Polaris 2009 Trail Boss 330 Manuals

Manuals and User Guides for Polaris 2009 Trail Boss 330. We have 2 Polaris 2009 Trail Boss 330 manuals available for free PDF download: Service Manual, Owner's Manual

Polaris 2009 Trail Boss 330 Service Manual

Polaris 2009 Trail Boss 330 Service Manual (230 pages)

Brand: Polaris | Category: Offroad Vehicle | Size: 6.85 MB

Table of Contents

Table of Contents

1
- Model Identification
  2
- Engine Serial Number Location
  2
- General Information
  2
- Replacement Keys
  3
- Publication Numbers
  3
- Paint Codes
  3
- Special Tools
  8
- Standard Torque Specifications
  9
  - Conversion Table
    11
- Glossary of Terms
  12
Table of Contents

13
- Periodic Maintenance Chart
  14
  - Maintenance and Lubrication
    15
- Pre-Ride Inspection
  20
  - Maintenance Quick Reference
    22
- Transmission Lubrication
  24
  - Pilot Screw Adjustment
    27
- Throttle Operation / Choke Adjustment
  28
  - Idle Speed Adjustment
    28
  - Fuel Lines
    29
- Fuel System
  29
  - Vent Lines
    29
  - Fuel Filter
    29
  - Carburetor Draining
    30
- Compression Test
  30
  - Engine Mounts
    31
- Battery Maintenance
  31
  - Spark Plug
    32
  - Ignition Timing
    32
- Air Box Sediment Tube Service
  34
- Recoil Housing/Pvt Drying
  34
  - Engine Oil Level
    35
  - Oil and Filter Change
    35
- Valve Clearance
  36
  - Intake Valve Clearance Adjustment
    37
  - Exhaust Valve Clearance Adjustment
    37
  - Camber and Caster
    38
  - Brake System Inspection
    40
  - Brake Pad Inspection
    41
  - Rear Axle
    43
  - Suspension Spring Preload Adjustment
    44
  - Front Suspension
    44
  - Rear Suspension
    44
- Wheel Removal / Installation
  45
  - Wheel Removal Front or Rear
    45
  - Tire Pressure
    46
- Tire Inspection
  46
Table of Contents

47
- Engine Service Data
  48
- Torque Patterns
  50
- Engine Removal
  51
  - Accessible Components
    51
- Piston Identification
  51
- Engine Installation Notes
  52
  - Honing to Deglaze
    52
- Engine Lubrication
  53
- Oil Pressure Test
  53
  - Honing to Oversize
    53
- Engine Exploded View
  56
  - Cam Chain Tensioner Inspection
    57
  - Camshaft Removal
    59
  - Automatic Compression Release Installation
    60
  - Camshaft Inspection
    60
  - Cylinder Head Removal
    61
  - Cylinder Head Inspection
    61
  - Cylinder Head Warpage
    62
  - Cylinder Head Disassembly
    62
  - Valve Inspection
    63
  - Valve Seat Reconditioning
    64
  - Combustion Chamber
    64
  - Cylinder Head Assembly
    67
- Engine Bottom End Disassembly
  68
  - Valve Sealing Test
    68
  - Piston Removal
    69
  - Cylinder Inspection
    69
  - Piston Ring Installed Gap
    71
  - Crankcase Disassembly
    71
  - Oil Pump Assembly
    75
  - Crankcase Separation
    75
  - Crankshaft Inspection
    76
- Crankcase & Bearing Assembly
  77
  - Crankcase Bearing Inspection
    77
  - Crankcase Inspection
    78
  - Bearing Installation
    78
- Crankshaft End Play Inspection
  79
- Engine Assembly/Inspection/Adjustments
  79
  - Crankshaft Installation
    80
  - Crankcase Reassembly
    80
  - Piston Ring Installation
    81
  - Piston Installation
    81
  - Cylinder Head Installation
    82
  - Cylinder Installation
    82
  - Cam Chain Tensioner Installation
    87
  - Recoil Assembly
    91
- Spark Plug Fouling Checklist
  92
- Troubleshooting
  92
Engine Notes

