Polaris PRO-X Snowmobiles Repair Service Manual 2004

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This workshop repair service manual PDF download for the 2004 PRO-X Polaris Snowmobile has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity.

APPLICABLE MODELS :

440 PRO X
550 PRO X
600 PRO X (X2)
700 PRO X (X2)
800 PRO X (X2)
800 PRO XR
PRO X

TABLE OF CONTENTS :

CHAPTER 1 – SPECIFICATIONS
CHAPTER 2 – GENERAL
CHAPTER 3 – MAINTENANCE
CHAPTER 4 – CLUTCHING
CHAPTER 5 – FUEL DELIVERY
CHAPTER 6 – FINAL DRIVE
CHAPTER 7 – CHASSIS
CHAPTER 8 – FRONT SUSPENSION
CHAPTER 9 – REAR SUSPENSION
CHAPTER 10 – ENGINE
CHAPTER 11 – BRAKES
CHAPTER 12 – STEERING
CHAPTER 13 – ELECTRICAL
CHAPTER 14 – WIRING DIAGRAMS
INDEX

OWNERS MANUAL SUPPLEMENTS

MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
P/N : 9918588
Total Pages : 326

This Polaris service manual, repair manual, workshop manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same manual your local dealer will use when doing a repair. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!

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9918588
TABLE OF CONTENTS
CHAPTER 1 – SPECIFICATIONS
440 PRO X
550 PRO X
600 PRO X (X2)
700 PRO X (X2)
800 PRO X (X2)
800 PRO XR
PRO X ENGINE SPECIFICATIONS
CHAPTER 2 – GENERAL
WELCOME NOTE FROM POLARIS RACING
PUBLICATION PART NUMBERS
MODEL NUMBER DESIGNATION
VEHICLE IDENTIFICATION NUMBER
PRO X INTRODUCTION
PISTON WASH AND SPARK PLUG SELECTION
TORQUE SEQUENCES
VARIABLE EXHAUST SPRINGS
TRAIL SET UP FOR THE 440 PRO X
PISTON INSPECTION
CYLINDER HEAD INSPECTION
CYLINDER HONING
PORT CHAMFERING
CRANKSHAFT
MAIN BEARING INSPECTION
INDEXING
RUNOUT INSPECTION
OIL PUMP
OPERATION AND TROUBLESHOOTING
BLEEDING
ADJUSTMENT
COOLING SYSTEM OVERVIEW
440 PRO XR COOLING
600 PRO X, X2 COOLING
700/800 PRO X, X2, XR
RECOIL SERVICE
SERVICE GLOSSARY
GENERAL SERVICE PRECAUTIONS
STANDARD TORQUE SPECIFICATIONS
FRACTION MEASUREMENT CHART
TAP DRILL CHART
CONVERSION CHART
CHAPTER 3 – MAINTENANCE
MAINTENANCE CHART
MAINTENANCE PRODUCTS
AIR FILTER MAINTENANCE
OIL/FUEL FILTER MAINTENANCE
LUBRICATION POINTS
CHAINCASE SERVICE
LARGE BLOCK WATER PUMP BELT TENSION
GENERAL SUSPENSION LUBRICATION POINTS
GENERAL TRACK INSPECTION AND MAINTENANCE
TRACK TENSION DATA
SPARK PLUG SELECTION
DRIVE BELT SERVICE
DRIVE BELT REMOVAL
BULB REPLACEMENT
HANDLEBAR ADJUSTMENT
