TRAIL BOSS Model #A01AA32AA Model #A01AA32AB TRAIL BOSS 325 SE Model #A01AA32AC Rev. 02. E 2000 Polaris Sales Inc.

Transcription

1 TRAIL BOSS Model #A0AAAA Model #A0AAAB TRAIL BOSS SE Model #A0AAAC Rev. 0 E 000 Polaris Sales Inc. PARTS MANUAL PN and MICROFICHE PN /0

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3 TABLE OF CONTENTS Trail Boss A0AAAA and TRAIL BOSS A0AAAB and Trail Boss SE A0AAAC Parts Manual A-ARM/STRUT MOUNTING... AIR BOX... AIR BOX (If built after /0/0)... B BUMPER and RACK MOUNTING... A C B A A A CARBURETOR... D- CLUTCH COVER... C CONTROLS - MASTER CYLINDER/BRAKE LINE... B CRANKCASE... C CRANKSHAFT and PISTON... C CYLINDER... C0 DECALS... DRIVE CLUTCH... DRIVEN CLUTCH... D E A C C ELECTRICAL/TAILLIGHT... C ENGINE MOUNTING... A- EXHAUST SYSTEM... A FRONT BRAKE... FRONT CAB... FRONT WHEEL... FUEL PUMP... FUEL TANK... GEAR SELECTOR... F G B A B D A C GEARCASE... C- GEARCASE MOUNTING... C HEADLIGHT G H... INTAKE and EXHAUST... I M MAGNETO... OIL COOLING... OIL PUMP and OIL FILTER... REAR BRAKE MASTER CYLINDER... REAR CAB... REAR CALIPER MOUNTING... REAR HOUSING... REAR WHEEL DRIVE... RECOIL STARTER... O R S A0 C D B C B A B B B0 C STARTING MOTOR... D STEERING - HANDLEBAR... B STEERING POST... B- STRUT... B SWING ARM/SHOCK MOUNTING... B TAILLIGHT/ELECTRICAL... C THROTTLE CONTROLS / THROTTLE CABLE A TOOL KIT... D T The illustrations used in this Parts Manual are for reference to replacement parts only. This manual is not to be used for assembly.

4 FRONT CAB TRAIL BOSS A0AAAA and TRAIL BOSS A0AAAB and TRAIL BOSS SE A0AAAC E 000 Polaris Sales Inc. 0 0 Screw 000 Nut, Speed - -0 Cover, Fuel Tank, White (AA)(AB) Cover, Fuel Tank, Med. Yellow (AC) Cover, Headlamp, Red (See Headlight Pg. A0, Ref. ) 00 Clip, Dart 0 Shield, Splash, LH 0 Rivet Cab, Front, White (Incl. Warning Decals)(AA)(AB) Cab, Front, Med Yellow (Incl. Warning Decals (AC) 0 Plug, Rack Hole 0 0 Bolt A 0 Washer, Flat 0 Washer, Flat Nut, Nylok 0 0 Mudflap, Front, LH Mudflap, Front, RH Footpad (See Bumper and Rack Mounting Pg. A, Ref. ) Shield, Splash, RH Tape, Foil Rivet -0 Strap, Fuel Pump Mounting Cover, Side Panel, Red, LH (AA)(AB) Cover, Side Panel, Red, RH (AA)(AB) Cover, Side Panel, Med Yellow, LH (AC) Cover, Side Panel, Med Yellow, RH (AC) /0

5 REAR CAB TRAIL BOSS A0AAAA and TRAIL BOSS A0AAAB and TRAIL BOSS SE A0AAAC 0 LH, RH Clip, Lid Hinge 0 Compartment, Tool Rivet 00 Decal - Carb/Filter Information 0 Grommet Rivet 0 Bumper, Rubber Asm., Seat, Red (Incl. -)(AA)(AB) Cover, Seat, Red (AA)(AB) Asm., Seat, Black (Incl. -)(AC) Cover, Seat, Black (AC) 0 Latch, Seat 0 0 Spring, Latch 0 Bracket, Lever Retainer 0 Rivet Screw 0 Washer, Flat - -0 Cab, Rear, White (AA)(AB) Cab, Rear, Med Yellow (AC) A 00 Bracket, Rear Seat Holddown 0 0 Foil, Rear Cab Foil, Rear Cab, Small 00 Tape, Foil Rivet Guard, Clutch Bolt Foot Pad (See Bumper and Rack Mounting Pg. A, Ref. ) 0 0 Mudflap, Rear, Lower, LH Mudflap, Rear, Lower, RH Nut, Nylok Mudflap, Rear, LH Mudflap, Rear, RH Washer, Flat Cover, Tool Box, White (AA)(AB) Cover, Tool Box, Med Yellow (AC) 0 Strap, Tool Compartment /0

