Polaris Trail Boss 330 2003 Bedienungsanleitung

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

2003 TRAIL BOSS 330

SERVICE MANUAL

Foreword

This manual is designed primarily for use by certified Polaris Master Service Dealer technicians in a properly

equipped shop and should be kept available for reference. All references to left and right side of the vehicle

are from the operator’s perspective when seated in a normal riding position.

Some procedures outlined in this manual require a sound knowledge of mechanical theory, tool use, and shop

procedures in order to perform the work safely and correctly. Technicians should read the text and be familiar

with service procedures before starting the work. Certain procedures require the use of special tools. Use

only the proper tools as specified.

This manual includes procedures for maintenance operations, component identification and unit repair, along

with service specifications for 2003 Polaris Trail Boss ATVs.Comments or suggestions about this manual may

be directed to: Service Publications Dept. @ Polaris Sales Inc. 2100 Hwy 55 Medina Minnesota 55340.

2003 Trail Boss 330 ATV Service Manual (PN 9918061)

publication. Due to constant improcvements in the design and quality of production components, some minor descrepancies may result

between the actual vehicle and the information presented in this publication. Depictions and/or procedures in this publication are intended

for reference use only. No liability can be accepted for ommisions or inaccuracies. Any reprinting or reuse of the depictions and/or

procedures contained within, whether whole or in part, is expressly prohibited. Printed in U.S.A.

UNDERSTANDING SAFETY LABELS AND INSTRUCTIONS

Throughout these instructions, important information is brought to your attention by the following symbols:

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!

DANGER

Failure to follow DANGER instructions will result in severe injury or death to the operator, bystander or person

inspecting or servicing the ATV.

WARNING

Failure to follow WARNING instructions could result in severe injury or death to the operator, bystander or

person inspecting or servicing the ATV.

CAUTION:

A CAUTION indicates special precautions that must be taken to avoid personal injury, or ATV or property

damage.

NOTE:

A NOTE provides key information to clarify instructions.

Trademarks

Polaris acknowledges the following products mentioned in this manual:

FLEXLOC, Registered Trademark of SPS Technologies

Loctite, Registered Trademark of the Loctite Corporation

STA-BIL, Registered Trademark of Gold Eagle

FOX, Registered Trademark of Fox Shox

Nyogel, Trademark of Wm. F. Nye Co.

Fluke, Registered Trademark of John Fluke Mfg. Co.

Mity Vac, Registered Trademark of Neward Enterprises, Inc.

Ammco, Registered Trademark of Ammco Tools, Inc.

Torx, Registered Trademark of Textron

Hilliard, Trademark of the Hilliard Corporation

CHAPTER INDEX

CHAPTER 1 GENERAL

CHAPTER 2 MAINTENANCE

CHAPTER 3 ENGINE

CHAPTER 4 FUEL SYSTEM

CHAPTER 5 BODY/SUSPENSION

CHAPTER 6 PVT SYSTEM

CHAPTER 7 FINAL DRIVE

CHAPTER 8 TRANSMISSION

CHAPTER 9 BRAKES

CHAPTER 10 ELECTRICAL

GENERAL INFORMATION

1.1

CHAPTER 1

GENERAL INFORMATION/

MAINTENANCE

2003 Model Identification 1.2..................

Serial Number Location 1.2...................

2003 Trailboss Model 1.3.....................

Replacement Keys 1.4.......................

Machine Dimensions 1.5.....................

Specifications - 2003 Trail Boss 330 1.6-1.7........

Publication Numbers 1.8.....................

Paint Codes 1.8.............................

Standard Torque Specifications 1.8............

Tap Drill Charts 1.9..........................

Decimal Equivalent Chart 1.9.................

Unit of Measure Conversion Table 1.10..........

Glossary of Terms 1.11........................

GENERAL INFORMATION

1.2

MODEL IDENTIFICATION

The machine model number must be used with any correspondence regarding warranty or service.

Machine Model Number Identification

Year Designation Basic Chassis

Designation Engine Designation

A03CA32AA

Emissions &

Model Option

ENGINE DESIGNATION NUMBERS

32 ES32PFE10 Single, Air Cooled, SOHC 4 Stroke, Electric Start............

VIN IDENTIFICATION

1 2 3 4 5 6 7 8 9 10 1112 13 14 15 16 17

4XAAA 32A*3P000000

Vehicle Descriptor Vehicle Identifier

Powertrain

Engine

Emissions Model

Year

Plant No.

Individual Serial No.

