2004-2006 POLARIS TRAIL BOSS 330 ATV Repair Manual

1 GENERAL INFORMATION 1.1 CHAPTER 1 GENERAL INFORMATION / MAINTENANC E 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 IDENTIFICA TION 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 A 03 CA 32 AA Emissions & Model Option ENGINE DESIGNATION NUMBERS 32 ES32PFE10 Single, Air Cooled, SOHC 4 Stroke, Electric Start ............ VIN IDENTIFICA TION 1 2 3 4 5 6 7 8 9 10 1 1 12 13 14 15 16 17 4 X A A A 3 2 A * 3 P 0 0 0 0 0 0 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 LOCA TION 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 LOCA TION 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 LOCA TION A B 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

GENERAL INFORMATION 1.6 MODEL: 2003 TRAIL BOSS 330 .......... MODEL NUMBER: A03CA32 . ENGINE MODEL: ES32PFE10 .. JETTING CHART AMBIENT TEMPERATURE Altitude Below 40F +40 F to +80 F Altitude Below 40 F Below 5C +40 F to +80 F +5 C to +26 C Meters (Feet) 0-1800 (0-6000) 117.5 122.5 (Feet) above 1800 120 115 above 1800 (above 6000) 120 115 CLUTCH CHART Shift Drive Clutch Driven Clutch Driven Altitude Shift Weight Drive Clutch Spring Driven Clutch Spring Driven Helix Altitude Weight Spring Spring Helix Meters 0-1800 20 40 Blue/Grey Black 2+2 Meters (Feet) 0-1800 (0-6000) 20--40 Blue/Grey Black 2+2 (Feet) 1800-3700 20 38 Blue/Grey Black 2+2 1800-3700 (6000-12000) 20--38 Blue/Grey Black 2+2 * 40 helix, black driven spring ENGINE Type 4 Cycle, Single Cyl. ....................... Displacement 329 cc ............... Bore 3.091 (78.5mm) ....................... Stroke 2.679 (68mm) ..................... Valve Clearance In & Ex 0.006  0.0008 (0.15  0.02 mm) BTDC on compression ...... Cooling Air with fan assisted oil cooler .................... Lubrication Type Wet Sump ............ Piston Marking None .............. Operating RPM200 6300 RPM ......... Idle RPM  50 (lights off) 1300 RPM ..... Compression Ratio 9.2:1 .......... Compression Pressure 70--90 PSI ....... CARBURETION Type BST 34 Mikuni ................ Main Jet 122.5 ............ Pilot Jet 42.5 ............. Jet Needle 4HB48--2 ........... Needle Jet P-0M ........... Pilot Screw 2 Turns Out .......... Pilot Air Jet 160 .......... Valve Seat 1.5 ........... Fuel Octane (R+M/2) 87 Non-Oxygenated or . 89 Oxygenated CLUTCH Type PVT .................... Belt 3211077 ..................... Belt Width (Projected) 1.188 (30.18mm) ..... Side Angle (Overall) 26 ...... Outside Circumference 40.86 .12 .... Center Distance 10.12 (254.5mm) .......... Clutch Offset 0.5 (12.7mm) ............ Drive Spring Grey ............. Driven Spring Black ............ Driven Helix 2+2 .............

GENERAL INFORMATION 1.7 MODEL: 2003 TRAIL BOSS 330 ............ MODEL NUMBER: A03CA32 ... ENGINE MODEL: ES32PFE10 .... ELECTRICAL FLUID Capacity Type Flywheel I.D. None Fuel Tank 3.25 gals. (12.30 L) ...... .......... CDI Part Number 4010697 Transmission 11.3 oz. (335 ml) PPS* ... ....... Alternator Output 210 watts Engine Oil 1.5 qts (1.4 L) PP4* ... ......... Ignition Timing 302 BTDC@5000RPM Brake (Hand) Dot 3 ..... ..................... Spark Plug / Gap NGK BKR6E / 0.036 (0.9 mm) Brake (Foot) Dot 3 ... ...................... Lights: Head (2) Dual Beam 30/30 watts ...... Tail 8.26 watts ........ Brake 26.9 watts ...... Indicator 1.0 watts ... Electric Start Standard ....... Electronic Speedo N/A .. Polaris Lubricants *PP6 Polaris Premium 60/40 Antifreeze/Coolant *PPS Polaris Premium Synthetic Gear Case Oil *PP4 Polaris 0W--40 Synthetic Engine Lubricant *PDD Premium Demand Drive Hub Fluid SUSPENSION / CHASSIS DRIVE TRAIN Body Style Gen IV Chain Type 520 O-Ring ........ ......... Front Suspension MacPherson Strut Gear Reduction-Rev 3.05/1 .. . Tow Capacity 850 lbs. (385.9 kg) Gear Reduction-High 2.68/1 ...... Turning Radius 75 (191 cm) Final Drive Ratio 11/40 78P ..... .... Toe Out 1/8 -1/4 (3-6.35 mm) Brake (Hand) Single Lever, Hyd. Disc ........... ....... Ground Clearance 5.5 (13.97 cm) Brake ( Auxiliary Foot) Hydraulic .. Front Vertical Travel 6.7 (17.02 cm) Rear Suspension Progressive Rate Swing Arm ... Rear Travel 9.0 (22.86 cm) ........ Rear Shock 2 Gas Charged Twin Tube ........ Shock Adjustment Cam .. TIRES Tire Size - Front 23 x 7 - 10 .... Tire Size - Rear 22 x 11 - 10 .... Tire Pressure - F/R 4/3 lbs. . Total Width 46 (117 cm) ........ Total Length 75 (191 cm) ....... Total Height 46 (117 cm) ........ Wheel Base 49.5 (125.73 cm) ....... Weight - Dry 505 lbs. (230 kg) ....... OPTIONAL SUSPENSION SPRINGS SPRING TYPE SOFT STANDARD FIRM Rear Compression Spring N/A 7041518-067 130 --165 lb/in. 7041303-067 250 lb/in. Front Strut Spring N/A 7041850-067 41 lb/in. 7041375-067 64 - 113 lb/in. LOAD CAPACITY Front Rack (Accy) 75 lbs. (34 kg) .... Rear Rack (Std) 125 lbs. (57 kg) ...... Tongue Weight 85 lbs. (14 kg) ....... Tow Hitch Std ...........

