2003 Polaris 600 Classic Factory Service & Work Shop Manual

2003 TRAIL LUXURY SNOWMOBILE SERVICE MANUAL The Way Out. 340 CLASSIC 500 CLASSIC 550 CLASSIC 600 CLASSIC 700 CLASSIC PN 9918049

TRAIL LUXURY SERVICE MANUAL Foreword This manual is designed primarily for use by Polaris snowmobile service technicians in a properly equipped shop. Persons using this manual should have a sound knowledge of mechanical theory, tool use, and shop procedures in order to perform the work safely and correctly. The technician should read the text and be famil- iar with service procedures before starting the work. Certain procedures require the use of special tools. Use only the proper tools, as specified. Cleanliness of parts and tools as well as the work area is of primary impor- tance. All references to left and right side of the vehicle are from the operator’s perspective when seated in a normal riding position. This manual includes procedures for maintenance operations, component identification and unit repair, along with service specifications for the Polaris Indy 500 Classic, 550 Classic, 600 Classic, 700 Classic snowmobiles. A table of contents is placed at the beginning of each chapter, and an alphabetic index is provided at the end of the manual for location of specific page numbers and service information. Keep this manual available for reference in the shop area. At the time of publication all information contained in this manual was technically correct. However, all materials and specifications are subject to change without notice. Comments or suggestions about this manual may be directed to: Polaris Sales Inc., Service Publications Department, 2100 Hwy 55 Medina, Minnesota 55340. Trail Luxury Snowmobile Service Manual (PN 9918049) Copyright 2002 Polaris Sales Inc. Printed in U.S.A.

UNDERSTANDING SAFETY LABELS AND INSTRUCTIONS Throughout these instructions, important information is brought to your attention by the following symbols: The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! DANGER Failure to follow DANGER instructions will result in severe injury or death to the operator, bystander or person inspecting or servicing the snowmobile. WARNING Failure to follow WARNING instructions could result in severe injury or death to the operator, bystander or person inspecting or servicing the snowmobile. CAUTION: A CAUTION indicates special precautions that must be taken to avoid personal injury, or snowmobile or prop- erty damage. NOTE: A NOTE provides key information to clarify instructions. Trademarks Polaris acknowledges the following products mentioned in this manual: FLEXLOC, Registered Trademark of SPS Technologies Loctite, Registered Trademark of the Loctite Corporation STA-BIL, Registered Trademark of Gold Eagle FOX, Registered Trademark of Fox Shox Nyogel, Trademark of Wm. F. Nye Co. Fluke, Registered Trademark of John Fluke Mfg. Co. Mity Vac, Registered Trademark of Neward Enterprises, Inc. Ammco, Registered Trademark of Ammco Tools, Inc. Torx, Registered Trademark of Textron Hilliard, Trademark of the Hilliard Corporation M 10, registered Trademark of FAST Industries

GENERAL MAINTENANCE ENGINE FUEL SYSTEM / CARBURETION DRIVE/DRIVEN CLUTCHES SUSPENSIONS BODY AND STEERING BRAKES AND FINAL DRIVE ELECTRICAL WIRING DIAGRAMS

CHAPTER 1 GENERAL INFORMATION Publication Part Numbers / Service Manuals 1.1 ............. Model Number Identification 1.2 ........................... Vehicle Identification Number (VIN) 1.3 ..................... Standard Bolt Torque Specifications 1.4 .................... Tap Drill Size Charts 1.6 .................................. Units of Measure Chart 1.7 ............................... Recommended Shop Supplies 1.8 ......................... General Precautions 1.12 .................................. Notes Page 1.13 .......................................... Decimal Equivalents .................................. 1.5 Glossary of Terms .................................... 1.9 - 1.11 2003 Specifications ................................... 1.14 -- 1.25

GENERAL INFORMATION 1.1 Publication Numbers Model Model No. Owner’s Manual Supplement Parts Manual Parts Microfiche 340 EDGE Classic S03ND3AS 9917463 9917786 9917787 500 Classic S03ND5CS 9917582 9917794 9917795 550 Classic S03ND5BS S03ND5BS(*) 9917448 9918171 9917792 9917793 600 Classic S03ND6ES 9917583 9917796 9917797 700 Classic S03ND7CS 9917584 9917796 9917797 2003 Snowmobile Owner’s Manual (All) - PN 9917436 2003 Snowmobile Assembly Manual - PN 9916508 2003 Service Manuals 2000--2003 120 XC SP 9918046 Trail Sport Super Sport, 340 EDGE, 500 EDGE, 440 PRO X FAN 9918048 Touring Wide Trak LX, 340 Touring, Sport Touring, Trail Touring, 500 Classic Touring, 600 Classic Touring, 700 Classic Touring, 800 Classic Touring 9918047 Frontier Frontier Classic, Frontier Touring 9918050 Trail Luxury 340 Classic EDGE, 500 Classic, 550 Classic, 600 Classic, 700 Classic 9918049 Deep Snow Trail RMK, 600/700/800 RMK, 700/800 SKS 9918051 Performance 500 XC, 500/600/700/800 XC SP, 800 XCR 9918052 High Performance 440 PRO X FAN, 440, 600, 700, 800 PRO X 9918053 Wallcharts 9918054 TRACK POSTER 9918459

