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Polaris TRAIL BOSS 2003 User Manual

Polaris TRAIL BOSS 2003
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ENGINE
3.4
SPECIAL T
OOLS
PART NUMBER TOOL
DESCRIPTION
2200634 Valve Seat
Reconditioning Kit
2870390 Piston Support
Block
2870159 Flywheel Puller
2871293 Slotted Nut Soc k e t
PV --43527 Oil Filter Wrench
TORQUE SPECIFICATIONS
ENGINE TORQUE SPECIFICATIONS
Fastener Size 330
ES32PFE10
Ft. Lbs. (Nm)
Camshaft
Chain Tension-
er Lever
6mm 5-6.5 (7-9 Nm)
Camshaft
Chain Tension-
er
6mm 5-6.5 (7-9 Nm)
Camshaft
Chain Tension-
er Cap
11mm 8-- 10 (11-- 14 Nm)
Camshaft
Sprocket
10mm 25-29 (34-40 Nm)
Carburetor
Adaptor
8mm 12-14 (16-20 Nm)
Connecting
Rod
8.5mm 29-33 (39-45 Nm)
Crankcase 8mm 14-15 (19-21 Nm)
Crankshaft
Slotted Nut
(Drive Sprock-
et)
28mm 35-51 (47-69 Nm)
Cylinder Base
Bolts
6mm 5-7 (7-9 Nm)
Cylinder Head
Bolts
10mm Refer to Engine
Assembly for torque pro-
cedure
Drive Clutch
Bolt
7/16 - 20 40 (55 Nm)
Flywheel 16mm 58-72 (78-98 Nm)
Oil Hose Fit-
tings
1/2 & 9/16 20 (27 Nm)
Oil Delivery Pi-
pe
12mm 11-15 (15-21 Nm)
Oil Drain Bolt
(Crankcase)
14mm 14-17 (19-23 Nm)
Oil Filter Pipe
Fitting (Con-
nector)
20mm 36-43 (49-59 Nm)
Oil Line Fitting 20 (27 Nm)
Oil Pump Cov-
er
6mm 4-5 (5-7 Nm)
Oil Relief Valve
Plug
14mm 14.5-16.5 (20-23 Nm)
Recoil Housing 6mm 5-6.5 (7-9 Nm)
Rocker Cover 6mm 7-8 (9-11 Nm)
Rocker Cover
Block Plug
28mm 39-44 (53-59)
Rocker Adjus-
ter Screw Lock
Nut
6mm 6-7 (8-10 Nm)
Stator Plate 6mm 5-6.5 (7-9 Nm)
Starter Motor 6mm 5-6.5 (7-9 Nm)
Spark Plug 14mm 9-11 (12-15 Nm)
ENGINE FASTENER TORQUE
PA
TTERNS
Tighten cylinder head, cylinder base, and crankcase
fasteners in 3 steps following the sequence outlined
below.
6mm
1
23
4
6
5
Cylinder Head
Cylinder Base
Crankcase
1
2
3
4
9
7
6
8
5
10
11

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Polaris TRAIL BOSS 2003 Specifications

General IconGeneral
BrandPolaris
ModelTRAIL BOSS 2003
CategoryOffroad Vehicle
LanguageEnglish

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