Trail Boss 330

PARTS MANUAL PN 9919483 and MICROFICHE PN 9919484 9/04

E 2004 Polaris Sales Inc.

TRAIL BOSS 330Model #A05CA32AATRAIL BOSS LE

Model #A05CA32ABTRAIL BOSS 330 INT’LModel #A05CA32FA

Rev. 01

This page left blank intentionally.

TABLE OF CONTENTSTRAIL BOSS 330 A05CA32AA and TRAIL BOSS LE A05CA32AB and TRAIL BOSS 330 INT’L A05CA32FA

Parts Manual

AA--ARM/STRUT MOUNTING B7. . . . . . . . . . . . .AIR BOX A11. . . . . . . . . . . . . . . . . . . . . . . . . . .

BBUMPER and RACK MOUNTING A6. . . . . . . . .

CCARBURETOR C10-11. . . . . . . . . . . . . . . . . . . . . . .CLUTCH COVER B12. . . . . . . . . . . . . . . . . . . . .CONTROLS -- MASTER

CYLINDER/BRAKE LINE B5. . . . . . . . . . . .CRANKCASE C6. . . . . . . . . . . . . . . . . . . . . . . .CRANKSHAFT and PISTON C8. . . . . . . . . . . . .CYLINDER C7. . . . . . . . . . . . . . . . . . . . . . . . . .

DDECALS A5. . . . . . . . . . . . . . . . . . . . . . . . . . .DRIVE CLUTCH B13. . . . . . . . . . . . . . . . . . . . . .DRIVEN CLUTCH B14. . . . . . . . . . . . . . . . . . . . .

EELECTRICAL C1. . . . . . . . . . . . . . . . . . . . . . . .ENGINE MOUNTING A7-8. . . . . . . . . . . . . . . . . .EXHAUST SYSTEM A10. . . . . . . . . . . . . . . . . . .

FFRONT BRAKE B1. . . . . . . . . . . . . . . . . . . . . .FRONT CAB A3. . . . . . . . . . . . . . . . . . . . . . . .FRONT WHEEL A14. . . . . . . . . . . . . . . . . . . . . .FUEL PUMP D2. . . . . . . . . . . . . . . . . . . . . . . . .FUEL TANK A12. . . . . . . . . . . . . . . . . . . . . . . . .

GGEAR SELECTOR C5. . . . . . . . . . . . . . . . . . . .

GGEARCASE C3-4. . . . . . . . . . . . . . . . . . . . . . . . .GEARCASE MOUNTING C2. . . . . . . . . . . . . . .

HHANDLEBAR B8. . . . . . . . . . . . . . . . . . . . . . . .

IINTAKE and EXHAUST C9. . . . . . . . . . . . . . . . .

MMAGNETO C14. . . . . . . . . . . . . . . . . . . . . . . . . .

OOIL COOLING A9. . . . . . . . . . . . . . . . . . . . . . .OIL PUMP and OIL FILTER C13. . . . . . . . . . . . . .

RREAR BRAKE MASTER CYLINDER B3. . . . . . .REAR CAB and SEAT A4. . . . . . . . . . . . . . . . .REAR CALIPER MOUNTING B2. . . . . . . . . . . .REAR HOUSING B9. . . . . . . . . . . . . . . . . . . . .REAR WHEEL DRIVE B10. . . . . . . . . . . . . . . . . .RECOIL STARTER C12. . . . . . . . . . . . . . . . . . . .

SSTARTING MOTOR D1. . . . . . . . . . . . . . . . . . .STEERING POST B6. . . . . . . . . . . . . . . . . . . . .STRUT A13. . . . . . . . . . . . . . . . . . . . . . . . . . . . .SWING ARM/SHOCK MOUNTING B11. . . . . . . .

TTAILLIGHT C1. . . . . . . . . . . . . . . . . . . . . . . . . .THROTTLE CONTROLS / THROTTLE CABLE B4TOOL KIT D3. . . . . . . . . . . . . . . . . . . . . . . . . . .

The illustrations used in this Parts Manual are for reference to replacement parts only. This manual is not to be used for assembly.

A3

FRONT CABTRAIL BOSS 330 A05CA32AA and TRAIL BOSS LE A05CA32AB and TRAIL BOSS 330 INT’L A05CA32FA

7

9

58

17

6

6

1312

10

1615

6

1 E 2004 Polaris Sales Inc.

17

18

18

14

11

17

3

2

4

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

1 2632284-0532632284-070

11

Asm., Panel/Foam, LH, Yellow (AA)(FA)Asm., Panel/Foam, LH, Black (AB)

2 5811797 1 Foam, Side Panel, LH3 5812138 1 Foam, Panel, LH4 5812484 1 Foil, Foam, Side Panel, RH5 2632633-053

2632633-07011

Asm., Panel/Foil, RH, Yellow (AA)(FA)Asm., Panel/Foil, RH, Black (AB)

6 7517916 4 Screw7 5435110-070

5435110-29311

Cover, Front, Black (AA)(FA)Cover, Front, Red (AB)

8 7670057 2 Nut, U-Type Speed9 2632992-070

2632992-293

1

1

Cab, Front, Black(Incl. Warning Decals)(AA)(FA)Cab, Front, Red(Incl. Warning Decals)(AB)

10 7512085 4 Screw11 7555783 2 Washer, Flat12 7542122 2 Nut, Nylok13 7555859 2 Washer, Flat14 7081040 8 Rivet15 7541925 4 Nut, Nylok16 7555792 2 Washer17 7670088 13 Clip, Dart18 5245394-067

5245533-06711

Shield, Splash, LHShield, Splash, RH

9/04

A4

REAR CAB and SEATTRAIL BOSS 330 A05CA32AA and TRAIL BOSS LE A05CA32AB and TRAIL BOSS 330 INT’L A05CA32FA

17

27

2

21

1

34

9

8

10

1112

22

6

7

13

16

18

26

28

23

25

5

29

24

21

14

15

1

4

19

20




1 7541925 6 Nut, Nylok2 5246091 1 Retainer, Seat Latch3 7512242 4 Screw4 7555859 10 Washer, Flat5 7512085 2 Screw6 5434040 1 Box, Tool7 7517375 2 Screw8 7621403 2 Rivet9 5211033 2 Bracket, Lever Retainer10 1040387 1 Latch, Seat11 7041370 1 Spring, Latch12 2683197-070

2682958-07011

Asm., Seat, Black (Incl. 8-12)Covering, Seat

13 5431787 1 Cover, Tool Box14 5432763 1 Guard, Rock15 7515179 6 Screw

16 5432221-0705434417-070

11

Footwell, Black, LHFootwell, Black, RH

17 7542122 8 Nut, Nylok18 7517376 8 Screw19 5245898 2 Mount, Cab, Rear20 7661637 2 Rivet21 7555792 4 Washer22 7170007 1 Decal, Carb/Filter Information23 5811087 1 Foil24 5811106 2 Foil, Rear Cab, Front25 5811111 1 Foil, Rear Fender26 5432117-070

