General:
Model Number Identification, VIN, Publication Numbers, General Service Precautions, Torque Specifications, Units of Measure, Tap Drill Sizes, Conversions
Maintenance:
Inspection Sheets, Recommended Products, Air Filter, Water Sediment Trap, Lubrication Points, Chaincase Fluid, Water Pump Belt, Suspension Lubrication, Track Inspection/Maintenance, Spark Plug Selection, Drive Belt, Headlight/Handlebar Adjustment, Brake Systems (Mechanical/Hydraulic), Reverse Adjustment, Storage, Battery, Exhaust System
Engine:
Torque Specs/Sequences, Piston/Cylinder Inspection, Honing, Port Chamfering, Bearing Inspection, Crankshaft Truing/Runout/Indexing, Oil Pump Operation/Bleeding/Adjustment, Cooling System (Diagrams for 600/700/800 Classic Touring & Widetrak LX), Recoil Service, Engine Removal, 340/550 Engine Service, 500 Engine Service, Liberty Small Block Service, Liberty Large Block Service, Variable Exhaust Service, Exhaust Valve Springs
Fuel Delivery:
Warnings, Jet Part Numbers, Mikuni TM 38/40 Carburetor Overview/Operation/Disassembly/Assembly/Synchronization, VM Carburetor Disassembly/Inspection/Assembly/Synchronization, Gasoline Volatility, Float Chamber Venting, Fuel Pump, Sediment Trap, Troubleshooting
Clutching:
Recommended Tools, Drive Clutch Weights/Spring Data/Exploded View/Removal/Service/Installation, Driven Clutch Exploded Views/Service (Polaris & TEAM), Clutch Operation, Driven Helix Angle, TEAM Helix Explanation, Drive Belt Data/Inspection/Deflection/Adjustments, Clutch Alignment, Belt to Sheave Inspection/Adjustment, Troubleshooting
Body And Steering:
Steering Assembly, Front Suspension Inspection/Alignment Specs/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
Suspensions:
Compression Adjustable Shocks, Front Suspension Setup/Adjustments, Spring Operation, Optional IFS Springs, Rear Suspension Operation
Brakes Final Drive:
Gearing Charts, HYVO Sprocket Part Numbers, Hydraulic Brake System Overview/Bleeding/Master Cylinder Service/Pad Replacement, Rear Suspension Removal, Jackshaft Removal/Installation, Chaincase Service, Driveshaft Installation, Final Assembly, Widetrak LX Brake Overview/Service, Transmission Removal/Service/Installation
Electrical:
Multimeter Usage, Detonation Elimination Technology, Ignition Timing Overview/Procedure, RMK Electrical Exploded Views, Battery Preparation/Load Test/Dynamic Testing, Starter Motor Static Testing/Assembly Exploded View, Unregulated/Regulated Voltage, 6 Pulse Alternators, Electrical Systems Testing, TPS Testing/Adjustment, Troubleshooting
Maintenance Procedures:
Scheduled maintenance, fluid changes, lubrication, filter replacement, belt adjustments, brake adjustments, track tensioning, storage procedures
Diagnostic Procedures:
Troubleshooting guides for various systems (engine, fuel, electrical, clutches), component testing, diagnostic charts
Repair Procedures:
Engine rebuilds (including specific engine models), carburetor service, clutch service and replacement, brake system repairs, suspension component replacement, electrical component repair, drive system service
Installation Procedures:
Engine removal and installation, suspension component installation, clutch installation, seat installation, ski installation
Technical Adjustments:
Carburetor synchronization, ignition timing, throttle position sensor (TPS) adjustment, clutch alignment, track tension adjustment, brake adjustments, suspension alignment
Depth:
Comprehensive, factory-level detail suitable for professional technicians and experienced DIY mechanics. Covers everything from routine maintenance to complete engine and driveline overhauls.
Scheduled Maintenance:
The manual provides comprehensive maintenance schedules and recommended product usage, covering tasks typically performed at varying mileage or seasonal intervals (e.g., pre-season inspection, regular lubrication, fluid checks).
Chaincase Fluid:
Details regarding the correct type and level of fluid for the chaincase are provided.
Coolant:
Information on the recommended coolant type and mixture for the liquid-cooled engine systems.
Brake Fluid:
Specifications for hydraulic brake fluid are included in the brake system service sections.
Troubleshooting Guides:
The manual includes extensive troubleshooting sections for common problems encountered with engine performance, fuel delivery, clutching, and electrical systems specific to these models.
Key Areas:
Emphasis on clutch maintenance, track tension, lubrication, and proper fuel system care as crucial for longevity and performance.