Trail Boss 330

PARTS MANUAL PN 9919483 and MICROFICHE PN 9919484 9/04
TRAIL BOSS 330

Model #A05CA32AA
TRAIL BOSS LE
Model #A05CA32AB
TRAIL BOSS 330 INTL
Model #A05CA32FA
Rev. 01
E 2004 Polaris Sales Inc.
This page left blank intentionally.
TABLE OF CONTENTS
TRAIL BOSS 330 A05CA32AA and TRAIL BOSS LE A05CA32AB and TRAIL BOSS 330 INTL A05CA32FA
Parts Manual
A-- ARM/STRUT MOUNTING . . . . . . . . . . . . . B7

AIR BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . A11
BUMPER and RACK MOUNTING . . . . . . . . . A6
CARBURETOR . . . . . . . . . . . . . . . . . . . . . . .
CLUTCH COVER . . . . . . . . . . . . . . . . . . . . .
CONTROLS - MASTER
CYLINDER/BRAKE LINE . . . . . . . . . . . .
CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . .
CRANKSHAFT and PISTON . . . . . . . . . . . . .
CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . .
INTAKE and EXHAUST . . . . . . . . . . . . . . . . . C9
B5
C6
C8
C7
MAGNETO . . . . . . . . . . . . . . . . . . . . . . . . . . C14
DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . A5
DRIVE CLUTCH . . . . . . . . . . . . . . . . . . . . . . B13
DRIVEN CLUTCH . . . . . . . . . . . . . . . . . . . . . B14
ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . C1
ENGINE MOUNTING . . . . . . . . . . . . . . . . . . A7-8
EXHAUST SYSTEM . . . . . . . . . . . . . . . . . . . A10
FRONT BRAKE . . . . . . . . . . . . . . . . . . . . . .
FRONT CAB . . . . . . . . . . . . . . . . . . . . . . . .
FRONT WHEEL . . . . . . . . . . . . . . . . . . . . . .
FUEL PUMP . . . . . . . . . . . . . . . . . . . . . . . . .
FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . .
HANDLEBAR . . . . . . . . . . . . . . . . . . . . . . . . B8
C10-11
B12
GEARCASE . . . . . . . . . . . . . . . . . . . . . . . . . C3-4
GEARCASE MOUNTING . . . . . . . . . . . . . . . C2
M
O
OIL COOLING . . . . . . . . . . . . . . . . . . . . . . . A9
OIL PUMP and OIL FILTER . . . . . . . . . . . . . . C13
REAR BRAKE MASTER CYLINDER . . . . . . .

REAR CAB and SEAT . . . . . . . . . . . . . . . . .
REAR CALIPER MOUNTING . . . . . . . . . . . .
REAR HOUSING . . . . . . . . . . . . . . . . . . . . .
REAR WHEEL DRIVE . . . . . . . . . . . . . . . . . .
RECOIL STARTER . . . . . . . . . . . . . . . . . . . .
B1
A3
A14
D2
A12
GEAR SELECTOR . . . . . . . . . . . . . . . . . . . . C5
STARTING MOTOR . . . . . . . . . . . . . . . . . . .
STEERING POST . . . . . . . . . . . . . . . . . . . . .
STRUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SWING ARM/SHOCK MOUNTING . . . . . . . .
B3
A4
B2
B9
B10
C12
D1
B6
A13
B11
TAILLIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . C1
THROTTLE CONTROLS / THROTTLE CABLE B4
TOOL 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.
FRONT CAB
2
7
3
8
9
10
11
12
13
16
15
14
18
17
17
18
17
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No.
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
Qty. Description
1
1
1
1
1
1
1
4
1
1
2
1
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)
Ref. Part No.
10
11
12
13
14
15
16
17
18
7512085
7555783
7542122
7555859
7081040
7541925
7555792
7670088
5245394-067
5245533-067
Qty. Description
4
2
2
2
8
4
2
13
1
1
Screw
Washer, Flat
Nut, Nylok
Washer, Flat
Rivet
Nut, Nylok
Washer
Clip, Dart
Shield, Splash, LH
Shield, Splash, RH
9/04
A3
REAR CAB and SEAT

2
3
10
29
9
5
28
11
12
21
27
23
22 1 21
24
26
20
13
25
19
18
17
16
14
4
15
Ref. Part No.
1
2
3
4
5
6
7
8
9
10
11
12
7541925
5246091
7512242
7555859
7512085
5434040
7517375
7621403
5211033
1040387
7041370
2683197-070
2682958-070
13 5431787
14 5432763
15 7515179
Qty. Description
6
1
4
10
2
1
2
2
2
1
1
1
1
1
1
6
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
Ref. Part No.
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
Qty. Description
1
1
8
8
2
2
4
1
1
2
1
1
1
2
14
1
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, Rear
9/04
A4
DECALS
2
6
7
8
9
10
12
11
13
14
15
16
18
17
Ref. Part No.
Qty.
1 7172662
7172663
7173006
7173007
2 7172660
7172661
7173004
7173005
3 5435424
7173013
1
1
1
1
1
1
1
1
1
1
4 7172559
5 7172658
7172659
7173011
7173012
6 7078465
1
1
1
1
1
1
Description
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
Ref. Part No.
7
8
9
10
11
12
13
14
15
16
17
18
7079773
7172562
7079906
7172656
7172657
7173002
7173003
7172666
7079959
7079925
7172566
7172667
7172665
7172560
7079924
Qty.
1
1
1
1
1
1
1
2
1
2
1
1
1
1
2
Description
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 & Rear
Decal, POLARIS, Rear
Decal, Reflector, Red
Decal, Passenger Warning
Decal, Tire Pressure/Load
Decal, Discretionary Warning
Decal, Warning, General, CPSC
Decal, Reflector, Amber
12/04
A5
BUMPER and RACK MOUNTING

