Polaris PN 9918061 - Manual

GENERAL INFORMATION 1.4 REPLACEMENT KEYS Replacement keys can be made from the originalkey. To identify which series the key is, take thefirst two digits on the original key and refer to thechart to the right for the proper part number. Should both keys become lost, ignition switchreplacement is req...

46 in117 cm 46 in117 cm 75 in191 cm 49.5 in126 cm 34 in86 cm FRONT SIDE GENERAL INFORMATION 1.5 MACHINE DIMENSIONS

GENERAL INFORMATION 1.6 MODEL: 2003 TRAIL BOSS 330 . . . . . . . . . . MODEL NUMBER: A03CA32 . ENGINE MODEL: ES32PFE10 . . JETTING CHART AMBIENT TEMPERATURE Altitude Below 40 ° F +40 E F to +80 E F Altitude Below 40 F Below 5 ° C +40 F to +80 F +5 E C to +26 E C Meters (Feet) 0-1800 (0-6000) 117.5 1...

GENERAL INFORMATION 1.8 PUBLICATION NUMBERS Year Model Model No. Owner’s Manual PN Parts Manual PN Parts Micro Fiche PN 2003 Trail Boss 330 A03CA32AA 9917492 9917862 9917863 2003 Trail Boss 330 A03CA32AA 9917492 9917862 9917863 NOTE: When ordering service parts be sure to use the correct parts manua...

GENERAL INFORMATION 1.9 SAE TAP DRILL SIZES Thread Size/Drill Size Thread Size/Drill Size #0-80 3/64 #1-64 53 #1-72 53 #2-56 51 #2-64 50 #3-48 5/64 #3-56 45 #4-40 43 #4-48 42 #5-40 38 #5-44 37 #6-32 36 #6-40 33 #8-32 29 #8-36 29 #10-24 24 #10-32 21 #12-24 17 #12-28 4.6mm 1/4-20 7 1/4-28 3 5/16-18 F ...

GENERAL INFORMATION 1.10 CONVERSION TABLE Unit of Measure Multiplied by Converts to ft. lbs. x 12 = in. lbs. in. lbs. x .0833 = ft. lbs. ft. lbs. x 1.356 = Nm in. lbs. x .0115 = kg-m Nm x .7376 = ft.lbs. kg-m x 7.233 = ft. lbs. kg-m x 86.796 = in. lbs. kg-m x 10 = Nm in. x 25.4 =mm mm x .03937 = in....

GENERAL INFORMATION 1.11 GLOSSARY OF TERMS ABDC: After bottom dead center. ACV: Alternating current voltage. Alternator: Electrical generator producing voltage alternating current. ATDC: After top dead center. BBDC: Before bottom dead center. BDC: Bottom dead center. BTDC: Before top dead center. CC...

2 MAINTENANCE 2.1 CHAPTER 2 MAINTENANCE Periodic Maintenance Chart 2.2-2.3 . . . . . . . . . . . . . . . Pre-Ride Inspection 2.3 . . . . . . . . . . . . . . . . . . . . . . Recommended Maintenance Products 2.4 . . . . . . Lubricant and Maintenance Quick Reference 2.5-2.6 Special Tools 2.7 . . . . . ...

MAINTENANCE 2.2 PERIODIC MAINTENANCE CHART Inspection, adjustment and lubrication intervals of important components is listed in the following chart.Maintenance intervals are based upon average riding conditions and a vehicle speed of approximately 10 mph.Inspect, clean, lubricate, adjust or replace...

MAINTENANCE 2.3 PERIODIC MAINTENANCE CHART, CONT. CHASSIS Frequency (Whichever comes first) Item Hours Calendar Miles (Km) Remarks " General Lubrication 50 hrs 3 months 500 (800) Lubricate All Fittings, Pivots, Cables, Etc. " Front Hubs/Fluid Check 50 hrs 6 months 500 (800) Check monthly ...

MAINTENANCE 2.4 POLARIS LUBRICANTS,MAINTENANCE AND SERVICE PRODUCTS Part No. Description Engine Lubricant 2870791 Fogging Oil (12 oz. Aerosol) 2871281 Engine Oil (Quart) Premium 4 Synthetic 0W-- 40 (4-- Cycle) (12 Count) 2871844 Engine Oil (Gallon) Premium 4 Synthetic 0W-- 40 (4-- Cycle) (4 Count) 2...

