2004 Polaris Trail Luxury 340 500 550 600 700 800 Classic Snowmobile Repair Manual

IIW I I'"'""-- I 1-IW POLARIS® The 'Nay Out. LIVE THE JUDI~& Rl~ TP MAlE IT BETTE LAJ.US n .. ....,. 2004 TRAIL LUXURY MANUAL Foreword This manual is designed primarily for use by Polaris snowmobile service technicians in a properly equipped shop. Per- sons 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 familiar 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 importance. 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 2004 Model Year information, along with service specifications. 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 avail able 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: Copyright 2003 Polaris Sales Inc. Polaris Sales Inc., Engineering Publications Department 2100 Hwy 55 Medina, Minnesota 55340. 2004 TRAIL LUXURY MANUAL (PN 9918583) Printed in U.S.A. i.1 J

IIYirJ~L'&J"II~IY---------------------------------------==================== UNDERSTANDING SAFETY LABELS AND INSTRUCTIONS Throughout these instructions, important information is brought to your attention by the following symbols: A The Safety Alert Symbol means ATTENTION! BECOME ALERTI YOUR SAFETY IS INVOLVED! A DANGER Failure to follow DANGER instructions will result in severe injury or death to the operator, bystander or person inspecting or servicing the snowmobile. A WARNING Failure to follow WARNING instructions could result in severe injury or death to the operator, bystander or person inspecting or servicing the snowmobile. CAUTlO:N: I A CAUTION indicates special precautions that must be taken to avoid personal injury, or snowmobile or property dam- age. 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 Willwood, Trademark of the Willwood Corporation Walker Evans Racing Shocks, Trademark of the Walker Evans Ent. i.2

TABLE OF CONTENTS w * a H&F¥& ¥ES£i!*&SHERR' I!} GENERAL MAINTENANCE ENGINE FUEL DELIVERY CLUTCHING BODY & STEERING SUSPENSIONS FINAL DRIVE ELECTRICAL WIRING DIAGRAMS INDEX

£;p E.l ~IVE.I ~II' .A L Model Number Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1 Vehicle Identification Number (VIN) ... . ... .... ..... .. .. . 1.2 Publication Part Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 Specifications 340 Classic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 .4 - 1.5 500 Classic. .. .... ... ... ... . ... .. ..... .. . 1. 6- 1.7 550 Classic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 .8 - 1.9 600 Classic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 .10 - 1 .11 700 Classic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 .12 - 1.13 800 Classic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 .14 - 1.15 Glossary of Terms . ... .. .. .... . .... . ..... ... . ..... ... . 1.16- 1.19 General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 .20 Standard Bolt Torque Specifications . . . . . . . . . . . . . . . . . . . . 1.21 Decimal Equivalents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 .22 Tap Drill Size Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.23 Units of Measure Conversion Chart . . . . . . . . . . . . . . . . . . . . . 1.24

--· ·-· .,., ...... -· .. ,.,..,. ·-·. MODEL NUMBER DESIGNATION YEAR DESIGNATION-------- - ---, sFo2ls D lscJs ENGINE DESIGNATION S=Snow---- MODEL I CHASSIS DESIGNATIONI------- '--------=T __ _J ' S= North American Model U= European Model MODEL LINE 14TH DIGITI MODEL TYPE 15TH DIGIT) ENGINE DESIGNATION NUMBERS S=Gen II L= Lite N= EDGE W=Mini Indy TUNNEL DECAL MODEL NO. V.I.N. NO. A= Inactive 8= Basic C= Inactive D= Deluxe E= Feature Option M-1 0 F= Inactive J= FTR/OPT 136 RMK (Edge) K= FTR/OPT 144 RMK (Edge) L= FTR/OPT 151 RMK (Edge) M= FTR/OPT 159 RMK (Edge) P=FTR/OPT Performance R= Inactive S= Switchback "' T= Touring U= Utility X= Racer Y=Pro X2 Z=Pro XR 1A- 121 F/C OHV 4 cycle Fuji 3A - 340 F/C Piston Port Fuji 4A- 440 F/C Cylinder Reed Fuji 48 - 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) 58 - 544 F/C Cylinder Reed 5C - 500 VES L/C Case Reed 2 Cylinder (domestic) 60 - 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) 7D-780 4 Stroke EFI 2 cyl (Dom.) 8A - 800 VES L/C Case Reed 3 Cylinder Fuji 88 - 800 L/C Case Reed 2 Cylinder (domestic) 8C - 800 VES L/C Case Reed 2 Cyl (domestic) MADEINU.SA POLARIS PATENT NOTICE Mid. by Polaris Industries Inc .. In Roseau, MN under one or more of the following patents: THIS VEHICLE CONFORMS TO ALL APPUCABLE U.S. FEDERAL AND STATE REQUIREMENTS AND CANADA MOTOR VEHICLE SAFETY STANDARDS IN EFFECT ON THE DATE OF MANUFACTURE. U.S. Patents 3,605,511 3,580,647 3,483,766 3,533,662 3,545,821 3,605,510 3,525,412 3,613,810 3 ,867,991 4,793,950 5,038,681 5,172,675 5,090,386 5,050,564 5,050,559 5,048,503 5,056,482 5,099,813 5,074,271 5,191,531 3,613, 811 Patented Canada 682,491/71 883,694171 864,394/71 Canadian Rd. MFD. DATE: 34,573/71 34,572171 1,227,823/ 87 7072133 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). 1.1