95
- Fuel Pump Exploded View
  97
- Fuel Flow Diagram
  98
  - Jetting Guidelines
    99
- Carburetor Jetting
  100
- CV Carburetor System Function (4 Cycle)
  100
- Pilot Screw
  100
  - Mikuni Jet Part Numbers
    100
- Assembly, CV Carburetor
  101
  - Mikuni CV Carb Operation
    101
  - Float System
    102
  - Main System
    103
  - Carburetor Cleaning
    105
  - Carburetor Inspection
    105
  - Carburetor Assembly
    106
  - Float Height Adjustment
    107
- Needle and Seat Leakage Test
  107
- Fuel Level
  108
- Fuel Pump Service
  108
  - Fuel Pump Disassembly
    108
- Troubleshooting
  109
Fuel System/Carburetion Notes

111
- Trail Boss Body Assembly Exploded View
  112
  - Front Cab Assembly
    112
- Trail Blazer Body Assembly Exploded View
  113
- Steering Assembly, Exploded View
  114
- Cover/Panel Removal
  115
- Side Panel Removal
  116
- A-Arm Replacement
  117
- Concentric Swing Arm Removal
  118
- Concentric Swing Arm Assembly/Installation
  119
- Strut Assembly
  120
  - Front Strut Cartridge Replacement
    121
  - Ball Joint Replacement
    121
- Decal Replacement
  123
- Steering Post Assembly
  123
Body / Steering / Suspension Notes

125
- Pvt System Fastener Torques
  126
  - Drive Clutch Operation
    126
- PVT System Operation Overview
  126
  - Driven Clutch Operation
    126
- Special Tools and Supplies
  126
- PVT Drying
  127
- PVT Maintenance/Inspection
  127
- PVT Disassembly
  129
- PVT Assembly
  130
- Drive Clutch Exploded View
  131
- PVT Sealing and Ducting Components
  131
- Drive Clutch Spring Specifications
  132
- Shift Weights
  133
- Drive Clutch Disassembly/Inspection
  134
- Drive Clutch Inspection
  134
- Drive Clutch Assembly
  136
- Drive Belt Tension
  137
- Drive Belt Removal/Inspection
  138
- Clutch Alignment /Offset
  139
  - Clutch Offset
    140
- Drive Belt Installation
  139
- Drive Clutch Bushing Service
  140
- Driven Clutch Disassembly/Inspection
  143
- Driven Clutch Assembly
  144
- Troubleshooting
  147
Table of Contents

149
- Front Hub Disassembly/Inspection
  150
  - Final Drive
    150
- Front Hub Assembly
  152
- Front Hub Installation
  152
- Front Hub Exploded View
  154
- Rear Axle Removal
  155
- Rear Housing Removal
  158
- Rear Housing Disassembly
  159
- Rear Housing Installation
  159
Table of Contents

161
- Special Tools
  162
- Torque Specifications
  162
  - Transmission Installation
    162
- Transmission Disassembly
  162
  - Transmission Removal
    162
- Transmission Assembly
  165
- Transmission Exploded View
  167
- Troubleshooting
  167
  - Troubleshooting Checklist
    167
Transmission Transmission Exploded View

169
- Hydraulic Brake System Operation
  171
- Brake System Service Notes
  172
- Brake Noise Troubleshooting
  173
- Hydraulic Caliper Bleeding
  173
- Brake Bleeding / Fluid Change
  174
- Master Cylinder Removal
  176
- Master Cylinder Installation
  177
- Front Pad Removal
  178
- Brake Burnishing
  179
- Front Pad Installation
  179
- Front Disc Inspection
  180
- Front Caliper Disassembly
  181
- Front Caliper Removal
  181
- Front Caliper Inspection
  182
- Front Caliper Reassembly
  182
- Front Caliper Installation
  183
  - Brake Burnishing Procedure
    186
- Rear Caliper Removal/Inspection
  187
- Rear Caliper Assembly
  188
- Rear Caliper Exploded View
  190
- Troubleshooting
  192
  - Electrical Service Notes
    194
  - Gear Position Indicator
    195
  - Fan Motor Current Draw
    203
  - Etc Operation Test
    204
  - Alternator Output Test
    210
  - Battery Identification
    211
  - Battery Charging
    212
  - Battery Testing
    213
  - Conventional Battery Installation
    215
  - Conventional Battery Testing
    215
  - Conventional Battery Specific Gravity Test
    216
  - Headlight Adjustment
    218
  - Headlight Lamp Replacement
    218
  - Brake Light Switch
    219
  - Headlamp Switch
    219
  - Voltage Drop Test
    221
  - Starter Motor Disassembly
    222
  - Armature Testing
    224
  - Starter Drive
    225

