Polaris TRAIL BOSS 2003 User Manual

TRANSMISSION
8.5
18. Inspect gear bushing. Replace if half of teflon
surface is gone.
19. Inspect output shaft gear, sprocket and bearing.
Replace if necessary.
NO
Output Shaft
G
ear
Sprocket
Bearing
20. Stretch chain tight on a flat surface and measure
the length of 8 pitches in a minimum of three
places on chain. Replace chain if measurement
is longer than 3.0904I.
Chain Stretch Limit
8 pitch length = 3.0904I Maximum
Measure
8 pitches
TRANSMISSION ASSEMBLY
1. Assemble input shaft assembly.
NOTE: Install bearings with numbers and letters
facing out so they can be read after assembly.
Sprocket cogs face the dog gear .
NOTE: Input gear cogs face inward on input shaft.
Input Shaft
Bushing
Sprocket
Dog Gear
Input Gear
Thrust Washer
2. Assemble output shaft with sprocket, gear and
bearing if they were disassembled.
3. Assemble output shaft assembly with chain to the
input shaft assembly.
4. Install shift shaft, driven sprocket and gear into
the case.

Polaris TRAIL BOSS 2003 Specifications

General

Brand	Polaris
Model	TRAIL BOSS 2003
Category	Offroad Vehicle
Language	English