1
21
2
3
20
22
21
5
21
7
10
11
19
13
12
17
18
17
14
15
16
Ref. Part No.
1
2
3
4
5
6
7
8
9
7517977
1014039-385
5432831
5334092
1014658-067
5810467
7512232
7515399
1013744-067
1013746-067
10 7515189
11 2410285
Qty.
2
1
2
2
1
1
6
4
1
1
2
2
Description
Ref. Part No.
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)
12
13
14
15
16
17
18
19
20
21
22
7542122
1014483-385
5248297-067
5248298-067
7621472
7512232
5247919
7670096
7542324
7558402
7512329
Qty.
2
1
1
1
5
4
2
2
2
4
2
Description
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
Screw
9/04
A6
ENGINE MOUNTING
3
4
10
11
10
11
37
36
32
15
33
14
13
12
To fuel
valve outlet.
32
35
34
17
33
33
To impulse fitting
RH side of carb.
16
32
To fuel inlet
LH side of carb.
32
18
31
19
20
7
29
21
30
22
7
28
27
12
26
14
23
25
7
24
A7
ENGINE MOUNTING
Ref. Part No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
8450003-1525
7052075
7542122
7558301
5247946
3084205
7547108
4010132
7512232
7512315
7552901
3021181
5430802
7555823
5247344
7172562
7080511
5411721
8360009-100
3089535
Qty.
AR
1
2
2
1
2
7
1
1
2
2
2
1
2
1
1
1
1
AR
1
Description
Ref. Part No.
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 & crankshaft assembly. Prior
authorization required for warranty
consideration.
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
7555815
3110046
1013413-067
7547089
7515417
5247342
5430261
7575202
7512566
5210748
4010095
7080003
8450103-600
2530009
8450040-600
7546601
3110050
Qty.
1
1
1
2
2
1
1
1
1
1
1
8
AR
1
AR
2
1
Description
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
7/04
A8
OIL COOLING
2
1

6
4
7
8
10
11
12
17
16
13
13
15
14
Ref. Part No.
1
2
3
4
5
6
7
8
9
5412355
7080851
7512084
7542122
5245416-067
7547069
7512232
7517659
2410534
Qty.
2
1
1
4
1
2
4
4
1
Description
Ref. Part No.
Hose, Inlet
Clamp, Hose
Screw
Nut, Nylok
Bracket, Oil Cooler, Top
Nutsert
Screw
Screw
Motor, Fan
10
11
12
13
14
15
7670111
5433353
4010934
7558301
7512163
1240204
1240191
16 5248139
17 7080999
Qty.
4
1
1
4
4
1
1
1
1
Description
U-Clip
Shroud
Thermister
Washer
Bolt
Asm., Oil Cooler (Incl. 8-12)
Cooler, Oil
Bracket, Oil Cooler, Lower
Cable Tie
4/04
A9
EXHAUST SYSTEM
4
2
6
1
20
19
18
17
11
7
15
16
15
10
11
12
14
13
Ref. Part No.
1
2
3
4
5
6
7
8
9
10
7555716
1261402-029
5412233
7515316
5010192
7041804
3085075
3080051
3086787
1260960-029
Qty.
2
1
2
3
2
4
1
2
2
1
Description
Ref. Part No.
Washer, Flat
Silencer
Dampener, Vibration
Bolt
Bushing
Spring, Exhaust
Gasket, Exhaust
Washer
Nut
Manifold
11
12
13
14
15
16
17
18
19
20
5243517
5411576
7512232
5248301
7041769
1260987-029
7556230
7512666
5410436
7542324
Qty.
2
1
2
1
2
1
1
1
2
2
Description
Seal, Exhaust
Dampener, Vibration
Screw
Bracket, Exhaust Pipe Support
Spring, Extension
Headpipe
Washer, Clean Out
Bolt
Washer, Rubber
Nut, Nylok
9/04
A10
AIR BOX

1
2
7
8
9
10
11
27
26
25
12
13
25
24
21
20
19
18
17
16
22
15
14
23
Ref. Part No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
7515180
7558301
5812023
5433767
7517317
5810317
5433769
5811482
5242044
5432601
7080699
5412101
5411866
7080511
Qty. Description
1
1
1
1
1
2
1
1
6
1
1
1
1
1
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
Ref. Part No.
15
16
17
18
19
20
21
22
23
24
25
26
27
5411588
7080413
5433180
5830128
5433919
7555932
5412111
5432377
5435299
5812111
7080650
5412099
7080413
1253372
Qty. Description
1
2
1
1
1
2
1
1
1
1
1
2
1
1
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., Filter
4/04
A11
FUEL TANK
4
3
After 4/01/04
Before 4/01/04
22
21
23
24
20
10
17
18
18
19
17
11
12
17
17
18
18 17
17
18
15
14
16
13
Ref. Part No.
1 2520362
2520409
2
3
4
5
6
7
8
9
5812123
2873626
8360009-600
5431053
7517451
7552801
7555859
5247184
5247185
10 5811951
11 5332457
12 7547069
Qty. Description
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
Ref. Part No.
13
14
15
16
17
18
19
20
21
7517505
5432559
5432733
7052161
7080003
8450040-600
2530009
7515136
7052364
22 7052362
23 7052346
24 7052350
A12
Qty. Description
1
1
1
1
8
AR
1
2
1
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
1 Fitting, Main Outlet
9/04
STRUT
1
2
3
4
6
7
8
10
17
11
12
16
13
13
15
14
Ref. Part No.
1
2
3
4
5
6
7
8
9
7547104
7555749
5810291
5432872
5432871
5132062
5243364
7041850-385
5412665
Qty. Description
2
2
2
2
2
2
2
2
2
Nut, Nylok
Washer
Spacer, Rubber
Ball, Pivot, Top
Ball, Pivot, Bottom
Spacer
Retainer, Spring
Spring, Compression, Silver
Bumper
Ref. Part No.
10
11
12
13
14
15
16
7041761
7080367
7542343
7558402
7080306
7518340
5134133
5134134
17 5211115
Qty. Description
2
2
4
6
2
4
1
1
2
Strut, Front
Clamp, Cable
Nut, Nylok
Washer, Flat
Fitting, Lubrication
Bolt
Support, Strut and Spindle, LH
Support, Strut and Spindle, RH
Washer
4/04
A13
FRONT WHEEL

