Polaris TRAIL BOSS 2003 User Manual

ENGINE
3.35
TENSIONER
BLADE
INSTALLA
TION
1. Install the tensioner blade and tighten the
mounting bolt to specified torque.
Tensioner Blade Mounting Bolt Torque:
5-6.5 ft. lbs. (7-9 Nm)
OIL FILTER INSTALLATION
1. Apply clean engine oil to oil filter gasket. Install
filter until gasket lightly touches seat and then
tighten an additional 3/4 of a turn.
Oil Filter Connector Torque:
36-43 ft. lbs. (49-59 Nm)
PISTON RING INSTALLATION
NOTE: Apply clean engine oil to all ring surfaces and
ring lands. Always check piston ring installed gap
before rings are installed on piston. See Page 3.36.
If the piston has been in service clean any
accumulated carbon from the ring grooves and oil
control ring holes.
1. Place the oil control ring expander in oil ring
groove with the end gap facing forward. The
expander has no up or down marking and can be
installed either way. The ends should butt
squarely together and must not overlap.
2. Install the oil ring top rail with the end gap at least
30° from the end of the expander.
3. Install the bottom rail with the gap at least 30°
from the end of the expander on the side opposite
the top rail gap.
Ring Profile
Top
“R1” Mark up
“R” Mark up
Second
4. Install the second ring with the “R” mark facing up.
Position the end gap toward the rear (intake) side
of the piston.
5. Install the top ring (chrome faced) with the “R1”
mark facing up and the end gap facing forward
(toward the exhaust).
6. Check to make sure the rings rotate freely in the
groove when compressed.
PISTON INSTALLATION
1. Clean the gasket surfaces on the cylinder and
crankcase. Remove all traces of old gasket
material.
2. Make sure the cylinder mounting bolt holes are
clean and free of debris.
3. Install a new circlip on one side of the piston with
the end gap facing up or down.
CAUTION: Circlips become deformed during the
removal process. Do not re-use old circlips. Do not
compress the new clip more than necessary upon
installation to prevent loss of radial tension. Severe
engine damage may result if circlips are re-used or
deformed during installation.

Polaris TRAIL BOSS 2003 Specifications

General

Brand	Polaris
Model	TRAIL BOSS 2003
Category	Offroad Vehicle
Language	English