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 manual. PAINT CODES PAINTED PART COLOR DESCRIPTION DITZLER NUMBER POLARIS NUMBER Springs Silver ---- P-385 Rims Bright White 2185 P-133 Rack(s) Black 9440 P-067 Frame Black 9440 P-067 FRAME COLOR - P067 Medium Gloss Black 9440 / 8520147. Order direct from Midwest Industrial Coatings 952--252--2000 See Quick Reference Manual for ordering info. STANDARD TORQUE SPECIFICA TIONS The following torque specifications are to be used as a general guideline. FOR SPECIFIC TORQUE VALUES OF FASTENERS Refer to exploded views in the appropriate section. There are exceptions in the steering, suspension, and engine sections. Bolt Size Threads/In Grade 2 Grade 5 Grade 8 Torque in. lbs. (Nm) #10 - 24 27 (3.1) 43 (5.0) 60 (6.9) .............. ................ .............. #10 - 32 31 (3.6) 49 (5.6) 68 (7.8) .............. ................ .............. Torque ft. lbs. (Nm) * 1/4 - 20 5 (7) 8 (11) 12 (16) .............. .................. ................ 1/4 - 28 6 (8) 10 (14) 14 (19) .............. .................. .............. 5/16 - 18 11 (15) 17 (23) 25 (35) .............. ................ .............. 5/16 - 24 12 (16) 19 (26) 29 (40) .............. ................ .............. 3/8 - 16 20 (27) 30 (40) 45 (62) .............. ................ .............. 3/8 - 24 23 (32) 35 (48) 50 (69) .............. ................ .............. 7/16 - 14 30 (40) 50 (69) 70 (97) .............. ................ .............. 7/16 - 20 35 (48) 55 (76) 80 (110) .............. ................ .............. 1/2 - 13 50 (69) 75 (104) 110 (152) .............. ................ ............. 1/2 - 20 55 (76) 90 (124) 120 (166) .............. ................ ............. Metric / Torque 6 x 1.0 72-78 In. lbs. 8 x 1.25 14-18 ft. lbs. 10 x 1.25 26-30 ft. lbs. .... ......