Advertisement

Polaris 2009 Trail Boss 330 Owner's Manual

Polaris 2009 Trail Boss 330 Owner's Manual (120 pages)

Polaris Industries All-Terrain Vehicles Owner's Manual

Brand: Polaris | Category: Offroad Vehicle | Size: 2.47 MB

Table of Contents

Table of Contents
6
Introduction
7
- Vehicle Identification Numbers
  9
- Safe Riding Gear
  11
- Eye Protection
  12
- Equipment Modifications
  12
Safety
12
- Safety Warnings
  13
- Handling Gasoline
  14
- Exposure to Exhaust
  14
- Protective Apparel
  15
- Carrying a Passenger
  15
- Operating at Excessive Speeds
  16
- Operating on Public Roads
  16
- Operating on Pavement
  16
- Physical Control of the Atv
  17
- Turning Improperly
  17
- Jumps and Stunts
  17
- Improper Hill Climbing
  17
- Descending Hills Improperly
  18
- Crossing Hillsides
  18
- Stalling While Climbing a Hill
  19
- Operating on Steep Hills
  19
- Operating on Slippery Terrain
  20
- Operating in Unfamiliar Terrain
  20
- Improper Tire Maintenance
  21
- Skidding or Sliding
  22
- Poor Visibility
  23
- Improper Cargo Loading
  23
- Operating a Damaged Atv
  24
- Physical Skills
  24
- Hot Exhaust Systems
  24
- Unauthorized Use of the Atv
  24
- General Warning
  25
- Discretionary Warning
  26
- Age 16 Warning
  28
- Clutch Cover Warning
  28
- Reverse Override Warning
  28
- Indicator Lights
  30
Features and Controls
30
- Throttle Lever
  31
- Parking Brake
  32
- Brake Lever
  32
- Brake Fluid
  34
- Hand Brake
  35
- Fuel Valve
  36
- Fuel Filter
  36
- Recoil Starter
  38
Operation
40
- Safe Operation Practices
  41
- Trail Etiquette
  42
- Starting the Engine
  44
- Driving Procedures
  46
- Turning the Vehicle
  47
- Driving on Slippery Surfaces
  48
- Driving Uphill
  49
- Driving Downhill
  51
- Driving through Water
  53
- Driving over Obstacles
  54
- Driving in Reverse
  55
- Parking on an Incline
  56
- Hauling Cargo
  57
- Towing Loads
  58
Emission Control Systems
59
Maintenance
60
- Periodic Maintenance Chart
  61
- Maintenance Chart Key
  61
- Lubrication Guide
  64
- Engine Oil
  65
- Oil Recommendations
  65
- Oil Level
  65
- Oil and Filter Change
  66
- Transmission Oil
  67
- Oil Change
  68
- Brake Inspections
  69
- Side Panel Removal
  70
- Toe Alignment
  71
- Throttle Cable Freeplay
  72
- Camber and Caster
  73
- Rear Spring
  73
- Tire Tread Depth
  74
- Front Wheel Hub Tightening
  74
- Wheel Removal
  75
- Wheel Installation
  75
- Air Filter
  77
- Recoil Housing
  78
- Drive Chain
  80
- Drive Chain Lubrication
  80
- Rear Drive Chain Slack
  81
- Headlight Beam Adjustment
  83
- Headlamp Replacement
  84
- Indicator Lamp Replacement
  85
- Spark Plugs
  86
- Spark Plug Inspection
  86
- Spark Plug Condition
  87
- Vehicle Immersion
  88
- Spark Arrestor
  89
- Pvt System
  90
- Pvt Drying
  92
- Battery Removal
  94
- Battery Installation
  95
- Battery Storage
  96
- Cleaning and Storage
  99
- Washing the Vehicle
  100
- Polishing the Vehicle
  100
- Storage Tips
  102
- Fluid Levels
  103
- Transporting the Vehicle
  105
Polaris Products
106
Troubleshooting
108
- Jetting Chart
  112
- Clutching Chart
  112
Specifications
112
Warranty
114
Maintenance Log
120

Advertisement

Related Products

Polaris Categories

Offroad Vehicle Swimming Pool Vacuum Utility Vehicle Automobile Accessories Snowmobiles

More Polaris Manuals