Trail Boss 330

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<p>PARTS MANUAL PN 9919483 and MICROFICHE PN 9919484 9/04</p> <p>TRAIL BOSS 330 Model #A05CA32AA TRAIL BOSS LE Model #A05CA32AB TRAIL BOSS 330 INTL Model #A05CA32FA Rev. 01E 2004 Polaris Sales Inc.</p> <p>This page left blank intentionally.</p> <p>TABLE OF CONTENTSTRAIL BOSS 330 A05CA32AA and TRAIL BOSS LE A05CA32AB and TRAIL BOSS 330 INTL A05CA32FA</p> <p>Parts Manual</p> <p>A-- ARM/STRUT MOUNTING . . . . . . . . . . . . . B7 AIR BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . A11</p> <p>A</p> <p>GEARCASE . . . . . . . . . . . . . . . . . . . . . . . . . C3-4 GEARCASE MOUNTING . . . . . . . . . . . . . . . C2</p> <p>G</p> <p>BUMPER and RACK MOUNTING . . . . . . . . . A6</p> <p>B C</p> <p>HANDLEBAR . . . . . . . . . . . . . . . . . . . . . . . . B8</p> <p>H I</p> <p>CARBURETOR . . . . . . . . . . . . . . . . . . . . . . . CLUTCH COVER . . . . . . . . . . . . . . . . . . . . . CONTROLS - MASTER CYLINDER/BRAKE LINE . . . . . . . . . . . . CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . . CRANKSHAFT and PISTON . . . . . . . . . . . . . CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . .</p> <p>C10-11 B12 B5 C6 C8 C7</p> <p>INTAKE and EXHAUST . . . . . . . . . . . . . . . . . C9</p> <p>MAGNETO . . . . . . . . . . . . . . . . . . . . . . . . . . C14</p> <p>M O</p> <p>DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . A5 DRIVE CLUTCH . . . . . . . . . . . . . . . . . . . . . . B13 DRIVEN CLUTCH . . . . . . . . . . . . . . . . . . . . . B14</p> <p>D</p> <p>OIL COOLING . . . . . . . . . . . . . . . . . . . . . . . A9 OIL PUMP and OIL FILTER . . . . . . . . . . . . . . C13</p> <p>ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . C1 ENGINE MOUNTING . . . . . . . . . . . . . . . . . . A7-8 EXHAUST SYSTEM . . . . . . . . . . . . . . . . . . . A10</p> <p>E</p> <p>REAR BRAKE MASTER CYLINDER . . . . . . . REAR CAB and SEAT . . . . . . . . . . . . . . . . . REAR CALIPER MOUNTING . . . . . . . . . . . . REAR HOUSING . . . . . . . . . . . . . . . . . . . . . REAR WHEEL DRIVE . . . . . . . . . . . . . . . . . . RECOIL STARTER . . . . . . . . . . . . . . . . . . . .</p> <p>R</p> <p>B3 A4 B2 B9 B10 C12</p> <p>FRONT BRAKE . . . . . . . . . . . . . . . . . . . . . . FRONT CAB . . . . . . . . . . . . . . . . . . . . . . . . FRONT WHEEL . . . . . . . . . . . . . . . . . . . . . . FUEL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . .</p> <p>F</p> <p>B1 A3 A14 D2 A12</p> <p>STARTING MOTOR . . . . . . . . . . . . . . . . . . . STEERING POST . . . . . . . . . . . . . . . . . . . . . STRUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SWING ARM/SHOCK MOUNTING . . . . . . . .</p> <p>S</p> <p>D1 B6 A13 B11</p> <p>GEAR SELECTOR . . . . . . . . . . . . . . . . . . . . C5</p> <p>G</p> <p>TAILLIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . C1 THROTTLE CONTROLS / THROTTLE CABLE B4 TOOL KIT . . . . . . . . . . . . . . . . . . . . . . . . . . . D3</p> <p>T</p> <p>The illustrations used in this Parts Manual are for reference to replacement parts only. This manual is not to be used for assembly.