MAINTENANCE 2.5 RECOMMENDED MAINTENANCE PRODUCTS - QUICKREFERENCE Item Type Notes See Pages Engine Oil Polaris Premium 4 Synthetic, 0W--40 Add to proper level on dipstick. 2.17-2.18 Transmission Polaris Synthetic Gear Case Lubricant Refer to procedures outlined later in this chapter. 2.8 Brake Fluid...

MAINTENANCE 2.6 MAINTENANCE QUICK REFERENCE CONT’D 7. Tie Rod End 6. Ball Joint 5. FrontWheelBearings 8. Rear Axle Bearings 9. Swing ArmBushings Ill. # Item Lube Rec. Method Frequency* 5 Front Wheel Bear-ings Sealed; Replace Inspect and replace bearings if necessary Annually © 6 Ball Joint Polaris A...

MAINTENANCE 2.7 SPECIAL TOOLS PART NUMBER TOOL DESCRIPTION CHAPTER TOOL USED IN PA -- 44689 Valve Clutch Adjuster 2 2870872 Shock Spanner Wrench 2, 5 8712100DX or 8712500 Tachometer 2,10 2200634 Valve Seat Reconditioning Kit 3 2870390 Piston Support Block 3 2870159 Flywheel Puller 3 2871293 Slotted ...

MAINTENANCE 2.8 TRANSMISSION LUBRICATION The transmission lubricant level should be checkedand changed in accordance with the maintenanceschedule. G Be sure vehicle is level beforeproceeding. G Check vent hose to be sure it isrouted properly and unobstructed. G Follow instructions on following pages...

MAINTENANCE 2.9 TRANSMISSION GEARSHIFT LINKAGE ADJUSTMENT/ INSPECTION Correctly Tightened Jam Nut Incorrectly Tightened Jam Nut Parallel Linkage rod will rotate 1/8 -1/4 turn if rod ends are tightened properly. G If shifting problems are encountered,the transmission linkage may requireadjustment. G ...

MAINTENANCE 2.10 THROTTLE OPERATION - ALL MODELS Check for smooth throttle opening and closing in allhandlebar positions. Throttle lever operation shouldbe smooth and lever must return freely withoutbinding. 1. Place the gear selector in neutral. 2. Set parking brake. 3. Start the engine and let it ...

MAINTENANCE 2.11 IDLE SPEED ADJUSTMENT 1. Start engine and warm it up thoroughly. Idle Screw CV Carburetor Idle Speed: 1300 ± 100 RPM 2. Adjust idle speed by turning the idle adjustmentscrew in (clockwise) to increase or out (counterclockwise) to decrease RPM. (Refer toIll. at right). NOTE: Adjustin...

MAINTENANCE 2.12 FUEL SYSTEM WARNING Gasoline is extremely flammable and explosiveunder certain conditions. G Always stop the engine and refueloutdoors or in a well ventilated area. G Do not smoke or allow open flamesor sparks in or near the area whererefueling is performed or wheregasoline is store...

MAINTENANCE 2.13 NOTE: The bowl drain screw is located on the bottom left side of the float bowl.1. Turn fuel valve to the off position.2. Place a clean container beneath the bowl drain spigot or bowl drain hose. ON OFF RES Fuel Valve 3. Turn drain screw out two turns and allow fuel in the float bow...

MAINTENANCE 2.14 Maintenance--Free batteries are permanently sealed at the time of manufacture. The use of lead--calcium and AGM technology instead of lead--antimony allows the battery acid to be fully absorbed. For this reason, a Maintenance--Free battery case is dark and the cell caps are not remo...

MAINTENANCE 2.15 ENGINE-TO-FRAME GROUND Inspect engine-to-frame ground cable connection. Besure it is clean and tight. Engine Ground Strap MAIN AIR FILTER CLEANING It is advisable to replace the filter when it is dirty.However, in an emergency it is permissible to cleanthe main filter if you observe...