6 BUMPER and RACK MOUNTING TRAIL BOSS A0AAAA and TRAIL BOSS A0AAAB and TRAIL BOSS SE A0AAAC Rack, Rear 0 Pad, Rack Mount Bolt 0 Screw Washer, Flat 00 Bushing 0 Dampener, Vibration -0-0 Bracket, Support Rack, LH Bracket, Support Rack, RH Nut, Flange 0 00 Plug, Rubber Hole 00-0 Support, Rear Fender 0 Washer, Rubber Nut, Nylok Frame, Main (AA) Frame, Main (AB)(AC) 0 Plug, Frame Bolt 0 Washer, Flat 00-0 Bumper (If built after //00) A Rivet (Used only with 0-0) 0 0 Cover, Bumper Mounting Bracket (Used only with 0-0) 0-0 Bumper (If built before //00) Screw Cap, Front Bumper, Red (AA)(AB) Cap, Front Bumper, Black (AC) Washer, Flat Screw Guard, Rock Bolt 0-0 Footpad Nut, Nylok 0 Rivet Trim, Footrest -0 Bracket, Heel Cleat Rivet Plug, End Cap 0 Reflector, Red /0

7 DECALS TRAIL BOSS A0AAAA and TRAIL BOSS A0AAAB and TRAIL BOSS SE A0AAAC LH 0 0 RH 00 Decal - MacPherson Strut 0 Logo - Polaris Star Kit - Trail Boss Tank Decals (AA)(AB) (Contains 00, LH and 0, RH) Decal - Tank Side, LH (AC) Decal - Tank Side, RH (AC) 0 00 Decal - Override Switch, WD (AA)(AB) Decal - Override Switch, WD (AC) 0 Decal - Warning, Age 0 Decal - x, CDS A 00 Decal - Passenger Warning 0 Decal - Warning, Rear Rack 00 Decal - Tire Pressure/Load Decal - Side Panel, POLARIS (AA)(AB) Decal - Side Panel, POLARIS (AC) 00 Decal - Discretionary Warning 0 Decal - Fuel Lever 00 Decal - Warning, General, CPSC /0

8 ENGINE MOUNTING TRAIL BOSS A0AAAA and TRAIL BOSS A0AAAB and TRAIL BOSS SE A0AAAC A

9 ENGINE MOUNTING TRAIL BOSS A0AAAA and TRAIL BOSS A0AAAB and TRAIL BOSS SE A0AAAC 000- AR Line, Fuel 00 Fitting, Tee Nut, Nylok 0 Washer, Flat -0 Bracket, Carburetor Mount 00 Screw and Washer 0 Nut, Flange Lock 00 Cable, Ground, Engine Screw 0 Bolt 0 Washer, Spring Lock 0 Mount, Rubber 00 Insulator, Motor Mount Washer, Flat 0-0 Bracket, Motor Mount, top 0 Decal - Drain Recoil 00 Clamp Boot, Clutch Intake AR Line, Fuel Engine, Short Block (ESPFE0/0)(If built before /0/00)NOTE: The Short Block assembly contains a crankcase assembly, cylinder and cylinder head assembly, and a piston and crankshaft assembly. Prior authorization required for warranty consideration. Engine, Short Block (ESPFE0)(If built after /0/00) NOTE: The Short Block assembly contains a crankcase assembly, cylinder and cylinder head assembly, and a piston and crankshaft assembly. Prior authorization required for warranty consideration. Washer 00 Mount, Rubber, Front 0-0 Mount, Engine, Rear 0 Nut, Flange Lock Screw -0 Mount, Lower Front 0 Bushing 0 Washer, Flat Bolt 0 0 Washer, Flat 000 Cable, Battery/Engine 0000 Clamp, Hose AR Line, Fuel 000 Filter 0 Nut, Nylok 000 Mount, Carburetor 0/00 A

10 EXHAUST SYSTEM TRAIL BOSS A0AAAA and TRAIL BOSS A0AAAB and TRAIL BOSS SE A0AAAC Nut, Nylok Washer, Flat 0 0 Washer, Rubber 0 00 Bushing 0 Dampener, Vibration Bolt, Carriage 0-0 Silencer Bolt 00 Mount, Torque Stop 0 0 Nut -0 Bracket, Mount, Silencer Screw 0 Screw Insert Washer A Asm., Exhaust Shield (If built before /0/00) Foam, Foil (If built before /0/00) Asm., Exhaust Shield (If built after /0/00) Foam, Foil (If built after /0/00) 0 Spring, Extension 00 Spring, Exhaust Seal, Exhaust Nut, Speed Screw Rivet 0 Screw -0 Bracket, Exhaust Shield -0 Bracket, Exhaust Pipe Support 00-0 Manifold 0-0 Headpipe 0/00

