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2003 TRAIL BOSS SERVICE MANUAL PN 9918061
59173 03 TrailBoss Cover 8/23/02 8:47 PM Page 1
2003 TRAIL BOSS
SERVICE MANUAL
PN 9918061
PN 9918061
Printed in USA
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2003TRAILBOSS330 SERVICEMANUAL Foreword ThismanualisdesignedprimarilyforusebycertifiedPolarisMasterServiceDealertechniciansinaproperly equippedshopandshouldbekeptavailableforreference. Allreferencestoleftandrightsideofthevehicle are from the operator’s perspective when seated in a normal riding position. Someproceduresoutlinedinthismanualrequireasoundknowledgeofmechanicaltheory,tooluse,andshop proceduresinordertoperformtheworksafelyandcorrectly. Techniciansshouldreadthetextandbefamiliar withserv
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UNDERSTANDINGSAFETYLABELSANDINSTRUCTIONS Throughout these instructions, important information is brought to your attention by the following symbols: TheSafetyAlertSymbolmeansATTENTION!BECOMEALERT!YOURSAFETYISINVOLVED! DANGER FailuretofollowDANGERinstructionswillresultinsevereinjuryordeathtotheoperator,bystanderorperson inspecting or servicing the ATV. WARNING Failure to follow WARNING instructions could result in severe injury or death to the operator, bystander or person inspecting or servicing
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CHAPTERINDEX CHAPTER1 GENERAL CHAPTER2 MAINTENANCE CHAPTER3 ENGINE CHAPTER4 FUELSYSTEM CHAPTER5 BODY/SUSPENSION CHAPTER6 PVTSYSTEM CHAPTER7 FINALDRIVE CHAPTER8 TRANSMISSION CHAPTER9 BRAKES CHAPTER10 ELECTRICAL
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GENERALINFORMATION CHAPTER1 GENERALINFORMATION/ 1 MAINTENANCE 2003 Model Identification.................. 1.2 Serial Number Location ................... 1.2 2003 Trailboss Model ..................... 1.3 Replacement Keys ....................... 1.4 Machine Dimensions ..................... 1.5 Specifications -2003 Trail Boss 330 ........ 1.6-1.7 Publication Numbers ..................... 1.8 Paint Codes ............................. 1.8 Standard Torque Specifications ............ 1.8 Tap Drill Cha
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GENERALINFORMATION MODELIDENTIFICATION The machine model number must be used with any correspondence regarding warranty or service. Machine ModelNumberIdentification A03 CA32AA Emissions & ModelOption YearDesignation Basic Chassis Designation Engine Designation ENGINEDESIGNATIONNUMBERS 32 ES32PFE10 ............ Single, Air Cooled, SOHC 4 Stroke, Electric Start VINIDENTIFICATION World Mfg. ID VehicleDescriptor Vehicle Identifier 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 3 2 A * 3 P 00 00 0 0 4 X
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GENERALINFORMATION 2003TRAILBOSSMODEL 2003TRAILBOSS330 1.3
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GENERALINFORMATION REPLACEMENTKEYS Replacementkeyscanbemadefromtheoriginal key. 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. Shouldbothkeysbecomelost,ignitionswitch replacement isrequired. Series # Part Number 20 4010278 21 4010278 22 4010321 31XX 23 4010321 27 4010321 Key Series Number 28 4010321 31 4110141 32 4110148 67 4010278 68 4010278 1.4
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GENERALINFORMATION MACHINE DIMENSIONS 46 in 117 cm FRONT 46 in 117 cm 75 in 191 cm 34 in 86 cm SIDE 49.5 in 126 cm 1.5
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GENERALINFORMATION MODEL: .......... 2003TRAILBOSS330 MODEL NUMBER: . A03CA32 ENGINEMODEL: .. ES32PFE10 JETTING CHART CARBURETION AMBIENT TEMPERATURE Type................ BST 34 Mikuni A Altitu ltitud de e Be Bello ow w 4 40 0F F +4 +40 0 FFttoo++880 0 F F Below 5C Main Jet ............ 122.5 +5 Cto+26 C 0-1800 Pilot Jet ............. 42.5 Meters 117.5 122.5 (0-6000) ((F Fe eet) et) Jet Needle........... 4HB48--2 aabov bove e1800 1800 120 120 1 11 15 5 Needle Jet........... P-0M (above6000
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GENERALINFORMATION MODEL: ............ 2003TRAILBOSS330 MODEL NUMBER: ... A03CA32 ENGINEMODEL: .... ES32PFE10 ELECTRICAL FLUID Capacity Type Flywheel I.D. ...... None Fuel Tank .......... 3.25 gals. (12.30 L) CDI Part Number... 4010697 Transmission ....... 11.3 oz. (335 ml) PPS* Alternator Output ... 210 watts Engine Oil ......... 1.5 qts (1.4 L) PP4* Ignition Timing ..... 302BTDC@5000RPM Brake (Hand) ..................... Dot 3 Spark Plug / Gap ... NGK BKR6E / 0.036 (0.9 mm) Brake (Foot) ..
