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Polaris TRAIL BOSS 2003 User Manual

Polaris TRAIL BOSS 2003
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MAINTENANCE
2.19
VALVE CLEARANCE
Inspect and adjust valve clearance while the engine
is cold and the piston positioned at Top Dead Center
(TDC) on compression stroke.
1. Remove the seat.
2. Remove body panels and fuel tank as necessary
to gain access to valve cover.
3. Remove the spark plug high tension lead and
remove the spark plug. CAUTION: Place a clean
shop towel into the spark plug cavity to prevent
dirt from entering.
4. Remove plastic valve plugs.
330 Valve Plugs
5. Remove timing inspection plug from recoil
housing.
CAUTION: Failure to position the crankshaft at TDC
on compression stroke will result in improper valve
adjustment.
6. Rotate engine slowly with recoil rope, watching
the intake valve(s) open and close.
NOTE: Observe the intake valve closing and then
start to open, continue to rotate until the “T aligns with
pointer. The camshaft lobes should be pointing
downward.
7. Verify accurate TDC positioning by observing the
“T” mark aligned with the pointer in the timing
inspection hole. In this position there should be
clearance on all valves.
0.006±0.0008I (0.15±0.02 mm)
BTDC on compression
INTAKE VALVE CLEARANCE:
INTAKE VALVE CLEARANCE
ADJUSTMENT
1. Insert a .006² (.15mm) feeler gauge between end
of intake valve stem and clearance adjuster
screw.
2. Using Valve/Clutch Adjuster (PA--44689), loosen
adjuster lock nut and turn adjusting knob until
there is a slight drag on the feeler gauge.
330 Engine
3. Hold adjuster screw and tighten adjuster lock nut
securely.
4. Re-check the valve clearance.
5. Repeat adjustment procedure if necessary until
clearance is correct with locknut secured.
EXHAUST VALVE
CLEARANCE
ADJUSTMENT
NOTE: The exhaust valve is adjusted the same as the
intake valve.

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Polaris TRAIL BOSS 2003 Specifications

General IconGeneral
BrandPolaris
ModelTRAIL BOSS 2003
CategoryOffroad Vehicle
LanguageEnglish

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