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2009 Trail Boss 330
Polaris 2009 Trail Boss 330 Service Manual
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TRANSMI
SSION
8.8
TRA
NSMISSIO
N
EXPLODED
VIEW
PartShark.com
877-999-5686
167
169
Table of Contents
Table of Contents
1
Model Identification
2
Engine Serial Number Location
2
General Information
2
Replacement Keys
3
Publication Numbers
3
Paint Codes
3
Special Tools
8
Standard Torque Specifications
9
Conversion Table
11
Glossary of Terms
12
Table of Contents
13
Periodic Maintenance Chart
14
Maintenance and Lubrication
15
Pre-Ride Inspection
20
Maintenance Quick Reference
22
Transmission Lubrication
24
Pilot Screw Adjustment
27
Throttle Operation / Choke Adjustment
28
Idle Speed Adjustment
28
Fuel Lines
29
Fuel System
29
Vent Lines
29
Fuel Filter
29
Carburetor Draining
30
Compression Test
30
Engine Mounts
31
Battery Maintenance
31
Spark Plug
32
Ignition Timing
32
Air Box Sediment Tube Service
34
Recoil Housing/Pvt Drying
34
Engine Oil Level
35
Oil and Filter Change
35
Valve Clearance
36
Intake Valve Clearance Adjustment
37
Exhaust Valve Clearance Adjustment
37
Camber and Caster
38
Brake System Inspection
40
Brake Pad Inspection
41
Rear Axle
43
Suspension Spring Preload Adjustment
44
Front Suspension
44
Rear Suspension
44
Wheel Removal / Installation
45
Wheel Removal Front or Rear
45
Tire Pressure
46
Tire Inspection
46
Table of Contents
47
Engine Service Data
48
Torque Patterns
50
Engine Removal
51
Accessible Components
51
Piston Identification
51
Engine Installation Notes
52
Honing to Deglaze
52
Engine Lubrication
53
Oil Pressure Test
53
Honing to Oversize
53
Engine Exploded View
56
Cam Chain Tensioner Inspection
57
Camshaft Removal
59
Automatic Compression Release Installation
60
Camshaft Inspection
60
Cylinder Head Removal
61
Cylinder Head Inspection
61
Cylinder Head Warpage
62
Cylinder Head Disassembly
62
Valve Inspection
63
Valve Seat Reconditioning
64
Combustion Chamber
64
Cylinder Head Assembly
67
Engine Bottom End Disassembly
68
Valve Sealing Test
68
Piston Removal
69
Cylinder Inspection
69
Piston Ring Installed Gap
71
Crankcase Disassembly
71
Oil Pump Assembly
75
Crankcase Separation
75
Crankshaft Inspection
76
Crankcase & Bearing Assembly
77
Crankcase Bearing Inspection
77
Crankcase Inspection
78
Bearing Installation
78
Crankshaft End Play Inspection
79
Engine Assembly/Inspection/Adjustments
79
Crankshaft Installation
80
Crankcase Reassembly
80
Piston Ring Installation
81
Piston Installation
81
Cylinder Head Installation
82
Cylinder Installation
82
Cam Chain Tensioner Installation
87
Recoil Assembly
91
Spark Plug Fouling Checklist
92
Troubleshooting
92
Engine Notes
95
Fuel Pump Exploded View
97
Fuel Flow Diagram
98
Jetting Guidelines
99
Carburetor Jetting
100
CV Carburetor System Function (4 Cycle)
100
Pilot Screw
100
Mikuni Jet Part Numbers
100
Assembly, CV Carburetor
101
Mikuni CV Carb Operation
101
Float System
102
Main System
103
Carburetor Cleaning
105
Carburetor Inspection
105
Carburetor Assembly
106
Float Height Adjustment
107
Needle and Seat Leakage Test
107
Fuel Level
108
Fuel Pump Service
108
Fuel Pump Disassembly
108
Troubleshooting
109
Fuel System/Carburetion Notes
111
Trail Boss Body Assembly Exploded View
112
Front Cab Assembly
112
Trail Blazer Body Assembly Exploded View
113
Steering Assembly, Exploded View
114
Cover/Panel Removal
115
Side Panel Removal
116
A-Arm Replacement
117
Concentric Swing Arm Removal
118
Concentric Swing Arm Assembly/Installation
119
Strut Assembly
120
Front Strut Cartridge Replacement
121
Ball Joint Replacement
121
Decal Replacement
123
Steering Post Assembly
123
Body / Steering / Suspension Notes
125
Pvt System Fastener Torques
126
Drive Clutch Operation
126
PVT System Operation Overview
126
Driven Clutch Operation
126
Special Tools and Supplies
126
PVT Drying
127
PVT Maintenance/Inspection
127
PVT Disassembly
129
PVT Assembly
130
Drive Clutch Exploded View
131
PVT Sealing and Ducting Components
131
Drive Clutch Spring Specifications
132
Shift Weights
133
Drive Clutch Disassembly/Inspection
134
Drive Clutch Inspection
134
Drive Clutch Assembly
136
Drive Belt Tension
137
Drive Belt Removal/Inspection
138
Clutch Alignment /Offset
139
Clutch Offset
140
Drive Belt Installation
139
Drive Clutch Bushing Service
140
Driven Clutch Disassembly/Inspection
143
Driven Clutch Assembly
144
Troubleshooting
147
Table of Contents
149
Front Hub Disassembly/Inspection
150
Final Drive
150
Front Hub Assembly
152
Front Hub Installation
152
Front Hub Exploded View
154
Rear Axle Removal
155
Rear Housing Removal
158
Rear Housing Disassembly
159
Rear Housing Installation
159
Table of Contents
161
Special Tools
162
Torque Specifications
162
Transmission Installation
162
Transmission Disassembly
162
Transmission Removal
162
Transmission Assembly
165
Transmission Exploded View
167
Troubleshooting
167
Troubleshooting Checklist
167
Transmission Transmission Exploded View
169
Hydraulic Brake System Operation
171
Brake System Service Notes
172
Brake Noise Troubleshooting
173
Hydraulic Caliper Bleeding
173
Brake Bleeding / Fluid Change
174
Master Cylinder Removal
176
Master Cylinder Installation
177
Front Pad Removal
178
Brake Burnishing
179
Front Pad Installation
179
Front Disc Inspection
180
Front Caliper Disassembly
181
Front Caliper Removal
181
Front Caliper Inspection
182
Front Caliper Reassembly
182
Front Caliper Installation
183
Brake Burnishing Procedure
186
Rear Caliper Removal/Inspection
187
Rear Caliper Assembly
188
Rear Caliper Exploded View
190
Troubleshooting
192
Electrical Service Notes
194
Gear Position Indicator
195
Fan Motor Current Draw
203
Etc Operation Test
204
Alternator Output Test
210
Battery Identification
211
Battery Charging
212
Battery Testing
213
Conventional Battery Installation
215
Conventional Battery Testing
215
Conventional Battery Specific Gravity Test
216
Headlight Adjustment
218
Headlight Lamp Replacement
218
Brake Light Switch
219
Headlamp Switch
219
Voltage Drop Test
221
Starter Motor Disassembly
222
Armature Testing
224
Starter Drive
225
4
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Polaris 2009 Trail Boss 330 Specifications
General
Brand
Polaris
Model
2009 Trail Boss 330
Category
Offroad Vehicle
Language
English
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