2004 Polaris Snowmobile Touring Factory Service Owners Parts Manuals

Includes 4 manuals -
Polaris 2004 Touring Service Manual - 321 pages
Polaris 2005 Touring and Widetrak Owners Manual - 150 pages
Polaris 2004 Frontier Touring Parts Manual - 50 Pages
Polaris 2004 Frontier Classic Parts Manual - 54 Pages


Covers Models -

340 Touring
Trail Touring
Sport Touring
600 Classic Touring
700 Classic Touring
800 Classic Touring
Widetrax LX

Factory Service Manual Chapters Include -

General
Maintenance
Engine
Fuel Delivery
Clutching
Body and Steering
Suspensions
Final Drive
Electrical
Wiring Diagrams
Index

General

Model Number Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1
Vehicle Identification Number (VIN) . . . . . . . . . . . . . . . . . . . . . 1.2
Publication Part Numbers / Service Manuals . . . . . . . . . . . . . 1.3
340 Touring Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4 -- 1.5
Trail Touring Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 - 1.7
Sport Touring Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8 -- 1.9
600 Classic Touring Specifications . . . . . . . . . . . . . . . . . . . . . . 1.10 -- 1.11
700 Classic Touring Specifications . . . . . . . . . . . . . . . . . . . . . . 1.12 -- 1.13
800 Classic Touring Specifications . . . . . . . . . . . . . . . . . . . . . . 1.14 -- 1.15
Widetrak LX Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.16 -- 1.17
Service Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.18 -- 1.21
General Service Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . 1.22
Standard Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . 1.23
Units of Measure Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.24
Tap Drill Size Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.25
Conversion Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.26

Maintenance

General Maintenance Inspection Sheet . . . . . . . . . . . . . . . . . 2.1 -- 2.2
Recommended Products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3
Air Filter Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4
Water Sediment Trap Maintenance . . . . . . . . . . . . . . . . . . . . . 2.5
Lubrication Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6
Chaincase Fluid Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7
Water Pump Belt Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8
General Suspension Lubrication Points . . . . . . . . . . . . . . . . . 2.9
General Track Inspection and Maintenance . . . . . . . . . . . . . . 2.10
Track Tension Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11
Spark Plug Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.12
Drive Belt Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.13
Headlight Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.14
Handlebar Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.15
Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.16
Brake Adjustment Mechanical brakes . . . . . . . . . . . . . . . . . . . 2.17
Widetrak LX Brake Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . 2.18
Hydraulic Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.19
Mechanical Reverse Adjustment . . . . . . . . . . . . . . . . . . . . . . . 2.20
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.21
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.22
Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.22

Engine

Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1
Torque Sequences . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2 -- 3.3
Piston to Cylinder Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4
Cylinder Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5
Cylinder Honing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6
Port Chamfering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7
Main Bearing Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.8
Crankshaft Truing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9
Crankshaft Runout Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.10
Crankshaft Indexing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.11
Oil Pump Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.12
Oil Pump Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.13
Oil Pump Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.14
Cooling System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.15
600/700/800 Classic Touring
Cooling Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.16
Widetrak LX Cooling Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.17
Recoil Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.18
Typical Engine Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.19 -- 3.21
340/550 Engine Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.22 -- 3.30
500 Engine Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.31 -- 3.36
Libertyt Small Block Service . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.37 -- 3.45
Libertyt Large Block Service . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.46 -- 3.55
Variable Exhaust Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.56 -- 3.58
Exhaust Valve Springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.59

Fuel Delivery

Fuel System Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1
Jet Part Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1 -- 4.3
Mikuni TM 38 / TM 40 Jet Needle Overview . . . . . . . . . . . . . . 4.4
Mikuni TM 38 / TM 40 Overview/Exploded View . . . . . . . . . . . 4.5 -- 4.6
Gasoline Volatility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.7
Float Chamber Venting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.8
Fuel System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.9
Mikuni Carburetor Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.10 -- 4.15
Component Effect Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.16
VM Carburetor Disassembly / Inspection / Assembly . . . . . . . 4.17 -- 4.20
VM Throttle Synchronization . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.21
TM Carburetor Disassembly / Inspection / Assembly . . . . . . . 4.22 -- 4.26
TM Throttle Synchronization . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.27 -- 4.28
Choke Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.29
Fuel Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.30
Sediment Trap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.31
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.32--4.33

Clutching

Recommended Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1
Drive Clutch Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2 - 5.3
Drive Clutch Spring Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4 -- 5.5
P--85 Clutch Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.6
Driven Clutch Exploded Views . . . . . . . . . . . . . . . . . . . . . . . . . 5.7
Clutch Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.8 -- 5.9
Drive Clutch Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.10
Drive Clutch Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.11 -- 5.17
Drive Clutch Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.18 -- 5.19
Driven Clutch Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.20
Polaris Driven Clutch Service . . . . . . . . . . . . . . . . . . . . . . . . . . 5.21 -- 5.24
TEAM Driven Clutch Service . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.25 -- 5.26
Driven Clutch Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.27
Driven Helix Angle and Effects . . . . . . . . . . . . . . . . . . . . . . . . . 5.28
TEAM Helix Explained . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.29
Drive Belt Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.30
Drive Belt Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.31
Belt Deflection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.32
Belt Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.33
Clutch Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.34 -- 5.35
Belt to Sheave Inspection and Adjustment . . . . . . . . . . . . . . . 5.36
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.37 -- 5.38

