Polaris ATV Trail Boss 325 User Manual

OWNER’S MANUAL SUPPLEMENT
2002 TRAIL BOSS 325
PN 9916980

IMPORTANT: This is a supplement to your owner’s manual. This information should remain with your owner’s manual at all

times.

Capacities

Body Style Gen IV

Gross Vehicle Weight 845 Lbs.

Fuel Capacity 3.7 U.S. Gal

Gearcase Oil 1 1 Ounces

Engine Oil Capacity 1.9 quarts includes oil

cooler 1.7 quarts engine
oil change only

Front Rack (Maximum ­Capacity)

Rear Rack 125 Lbs.

Tongue Weight 30 Lbs.

Tow Hitch Standard

Tow Capacity 850 Lbs.

Turn Radius 60²

Ground Clearance 5.5²

Height 46

Length 76.5

Seat Height 34

Dry Weight 504

Wheel Base 49.5²

Width 40

Accessory (75 Lbs.)

Drive System

Drive System Type PVT

Shift Type Side Lever (F-R-N)

Gear Reduction - Low Not Applicable

Gear Reduction - Reverse 3.05/1

Gear Reduction - Foward 2.68/1

Front Drive (ratio) Not Applicable

Final Drive (ratio) 1 1/40 78P

Center Drive (ratio) Not Applicable

Drive Chain 520 O-Ring

Front Tire 23 x 7-10

Rear Tire 22 x 11-10

Tire Pressure (front) 4

Tire Pressure (rear) 3

Suspension and Brakes

Front Susp. - Mac Strut 6.7² Travel

Rear Susp. - Progresseive
Rate Swing Arm

Shock Adjustment CAM

Front Brake Fixed disc, hydraulic

Rear Brake Hydraulic, opposed

Auxiliary Brake Hydraulic, opposed pis-

Park Brake Hydraulic lock, all wheel

9² Travel

floating caliper

piston caliper, rear axle
fixed disc

ton, caliper, rear axle
fixed disc

Engine & Cooling

Engine Model Number ES-32PFE-09

Engine Type 4 Cycle, Single Cylinder

Lubrication Wet Sump

Bore x Stroke 78 x 68

Displacement 325

Compression Ratio 9.0/1 Effective

Engine Cooling Air with fan assisted oil

cooler

Alternator Output (watts) 200

Carburetion BST31

Main Jet 120

Pilot Jet 50

Needle Jet P-2 (829)

Pilot Air Jet 175

Pilot Screw 2.0 turns

Jet Needle 5F14-2

Ignition CDI

Timing 30° @ 5000 ± 2

Spark Plug Gap .9 mm/.036 in.

Spark Plug Type BKR6E

Exhaust USFS Appr.

1

Features

Headlight (watts) 2 Dual Beam 30/30

Taillight (watts) 8.26

Brake Light (watts) 26.9

3-Point Hitch Not Available

Battery 12V 14 AH

DC Plug In - Rear Accessory

DC Socket - Forward Not Available

High Beam Indicator Standard

High Temp Indicator Standard

Windshield Accessory

Low Oil Light Not Applicable

Neutral Indicator Standard

Reverse Indicator Standard

Speedometer Accessory

Tool Kit Standard

Electric Start Standard

Carburetor Jetting Clutching Chart

Altitude AMBIENT

TEMPERATURE

Meters

(Feet)

0-1800

(0-6000)

1800 & above

(6000 & above)

PN 9916980 Rev 01 5/01
E 2001 Polaris Sales Inc.

Printed in U.S.A.

Below

+40° F

Below +5°

C

115

+40° F&

Above

+5° C&

Above

120 Meters

(Feet)

Altitude Shift

0-1800

(0-6000)

1 17.5 1 12.5 1800 & above

(6000 & above)

Weight

10RH

5630709

16 Mod

5630280

Drive
Clutch
Spring

Blue/

Green

7041157

Blue/

Green

7041157

Driven
Clutch
Spring

Black

7041782

Black

7041782

Driven

Helix

40°

5131446

2+2

40°

5131446

2+2

2