Polaris TRAIL BOSS 2003 User Manual

ENGINE
3.25
5. Measure connecting rod small end ID.
Connecting Rod Small End I.D.
.7095-.7101I (18.007-18.023 mm)
6. Measure piston ring to groove clearance by
placing the ring in the ring land and measuring
with a thickness gauge. Replace piston and rings
if ring-to-groove clearance exceeds service
limits.
Piston
Ring
Feeler Gauge
Ring to groove clearance
Piston Ring-to-Groove Clearance
Top Ring Std: .0014-.0030I (.035-.075 mm)
Limit: .0059I (.15 mm)
Second Ring Std: .0010-.0026I (.025-.065
mm)
Limit: .0059I (.15 mm)
PISTON RING INSTALLED
GAP
1. Place each piston ring inside cylinder using piston
to push ring squarely into place as shown.
25-50mm
Cylinder
Piston Ring
Feeler Gauge
Piston ring end gap installed
2. Measure installed gap with a feeler gauge at both
the top and bottom of the cylinder.
NOTE: A difference in end gap indicates cylinder
taper. The cylinder should be measured for
excessive taper and out of round.
3. If the bottom installed gap measurement exceeds
the service limit, replace the rings.
NOTE: Always check piston ring installed gap after
re-boring a cylinder or when installing new rings. A
re-bored cylinder should always be scrubbed
thoroughly with hot soapy water, rinsed, and dried
completely. Wipe cylinder bore with an oil rag
immediately to remove residue and prevent rust.
Piston Ring Installed Gap
Top Ring
Std: .0079-.0138I (.20-.36 mm)
Limit: .039I (1.0 mm)
Second Ring
Std: .0138-.0197I (.35-.50 mm)
Limit: .039I (1.0 mm)
Oil Ring
Std: .0079-.0276I (.20-.70 mm)
Limit: .059I (1.5 mm)
CRANKCASE DISASSEMBLY
NOTE: The recoil starter, starter motor, starter drive,
flywheel, stator, cam chain and sprockets can be
serviced with the engine in the frame.

Polaris TRAIL BOSS 2003 Specifications

General

Brand	Polaris
Model	TRAIL BOSS 2003
Category	Offroad Vehicle
Language	English