5432117-29311

Cab, Rear, Black (AA)(FA)Cab, Rear, Red (AB)

27 7511930 2 Bolt28 7081040 14 Rivet29 5811107 1 Foil, Rear Cab, Rear

9/04

A5

DECALSTRAIL BOSS 330 A05CA32AA and TRAIL BOSS LE A05CA32AB and TRAIL BOSS 330 INT’L A05CA32FA

16

13

6

8

7

17

4

14

9

1

5

12

2

11

15


10

18

3



1 7172662717266371730067173007

1111

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)

2 7172660717266171730047173005

1111

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)

3 54354247173013

11

Badge, 50 Years (If built before 7/05/04)Urocal, 50th Anniversary (If built after7/05/04)

4 7172559 1 Decal, Warning, Age5 7172658

717265971730117173012

1111

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)

6 7078465 1 Logo, Polaris Star

7 7079773 1 Decal, Front Cover, “POLARIS”8 7172562 1 Decal, Drain Recoil9 7079906 1 Decal, Override Switch, 2WD10 7172656

717265771730027173003

1111

Decal, Tank Side, LH (AA)(FA)Decal, Tank Side, RH (AA)(FA)Decal, Tank Side, LH (AB)Decal, Tank Side, RH (AB)

11 7172666 2 Decal, Rack Warning, Front & Rear12 7079959 1 Decal, “POLARIS”, Rear13 7079925 2 Decal, Reflector, Red14 7172566 1 Decal, Passenger Warning15 7172667 1 Decal, Tire Pressure/Load16 7172665 1 Decal, Discretionary Warning17 7172560 1 Decal, Warning, General, CPSC18 7079924 2 Decal, Reflector, Amber

12/04

A6

BUMPER and RACK MOUNTINGTRAIL BOSS 330 A05CA32AA and TRAIL BOSS LE A05CA32AB and TRAIL BOSS 330 INT’L A05CA32FA

2

4

1

22

20

21

3

5

14

8

15

10

12

11

6

13

9

7

8

21


21

16

18

17

17

19



1 7517977 2 Bolt2 1014039-385 1 Rack, Rear3 5432831 2 Plug, End Cap4 5334092 2 Spacer5 1014658-067 1 Frame, Main6 5810467 1 Plug, Frame7 7512232 6 Screw8 7515399 4 Screw9 1013744-067

1013746-06711

Support Rack, Front, LHSupport Rack, Front, RH

10 7515189 2 Screw (AA)(AB)11 2410285 2 Asm., Headlight (AA)(AB)

12 7542122 2 Nut, Nylok (AA)(AB)13 1014483-385 1 Bumper, Front14 5248297-067 1 Shield, Radiator Side, LH15 5248298-067 1 Shield, Radiator Side, RH16 7621472 5 Rivet17 7512232 4 Screw18 5247919 2 Bracket, Grill Mount19 7670096 2 Nut, Chimney20 7542324 2 Nut, Nylok21 7558402 4 Washer, Flat22 7512329 2 Screw

9/04

A7

ENGINE MOUNTINGTRAIL BOSS 330 A05CA32AA and TRAIL BOSS LE A05CA32AB and TRAIL BOSS 330 INT’L A05CA32FA

1

2

6

7

15

11

10

98

1412

16

18

17

19

23

22

21

252627

30

28

29

31

32

34

3613

24

37

5

34

4

3

32

3232

12

77

7

7

7

14

1011

20

33

3333

35


To impulse fittingRH side of carb.

To fuelvalve outlet.

To fuel inletLH side of carb.

A8

ENGINE MOUNTINGTRAIL BOSS 330 A05CA32AA and TRAIL BOSS LE A05CA32AB and TRAIL BOSS 330 INT’L A05CA32FA



1 8450003-1525 AR Line, Fuel2 7052075 1 Fitting, Tee3 7542122 2 Nut, Nylok4 7558301 2 Washer, Flat5 5247946 1 Bracket, Carburetor Mount6 3084205 2 Screw and Washer7 7547108 7 Nut, Flange Lock8 4010132 1 Cable, Ground, Engine9 7512232 1 Screw10 7512315 2 Bolt11 7552901 2 Washer, Spring Lock12 3021181 2 Mount, Rubber13 5430802 1 Insulator, Motor Mount14 7555823 2 Washer, Flat15 5247344 1 Bracket, Engine Mount, Top16 7172562 1 Decal, Drain Recoil17 7080511 1 Clamp18 5411721 1 Boot, Clutch Intake19 8360009-100 AR Line, Fuel20 3089535 1 Engine, Short Block ES320PFE103

NOTE: The Short Block assemblycontains a crankcase assembly, cylin-der and cylinder head assembly, and apiston & crankshaft assembly. Priorauthorization required for warrantyconsideration.

21 7555815 1 Washer22 3110046 1 Mount, Rubber, Front23 1013413-067 1 Mount, Engine, Rear24 7547089 2 Nut, Flange Lock25 7515417 2 Screw26 5247342 1 Mount, Lower Front27 5430261 1 Bushing28 7575202 1 Washer, Lock29 7512566 1 Bolt30 5210748 1 Washer, Flat31 4010095 1 Cable, Battery/Engine32 7080003 8 Clamp, Hose33 8450103-600 AR Line, Fuel34 2530009 1 Filter35 8450040-600 AR Line, Fuel36 7546601 2 Nut, Nylok37 3110050 1 Mount, Carburetor

7/04

A9

OIL COOLINGTRAIL BOSS 330 A05CA32AA and TRAIL BOSS LE A05CA32AB and TRAIL BOSS 330 INT’L A05CA32FA

12

1

11

9

13

8

10

5

6

15

16

4

14

1

7

7

17

2

3

13




1 5412355 2 Hose, Inlet2 7080851 1 Clamp, Hose3 7512084 1 Screw4 7542122 4 Nut, Nylok5 5245416-067 1 Bracket, Oil Cooler, Top6 7547069 2 Nutsert7 7512232 4 Screw8 7517659 4 Screw9 2410534 1 Motor, Fan

10 7670111 4 U-Clip11 5433353 1 Shroud12 4010934 1 Thermister13 7558301 4 Washer14 7512163 4 Bolt15 1240204

124019111

Asm., Oil Cooler (Incl. 8-12)Cooler, Oil

16 5248139 1 Bracket, Oil Cooler, Lower17 7080999 1 Cable Tie

4/04

A10

EXHAUST SYSTEMTRAIL BOSS 330 A05CA32AA and TRAIL BOSS LE A05CA32AB and TRAIL BOSS 330 INT’L A05CA32FA

1214

13

15

2

16

1920

18

1

3

11

5

4

6

6

6

15

10

11


7

98

17



1 7555716 2 Washer, Flat2 1261402-029 1 Silencer3 5412233 2 Dampener, Vibration4 7515316 3 Bolt5 5010192 2 Bushing6 7041804 4 Spring, Exhaust7 3085075 1 Gasket, Exhaust8 3080051 2 Washer9 3086787 2 Nut10 1260960-029 1 Manifold

