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Polaris Trail Boss 330 2003 Service Manual

Polaris Trail Boss 330 2003
213 pages
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PN 9918061
Printed in USA
2003 TRAIL BOSS SERVICE MANUAL PN 9918061
2003 TRAIL BOSS
SERVICE MANUAL
PN 9918061
59173 03 TrailBoss Cover 8/23/02 8:47 PM Page 1

Table of Contents

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Polaris Trail Boss 330 2003 Specifications

General IconGeneral
BrandPolaris
ModelTrail Boss 330 2003
CategoryOffroad Vehicle
LanguageEnglish

Summary

CHAPTER 1 GENERAL INFORMATION/MAINTENANCE

Model Identification

Explains how to identify the machine model number for warranty and service correspondence.

Specifications - 2003 Trail Boss 330

Lists detailed specifications for carburetion, engine, and clutch systems.

CHAPTER 2 MAINTENANCE

Periodic Maintenance Chart

Outlines inspection, adjustment, and lubrication intervals for key components.

Pre-Ride / Daily Inspection

Details essential checks to perform before each ride for safety and performance.

Fuel System

Covers fuel lines, fuel filter replacement, and carburetor draining.

Oil and Filter Change

Step-by-step procedure for changing engine oil and replacing the oil filter.

Valve Clearance

Explains inspection and adjustment of intake and exhaust valve clearances.

Brake System Inspection

Details recommended checks for brake system components for proper operation.

CHAPTER 3 ENGINE

Engine Service Data

Lists detailed service data and specifications for the ES32PFE10 engine.

Engine Removal

Provides a step-by-step procedure for removing the engine from the vehicle frame.

Cylinder Hone Selection/Honing Procedure

Details the process for honing the cylinder for proper ring seating and bore.

Troubleshooting (Engine)

Lists common engine problems and their probable causes and remedies.

CHAPTER 4 FUEL SYSTEM/CARBURETION

Troubleshooting (Fuel System)

Lists common fuel system issues and their causes and remedies.

CHAPTER 6 CLUTCH

PVT Operation Overview

Explains the basic operation of the Polaris Variable Transmission (PVT) system.

PVT Maintenance/Inspection

Outlines periodic inspection and maintenance for PVT system components.

PVT Disassembly

Provides step-by-step instructions for disassembling the PVT system.

PVT Assembly

Details the procedure for correctly assembling the PVT system components.

Drive Belt Removal/Inspection

Explains how to remove and inspect the drive belt for wear and damage.

Troubleshooting (Clutch)

Lists common clutch problems, their probable causes, and remedies.

CHAPTER 8 TRANSMISSION SERVICE

Transmission Removal/Install

Outlines the steps for removing and installing the transmission assembly.

Transmission Disassembly

Details the process of disassembling the transmission components.

Transmission Assembly

Provides instructions for reassembling the transmission components.

Troubleshooting (Transmission)

Lists common transmission shifting issues and their causes and remedies.

CHAPTER 9 BRAKES

Fluid Replacement/Bleeding Procedure

Details the process for changing brake fluid and bleeding the system.

Troubleshooting (Brakes)

Lists common brake system problems, their causes, and remedies.

CHAPTER 10 ELECTRICAL

Ignition System Testing

Guides through troubleshooting steps for ignition system issues.

Charging System Testing

Details procedures for testing the vehicle's charging system.

Battery Service

Provides instructions for battery inspection, testing, and service.

Starter System Testing

Guides through testing the starter system for common failure conditions.

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