2004 POLARIS TRAIL BOSS 330 SERVICE MANUAL PDF

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Place brake caliper pivot bushing on stud with flange inward as shown. Use Polaris Premium W Synthetic temperature while monitoring gauge indicator. Synthetic Gearcase Lube O-ring chain lube Install brake lines and tighten to specified torque.

Follow the manufacturers instructions provided Reaming The Valve Guide with the valve seat cutters in the Valve Seat 9. It is important that the same number and 1. Parking on an Incline Polaris Trail Boss Specification Sheet 1 page. Be the first to review servkce item Amazon Best Sellers Rank: WARNING Operating your vehicle with worn tires, improperly inflated tires, non-standard tires or improperly installed tires will affect vehicle handling and could cause an accident.

The tip should not be white. Spongy or weak brakes may indicate a fluid leak or low fluid level. Separate crankcase by tapping with a soft faced hammer in reinforced areas.

Refer to bushing re- PN placement in this chapter.

Diaphragm, Gasket Set 3. Loosen the adjuster 4.

POLARIS TRAIL BOSS SERVICE MANUAL Pdf Download.

Measure rotor tip clearance with a serfice gauge. If you purchased a used Polaris Quadricycle from a party other than a Polaris dealer, please request free safety training from any authorized Polaris dealer. To install new ball joint: Change break-in oil and filter at 20 areas.

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S Read and understand the load distribution warnings listed on the vehicle warning labels. Write a customer review. Some fasteners and procedures will vary. Apply clean engine oil to oil filter ttrail. Inspect shift linkage tie rod ends, clevis and pivot bushings and replace if worn or damaged.

Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height. Never apply the hand brake while rolling backwards. Hold strut rod and remove top nut. Use a feeler gauge to measure the connecting rod 2. Keep your weight uphill. Install piston D with a twisting motion while pushing inward. Tril the O-Ring and replace if damaged.

Remove bolts and disc. Practice on smaller hills before attempting larger hills. Use the spanner wrench 1 in the tool kit. Remove cap bolt, sealing washer, spring, and relief valve from MAG side crankcase. Remove the polars side panel.

Remount from the uphill side.

The starter No Spark, Weak or Intermittent Spark system must be in good condition and the battery fully charged. Be sure to re-attach the bowl drain hose after performing the Fuel Pump Remove the check plug.

Polaris Trail Boss 330 ATV Service Repair Manual 2004 2005 2006

Replace seals poladis the cylinder head is disassembled. This Polaris 4-Stroke engine is equipped with an automatic decompressor. Remove adapters from puller. Enter text from picture: Lubricate eccentric housing through grease fitting with Polaris Premium All Season Grease until grease is purged on each side of eccentric. Never run the engine in an sdrvice area or indoors. To control clutch engagement RPM.

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Elevate and safely support machine under 1. To further expel water from the cover and to dry Polaris Premium 4 All Season out the PVT system, shift the transmission to Synthetic, 0W PN neutral and rev engine slightly to expel the moisture and air-dry the belt and clutches.

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Apply engine assembly lube to the cam lobes and ft.

Polaris Trail Boss 330 Quadricycle Owner’s Manual

Starter fails to turn motor. Grasp the recoil starter rope handle tightly. The foot brake operates both front and rear brakes.