i bought a used 2003 trailboss 325 and i dont have any literature on it got a parts manual online to look at but can do the obvious fluid checks and stuff but i have no idea how to tighten the chain its got about 2in of play in it and its suppose to have 3/8in is this correct. i am going to order the manual on line but untill i get it if you have any tips or advice i'd appreciate it thanks Lynda[img]i/expressions/face-icon-small-blush.gif[/img]

 

1. Pull Down the Suspension till it is bottomed out.
2. Loosen the bearing carrier bolts on the rear axle.
3. Insert punch through hole in chain sproket into bearing carrier.
4. Adjust till you have 3/8" slack in the chain on top midway up swingarm.
5. Tighten carrier bolts to 45 ft. lbs. DO NOT OVER TIGHTEN.
6. Remove Punch from sproket and release suspension and recheck tension.
7. Lubricate chain and ride ride ride....


Lubrication - I use marine high temperature grease in my swingarm and bearing carrier for waterproofing and to prevent wash out. Grease needle for tie rods lubrication will save you a few dollars in the long run.
Fogging oil is sufficient on the shifter pivot points.
Dont forget to grease your steering post bushing at the top.
Keep and eye on your clutches and belt. Belt should have a life time warranty on it check with local polaris dealer as long as you do not burn it or abuse maintenance there you should be ok on the warranty. Clutches should be serviced at the recommended intervals so you can take advantage of the warranty. i.e. check if for sticking shift weights and ensure it is not binding or the face is becoming worn. Usually you never have to touch the clutch but then there is always the oh my gosh how did this happen.

Hope this helps.

 

thanks so much one more thing do you know what the valve clearance is for the intact and the exhaust?? thanks again

 

you also have to loosen the brake caliper. roll it forward and it will take up slack.