2004 Polaris 440 PRO XR, 550 PRO X, 600 PRO X, X2, 700 PRO X, X2, 800 PRO X, X2, XR snowmobile service manual

Product Information

Table of Contents

1. General Information

• 1.1 Safety Information
• 1.2 Vehicle Identification
• 1.3 Specifications
• 1.4 Maintenance Schedule
• 1.5 Warranty Policy

2. Engine

• 2.1 Engine Removal and Installation
• 2.2 Disassembly and Inspection
• 2.3 Reassembly
• 2.4 Engine Cooling System

3. Fuel System

• 3.1 Carburetion
• 3.2 Fuel Injection System
• 3.3 Fuel Pump and Lines
• 3.4 Air Intake System

4. Clutching

• 4.1 Drive Clutch
• 4.2 Driven Clutch
• 4.3 Clutch Alignment
• 4.4 Clutch Tuning

5. Body and Steering

• 5.1 Hood and Bodywork
• 5.2 Steering System
• 5.3 Seat and Foam

6. Suspension

• 6.1 Front Suspension and Ski
• 6.2 Rear Suspension
• 6.3 Shocks

7. Brakes

• 7.1 Brake System Maintenance
• 7.2 Brake Adjustment
• 7.3 Brake Bleeding

8. Final Drive

• 8.1 Chaincase
• 8.2 Drive Shaft
• 8.3 Sprockets

9. Electrical Systems

• 9.1 Ignition System
• 9.2 Electrical Components
• 9.3 Battery Maintenance
• 9.4 Wiring Diagrams

10. Troubleshooting

• 10.1 Engine Troubleshooting
• 10.2 Carburetion Troubleshooting
• 10.3 Fuel Injection System Troubleshooting
• 10.4 Electrical Troubleshooting

11. Technical Data

• 11.1 Torque Specifications
• 11.2 Standard Bolt Torque Specifications
• 11.3 Sealant and Adhesive Recommendations

12. Tools and Service Products

• 12.1 Service Tools
• 12.2 Service Products

13. Index
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This manual/handbook is a valuable resource for mechanics, technicians, and owners as it provides detailed instructions and specifications for the 2004 Polaris 440 PRO XR, 550 PRO X, 600 PRO X, X2, 700 PRO X, X2, 800 PRO X, X2, XR snowmobile. It includes maintenance procedures, troubleshooting guides, and repair instructions, helping users to efficiently service and repair their snowmobile.

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