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 5/16-24 I 3/8-16 O 3/8-24 Q 7/16-14 U 7/16-20 25/64 1/2-13 27/64 1/2-20 29/64 9/16-12 31/64 9/16-18 33/64 5/8-11 17/32 5/8-18 37/64 3/4-10 21/32 3/4-16 11/16 7/8-9 49/64 7/8-14 13/16 1-8 7/8 1-12 59/64 1 1/8-7 63/64 1 1/8-12 1 3/64 1 1/4-7 1 7/64 1 1/4-12 1 11/64 1 1/2-6 1 11/32 1 1/2-12 1 27/64 1 3/4-5 1 9/16 1 3/4-12 1 43/64 2-4 1/2 1 25/32 2-12 1 59/64 2 1/4-4 1/2 2 1/32 2 1/2-4 2 1/4 2 3/4-4 2 1/2 3-4 2 3/4 METRIC TAP DRILL SIZES Tap Size Drill Size Decimal Equiva- lent Nearest Fraction 3 x .50 3 x .60 4 x .70 4 x .75 5 x .80 5 x .90 6 x 1.00 7 x 1.00 8 x 1.00 8 x 1.25 9 x 1.00 9 x 1.25 10 x 1.25 10 x 1.50 11 x 1.50 12 x 1.50 12 x 1.75 #39 3/32 #30 1/8 #19 #20 #9 16/64 J 17/64 5/16 5/16 11/32 R 3/8 13/32 13/32 0.0995 0.0937 0.1285 0.125 0.166 0.161 0.196 0.234 0.277 0.265 0.3125 0.3125 0.3437 0.339 0.375 0.406 0.406 3/32 3/32 1/8 1/8 11/64 5/32 13/64 15/64 9/32 17/64 5/16 5/16 11/32 11/32 3/8 13/32 13/32 DECIMAL EQUIV ALENTS 1/64 .0156 ................ 1/32 .0312 1 mm = .0394 ........... ... 3/64 .0469 ................ 1/16 .0625 ........... 5/64 .0781 2 mm = .0787 ................ ... 3/32 .0938 ........... 7/64 .1094 3 mm = .1181 .............. ... 1/8. .1250 ... 9/64 .1406 ................ 5/32 .1563 4 mm = .1575 ........... ... 11/64 .1719 ............... 3/16 .1875 5 mm = .1969 ........... ... 13/64 .2031 ............... 7/32 .2188 ........... 15/64 .2344 6 mm = .2362 ............... ... 1/4 .25 .... 17/64 .2656 7 mm = .2756 ............... ... 9/32 .2813 ........... 19/64 .2969 ............... 5/16 .3125 8 mm = .3150 ........... ... 21/64 .3281 ............... 11/32 .3438 9 mm = .3543 .......... ... 23/64 .3594 ............... 3/8 .375 .... 25/64 .3906 10 mm = .3937 ............... ... 13/32 .4063 ......... 27/64 .4219 11 mm = .4331 ............... ... 7/16 .4375 ........... 29/64 .4531 ............... 15/32 .4688 12 mm = .4724 ......... ... 31/64 .4844 ............... 1/2 .5 13 mm = .5118 .... .............. 33/64 .5156 ............... 17/32 .5313 ......... 35/64 .5469 14 mm = .5512 ............... ... 9/16 .5625 ........... 37/64 .5781 15 mm = .5906 ............... ... 19/32 .5938 ......... 39/64 .6094 ............... 5/8 .625 16 mm = .6299 .... ............ 41/64 .6406 ............... 21/32 .6563 17 mm = .6693 ......... ... 43/64 .6719 .............. 11/16 .6875 .......... 45/64 .7031 18 mm = .7087 ............... ... 23/32 .7188 ......... 47/64 .7344 19 mm = .7480 ............... ... 3/4 .75 .... 49/64 .7656 ............... 25/32 .7813 20 mm = .7874 ......... ... 51/64 .7969 ............... 13/16 .8125 21 mm = .8268 ......... ... 53/64 .8281 ............... 27/32 .8438 ......... 55/64 .8594 22 mm = .8661 ............... ... 7/8 .875 .... 57/64 .8906 23 mm = .9055 ............... ... 29/32 .9063 ......... 59/64 .9219 .............. 15/16 .9375 24 mm = .9449 ......... ... 61/64 .9531 ............... 31/32 .9688 25 mm = .9843 ......... ... 63/64 .9844 ............... 1 1.0 .....

GENERAL INFORMATION 1.10 CONVERSION T ABLE 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. in. x 2.54 = cm mile (mi.) x 1.6 = km km x .6214 = mile (mi.) Ounces (oz) x 28.35 = Grams (g) Fluid Ounces (fl. oz.) x 29.57 = Cubic Centimeters (cc) Cubic Centimeters (cc) x .03381 = Fluid Ounces (fl. oz.) Grams (g) x 0.035 = Ounces (oz) lb. x .454 = kg kg x 2.2046 = lb. Cubic inches (cu in) x 16.387 = Cubic centimeters (cc) Cubic centimeters (cc) x 0.061 = Cubic inches (cu in) Imperial pints (Imp pt) x 0.568 = Liters (l) Liters (l) x 1.76 = Imperial pints (Imp pt) Imperial quarts (Imp qt) x 1.137 = Liters (l) Liters (l) x 0.88 = Imperial quarts (Imp qt) Imperial quarts (Imp qt) x 1.201 = US quarts (US qt) US quarts (US qt) x 0.833 = Imperial quarts (Imp qt) US quarts (US qt) x 0.946 = Liters (l) Liters (l) x 1.057 = US quarts (US qt) US gallons (US gal) x 3.785 =Liters (l) Liters (l) x 0.264 = US gallons (US gal) Pounds - force per square inch (psi) x 6.895 = Kilopascals (kPa) Kilopascals (kPa) x 0.145 = Pounds - force per square inch (psi) Kilopascals (kPa) x 0.01 = Kilograms - force per square cm Kilograms - force per square cm x 98.1 = Kilopascals (kPa)   xR 2 x H (height) = Cylinder Volume C to F: 9(C + 40)  5 - 40 = F F to C: 5(F + 40)  9 - 40 = C