2003 Polaris Trail Boss 330 ATV Service Repair Manual

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

This downloadable service manual contains instructions and technical information to maintain and repair your 2003 Polaris Trail Boss 330 ATV. This is the same manual technicians use to diagnose and repair your ATV. Whether it’s routine maintenance, such as tune-ups and brake service, or more extensive repairs involving engine and transmission disassembly, the service manual provides the most accurate information to perform the job. The bookmarks panel in this manual makes it easy to quickly navigate chapters and sub-chapters.

Topics:

General Information

• Model Identification
• Machine Dimensions
• Specifications – 2003 Trail Boss 330
• Standard Torque Specifications

Maintenance and Adjustment

• 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
• Electrical
• 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

• 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
• Troubleshooting

Fuel System

• 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
• Troubleshooting

Chassis

• 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

PVT and Drive

• 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
• Troubleshooting

Axles

• 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

Transmission

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

Brakes

• Specifications/Torques
• 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
• Troubleshooting
• Rear Caliper Exploded View

Electrical System

• 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