Body Style

Check Digit

World Mfg. ID

* This could be either

a number or a letter

ENGINE SERIAL NUMBER LOCATION

Whenever corresponding about an engine, be sure to refer to the engine model number and serial number. This

information can be found on the sticker applied to the recoil housing on the right side of engine.(A) An additional

number is stamped on the center top of crankcase beneath the cylinder coolant elbow.

UNIT MODEL NUMBER AND SERIAL NUMBER LOCATION

The machine model number and serial number are

important for vehicle identification. The machine

serial number is stamped on the lower left side of

the frame tube.(B)

TRANSMISSION I.D. NUMBER

LOCATION

Front

The transmission I.D. number is located

on top of the transmission, right side of

machine.

GENERAL INFORMATION

1.3

2003 TRAILBOSS MODEL

2003 TRAILBOSS 330

GENERAL INFORMATION

1.4

REPLACEMENT KEYS

Replacement keys can be made from the original

key. To identify which series the key is, take the

first two digits on the original key and refer to the

chart to the right for the proper part number.

Should both keys become lost, ignition switch

replacement is required.

Series # Part Number

20 4010278

21 4010278

22 4010321

23 4010321

27 4010321

28 4010321

31 4110141

32 4110148

67 4010278

68 4010278

31XX

Key Series

Number

46 in

117 cm

46 in

117 cm

75 in

191 cm

49.5 in

126 cm

34 in

86 cm

FRONT

SIDE

GENERAL INFORMATION

1.5

MACHINE DIMENSIONS

Dieses Handbuch passt für folgende Modelle

Inhaltsverzeichnis

Andere Polaris Geländefahrzeug Handbücher

Polaris

Polaris Sportsman 9920364 Bedienungsanleitung

Polaris

Polaris 2000 120 XCR Bedienungsanleitung

Polaris

Polaris SNOWMOBILE 2001 Leitfaden

Polaris

Polaris PREDATOR 2003 Bedienungsanleitung

Polaris

Polaris 2012 RANGER RZR 570 Bedienungsanleitung

Polaris

Polaris Outlaw 9921488 Bedienungsanleitung

Polaris

Polaris 800 switchback assault Bedienungsanleitung

Polaris

Polaris RZR XP 1000 2014 Bedienungsanleitung

Polaris

Polaris 600 RUSH PRO-R Bedienungsanleitung

Polaris

Polaris RANGER RZR S Bedienungsanleitung

Polaris

Polaris Ranger 2005 Leitfaden

Polaris

Polaris 2879790 Bedienungsanleitung

Polaris

Polaris 120 XC SP Bedienungsanleitung

Polaris

Polaris Hawkeye Betriebsanleitung

Polaris

Polaris GENERAL 1000 2017 Leitfaden

Polaris

Polaris 2005 Fusion 900 Einrichtungshandbuch

Polaris

Polaris Trail Blazer Bedienungsanleitung

Polaris

Polaris MS4000 Bedienungsanleitung

Polaris

Polaris 2000 Sportsman 6X6 Leitfaden

Polaris

Polaris 2008 sportsman 800efi Bedienungsanleitung

Polaris

Polaris Sportsman 9921161 Bedienungsanleitung

Polaris

Polaris Sportsman X2 850 Leitfaden

Polaris

Polaris Outlaw 9921123 Bedienungsanleitung

Polaris

Polaris Sportsman 500 EFI Bedienungsanleitung

Beliebte Geländefahrzeug Handbücher anderer Marken

Yamaha

Yamaha Tri Moto 125 Bedienungsanleitung

Yamaha

Yamaha YFM350X Warrior Bedienungsanleitung

APRILIA

APRILIA QUASAR 100 Bedienungsanleitung

Suzuki

Suzuki LT-A700X Bedienungsanleitung

Ski-Doo

Ski-Doo SCANDIC WT Handbuch

Suzuki

Suzuki LT-Z400 Bedienungsanleitung

Arctic Cat

Arctic Cat 120 sno pro Bedienungsanleitung

Yamaha

Yamaha RS90PB Bedienungsanleitung

Dinli

Dinli DL702 Bedienungsanleitung

Yamaha

Yamaha SXV70ML Bedienungsanleitung

Baja motorsports

Baja motorsports ATV 90 Handbuch

Arctic Cat

Arctic Cat ALTERRA 450 Bedienungsanleitung

Yamaha

Yamaha YFM45FAT Handbuch

Can-Am

Can-Am DS 70 Handbuch

Ski-Doo

Ski-Doo SKANDIC Handbuch

Yamaha

Yamaha VT500B Bedienungsanleitung

GAS GAS

GAS GAS K2 QUAD 250 - SERVICE Bedienungsanleitung

GMX

GMX GMXK150WHI Bedienungsanleitung