2004 POLARIS TRAIL BOSS 330 SERVICE MANUAL PDF

Quick Links. Table of Contents. Polaris industries all-terrain vehicle owner's manual pages. Polaris industries all-terrain vehicles owner's manual pages. All information contained within this publication is based on the latest product information at the time of publication. Due to constant improcvements in the design and quality of production components, some minor descrepancies may result between the actual vehicle and the information presented in this publication.

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Quick Links. Table of Contents. Polaris industries all-terrain vehicle owner's manual pages. Polaris industries all-terrain vehicles owner's manual pages. All information contained within this publication is based on the latest product information at the time of publication. Due to constant improcvements in the design and quality of production components, some minor descrepancies may result between the actual vehicle and the information presented in this publication. Serial Number Location To identify which series the key is, take the first two digits on the original key and refer to the chart to the right for the proper part number.

Should both keys become lost, ignition switch replacement is required. Page Center Distance: Distance between center of crankshaft and center of driven clutch shaft. Chain Pitch: Distance between chain link pins No. Polaris measures chain length in number of pitches. CI: Cubic inches.

Recommended Maintenance Products. Page Periodic Maintenance Chart Inspect, clean, lubricate, adjust or replace parts as necessary. NOTE: Inspection may reveal the need for replacement parts. Always use genuine Polaris parts. Description Loctite Retaining Compound 10 ml. Aerosol Sealant 50 ml. Item Lube Rec. Page 23 Semi-annually or 50 hours of operation refer to Maintenance Schedule for additional information Annually or hours of operation refer to Maintenance Schedule for additional information Grease conforming to NLGI No.

Inspect shift linkage tie rod ends, clevis and pivot bushings and replace if worn or damaged. Linkage rod will rotate 2. Place gear selector in neutral. Throttle lever operation should only. Actual final settings may be different depending be smooth and lever must return freely without on the atmospheric conditions in your area. Tighten locknut and slide boots over cable adjuster until they touch at the middle point of the adjuster.

Start engine and warm it up thoroughly. With engine running, turn the handlebars from full left to full right with transmission in neutral. Check fuel tank, oil tank, carburetor, battery and WARNING transmission vent lines for signs of wear, deterioration, damage or leakage. Replace every Gasoline is extremely flammable and explosive two years.

Be sure vent lines are routed properly and Always stop the engine and refuel secured with cable ties. Page Compression Test Serious burns can result from contact with skin, eyes or clothing. Compression readings External: Flush with water. The use of lead- -calcium and AGM technology instead of 1. Remove spark plug high tension lead.

Clean plug lead- -antimony allows the battery acid to be fully area so no dirt and debris can fall into engine absorbed. Be sure it is clean and tight. It is recommended that the air filter and pre filter be replaced annually.

When riding in extremely dusty Engine Ground Strap conditions, replacement is required more often. The pre filter should be cleaned before each ride using the following procedure: 1. Page Engine Oil Level Ill. To further expel water from the cover and to dry Polaris Premium 4 All Season out the PVT system, shift the transmission to Synthetic, 0W PN neutral and rev engine slightly to expel the moisture and air-dry the belt and clutches.

Page Oil And Filter Change Remove dipstick and fill tank with 2 quarts 1. Place gear selector in neutral and set parking brake. Remove the seat. Remove body panels and fuel tank as necessary to gain access to valve cover. Try to move the wheel outlined in this chapter, Polaris recommends steering and hub by pushing inward and component repair and adjustment be performed by an pulling outward. Place machine on a smooth level surface. Drive chapter for more information. This will tell G Do not perform clean out immediately you which tie rod needs adjusting.

NOTE: Be sure after the engine has been run, as the ex- handlebars are straight ahead before determining haust system becomes very hot. Page Brake Pad Inspection Check brake system hoses and fittings for cracks, deterioration, abrasion, and leaks.

The sprockets outer Repeat this procedure several times to check different spots on the chain. Remove the wheel nuts and remove the wheel. Check controls for proper operation, positioning and adjustment. Tapered nuts - install with tapered side against wheel Brake control and switch must be positioned to allow brake lever to travel throughout entire Check that all cotter pins are in place.

Refer to specific fastener torques listed in each chapter. Torque Patterns. If the piston has an identification mark, follow the directions for piston placement Crankshaft below. Page Engine Installation Notes Change break-in oil and filter at 20 areas. Rinse thoroughly, dry with compressed air, hours or miles, whichever and oil the bore immediately with Polaris 4 Cycle comes first. Lubricant to prevent the formation of surface rust.

Engine Lubricant PN Remove cam chain tensioner plug, sealing washer, spring and pin. Maintain inward pressure while removing. Remove the two 6x25 mm cam chain tensioner flange bolts. Measure free length of tensioner spring. Replace 4. Remove cylinder block plug using a 14 mm hex spring if excessively worn.

Cylinder block plug Tensioner Spring Free Length: 5. Measure O. Inspect it for wear or damage. Remove cam shaft end plug A. Remove camshaft sprocket flange bolt and washer. Measure I. Compare to specifications. Inspect cam sprocket teeth for wear or damage. Replace if necessary. Remove release lever shaft and return spring spacer. Inspect shaft for wear or galling. Thoroughly clean the cam shaft, making sure the oil feed holes are not obstructed. Measure height of each cam lobe using a 1.

Loosen each of the four cylinder head bolts micrometer. Remove spring retainer and spring. Lay a straight edge across the surface of the cylinder. Remove valve seals. Hardened, cracked or worn valve seals will cause excessive oil consumption and carbon buildup. Inspect split keeper groove for wear or flaring of the keeper seat area B.

NOTE: The valves cannot be re-faced or end ground. If any of the above conditions exist, the valve seat must be reconditioned. See Valve Seat Reconditioning, Page 3. If the valve seat is cracked the cylinder head must be replaced.

Follow the manufacturers instructions provided Reaming The Valve Guide with the valve seat cutters in the Valve Seat 9. Allow cylinder head to cool to room temperature.

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Polaris Trail Boss 330 2003 Service Manual

Polaris Trail Boss Service Manual. Free shipping. Skip to main content. Email to friends Share on Facebook - opens in a new window or tab Share on Twitter - opens in a new window or tab Share on Pinterest - opens in a new window or tab. Add to Watchlist. People who viewed this item also viewed. Picture Information.

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