MAINTENANCE 2.16 NOTE: Apply a small amount of general purpose grease to the sealing edges of the filter before reinstalling. ILL.1 Filter Clamp Main Filter Filter Support Front Air Box Proper Filter Placement Ill.3 NOTE: The air filter should rest on the filter support. Proper placement of the air ...

MAINTENANCE 2.17 sealed properly, water may enter therecoil housing and damage components. G Water will enter the recoil housing ifthe starter handle is disengagedfrom the rope guide when underwater. G After travelling in wet areas, therecoil housing and starter shouldalways be drained completely by...

MAINTENANCE 2.18 OIL AND FILTER CHANGE 1. Place vehicle on a level surface. 2. Clean area around drain plug at bottom of oil pan. 3. Run engine two to three minutes until warm. Stopengine. 4. Place a drain pan beneath oil pan and removedrain plug from under the crankcase. CAUTION: Oil may be hot. Do...

MAINTENANCE 2.19 VALVE CLEARANCE Inspect and adjust valve clearance while the engineis cold and the piston positioned at Top Dead Center(TDC) on compression stroke. 1. Remove the seat. 2. Remove body panels and fuel tank as necessaryto gain access to valve cover. 3. Remove the spark plug high tensio...

MAINTENANCE 2.20 1. Insert .006 ² feeler gauge between end of exhaust valve stem and adjuster screw. EXHAUST VALVE CLEARANCE: 0.006 ± 0.0008 I (0.15 ± 0.02 mm) BTDC on compression 2. Loosen locknut and turn adjuster screw until thereis a slight drag on feeler gauge. 3. When clearance is correct, hol...

MAINTENANCE 2.21 G If abnormal movement is detected, inspect the hub and wheel assemblyto determine the cause. G Refer to the Body/Steering or FinalDrive chapter for more information. CAMBER AND CASTER The camber and caster are non-adjustable. WHEEL ALIGNMENT METHOD: STRAIGHTEDGE OR STRING Be sure t...

MAINTENANCE 2.22 TOE ALIGNMENT ADJUSTMENT If toe alignment is incorrect, measure the distancebetween vehicle center and each wheel. This will tellyou which tie rod needs adjusting. NOTE: Be sure handlebars are straight ahead before determiningwhich tie rod(s) need adjustment. CAUTION: During tie rod...

MAINTENANCE 2.23 5. If particles are still suspected to be in the muffler,drive the machine onto the incline so the front ofthe machine is one foot higher than the rear. Setthe hand brake and block the wheels. Make surethe machine is in neutral and repeat Steps 2 and3. SEE PREVIOUS WARNING 6. Repeat...

MAINTENANCE 2.25 After inspection, again slowly move the ATV forwarduntil all the chain slack is on the top side of the chainand inspect the deflection. Repeat this procedureseveral times to check different spots on the chain. The chain is correctly adjusted when the tightestportion of the chain its...

MAINTENANCE 2.26 CAUTION: DO NOT OVER-TIGHTEN ECCENTRICCLAMP BOLTS. PRE-MATURE BEARING FAILURE MAY RESULT. Torque the nut Eccentric Clamp Without Hitch WITHOUT TRAILER HITCH - 30 ft. lbs. (41 Nm) 7. Tighten caliper mounting bracket bolts 10-12 ft.lbs. (14 - 17 Nm) 10-12 ft. lbs Caliper Mount Bracket...

MAINTENANCE 2.28 TIRE PRESSURE Tire Pressure Inspection (PSI - Cold) Front Rear 4 3 TIRE INSPECTION WARNING Operating an ATV with worn tires will increasethe possibility of the vehicle skidding and pos-sible loss of control. Worn tires can cause an accident. Always replace tires when the tread depth...

3 ENGINE 3.1 CHAPTER 3 ENGINE Engine Service Data 3.2-3.3 . . . . . . . . . . . . . . . . . . . . . . . . . Special Tools and Torque Specifications 3.4 . . . . . . . . Torque Patterns 3.4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Piston Identification 3.5 . . . . . . . . . . . . . . ...

