Hey everyone! New Polaris 2003 Magnum 330 4x4 owner here.
Just brought her home this past Sunday. Still in the bed of the pickup truck, going to take it out to the farm this weekend and unload it there.




I have the front plastic, rack and fender taken off in this pic, because I wanted to replace the valve cover seal. The PO said it was leaking very slightly but we can't have that!

 

i was gonna say, thats half a magnum lol...im in the same process(taking a break in the a/c) taking off the plastic is the worst part of the whole ordeal

 

Got the valve cover done.

The super thin bead of brown RTV that was on there looked like the original factory, and in the usual leaky place, right above the exhaust port, there wasn't really any.

Used copper rtv, the highest temp rating I could find. Much better now.

One thing that I didn't really find mentioned anywhere (including the polaris factory repair manual that came with it) -- the two bolts *inside* the valve cover, like in the pic below.



Good thing I didn't crack the valve cover trying to get it off before I realized there must've been bolts inside...

 

Next, after the valve cover, it was time to do the oil lines. I wouldn't say they were dripping, but I also couldn't trust the oil lines made in such a way that the metal part could freely spin inside that crimped jacket. It was obviously going to start leaking sooner or later.

I didn't want to spend $100s on the replacement lines either, so I took the original lines apart i.e. removed the crimped pieces and then put a flare on the ends:



Then I put some oil cooler hose with a clamp. The flare creates an obstruction that should prevent the line from coming off. I made sure the flare wasn't sharp by sanding it down; I don't want it to cut into the hose.



I used the normal clamps (instead of the silly clamps that it came with) on the oil cooler side too.

Ran the engine to warm it up, no leaks. Will do some riding this weekend to confirm that everything is holding up.

 

Replacement lines aren't cheap and looks like the way you have it should work ok. Yes those silly spring clamps were a joke. The early model Trail Boss and Magnum(2000) had clamps at both ends,barbed fittings at the oil entry and some lines would blow off.. Can't remember how many updated oil line kits I had to install when Polaris changed these out.. Good luck with it.

 

What I really want is a third light. The one that the sportsman has on the pod on the handlebars...

Mine has just the basic pod with the P-R-N-L-H indicator lights.

I am not sure that attaching a light to the front of the plastic pod is a good idea, it will shake too much...

 

Did the engine oil and filter, transmission fluid, rear diff and front diff today.
I swear it feels like the shift lever moves easier than before, but probably placebo effect lol.

 

If the gear case oil was dirty and thick it may not be a placebo effect.. It may very well shift better with good fresh oil.

 

Next weekend's project: replacing the torn cv boot on the right front axle.

 

Drumming up an old post for a question. I too have a 2003 magnum 330. The oil lines are leaking, I got them off but all the replacements look like they have threaded ends on both sides of the hoses, do I need to replace the entire cooler to replace the lines?