2004 Polaris Snowmobile Touring Service Owners Parts Manuals (PS016098)

2004 Polaris Snowmobile Touring Service Owners Parts Manuals (PS016098)

• This manual presented for you in electronic format you can just print out the page you need then dispose of it when you have completed your task. This manual has detailed illustrations as well as step by step written instructions with the necessary diagrams or pictures. These manuals are your number one source for repair and service information, specifically written for the do-it-yourself as well as the experienced mechanics worldwide used to use this factory manual to fix your vehicle. Using this repair manual is an inexpensive way to keep your car working properly. it is this level of detail, along with illustrations, that guide the reader through each service, repairs, maintenance procedure.
• 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:
  
  Repair and maintenance procedures from the people that actually manufactured your vehicle. You cannot get more detailed or accurate information than you will find in the OEM Factory Service Manual. This is the manual that the dealerships use to fix/repair/service your vehicle. Diagrams/photos/troubleshooting procedures/maintenance schedules etc are all included to help you fix your problem fast.

  GET THE INFORMATION YOU WANT NOW:
  
  With this pdf manual, you can find the information you require much faster than a conventional paper repair book. Fully indexed and searchable pdf manuals are portable and practicle. Read it in your smartphone as well as your pc/mac/tablet. You can print out just the information you need to complete your job, then dispose of the printouts later when you are done.

  INSTANT DELIVERY:
  
  Pdf repair manuals do not get dirty, greasy, torn or soiled, and you can get your instant download link straight after your payment with credit card or PayPal. No waiting for weeks for the snail mail to arrive. The download link will be in your inbox immediately after you send the payment. Simply click on the link and download the manual to your computer.

  SUPPORT:
  
  We provide free downloads of your purchase in the future..in case of a lost or corrupted computer/drive. Just drop us an email and we will send you a fresh download link within 24hrs.

  COMPUTER REQUIREMENTS:
  
  PDF documents can be read on all PC’s or macs.This manual is compatible with all versions of Windows – 95, 98, 2000, NT, ME, XP, Vista and Windows 7 (all editions, Home, Pro etc.) We provide you with a link to get the latest version of Adobe Acrobat PDF Reader for free in the email containing your download link.