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TRAIL BOSS 325 2001
Polaris TRAIL BOSS 325 2001 User Manual
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Newton
Metre
to
Pound
Foot
and
Pound
Inch
GENERAL
INFORMA
TION
1.8
TORQUE
CONVER
SION
S
9
11
Table of Contents
Chapter 1 General Information
1
Table of Contents
1
General Information
3
Model Identification
3
Serial Number Location
3
Machine Dimensions
4
Paint Codes
8
Publication Numbers
8
Replacement Keys
8
Standard Torque Specifications
9
Conversion Table
13
Glossary of Terms
15
Chapter 2 Maintenance
17
Periodic Maintenance Chart
19
Pre-Ride Inspection
20
Recommended Lubricants
21
Transmission Lubrication
25
Fuel System
30
Compression Test
32
Battery Maintenance
33
Air Box Sediment Tube Service
35
Air Filter Service
35
Recoil Housing
36
Oil Change/Filter
37
Valve Clearance
39
Wheel Removal/Installation
52
Tire Inspection
53
Chapter 3 Engine
55
Torque Specifications
57
Piston Identification
58
Torque Patterns
58
Engine Removal
61
Engine Installation Notes
62
Engine Lubrication
64
Oil Pressure Test
64
Engine Bottom End Disassembly
87
Chapter 4 Fuel System/Carburetion
125
Jetting Guidelines
127
Fuel Flow Diagram
129
Mikuni Jet Part Numbers
129
Mikuni BST Carburetor, Exploded View
134
Fuel Pump Exploded View
143
Troubleshooting
144
Chapter 5 Body and Steering
147
Body Assembly Exploded View
150
Steering Assembly, Exploded View
152
A-Arm Replacement
153
Concentric Swingarm Assembly/Installation
155
Strut Assembly Exploded View
156
Front Strut Weldment Replacement
157
Front Strut Ball Joint Replacement
158
Decal Replacement
159
Chapter 6 Clutches
161
Steering Post Assembly
159
PVT Maintenance/Inspection
165
PVT Disassembly
167
PVT Assembly
169
PVT Sealing and Ducting Components
170
Drive Clutch Spring Specifications
172
Shift Weights
173
Drive Clutch Exploded View
175
Drive Clutch Assembly
179
Drive Belt Tension
180
Drive Belt Removal/Inspection
181
Drive Belt Installation
182
Clutch Alignment /Offset
183
Drive Clutch Bushing Service
184
Driven Clutch Disassembly/Inspection
188
Driven Clutch Assembly
191
Troubleshooting
196
Chapter 7 Final Drive 7
199
Front Hub Disassembly/Inspection
202
Front Hub Assembly
204
Front Hub Installation
205
Front Hub Exploded View
206
Concentric Swingarm Rear Axle Removal
207
Concentric Swingarm Rear Axle Disassembly
209
Concentric Swingarm Rear Axle Assembly
210
Concentric Swingarm Rear Axle Installation
212
Concentric Swingarm Rear Housing Removal
214
Concentric Swingarm Rear Housing Installation
216
Chapter 8 Transmission Service
217
Torque Specifications
219
Transmission Disassembly
221
Transmission Assembly
227
Transmission Exploded View
229
Chapter 9 Brakes
231
Troubleshooting
231
Brake Pad Kits
234
Brake System Service Notes
234
Brake Noise Troubleshooting
235
Hydraulic Brake System Operation
236
Dual Hydraulic Caliper Bleeding
237
Fluid Replacement/Bleeding Procedure
238
Master Cylinder Removal
240
Master Cylinder Disassembly
241
Master Cylinder Assembly
242
Master Cylinder Inspection
242
Master Cylinder Installation
244
Front Pad Removal
245
Front Pad Assembly
246
Front Disc Inspection
247
Front Caliper Disassembly
249
Front Caliper Removal
249
Front Caliper Inspection
250
Front Caliper Assembly
251
Front Caliper Installation
252
Troubleshooting
261
Chapter 10 Electrical
263
Special Tools
265
Timing Check Procedure
268
Typical Ignition Timing Curve
269
Flywheel Identification
270
Ignition System Troubleshooting
274
Battery Service
275
Charging System Testing
279
Starter System Troubleshooting
282
Starter Drive
289
4
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Polaris TRAIL BOSS 325 2001 Specifications
General
Brand
Polaris
Model
TRAIL BOSS 325 2001
Category
Offroad Vehicle
Language
English
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