11 5243517 2 Seal, Exhaust12 5411576 1 Dampener, Vibration13 7512232 2 Screw14 5248301 1 Bracket, Exhaust Pipe Support15 7041769 2 Spring, Extension16 1260987-029 1 Headpipe17 7556230 1 Washer, Clean Out18 7512666 1 Bolt19 5410436 2 Washer, Rubber20 7542324 2 Nut, Nylok

9/04

A11

AIR BOXTRAIL BOSS 330 A05CA32AA and TRAIL BOSS LE A05CA32AB and TRAIL BOSS 330 INT’L A05CA32FA

19

7

17

10

18

27

8

9

26

3

4

22

24

23

12

11

13

1

2

20

141516

5

25

24

25


21

6



1 7515180 1 Screw2 7558301 1 Washer, Flat3 5812023 1 Seal, Intake4 5433767 1 Duct, Inlet5 7517317 1 Screw6 5810317 2 Pad, Fuel Tank Bracket7 5433769 1 Cover, Air Box8 5811482 1 Seal, Air Box Cover9 5242044 6 Clip10 5432601 1 Collar, Carb Inlet11 7080699 1 Clamp, Hose12 5412101 1 Cap, Rubber13 5411866 1 Hose, Breather14 7080511 1 Clamp, Narrow Band

15 5411588 1 Boot, Carburetor16 7080413 2 Clamp, Narrow Band17 5433180 1 Duct, Carb Inlet18 5830128 1 Gasket, Carb Inlet19 5433919 1 Box, Air Intake, 4 Stroke20 7555932 2 Washer, Nylon21 5412111 1 Hose, Drain, Formed22 5432377

543529911

Plug, Trap (If built before 6/01/04)Plug, Trap (If built after 6/01/04)

23 5812111 1 Foil, Air Box, RH24 7080650 1 Clamp, Hose25 5412099 2 Cap, Rubber26 7080413 1 Clamp, Narrow Band27 1253372 1 Asm., Filter

4/04

A12

FUEL TANKTRAIL BOSS 330 A05CA32AA and TRAIL BOSS LE A05CA32AB and TRAIL BOSS 330 INT’L A05CA32FA

4

5 7

9

8

10

18

19

15

16

18

2

36

14

18

13

17

17

1818

11

12

17

17

17

17


21

20

22

23

1Before 4/01/04 After 4/01/04

24



1 2520362

2520409

1

1

Asm., Fuel Tank(Incl. 5,22,23)(If built before 4/01/04)Asm., Fuel Tank(Incl. 5,20,21)(If built after 4/01/04)

2 5812123 1 Gasket3 2873626 1 Kit, Fuel Gauge4 8360009-600 AR Hose, Vent5 5431053 1 Vent, Tank6 7517451 2 Screw7 7552801 2 Washer, Spring Lock8 7555859 2 Washer, Flat9 5247184

524718511

Bracket, Fuel Cover Mount, LHBracket, Fuel Cover Mount, RH

10 5811951 1 Seal, Foam11 5332457 2 Tube12 7547069 4 Nutsert

13 7517505 1 Screw14 5432559 1 Knob, Fuel Valve15 5432733 1 Nut, Fuel Valve16 7052161 1 Valve, 3-Way17 7080003 8 Clamp, Hose18 8450040-600 AR Line, Fuel19 2530009 1 Filter, Fuel20 7515136 2 Screw (If built after 4/01/04)21 7052364 1 Fitting, Fuel, Dual Outlet

(If built after 4/01/04)22 7052362 2 Grommet, Flanged

(If built before 4/01/04)23 7052346 1 Fitting, Fuel Outlet, Reserve

(If built before 4/01/04)24 7052350 1 Fitting, Main Outlet

(If built before 4/01/04)9/04

A13

STRUTTRAIL BOSS 330 A05CA32AA and TRAIL BOSS LE A05CA32AB and TRAIL BOSS 330 INT’L A05CA32FA

123

4

5

6

7

8

9

10

11

12

13

14

16

13

15

17




1 7547104 2 Nut, Nylok2 7555749 2 Washer3 5810291 2 Spacer, Rubber4 5432872 2 Ball, Pivot, Top5 5432871 2 Ball, Pivot, Bottom6 5132062 2 Spacer7 5243364 2 Retainer, Spring8 7041850-385 2 Spring, Compression, Silver9 5412665 2 Bumper

10 7041761 2 Strut, Front11 7080367 2 Clamp, Cable12 7542343 4 Nut, Nylok13 7558402 6 Washer, Flat14 7080306 2 Fitting, Lubrication15 7518340 4 Bolt16 5134133

513413411

Support, Strut and Spindle, LHSupport, Strut and Spindle, RH

17 5211115 2 Washer

4/04

A14

FRONT WHEELTRAIL BOSS 330 A05CA32AA and TRAIL BOSS LE A05CA32AB and TRAIL BOSS 330 INT’L A05CA32FA

1

23

4

5

6 7 8

9

16

11

13

1417

10

15


12



1 ------ -- -- -- -- 1 Support, Strut and Spindle(See Strut Pg. A13, Ref. 16)

2 3610093 1 Seal, Lip3 3514527 1 Bearing, Ball, Sealed4 7512325 4 Bolt5 5247961 1 Brake, Disc6 7515513 4 Stud7 5133294 1 Hub, Wheel, Front8 5412324

541251422

Tire, 23x7-10 (AA)(AB)Tire, Front, 23x7-10 (FA)

9 1520175-486 2 Rim, Front10 7547237 8 Nut, Flange11 3514464 1 Bearing, Ball, Sealed12 7556333 2 Washer, Flat13 7661407 2 Pin, Cotter14 5411164 2 Hub, Dust Cover15 7542712 2 Nut16 5631551 1 Spacer, Tapered17 1525017 2 Valve, Rim

9/04

B1

FRONT BRAKETRAIL BOSS 330 A05CA32AA and TRAIL BOSS LE A05CA32AB and TRAIL BOSS 330 INT’L A05CA32FA

13

3

4

967

8

514

15

16

12

11

10


12

2



19108681910869

11

Asm., Brake Caliper, LH (Incl. 3-5,13)Asm., Brake Caliper, RH (Incl. 3-5,13)

1930642 1 Kit, Boot, Front Brake (Incl. 5,12)1 1910499 2 Bolt, Banjo2 5410988 4 Seal3 7515489 2 Screw, Socket Set4 5134639

513464011

Caliper, Brake, LHCaliper, Brake, RH

5 5410494 1 Boot, Pin Seal6 5410779 1 Ring, Square, Molded, .0947 5410780 1 Ring, Square, Molded, .103 x .134

