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Polaris TRAIL BOSS 2003 User Manual

Polaris TRAIL BOSS 2003
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ENGINE
3.28
PRESSURE RELIEF VAL
VE
The pressure relief valve opens to relieve any excess
pressure from the oil pump if oil pressure reaches
approximately 71 psi. It must be clean and have
adequate spring pressure in order to seal properly.
1. Remove cap bolt, sealing washer, spring, and
relief valve from MAG side crankcase.
2. Inspect free length of spring and check coils for
distortion.
Relief Valve Spring Free Length:
Std: 2.175² (5.52 cm)
3. Inspect valve for wear.
4. Check seat area for nicks or foreign material that
may prevent proper sealing of valve.
OIL PUMP
REMOV
AL/INSPECTION
1. Remove the five screws on the oil pump cover
withanimpactdriver.
2. Inspect rotors and mating surface of oil pump
cover. Check for nicks, burrs, or surface
irregularities.
3. Measure pump end clearance using a feeler
gauge and straight edge.
Outer Feed Rotor to Crankcase Clearance:
Std: .001-.003 (.0254-.0762 mm)
Wear Limit: .004 (.1016 mm)
4. Measure clearance between outer feed rotor and
crankcase pocket with a feeler gauge.
Pump End Clearance:
Std: .001-.003 (.0254-.0762 mm)
Wear Limit: .004 (.1016 mm)

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Polaris TRAIL BOSS 2003 Specifications

General IconGeneral
BrandPolaris
ModelTRAIL BOSS 2003
CategoryOffroad Vehicle
LanguageEnglish

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