This manual covers the 2004 Polaris Trail, Sport, Classic, Touring, and Widetrak LX snowmobiles, equipped with engine sizes ranging from 340cc to 800cc. Polaris, a renowned American manufacturer, has a long history of producing capable powersports vehicles. The 2004 lineup represents a period of refinement, offering robust performance and utility for trail riding, touring, and various work applications. These snowmobiles are engineered for reliability and are designed to meet the demands of diverse winter conditions, making them a strong choice within their market segment.
This comprehensive workshop service repair manual provides detailed information for the maintenance, troubleshooting, and repair of your 2004 Polaris snowmobile. It covers all major systems, including the engine, fuel, ignition, drive, suspension, steering, brakes, and electrical components. The manual includes procedures for scheduled maintenance, component overhauls, and detailed diagnostic steps for fault finding. With its extensive coverage and technical specifications, this manual is an essential resource for owners, mechanics, and technicians seeking to ensure the optimal performance and longevity of their snowmobile.
Model:
Various (Trail, Sport, Classic, Touring, Widetrak LX)
Product Name:
Polaris 340, 500, 600, 700, 800 Trail, Sport, Classic, Touring, Widetrak LX Snowmobile Complete Workshop Service Repair Manual
Chassis Codes:
Not specified in product information, typically model-specific internal designations.
Engine Codes:
Various (e.g., 340cc, 500cc, 600cc, 700cc, 800cc - specific designations not provided in product info).
Segment:
High-performance and utility snowmobiles for trail riding, touring, and work applications.
Competitors:
Arctic Cat, Ski-Doo, Yamaha snowmobiles of the same era.
Value Proposition:
Provides essential factory-authorized procedures and specifications for maintaining, troubleshooting, and repairing a wide range of 2004 Polaris snowmobile models, covering multiple engine displacements and configurations.
Vehicle Models Covered:
Polaris 340, 500, 600, 700, 800 Trail, Sport, Classic, Touring, Widetrak LX Snowmobiles
Model Years Covered:
2004
Estimated Pages:
Thousands of pages (typical for a complete workshop manual covering multiple models and engine sizes). Exact count not specified.
Type:
Complete Workshop Service Repair Manual
Format:
Downloadable (likely PDF)
Major Systems:
Engine, Fuel System, Ignition System, Drive System (Clutching, Chaincase, Track), Suspension (Front and Rear), Steering, Brakes, Electrical System (Lighting, Ignition, Gauges), Cooling System, Bodywork, Chassis, Lubrication
Maintenance:
Scheduled maintenance (oil changes, filter replacements, lubrication), inspections, adjustments.
Repair And Rebuild:
Complete engine overhaul, transmission disassembly and reassembly, clutch servicing, suspension component replacement, brake system repair, electrical component troubleshooting and repair, track and skid frame servicing.
Troubleshooting:
Diagnostic procedures, fault finding, symptom analysis for various systems.
Depth:
Comprehensive, covering everything from basic adjustments and routine maintenance to full mechanical and electrical system overhauls and rebuilds. Includes detailed diagrams, specifications, and torque values.
Format:
Digital Download (likely PDF). Searchable text and high-resolution diagrams are expected for optimal usability.
Quality:
High-resolution digital reproduction of original factory documentation. Optimized for clear viewing of diagrams and text.
Binding:
Not applicable (Digital Download)
Paper:
Not applicable (Digital Download)
Engine Sizes:
340cc, 500cc, 600cc, 700cc, 800cc (specific engine designations like Liberty, Fuji, etc., are not detailed in the product title but would be covered in the manual).
Horsepower Range:
Varies significantly by engine size (e.g., 340cc typically 40-50 HP, 800cc up to 130-140+ HP). Specific figures would be in the manual.
Torque Range:
Varies by engine size. Specific figures would be in the manual.
Carburetion:
Typically Mikuni or Keihin carburetors. Manual will detail jetting, adjustments, and troubleshooting.
Fuel Type:
Leaded or Unleaded gasoline (depending on specific engine and octane requirements). Manual will specify.
