
  - Toe Alignment
    39
  - Brake Pad Inspection
    40
  - Drive Chain Inspection
    41
  - Sprocket Inspection
    41
  - Shock Spanner Wrench 2
    43
- Wheel Removal / Installation
  44
  - Torque Table
    44
- Tire Inspection
  45
Chapter 3 Engine

46
- Engine Service Data
  47
- Torque Patterns
  49
  - Piston Support Block
    49
- Engine Removal
  50
  - Accessible Components
    50
- Piston Identification
  50
- Engine Installation Notes
  51
  - Honing to Deglaze
    51
  - Honing to Oversize
    52
- Engine Lubrication
  52
- Oil Pressure Test
  52
  - Oil Cooler Assembly
    53
- Engine Exploded View
  55
  - Rocker Arm/Shaft Inspection
    57
    
    Camshaft Removal
    58
    
    Automatic Compression Release Installation
    59
    
    Camshaft Inspection
    59
  - Cylinder Head
    60
  - Cylinder Head Warpage
    61
  - Cylinder Head Disassembly
    61
  - Valve Inspection
    62
  - Valve Seat
    63
  - Combustion Chamber
    63
  - Cylinder Head Assembly
    66
- Engine Bottom End Disassembly
  67
  - Valve Sealing Test
    67
  - Piston Removal
    68
  - Cylinder Inspection
    68
  - Piston Inspection
    69
  - Crankcase Disassembly
    70
  - Piston Ring Installed Gap
    70
  - Starter Drive Removal/Inspection
    71
  - Oil Pump
    73
  - Pressure Relief Valve
    73
  - Oil Pump Removal/Inspection
    73
  - Oil Pump Assembly
    74
  - Crankcase Separation
    74
  - Crankshaft Inspection
    75
- Crankcase & Bearing Assembly
  76
- Crankshaft End Play Inspection
  78
- Engine Assembly/Inspection
  78
  - Crankcase Reassembly
    79
  - Crankshaft Installation
    79
  - Crankcase Oil Strainer Inspection
    79
  - Piston Ring Installation
    80
  - Piston Installation
    80
  - Cylinder Head Installation
    81
  - Cylinder Installation
    81
  - Flywheel Installation
    87
  - Recoil Disassembly/Inspection
    87
  - Recoil Assembly
    89
- Spark Plug Fouling Checklist
  90
- Troubleshooting
  90
Fuel System/Carburetion Chapter 4 Fuel System/Carburetion

92
- Chapter 4 Fuel System/Carburetion
  94
- Fuel Pump Exploded View
  94
- Fuel Flow Diagram
  95
- Carburetor Jetting
  96
  - Carburetor Float Adjustment Tool
    96
- Assembly, CV Carburetor
  97
  - Float System
    99
  - Main System
    99
  - Carburetor Cleaning
    100
- CV Carburetor System Function (4 Cycle)
  97
- Needle & Seat Leakage Test
  102
- Fuel Level
  103
  - Fuel Pump Disassembly
    103
- Fuel Pump Service
  103
- Troubleshooting
  104
Chapter 5 Body and Steering

106
- Body Assembly Exploded View
  107
  - Front Cab Assembly
    107
- Steering Assembly, Exploded View
  108
  - Ball Joint Replacement Tool
    109
- Cover/Panel Removal
  110
- Side Panel Removal
  110
- A-Arm Replacement
  111
- Concentric Swing Arm Removal
  112
- Concentric Swing Arm Assembly/Installation
  113
- Strut Assembly
  114
  - Ball Joint Replacement
    115
- Decal Replacement
  117
Clutch Chapter 6 Pvt System

118
- Steering Post Assembly
  117
- Clutch Puller
  119
- Driven Clutch Operation
  119
- Chapter 6 Pvt System
  120
- PVT Drying
  120
- PVT Maintenance/Inspection
  120
- PVT over Heating
  121
- PVT Disassembly
  122
- PVT Assembly
  123
- Drive Clutch Exploded View
  124
- PVT Sealing and Ducting Components
  124
- Drive Clutch Spring Specifications
  125
- Shift Weights
  126
- Drive Clutch Inspection
  127
  - Drive Clutch Disassembly
    127
  - Spider Removal
    128
- Drive Clutch Assembly
  129
- Drive Belt Tension
  130
- Drive Belt Removal/Inspection
  131
- Drive Belt Installation
  132
  - Clutch Bushing Replacement Tool Kit
    133
  - Clutch Offset
    133
- Drive Clutch Bushing Service
  133
  - Clutch Compression Tool
    136
- Driven Clutch Disassembly/Inspection
  136
- Driven Clutch Assembly
  137
- Troubleshooting
  140
Chapter 7 Final Drive 7

142
- Front Hub Disassembly/Inspection
  143
  - Final Drive
    143
- Front Hub Assembly
  144
- Front Hub Installation
  145
- Front Hub Exploded View
  146
- Rear Axle Removal
  147
- Rear Axle Assembly
  148
- Rear Axle Disassembly
  148
- Rear Axle Installation
  149
- Rear Axle Exploded View
  150
- Rear Housing Removal
  151
- Rear Housing Service
  151
- Rear Housing Installation
  152
Chapter 8 Transmission Service

154
- Special Tools
  155
- Torque Specifications
  155
  - Center Distance Tool
    155
  - Transmission Installation
    155
- Transmission Disassembly
  155
- Transmission Assembly
  158
- Transmission Exploded View
  160
Brakes Chapter 9 Brakes

162
- Specifications
  163
- Brake Noise Troubleshooting
  164
- Brake System Service Notes
  164
- Chapter 9 Brakes
  164
- Special Tools
  164
- Hydraulic Brake System Operation
  165
- Brake System Main Components
  166
- Dual Hydraulic Caliper Bleeding
  166
- Fluid Replacement/Bleeding Procedure
  167
- Master Cylinder Disassembly
  168
- Master Cylinder Installation
  169
- Front Pad Removal
  170
- Front Pad Assembly
  171
- Front Disc Inspection
  172
- Front Caliper Disassembly
  173
- Front Caliper Removal
  173
- Front Caliper Inspection
  174
- Front Caliper Reassembly
  175
- Front Caliper Installation
  176
  - Rear Brake Pad
    178
- Rear Caliper Removal/Inspection
  179
- Rear Caliper Assembly
  180
  - Rear Brake Disc
    181
- Troubleshooting
  182
Electrical Chapter 10 Electrical

184
- Chapter 10 Electrical
  185
- Timing Check Procedure
  185
  - Timing Light
    185
  - Electrical Service Notes
    185
  - Gear Position Indicator
    186
  - Reverse Limit System
    187
- Fan Motor Current Draw Test
  189
  - Oil Cooler Fan Control
    189
  - Flywheel Identification
    191
  - Components of Es32Pf/200 Watt Alternator
    192
- Thermistor / Fan Control Testing
  189
- Ignition System Testing
  193
- Cranking Output Tests
  194
- Ignition System Troubleshooting
  194
- Charging System Testing
  195
  - Alternator Output Test
    196
- Battery Service
  197
  - Battery Inspection
    197
  - Battery Installation
    198
  - Load Test
    199
    
    Off Season Storage
    199
    
    Charging Procedure
    199
  - Headlight Adjustment
    200
  - Headlight Lamp Replacement
    200
  - Headlight Assembly Removal
    200
  - Headlamp Replacement
    201
  - Brake Light Switch
    202
- Starter System Testing
  203
- Starter System Troubleshooting
  204
  - Starter Motor
    204
  - Voltage Drop Test
    204
  - Armature Testing
    206
  - Starter Assembly
    206
- Starter Drive
  207

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