Polaris Trail Boss 325 Specs and Review

The Polaris Trail Boss 325 launched alongside the Magnum 325 and stayed in the ATV limelight for 14 years before paving the way for the Sportsman and other current ATV lineups. This vehicle dominated beaten paths, farms, and yes – the drag-race scene!

The Polaris Trail Boss 325 was an entry-level vehicle that balanced utility and play. It featured various color options, an impressive 9-inch rear wheel travel, and a sharp turning radius. Unlike its 330-class siblings, this quad enjoyed a 14-year production run from 2000 to 2013.

The original 324 cm3 Trail Boss later became known as the Polaris Trail Blazer when its powerplant got converted to a 330-class engine in 2003. But that did not halt its popularity with consumers. If anything, it improved it. Want to know more about this seemingly underrated machine? Stick around and continue reading.

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Best of Both Worlds

The Polaris Trail Boss 325 is both a conservative and progressive machine. I say this because the vehicle sports close to bare-minimum features such as rear racks, hi- and low-beam headlights, standard footwells, and a single two-wheel driveline mode.

But at the same time, it underwent numerous improvements in its power delivery, wheel travel, and exterior finish throughout its production. Not to mention that its four-wheel hydraulic disc brake system and hauling ability make the Trail Boss stand out from the competition.

Depending on the year and trim, slight variances are noticeable in some Polaris Trail Boss 325 parts. For instance, the carburetor size varied from 30 mm to 34 mm. Displacement increased from 324 to 329 cm3, together with the Polaris Magnum 325. The lubrication system changed from dry to wet-sump type for later-year versions. While rear-wheel travel is already impressive, this further increased from 9.0 to 10.5 for the 2012 Polaris Trail Boss®.

Unlike most of its same- and higher-displacement siblings, the Polaris Trail Boss 325 did not have any special-edition trims produced. But despite its limited options, riders and enthusiasts still gravitated towards the four-wheeler due to its features and a reasonable list price of $3,499 – exclusive of any package inclusions one can avail from the dealer.

Consequently, the Polaris Trail Boss 325 appealed to ranchers who needed a yard worker (for a fraction of a tractor’s cost) and off-roaders looking for an outdoor adventure.

2000 Polaris Trail Boss 325 Specs

Engine

The Polaris 325 Trail Boss is brought to life by a four-stroke, air-cooled (with fan-assisted stage 3 oil cooler) single-cylinder engine. It has a bore-stroke ratio of 78 mm x 68 mm (3.07 x 2.68 inches), an engine displacement of 324 cm3 (19.77 in3), and a 9.2:1 compression ratio – delivered by a 31-mm Mikuni BST carburetor.

The quad has a valve clearance of 0.006 inches @ BTDC on compression for both intake and exhaust. Fuel tank capacity is 3.7 US gallons (14 Liters) with a minimum of 87 (oxygenated) or 89 (non-oxygenated) PON rating.

The maximum power output for this quad based on Dyno tests is 19 hp (18.7 bhp), while top speed varies. A 2001 Polaris Trail Boss 325 gives no more than 45 mph (72.4 kph), while an ’05 model reportedly can reach 53 mph (85.3 kph) in stock condition. For both speed and power, a flawless, pleasant-sounding exhaust system is important.

Drivetrain

An RPM- and torque-sensing Polaris Variable Transmission with a one-way clutch and E-Z shift controls the Polaris Trail Boss 325. A primary Concentric Drive System handled by a 520 O-ring chain transfers power from the engine to the wheels. This advanced drive system design results in better power delivery to the ground and consistent chain tension at all times – thanks to the alignment of the swing arm’s pivot point with the center of the drive sprocket.

Ignition

The vehicle has a DC-CDI (Capacitor Discharge Ignition) electric start system with an auxiliary mechanical recoil starter. The ignition timing is 30°±2° BTDC @ 5,000 RPM and uses a triple-phase output alternator (rated output of 200 watts). Like the Magnum 325, a 12V, 14 Ah 210-CCA battery with 5.28 x 3.54 x 6.54 inches (134 x 90 x 166 mm – L x W x H) dimensions powers the quad. Current 14AH-BS battery (view on Amazon) formats should fit all Polaris Trail Boss 325 models.

Lubrication

Engine oil capacity is 1.9 US quarts/1.8 Liters of Polaris SAE 0W-40 Synthetic Engine Lubricant (without molybdenum additives) or its equivalent. Ideally, one should never substitute or mix oil brands. But if you cannot help it, make sure to use oil variants that meet manufacturer specs and MA JASO T 903 standards. For transmission, use 11.3 ounces of Polaris Premium Synthetic Gear Case Oil. For brakes, use DOT 3 premium brake fluid.

