Polaris Trail Boss 330 2003 User manual

PN 9918061
Printed in USA
2003 TRAIL BOSS SERVICE MANUAL PN 9918061
2003 TRAIL BOSS
SERVICE MANUAL
PN 9918061
59173 03 TrailBoss Cover 8/23/02 8:47 PM Page 1

2003 TRAIL BOSS 330
SERVICE MANUAL
Foreword
This manual is designed primarily for use by certified Polaris Master Service Dealer technicians in a properly
equipped shop and should be kept available for reference. All references to left and right side of the vehicle
are from the operator’s perspective when seated in a normal riding position.
Some procedures outlined in this manual require a sound knowledge of mechanical theory, tool use, and shop
procedures in order to perform the work safely and correctly. Technicians should read the text and be familiar
with service procedures before starting the work. Certain procedures require the use of special tools. Use
only the proper tools as specified.
This manual includes procedures for maintenance operations, component identification and unit repair, along
with service specifications for 2003 Polaris Trail Boss ATVs.Comments or suggestions about this manual may
be directed to: Service Publications Dept. @ Polaris Sales Inc. 2100 Hwy 55 Medina Minnesota 55340.
2003 Trail Boss 330 ATV Service Manual (PN 9918061)
ECopyright 2002 Polaris Sales Inc. All information contained within this publication is based on the latest product information at the time of
publication. Due to constant improcvements in the design and quality of production components, some minor descrepancies may result
between the actual vehicle and the information presented in this publication. Depictions and/or procedures in this publication are intended
for reference use only. No liability can be accepted for ommisions or inaccuracies. Any reprinting or reuse of the depictions and/or
procedures contained within, whether whole or in part, is expressly prohibited. Printed in U.S.A.

UNDERSTANDING SAFETY LABELS AND INSTRUCTIONS
Throughout these instructions, important information is brought to your attention by the following symbols:
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!
DANGER
Failure to follow DANGER instructions will result in severe injury or death to the operator, bystander or person
inspecting or servicing the ATV.
WARNING
Failure to follow WARNING instructions could result in severe injury or death to the operator, bystander or
person inspecting or servicing the ATV.
CAUTION:
A CAUTION indicates special precautions that must be taken to avoid personal injury, or ATV or property
damage.
NOTE:
A NOTE provides key information to clarify instructions.
Trademarks
Polaris acknowledges the following products mentioned in this manual:
FLEXLOC, Registered Trademark of SPS Technologies
Loctite, Registered Trademark of the Loctite Corporation
STA-BIL, Registered Trademark of Gold Eagle
FOX, Registered Trademark of Fox Shox
Nyogel, Trademark of Wm. F. Nye Co.
Fluke, Registered Trademark of John Fluke Mfg. Co.
Mity Vac, Registered Trademark of Neward Enterprises, Inc.
Ammco, Registered Trademark of Ammco Tools, Inc.
Torx, Registered Trademark of Textron
Hilliard, Trademark of the Hilliard Corporation

CHAPTER INDEX
CHAPTER 1 GENERAL
CHAPTER 2 MAINTENANCE
CHAPTER 3 ENGINE
CHAPTER 4 FUEL SYSTEM
CHAPTER 5 BODY/SUSPENSION
CHAPTER 6 PVT SYSTEM
CHAPTER 7 FINAL DRIVE
CHAPTER 8 TRANSMISSION
CHAPTER 9 BRAKES
CHAPTER 10 ELECTRICAL

1
GENERAL INFORMATION
1.1
CHAPTER 1
GENERAL INFORMATION/
MAINTENANCE
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 IDENTIFICATION
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
A03CA32AA
Emissions &
Model Option
ENGINE DESIGNATION NUMBERS
32 ES32PFE10 Single, Air Cooled, SOHC 4 Stroke, Electric Start............
VIN IDENTIFICATION
1 2 3 4 5 6 7 8 9 10 1112 13 14 15 16 17
4XAAA 32A*3P000000
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 LOCATION
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 LOCATION
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
LOCATION
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