2
5
4
6
9
10
11
12
17
13
14
16
15
Ref. Part No.
1 ------2
3
4
5
6
7
8
3610093
3514527
7512325
5247961
7515513
5133294
5412324
5412514
Qty. Description
1 Support, Strut and Spindle

(See Strut Pg. A13, Ref. 16)
1 Seal, Lip
1 Bearing, Ball, Sealed
4 Bolt
1 Brake, Disc
4 Stud
1 Hub, Wheel, Front
2 Tire, 23x7-10 (AA)(AB)
2 Tire, Front, 23x7-10 (FA)
Ref. Part No.
9
10
11
12
13
14
15
16
17
1520175-486
7547237
3514464
7556333
7661407
5411164
7542712
5631551
1525017
Qty. Description
2
8
1
2
2
2
2
1
2
Rim, Front
Nut, Flange
Bearing, Ball, Sealed
Washer, Flat
Pin, Cotter
Hub, Dust Cover
Nut
Spacer, Tapered
Valve, Rim
9/04
A14
FRONT BRAKE
1
2
2
16
15
5
14
13
6
7
12
11
10
Ref. Part No.
Qty.
1910868
1910869
1930642
1910499
5410988
7515489
5134639
5134640
5410494
5410779
5410780
1
1
1
2
4
2
1
1
1
1
1
1
2
3
4
5
6
7
Description
Asm., Brake Caliper, LH (Incl. 3-5,13)

Asm., Brake Caliper, RH (Incl. 3-5,13)
Kit, Boot, Front Brake (Incl. 5,12)
Bolt, Banjo
Seal
Screw, Socket Set
Caliper, Brake, LH
Caliper, Brake, RH
Boot, Pin Seal
Ring, Square, Molded, .094
Ring, Square, Molded, .103 x .134
Ref. Part No.
8
9
10
11
12
13
14
15
16
5132294
1930665
2202412
1910412
5410495
7080352
7558402
7552901
7512365
Qty.
1
1
2
2
1
2
4
4
4
Description
Piston, Brake, Long

Kit, Piston and Seal (Incl. 6-8)
Asm., Brake Pad
Mount, Caliper
Boot, Bushing
Screw, Bleeder
Washer, Flat
Washer, Spring Lock
Screw
4/04
B1
REAR CALIPER MOUNTING

2
2
3, 4
4
3, 4
1, 2
1,2, 6
7
8
9
10
11
12
13
14 15
16
17
Ref. Part No.
Qty.
1910806
2201873
2201870
2201872
2201869
1910412
2202414
5410988
1910770
1
1
1
1
1
1
1
4
1
1
2
3
4
5
6
7
8
Description
Asm., Caliper (Incl. 1-6)

Kit, Anvil Body
Kit, Slide Bolt
Kit, Seal
Kit, Piston and Seal
Mount, Caliper
Kit, Brake Pad
Seal
Line, Brake, JB to Rear
Ref. Part No.
9
10
11
12
13
14
15
16
17
1910769
1910886
1910499
7515102
5247210-067
7555883
7547066
7552901
7512365
Qty.
1
1
1
1
1
1
1
2
2
Description
Line, Brake, Front M/C to Rear

Bolt, Banjo w/Bleeder
Bolt, Banjo
Screw
Mount, Caliper, Lower
Washer
Nut
Washer
Screw
4/04
B2
REAR BRAKE MASTER CYLINDER

1
3
5
4
18
17
16
15
12
12
13
14
11
9
10
7
9
Ref. Part No.
1
2
3
4
5
6
7
8
7670102
7517386
1930854
7080003
1910812
1910499
5410988
-------
9 7515158
Qty. Description
1
1
1
2
1
1
2
1
Clip
Screw
Reservoir
Clamp, Hose, Red
Hose, Reservoir
Bolt, Banjo
Seal
Line, Foot Brake, Rear (See Rear Caliper Mounting Pg. B2, Ref. 9)
3 Screw
Ref. Part No.
10
11
12
13
14
15
16
17
18
1910791
1910764-067
7555919
5433189
1910767-067
7041750
7661401
7512232
7558301
Qty. Description
1
1
2
2
1
1
1
1
1
Asm., Foot Brake Master Cylinder

Mount, Brake
Washer
Bushing, Pedal Pivot
Rod, Brake
Spring, Torsion
Pin, Cotter
Screw
Washer, Flat
9/04
B3
THROTTLE CONTROL / THROTTLE CABLE

1
2

6
Ref. Part No.
1 5434113
2 5410193
3 5411439
Qty.
Description
Ref. Part No.
1 Cover, Throttle Control

1 O-Ring
1 O-Ring
4 7081170
5 2010204
6 2010191
Qty.
Description
1 Cable, Throttle
1 Asm., Throttle Control (Incl. 6)
1 Asm., Throttle Clamp
4/04
B4
CONTROLS - MASTER CYLINDER/BRAKE LINE

4
4
5
6
17
15
16
9
12
10
12
11
13
14
2
1
2
Ref. Part No.
1
2
3
4
5
2010238
1910499
5410988
4110164
7517899
2201834
6 2201836
7 2201833
Qty. Description
1
3
6
1
2
1
Asm., Master Cylinder

Bolt, Banjo
Seal
Switch
Screw
Kit, Master Cylinder Cap
(Incl. Cap, Screws, Sight, Gasket)
1 Kit, Master Cylinder Park Brake Lever
(Incl. Lever, Spring)
1 Kit, Master Cylinder Clamp
(Incl. Clamp, Screws)
Ref. Part No.
8 2201835
9
10
11
12
13
14
15
16
17
1910770
7621462
7080539
8360052305
1910838
7512024
1910839
7052292
1910768
Qty. Description
1 Kit, Master Cylinder Lever