11 HEADLIGHT TRAIL BOSS A0AAAA and TRAIL BOSS A0AAAB and TRAIL BOSS SE A0AAAC Cover, Headlamp Socket 000 Bulb, Headlamp 00 Retainer, Headlamp Bulb 00 Asm., Headlamp w/bulb Seal (Incl. -) - -0 Cover, Headlamp, Red (AA)(AB) Cover, Headlamp, Med Yellow (AC) 000 Screw 00 Screw, Adjusting 000 Cable, Choke Switch, Ignition (Incl.,) Blank, Key, Series 000, 00, 00 Blank, Key, Series 00, 00, 00, 00. 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. A0 0-0 Bracket, Ignition Panel 00 Bulb Panel, Indicator Bulb Panel, Ignition Cover, Key Nut, Ignition Switch 00 Nut, Choke 000 Spring, Adjust 0 Screw 00 Spring, Adjust 0 0 Reflector, Amber /0

12 FUEL TANK TRAIL BOSS A0AAAA and TRAIL BOSS A0AAAB and TRAIL BOSS SE A0AAAC Cap, Gas Tank (Incl. ) Gasket AR Line, Fuel 0 Vent, Tank Screw 0 Washer, Spring Lock Washer, Flat -0-0 Bracket, Mounting, Rear, LH Bracket, Mounting, Rear, RH Washer, Flat 0 Seal, Foam 0 Tube A 0 Nutsert 0 Pad, Fuel Tank Bracket 0 Screw Knob, Fuel Valve Nut, Fuel Valve 00 Clip, Routing 0 Valve, -Way AR Line, Fuel Clamp, Hose, Red 0 Fitting, Fuel Outlet, Reserve 0 Fitting, Fuel Outlet, Main 0 Asm., Fuel Tank (Incl.,,) 0/00

13 AIR BOX TRAIL BOSS A0AAAA and TRAIL BOSS A0AAAB 0 0 Screw Duct, Inlet Gasket, Intake Cover, Air Box Seal, Cover Nut, Nylok Washer, Flat Hose, Breather 00 Clamp, Hose 0 00 Clamp, Hose 0 Gasket, Carburetor Inlet Duct 0 Duct, Carburetor Inlet 00 Clamp, Narrow Band Boot, Carburetor A 00 Clamp, Narrow Band Cap, End 00 Clamp, Hose Box, Air, Intake 0-0 Mount, Air Box 0 Screw 0 Foil, Air Box Plug, Trap 00-0 AR Line, Fuel 000 Clamp, Hose 0 Clip 0 Collar, Carburetor Inlet 00 Filter, Air Intake Filter, Precleaner Sleeve /00

14 AIR BOX (If built after //00) TRAIL BOSS A0AAAB and TRAIL BOSS SE A0AAAC Screw Washer, Flat Filter, Air Box Vent 0 Seal, Intake Duct, Inlet Screw 0 Pad, Fuel Tank Bracket Cover, Air Box Seal, Air Box Cover 0 0 Clip 0 Collar, Carb Inlet 00 Clamp, Hose 0 Cap, Rubber Hose, Breather 00 Clamp, Narrow Band Boot, Carburetor 00 Clamp, Narrow Band 0 Duct, Carb Inlet 0 Gasket, Carb Inlet 0 Box, Air Intake, Stroke Washer, Nylon Plug, Trap Foil, Air Box, RH 000 Clamp, Hose 0 Cap, Rubber 00 Clamp, Narrow Band 0 Precleaner Asm., Filter (Incl. ) /0 A

15 THROTTLE CONTROL / THROTTLE CABLE TRAIL BOSS A0AAAA and TRAIL BOSS A0AAAB and TRAIL BOSS SE A0AAAC Cover, Throttle Control O-Ring O-Ring Cable, Throttle (If built before /0/0) Cable, Throttle (If built after /0/0 Asm., Throttle Control (Incl. ) (If built before /0/0) Asm., Throttle Control (Incl. ) (If built after /0/0) 00 Asm., Throttle Clamp 0/00 A

16 CONTROLS - MASTER CYLINDER/BRAKE LINE TRAIL BOSS A0AAAA and TRAIL BOSS A0AAAB and TRAIL BOSS SE A0AAAC 0 00 Asm., Master Cylinder (Incl. -) 00 Line, Brake, Pod 0 Switch 00 Line, Brake 0 Kit - Master Cylinder Cap (Incl. Cap, Screws, Sight, Gasket) Screw 0 Kit - Master Cylinder Park Brake Lever (Incl. Lever, Spring) 0 Kit - Master Cylinder Clamp (Incl. Clamp, Screws) 0 Kit - Master Cylinder Lever (Incl. Pin, Lever, Clip) 00 Clamp, Nylon 0 Rivet, Pop 0 Line, Brake, Left Front 0 Screw 0 Line, Brake, Right Front 0 Fitting, Cross /00 B

