Official Polaris 340 CLASSIC, 500 CLASSIC, 550 CLASSIC, 600 CLASSIC EDGE, 700 CLASSIC EDGE - Trail Luxury Snowmobile Service Manual 2003

Polaris Trail Luxury Snowmobile Service Manual - 2003 Edition

Engineered for the Polaris service technician, this technical manual provides the rigorous system benchmarks and diagnostic protocols required to maintain the 2003 Trail Luxury fleet. It integrates high-precision service specifications with factory-sanctioned repair procedures to ensure mechanical integrity and peak performance. A critical uptime detail included is the requirement for a specific 60/40 mixture of antifreeze and distilled water in liquid-cooled systems; utilizing standard tap water is strictly prohibited as it leads to internal filter contamination and reduced thermal efficiency.

Technical Applicability & Model Configurations

This documentation is specifically calibrated for the 2003 Trail Luxury series utilizing the EDGE chassis and specialized engine platforms. Refer to the 17-digit Vehicle Identification Number (VIN) for exact machine verification.

• EDGE Chassis / 340 Series
  • 340 Classic / 340 EDGE Classic (Model S03ND3AS / S03NB3AS)
• EDGE Chassis / 500-700 Liquid Cooled Series
  • 500 Classic (Model S03ND5CS)
  • 600 Classic / 600 Classic EDGE (Model S03ND6ES)
  • 700 Classic / 700 Classic EDGE (Model S03ND7CS)
• EDGE Chassis / 550 Fan Cooled Series
  • 550 Classic (Model S03ND5BS)

Operational Reliability & System Accuracy

• Factory Calibration Data: Access exact jetting charts and clutch offset specifications to maintain engine performance across varying altitudes and ambient temperatures.
• Safety Critical Torques: Follow precise fastener torque sequences for cylinder heads and steering components to prevent mechanical failure and ensure rider safety.
• Service Interval Mapping: Utilize the 500-mile initial and 1500-mile periodic maintenance inspection sheets to track system wear and schedule preventative component replacement.

Document Metadata

• Print Number: PN 9918049
• Total Pages: 359 Pages
• Technical Classification: Service / Workshop Manual

Calibration Data & Factory Benchmarks

• Cylinder Head Torque: 18–22 ft. lbs. (Domestic Big Block 700) / 18–20 ft. lbs. (340/550 Fuji Fan).
• Fuel Requirements: 87 Non-Oxygenated or 89 Oxygenated gasoline (R+M/2 method).
• Spark Plug Gap: 0.028" (0.7 mm) for NGK BR8ES/BR9ES; 0.025" (0.64 mm) for Champion RN57YCC.
• Chaincase Lubricant: 11 fl. oz. (325–384cc) Polaris Synthetic Chaincase Lubricant.

Visual Navigation Aids

• System Architecture: Detailed exploded views of P-85 and P-90 drive/driven clutch assemblies.
• Electrical Schematics: Full-page wiring diagrams for ignition, lighting, and electric start circuits.
• Steering Geometry: Alignment diagrams for IFS (Independent Front Suspension) including camber and toe-out settings.

Table of Contents

• Chapter 1: General Information (VIN Keys, Torque Specs, Recommended Supplies)
• Chapter 2: Maintenance and Tune-Up (Lubrication, Track Tension, Inspection Sheets)
• Chapter 3: Engines (Disassembly/Assembly for Fuji and Domestic Liberty Twins)
• Chapter 4: Fuel System / Carburetion (Mikuni VM and TM Series, Synchronization, Fuel Pumps)
• Chapter 5: Drive / Driven Clutches (PVT Theory, Offset Adjustment, Troubleshooting)
• Chapter 6: Body and Steering (IFS Alignment, Handlebar Centering, Component Replacement)
• Chapter 7: Suspensions (EDGE and M-10 Setup, Shock Rebuilding, Spring Rates)
• Chapter 8: Brakes and Final Drive (Hydraulic Bleeding, Chaincase Tensioning)
• Chapter 9: Electrical (Timing Procedures, TPS Testing, Component Troubleshooting)

Operational Limits & Maintenance Specifications

• Drive Chain Tension: Finger tighten adjuster bolt, then back off exactly 1/4 turn to prevent premature sprocket wear.
• TPS Calibration: Domestic engines require 4.0 to 4.2 volts at Wide Open Throttle (WOT) for correct timing curves.
• Track Alignment: Ensure rails are evenly spaced within track windows; torque idler shaft bolts to 35–40 ft. lbs.
• Fluid Specifications: Use only Polaris DOT 3 High Temperature Brake Fluid; replace every two years to mitigate hygroscopic degradation.