GENERAL INFORMATION 1.2 MODEL NUMBER IDENTIFICATION YEAR DESIGNATION ENGINE DESIGNATION MODEL / CHASSIS DESIGNATION 2002 MODEL DESIGNATION S02 SD 5 BS S=Snow U= European Model S= North American Model MODEL LINE (4TH DIGIT) MODEL TYPE (5TH DIGIT) S=Gen II A= Feature Option L= Lite B= Basic N= EDGE C= Feature Option W=Mini Indy D= Deluxe E= Feature Option M--10 F= Feature Option J= 136 RMK (Edge) K= 144 RMK (Edge) L= 151 RMK (Edge) M= 156 RMK (Edge) P= Performance R= RMK (Gen II) S= SKS T= Touring U= Utility X= Racer 2002 ENGINE DESIGNATION NUMBERS 1A - 121 F/C OHV 4 cycle Fuji 3A - 340 F/C Piston Port Fuji 4A - 440 F/C Cylinder Reed Fuji 4B - 488 L/C Piston Port Fuji 4C - 440VES L/C Case Reed (domestic) 4D -- 440 F/C Piston Port 4E - 488 F/C Piston Port Fuji 5A - 497 L/C Case Reed 2 Cyl (domestic) 5B - 544 F/C Cylinder Reed 5C - 500 VES L/C Case Reed 2 Cylinder (domestic) 6D - 600/700 L/C Case Reed 2 Cylinder (domestic) 6E - 600/440 VES L/C Case Reed 2 Cylinder (domestic) 7A - 700 L/C Case Reed 2 Cylinder (domestic) 7C -- 700 VES L/C Case Reed 2 Cyl (domestic) 8A - 800 VES L/C Case Reed 3 Cylinder Fuji 8B - 800 L/C Case Reed 2 Cylinder (domestic) 8C -- 800 VES L/C Case Reed 2 Cyl (domestic) MODEL NO. V.I.N. NO. MFD. DATE: THIS VEHICLE CONFORMS TO ALL APPLICABLE U.S. FEDERAL AND STATE REQUIREMENTS AND CANADA MOTOR VEHICLE SAFETY STANDARDS IN EFFECT ON THE DATE OF MANUFACTURE. MADE IN U.S.A. 7072133 Mfd. by Polaris Industries Inc.. in Roseau, MN under one or more of the following patents: U.S. Patents 3,605,511 3,613,810 5,050,559 3,580,647 3,867,991 5,048,503 3,483,766 4,793,950 5,056,482 3,533,662 5,038,881 5,099,813 3,545,821 5,172,675 5,074,271 3,605,510 5,090,386 5,191,531 3,525,412 5,050,564 3,613,811 PATENT NOTICE Patented Canada 882,491/71 883,694/71 864,394/71 Canadian Rd. 34,573/71 34,572/71 1,227,823/87 TUNNEL DECAL These numbers should be referred to in any correspondence regarding warranty, service or replacement parts. The machine model and serial number identification decal is located on the right front side of the tunnel. The serial number is permanently stamped into the tunnel. The model number is embossed on the decal. Whenever corresponding about an engine it is important that the engine model and serial numbers be called out. Laser engraved model and serial numbers are located on the crankcase (intake side).

GENERAL INFORMATION 1.3 Vehicle Identification Number Current snowmobiles have a 17 digit Vehicle Identification Number (VIN). The VIN is organized as follows: Digits 1-3: World Manufacturer Identifier. For Polaris, this is 4XA. Digits 4-9: Vehicle Descriptor Section. Digits 10-17: Vehicle Indicator Section. Digits 4-8 of the VIN identify the body style, type, engine type, and series. The VIN and the model number must be used with any correspondence regarding service or repair. 1 2 3 4 5 6 7 8 9 10 1 1 12 13 14 15 16 17 S N 1 S B 5 B S 0 2 2 0 0 0 0 0 0 Vehicle Descriptor Vehicle Identifier Type Engine Size Engine Modifier Model Year Manufacturing. Location Code Individual Serial No. Body Style Series World Mfg. ID Example of Current VIN Number Check Digit Vehicle Identification Number / Model Number Key Body Style T ype Engine Size Engine Modifier Series L=Lite B=Base Model 1=100-199 cc A=Fan S=Domestic N=Edge D=Deluxe 2=200-299 cc B=Liquid Twin U=Europe S=Gen II P=Performance 3=300-399 cc C=Case Reed Twin W=Mini R=RMK 4=400-499 cc D=Liquid Triple S=SKS 5=500-599 cc E=Case Reed Triple T=Touring 6=600-699 cc U=Utility 7=700-799 cc X=Racer 8=800-899 cc Year / Letter Identification The tenth digit of a 17 digit VIN is the model year of the vehicle. Example: W = 1998; X = 1999 etc. Refer to the listing below. 1 = 2001 2 = 2002 3 = 2003

2003 Polaris 600 Classic Factory Service & Work Shop Manual

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