(Incl. Pin, Lever, Clip)
1 Line, Brake, JB Rear
2 Rivet
2 Clamp, Nylon
AR Tubing, Convoluted
1 Line, Brake, Left Front
2 Screw
1 Line, Brake, Right, Front
1 Fitting, Cross
1 Line, Brake
9/04
B5
STEERING POST
2
4
5
11
7
8
10
Ref. Part No.
1 7542324
7542343
2 5433866
3 1013927-067
4 5246732
5 7517428
Qty. Description
4
4
2
1
1
4
Nut, Nylok (If built before 5/10/04)

Nut, Nylok, Flange (If built after 5/10/04)
Bushing, Steering, Upper
Post, Steering
Bracket, Steering Upper
Bolt, Carriage
Ref. Part No.
6
7
8
9
10
11
7556162
5222393
3514352
7547158
7661633
7558402
Qty. Description
2
1
1
1
1
2
Bushing
Flangette
Bearing
Nut
Pin, Cotter
Washer, Flat (If built before 5/10/04)
9/04
B6
A-ARM/STRUT MOUNTING
3
4
1
5
6
7
8
10
7
11
27
9
12
26
25
12
13
25
26
14
22
21
24
22
15
20
19
23
18
16
17
Ref. Part No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
7542439
7558403
5411291
7061034
7542711
5020927
7517909
7061054
5411920
7547028
1820806
7556099
7547177
7661407
5211121
Qty.
2
2
2
2
2
2
2
2
2
2
2
4
2
2
2
Description
Nut, Nylok
Washer
Boot, Seal, Rod End
Rod End, RH
Nut
Tie Rod
Screw
Rod End, LH
Boot, Seal
Nut, Jam, LH
Asm., Tie Rod (Incl. 3-8)
Washer, Flat
Nut, Lock
Pin, Cotter
Bracket, Ball Joint
Ref. Part No.
16
17
18
19
20
21
Qty.
7512284
7661203
7542438
5410548
7080927
-------
4
4
2
2
2
1
22 5434551
23 2202278
2202279
24 5133806
25 7512492
7518364
26 7555832
27 7518033
4
1
1
2
4
4
4
2
Description
Screw
Pin, Cotter
Nut, Castle
Boot, Rubber
Joint, Ball
Support, Strut/Spindle
(See Strut Pg. A13, Ref. 16)
Bushing, A-Arm, Long
Kit, A-Frame, LH (Incl. 22,25,26)
Kit, A-Frame, RH (Incl. 22,25,26)
Shaft, A-Arm
Screw (If built before 5/10/04)
Screw (If built after 5/10/04)
Washer (If built before 5/10/04)
Screw
4/04
B7
HANDLEBAR
10
8
7
5
21
12 11
20
19
17
19
13
18
14
15
16
Ref. Part No.
Qty. Description
1
2
3
4
5
6
4010315
7078465
7518176
5434643-070
7515189
-------
1
1
2
1
4
1
7
8
9
10
11
12
13
5433903
4010592
7081177
5433834-070
5432952
7517625
5334127-067
1
1
1
2
1
1
1
Panel Indicator Light

Logo Star
Screw
Panel, Instrument
Screw
Asm., Master Cylinder
(See Control - Master Cylinder/Brake
Line Pg. B5 for Details)
Spacer, Switch, LH
Switch, Handlebar, Hi/LO/Off
Cable, Choke
Grip, Handlebar
Plug, Hole
Screw
Tube, Handlebar
Ref. Part No.
14
15
16
17
Qty. Description
5631516
7542122
7080138
-------
1
4
1
1
18 5631517
19 4011002
4010278
4010321
1
1
1
1
5433733
5433534
20 5248182
21 7080922
1
1
1
1
Block, Handlebar
Nut, Nylok
Cable Tie
Asm., Throttle Control (See Throttle Controls/Throttle Cable Pg. B4, Ref. 5)
Block, Handlebar, Pegged
Switch, Key, 3 Position
Blank, Key, Series 2000, 6700, 6800
Blank, Key, Series 2200, 2300, 2700,
2800. NOTE: Your key can be duplicated only by obtaining a key blank
from Polaris and having it cut by mating it with your existing key.
Nut, Ignition
Cover, Key
Bracket, Instrument Panel
Nut, Choke Slide
4/04
B8
REAR HOUSING
1
2 3

7
8
10
11
12
13
14
15
24
12
16
23
11
10
17
22
18
19
21
18
20
Ref. Part No.
1
2
3
4
5
6
7
8
9
10
11
12
7670160
7515102
5133428
7547217
5245716
5631457
7512365
7670161
5410889
3610070
3554518
3554517
Qty.
1
1
1
3
1
1
3
1
2
2
2
2
Description
Ref. Part No.
Ring, Retaining
Screw
Nut, Axle
Nut, Nylok
Disc, Brake
Hub, Brake Disc
Screw
Ring, Retaining
O-Ring
Seal
Bearing, Cone, Tapered
Bearing, Cup, Tapered
13
14
15
16
17
18
19
20
21
22
23
24
5134460
7080306
3221192
5133967
3221193-076
7542439
5211585-067
5630586
3222109
1520795
7515528
7518378
Qty.
1
1
1
1
1
6
1
1
1
1
3
3
Description
Housing, Axle, Rear

Fitting, Lubrication
Link, Connector, 520
Axle, Rear
Chain, 520 O-Ring
Nut, Nylok
Guard, Sprocket
Spacer
Sprocket, 36T
Asm., Hub, Sprocket (Incl. 24)
Screw
Stud
4/04
B9
REAR WHEEL
2
1
3
4
6
7
12
11
9
10
2
1
Ref. Part No.
1
2
3
4
5
6
7
7512673
5131777
7542714
7555796
7543005
7661404
5411164
Qty.
8
2
8
2
2
2
2
Description
Ref. Part No.
Bolt
Hub, Rear Wheel, Large Flange
Nut
Washer
Nut, Castle
Pin, Cotter
Cover, Dust, Hub
8
9
10
11
12
7555745
1525017
7670081
1520183-486
5412323
5412515
Qty.
2
2
8
2
2
2
Description
Washer, Flat
Valve, Rim
Pushnut
Rim, Rear
Tire, 22x11-10 (AA)(AB)
Tire, 22x12-10 (FA)
9/04
B10
SWING ARM/SHOCK MOUNTING