</p> <p>FRONT CABTRAIL BOSS 330 A05CA32AA and TRAIL BOSS LE A05CA32AB and TRAIL BOSS 330 INTL A05CA32FA1 2 E 2004 Polaris Sales Inc.</p> <p>7 3 4 5</p> <p>6</p> <p>8 9 10 11</p> <p>12 13 16 14 18</p> <p>15</p> <p>6 17</p> <p>6</p> <p>17</p> <p>18</p> <p>17</p> <p>Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current. Ref. Part No. Qty. Description Ref. Part No. Qty. Description</p> <p>1 2632284-053 2632284-070 2 5811797 3 5812138 4 5812484 5 2632633-053 2632633-070 6 7517916 7 5435110-070 5435110-293 8 7670057 9 2632992-070 2632992-293</p> <p>1 1 1 1 1 1 1 4 1 1 2 1</p> <p>Asm., Panel/Foam, LH, Yellow (AA)(FA) Asm., Panel/Foam, LH, Black (AB) Foam, Side Panel, LH Foam, Panel, LH Foil, Foam, Side Panel, RH Asm., Panel/Foil, RH, Yellow (AA)(FA) Asm., Panel/Foil, RH, Black (AB) Screw Cover, Front, Black (AA)(FA) Cover, Front, Red (AB) Nut, U-Type Speed Cab, Front, Black (Incl. Warning Decals)(AA)(FA) 1 Cab, Front, Red (Incl. Warning Decals)(AB)</p> <p>10 11 12 13 14 15 16 17 18</p> <p>7512085 7555783 7542122 7555859 7081040 7541925 7555792 7670088 5245394-067 5245533-067</p> <p>4 2 2 2 8 4 2 13 1 1</p> <p>Screw Washer, Flat Nut, Nylok Washer, Flat Rivet Nut, Nylok Washer Clip, Dart Shield, Splash, LH Shield, Splash, RH</p> <p>9/04</p> <p>A3</p> <p>REAR CAB and SEATTRAIL BOSS 330 A05CA32AA and TRAIL BOSS LE A05CA32AB and TRAIL BOSS 330 INTL A05CA32FA</p> <p>1</p> <p>2 3 4 E 2004 Polaris Sales Inc. 10 9 5 7 6 23 25 19 22 1 21 24 20 13 8 11 12</p> <p>29</p> <p>28 27 26</p> <p>21</p> <p>18 17 16</p> <p>14</p> <p>4 15</p> <p>Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current. Ref. Part No. Qty. Description Ref. Part No. Qty. Description</p> <p>1 2 3 4 5 6 7 8 9 10 11 12</p> <p>7541925 5246091 7512242 7555859 7512085 5434040 7517375 7621403 5211033 1040387 7041370 2683197-070 2682958-070 13 5431787 14 5432763 15 7515179</p> <p>6 1 4 10 2 1 2 2 2 1 1 1 1 1 1 6</p> <p>Nut, Nylok Retainer, Seat Latch Screw Washer, Flat Screw Box, Tool Screw Rivet Bracket, Lever Retainer Latch, Seat Spring, Latch Asm., Seat, Black (Incl. 8-12) Covering, Seat Cover, Tool Box Guard, Rock Screw</p> <p>16 5432221-070 5434417-070 17 7542122 18 7517376 19 5245898 20 7661637 21 7555792 22 7170007 23 5811087 24 5811106 25 5811111 26 5432117-070 5432117-293 27 7511930 28 7081040 29 5811107</p> <p>1 1 8 8 2 2 4 1 1 2 1 1 1 2 14 1</p> <p>Footwell, Black, LH Footwell, Black, RH Nut, Nylok Screw Mount, Cab, Rear Rivet Washer Decal, Carb/Filter Information Foil Foil, Rear Cab, Front Foil, Rear Fender Cab, Rear, Black (AA)(FA) Cab, Rear, Red (AB) Bolt Rivet Foil, Rear Cab, Rear9/04</p> <p>A4</p> <p>DECALSTRAIL BOSS 330 A05CA32AA and TRAIL BOSS LE A05CA32AB and TRAIL BOSS 330 INTL A05CA32FA2 1 3 4 5 6 7</p> <p>8 9 10 12 11 E 2004 Polaris Sales Inc. 14 15 13</p> <p>16 18 17</p> <p>Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current. Ref. Part No. Qty. Description Ref. Part No. Qty. Description</p> <p>1 7172662 7172663 7173006 7173007 2 7172660 7172661 7173004 7173005 3 5435424 7173013 4 7172559 5 7172658 