17 STRUT TRAIL BOSS A0AAAA and TRAIL BOSS A0AAAB and TRAIL BOSS SE A0AAAC 0 00 Grommet 0 Nut, Nylok, Thin Washer 0 Spacer, Rubber Pivot, Ball, Top Pivot, Ball, Bottom 0 Spacer Retainer, Spring 00-0 Spring, Compression 0 0 Bumper B 0 Strut, Front 00 Clamp, Cable Nut, Nylok 0 Washer, Flat 000 Fitting, Lubrication Bolt 0 00 Support, Strut/Spindle, LH Support, Strut/Spindle, RH Washer /00

18 A- ARM/STRUT MOUNTING TRAIL BOSS A0AAAA and TRAIL BOSS A0AAAB and TRAIL BOSS SE A0AAAC E 000 Polaris Sales Inc Nut, FLEXLOC Bushing 0 Boot, Seal Boot, Seal, Rod End 00 Rod End, RH Nut 00 Tie Rod Screw 00 Rod End, LH 0 0 Nut, Jam, LH 00 Asm., Tie Rod (Incl. -) 0 Washer, Flat 0 Nut 0 Pin, Cotter 0 Bracket, Ball Joint Screw Nut, Castle 0 Boot, Rubber 00 Joint, Ball Support, Strut/Spindle (See Strut Pg. B, Ref. ) 0 Bushing, A-Arm, Long 00 Bushing 00 Fitting, Lubrication Kit, A-Frame, LH (Incl. -,,) Kit, A-Frame, RH (Incl. -,,) 00 Shaft, A-Arm Screw 0 Washer, Spring Lock Screw /00 B

19 FRONT WHEEL TRAIL BOSS A0AAAA and TRAIL BOSS A0AAAB and TRAIL BOSS SE A0AAAC Support, Strut and Spindle (See Strut Pg. B, Ref. ) 000 Seal, Hub, Front Bearing, Ball Disc, Brake 00 Hub, Wheel (If built before //00) Hub, Wheel (If built after //00) Tire, Front (x-0) Rim, Front (AA)(AB) Rim, Front (AC) 0 Valve, Rim 00 Spacer, Hub, Front 0 Washer Nut, Castle 0 Pin, Cotter Screw (If built after //00) 0 Cap, Hub (If built before //00) Cap, Hub (If built after //00) 00 O-Ring Nut, Flange Lock Stud Bolt /0 B

20 FRONT BRAKE TRAIL BOSS A0AAAA and TRAIL BOSS A0AAAB and TRAIL BOSS SE A0AAAC 0 0 Asm., Front Brake Caliper, LH (Incl. -,,0) 0 Asm., Front Brake Caliper, RH (Incl. -,,0) 00 Screw, Bleeder Screw, Socket Set 0 0 Caliper,Brake,LH(AB) Caliper,Brake,RH(AB) Kit - Front Brake Boot (Incl. 0,) 0 Kit - Piston and Seal (Incl. -) 0 Ring, Molded Square (.0) 00 Ring, Molded Square (.0 x.) Piston, Brake, Long 0 Kit - Front Brake Pad (Complete Set of Pads) 0 Mount, Caliper 0 0 Boot, Bushing 0 Boot, Pin Seal 0 Washer, Flat 0 Washer, Spring Lock Screw 0/00 B

21 STEERING - HANDLEBAR TRAIL BOSS A0AAAA and TRAIL BOSS A0AAAB and TRAIL BOSS SE A0AAAC Asm., Throttle Control (See Throttle Control/Throttle Cable Pg. A, Ref. ) -0 Tube, Handlebar Screw Screw 0 Washer Pad, Handlebar 0 Mount, Handlebar Pad Kit - Handlebar Block (Incl.,,) Block, Handlebar B Asm., Master Cyl. (See Controls-Master Cylinder/Brake Line Pg. B for Details) 0 0 Spacer, Switch 00 Switch, Handlebar -00 Grip, Handlebar Plug, Hole Screw, Set 00 Clip, Cable Retaining Nut, Nylok 0/00

22 STEERING POST TRAIL BOSS A0AAAA 0 0 Asm., Steering Post (Incl.,) Bushing, Steering, Console 000 Fitting Bracket, Ignition Panel (See Headlight Pg. A0, Ref. 0) Bolt Rivet 0 O-Ring Washer B Pin, Cotter 0 0 Nut, Hex, Slotted Spacer, Steering Post 0 Bushing, Steering, Lower Plug, Grease 00 Fitting, Lubrication Bushing, Steering, Upper -0 Bracket, Upper Steering Bushing Nut, Nylok /00

23 STEERING POST TRAIL BOSS A0AAAB and TRAIL BOSS SE A0AAAC S 0 Nut, Nylok 000 Fitting, Zerk Bushing, Steering, Upper 0-0 Post, Steering Bracket, Steering Post Bolt, Carriage Bushing Flangette Bearing 0 Nut Pin, Cotter 0 Washer, Flat /0 B