3
5
10
6
11
1
7
32
12
13
14
15
12
31
16
17
19
30
29
20
26
18
28
25
26
21
24
23
27
22
Ref. Part No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
5630551
7041986-385
7542439
7515415
5241147
7042318
5134321
5133166
5434545
7661046
5432727
7080510
7547082
7556035
5133167
5434546
Qty.
1
1
2
1
1
1
2
1
1
2
1
2
1
1
2
1
Description
Ref. Part No.
Cam, Adjusting
Spring, Compression
Nut, Nylok
Screw
Retainer, Shock
Shock, Rear
Bolt, Swing Arm Pivot
Bushing, Swing Arm Pivot, LH
Bushing, Swing Arm, LH
Rivet
Guide, Pad, Chain
Fitting
Nut
Washer, Flat
Bushing, Swing Arm, Pivot, RH
Bushing, Swing Arm, RH
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
5247488
7515399
1541987-067
7078572
5432854
7515304
5332828
7558402
7542343
7555883
7547066
7170915
2200472
7512576
7515438
7517761
Qty.
2
2
1
1
1
1
1
1
1
4
2
1
1
2
1
1
Description
Bracket, Bolt Lock

Bolt
Asm., Swing Arm (Incl. 9,12,15)
Decal, Chain Free Play
Guard, Chain
Screw
Bushing
Washer, Flat
Nut, Flange
Washer
Nut, Nylok
Decal, Hitch
Kit, Hitch (Incl. 27-30)
Bolt
Screw
Screw
4/04
B11
CLUTCH COVER
3
4
7
8
10
25
11
12
13
24
23
22
21
14
12
15
19
16
20
18
17
Ref. Part No.
1
2
3
4
5
6
7
8
9
10
11
12
13
5247524-067
7517386
7670088
2632513
5434491
2202438
5434401
7510000
7080909
5521578
5434255-070
7512094
7172563
Qty. Description
1
2
1
1
1
1
1
3
1
1
1
9
1
Bracket, Clutch Cover

Screw
Clip, Plastic Dart
Foam, Clutch Air Inlet
Plate, Backing
Kit, Clutch Cover, Inner
Duct, Inlet
Bolt and Washer
Clamp, Narrow Band
Seal, Clutch Cover
Cover, Clutch, Outer
Screw
Decal, Warning, Clutch Cover
Ref. Part No.
Qty. Description
14
15
16
17
18
19
20
21
7172746
5434264
5410542
7080707
7517386
5434213
5411489
-------
1
1
1
2
1
1
1
3
22
23
24
25
5242046
5410575
5411795
5410489
1
1
1
1
Decal, Automatic Transmission

Plug, Drain, Clutch Cover
O-Ring
Clamp
Screw
Duct, Air Outlet
Boot, Duct
Screw and Washer
(See Crankcase Pg. C6, Ref. 8)
Bracket, Clutch Seal
Seal, Cover Case
Stopper, Inner Clutch Cover
Seal, Cover Case, Transmission
4/04
B12
DRIVE CLUTCH

4
1
2
12
11
10
Ref. Part No.
1321976
1
2
3
4
5
6
7518062
3576510
7041157
5430945
1321457
5431936
Qty. Description
1 Asm., Drive Clutch, Wide

(Incl. All Less 3,8)
6 Screw
1 Bearing, Cover
1 Spring, Clutch
6 Washer, Multilube
3 Roller and Bushing
6 Button, Clutch
Ref. Part No.
7 5210752
5242981
5210753
5210754
8 5630709
9 7512266
10 7541906
11 3576504
12 5020422
Qty. Description
AR
AR
AR
AR
3
3
3
1
3
Spacer, .020
Spacer, .025
Spacer, .032
Spacer, .050
Weight, Shift, 10RH
Bolt, Shoulder
Nut, FLEXLOC
Bearing, Moveable, 1/2 Inch
Pin, Roller
6/03
B13
DRIVEN CLUTCH
1
16
17
5
6
15
14
13
12
11
10
9
Ref. Part No.
1
2
3
4
5
6
7
8
9
7556120
3211077
1321848
5220646
7552901
7515384
7555898
7556076
7556804
Qty. Description
AR
1
1
1
1
1
AR
AR
AR
Bushing
Belt, Drive
Asm., Driven Clutch (Incl. 7-17)
Washer, Domed
Washer, Spring Lock
Bolt
Washer
Washer
Washer
Ref. Part No.
10
11
12
13
14
15
16
17
3576504
3576511
7041782
5131446
5210752
7710448
7511854
5430766
Qty. Description
1
1
1
1
1
1
3
3
Bearing, Moveable, 1/2 Inch

