2004 Polaris Touring Service Manual
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- 2004 Polaris Touring Wildtrak LX
Original 2004 Polaris Touring Snowmobiles Factory Service Manual.
This manual includes diagnostics/troubleshooting/repair procedures, hi-resolution images and detailed diagrams.
All information contained in this manual is based on the latest product information available and it is the most complete manual used by authorized Polaris service shops.
Polaris manual part number: 9918584
Models covered:
- 340 TOURING
- TRAIL TOURING
- SPORT TOURING
- 600 CLASSIC TOURING
- 700 CLASSIC TOURING
- 800 CLASSIC TOURING
- WIDETRAK LX
Manual Chapters
1 - GENERAL
2 - MAINTENANCE
3 - ENGINE
4 - FUEL/CARBURETION
5 - CLUTCHING
6 - BODY AND STEERING
7 - SUSPENSION
8 - BRAKES/FINAL DRIVE
9 - ELECTRICAL
10 - WIRING DIAGRAMS
INDEX
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Full list of manual chapters:
TABLE OF CONTENTS
CHAPTER 1 - GENERAL
MODEL NUMBER IDENTIFICATION
VEHICLE IDENTIFICATION NUMBER (VIN)
PUBLICATION PART NUMBERS / SERVICE MANUALS
340 TOURING SPECIFICATIONS
TRAIL TOURING SPECIFICATIONS
SPORT TOURING SPECIFICATIONS
600 CLASSIC TOURING SPECIFICATIONS
700 CLASSIC TOURING SPECIFICATIONS
800 CLASSIC TOURING SPECIFICATIONS
WIDETRACK LX SPECIFICATIONS
SERVICE GLOSSARY
GENERAL SERVICE PRECAUTIONS
STANDARD TORQUE SPECIFICATIONS
UNITS OF MEASURE CHART
TAP DRILL SIZE CHART
CONVERSION CHART
CHAPTER 2 - MAINTENANCE
GENERAL MAINTENANCE INSPECTION SHEET
RECOMMENDED PRODUCTS
AIR FILTER MAINTENANCE
WATER SEDIMENT TRAP MAINTENANCE
LUBRICATION POINTS
CHAINCASE FLUID LEVEL
WATER PUMP BELT TENSION
GENERAL SUSPENSION LUBRICATION POINTS
GENERAL TRACK INSPECTION AND MAINTENANCE
TRACK TENSION DATA
SPARK PLUG SELECTION
DRIVE BELT INFORMATION
HEADLIGHT ADJUSTMENT
HANDLEBAR ADJUSTMENT
BRAKE SYSTEM
BRAKE ADJUSTMENT MECHANICAL BRAKES
WIDETRACK LX BRAKE ADJUSTMENT
HYDRAULIC BRAKE SYSTEM
MECHANICAL REVERSE ADJUSTMENT
STORAGE
BATTERY
EXHAUST SYSTEM
CHAPTER 3 - ENGINE
TORQUE SPECIFICATIONS
TORQUE SEQUENCES
PISTON TO CYLINDER INSPECTION
CYLINDER INSPECTION
CYLINDER HONING
PORT CHAMFERING
MAIN BEARING INSPECTION
CRANKSHAFT TRUING
CRANKSHAFT RUNOUT INSPECTION
CRANKSHAFT INDEXING
OIL PUMP OPERATION
OIL PUMP BLEEDING
OIL PUMP ADJUSTMENT
COOLING SYSTEM OVERVIEW
600/700/800 CLASSIC TOURING COOLING DIAGRAM
WIDETRACK LX COOLING DIAGRAM
RECOIL SERVICE
TYPICAL ENGINE REMOVAL
340/550 ENGINE SERVICE
500 ENGINE SERVICE
LIBERTY SMALL BLOCK SERVICE
LIBERTY LARGE BLOCK SERVICE
VARIABLE EXHAUST SERVICE
EXHAUST VALVE SPRINGS