24 REAR HOUSING TRAIL BOSS A0AAAA and TRAIL BOSS A0AAAB and TRAIL BOSS SE A0AAAC Ring, Retaining 0 Retainer, Nut 0 Nut, Jam Seal, Foam Nut, Nylok Disc, Brake Stud 0 Asm., Brake Disc Hub (Incl. ) 0 00 Ring, Retaining (If built before 0//00) Ring, Retaining (If built after 0//00) 0 00 Spacer, Axle 0 O-Ring 000 Seal B Bearing, Cone, Tapered Bearing, Cup, Tapered 0 Housing, Axle, Rear 000 Fitting, Lubrication 0 Link, Connector Axle, Rear 0-0 Chain, 0, O-Ring 0 0 Nut, Flange Lock -0 Guard, Sprocket, T 0 Spacer 0 Sprocket, 0T 0 Asm., Sprocket Hub (Incl. ) 0 Bolt 0/00

25 REAR WHEEL TRAIL BOSS A0AAAA and TRAIL BOSS A0AAAB and TRAIL BOSS SE A0AAAC 0 Bolt Hub, Rear Wheel, Large Flange Nut Washer, Cone 00 Nut, Castle 0 Pin, Cotter Cover, Dust, Hub Washer, Flat 0 Valve, Rim 0 00 Pushnut Rim, Rear, White (AA)(AB) Rim, Rear, Black (AC) Tire (x-0) /0 B0

26 SWING ARM/SHOCK MOUNTING TRAIL BOSS A0AAAA and TRAIL BOSS A0AAAB and TRAIL BOSS SE A0AAAC 0 0 Nut, Nylok Spring, Comp. (If built before /0/0) Spring, Comp. (If built after /0/0) 0 Cam, Adjusting 0 00 Shock, Rear (If built before /0/0) Shock, Rear (If built after /0/0) 0 Retainer, Spring Screw 0 Rivet Guide, Pad, Chain 000 Fitting 0 0 Nut 0 Washer, Flat Bushing, Swing Arm, RH Bolt, Swing Arm Pivot Bushing, Swing Arm Pivot, RH B 0 Asm., Swing Arm (Incl.,,) 0 Decal - Chain Free Play Guard, Chain 0 Screw Bushing 0 0 Washer, Flat Nut, Flange 0 Nut, Nylok Washer 0 Decal - Hitch 00 Kit - Hitch (Incl. -) Bolt Screw Bushing, Swing Arm, LH Bushing, Swing Arm Pivot, LH /0

27 REAR CALIPER MOUNTING TRAIL BOSS A0AAAA and TRAIL BOSS A0AAAB and TRAIL BOSS SE A0AAAC Frame 0 Screw 0 Washer, Flat 0 Asm., Caliper 0 Seal 00 Line, Brake 00 Line, Brake, Foot, Rear 00 Clamp, Nylon Rivet 00 Clip, Silencer 0 0 Bolt, Banjo Bushing, Caliper Mount B 0 Washer, Flat 0 Washer, Spring Lock Bolt Mount, Caliper, Lower Mount, Caliper, Upper Bolt -0 Guard, Disc, Brake Kit - Brake Pad (Incl. Spacer and Pin) Spacer Pin /00

28 REAR BRAKE MASTER CYLINDER TRAIL BOSS A0AAAA and TRAIL BOSS A0AAAB and TRAIL BOSS SE A0AAAC 0 0 Bolt 0-0 Bracket, Reservoir Mount Nut, Nylok 0 Screw 0000 Clamp, Hose 0 Hose, Reservoir 0 Reservoir Screw Guard, Prop Shaft, Side 0 0 Pin, Cotter Washer 0 Bushing 0-0 Mount, Brake 0 Bolt, Banjo 0 Seal Line, Foot Brake, Rear (See Rear Caliper Mounting Pg. B, Ref. ) 0 Washer, Spring Lock Screw 0 Asm., Foot Brake Master Cylinder 0 Nut, Nylok 0-0 Rod, Brake 00 Spring, Torsion Screw 0/00 B

29 OIL COOLING TRAIL BOSS A0AAAA and TRAIL BOSS A0AAAB and TRAIL BOSS SE A0AAAC 0 0 Kit - Oil Hose, Integrated Valve (Incl.,) 0 Hose, Cooler, /, 0 Degree Nut, Nylok -0 Bracket, Cooling Fan (If built before /0/00) -0 Bracket, Oil Cooler (If built after /0/00) Screw Screw 0 Motor, Fan 0 U-Clip Shroud 0 00 Thermister 0 Washer, Flat 0 Washer, Lock Screw 0 Valve, Plastic B 00 0 Cooler, Oil to Air (If built before //0) Cooler, Oil (If built after //0) 0 Rivet Shroud, Cooler, LH (If built before /0/00) Shroud, Cooler, RH (If built before /0/00) Shroud, Cooler, LH (If built after /0/00) Shroud, Cooler, RH (If built after /0/00) Mount, Rubber 00 Bracket, Lower 0 00 Clamp, Hose 00 Clamp, Hose 0 0 Hose, Cooler (If built before //0) Hose, Oil Cooler (If built after //0) 00 P-Clamp 00 Cable Tie /0