Type:
CDI (Capacitor Discharge Ignition) systems. Manual will cover ignition timing, coil testing, and module troubleshooting.
Type:
Liquid-cooled or Fan-cooled (depending on model). Manual details radiator, coolant, pump, and fan operation and maintenance.
Type:
CVT (Continuously Variable Transmission) with Polaris P90 primary and secondary clutch system.
Gearbox:
Not applicable, all models use CVT.
Clutch Service:
Detailed procedures for clutch inspection, maintenance, replacement, and tuning (weights, springs, helix).
Chaincase:
Serviceable chaincase with specific gear oil requirements and maintenance intervals.
Length Overall:
Varies by model. Manual will provide specific dimensions for each variant.
Width Overall:
Varies by model (especially Widetrak LX). Manual will provide specific dimensions.
Dry Weight:
Varies by model and engine size. Manual will provide specific weight data for each variant.
Ground Clearance:
Varies by model. Manual will provide specific data.
Crash Test Data:
Not applicable to snowmobiles in the same way as automobiles. Safety focus is on operational stability and rider protection.
Braking System:
Hydraulic disc brakes. Manual covers brake caliper maintenance, pad replacement, fluid flushing, and lever adjustments.
Throttle Control:
Handlebar throttle lever. Manual covers cable inspection and adjustment.
Hand Warmers Thumb Warmer:
Standard on most models. Manual covers electrical system diagnostics for these components.
Track System:
Suspension and track alignment, tension adjustment, and wear inspection are critical for safe operation. Manual details these procedures.
Display Panel:
Basic LCD displays with speed, RPM, fuel level, engine temp warning, and odometer. Manual covers instrument cluster diagnostics.
None:
No electronic driver assistance systems as commonly understood in modern vehicles.
None:
No electronic connectivity features.
Break In Service:
Typically includes clutch and chaincase inspection, and basic engine check after initial hours of operation (e.g., 10-20 hours). Detailed in manual.
Annual Maintenance:
Includes lubrication, chaincase oil change, spark plug replacement, drive belt inspection, coolant check, track and suspension inspection. Manual provides specific mileage/hour intervals.
Engine Oil:
Specific oil viscosity and type (e.g., 0W-40, 2-stroke oil injection type) will be detailed by engine variant in the manual. Polaris branded oils or equivalent.
Chaincase Oil:
Typically SAE 80W-90 or 75W-90 synthetic gear oil. Manual specifies exact type and capacity.
Coolant:
Ethylene glycol-based antifreeze. Manual specifies mixture ratio and type.
Brake Fluid:
DOT 3 or DOT 4 hydraulic brake fluid. Manual specifies type.
Common Wear Items:
Drive belts, carbides, hyfax (slides), suspension bushings, shock absorbers, primary/secondary clutch components, exhaust system components.
Engine Specific Concerns:
While the manual is comprehensive, specific to popular models of this era, potential concerns could include crank seals (on older Liberty twin engines), clutch alignment issues, and carburetor tuning complexities depending on altitude and temperature.
Spark Plugs:
Specific spark plug type and gap (e.g., NGK, Champion) will be listed for each engine in the manual.
Track Tension:
Specific tension values and adjustment procedures will be detailed.
Torque Values:
Comprehensive list of torque specifications for all critical fasteners (engine, suspension, chassis) provided.
Manufacturer:
Polaris Industries, Inc. is a long-standing American manufacturer known for its powersports vehicles, including snowmobiles, ATVs, and motorcycles.
Lineup Overview:
The 2004 model year represents a period of refinement and technological advancement for Polaris's snowmobile offerings, building on established platforms like the RMK, XC, and Indy series, with variations for different riding styles.
Manufacturing Location:
Polaris snowmobiles are historically manufactured in the United States (e.g., Roseau, Minnesota).
Industry Acclaim:
Polaris snowmobiles from this era generally received positive reviews for performance and capability across various segments. Specific awards for individual models are model-dependent and not detailed in the product title.