7172659 7173011 7173012 6 7078465</p> <p>1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1</p> <p>Decal, Side Panel, Lower, LH (AA)(FA) Decal, Side Panel, Lower, RH (AA)(FA) Decal, Side Panel, Lower, LH (AB) Decal, Side Panel, Lower, RH (AB) Decal, Side Panel, Upper, LH (AA)(FA) Decal, Side Panel, Upper, RH (AA)(FA) Decal, Side Panel, Upper, LH (AB) Decal, Side Panel, Upper, RH (AB) Badge, 50 Years (If built before 7/05/04) Urocal, 50th Anniversary (If built after 7/05/04) Decal, Warning, Age Decal, Tank Side, Upper, LH (AA)(FA) Decal, Tank Side, Upper, RH (AA)(FA) Decal, Tank Side, Upper, LH (AB) Decal, Tank Side, Upper, RH (AB) Logo, Polaris Star</p> <p>7 8 9 10</p> <p>11 12 13 14 15 16 17 18</p> <p>7079773 7172562 7079906 7172656 7172657 7173002 7173003 7172666 7079959 7079925 7172566 7172667 7172665 7172560 7079924</p> <p>1 1 1 1 1 1 1 2 1 2 1 1 1 1 2</p> <p>Decal, Front Cover, POLARIS Decal, Drain Recoil Decal, Override Switch, 2WD Decal, Tank Side, LH (AA)(FA) Decal, Tank Side, RH (AA)(FA) Decal, Tank Side, LH (AB) Decal, Tank Side, RH (AB) Decal, Rack Warning, Front &amp; Rear Decal, POLARIS, Rear Decal, Reflector, Red Decal, Passenger Warning Decal, Tire Pressure/Load Decal, Discretionary Warning Decal, Warning, General, CPSC Decal, Reflector, Amber12/04</p> <p>A5</p> <p>BUMPER and RACK MOUNTINGTRAIL BOSS 330 A05CA32AA and TRAIL BOSS LE A05CA32AB and TRAIL BOSS 330 INTL A05CA32FA</p> <p>1 21 2 3 21 5 7 8 9 4 E 2004 Polaris Sales Inc.</p> <p>20 22 21</p> <p>6</p> <p>10 11 19 17 18 17 15 16 14 8 13 12</p> <p>Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current. Ref. Part No. Qty. Description Ref. Part No. Qty. Description</p> <p>7517977 1014039-385 5432831 5334092 1014658-067 5810467 7512232 7515399 1013744-067 1013746-067 10 7515189 11 2410285</p> <p>1 2 3 4 5 6 7 8 9</p> <p>2 1 2 2 1 1 6 4 1 1 2 2</p> <p>Bolt Rack, Rear Plug, End Cap Spacer Frame, Main Plug, Frame Screw Screw Support Rack, Front, LH Support Rack, Front, RH Screw (AA)(AB) Asm., Headlight (AA)(AB)</p> <p>12 13 14 15 16 17 18 19 20 21 22</p> <p>7542122 1014483-385 5248297-067 5248298-067 7621472 7512232 5247919 7670096 7542324 7558402 7512329</p> <p>2 1 1 1 5 4 2 2 2 4 2</p> <p>Nut, Nylok (AA)(AB) Bumper, Front Shield, Radiator Side, LH Shield, Radiator Side, RH Rivet Screw Bracket, Grill Mount Nut, Chimney Nut, Nylok Washer, Flat Screw9/04</p> <p>A6</p> <p>ENGINE MOUNTINGTRAIL BOSS 330 A05CA32AA and TRAIL BOSS LE A05CA32AB and TRAIL BOSS 330 INTL A05CA32FA</p> <p>1 3 4 5 6 37 36 32 33 32 35 33To impulse fitting RH side of carb. To fuel valve outlet.</p> <p>8 2 10 11</p> <p>9</p> <p>10 7 11 7</p> <p>4 3 E 2004 Polaris Sales Inc. 15 14 13 12</p> <p>34 33 32 32 31 16To fuel inlet LH side of carb.