30 CLUTCH COVER TRAIL BOSS A0AAAA and TRAIL BOSS A0AAAB and TRAIL BOSS SE A0AAAC Nutsert 0-0 Bracket, Clutch Cover Screw 0 Seal, Cover Washer, Flat Seal 00 Kit - Inner Clutch Cover (Incl.,,) Shield 0 Bolt w/rubber Washer 0 0 Duct, Inlet 0 Seal, Clutch Cover 000 Clamp, Narrow Band Cover, Clutch, Front 00 Clip, Clutch Cover 0 Screw 0 Decal - Clutch Cover Warning 0 Decal - Automatic Transmission 0 Screw 00 Cable Tie 0 0 Boot, Clutch Intake Screw Duct, Clutch, Outlet 0 Spacer 00 Screw and Washer 00-0 Bracket, Retainer, Seal 0 Seal, Cover, Case 0/00 C

31 DRIVE CLUTCH TRAIL BOSS A0AAAA and TRAIL BOSS A0AAAB and TRAIL BOSS SE A0AAAC 0 Bolt 0 Washer, Spring Lock 0 Bearing, Cover 0 Spring, Clutch 0 Washer, Multilube Roller and Bushing Button, Clutch AR AR AR AR Spacer (.00) Spacer (.0) Spacer (.0) Spacer (.00) 00 Weight, Shift (0RH) 0 Bolt, Shoulder 0 Nut, FLEXLOC 0 Bearing, Moveable, /I 00 Pin, Roller Asm., Drive Clutch, ATV-0, (Incl. All Less,) / C

32 DRIVEN CLUTCH TRAIL BOSS A0AAAA and TRAIL BOSS A0AAAB and TRAIL BOSS SE A0AAAC 0 0 AR Bushing 0 Belt, Drive Asm., Driven Clutch (Incl. -) 0 Washer, Domed 0 Washer, Spring Lock Bolt AR Washer 0 AR Washer 0 AR Washer C 0 0 Bearing, Moveable, / Bearing, Moveable, 0 Spring, Clutch, Black Ramp, Stationary 0 Spacer 0 Ring, Retaining Bolt 0 Button, Ramp /

33 ELECTRICAL/TAILLIGHT TRAIL BOSS A0AAAA and TRAIL BOSS A0AAAB and TRAIL BOSS SE A0AAAC Harness, Main 0 Kit - Circuit Breaker, Fan -0 Isolator, Taillight 0 Rivet, Pop 00 Nut, Speed Washer, Nylon 0 Taillight w/brake Light 00 Lens, Taillight 00 Screw, Taillight Bulb, Taillight 00 Gasket, Taillight 00 Backing, Taillight/Brake Light 00 Clip, Rosebud 00 Cable Tie 00 Clip, Routing 0 Screw 0 Screw 00 Limiter, LR- Nut, Nylok 0 0 Washer Sink, Heat C 00-0 Trim, Edge 00 Rectifier, Regulator, LR 00 Switch, Thermistor, LR0 00 Bolt 000 Cable, Solenoid/Starter Switch, Magnetic (See Magneto Pg. D, Ref. 0) 000 Cable, Battery/Solenoid 0 Screw Battery 00 Pad, Battery 00 Clip, Silencer 0 AR Tube, Battery Vent 0 Strap, Battery Holddown 000 Hook, Battery Strap 000 Cable, Battery/Engine 00 Kit - Battery Bolt, Short Cover, Battery -0 Bracket, Taillight Mount 0 Rivet /00

34 GEARCASE MOUNTING TRAIL BOSS A0AAAA and TRAIL BOSS A0AAAB and TRAIL BOSS SE A0AAAC + 0 Screw 0 Nut, Flange -0 Bracket, Transmission Mount Screw 0 Washer, Flat 0 0 AR AR AR Shim (.00) Shim (.00) Shim (.00) 0-0 Mount, Transmission -0 Spacer Screw 0 Screw 0 Nut Plug, Drain (See Gearcase Pg. C, Ref. ) 0 Ring, Retaining 0 Sprocket, T 0 Screw 0/00 C

35 GEAR SELECTOR TRAIL BOSS A0AAAA and TRAIL BOSS A0AAAB and TRAIL BOSS SE A0AAAC 0 00 Cover 0 Screw 00 Knob, Gear Selector Spacer, Shifter 0 Mount, Gear Selector 00 Rod End, mm, RH 0 Nut, FLEXLOC 0 Nut, RH Rod, Shift Linkage 0 0 Nut, LH 00 Rod End, mm, LH Washer, Flat Bolt 0-0 Handle, Gear Selector /00 C