Bearing, Moveable, 1 Inch
Spring, Clutch, Black
Ramp, Stationary
Spacer
Ring, Retaining
Bolt
Button, Ramp
6/03
B14
ELECTRICAL/TAILLIGHT
(AA)(AB)
1
3
2
4
6
9
31
32
30
29
10
28
11
12
13
10
23
13
20
14
21
22
27
24
26
19
25
16
15
17
18
14
Ref. Part No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
2410504
2201795
2410320
4032029
4032046
4030043
4032045
------7670054
4020149
7080138
7670109
7518287
7512024
4010995
7571602
8360012-04
4011088
Qty. Description
1
1
1
2
1
1
1
1
2
3
12
3
4
4
1
4
1
1
Harness, Main
Kit, Circuit Breaker, Fan
Taillight w/Brake Light (AA)(AB)
Screw, Taillight (AA)(AB)
Lens, Taillight (AA)(AB)
Bulb, Taillight (AA)(AB)
Gasket, Taillight (AA)(AB)
Backing, Taillight/Brake Light (AA)(AB)
Nut, Speed (AA)(AB)
Clip, Rosebud
Cable Tie
Clip, Routing
Nut
Screw
Limiter, RPM
Washer
Trim, Edge
Module, Controller
Ref. Part No.
19 7512007
20 4010093
21 - - - - - - 22 4010094
23 7512027
24 4011138
4140006
5432077
25 2202147
26 5810290
27 7670102
28 5412499
29 7010032
30 4010095
31 2202848
2200361
32 5431769
Qty. Description
2 Bolt
1 Cable, Solenoid/Starter
1 Switch, Magnetic
(See Magneto Pg. C14, Ref. 8)
1 Cable, Battery/Solenoid
2 Screw
1 Battery (AA)(AB)
1 Battery (FA)
1 Tube, Vent (FA)
1 Kit, Fusible Link
3 Pad, Battery
1 Clip, Silencer
1 Strap, Battery Holddown
2 Hook, Battery Strap
1 Cable, Battery/Engine
1 Kit, Battery Bolt (AA)(AB)
1 Kit, Battery Bolt, Short (FA)
1 Cover, Battery
9/04
C1
GEARCASE MOUNTING
2
2
16
15
2
14
1
4
4
13
+
12
11
1
5
8
7
9
10
1
2
Ref. Part No.
1
2
3
4
5
6
7
8
9
7518364
7547089
5248185
7555806
1012886-067
5243296
7517646
7517631
7542440
Qty. Description
4
6
2
2
1
1
1
1
1
Bolt, Flange
Nut, Flange
Bracket, Transmission Mount
Washer, Flat
Mount, Transmission
Spacer
Screw
Screw
Nut
Ref. Part No.
10 - - - - - - 11
12
13
14
15
16
7710434
3221043
7517640
8450003-1525
7512024
7080693
Qty. Description
1 Plug, Drain
(See Gearcase Pg. C4, Ref. 35)
1 Ring, Retaining
1 Sprocket, 11T
1 Screw
AR Line, Fuel
1 Screw
1 Clamp, Hose
9/04
C2
GEARCASE
2 3 4
13
14
20
24
23
22
15
16
17
19
10 11
12

27
18
29
30
28
31
32
21
26
25
37 36 35
12
40
38
39
41
C3
26
33
34
GEARCASE
Ref. Part No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
1341306
3233018
3233177
3233673
3233674
3233010
3233675
3233676
3233677
3233678
3233105
3233106
3233019
3233961
3233547
3233045
3233040
3233548
3233679
3234002
3233749
Qty. Description
1
2
1
1
1
1
1
1
1
1
1
2
2
1
1
1
1
1
1
1
4
Asm., Gearcase (Incl. 1-41)

Bearing
Ring, Retaining
Washer, Thrust
Sprocket, 19T
Washer, Thrust
Dog, Engagement, High/Reverse
Shaft, Input
Gear, 21T
Bushing
Washer
Ring, Retaining
Bearing
Nut
Bellcrank
Ring, Retaining
Washer
O-Ring
Shaft, Shift
Switch, 3 Position
Screw
Ref. Part No.
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
3233680
3233681
3233872
3233682
3233478
3233788
3233524
3234049
3233529
3233684
3233685
3234048
3233636
3233252
3233687
3233527
3233035
3233111
3233688
3233689
3233690
Qty. Description
1
1
1
1
1
2
1
1
2
1
1
1
1
9
1
1
1
1
1
1
1
Bullet, Shifting
Spring, Compression
Washer, Nylon
Plug, Detent, Extension
Dipstick
Seal, Triple Lip
Tube, Vent
Gearcase, RH
Pipe, Knock
Shaft, Shift
Fork, Shift
Gearcase, LH
Decal - Switch
Screw
Plug, Drain
Bushing, Pivot
Washer
Chain, Silent, 60P, 11W
Sprocket, 51T
Shaft, Output
Gear, 64T
11/02
C4
GEAR SELECTOR
1
2
7
5
8
9
10
9
8
11
12
11
Ref. Part No.
1
2
3
4
5
6
5411006
7512024
5411007
1013678-067
7556250
7542324
Qty. Description
1
1
1
1
1
2
Cover
Screw
Knob, Gear Selector
Handle, Gear Selector
Washer
Nut, Nylok
Ref. Part No.
7
8
9
10
11
12
7558402
5435042
7515175
1821491
7542122
7515319
Qty. Description
2
2
2
1
2
2
Washer, Flat
Mount, Gear Selector
Screw
Asm., Shift Linkage
Nut, Nylok
Bolt
9/04
C5
CRANKCASE
7
9
4
10
2
11
12
13
19
12
18
17
16
15
14
Ref. Part No.
1 3083669
2 3086838
3 3087125
4
5
6
7
8
9
3087157
3087116
3086395
3087266
3084205
3084839
Qty. Description
1 Bushing, Starter
2 Pin, Dowel
1 Asm., Crankcase
(Incl. 1-6,9,13,15,18,19)
1 Plug, Blind
2 Pin, Dowel
1 Bearing, Ball
2 Knock, Pipe
3 Screw and Washer
1 Seal, Oil
Ref. Part No.
10
11
12
13
14
15
16
17
18
19
3087128
3087065
3087066
3087155
3084849
3087156
3086749
3082956
3087117
3086399
Qty. Description
1
1
2
1
1
2
1
1
8
1
Gauge, Oil
O-Ring
Union
Plug, Flange
Union, Oil Pump
Bolt, Flange
Plug
Gasket
Bolt, Flange
Bolt, Flange
4/04
C6
CYLINDER
1
7
4
29
1
28
27
26
9
10
11
13
12
10
11
14
25
24
23
15
16

17
11
16
22
17
18
19
21
4
20
Ref. Part No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
3087259
3086414
3087159
3084874
3089272
3089271
3085850
3087034
3084858
3084994
3084798
3084859
3086418
3089270
Qty. Description
2
2
4
13
1
1
1
1
1
2
3
1
4
1
Cover, Valve
O-Ring
Bolt, Flange
Bolt, Flange
Plug
Cover, Breather
Pipe
Gasket, Cover
Seal, Intake Valve
Guide, Valve
Fin, Damper A
Seal, Exhaust Valve
Bolt and Washer
Asm., Cylinder Head
(Incl. 3,4,10-12,16)
Ref. Part No.
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
3086421
3085326
3080530
3086787
3087266
3086407
3087236
3087238
3087050
3083166
3081497
3081330
3086416
3087275
3087160
Qty. Description
1
2
2
2
2
1
1
1
1
1
1
2
1
2
2
Gasket, Exhaust
Stud
Washer, Lock
Nut
Knock, Pipe
Gasket, Cylinder
Cylinder, Unit
Gasket, Head
Adapter
Asm., Adapter Band (Incl. 25)
Screw
Bolt, Socket Head
Gasket, Cam
Knock, Pipe
Bolt, Flange
6/03
C7
CRANKSHAFT and PISTON