Body and Steering

Steering Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1 -- 6.2
Front Suspension Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3 -- 6.4
IFS Alignment Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.5
IFS Setup Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.6
Camber inspection / Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . 6.7 -- 6.8
Handlebar Centering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.9
Toe Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.10
Carbide Placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.11
Ski Spindle Bushing Removal / Replacement . . . . . . . . . . . . . 6.12 -- 6.13
Steering Arm Orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.14
Ski Skag Removal / Installation . . . . . . . . . . . . . . . . . . . . . . . . . 6.15
Ski Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.15 -- 6.16
Torsion Bar Removal / Installation . . . . . . . . . . . . . . . . . . . . . . . 6.16
Handlebar Torque / Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . 6.17
Seat Removal / Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.18 -- 6.20
Hood Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.20
Nosepan Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.21
Decal Removal / Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.22 -- 6.24
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2

Suspension

Compression Adjustable Shocks . . . . . . . . . . . . . . . . . . . . . . . 7.1
Front Suspension Set up and Adjustments . . . . . . . . . . . . . . 7.2
Spring Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3
Optional IFS Springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4
Rear Suspension operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.5

Brakes/Final Drive

Gearing Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1 -- 8.2
HYVO Sprocket Part Numbers . . . . . . . . . . . . . . . . . . . . . . . . . 8.3
Hydraulic Brake System Overview . . . . . . . . . . . . . . . . . . . . . . 8.4
Brake Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5
Master Cylinder Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.6 -- 8.13
Brake Pad Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.14
Rear Suspension Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.15 -- 8.17
Jackshaft Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.18
Chaincase Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.19
Jackshaft Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.19 -- 8.20
Driveshaft Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.21 -- 8.22
Final Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.23 -- 8.26
Widetrak LX
. . . . . . . . . . . Brake Overview . . . . . . . . . . . . . . . . . . . . . . . . . . 8.27
. . . . . . . . . . . Brake Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.28 -- 8.29
. . . . . . . . . . . Transmission Removal . . . . . . . . . . . . . . . . . . . . 8.30 -- 8.31
. . . . . . . . . . . Transmission Service . . . . . . . . . . . . . . . . . . . . . 8.32 -- 8.40
. . . . . . . . . . . Transmission Installation . . . . . . . . . . . . . . . . . . 8.41 -- 8.43

Electrical

Multimeter Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1 -- 9.3
Detionation Elimination Technology . . . . . . . . . . . . 9.4 -- 9.6
Ignition Timing Overview . . . . . . . . . . . . . . . . . . . . . 9.7 -- 9.8
RMK Electrical Exploded Views . . . . . . . . . . . . . . . 9.9 -- 9.11
Timing Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.12
Preparing a New Battery . . . . . . . . . . . . . . . . . . . . . 9.13
Load Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.14
Dynamic Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.15
Starter Motor Static Testing . . . . . . . . . . . . . . . . . . . 9.16
Starter Assembly Exploded View . . . . . . . . . . . . . . 9.17
Unregulated Voltage . . . . . . . . . . . . . . . . . . . . . . . . . 9.18 - 9.19
Regulated Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.19
6 Pulse Alternators . . . . . . . . . . . . . . . . . . . . . . . . . . 9.20
Electrical Systems Testing . . . . . . . . . . . . . . . . . . . . 9.21 - 9.26
TPS Testing / Adjustment . . . . . . . . . . . . . . . . . . . . 9.27 -- 9.30
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.31

File Size - 148 MB
File Format - Adobe pdf
File Delivery - zip


There are 3 ways to approach car maintenance/repair.

1. Call your Dealer/Service Center/Workshop. Pay $60 to get your vehicle towed or transported to their shop. Wait a few days for an appointment. Get your car back about a week later, and be a few hundred dollars out of pocket.

Result = $1000 dollars out of pocket, fixed car, empty wallet.

2. Try and fix the problem on your own. Create a shopping list and go and buy a few dollars worth of parts. Start the repair/service. Realize you don't have the rights parts or knowledge to fix it. Go and buy more parts to replace the ones you broke trying to fix the original problem. Keep trying/buying until eventually you are having a breakdown yourself.

Result = $300 dollars spent, hours wasted, car still not fixed.

3. Download the original OEM Factory Service Manual for your vehicle from A1 Manuals. Read and study it to determine the problem/resolution. Create a shopping list and buy a few dollars worth of parts that you actually need. Start the repair...and fix it first time.

Result = $50 spent, repair is done, get on with your life and enjoy the ride.



THIS MANUAL COVERS:
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