36 GEARCASE TRAIL BOSS A0AAAA and TRAIL BOSS A0AAAB and TRAIL BOSS SE A0AAAC C

37 GEARCASE TRAIL BOSS A0AAAA and TRAIL BOSS A0AAAB and TRAIL BOSS SE A0AAAC 0 Asm., Gearcase (Incl. -) 0 Bearing Ring, Retaining Washer, Thrust Sprocket, T 00 Washer, Thrust Dog, Engagement, High/Reverse Shaft, Input Gear, T Bushing 0 0 Washer 0 Ring, Retaining 0 Bearing 0 Nut 0 Washer Bellcrank 0 Ring, Retaining 00 Washer O-Ring Shaft, Shift 0 Switch Screw 0 Bullet, Shifting Spring, Compression Washer Plug, Detent, Extension Dipstick Seal Tube, Vent Gearcase, RH 0 Pipe, Knock Shaft, Shift Fork, Shift Gearcase, LH Decal - Switch Screw Plug, Drain Bushing, Pivot 0 Washer Chain, Silent, 0P, W 0 Sprocket, T Shaft, Output 0 Gear, T / C

38 CRANKCASE TRAIL BOSS A0AAAA and TRAIL BOSS A0AAAB and TRAIL BOSS SE A0AAAC Bushing, Starter 000 Pin, Dowel 00 0 Asm., Crankcase (Incl. -,,,,,0)(AA) Asm., Crankcase (Incl. -,,,,,0)(AB)(AC) 0 Plug (AB) 00 Pin, Dowel 0 Bearing, Ball 0 Pin, Straight 00 Screw and Washer 0 Seal, Oil Gauge, Oil (AA) Gauge, Oil (AB)(AC) 00 O-Ring 00 Union 0 Plug Union (If built before //0) Union (If built after //0) 0 Union, Oil Pump 0 Bolt, Flange 0 Plug 0 Gasket 0 Bolt, Flange 0 0 Bolt, Flange /0 C

39 CYLINDER TRAIL BOSS A0AAAA and TRAIL BOSS A0AAAB and TRAIL BOSS SE A0AAAC Cover, Valve 0 O-Ring 0 Bolt, Flange 0 Bolt, Flange 0 Plug, Cylinder Block 00 Cover, Breather 00 Pipe 00 Gasket 0 Seal, Intake Valve 0 0 Guide, Valve 0 Fin Damper A 0 Seal, Exhaust Valve 0 Bolt and Washer 00 Asm., Cylinder Head (Incl.,,0-,,) 0 Gasket, Exhaust 0 Stud 000 Washer 00 Nut 0 00 Pin, Straight (AA) Pin, Straight (AB)(AC) 0 00 Gasket, Cylinder 0 Cylinder 0 Gasket, Head 0 Gasket, Cam 000 Adapter 0 Asm., Adapter Band (Incl. ) 0 Screw 00 Bolt 0 Bolt, Flange /0 C0

40 CRANKSHAFT and PISTON TRAIL BOSS A0AAAA and TRAIL BOSS A0AAAB and TRAIL BOSS SE A0AAAC Piston Ring Set (STD) Piston Ring Set (0. O/S) Piston Ring Set (0.0 O/S) Piston Set (STD)(Incl.,) Piston Set (0. O/S)(Incl.,) Piston Set (0.0 O/S)(Incl.,) 0 Pin, Piston 0 Clip 0 Bolt 0 Asm., Connecting Rod (Incl.,) 00 Crankshaft, Complete (Incl. ) 0 Key, Woodruff Spacer Spacer Spacer Spacer 0 0 Sprocket 0 Nut 00 Washer 00 Nut, Lock Nut 0 Bearing, Ball Bearing (STD) Bearing (0.0 U/S)(If built after //) Bearing (0. U/S)(If built after //) /00 C

41 INTAKE and EXHAUST TRAIL BOSS A0AAAA and TRAIL BOSS A0AAAB and TRAIL BOSS SE A0AAAC Screw, Adjusting 0 Nut 00 Asm., Rocker Arm (Incl.,) 00 Shaft, Rocker 0 Washer, Wave 00 Collet, Valve 0 Retainer, Spring 0 Spring, Valve 0 Lever, Release 0 00 Spring, Return 00 Camshaft (Incl.,0,) 0 Pin, Dowel 0 Valve, Intake 0 Valve, Exhaust C 0 Guide, Chain 0 Chain, Timing 0 Gasket, Tensioner 0 Tensioner 0 Pin (AB)(AC) 0 0 Spring (AB)(AC) 0 Plug (AB)(AC) 00 Gasket (AB)(AC) 0 Bolt, Flange 0 Sprocket 0 Washer 0 Bolt, Flange 0 Lever 0 Bolt, Pivot /0