1
2
3
4
5
6
15
7
16
8
9
10
15
11
13
12
6
14
Ref. Part No.
1 3087244
3087245
3087246
2 3087241
3087242
3087243
3 3086846
4 3084167
5 3087240
6 3087239
7 3087051
8 3240168
Qty. Description
1
1
1
1
1
1
1
2
2
1
1
2
Ring, Piston Set (STD)

Ring, Piston Set (0.25 O/S)
Ring, Piston Set (0.50 O/S)
Set, Piston (STD)(Incl. 4)
Set, Piston (0.25 O/S)(Incl. 4)
Set, Piston (0.50 O/S)(Incl. 4)
Pin, Piston
Clip, Piston Pin
Bolt, Connecting Rod
Asm., Connecting Rod (Incl. 5,14)
Crankshaft, Complete (Incl. 16)
Key, Woodruff
Ref. Part No.
9 3086434
3086435
3086436
3086437
10 3086492
11 3085528
12 3086767
13 3083905
14 3086426
15 3086427
3086798
3086799
16 3085815
Qty. Description
1
1
1
1
1
1
1
1
2
2
2
2
2
Spacer
Spacer
Spacer
Spacer
Sprocket 1
Nut, Slit
Washer
Nut, Lock
Nut
Bearing (STD)
Bearing (0.05)
Bearing (0.25)
Bearing, Ball
4/04
C8
INTAKE and EXHAUST

4
1
1
2
11
5
6
7
10
21
20
19
22
23
12
18
17
24
26
25
16
27
13
14
28
15
Ref. Part No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
3084911
3084912
3084910
3087053
3085836
3084908
3087203
3087248
3086439
3086804
3087247
3084899
3085778
3086441
Qty. Description
2
2
2
1
1
4
2
2
1
1
1
1
1
1
Screw, Adjusting
Nut
Asm., Rocker Arm (Incl. 1,2)
Shaft, Rocker
Washer, Wave
Collet, Valve
Retainer, Spring, Valve
Spring, Valve
Lever, Release
Spring, Return
Camshaft (Incl. 9-12)
Pin, Dowel
Valve, Intake
Valve, Exhaust
Ref. Part No.
15
16
17
18
19
20
21
22
23
24
25
26
27
28
3086445
3086444
3086448
3086493
3087132
3087131
3087129
3087130
3083361
3086443
3087249
3086449
3086446
3084924
Qty. Description
1
1
1
1
1
1
1
1
2
1
1
1
1
1
Guide, Chain
Chain, Timing
Gasket, Tensioner
Asm., Tensioner
Pin
Spring
Plug
Gasket
Asm., Bolt and Washer
Sprocket 2
Washer
Bolt, Flange
Lever
Bolt, Pivot
4/04
C9
CARBURETOR
45
3
4
44
5
43
7
37
40
41
42
39
38
36
35
34
10
11
33
14
13
12
31
12
15
29
26
16
28
25
27
24
17
23
22
18
21
20
19
C10
30
32
CARBURETOR
Ref. Part No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
3130507
3130508
3131554
3130752
3130732
3131588
3130541
3130540
3130504
3130014
3131458
3130515
------3130518
3130519
3130361
3130594
3130532
3130520
3130590
3130521
3130529
3130591
Qty. Description
1
1
1
1
1
1
2
2
1
1
1
2
1
1
1
1
1
1
4
1
1
1
2
Ring
E-Ring
Needle, Jet
Ring
Asm., Diaphragm
Jet, Needle
Screw
Washer, Spring
Asm., Jet Block
Washer
Jet, Main (#122.5)
Seal
Packing
E-Ring
Cap
Pin, Float
Plate
O-Ring
Screw
Asm., Float Body
Screw
Asm., Float
Screw
Ref. Part No.
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
3131360
3130533
3130526
3131423
3130836
3130502
3130589
3130514
3130501
3130513
3130543
3130535
3130511
3130199
3130538
3131228
3130625
3131590
3084205
3131129
3130503
3130924
Qty. Description
1
1
1
1
1
1
1
1
2
1
1
4
1
1
1
1
1
1
2
1
1
4
Valve, Needle
O-Ring
Jet, Pilot, #42.5
Screw, Adjust
Spring
Valve, Throttle, 100
Spring
Shaft
Screw
Asm., Throttle Shaft
Guide, Cable
Screw
Cover
Cap, Plunger
Spring
Asm., Plunger
Jet, Air , Pilot, #160
Asm., Carburetor (Incl. 1-33,37-45)
Asm., Screw and Washer
Spring
Asm., Cover
Screw
4/04
C11
RECOIL STARTER
7
8
9
14
11
13
10
12
Ref. Part No.
1
2
3
4
5
6
7
8
3084822
3083463
3083378
3083379
3084744
3085266
3086749
3082956
Qty. Description
1
1
1
1
1
1
2
2
Reel
Spring, Return
Ratchet
Spring, Friction
Plate, Friction
Plug
Gasket
Ref. Part No.
9
10
11
12
13
3083669
3083185
3084750
3087150
3087163
3087164
14 3085083
Qty. Description
1
1
1
9
1
1
1
Bushing, Starter
Spring, Power
Bushing
Bolt, Flange
Asm., Recoil (Incl. 1-6,9-11,13,14)
Starter Case (Incl. 11)
Asm., Rope
1/03
C12
OIL PUMP and OIL FILTER

