POLARIS TRAIL BOSS 2003 Service Repair Manual + Wiring

POLARIS TRAIL BOSS 2003 Service Repair Manual + Wiring

Loaded with illustrations, instructions, photos, and diagrams, complete to service and repair your POLARIS. Read and print pages, or copy the entire manual to your hard drive.

210 Pages

Models Covered :  

 POLARIS TRAIL BOSS 2003

Model Year:

 2003

Manual Covers :

• General Information
• Maintenance
• Engine
• Fuel System
• Body
• Suspension
• PVT System
• Final drive
• Transmission
• Brakes
• Electrical
• Wiring Diagram

This manual is the same as the manual used by workshops. Service Manual contains detailed instructions and step by step diagrams for all workshop procedures.

 Language: English 
Format: PDF – Indexed and Searchable

COMPATIBLE WITH ALL WINDOWS & MAC COMPUTERS 
(WINDOWS 11, WINDOWS 10, WINDOWS 8 ETC.) 

Windows/Mac/Tablet/Phone Friendly

• Starting issues: This is a frequent complaint, which can often be linked to electrical problems.
  • Starter solenoid failures: The starter solenoid can fail, causing the engine not to start when turning the key. To troubleshoot, you can test for 12V power at the white/red wire going to the solenoid.
  • Ignition switch: A bad ignition switch or wiring harness can also cause no-start conditions, especially when there is no electrical power or the key fails to engage the starter.
  • Carburetor issues: If the engine starts but stalls without the choke, it likely indicates a dirty carburetor, clogged pilot jets, or improper idle speed adjustment.
• Recalled fuel tank grommet: The 2003 Trail Boss 330 was included in a recall related to a faulty fuel tank grommet that could cause a fuel leak and fire hazard.
• Overheating: Overheating and related temperature light problems can occur. This could be caused by issues with the oil cooler, cooling fan sensor, or trapped air in the cooling system.
• Charging system failures: Some owners report issues with the electrical charging system, which may be caused by a faulty stator or problems with the Electronic Control Module (ECM). Checking the wiring harnesses for damage is a necessary step.
• Starter grinding: If you hear a grinding noise from the starter, it could be a sign of a sticking starter solenoid or a worn starter gear. 

• Engine: 329cc, 4-stroke, single cylinder, air with fan-assisted oil cooler.
• Carburetion: BST34 Mikuni carburetor.
• Transmission: Variable PVT automatic, with forward, neutral, and reverse.
• Weight: 505 pounds (dry weight).
• Tires: 23×7-10 (front) and 22×11-10 (rear).
• Fuel tank capacity: 3.5 gallons. 

• Used vehicles: Since the 2003 Trail Boss is an older model, the only option is the used market. Check online marketplaces like eBay or dealerships that specialize in used ATVs.
• Used parts: Online marketplaces like eBay list a wide variety of used and new parts for the 2003 Polaris Trail Boss 330, including axle shafts, solenoids, and clutches.
• Aftermarket parts: Retailers such as Dennis Kirk and RevZilla carry parts and accessories for the 2003 Trail Boss 330.
• Repair manuals: The owner’s manual supplement for the 2003 Trail Boss 330 can be found on the Polaris website.