2003 Polaris Trail Boss 330 ATV Service Repair Manual

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Covers: 2003 Polaris Trail Boss 330 ATV A03CA32AA
Pages: 213
Format: PDF
Compatibility: Windows/Mac/Tablet

This service manual contains all the necessary instructions needed for any repair your 2003 Trail Boss 330 ATV may require. This is the same manual Polaris technicians use to diagnose and repair your 2003 Trail Boss 330. Whether it’s routine maintenance, such as tune-ups and brake service, or more extensive repairs involving engine and transmission disassembly, this manual provides the most accurate information to perform the job.

Topics in the 2003 Polaris Trail Boss 330 ATV Service Repair Manual:

2003 Model Identification
Serial Number Location
2003 Trailboss Model
Replacement Keys
Machine Dimensions
Specifications – 2003 Trail Boss 330
Publication Numbers
Paint Codes
Standard Torque Specifications
Tap Drill Charts
Decimal Equivalent Chart
Unit of Measure Conversion Table
Glossary of Terms

Periodic Maintenance Chart
Pre-Ride Inspection
Recommended Maintenance Products
Lubricant and Maintenance Quick Reference
Special Tools
Transmission Lubrication
Transmission Linkage Adjustment
Throttle Operation / Choke Adjustment
Carburetor Adjustments
ETC Switch Adjustment
Fuel System
Compression Test
Battery Maintenance
Oil Cooler Maintenance
Air Filter Service
Air Box Sediment Tube Service
Breather Filter
Recoil Housing/PVT Drying
Oil Level/Change/Filter
Valve Clearance
Steering and Toe Alignment
Exhaust System Maintenance
Brake System Service
Drive Chain and Sprocket Service
Suspension Service / Controls
Wheel Removal / Installation
Tire Inspection

Engine Service Data
Special Tools and Torque Specifications
Torque Patterns
Piston Identification
Engine Removal
Engine Installation Notes
Cylinder Honing
Engine Lubrication
Oil Pressure Test
Lubrication/Oil Flow
Engine Exploded View
Engine Top End Disassembly
Valve/ Valve Seat Service
Engine Bottom End Disassembly
Crankcase & Bearing Assembly
Crankshaft End Play Inspection
Engine Assembly/Inspection
Recoil Disassembly/Inspection/Reassembly
Spark Plug Fouling Checklist

Exploded View, Mikuni BST 34 Carburetor
Fuel Pump Exploded View
Fuel Tank Asm
Fuel Flow Diagram
Special Tools & Jetting Guidelines
Carburetor Jetting
Main Jet / Pilot Jet Part Numbers
CV Carburetor System Function (4 Cycle)
CV Carburetor Vent System (4 Cycle)
CV Carburetor Operation
Disassembly Notes, CV Carburetor
Cleaning, CV Carburetor
Inspection, CV Carburetor
Assembly, CV Carburetor
Float Adjustment, CV Carburetor
Needle & Seat Leakage Test
Fuel Level
Fuel Pump Service

Body Assembly, Exploded View
Steering Assembly, Exploded View
Torque Specifications and Special Tools
Cover/Panel Removal
Side Panel Removal
A-Arm Replacement
Concentric Swing Arm Removal
Concentric Swing Arm Assembly/Installation
Front Strut Exploded View
Strut Assembly and Service
Front Strut Ball Joint Replacement
Steering Post Assembly
Decal Replacement

Service Tools and Supplies
PVT System Torques
PVT System Operation Overview
PVT Maintenance/Inspection
PVT Drying
PVT Over heating
PVT Disassembly
PVT Assembly
PVT Sealing and Ducting Components
Drive Clutch Exploded View
Drive Clutch Spring Specifications
Shift Weights
Drive Clutch Inspection
Drive Clutch Disassembly/Inspection
Drive Clutch Assembly
Drive Belt Tension
Drive Belt Removal/Inspection
Drive Belt Installation
Clutch Alignment /Offset
Drive Clutch Bushing Service
Driven Clutch Disassembly/Inspection
Driven Clutch Assembly
Driven Clutch Bushing Service

Torque Specifications
Front Hub Disassembly/Inspection
Front Hub Assembly
Front Hub Installation
Front Hub Exploded View
Rear Axle Removal
Rear Axle Disassembly
Rear Axle Assembly
Rear Axle Installation
Rear Axle Exploded View
Rear Housing Removal
Rear Housing Service
Rear Housing Installation

Special Tools
Torque Specifications
Transmission Remove/Install
Transmission Disassembly
Transmission Assembly
Transmission Exploded View

Special Tools
Brake System Service Notes
Brake Noise Troubleshooting
Hydraulic Brake System Operation
Brake System Main Components
Dual Hydraulic Caliper Bleeding
Fluid Replacement/Bleeding Procedure 9
Master Cylinder Disassembly
Master Cylinder Installation
Front Pad Removal
Front Pad Assembly
Front Disc Inspection
Front Disc Removal/Replacement
Front Caliper Removal
Front Caliper Disassembly
Front Caliper Inspection
Front Caliper Assembly
Front Caliper Installation
Front Caliper Exploded View
Rear Pad Removal
Rear Pad Installation
Rear Caliper Removal/Inspection
Rear Caliper Assembly
Rear Disc Inspection
Rear Caliper Exploded View

Special Tools and Electrical Service Notes
Timing Check Procedure
Transmission Gear Position Switch Testing
Speed Limiter System/Troubleshooting
Oil Cooler Fan Circuit Operation
Thermistor / Fan Control Testing
Fan Motor Current Draw Test
Electronic Throttle Control System Operation
Flywheel Identification — DC/CDI Operation
ES32PF 200 Watt Alternator, Exploded View
Ignition System Testing
Ignition System Troubleshooting
Cranking Output Tests
Charging System Testing
Battery Service
Headlight/Tail Light Service
Starter System Testing
Starter System Troubleshooting
Starter Motor Service
Starter Drive
Wiring Diagram


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