2
3
4
5
6
11
10
9
8
Ref. Part No.
1
2
3
4
5
6
3086749
3082956
3086455
3086222
3087256
3086454
Qty. Description
1
1
1
1
1
1
Plug
Gasket
Spring, Relief Valve
Valve, Oil Relief
Bolt, Flange
Unit, Strainer, Oil
Ref. Part No.
7
8
9
10
11
3084963
3087255
3086450
3086452
3086453
Qty. Description
1
5
1
1
1
Filter, Oil
Screw, Counter Sunk
Cover, Oil Pump
Rotor, Inner
Rotor, Outer
1/03
C13
MAGNETO
2
1
11
10
9
8
7
5
6
Ref. Part No.
1
2
3
4
5
6
3087036
3087037
3070172
3084978
3089275
3081657
Qty. Description
1
1
1
1
1
5
Asm., Ignition Coil (Incl. 3)

Cap, Spark Plug
Plug, Spark
O-Ring
Asm., Plate
Ref. Part No.
7 3089273
3087251
8 4011072
9 7552801
10 7542105
11 3088209
Qty. Description
1
1
1
2
2
1
Asm., Magneto (Incl. 5)

Magneto, Complete
Switch, Magnetic
Washer, Spring Lock
Nut
CDI System
4/04
C14
STARTING MOTOR
4
1
6
7
1
11
12
5
13
10
9
14
15
17
16
Ref. Part No.
1
2
3
4
5
6
7
8
3084981
3084982
3085353
3088169
3083649
3084408
3082038
3085034
3085033
Qty. Description
1
1
1
1
2
3
2
1
1
Asm., Motor, Starting (Incl. 1-5,7-11)

Set, Washer
Asm., Armature
Brush
Nut, Flange
O-Ring
Cover, Rear
Asm., Front Bracket (Incl. 9)
Ref. Part No.
9
10
11
12
13
14
15
16
17
3240114
3084983
3084405
7555908
3084412
3084411
3084410
3084409
3087030
Qty. Description
1
2
2
1
1
1
1
1
1
O-Ring
Asm., Set Bolt (Incl. 5)
Ring, Rubber
Washer, Thrust
Clip
Spring, Weight
Spring, Return
Clip
Asm., Gear Shaft (Incl. 13-16)
4/04
D1
FUEL PUMP

2
Ref. Part No.
3085275
1 3084999
2 3085356
Qty. Description
Ref. Part No.
1 Asm., Fuel Pump (Incl. 1-4)

1 Asm., Screw and Washer
2 Asm., Screw and Washer
3 3084591
4 3084998
Qty. Description
4 Screw
1 Diaphragm, Gasket Set
4/04
D2
TOOL KIT
1
2
3
4
5
6
7
8
Ref. Part No.
1
2
3
4
2874926
2682572
9919482
-------------
Qty. Description
1
1
1
1
1
Ref. Part No.
Tool Kit (Incl. 3,4,5,7,8)

Pouch, Tool Kit
Owners Manual, 05 Trail Boss 330
Wrench, Box, Special
Wrench, 10-12 Spanner
5
6
7
8
------2870725
2874858
-------
Qty. Description
1
1
1
1
Screwdriver
Gauge, Tire Pressure
Wrench, Torx, T-27
Wrench, Open End, 12-14
9/04
D3
This page left blank intentionally.
PRINTED IN THE USA
PARTS MANUAL PN 9919483 and MICROFICHE PN 9919484 9/04

Trail Boss 330

Transféré par

Informations du document

Description originale:

Copyright

Formats disponibles

Partager ce document

Partager ou intégrer le document

Options de partage

Avez-vous trouvé ce document utile ?

Ce contenu est-il inapproprié ?

Droits d'auteur :

Formats disponibles

Trail Boss 330

Transféré par

Droits d'auteur :

Formats disponibles

PARTS MANUAL PN 9919483 and MICROFICHE PN 9919484 9/04

TRAIL BOSS 330

This page left blank intentionally.

A-- ARM/STRUT MOUNTING . . . . . . . . . . . . . B7

BUMPER and RACK MOUNTING . . . . . . . . . A6

INTAKE and EXHAUST . . . . . . . . . . . . . . . . . C9

REAR BRAKE MASTER CYLINDER . . . . . . .

E 2004 Polaris Sales Inc.

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

Ref. Part No.

REAR CAB and SEAT

E 2004 Polaris Sales Inc.

Ref. Part No.

E 2004 Polaris Sales Inc.

Decal, Side Panel, Lower, LH (AA)(FA)

Ref. Part No.

Decal, Front Cover, POLARIS

BUMPER and RACK MOUNTING

E 2004 Polaris Sales Inc.

Ref. Part No.

Nut, Nylok (AA)(AB)

Ref. Part No.

E 2004 Polaris Sales Inc.

Ref. Part No.

E 2004 Polaris Sales Inc.

Ref. Part No.

E 2004 Polaris Sales Inc.

Ref. Part No.

1 Asm., Fuel Tank

Ref. Part No.

E 2004 Polaris Sales Inc.

Ref. Part No.

E 2004 Polaris Sales Inc.

1 Support, Strut and Spindle

Ref. Part No.

E 2004 Polaris Sales Inc.

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

Ref. Part No.

Piston, Brake, Long

REAR CALIPER MOUNTING

E 2004 Polaris Sales Inc.

Asm., Caliper (Incl. 1-6)

Ref. Part No.

Line, Brake, Front M/C to Rear

REAR BRAKE MASTER CYLINDER

E 2004 Polaris Sales Inc.

Ref. Part No.

Asm., Foot Brake Master Cylinder

THROTTLE CONTROL / THROTTLE CABLE

E 2004 Polaris Sales Inc.

Ref. Part No.

1 Cover, Throttle Control

CONTROLS - MASTER CYLINDER/BRAKE LINE

E 2004 Polaris Sales Inc.

Asm., Master Cylinder

Ref. Part No.

1 Kit, Master Cylinder Lever

E 2004 Polaris Sales Inc.

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

Ref. Part No.

Ref. Part No.

E 2004 Polaris Sales Inc.

Panel Indicator Light