42 RECOIL STARTER TRAIL BOSS A0AAAA and TRAIL BOSS A0AAAB and TRAIL BOSS SE A0AAAC 0 0 Reel 0 Spring, Return 0 Ratchet 0 Spring, Friction 0 Plate, Friction 0 Bolt and Washer 0 Plug 0 Gasket 0 Bushing, Starter C 0 0 Spring, Spiral 00 Bushing 0 Gasket, Recoil 0 Bolt, Flange Rope Asm., Recoil (Incl. -,-,,) Starter Case (Incl. )(AA) Starter Case (Incl. )(AB)(AC) /0

43 OIL PUMP and OIL FILTER TRAIL BOSS A0AAAA and TRAIL BOSS A0AAAB and TRAIL BOSS SE A0AAAC 0 0 Plug 0 Gasket 0 Spring 0 Valve, Relief 00 Bolt, Flange 0 Strainer, Oil 0 Filter, Oil 00 Screw 00 Cover, Oil Pump 0 0 Rotor, Inner 0 Rotor, Outer /00 C

44 CARBURETOR TRAIL BOSS A0AAAA and TRAIL BOSS A0AAAB and TRAIL BOSS SE A0AAAC D

45 CARBURETOR TRAIL BOSS A0AAAA and TRAIL BOSS A0AAAB and TRAIL BOSS SE A0AAAC 00 Ring 00 E-Ring 00 Needle, Jet 0 Ring 0 Diaphragm 0 Jet, Needle (AA) Jet, Needle (AB)(AC) 0 Screw 00 Washer, Spring Asm., Jet Block 0 00 Washer 0 Jet, Main (#) 0 Seal 0 Packing 0 E-Ring 0 Cap 0 Pin, Float 0 Plate 0 O-Ring 00 Screw 0 00 Asm., Float Body 0 Screw 0 Asm., Float 0 Screw 0 0 Valve, Needle (.)(AA) Valve, Needle (.)(AB)(AC) 0 O-Ring Jet, Pilot (#0) 0 O-Ring 0 Washer 0 Spring 0 Adjuster 0 Screw, Adjust 0 Ring 0 Spring Valve, Throttle (0) 0 Spring 0 Ring 00 Screw 0 Asm., Throttle Shaft 0 Guide, Cable 0 0 Screw 0 Cover 0 O-Ring 0 Holder, Guide 0 Spring 0 Asm., Plunger Jet, Air (#) Asm., Carburetor (Incl. -,-)(AA) Asm., Carburetor (Incl. -,-)(AB)(AC) 00 Screw and Washer Spring 0 Asm., Cover 0 Screw /0 D

46 MAGNETO TRAIL BOSS A0AAAA and TRAIL BOSS A0AAAB and TRAIL BOSS SE A0AAAC 0 0 Coil, Ignition 00 Cap, Spark Plug 0 Plug, Spark 0 O-Ring 00 Asm., Plate 0 Bolt and Washer 0 CDI System 00 Nut 000 Washer, Spring 0 0 Switch, Magnetic 0 Flywheel w/ring Gear /00 D

47 STARTING MOTOR TRAIL BOSS A0AAAA and TRAIL BOSS A0AAAB and TRAIL BOSS SE A0AAAC 0 0 Motor, Starting (Incl. -,-) 0 Washer Set 0 Armature 00 Brush, Carbon 0 Nut, Flange 00 O-Ring 00 Bolt and Washer 00 Bracket, Rear 00 Asm.,FrontBracket(Incl.) D 0 O-Ring 0 0 Asm., Set Bolt (Incl. ) 00 Ring, Rubber 0 Washer, Gear Shaft 0 Clip 0 Spring, Weight 00 Spring, Return 00 Clip 000 Asm., Gear Shaft (Incl. -) /00

48 FUEL PUMP TRAIL BOSS A0AAAA and TRAIL BOSS A0AAAB and TRAIL BOSS SE A0AAAC 0 Asm., Fuel Pump (Incl. -) 0 Screw and Washer 0000 Screw and Washer 0 Screw 0 Diaphragm Gasket Set / D

49 TOOL KIT TRAIL BOSS A0AAAA and TRAIL BOSS A0AAAB and TRAIL BOSS SE A0AAAC 0 Kit - Tool (Incl. -) 0 Gauge, Tire Pressure 000 Wrench, Open End, -0mm 000 Wrench, Open End, -mm 0 Wrench, Box, Special 0 Screwdriver, Phillips Pouch, Tool Kit 0 Owner s Manual, 0 ATV Supplement, Owner s Manual 0 Trail Boss /00 D

50 PRINTED IN THE USA PARTS MANUAL PN and MICROFICHE PN /0