</p> <p>17</p> <p>18</p> <p>19 20</p> <p>7 29 30 7 28 27 12 14 7 26 25 7</p> <p>21 22 23</p> <p>24</p> <p>A7</p> <p>ENGINE MOUNTINGTRAIL BOSS 330 A05CA32AA and TRAIL BOSS LE A05CA32AB and TRAIL BOSS 330 INTL A05CA32FAPart numbers may change after the making of the microfiche or paper copies. Electronic records are the most current. Ref. Part No. Qty. Description Ref. Part No. Qty. Description</p> <p>1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20</p> <p>8450003-1525 7052075 7542122 7558301 5247946 3084205 7547108 4010132 7512232 7512315 7552901 3021181 5430802 7555823 5247344 7172562 7080511 5411721 8360009-100 3089535</p> <p>AR 1 2 2 1 2 7 1 1 2 2 2 1 2 1 1 1 1 AR 1</p> <p>Line, Fuel Fitting, Tee Nut, Nylok Washer, Flat Bracket, Carburetor Mount Screw and Washer Nut, Flange Lock Cable, Ground, Engine Screw Bolt Washer, Spring Lock Mount, Rubber Insulator, Motor Mount Washer, Flat Bracket, Engine Mount, Top Decal, Drain Recoil Clamp Boot, Clutch Intake Line, Fuel Engine, Short Block ES320PFE103 NOTE: The Short Block assembly contains a crankcase assembly, cylinder and cylinder head assembly, and a piston &amp; crankshaft assembly. Prior authorization required for warranty consideration.</p> <p>21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37</p> <p>7555815 3110046 1013413-067 7547089 7515417 5247342 5430261 7575202 7512566 5210748 4010095 7080003 8450103-600 2530009 8450040-600 7546601 3110050</p> <p>1 1 1 2 2 1 1 1 1 1 1 8 AR 1 AR 2 1</p> <p>Washer Mount, Rubber, Front Mount, Engine, Rear Nut, Flange Lock Screw Mount, Lower Front Bushing Washer, Lock Bolt Washer, Flat Cable, Battery/Engine Clamp, Hose Line, Fuel Filter Line, Fuel Nut, Nylok Mount, Carburetor</p> <p>7/04</p> <p>A8</p> <p>OIL COOLINGTRAIL BOSS 330 A05CA32AA and TRAIL BOSS LE A05CA32AB and TRAIL BOSS 330 INTL A05CA32FA</p> <p>2 1 3 6 4 5 7 8 1 9 E 2004 Polaris Sales Inc.</p> <p>10</p> <p>11</p> <p>12</p> <p>17 16 7 13</p> <p>13 15 14</p> <p>Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current. Ref. Part No. Qty. Description Ref. Part No. Qty. Description</p> <p>1 2 3 4 5 6 7 8 9</p> <p>5412355 7080851 7512084 7542122 5245416-067 7547069 7512232 7517659 2410534</p> <p>2 1 1 4 1 2 4 4 1</p> <p>Hose, Inlet Clamp, Hose Screw Nut, Nylok Bracket, Oil Cooler, Top Nutsert Screw Screw Motor, Fan</p> <p>10 11 12 13 14 15</p> <p>7670111 5433353 4010934 7558301 7512163 1240204 1240191 16 5248139 17 7080999</p> <p>4 1 1 4 4 1 1 1 1</p> <p>U-Clip Shroud Thermister Washer Bolt Asm., Oil Cooler (Incl. 8-12) Cooler, Oil Bracket, Oil Cooler, Lower Cable Tie4/04</p> <p>A9</p> <p>EXHAUST SYSTEMTRAIL BOSS 330 A05CA32AA and TRAIL BOSS LE A05CA32AB and TRAIL BOSS 330 INTL A05CA32FA3 4</p> <p>5</p> <p>2 6 1</p> <p>20</p> <p>19 18 17 6</p> <p>11 7 15 16 15 10 11 14 13 12 6 8 9</p> <p>E 2004 Polaris Sales Inc.</p> <p>Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current. Ref. Part No. Qty. Description Ref. Part No. Qty. Description</p> <p>1 2 3 4 5 6 7 8 9 10</p> <p>7555716 1261402-029 5412233 7515316 5010192 7041804 3085075 3080051 3086787 1260960-029</p> <p>2 1 2 3 2 4 1 2 2 1</p> <p>Washer, Flat Silencer Dampener, Vibration Bolt Bushing Spring, Exhaust Gasket, Exhaust Washer Nut Manifold</p> <p>11 12 13 14 15 16 17 18 19 20</p> <p>5243517 5411576 7512232 5248301 7041769 1260987-029 7556230 7512666 5410436 7542324</p> <p>2 1 2 1 2 1 1 1 2 2</p> <p>Seal, Exhaust Dampener, Vibration Screw Bracket, Exhaust Pipe Support