BRAKE SYSTEM MAINTENANCE
BLEEDING BRAKES
CLEANING
STORAGE
BATTERY MAINTENANCE
EXHAUST SYSTEM
CHAPTER 4 – CLUTCHING
RECOMMENDED TOOLS
CLUTCH WEIGHTS
DRIVE CLUTCH SPRINGS
DRIVEN CLUTCH SPRINGS
P-85 DRIVE CLUTCH EXPLODED VIEW
TEAM DRIVEN CLUTCH EXPLODED VIEW
CLUTCH OPERATION EXPLANATION
DRIVEN CLUTCH ADJUSTMENTS
DRIVE CLUTCH REMOVAL
DRIVE CLUTCH IDENTIFICATION
DRIVE CLUTCH DISASSEMBLY AND INSPECTION
SPIDER ROLLER REMOVAL/INSTALLATION
SPIDER BUTTON SHIMMING
DRIVE CLUTCH ASSEMBLY
SPIDER INDEXING
DRIVE CLUTCH INSTALLATION
DRIVEN CLUTCH REMOVAL
TEAM ROLLER CLUTCH SERVICE
DRIVEN CLUTCH INSTALLATION
HELIX ANGLES AND EFFECTS
TEAM HELIX DESIGNATION EXPLAINED
DRIVE BELT DATA/INSPECTION
BELT WEAR/BURN DIAGNOSIS
BELT DEFLECTION
BELT REMOVAL
CLUTCH OFFSET
CLUTCH ALIGNMENT ADJUSTMENT
BELT TO SHEAVE INSPECTION/ADJUSTMENT
TROUBLESHOOTING
CHAPTER 5 – FUEL DELIVERY
FUEL SYSTEM WARNINGS
JET PART NUMBERS
MIKUNI TM OVERVIEW
MIKUNI TM 38/40 EXPLODED VIEW
MIKUNI TMX-34 EXPLODED VIEW
MIKUNI VM34SS
GASOLINE VOLATILITY/FUEL OIL RATIO CHART
FUEL DELIVER SYSTEM
MIKUNI CARBURETOR COMPONENTS
TMX-34 SERVICE
CARBURETOR ADJUSTMENTS
FINE TUNING
MIKUNI CARBURETOR COMPONENT EFFECT CHART
VM THROTTLE SYNCHRONIZATION PROCEDURE
MIKUNI TM SERVICE
TM THROTTLE SYNCHRONIZATION
CHOKE ADJUSTMENTS
FUEL PUMPS
TROUBLESHOOTING
CHAPTER 6 – FINAL DRIVE
GEARING CHART
SPROCKET PART NUMBERS
SPROCKET PART NUMBERS (440 PRO XR)
REAR SUSPENSION REMOVAL
CHAINCASE REMOVAL
CHAINCASE BEARING REMOVAL
JACKSHAFT REMOVAL
DRIVESHAFT REMOVAL
CHAINCASE BEARING ASSEMBLY
JACKSHAFT INSTALLATION
DRIVESHAFT INSTALLATION
TRACK INSTALLATION
FINAL ASSEMBLY
CHAINCASE TENSION ADJUSTMENT
CHAINCASE OIL LEVEL
CHAPTER 7 – CHASSIS
HANDLEBAR TORQUE
SEAT COVER REPLACEMENT
HOOD REPAIR
TAILLIGHT ASSEMBLY
NOSEPAN REPLACEMENT
DECAL REMOVAL/APPLICATION
CHAPTER 8 – FRONT SUSPENSION
SUSPENSION ADJUSTMENTS
IFS SHOCK SPRINGS
SPRINGS EXPLANATION
COMPRESSION ADJUSTABLE SHOCKS
IFS SHOCK INFORMATION
IFS DETAILED SHOCK SPECIFICATIONS
440 PRO XR
550 PRO X
600/700/800 PRO X
600/700/800 PRO X2
800 PRO XR
TROUBLESHOOTING
CHAPTER 9 – REAR SUSPENSION
REAR SUSPENSION OPERATION
SUSPENSION ADJUSTMENT PROCEDURES
REAR TORSION SPRING TENSION
TORSION SPRING MATRIX
FRONT TORQUE ARM LIMITER STRAP ADJUSTMENT
HI-FAX REPLACEMENT/REMOVAL
TRACK CLIPS
TYPICAL LUBRICATION POINTS
PRO X REAR SUSPENSION COMPONENTS
