Cylinder Out of Round Limit:. Remove the two 6x25 mm cam chain tensioner flange bolts. Consequently the vacuum slide 2 moves upward. Turn clutch sheave counterclockwise until 8. Screw and Washer Assembly 4. Replace bearing if moisture, dirt, corrosion, or roughness is evident.
Replace if excessively worn or damaged. If proper Belt belt deflection cannot be obtained, measure drive belt Width width, length, and center distance of drive and driven clutch, outlined in this section;. Remove the anvil bolts and separate caliper halves and remove pistons with piston pliers. Inspect the crankshaft main bearings. Use new bolts with pre-applied 37 Nm locking agent. The fuel in float chamber 3 is metered by main jet 4 , and the metered fuel enters needle jet 5 , in which it mixes with the air admitted through main air jet 6 to form an emulsion.
Place a drain pan beneath the transmission oil drain plug area. Replace the disc if any deep scratches are evident. E Emission Control System Service California J Have an authorized Polaris dealer perform these services. Each section has sub-sections wich titles appear in smaller print than the section title. Remove spark plug high tension lead.
Ball Joint 41 Nm Stud A-Arm Tube A-Arm Shaft 25 ft. Recharge to full capacity every Maintenance batteries. Use either of the following methods to remove and install a new garter spring. If the and possibly more often in very dirty filter has been soaked with fuel or oil it must be conditions. This procedure should be used to change fluid or bleed brakes during regular maintenance. Torque to 8- -10 ft.
Push mounting bracket inward and slip outer brake pad past edge. If oil level begins to rise, discontinue use and determine cause. Piston should slide in and out of bore smoothly, with light resistance. Visually inspect disc for scoring, scratches, or gouges. Different types of batteries require different service procedures. Severe injury may occur if machine tips or falls.
Lubricate mounting bracket pins with a light film of Polaris Premium All Season Grease, and install rubber dust boots. Inspect output shaft gear, sprocket and bearing. Install moveable sheave with spacer washers. Loosen two eccentric clamp bolts. Remove ramp buttons from moveable sheave.
Cylinder Removal Follow engine disassembly procedures to remove valve cover, camshaft and rocker arms, and cylinder head. Inspect it for wear or damage. Doing so will damage the case and shorten the life of the battery. Cylinder Standard Bore Size: 3. Remove drive chain and sprocket.
Replace starter drive if gear teeth are cracked, worn, or broken. Center the pilot screw between the points in Step Lock- 5 and 6. The headlight beam can be adjusted up and down and side to side. Install spindle nut and tighten to specification. Polaris Trailboss 330 2009 Factory Service Repair Manual meets all your information needs to repair or make some adjustments to your Polaris Trailboss 330 2009. All models for the above stated years and all engine types are included. Remove cylinder block plug using a 14 mm hex spring if excessively worn.
Hold strut rod and remove top nut. Place the transmission in neutral and start the reservoir to the indicated level inside engine. Torque Specifications and Special Tools. Screw and Washer Assembly 6. Inspect surface of commutator for wear or discoloration.
Remove skid plate if necessary. Inspect shift fork shaft O-ring. Place the carburetor on a level surface as shown Float arms even at right to remove weight from float arm. Center Distance: Distance between center of crankshaft and center of driven clutch shaft. Always use genuine Polaris parts. Lower the vehicle to the ground.