2003 Polaris Snowmobile 340, 500, 550, 600, 700 Classic Service Manual
Comprehensive service manual covering 2003 Polaris 340, 500, 550, 600, and 700 Classic snowmobiles. Includes detailed diagrams and procedures for all major systems.
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Models Covered & Key Technical Specifications
2003 Polaris 340 CLASSIC, 500 CLASSIC, 550 CLASSIC, 600 CLASSIC, 700 CLASSIC (9918049)
This comprehensive service manual provides extensive information for the 2003 Polaris Trail Luxury Snowmobile series. | Official Polaris Documentation.
- General Information Category: 116 pages covering specifications, maintenance, and engine data.
- Maintenance and Tune Up Category: 57 pages detailing routine servicing, adjustments, and inspections.
- Engine Category: 159 pages dedicated to engine disassembly, assembly, and troubleshooting.
- Fuel System / Carburetion Category: 33 pages covering fuel delivery, carburetor operation, and maintenance.
- Drive / Driven Clutches Category: 57 pages focused on clutch components, operation, and service procedures.
- Troubleshooting Category: 16 pages offering solutions for common mechanical and electrical issues.
Professional Workshop Service Manual & Technical Specifications
Definitive Service Manual: Polaris 340 CLASSIC, 500 CLASSIC, 550 CLASSIC, 600 CLASSIC, 700 CLASSIC - 2003 Trail Luxury Snowmobile Service Manual
Serial-Range: 2003 // Diagnostic-Area: Component Manuals // Product-Line: Snowmobile Maintenance
The repository is divided into sections covering:
- General Information: Includes publication numbers, model identification, and standard torque specifications.
- Maintenance and Tune Up: Details air filter, fuel filter, and lubrication procedures.
- Engines: Covers engine specifications, removal, installation, and disassembly.
- Fuel System / Carburetion: Explains fuel delivery, carburetor operation, and jetting charts.
- Drive / Driven Clutches: Focuses on clutch components, operation, and maintenance.
- Troubleshooting: Offers solutions for common issues across all systems.
This manual documents torque specifications for engine components to ensure proper seal compression uniformity.
Key System Overviews
General Information
Provides essential data including model numbers, engine specifications, and general maintenance guidelines. It includes crucial details on torque specifications for various engine parts, ensuring proper assembly and preventing damage.
Maintenance and Tune Up
This section details routine maintenance tasks such as air filter cleaning, fuel system checks, and lubrication points. It emphasizes the importance of regular servicing for optimal performance and longevity.
Engines
Delves into engine disassembly and assembly procedures, covering everything from basic component removal to detailed reassembly steps. It provides critical specifications for engine rebuilds and diagnostics.
Fuel System / Carburetion
Explains the intricacies of the fuel system, including carburetor operation, jetting charts, and troubleshooting common fuel-related issues. Proper fuel mixture is essential for engine efficiency.
Drive / Driven Clutches
Focuses on the drive and driven clutch systems, detailing their operation, maintenance, and adjustment procedures. Correct clutch operation is vital for power transmission and overall vehicle performance.
Component Specifications Table
| Assessment-Parameter | System-Path | Calibration-Standards |
|---|---|---|
| Engine Type | Fan Cooled Piston Port | Not Specified |
| Displacement | 339 cc | Not Specified |
| Bore | 2.4528" (62.3mm) | Not Specified |
| Stroke | 2.1889" (55.6mm) | Not Specified |
| Cylinder Head Torque | 18-20 ft.lbs. (25-28Nm) | Not Specified |
| Flywheel Torque | 60-65 ft.lbs. (83-90Nm) | Not Specified |
| Main Jet (Standard) | 150 | Not Specified |
| Pilot Jet (Standard) | 35 | Not Specified |
| Drive Clutch Type | P-90 | Not Specified |
| Driven Clutch Type | P-85 | Not Specified |
| Drive Belt Part Number | 3211081 | Not Specified |
| Chaincase Oil Capacity | 11 fl. oz. (325cc) | Not Specified |
| Fuel Tank Capacity | 11.8 gallons (45.4 liters) | Not Specified |
| Oil Tank Capacity | 3.25 quarts (3.1) | Not Specified |
| Ignition Timing | 26.5° BTDC@3000RPM ±1.5° | Not Specified |
| Spark Plug Gap | NGK BR8ES / 0.028" (0.7mm) | Not Specified |
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