Does anyone have a shop manual that covers an '03 Polaris 330 Magnum 4x4? I need some specs.

1: Rod bearing clearance
2: Rod bolt torque
3: Crankcase bolt torque
4: Head bolt torque

Thanks!

 

This link should fix you up.Index of /ORV Manuals/Polaris/Magnum/2003

 

How about one for a 2004 500HO ??

 

Index of /ORV Manuals/Polaris/Sportsman/2004

 

Thank you very much! Do you have a link to all of the manuals by chance? I am also needing one for a 425 magnum, and since I have a 400 sport as well, it wouldn't hurt to have access to it too.

EDIT: And since you are a Polaris tech, maybe you can help with the 425. It will not evacuate the crankcase oil. I can drain it, fill the tank, then fire the bike up and it will run fine for 15-20 seconds until the oil builds up and locks the piston. Backstory: I got the bike cheap in a trade. When it died and wouldn't run one day, the previous owner took it to the dealer. The dealer said the cam needed replaced, but that didn't fix the issue. The dealer went out of business and the owner had to go pick the bike up.

I can't seem to find a check valve or anything that could be causing the problem.

 

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5 buck manuals are offered here.Polaris ATV Service Manuals PDF Download
Look on the left side of the engine(or in you manual under oil flow),you'll see a blind plug, under the plug is a spring, a rod and bearing.This is the pressure relief valve. Could be stopped up and need to be cleaned. Plus if the piston is starting to lock up along with the cam problem,this can get a bit expensive.

 

I haven't found a pressure relief valve. I did find the check valve that keeps oil from returning to the crankcase when not running, and it was clear of obstruction.

The oil line that runs from the engine to the tank (lower of the 2 lines) spits oil out. Its not a good solid flow, but an inconsistant "spitting".

 

Look at the oil cooling routing chart in your manual. Starts out at oil tank to oil pump(feed) then the one way check valve,then as it makes it's way through the the engine the oil is back to the pump pick up screen,then oil pump (scavenge)then the return line to the tank. Problem could be the oil pump itself. Either in the feed( rotors) or the pick up screen/oil pump scavenge that could be causing the piston problems.

 

I finally decided to pull the engine and see what is wrong. I have split a couple dozen atv/motorcycle cases in the past, but this set was the hardest. It took an hour to work them apart after getting all the bolts out.

I have the oil pump out now, and my question to you: The pick up screen is a piece of stamped sheet metal with the screen welded/epoxied to it. In between the two is some type of fibrous material that is packed in there. Is there supposed to be anything in there? I would imagine the screen is all that is needed, but maybe Polaris thought they needed a filter media too? At first I thought it was a blue shop rag, and if there isn't supposed to be anything in there, then that is probably what it is.

The oil pump gears looked great. So far I have not saw anything damaged inside the engine.

 

Look at this image,plus look at the parts diagram for a list of parts. Dirt Cheap Yamaha, Honda, Arctic Cat & Polaris OEM Parts & Accessories – Cycle Parts Warehouse