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GENERALINFORMATION PUBLICATIONNUMBERS Year Model ModelNo. Owner’s Parts Parts ManualPN ManualPN Micro FichePN 2 20 00 03 3 T Tra raiill B Bos osss 3 33 30 0 A A0 03 3C CA A3 32 2A AA A 99991177449922 99991177886622 99991177886633 NOTE: When ordering service parts be sure to use the correct parts manual. PAINTCODES PAINTEDPART COLOR DITZLER POLARIS DESCRIPTION NUMBER NUMBER Springs Silver ---- P-385 Rims Bright White 2185 P-133 Rack(s) Black 9440 P-067 Frame Black 9440 P-067 FRAME COLOR - P067 Me
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GENERALINFORMATION SAETAPDRILLSIZES DECIMALEQUIVALENTS 1/64 ................ .0156 Thread Size/Drill Size Thread Size/Drill Size 1/32 ........... .0312 ... 1 mm = .0394 3/64 ................ .0469 #0-80 3/64 1/2-13 27/64 1/16........... .0625 #1-64 53 1/2-20 29/64 5/64 ................ .0781 ... 2 mm = .0787 #1-72 53 9/16-12 31/64 3/32........... .0938 #2-56 51 9/16-18 33/64 7/64 .............. .1094 ... 3 mm = .1181 #2-64 50 1/8. ... .1250 5/8-11 17/32 #3-48 5/64 9/64 ................ .1406
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GENERALINFORMATION CONVERSIONTABLE Unit of Measure Multiplied by Convertsto ft. lbs. x12 =in.lbs. in. lbs. x .0833 = ft. lbs. ft. lbs. x 1.356 =Nm in. lbs. x .0115 =kg-m Nm x .7376 = ft.lbs. kg-m x 7.233 = ft. lbs. kg-m x 86.796 =in.lbs. kg-m x10 =Nm in. x 25.4 =mm mm x .03937 =in. in. x2.54 =cm mile (mi.) x1.6 =km km x .6214 = mile (mi.) Ounces (oz) x 28.35 = Grams (g) Fluid Ounces (fl. oz.) x 29.57 = Cubic Centimeters (cc) Cubic Centimeters (cc) x .03381 = Fluid Ounces (fl. oz.) Grams (g) x 0.
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GENERALINFORMATION GLOSSARYOFTERMS ABDC: After bottom dead center. ACV: Alternating current voltage. Alternator: Electrical generator producing voltage alternating current. ATDC: After top dead center. BBDC: Before bottom dead center. BDC: Bottom dead center. BTDC: Before top dead center. CC: Cubic centimeters. Center Distance: Distance between center of crankshaft and center of driven clutch shaft. ChainPitch: Distancebetweenchainlinkpins(No.35=3/8or1cm). Polarismeasureschainlengthinnumberofpi
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GENERALINFORMATION NOTES 1.12
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MAINTENANCE CHAPTER2 MAINTENANCE Periodic Maintenance Chart ............... 2.2-2.3 Pre-Ride Inspection ...................... 2.3 Recommended Maintenance Products ...... 2.4 Lubricant and Maintenance Quick Reference 2.5-2.6 Special Tools ............................ 2.7 2 Transmission Lubrication.................. 2.8 Transmission Linkage Adjustment .......... 2.9 Throttle Operation / Choke Adjustment...... 2.10 Carburetor Adjustments................... 2.10-2.11 ETC Switch Adjustment .........
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MAINTENANCE PERIODICMAINTENANCE CHART Inspection, adjustment and lubrication intervals of important components is listed in the following chart. Maintenanceintervalsarebaseduponaverageridingconditionsandavehiclespeedofapproximately10mph. Inspect, clean, lubricate, adjust or replace parts as necessary. NOTE: Inspection may reveal the need for replacement parts. Always use genuine Polaris parts. = CAUTION: Duetothenatureoftheseadjustments,itisrecommendedthatservicebeperformedby an authorized Pol
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MAINTENANCE PERIODICMAINTENANCECHART, CONT. CHASSIS Frequency (Whichever comesfirst) Item Hours Calendar Miles Remarks (Km) General Lubrication 50 hrs 3 months 500 (800) Lubricate All Fittings, Pivots, Cables, Etc. Front Hubs/Fluid Check 50 hrs 6 months 500 (800) Check monthly Front Hubs/Fluid Change 100 hrs 12 months 1000 (1600) Check monthly Front Wheel Bearings (2x4) Annually 12 months Inspect and replace if necessary Front Hub Spindle Nut Torque Annually 12 months Inspect Torque an