8 5132294 1 Piston, Brake, Long9 1930665 1 Kit, Piston and Seal (Incl. 6-8)10 2202412 2 Asm., Brake Pad11 1910412 2 Mount, Caliper12 5410495 1 Boot, Bushing13 7080352 2 Screw, Bleeder14 7558402 4 Washer, Flat15 7552901 4 Washer, Spring Lock16 7512365 4 Screw

4/04

B2

REAR CALIPER MOUNTINGTRAIL BOSS 330 A05CA32AA and TRAIL BOSS LE A05CA32AB and TRAIL BOSS 330 INT’L A05CA32FA

4

6

1312

3,2

1

11

7

87

16

9


12

2

2 2,1, 1,643, 4

1

17

5

14 15

10



1910806 1 Asm., Caliper (Incl. 1-6)1 2201873 1 Kit, Anvil Body2 2201870 1 Kit, Slide Bolt3 2201872 1 Kit, Seal4 2201869 1 Kit, Piston and Seal5 1910412 1 Mount, Caliper6 2202414 1 Kit, Brake Pad7 5410988 4 Seal8 1910770 1 Line, Brake, JB to Rear

9 1910769 1 Line, Brake, Front M/C to Rear10 1910886 1 Bolt, Banjo w/Bleeder11 1910499 1 Bolt, Banjo12 7515102 1 Screw13 5247210-067 1 Mount, Caliper, Lower14 7555883 1 Washer15 7547066 1 Nut16 7552901 2 Washer17 7512365 2 Screw

4/04

B3

REAR BRAKE MASTER CYLINDERTRAIL BOSS 330 A05CA32AA and TRAIL BOSS LE A05CA32AB and TRAIL BOSS 330 INT’L A05CA32FA

10

14

7

16

1

6

15

12 13

7 8

2

4

4

5

3


11

9

9

12

17

18



1 7670102 1 Clip2 7517386 1 Screw3 1930854 1 Reservoir4 7080003 2 Clamp, Hose, Red5 1910812 1 Hose, Reservoir6 1910499 1 Bolt, Banjo7 5410988 2 Seal8 ------ -- -- -- -- 1 Line, Foot Brake, Rear (See Rear Cal-

iper Mounting Pg. B2, Ref. 9)9 7515158 3 Screw

10 1910791 1 Asm., Foot Brake Master Cylinder11 1910764-067 1 Mount, Brake12 7555919 2 Washer13 5433189 2 Bushing, Pedal Pivot14 1910767-067 1 Rod, Brake15 7041750 1 Spring, Torsion16 7661401 1 Pin, Cotter17 7512232 1 Screw18 7558301 1 Washer, Flat

9/04

B4

THROTTLE CONTROL / THROTTLE CABLETRAIL BOSS 330 A05CA32AA and TRAIL BOSS LE A05CA32AB and TRAIL BOSS 330 INT’L A05CA32FA

3

1

6

5

4

2




1 5434113 1 Cover, Throttle Control2 5410193 1 O-Ring3 5411439 1 O-Ring

4 7081170 1 Cable, Throttle5 2010204 1 Asm., Throttle Control (Incl. 6)6 2010191 1 Asm., Throttle Clamp

4/04

B5

CONTROLS - MASTER CYLINDER/BRAKE LINETRAIL BOSS 330 A05CA32AA and TRAIL BOSS LE A05CA32AB and TRAIL BOSS 330 INT’L A05CA32FA

14

17

9

12

13

1516

3

1011

1 2

8

7

6

5

12

4

4


2

1

12



2010238 1 Asm., Master Cylinder1 1910499 3 Bolt, Banjo2 5410988 6 Seal3 4110164 1 Switch4 7517899 2 Screw5 2201834 1 Kit, Master Cylinder Cap

(Incl. Cap, Screws, Sight, Gasket)6 2201836 1 Kit, Master Cylinder Park Brake Lever

(Incl. Lever, Spring)7 2201833 1 Kit, Master Cylinder Clamp

(Incl. Clamp, Screws)

8 2201835 1 Kit, Master Cylinder Lever(Incl. Pin, Lever, Clip)

9 1910770 1 Line, Brake, JB Rear10 7621462 2 Rivet11 7080539 2 Clamp, Nylon12 8360052305 AR Tubing, Convoluted13 1910838 1 Line, Brake, Left Front14 7512024 2 Screw15 1910839 1 Line, Brake, Right, Front16 7052292 1 Fitting, Cross17 1910768 1 Line, Brake

9/04

B6

STEERING POSTTRAIL BOSS 330 A05CA32AA and TRAIL BOSS LE A05CA32AB and TRAIL BOSS 330 INT’L A05CA32FA

S

1

1

23

45

6

2

5

6

7

8

9

10

11




1 75423247542343

44

Nut, Nylok (If built before 5/10/04)Nut, Nylok, Flange (If built after 5/10/04)

2 5433866 2 Bushing, Steering, Upper3 1013927-067 1 Post, Steering4 5246732 1 Bracket, Steering Upper5 7517428 4 Bolt, Carriage

6 7556162 2 Bushing7 5222393 1 Flangette8 3514352 1 Bearing9 7547158 1 Nut10 7661633 1 Pin, Cotter11 7558402 2 Washer, Flat (If built before 5/10/04)

9/04

B7

A-ARM/STRUT MOUNTINGTRAIL BOSS 330 A05CA32AA and TRAIL BOSS LE A05CA32AB and TRAIL BOSS 330 INT’L A05CA32FA

1

3

45

6

10

8

11

13

21

2015

19

161823

24

22

26 25

27

12

17

2625 22

2

12

79

7


14



1 7542439 2 Nut, Nylok2 7558403 2 Washer3 5411291 2 Boot, Seal, Rod End4 7061034 2 Rod End, RH5 7542711 2 Nut6 5020927 2 Tie Rod7 7517909 2 Screw8 7061054 2 Rod End, LH9 5411920 2 Boot, Seal10 7547028 2 Nut, Jam, LH11 1820806 2 Asm., Tie Rod (Incl. 3-8)12 7556099 4 Washer, Flat13 7547177 2 Nut, Lock14 7661407 2 Pin, Cotter15 5211121 2 Bracket, Ball Joint

16 7512284 4 Screw17 7661203 4 Pin, Cotter18 7542438 2 Nut, Castle19 5410548 2 Boot, Rubber20 7080927 2 Joint, Ball21 ------ -- -- -- -- 1 Support, Strut/Spindle

(See Strut Pg. A13, Ref. 16)22 5434551 4 Bushing, A-Arm, Long23 2202278

220227911

Kit, A-Frame, LH (Incl. 22,25,26)Kit, A-Frame, RH (Incl. 22,25,26)

24 5133806 2 Shaft, A-Arm25 7512492

751836444

Screw (If built before 5/10/04)Screw (If built after 5/10/04)