CHAPTER 4 - FUEL/CARBURETION
FUEL SYSTEM WARNINGS
JET PART NUMBERS
MIKUNI TM 38 / TM 40 JET NEEDLE OVERVIEW
MIKUNI TM 38 / TM 40 OVERVIEW/EXPLODED VIEW
GASOLINE VOLATILITY
FLOAT CHAMBER VENTING
FUEL SYSTEM OVERVIEW
MIKUNI CARBURETOR OPERATION
COMPONENT EFFECT CHARTS
VM CARBURETOR DISASSEMBLY / INSPECTION / ASSEMBLY
VM THROTTLE SYNCHRONIZATION
TM CARBURETOR DISASSEMBLY / INSPECTION / ASSEMBLY
TM THROTTLE SYNCHRONIZATION
CHOKE ADJUSTMENTS
FUEL PUMPS
SEDIMENT TRAP
TROUBLESHOOTING
CHAPTER 5 - CLUTCHING
RECOMMENDED TOOLS
DRIVE CLUTCH WEIGHTS
DRIVE CLUTCH SPRING DATA
P-85 CLUTCH EXPLODED VIEW
DRIVEN CLUTCH EXPLODED VIEWS
CLUTCH OPERATION
DRIVE CLUTCH REMOVAL
DRIVE CLUTCH SERVICE
DRIVE CLUTCH INSTALLATION
DRIVEN CLUTCH REMOVAL
POLARIS DRIVEN CLUTCH SERVICE
TEAM DRIVEN CLUTCH SERVICE
DRIVEN CLUTCH INSTALLATION
DRIVEN HELIX ANGLE AND EFFECTS
TEAM HELIX EXPLAINED
DRIVE BELT DATA
DRIVE BELT INSPECTION
BELT DEFLECTION
BELT ADJUSTMENTS
CLUTCH ALIGNMENT
BELT TO SHEAVE INSPECTION AND ADJUSTMENT
TROUBLESHOOTING
CHAPTER 6 - BODY AND STEERING
STEERING ASSEMBLY
FRONT SUSPENSION INSPECTION
IFS ALIGNMENT SPECIFICATIONS
IFS SETUP WIDTH
CAMBER INSPECTION / ADJUSTMENT
HANDLEBAR CENTERING
TOE ADJUSTMENT
CARBIDE PLACEMENT
SKI SPINDLE BUSHING REMOVAL / REPLACEMENT
STEERING ARM ORIENTATION
SKI SKAG REMOVAL / INSTALLATION
SKI INSTALLATION
TORSION BAR REMOVAL / INSTALLATION
HANDLEBAR TORQUE / SEQUENCE
SEAT REMOVAL / INSTALLATION
HOOD REPAIR
NOSEPAN REPLACEMENT
DECAL REMOVAL / INSTALLATION
TROUBLESHOOTING
CHAPTER 7 - SUSPENSION
COMPRESSION ADJUSTABLE SHOCKS
FRONT SUSPENSION SET UP AND ADJUSTMENTS
SPRING OPERATION
OPTIONAL IFS SPRINGS
REAR SUSPENSION OPERATION
CHAPTER 8 - BRAKES/FINAL DRIVE
GEARING CHARTS
HYVO SPROCKET PART NUMBERS
HYDRAULIC BRAKE SYSTEM OVERVIEW
BRAKE BLEEDING
MASTER CYLINDER SERVICE
BRAKE PAD REPLACEMENT
REAR SUSPENSION REMOVAL
JACKSHAFT REMOVAL
CHAINCASE SERVICE
JACKSHAFT INSTALLATION
DRIVESHAFT INSTALLATION
FINAL ASSEMBLY
WIDETRAK LX
BRAKE OVERVIEW
BRAKE SERVICE
TRANSMISSION REMOVAL
TRANSMISSION SERVICE
TRANSMISSION INSTALLATION
CHAPTER 9 - ELECTRICAL
MULTIMETER USAGE
DETONATION ELIMINATION TECHNOLOGY
IGNITION TIMING OVERVIEW
RMK ELECTRICAL EXPLODED VIEWS
TIMING PROCEDURES
PREPARING A NEW BATTERY
LOAD TEST
DYNAMIC TESTING
STARTER MOTOR STATIC TESTING
STARTER ASSEMBLY EXPLODED VIEW
UNREGULATED VOLTAGE
REGULATED VOLTAGE
6 PULSE ALTERNATORS
ELECTRICAL SYSTEMS TESTING
TPS TESTING / ADJUSTMENT
TROUBLESHOOTING
CHAPTER 10 - WIRING DIAGRAMS
INDEX
A-C
D-H
I-P
R-T
U-W
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