Tires

The front steel wheels on the Boss 325 use Carlisle™ 23 x 7-10 tires (view on Amazon), while the rear steel wheels with Carlisle™ 22 x 11-10 tires. Recommended tire pressure differs for front and rear knobbies – 4 psi/27.58 kPa (0.28 kg-f/cm2) for the front and 3 psi/20.68 kPa (0.21 kg-f/cm2). Make sure to replace tires with a tread depth of 1/8 inch (3 mm) or less.

Brakes

The disc brake system consists of a single-lever, all-wheel hydraulic disc brakes, and an auxiliary hydraulic foot brake. To ensure stopping power, inspect brake deflection, and pad wear daily. You should also check brake fluid level and lever travel each time before you ride. Verify that Polaris 325 Trail Boss parts such as the auxiliary brake and brake lights also work.

Suspension

Enclosed in a Gen II-type chassis are a MacPherson Strut front suspension and a progressive-rate swingarm rear suspension with 2-inch gas-charged twin-tube shocks and 9.0 inches (227 mm) of travel. This long-travel suspension design, mated with a wheelbase of 49.75 inches (1,264 mm), contributes to the 5.0 feet (152 cm) turning radius, making for excellent cornering angles and sharp turns.

Dimensions

The overall vehicle dimensions are 71.5 x 46.5 x 46 inches (1,816 x 1,181 x 1,168 mm – L x W x H) with a ground clearance of 5.5 inches (139.7 mm). The seat height is 34 inches. Dry weight is 504 lbs (228.8 Kg); GVWR is approximately 1,000 lbs – a combination of curb weight, a maximum combined rack capacity of 200 lbs (90.7 Kg), cargo, accessories, plus operator. The Trail Boss has similar towing and tongue capacities as its Magnum sibling – 850 lbs and 30 lbs each.

Exterior

The Boss 325 has a steel frame and plastic body in red/white, red/black, blue, blue/black, green, and yellow/black with black or silver trims. The four-wheeler comes standard with full floorboards, a rear cargo rack, tow hitch, brake light, adjustable handlebars, a tool kit, hand grips, front and rear fenders, body-matching springs, and rims in Fire Red and Bright White.

Cover your ATV with a Weatherproof ATV Cover with Built-In Reinforced Securing Straps and Free Storage Bag (view on Amazon) to keep your plastics pristine. This dual-purpose quad cover perfectly fits a 2002 Polaris Trail Boss 325.

What is a Polaris Trail Boss 325 Worth?

The cost of this four-wheeler increased six times (only incrementally) within its 14-year production run. References for the MSRP of its ’00 model are a bit obscure, but pricing for other Polaris 325 Trail Boss versions are conveniently available in various online resources and blog sites. Resale price and trade-in values are relatively close to its original list price.

Moreover, tons of secondhand units in mint condition are sold in various trader sites for $1,500 on average. For your benefit, I went ahead and consolidated a full run-down of list prices, average retail, and trade-in values below:

Model Year & TrimList PriceRetail/Trade-in
2000 Polaris Trail Boss 325N/A$350 – $1,605
2001 Polaris Trail Boss 325$3,499$605 – $1,590
2002 Polaris Trail Boss 325$3,699$670 – $1,700
2003 Polaris Trail Boss 330$3,699$700 – $1,815
2004 Polaris Trail Boss 330$3,699$740 – $1,895
2005 Polaris Trail Boss 330$3,799$845 – $2,005
2006 Polaris Trail Boss 330$3,899$990 – $2,140
2007 Polaris Trail Boss 330$3,899$1,115 – $2,205
2008 Polaris Trail Boss 330$3,999$1,275 – $1,950
2009 Polaris Trail Boss 330$4,099$1,355 – $2,095
2010 Polaris Trail Boss 330$4,299$1,420 – $2,230
2011 Polaris Trail Boss 330$4,299$1,490 – $2,290
2012 Polaris Trail Boss 330$4,399$1,555 – $2,550
2013 Polaris Trail Boss 330$4,399$1,635 – $2,690
(Source: Nada Guides, Kelley Blue Book, and trader/auction sites)

Random model years can be found in auctions or sold by private owners. However, you may find resale units scarce, especially in locations outside the U.S. Pre-loved Trail Bosses are usually in excellent working condition, with little to no exterior damage, and with low hours and mileage. While most of the quads for resale have only seen the farm, others have been used by former owners as an off-road companion.

Should you happen to be eyeing something similar, exercise due diligence in thoroughly inquiring about the vehicle’s history and usage. If possible, take the 4×4 out for a test drive to get a feel of or hint at potential hidden problems before deciding to make the purchase.

