2004 Polaris PRO X Snowmobile Service Manual

Complete service and repair documentation for 2004 Polaris 440 PRO XR, 550 PRO X, 600 PRO X, 700 PRO X, 800 PRO X snowmobiles. Covers all components and systems.

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Document Details

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Document Number / Seller:
32139 / Lisa Clark
File Size:
16.61 MB
File Type:
PDF
Language:
English
Printable:
Yes
Category:
Snowmobile
Last updated / verified
Sep 25, 2025

Models Covered & Key Technical Specifications

2004 Polaris PRO X Snowmobile Service Manual Complete service and repair documentation for 2004 Polaris 440 PRO XR, 550 PRO X, 600 PRO X (X2), 700 PRO X (X2), 800 PRO X (X2, XR) snowmobiles. Technical-Library | Binder.

  • Nominal Tolerance Values: 165/in for stock IFS spring rates ensures proper suspension performance.
  • Principal Interference Fit: 2.0” / 5cm provides the IFS spring pre-load for the 440 PRO XR, optimizing front suspension response.
  • Rated Electrical Load: 280 watts is the typical alternator output, supporting all electrical system needs reliably.
  • Calibrated Production Data: 9.22” / 23cm is the front vertical travel, ensuring smooth operation over varied terrain.
  • Documented Production Data: 14”/35.5 cm denotes the standard width for the track, providing optimal traction and stability.
  • Design Production Data: 121”/307 cm is the standard length for the track, ensuring proper fitment and performance.

Professional Workshop Service Manual & Technical Specifications

Polaris 2004 Pro X Snowmobile Service Manual: Technical-Guide

Technical-Benchmarks: 2004 PRO X // Year-Coverage: 2004 Snowmobile // Technical-Benchmarks: Service & Maintenance Manual

Integrated-Framework Rating Architecture
Suspension Spring Rate 165#/in Front IFS Spring Rate
IFS Spring Pre-Load 2.0" / 5cm 440 PRO XR IFS Spring Pre-Load
Alternator Output 280 watts Electrical System Nominal Output
Front Vertical Travel 9.22" / 23cm IFS Suspension Geometry
Track Width 14"/35.5 cm Track System Dimension
Track Length 121"/307 cm Track System Dimension

Coverage is segmented into the following chapters:

  • Specifications
  • General Information
  • Maintenance
  • Clutching
  • Fuel Delivery
  • Final Drive
  • Rear Suspension

This manual meticulously documents the operational procedures, maintenance schedules, and technical specifications required for the Polaris 440 PRO XR, 550 PRO X, 600 PRO X, 700 PRO X, and 800 PRO X snowmobiles. It details disassembly, assembly, and adjustment procedures for critical components including the engine, clutches, suspension, and fuel system. The document includes detailed diagrams and tables for easy reference.

FAQ

Check the **standard** spark plug condition and gap. keyboard_arrow_down

12-14 Ft. Lbs (16.6-19.3 Nm) is the specified torque for spark plug installation, ensuring a proper seal.

What does the **necessary** adjustment procedures entail for the drive clutch? keyboard_arrow_down

200 ft. lbs. (276 Nm) is the spider torque specification for P85 and P90 drive clutches, crucial for maintaining balance and performance.

Reference the **recommended** pressure specifications for the IFS shocks. keyboard_arrow_down

200 psi is the typical Nitrogen Pressure for Walker Evans IFS shocks, ensuring optimal damping performance across varying conditions.

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This manual has been a game changer for my snowmobile maintenance! The detailed instructions and illustrations made repairs a breeze. Plus, the download process was fast and easy! I received the link almost immediately after purchase. Highly recommend!