440 PRO XR SHOCK TRAVEL BARS
TRAVEL BAR EXPLANATION
REAR SUSPENSION SHOCK INFORMATION
FRONT TRACK SHOCK (FTS) DETAILED SHOCK SPECIFICATIONS
440 PRO XR
550 PRO X
PRO X
PRO X2
800 PRO XR
REAR TRACK SHOCK (RTS) DETAILED SHOCK SPECIFICATIONS
440 PRO XR
550 PRO X
PRO X
PRO X2
800 PRO XR
SHOCK VALVE PART NUMBERS
SHOCK REBUILDING TOOLS
TYPICAL SHOCK VALVING ARRANGEMENT
WALKER EVANS SHOCK REBUILDING
ARVIN SHOCK REBUILDING
SUSPENSION TROUBLESHOOTING
CHAPTER 10 – ENGINE
ENGINE TORQUE SPECIFICATIONS
ENGINE TORQUE SEQUENCES
ENGINE REMOVAL (TYPICAL)
ENGINE DISASSEMBLY 550 PRO X
ENGINE ASSEMBLY 550 PRO X
ENGINE DISASSEMBLY 440/600
ENGINE ASSEMBLY 440/600
ENGINE DISASSEMBLY 700/800
ENGINE ASSEMBLY 700/800
440 PRO XR VARIABLE EXHAUST SYSTEM (VES)
VES SERVICE
VES SPRINGS
TROUBLESHOOTING
CHAPTER 11 – BRAKES
HYDRAULIC BRAKE SYSTEM OVERVIEW
BRAKE BLEEDING
MASTER CYLINDER SERVICE
BRAKE PAD REPLACEMENT
CHAPTER 12 – STEERING
STEERING ASSEMBLY EXPLODED VIEW AND TORQUE VALUES
550/600/700/800 PRO X, X2, XR
440 PRO XR
STEERING INSPECTION
CAMBER DEFINITION
RADIUS ROD AND TIE ROD INFORMATION
ROD END ENGAGEMENT GUIDELINES
IFS STEERING ALIGNMENT SPECIFICATIONS
SPINDLE CENTERING
SET UP WIDTH
CAMBER ADJUSTMENT
CAMBER ADJUSTMENT PROCEDURE
STEERING ADJUSTMENT
HANDLEBAR CENTERING
TOE ADJUSTMENT
SKI SPINDLE BUSHING REMOVAL
STEERING ARM ORIENTATION
SKI INSTALLATION
TORSION BAR REMOVAL
TORSION BAR INSTALLATION
CHAPTER 13 – ELECTRICAL
TYPICAL MULTIMETER USAGE
CHANGING TIMING CURVE ON THE 440 PRO XR
IGNITION TIMING EXPLANATION
IGNITION TIMING SPECIFICATION CHART
TIMING PROCEDURE
PREPARING A NEW BATTERY
DETONATION ELIMINATION TECHNOLOGY
EFFECT OF THE DET SYSTEM
COMPOSITION OF THE DET
BATTERY TESTING
ELECTRIC START LOAD TESTING
DYNAMIC TESTING OF THE ELECTRIC STARTING SYSTEM
ELECTRIC STARTER MOTOR TESTING
STARTER ASSEMBLY
STARTER INSTALLATION
UNREGULATED VOLTAGE
REGULATED VOLTAGE
2 AND 6 PULSE ALTERNATORS
BULB AND SWITCH TESTING
IGNITION SWITCH TESTING
SPEED CONTROL ASSURANCE ADJUSTMENT
SPEED CONTROL ASSURANCE REPLACEMENT
AUXILIARY SHUT OFF TESTING
FUEL SENDER TESTING
TPS ADJUSTMENT
TROUBLESHOOTING
CHAPTER 14 – WIRING DIAGRAMS
INDEX
A-C
D-G
H-P
R-T
U-W
OWNERS MANUAL SUPPLEMENTS

 

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Polaris PRO-X Snowmobiles Repair Service Manual 2004.pdf

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