ENGINE 3.2 ES32PFE10 ENGINE SERVICE DATA Cylinder Head / Valve ES32PFE10 Rocker Arm Rocker arm ID .8669-.8678 ² (22.020-22.041 mm) Rocker shaft OD .8656-.8661 ² (21.987-22.0 mm) Rocker shaft Oil Clearance Std .0008-.0021 ² (.020-.054 mm) Limit .0039 ² (.10 mm) Camshaft Cam lobe height In Std 1.3001-...

ENGINE 3.3 ES32PFE10 ENGINE SERVICE DATA Cylinder / Piston / Connecting Rod ES32PFE10 Cylinder Surface warpage limit (mating with cylinderhead) .0020 ² (0.050 mm) Cylinder bore Std 3.0906-3.0913 ² (78.50-78.520 mm) Taper limit .0020 ² (0.050 mm) Out of round limit .0020 ² (0.050 mm) Piston clearance...

ENGINE 3.4 SPECIAL TOOLS PART NUMBER TOOL DESCRIPTION 2200634 Valve Seat Reconditioning Kit 2870390 Piston Support Block 2870159 Flywheel Puller 2871293 Slotted Nut Socket PV -- 43527 Oil Filter Wrench TORQUE SPECIFICATIONS ENGINE TORQUE SPECIFICATIONS Fastener Size 330 ES32PFE10 Ft. Lbs. (Nm) Camsh...

ENGINE 3.5 PISTON IDENTIFICATION The piston may have an identification mark or thepiston may not have an identification mark forpiston placement. If the piston has an identification mark, follow the directions for piston placementbelow. If the piston does not have an identificationmark, the directio...

ENGINE 3.6 ENGINE INSTALLATION NOTES After the engine is installed in the frame, review thischecklist and perform all steps that apply. General Items G Install previously removed components using new gaskets,seals, and fasteners where applicable. G Perform regular checks on fluidlevels, controls, an...

ENGINE 3.7 If cylinder wear or damage is excessive, it will benecessary to replace the cylinder. Hone only enoughto deglaze the outer layer of the cylinder bore. EXAMPLE OF CROSS HATCH PATTERN HONING TO OVERSIZE If cylinder wear or damage is excessive, it will benecessary to oversize the cylinder us...

ENGINE 3.8 3. Start engine and allow it to reach operatingtemperature while monitoring gauge indicator. Oil Pressure at 3000 RPM (Engine Hot): Standard: 71-99 PSI Minimum: 20 PSI at idle ES32PF10 NOTE: Use Polaris Premium 0--40W Synthetic Engine Lubricant ( PN 2871281 ). OIL COOLER ASSEMBLY Inlet Ho...

ENGINE 3.9 OIL FLOW DIAGRAM - ES32PF Engine Sump Crankcase Oil Passage Oil Pump Oil Pickup Screen Bypass Oil Filter Oil Passage In Cylinder Chain Room Cam Shaft Journal Rocker Arm / Rocker Shaft / Sprocket / Chain Cam Lobe Cam Shaft Journal Indirect Lubrication Crankcase Oil Passage Crankshaft Small...

ENGINE 3.10 ES32PFE ENGINE EXPLODED VIEW Crankcase Cylinder/ Cylinder Head Crankshaft and Piston Valve Train ES32PF

ENGINE 3.11 ENGINE REMOVAL REFER TO PAGE 3.5 - 3.6 FOR ENGINE REMOVAL / INSTALLATION NOTES. CAM CHAIN TENSIONER REMOVAL 1. Remove ignition timing inspection plug from recoilhousing. To position crankshaft at Top Dead Center (TDC)on compression stroke: 2. Rotate engine slowly in the direction of rota...

ENGINE 3.12 4. Measure free length of tensioner spring. Replacespring if excessively worn. Tensioner Spring Free Length: 2.06 ² (5.23 cm) Std. 1.92 ² (4.88 cm) Limit 5. Replace entire tensioner assembly if any part isworn or damaged. ROCKER ARM/SHAFT INSPECTION 1. Remove rocker cover. 2. Mark or tag...

ENGINE 3.13 Rocker Arm & Support I.D.: .8669-.8678 I (22.020-22.041 mm) 7. Measure I.D. of both rocker arm shaft supportareas and visually inspect surface. Compare tospecifications. Rocker Shaft Oil Clearance: Std: .0008-.0021 I (.020-.054 mm) Limit: .0039 I (.10 mm) 8. Inspect rocker adjuster s...