Polaris Trail Boss 325 Problems

Yellow 2001 Polaris Trail Boss 325 ATV

A vehicle’s drawback is a significant factor to consider when purchasing a secondhand unit. Knowing this information is not meant to veer you away from the purchase but rather to help you prepare for possible problems that you may encounter with the vehicle in the future. On this note, here are some commonly reported challenges owners have had with the Polaris 325 Trail Boss:

  • The foot brake doesn’t activate the brake lights.
  • The stock exhaust pipe is too loud, even with a muffler.
  • The carriage bolt that provides the upper muffler support is a pain to work on when replacing the stock exhaust.
  • The exhaust pipe wears in or grooves into the muffler’s back opening over time (especially when the vehicle is used for mudding and water crossings).
  • Instrumentation is a bit primitive. Some owners end up spending roughly $215 (including installation) to get a decent set of the speedometer, hour meter, and odometer, among other things.
  • The HOT light indicator comes on when the machine gets wet.

Determining the Model Year

Your machine’s VIN or Vehicle Identification Number will tell you the manufacture year of your quad. You can find the VIN stamped into the frame on the left-hand lower frame rail near the rear A-arm mount. Once you find this 17-digit alphanumeric code, look for the 10th digit – the letter or number in that position will indicate the model year. Then, use the table below as your guide:

VIN-to-Year Chart
A 1980 L 1990 Y 2000 A 2010
B 1981 M 1991 1 2001 B 2011
C 1982 N 1992 2 2002 C 2012
D 1983 P 1993 3 2003 D 2013
E 1984 R 1994 4 2004 E 2014
F 1985 S 1995 5 2005 F 2015
G 1986 T 1996 6 2006 G 2016
H 1987 V 1997 7 2007 H 2017
J 1988 W 1998 8 2008 J 2018
K 1989 X 1999 9 2009 K 2019

How to Make Your Trail Boss 325 Faster

Among the first few things you would need to do is check all your vehicle’s inputs and outputs. Begin by checking your air input. Then, make sure your air cleaner is smoothly flowing and not clogged. Cleaning your carburetor with carb cleaner goes a long way too. Make sure to tidy up your muffler while you’re at it, including its plugs on the bottom.

It will be a good idea to change out your air cleaner to a performance type. Other experienced owners run a fuel additive like Polaris Carbon Plus or Star Tron Enzyme Fuel Treatment in their fuel, but this may not be advisable for everyone.

Ensuring your clutches are in tip-top shape and your PVT belt is not worn are also sure ways of making your Trail Boss faster. Since these checks are part of required maintenance, they should be fairly easy to perform and complete.

Chain tension adjustment, an inspection of sheave faces and sealing components, and checking for belt slippage are but a few of the steps entailed. Remember not to skip on these, as doing these measures guarantees you a hassle-free and enjoyable ride.

A big-bore kit will do wonders for your quad’s top-end speed and is, in fact, the route that most racing outfits take. However, this requires a certain level of mechanical skill for the changes not to go awry. It is also quite expensive, which may prove disadvantageous if you are on a budget.

Removing the front and rear racks will help lighten up your vehicle (if you have not already done so) and make it quicker. You can also get different springs for the primary clutch to alter the way your wheeler engages, resulting in faster delivery of usable power to the ground.

Modifications

There are lots of tweaks that you can do on your 4×4 to increase your top end. But if you find advanced performance upgrades a bit overwhelming, you can start with these mods on your quad:

About Polaris

In the early 2000s, Polaris Inc. has been among the first ATV manufacturers to introduce the public to mid-sized utility-rec vehicles – and the Polaris Trail Boss 325 was one of them. Other than this, the American firm was also famous for its snowmobiles and motorcycles. Since the company’s founding in 1954, Polaris has evolved into an industry leader, strengthening its legacy through its quality manufacturing practices and ground-breaking contributions to the ATV scene, such as automatic transmission, Independent Rear Suspension, Polaris Variable Transmission, and Electronic Fuel Injection.

Conclusion – Polaris Trail Boss 325 Review

Purpose-built, middleweight, and aptly priced – the Polaris Trail Boss attracted riders of all skill levels. Beginners appreciated its ease of operation, and experienced riders adored its long-travel suspension and reliability. Farmers loved its hauling capability and hardworking nature. The Polaris Trail Boss 325 is guaranteed to offer something for every kind of driver. This mean machine is, indeed, the king of the trails!

Kris Peter

Adventure seeker and off-road enthusiast. I love the thrill of going off-road and taking on the elements.

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