26 7555832 4 Washer (If built before 5/10/04)27 7518033 2 Screw

4/04

B8

HANDLEBARTRAIL BOSS 330 A05CA32AA and TRAIL BOSS LE A05CA32AB and TRAIL BOSS 330 INT’L A05CA32FA

4

2

20

6

8

10

12

13

15

17

21

19

9

5

1819

16

711

3

14

1




1 4010315 1 Panel Indicator Light2 7078465 1 Logo Star3 7518176 2 Screw4 5434643-070 1 Panel, Instrument5 7515189 4 Screw6 ------ -- -- -- -- 1 Asm., Master Cylinder

(See Control - Master Cylinder/BrakeLine Pg. B5 for Details)

7 5433903 1 Spacer, Switch, LH8 4010592 1 Switch, Handlebar, Hi/LO/Off9 7081177 1 Cable, Choke10 5433834-070 2 Grip, Handlebar11 5432952 1 Plug, Hole12 7517625 1 Screw13 5334127-067 1 Tube, Handlebar

14 5631516 1 Block, Handlebar15 7542122 4 Nut, Nylok16 7080138 1 Cable Tie17 ------ -- -- -- -- 1 Asm., Throttle Control (See Throttle Con-

trols/Throttle Cable Pg. B4, Ref. 5)18 5631517 1 Block, Handlebar, Pegged19 4011002

40102784010321

54337335433534

111

11

Switch, Key, 3 PositionBlank, Key, Series 2000, 6700, 6800Blank, Key, Series 2200, 2300, 2700,2800. NOTE: Your key can be dupli-cated only by obtaining a key blankfrom Polaris and having it cut by mat-ing it with your existing key.Nut, IgnitionCover, Key

20 5248182 1 Bracket, Instrument Panel21 7080922 1 Nut, Choke Slide

4/04

B9

REAR HOUSINGTRAIL BOSS 330 A05CA32AA and TRAIL BOSS LE A05CA32AB and TRAIL BOSS 330 INT’L A05CA32FA

1

6

11

16

20

19

8

5

13 14

9

21

17

22

10

12

3

24

910

1112

15

4


18

7

23

18

2



1 7670160 1 Ring, Retaining2 7515102 1 Screw3 5133428 1 Nut, Axle4 7547217 3 Nut, Nylok5 5245716 1 Disc, Brake6 5631457 1 Hub, Brake Disc7 7512365 3 Screw8 7670161 1 Ring, Retaining9 5410889 2 O-Ring10 3610070 2 Seal11 3554518 2 Bearing, Cone, Tapered12 3554517 2 Bearing, Cup, Tapered

13 5134460 1 Housing, Axle, Rear14 7080306 1 Fitting, Lubrication15 3221192 1 Link, Connector, 52016 5133967 1 Axle, Rear17 3221193-076 1 Chain, 520 O-Ring18 7542439 6 Nut, Nylok19 5211585-067 1 Guard, Sprocket20 5630586 1 Spacer21 3222109 1 Sprocket, 36T22 1520795 1 Asm., Hub, Sprocket (Incl. 24)23 7515528 3 Screw24 7518378 3 Stud

4/04

B10

REAR WHEELTRAIL BOSS 330 A05CA32AA and TRAIL BOSS LE A05CA32AB and TRAIL BOSS 330 INT’L A05CA32FA

1

2

9

3

8

4

56

7

21

11

612

98

5

4

7

10




1 7512673 8 Bolt2 5131777 2 Hub, Rear Wheel, Large Flange3 7542714 8 Nut4 7555796 2 Washer5 7543005 2 Nut, Castle6 7661404 2 Pin, Cotter7 5411164 2 Cover, Dust, Hub

8 7555745 2 Washer, Flat9 1525017 2 Valve, Rim10 7670081 8 Pushnut11 1520183-486 2 Rim, Rear12 5412323

541251522

Tire, 22x11-10 (AA)(AB)Tire, 22x12-10 (FA)

9/04

B11

SWING ARM/SHOCK MOUNTINGTRAIL BOSS 330 A05CA32AA and TRAIL BOSS LE A05CA32AB and TRAIL BOSS 330 INT’L A05CA32FA

4

52

6

28

1

29

3

31

10

11

15

12

19

9

7

8

16

13 14

25 24

2322

21

30

26

27

12

7

3

20

26


17

18

32

4



1 5630551 1 Cam, Adjusting2 7041986-385 1 Spring, Compression3 7542439 2 Nut, Nylok4 7515415 1 Screw5 5241147 1 Retainer, Shock6 7042318 1 Shock, Rear7 5134321 2 Bolt, Swing Arm Pivot8 5133166 1 Bushing, Swing Arm Pivot, LH9 5434545 1 Bushing, Swing Arm, LH10 7661046 2 Rivet11 5432727 1 Guide, Pad, Chain12 7080510 2 Fitting13 7547082 1 Nut14 7556035 1 Washer, Flat15 5133167 2 Bushing, Swing Arm, Pivot, RH16 5434546 1 Bushing, Swing Arm, RH

17 5247488 2 Bracket, Bolt Lock18 7515399 2 Bolt19 1541987-067 1 Asm., Swing Arm (Incl. 9,12,15)20 7078572 1 Decal, “Chain Free Play”21 5432854 1 Guard, Chain22 7515304 1 Screw23 5332828 1 Bushing24 7558402 1 Washer, Flat25 7542343 1 Nut, Flange26 7555883 4 Washer27 7547066 2 Nut, Nylok28 7170915 1 Decal, Hitch29 2200472 1 Kit, Hitch (Incl. 27-30)30 7512576 2 Bolt31 7515438 1 Screw32 7517761 1 Screw

4/04

B12

CLUTCH COVERTRAIL BOSS 330 A05CA32AA and TRAIL BOSS LE A05CA32AB and TRAIL BOSS 330 INT’L A05CA32FA

6

2510 11

12

13

14

20

212223

7 9

8

17

19

24

18

12

2

1

15

16


3

4 5



1 5247524-067 1 Bracket, Clutch Cover2 7517386 2 Screw3 7670088 1 Clip, Plastic Dart4 2632513 1 Foam, Clutch Air Inlet5 5434491 1 Plate, Backing6 2202438 1 Kit, Clutch Cover, Inner7 5434401 1 Duct, Inlet8 7510000 3 Bolt and Washer9 7080909 1 Clamp, Narrow Band10 5521578 1 Seal, Clutch Cover11 5434255-070 1 Cover, Clutch, Outer12 7512094 9 Screw13 7172563 1 Decal, Warning, Clutch Cover

14 7172746 1 Decal, “Automatic Transmission”15 5434264 1 Plug, Drain, Clutch Cover16 5410542 1 O-Ring17 7080707 2 Clamp18 7517386 1 Screw19 5434213 1 Duct, Air Outlet20 5411489 1 Boot, Duct21 ------ -- -- -- -- 3 Screw and Washer

(See Crankcase Pg. C6, Ref. 8)22 5242046 1 Bracket, Clutch Seal23 5410575 1 Seal, Cover Case24 5411795 1 Stopper, Inner Clutch Cover25 5410489 1 Seal, Cover Case, Transmission

4/04

B13

DRIVE CLUTCHTRAIL BOSS 330 A05CA32AA and TRAIL BOSS LE A05CA32AB and TRAIL BOSS 330 INT’L A05CA32FA

12 3

612

4 5 6

7

11

10

8 9E 2004 Polaris Sales Inc.



