Polaris Trail Boss 2009 Service manual

Polaris Trail Boss · 2009 · service manual · 230 pages

Technical data

Numbers below were extracted automatically from the document. Verify them against the original manual before you order parts or apply torque.

Tightening torque

Values extracted from the document text. Check against the original before service work.

ItemValueAlsoPDF page
Spark Plug14.9 N·m11 ft·lbp. 32
Pinch Clamp Bolt40.7 N·m41 N·mp. 43
Without contacting switch body67.8 N·m68 N·mp. 45
Front Wheel Nuts36.6 N·m37 N·mp. 45
Rear Wheel Nuts67.8 N·m68 N·mp. 45
Front Spindle Nut54.2 N·m54 N·mp. 45
Rear Hub Retaining Nut108.5 N·m108 N·mp. 45
SPECIAL TOOLS Oil Line Fitting27 N·mp. 50
Camshaft 11mm 8--1014 N·mp. 50
Drive Clutch 7/1655 N·mp. 50
Lower Bracket Oil Cooler Thermistor5 N·m44 in·lbp. 54
6mm case bolts8.8 N·m6.5 ft·lbp. 83
Front A-Arm Attaching Bolt40.7 N·m41 N·mp. 115
Front A-Arm Ball Joint Stud Nut33.9 N·m35 N·mp. 115
Rear Axle Nut162.7 N·m165 N·mp. 115
Rear Shock Bolt33.9 N·m35 N·mp. 115
Rear Wheel Hub Nut108.5 N·m110 N·mp. 115
Rear Wheel Nut67.8 N·m69 N·mp. 115
Strut Rod Retaining Nut20.3 N·m21 N·mp. 115
Strut Casting Pinch Bolt20.3 N·m21 N·mp. 115
Swing Arm Pivot Bolt203.4 N·m207 N·mp. 115
Vehicle Frame Bolt40.7 N·m30 ft·lbp. 117
A-Arm Shaft33.9 N·m25 ft·lbp. 117
Bushing35 N·mp. 117
Cotter Pin10.8 N·m8 ft·lbp. 117
Vise and nut162.7 N·m163 N·mp. 119
Jam Nut61 N·m45 ft·lbp. 120
Lower A--Arm Pivot33.9 N·m25 ft·lbp. 120
Lower A--Arm Pivot35 N·mp. 120
Pinch bolts20.3 N·m21 N·mp. 121
Strut Rod Nut plate20.3 N·m21 N·mp. 121
Drive Clutch54.2 N·m54 N·mp. 126
Driven Clutch23 N·m23 N·mp. 126
PVT Inner Cover16.3 N·m16 N·mp. 126
Drive Clutch Cover10.2 N·m10 N·mp. 126
Drive Clutch Spider (EBS)271.2 N·m271 N·mp. 126
Spindle Nut55.3 N·mp. 154
Axle nut pinch bolt5.6 N·m6 N·mp. 157
Sprocket guard nuts40.7 N·m30 ft·lbp. 157
Eccentric clamp bolts47.5 N·m35 ft·lbp. 157
Mounting bolts24.4 N·m25 N·mp. 157
Transmission Case16.3 N·m16.6 N·mp. 162
Bell Crank Nut16.3 N·m16.6 N·mp. 162
Transmission Drain19 N·m19.3 N·mp. 162
Transmission Mounting33.9 N·m34.5 N·mp. 162
Swing Arm Pivot Bolts203.4 N·m207.5 N·mp. 162
Drain plug19 N·m19 N·mp. 166
Front Brake Caliper Bleeding Procedure0.56 N·mp. 175
Line and banjo bolt20.3 N·m15 ft·lbp. 177
Line and banjo bolt21 N·mp. 177
Clamp bolts2.8 N·m3 N·mp. 177
Brake Line Banjo Bolt20.3 N·m21 N·mp. 177
Brake Disc Thickness Variance24.4 N·m25 N·mp. 180
Front Caliper Mounting Bolt24.4 N·m25 N·mp. 183
Front Wheel Nut36.6 N·m37 N·mp. 183
Brake lines20.3 N·m21 N·mp. 189
Tension spring bolts10.8 N·m11 N·mp. 191
MC Bolts21 N·mp. 191

Spark plugs

Values extracted from the document text. Check against the original before service work.

ItemValueAlsoPDF page
ES32PFE—p. 51

Service intervals

Values extracted from the document text. Check against the original before service work.

ItemValueAlsoPDF page
Coolant change2 yearsp. 15
Brake inspection2 yearsp. 22
Air filter service50 hoursp. 33

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