ENGINE 3.14 CAMSHAFT REMOVAL CONT’D 6. Inspect cam sprocket teeth for wear or damage.Replace if necessary. Inspect for Areas of Tooth Wear or Damage 7. Remove camshaft. Return spring (spacer) Dowel pin Release lever AUTOMATIC COMPRESSION RELEASE REMOVAL/ INSPECTION NOTE: The automatic compression re...

ENGINE 3.15 2. Thoroughly clean the cam shaft, making sure theoil feed holes are not obstructed. 3. Measure height of each cam lobe using amicrometer. Compare to specifications. 4. Measure camshaft journal outside diameter(O.D.) Journal O.D. Journal Camshaft Journal O.D.: Mag & PTO End: 1.4935-1...

ENGINE 3.16 CYLINDER HEAD WARPAGE 1. Lay a straight edge across the surface of thecylinder. head at several different points andmeasure warpage by inserting a feeler gaugebetween the straight edge and the cylinder headsurface. If warpage exceeds the service limit,replace the cylinder head. Cylinder ...

ENGINE 3.17 5. Remove valve seals. CAUTION: Replace seals whenever the cylinder head is disassembled.Hardened, cracked or worn valve seals will causeexcessive oil consumption and carbon buildup. VALVE INSPECTION 1. Remove all carbon from valve with a soft wirewheel. 2. Check valve face for runout, p...

ENGINE 3.18 7. Subtract valve stem measurement to obtain stemto guide clearance. NOTE: Be sure to measure each guide and valve combination individually. 8. Replace valve and/or guide if clearance isexcessive. Compare to specifications. Valve Guide I.D.: .2362-.2367 I (6.0-6.012 mm) NOTE: If valve gu...

ENGINE 3.19 4. Follow the manufacturers instructions providedwith the valve seat cutters in the Valve SeatReconditioning Kit ( PN 2200634 ). Abrasive stone seat reconditioning equipment can also be used.Keep valves in order with their respective seat. NOTE: Valve seat width and point of contact on t...

ENGINE 3.21 NOTE: When using an interference angle, the seat contact point on the valve will be very narrow, and isa normal condition. Look for an even and continuouscontact point on the black marker, all the way aroundthe valve face. Seat Width Valve Seat Width: Intake Std: .039 I (1.0 mm) Limit: ....

ENGINE 3.22 CYLINDER HEAD ASSEMBLY CONT’D 5. Dip valve spring and retainer in clean engine oiland install spring with closely spaced coils towardthe cylinder head. Closely spaced coils toward cylinder head 6. Place retainer on spring and install valve springcompressor. Compress spring only enough to...

ENGINE 3.23 PISTON REMOVAL 1. Remove circlip. Note that opening for circlip access is on the intake side. 2. Remove piston circlip and push piston pin out ofpiston. If necessary, heat the crown of the piston slightly with a propane torch. CAUTION: Do not apply heat to the piston rings. The ring may ...

ENGINE 3.24 CYLINDER INSPECTION CONT’D 5. Record measurements. If cylinder is tapered orout of round beyond .002, the cylinder must bere-bored oversize, or replaced. Cylinder Taper Limit: .002 Max. Cylinder Out of Round Limit: .002 Max. Standard Bore Size: 3.0906-3.0913 I (78.50-78.520 mm) PISTON IN...

ENGINE 3.25 5. Measure connecting rod small end ID. Connecting Rod Small End I.D. .7095-.7101 I (18.007-18.023 mm) 6. Measure piston ring to groove clearance byplacing the ring in the ring land and measuringwith a thickness gauge. Replace piston and ringsif ring-to-groove clearance exceeds serviceli...

ENGINE 3.26 STARTER DRIVE REMOVAL/INSPECTION 1. Remove recoil housing bolts and removehousing. 2. Remove starter drive assembly. Note the thrustwasher located at the rear of the drivemechanism. 3. Inspect the thrust washer for wear or damage andreplace if necessary. 4. Measure the OD of the starter ...