1321976 1 Asm., Drive Clutch, Wide(Incl. All Less 3,8)

1 7518062 6 Screw2 3576510 1 Bearing, Cover3 7041157 1 Spring, Clutch4 5430945 6 Washer, Multilube5 1321457 3 Roller and Bushing6 5431936 6 Button, Clutch

7 5210752524298152107535210754

ARARARAR

Spacer, .020Spacer, .025Spacer, .032Spacer, .050

8 5630709 3 Weight, Shift, 10RH9 7512266 3 Bolt, Shoulder10 7541906 3 Nut, FLEXLOC11 3576504 1 Bearing, Moveable, 1/2 Inch12 5020422 3 Pin, Roller

6/03

B14

DRIVEN CLUTCHTRAIL BOSS 330 A05CA32AA and TRAIL BOSS LE A05CA32AB and TRAIL BOSS 330 INT’L A05CA32FA

23

45

6

7

10

12

13

15

1617

1

9

14

8

11




1 7556120 AR Bushing2 3211077 1 Belt, Drive3 1321848 1 Asm., Driven Clutch (Incl. 7-17)4 5220646 1 Washer, Domed5 7552901 1 Washer, Spring Lock6 7515384 1 Bolt7 7555898 AR Washer8 7556076 AR Washer9 7556804 AR Washer

10 3576504 1 Bearing, Moveable, 1/2 Inch11 3576511 1 Bearing, Moveable, 1 Inch12 7041782 1 Spring, Clutch, Black13 5131446 1 Ramp, Stationary14 5210752 1 Spacer15 7710448 1 Ring, Retaining16 7511854 3 Bolt17 5430766 3 Button, Ramp

6/03

C1

ELECTRICAL/TAILLIGHTTRAIL BOSS 330 A05CA32AA and TRAIL BOSS LE A05CA32AB and TRAIL BOSS 330 INT’L A05CA32FA

1

5

4

67

89

11

13

2220

30 29

28

26

2413

16

19

15

3

23

32

31

21

17

10

12

14

10

2

27

25

1814


(AA)(AB)



1 2410504 1 Harness, Main2 2201795 1 Kit, Circuit Breaker, Fan3 2410320 1 Taillight w/Brake Light (AA)(AB)4 4032029 2 Screw, Taillight (AA)(AB)5 4032046 1 Lens, Taillight (AA)(AB)6 4030043 1 Bulb, Taillight (AA)(AB)7 4032045 1 Gasket, Taillight (AA)(AB)8 ------ -- -- -- -- 1 Backing, Taillight/Brake Light (AA)(AB)9 7670054 2 Nut, Speed (AA)(AB)10 4020149 3 Clip, Rosebud11 7080138 12 Cable Tie12 7670109 3 Clip, Routing13 7518287 4 Nut14 7512024 4 Screw15 4010995 1 Limiter, RPM16 7571602 4 Washer17 8360012-04 1 Trim, Edge18 4011088 1 Module, Controller

19 7512007 2 Bolt20 4010093 1 Cable, Solenoid/Starter21 ------ -- -- -- -- 1 Switch, Magnetic

(See Magneto Pg. C14, Ref. 8)22 4010094 1 Cable, Battery/Solenoid23 7512027 2 Screw24 4011138

41400065432077

111

Battery (AA)(AB)Battery (FA)Tube, Vent (FA)

25 2202147 1 Kit, Fusible Link26 5810290 3 Pad, Battery27 7670102 1 Clip, Silencer28 5412499 1 Strap, Battery Holddown29 7010032 2 Hook, Battery Strap30 4010095 1 Cable, Battery/Engine31 2202848

220036111

Kit, Battery Bolt (AA)(AB)Kit, Battery Bolt, Short (FA)

32 5431769 1 Cover, Battery

9/04

C2

GEARCASE MOUNTINGTRAIL BOSS 330 A05CA32AA and TRAIL BOSS LE A05CA32AB and TRAIL BOSS 330 INT’L A05CA32FA

7

1

13

3

2

1211

5

6

4

2

2

2

1

1

1

4

4

8

910 2

3

+

2

16

14


15

1

1



1 7518364 4 Bolt, Flange2 7547089 6 Nut, Flange3 5248185 2 Bracket, Transmission Mount4 7555806 2 Washer, Flat5 1012886-067 1 Mount, Transmission6 5243296 1 Spacer7 7517646 1 Screw8 7517631 1 Screw9 7542440 1 Nut

10 ------ -- -- -- -- 1 Plug, Drain(See Gearcase Pg. C4, Ref. 35)

11 7710434 1 Ring, Retaining12 3221043 1 Sprocket, 11T13 7517640 1 Screw14 8450003-1525 AR Line, Fuel15 7512024 1 Screw16 7080693 1 Clamp, Hose

9/04

C3

GEARCASETRAIL BOSS 330 A05CA32AA and TRAIL BOSS LE A05CA32AB and TRAIL BOSS 330 INT’L A05CA32FA

20

2126

31

35

18

17

32

14

23

33

22

1516

34

45

11

40

10

1

1213

8

3938

3028

24

67

41

27

25

29

3637

32

9

19

26

1

12


C4

GEARCASETRAIL BOSS 330 A05CA32AA and TRAIL BOSS LE A05CA32AB and TRAIL BOSS 330 INT’L A05CA32FA



1341306 1 Asm., Gearcase (Incl. 1-41)1 3233018 2 Bearing2 3233177 1 Ring, Retaining3 3233673 1 Washer, Thrust4 3233674 1 Sprocket, 19T5 3233010 1 Washer, Thrust6 3233675 1 Dog, Engagement, High/Reverse7 3233676 1 Shaft, Input8 3233677 1 Gear, 21T9 3233678 1 Bushing10 3233105 1 Washer11 3233106 2 Ring, Retaining12 3233019 2 Bearing13 3233961 1 Nut14 3233547 1 Bellcrank15 3233045 1 Ring, Retaining16 3233040 1 Washer17 3233548 1 O-Ring18 3233679 1 Shaft, Shift19 3234002 1 Switch, 3 Position20 3233749 4 Screw