Spring, Extension Headpipe Washer, Clean Out Bolt Washer, Rubber Nut, Nylok9/04</p> <p>A10</p> <p>AIR BOXTRAIL BOSS 330 A05CA32AA and TRAIL BOSS LE A05CA32AB and TRAIL BOSS 330 INTL A05CA32FA</p> <p>E 2004 Polaris Sales Inc. 1 2 3</p> <p>4</p> <p>5</p> <p>6</p> <p>7 8 9 27 25 10 11 26 12 13 25 24 21 22 23 20 18</p> <p>19</p> <p>17 16 15 14</p> <p>Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current. Ref. Part No. Qty. Description Ref. Part No. Qty. Description</p> <p>1 2 3 4 5 6 7 8 9 10 11 12 13 14</p> <p>7515180 7558301 5812023 5433767 7517317 5810317 5433769 5811482 5242044 5432601 7080699 5412101 5411866 7080511</p> <p>1 1 1 1 1 2 1 1 6 1 1 1 1 1</p> <p>Screw Washer, Flat Seal, Intake Duct, Inlet Screw Pad, Fuel Tank Bracket Cover, Air Box Seal, Air Box Cover Clip Collar, Carb Inlet Clamp, Hose Cap, Rubber Hose, Breather Clamp, Narrow Band</p> <p>15 16 17 18 19 20 21 22 23 24 25 26 27</p> <p>5411588 7080413 5433180 5830128 5433919 7555932 5412111 5432377 5435299 5812111 7080650 5412099 7080413 1253372</p> <p>1 2 1 1 1 2 1 1 1 1 1 2 1 1</p> <p>Boot, Carburetor Clamp, Narrow Band Duct, Carb Inlet Gasket, Carb Inlet Box, Air Intake, 4 Stroke Washer, Nylon Hose, Drain, Formed Plug, Trap (If built before 6/01/04) Plug, Trap (If built after 6/01/04) Foil, Air Box, RH Clamp, Hose Cap, Rubber Clamp, Narrow Band Asm., Filter4/04</p> <p>A11</p> <p>FUEL TANKTRAIL BOSS 330 A05CA32AA and TRAIL BOSS LE A05CA32AB and TRAIL BOSS 330 INTL A05CA32FA</p> <p>4 3 2 Before 4/01/04 22 23 24 21 After 4/01/04 1 5</p> <p>6 7 8 9</p> <p>20 17 18 18 17 11 12 10</p> <p>19 17 18 17 17 18 18</p> <p>17</p> <p>E 2004 Polaris Sales Inc. 15 14</p> <p>16</p> <p>13</p> <p>Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current. Ref. Part No. Qty. Description Ref. Part No. Qty. Description</p> <p>1 2520362 2520409 5812123 2873626 8360009-600 5431053 7517451 7552801 7555859 5247184 5247185 10 5811951 11 5332457 12 7547069 2 3 4 5 6 7 8 9</p> <p>1 Asm., Fuel Tank (Incl. 5,22,23)(If built before 4/01/04) 1 Asm., Fuel Tank (Incl. 5,20,21)(If built after 4/01/04) 1 Gasket 1 Kit, Fuel Gauge AR Hose, Vent 1 Vent, Tank 2 Screw 2 Washer, Spring Lock 2 Washer, Flat 1 Bracket, Fuel Cover Mount, LH 1 Bracket, Fuel Cover Mount, RH 1 Seal, Foam 2 Tube 4 Nutsert</p> <p>13 14 15 16 17 18 19 20 21</p> <p>7517505 5432559 5432733 7052161 7080003 8450040-600 2530009 7515136 7052364</p> <p>1 1 1 1 8 AR 1 2 1</p> <p>22 7052362 23 7052346 24 7052350</p> <p>Screw Knob, Fuel Valve Nut, Fuel Valve Valve, 3-Way Clamp, Hose Line, Fuel Filter, Fuel Screw (If built after 4/01/04) Fitting, Fuel, Dual Outlet (If built after 4/01/04) 2 Grommet, Flanged (If built before 4/01/04) 1 Fitting, Fuel Outlet, Reserve (If built before 4/01/04) 1 Fitting, Main Outlet (If built before 4/01/04)9/04</p> <p>A12</p> <p>STRUTTRAIL BOSS 330 A05CA32AA and TRAIL BOSS LE A05CA32AB and TRAIL BOSS 330 INTL A05CA32FA1 2</p> <p>3 4 E 2004 Polaris Sales Inc.</p> <p>5 6 7 8</p> <p>9</p> <p>10</p> <p>17 16 13 15</p> <p>11 12</p> <p>13</p> <p>14</p> <p>Part numbers may change after the making of the mi...</p>