2003 Polaris 340, 500, 550, 600, 700 Classic Snowmobile Service Manual (P/N 9918049)

Polaris' 2003 Trail Luxury Snowmobile Service Manual covers the 340, 500, 550, 600, and 700 Classic lineup. This is publication P/N 9918049, copyright 2002.

Supplied as a 359-page English PDF in one file.

• Engine repair: Engine removal and installation, top-end and crankcase service, crankshaft truing, V.E.S. inspection, water pump seal replacement, and recoil starter disassembly.

• Fuel system: Mikuni VM and TM carburetor inspection, carburetor synchronization, needle-and-seat leak testing, choke adjustment, and fuel pump diagnosis.

• Drive and driven clutches: P-85 and P-90 service information, spider indexing, bushing replacement, belt alignment, and Polaris Electric Reverse roller clutch repair.

• Steering and suspension: EDGE steering alignment, FAST M-10 setup, Fox shock service, and Ryde FX adjustment and valving data.

• Brakes and final drive: Hayes master cylinder repair, caliper rebuilding, hydraulic brake bleeding, HYVO chaincase inspection, and track and jackshaft removal.

• Electrical diagnosis: Throttle Position Sensor (TPS) adjustment, stator resistance testing, starting and charging system tests, and model-specific wiring diagrams.

Written primarily for Polaris snowmobile service technicians in a properly equipped shop, this manual assumes sound mechanical knowledge and familiarity with tools and shop procedures.

Engine Repair and Model-Specific Data

The engine sections cover cylinder honing, piston and connecting-rod inspection, crankshaft indexing, oil pump adjustment, and fan and liquid cooling. Torque sequence charts, wear limits, clearances, and troubleshooting tables support internal engine repair.

Separate 550 Classic specifications cover EC55PM040 and EC55PM060 engines. Their carburetor settings and ignition components differ, including separate PTO/MAG jetting for EC55PM060. These distinctions help match the tuning and ignition data to the installed engine before diagnosis.

Water pump seal procedures identify the small-block mechanical seal guide 2872010 and big-block installation tool 2872389. Variable Exhaust System (V.E.S.) coverage includes system operation, valve cleaning, bellows inspection, spring identification, and troubleshooting.

Carburetion and Clutch Service

The manual provides jetting and clutching charts to dial in model-specific setups based on altitude and temperature. The Mikuni TM 38 / TM 40 exploded view and component-effect charts relate carburetor circuits to throttle opening.

The TM carburetor section warns that pressurizing the float chamber with compressed air can damage the floats or inlet needle and seat.

P-85 and P-90 driven clutch helix references accompany belt-deflection, offset, and alignment procedures. Drive clutch repair covers spider button shimming and roller inspection. The manual warns that an air impact wrench can loosen the spider and damage the crankshaft.

Polaris restricts drive clutch disassembly and repair to trained, authorized dealer technicians using the specified tools and procedures.

EDGE and M-10 Suspension, Steering, and Brakes

Suspension coverage includes EDGE scissor-stop settings and FAST M-10 Full Range Adjuster (FRA), X-over tube, preload, and sag adjustments. Setup decals and typical shock valving arrangements illustrate the settings and component layout.

Fox PS3 procedures cover disassembly, seal replacement, internal floating piston positioning, reassembly, and recharging. Ryde FX coverage provides adjustment information, valving part numbers, and special-tool references.

The chassis chapters add ski spindle bushing replacement, Hayes master cylinder cartridge replacement, and HYVO chaincase bearing and seal service. Mechanical reverse inspection and linkage adjustment are also covered.

Electrical Tests and Maintenance Reference

Electrical exploded views identify starter and ignition components. Diagnostic aids include the Dynamic Testing of the Electric Starting System and Condition: No Spark flowcharts, CDI connector views, and coolant-temperature sensor tests. TPS testing uses Polaris test kit 2201519.

This publication features reference tables documenting fastener torque specifications, fuel ratios, and fluid capacities, alongside standard bolt torque values for Grades 2, 5, and 8 hardware. It outlines inspection sheets for the 500-mile and 1500-mile maintenance intervals.

Always review factory safety protocols and use appropriate personal protective equipment, especially when working with pressurized shocks or spring-loaded clutches.

File Format and Readability

The page count includes one cover, three other introductory pages, ten chapter-opening pages, four index pages, one notes page, and 15 blank pages. These are already included in the total.

Embedded PDF bookmarks link to all ten chapters, the contents, and the index. Main text is searchable; details within the wiring diagrams, setup decals, and some charts are not.

The four wiring pages cover the 340, 500, 550, and combined 600/700 Classic layouts. Small wire codes and connector numbers require zooming for comfortable reading.