21 3233680 1 Bullet, Shifting22 3233681 1 Spring, Compression23 3233872 1 Washer, Nylon24 3233682 1 Plug, Detent, Extension25 3233478 1 Dipstick26 3233788 2 Seal, Triple Lip27 3233524 1 Tube, Vent28 3234049 1 Gearcase, RH29 3233529 2 Pipe, Knock30 3233684 1 Shaft, Shift31 3233685 1 Fork, Shift32 3234048 1 Gearcase, LH33 3233636 1 Decal - Switch34 3233252 9 Screw35 3233687 1 Plug, Drain36 3233527 1 Bushing, Pivot37 3233035 1 Washer38 3233111 1 Chain, Silent, 60P, 11W39 3233688 1 Sprocket, 51T40 3233689 1 Shaft, Output41 3233690 1 Gear, 64T

11/02

C5

GEAR SELECTORTRAIL BOSS 330 A05CA32AA and TRAIL BOSS LE A05CA32AB and TRAIL BOSS 330 INT’L A05CA32FA

1

2

3

6 4

8

11

10

1211

89

9

5


7



1 5411006 1 Cover2 7512024 1 Screw3 5411007 1 Knob, Gear Selector4 1013678-067 1 Handle, Gear Selector5 7556250 1 Washer6 7542324 2 Nut, Nylok

7 7558402 2 Washer, Flat8 5435042 2 Mount, Gear Selector9 7515175 2 Screw10 1821491 1 Asm., Shift Linkage11 7542122 2 Nut, Nylok12 7515319 2 Bolt

9/04

C6

CRANKCASETRAIL BOSS 330 A05CA32AA and TRAIL BOSS LE A05CA32AB and TRAIL BOSS 330 INT’L A05CA32FA

36

12

13

9

5

15

18

19

16

7

17

14

12

10

11

8

12

4




1 3083669 1 Bushing, Starter2 3086838 2 Pin, Dowel3 3087125 1 Asm., Crankcase

(Incl. 1-6,9,13,15,18,19)4 3087157 1 Plug, Blind5 3087116 2 Pin, Dowel6 3086395 1 Bearing, Ball7 3087266 2 Knock, Pipe8 3084205 3 Screw and Washer9 3084839 1 Seal, Oil

10 3087128 1 Gauge, Oil11 3087065 1 O-Ring12 3087066 2 Union13 3087155 1 Plug, Flange14 3084849 1 Union, Oil Pump15 3087156 2 Bolt, Flange16 3086749 1 Plug17 3082956 1 Gasket18 3087117 8 Bolt, Flange19 3086399 1 Bolt, Flange

4/04

C7

CYLINDERTRAIL BOSS 330 A05CA32AA and TRAIL BOSS LE A05CA32AB and TRAIL BOSS 330 INT’L A05CA32FA

3

21

20

14

10

4

9 12

16

12

22

27

5

11 13

29

19

2324

25

26

15

18

17

10

12

1617

4

11

11

4

6 7

828




1 3087259 2 Cover, Valve2 3086414 2 O-Ring3 3087159 4 Bolt, Flange4 3084874 13 Bolt, Flange5 3089272 1 Plug6 3089271 1 Cover, Breather7 3085850 1 Pipe8 3087034 1 Gasket, Cover9 3084858 1 Seal, Intake Valve10 3084994 2 Guide, Valve11 3084798 3 Fin, Damper A12 3084859 1 Seal, Exhaust Valve13 3086418 4 Bolt and Washer14 3089270 1 Asm., Cylinder Head

(Incl. 3,4,10-12,16)

15 3086421 1 Gasket, Exhaust16 3085326 2 Stud17 3080530 2 Washer, Lock18 3086787 2 Nut19 3087266 2 Knock, Pipe20 3086407 1 Gasket, Cylinder21 3087236 1 Cylinder, Unit22 3087238 1 Gasket, Head23 3087050 1 Adapter24 3083166 1 Asm., Adapter Band (Incl. 25)25 3081497 1 Screw26 3081330 2 Bolt, Socket Head27 3086416 1 Gasket, Cam28 3087275 2 Knock, Pipe29 3087160 2 Bolt, Flange

6/03

C8

CRANKSHAFT and PISTONTRAIL BOSS 330 A05CA32AA and TRAIL BOSS LE A05CA32AB and TRAIL BOSS 330 INT’L A05CA32FA

7

16

6

5

14

15

10

8

11

2

1

4

9

1312

5

15

6

4

8

3




1 308724430872453087246

111

Ring, Piston Set (STD)Ring, Piston Set (0.25 O/S)Ring, Piston Set (0.50 O/S)

2 308724130872423087243

111

Set, Piston (STD)(Incl. 4)Set, Piston (0.25 O/S)(Incl. 4)Set, Piston (0.50 O/S)(Incl. 4)

3 3086846 1 Pin, Piston4 3084167 2 Clip, Piston Pin5 3087240 2 Bolt, Connecting Rod6 3087239 1 Asm., Connecting Rod (Incl. 5,14)7 3087051 1 Crankshaft, Complete (Incl. 16)8 3240168 2 Key, Woodruff

9 3086434308643530864363086437

1111

SpacerSpacerSpacerSpacer

10 3086492 1 Sprocket 111 3085528 1 Nut, Slit12 3086767 1 Washer13 3083905 1 Nut, Lock14 3086426 2 Nut15 3086427

30867983086799

222

Bearing (STD)Bearing (0.05)Bearing (0.25)

16 3085815 2 Bearing, Ball4/04

C9

INTAKE and EXHAUSTTRAIL BOSS 330 A05CA32AA and TRAIL BOSS LE A05CA32AB and TRAIL BOSS 330 INT’L A05CA32FA

11

12

23

9 10

13

14

8

76

4

2

16

24

2

15

27

1817

2526

28

1

31

76

8

5

21

22

2019




1 3084911 2 Screw, Adjusting2 3084912 2 Nut3 3084910 2 Asm., Rocker Arm (Incl. 1,2)4 3087053 1 Shaft, Rocker5 3085836 1 Washer, Wave6 3084908 4 Collet, Valve7 3087203 2 Retainer, Spring, Valve8 3087248 2 Spring, Valve9 3086439 1 Lever, Release10 3086804 1 Spring, Return11 3087247 1 Camshaft (Incl. 9-12)12 3084899 1 Pin, Dowel13 3085778 1 Valve, Intake14 3086441 1 Valve, Exhaust

15 3086445 1 Guide, Chain16 3086444 1 Chain, Timing17 3086448 1 Gasket, Tensioner18 3086493 1 Asm., Tensioner19 3087132 1 Pin20 3087131 1 Spring21 3087129 1 Plug22 3087130 1 Gasket23 3083361 2 Asm., Bolt and Washer24 3086443 1 Sprocket 225 3087249 1 Washer26 3086449 1 Bolt, Flange27 3086446 1 Lever28 3084924 1 Bolt, Pivot

