POLARIS TRAIL BOSS 2003 Factory Service Repair Manual + Wiring

POLARIS TRAIL BOSS 2003 Factory Service Repair Manual + Wiring

Loaded with illustrations, instructions, photos, and diagrams, complete to service and repair your POLARIS. 

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.