\::U;;;;JYJ;;n~·U ... IIYrVnltfiM IIVIY---------------------~~-= 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 SN1 . Digits 4-9: Vehicle Descriptor Section. Digits 10-17: Vehi cl e Indicator Section. Digits 4-8 of the VIN identify the body style, type, engine type, and series. The VIN and th e model number must be used with any correspondence regarding service or repair. Example of Current VIN Number World Mfg. ID Vehicle Descriptor Vehicle Identifier 1 2 14 17 SN 8 58S022 0 00 0 00 Body Style I 1. I Se~ies I MJdel I EnglneE . Year Individual Serial No Size nglne Check Manufacturing. . Type Modifier Digit Location Code Vehicle Identification Number I Model Number Key Bod~ St)lle ~ Engine ~ize Engine Modifier Series L=Lite B=Base Model 1 = 1 00-199 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=Ca se Reed Tri ple T =Touring 6=600-699 cc U=Utility 7=700-799 cc X=: Racer 8=800-899 cc 1.2 )

Publication Part Numbers Model Mod~l No. Owner's Manual Owners Manuat Parts Microfiche Supplement Manual 340 Classic S04ND3AS 9918199 9918428 9918873 9918874 500 Classic S04ND4BS(A) 9918199 9918402 9918867 9918868 550 Classic S04ND5BS 9918199 9918201 9918835 9918836 600 Classic S04ND6ES(A,B) 9918199 9918482 9918863 9918864 700 Classic S04ND7CS(A) 9918199 9918396 9918841 9918842 800 Classic S04ND8CS(A,B) 9918199 9918397 9918841 9918842 2004 Service Manuals rsjrvtee filliriuat$ " "' .~ "" "'"·"· ~ .,.. ~. ... ~ ~~ - ..... .. T 2'00A !' 120 PRO X 9918581 120 PROX Trail Sport 9918582 Super Sport, 340 EDGE, 500 EDGE Touring 9918584 Wide Trak LX, 340 Touring, Sport Touring, Trail Touring, 600/700/800 Classic Touring Frontier 9918585 Frontier Classic, Frontier Touring Trail Luxury 9918583 340 EDGE Classic , 500 Classic, 550 Classic, 600 Classic, 700 Classic, 800 Classic Deep Snow 9918587 Trail RMK, 600/700/800 RMK, 700/800 Switchback ~ Performance 9918586 500/600/700/800 XC SP PROX 9918588 440, 550, 600, 700, 800 PRO X Wallcharts 9918589 Track Poster 9918459 Flat Rate Manual 9918590 Snowmobile Care and Adjusting for the Perfect Ride (DVD) 9918923 Snowmobile Care and Adjusting for the Perfect Ride (VHS) 9918908 1.3

(:it:;/Vt:;HAL. 1/VJ-UHMA IIUIV=================== MODEL: . . . . . . . . . . . . . . 340 CLASSIC MODEL NUMBER: .... . S04ND3AS ENGINE MODEL: . . . . . . EC34- 2PM070 ENGI NE Engine Type Fuji Engine Displacement cc's's 339 Bore in I mm 2.45" I 62.3mm Stroke in I mm 2.19" I 55.6mm Cylinders 2 Piston I Cylinder Clearance .003- .005" in/ mm .080 - .130mm Piston Ring End Gap in I mm .008 - .014" . 20- .35mm Piston Marking 34A Piston Ring Mark ing RN Operating RPM ±200 7000 Idle RPM ±200 1600 Engagement RPM ±300 4100 Altitude Below -30'F -30' to -10 'F Below-34'C -34' to -23' C 0- 600 185 180 (0- 2000) 114 #3 600-1200 175 170 (2000-4000) 113 113 1200- 1800 165 160 (4000-6000) 113 113 Meters 1800-2400 (Feet) (6000-8000) 155 150 113 113 2400-3000 145 140 (8000- 10000) #3 #3 3000-3700 135 130 (10000 - 12000) 113 #2 DRIVE CLUTCH Altitude Sffift Clutch Weight S!>rlna 0·900 10 Bushed 7042287 (0-3000) Meters 900-1800 10MB Bushed 7042287 (3000-6000) (Feet) 1800..2700 10MW Bushed 7042287 {6000·9000) 2700-3700 10MR Bushed 7042287 (9000-12000) 1.4 CARBURETION Type Mikuni VM 30 SS Main Jet 170 Pilot Jet 35 Jet Needle 5DP13/3 Needle Jet 0-6 (169) Throttle Gap UnderCutaway .240" in/ mm 6.1mm Cutaway 2.5 Valve Seat 1.5 Vi ton Starter Jet 1.5 Fuel Screw NI A Pilot Air Jet 2.5 Air Screw 1.5 Turns Fuel Octane (R+M/2) 87 Oct. NonOxy I 89 Oct. Oxy AMBIENT "tEMP .ERAtURE - 10' to +10'F + lO'to +30' F +30°10 +50' F Above +50' F -23' to - 12'C -12' to -l'C -1 ' to +10'C Above +10' C 170 165 160 150 113 #3 113 113 160 155 150 140 113 113 113 112 150 145 140 130 113 113 112 112 140 135 130 120 113 112 #2 111 130 125 120 110 112 112 #1 #1 120 115 110 100 112 #1 #1 111 DRIVEN CLUTCH Clutch Driven Chaiocasa Spring HeliX Gearing Red / Black 36' 16- 41 : 72 p Rev Roller Red I Black 36° 16- 41 : 72 p Rev Roller Red I Black 36' 16-41 : 72 p Rev Roller Red I Black 36' 16-41 : 72 p Rev Roller ) )

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2004 Polaris Trail Luxury 340 500 550 600 700 800 Classic Snowmobile Repair Manual

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