4/04

C10

CARBURETORTRAIL BOSS 330 A05CA32AA and TRAIL BOSS LE A05CA32AB and TRAIL BOSS 330 INT’L A05CA32FA

41

32

29

9

44

5

43

12

4

6

36

33

31

1230

1312

1415

21

19

26

1110

3

22

20

16

24

18

25

35

23

45

3839

8

7

40

34

28

27

17

42

37


C11

CARBURETORTRAIL BOSS 330 A05CA32AA and TRAIL BOSS LE A05CA32AB and TRAIL BOSS 330 INT’L A05CA32FA



1 3130507 1 Ring2 3130508 1 E-Ring3 3131554 1 Needle, Jet4 3130752 1 Ring5 3130732 1 Asm., Diaphragm6 3131588 1 Jet, Needle7 3130541 2 Screw8 3130540 2 Washer, Spring9 3130504 1 Asm., Jet Block10 3130014 1 Washer11 3131458 1 Jet, Main (#122.5)12 3130515 2 Seal13 ------ -- -- -- -- 1 Packing14 3130518 1 E-Ring15 3130519 1 Cap16 3130361 1 Pin, Float17 3130594 1 Plate18 3130532 1 O-Ring19 3130520 4 Screw20 3130590 1 Asm., Float Body21 3130521 1 Screw22 3130529 1 Asm., Float23 3130591 2 Screw

24 3131360 1 Valve, Needle25 3130533 1 O-Ring26 3130526 1 Jet, Pilot, #42.527 3131423 1 Screw, Adjust28 3130836 1 Spring29 3130502 1 Valve, Throttle, 10030 3130589 1 Spring31 3130514 1 Shaft32 3130501 2 Screw33 3130513 1 Asm., Throttle Shaft34 3130543 1 Guide, Cable35 3130535 4 Screw36 3130511 1 Cover37 3130199 1 Cap, Plunger38 3130538 1 Spring39 3131228 1 Asm., Plunger40 3130625 1 Jet, Air , Pilot, #16041 3131590 1 Asm., Carburetor (Incl. 1-33,37-45)42 3084205 2 Asm., Screw and Washer43 3131129 1 Spring44 3130503 1 Asm., Cover45 3130924 4 Screw

4/04

C12

RECOIL STARTERTRAIL BOSS 330 A05CA32AA and TRAIL BOSS LE A05CA32AB and TRAIL BOSS 330 INT’L A05CA32FA

13

6

4

7

10

5

312

11

8

12

14

9

8

7




1 3084822 1 Reel2 3083463 1 Spring, Return3 3083378 1 Ratchet4 3083379 1 Spring, Friction5 3084744 1 Plate, Friction6 3085266 1 Asm., Bolt and Washer7 3086749 2 Plug8 3082956 2 Gasket

9 3083669 1 Bushing, Starter10 3083185 1 Spring, Power11 3084750 1 Bushing12 3087150 9 Bolt, Flange13 3087163

308716411

Asm., Recoil (Incl. 1-6,9-11,13,14)Starter Case (Incl. 11)

14 3085083 1 Asm., Rope

1/03

C13

OIL PUMP and OIL FILTERTRAIL BOSS 330 A05CA32AA and TRAIL BOSS LE A05CA32AB and TRAIL BOSS 330 INT’L A05CA32FA

11

9

1

10

8

2

4

7

5

6

3




1 3086749 1 Plug2 3082956 1 Gasket3 3086455 1 Spring, Relief Valve4 3086222 1 Valve, Oil Relief5 3087256 1 Bolt, Flange6 3086454 1 Unit, Strainer, Oil

7 3084963 1 Filter, Oil8 3087255 5 Screw, Counter Sunk9 3086450 1 Cover, Oil Pump10 3086452 1 Rotor, Inner11 3086453 1 Rotor, Outer

1/03

C14

MAGNETOTRAIL BOSS 330 A05CA32AA and TRAIL BOSS LE A05CA32AB and TRAIL BOSS 330 INT’L A05CA32FA

7

4

6

1

2

11

8

3

5

10


9



1 3087036 1 Asm., Ignition Coil (Incl. 3)2 3087037 1 Cap, Spark Plug3 3070172 1 Plug, Spark4 3084978 1 O-Ring5 3089275 1 Asm., Plate6 3081657 5 Asm., Bolt and Washer

7 30892733087251

11

Asm., Magneto (Incl. 5)Magneto, Complete

8 4011072 1 Switch, Magnetic9 7552801 2 Washer, Spring Lock10 7542105 2 Nut11 3088209 1 CDI System

4/04

D1

STARTING MOTORTRAIL BOSS 330 A05CA32AA and TRAIL BOSS LE A05CA32AB and TRAIL BOSS 330 INT’L A05CA32FA

9

11

1

5

10

4

3

17

12

16

15

14

13

67

8

21


5



3084981 1 Asm., Motor, Starting (Incl. 1-5,7-11)1 3084982 1 Set, Washer2 3085353 1 Asm., Armature3 3088169 1 Brush4 3083649 2 Nut, Flange5 3084408 3 O-Ring6 3082038 2 Asm., Bolt and Washer7 3085034 1 Cover, Rear8 3085033 1 Asm., Front Bracket (Incl. 9)

9 3240114 1 O-Ring10 3084983 2 Asm., Set Bolt (Incl. 5)11 3084405 2 Ring, Rubber12 7555908 1 Washer, Thrust13 3084412 1 Clip14 3084411 1 Spring, Weight15 3084410 1 Spring, Return16 3084409 1 Clip17 3087030 1 Asm., Gear Shaft (Incl. 13-16)

4/04

D2

FUEL PUMPTRAIL BOSS 330 A05CA32AA and TRAIL BOSS LE A05CA32AB and TRAIL BOSS 330 INT’L A05CA32FA

4

1

3 2

2

4




3085275 1 Asm., Fuel Pump (Incl. 1-4)1 3084999 1 Asm., Screw and Washer2 3085356 2 Asm., Screw and Washer

3 3084591 4 Screw4 3084998 1 Diaphragm, Gasket Set

4/04

D3

TOOL KITTRAIL BOSS 330 A05CA32AA and TRAIL BOSS LE A05CA32AB and TRAIL BOSS 330 INT’L A05CA32FA

1

34

5

6

2


7

8



2874926 1 Tool Kit (Incl. 3,4,5,7,8)1 2682572 1 Pouch, Tool Kit2 9919482 1 Owner’s Manual, ’05 Trail Boss 3303 ------ -- -- -- -- 1 Wrench, Box, Special4 ---- -- -- -- -- -- 1 Wrench, 10-12 Spanner

5 ------ -- -- -- -- 1 Screwdriver6 2870725 1 Gauge, Tire Pressure7 2874858 1 Wrench, Torx, T-278 ------ -- -- -- -- 1 Wrench, Open End, 12-14

9/04

This page left blank intentionally.

PRINTED IN THE USA PARTS MANUAL PN 9919483 and MICROFICHE PN 9919484 9/04

Documents

Trail Boss 330