2004 Polaris 440 PRO XR, 550 PRO X, 600/700 PRO X/X2, 800 PRO X/X2/XR Snowmobile Service Manual (P/N 9918588)

This factory service manual (P/N 9918588) covers the 2004 Polaris 440 PRO XR, 550 PRO X, 600/700 PRO X and PRO X2, and 800 PRO X, PRO X2 and PRO XR. It combines routine shop maintenance with engine teardown, chassis service, drivetrain repair, and electrical diagnosis.

• Engine service: Fuji and Liberty engine disassembly, piston and cylinder inspection, crankshaft checks, oil-pump servicing, recoil starter assembly, and Variable Exhaust System maintenance.

• Fuel delivery: Mikuni TMX, VM, and TM carburetor service, synchronization, needle-and-seat testing, fuel-pump inspection, jetting charts, and fuel-system troubleshooting.

• Clutches and final drive: P-85 drive-clutch indexing, TEAM driven-clutch service, belt diagnosis, HYVO chaincase work, and track and driveshaft removal.

• Suspension: Front and rear setup, torsion springs, weight transfer, limiter straps, and Walker Evans, Ryde FX, and Arvin shock rebuilding.

• Steering and brakes: CRC steering alignment, camber and toe adjustment, spindle-bushing replacement, and Hayes hydraulic brake bleeding, pad replacement, and master-cylinder service.

• Electrical diagnosis: Ignition timing curves, TPS testing, DET troubleshooting, starter and charging-system checks, throttle safety switches, and model-specific wiring diagrams.

Written for service technicians familiar with mechanical procedures, this manual assumes a properly equipped workshop and the appropriate tools. It reserves drive-clutch maintenance and repair for authorized Polaris dealers with factory service training.

Engine Inspection, Carburetors, and Cooling

Engine sections cover top-end and crankcase work, including cylinder inspection, honing, piston-ring checks, crankshaft indexing, and bearing inspection. Cylinder-head and crankcase-bolt torque tables accompany torque-sequence drawings; Piston Wash charts and fuel/oil ratio charts support engine-condition assessment and fuel preparation.

The carburetor chapters include Mikuni TM 38/40 exploded views, throttle-valve cutaway information, and separate synchronization procedures for the applicable carburetor types. Cooling-system schematics accompany bleeding procedures, while VES coverage includes spring identification and valve servicing.

440 PRO XR trail use: The manual specifies low-compression head kit P/N 2202188 for operation on 92-octane nonoxygenated fuel. It requires authorized-dealer installation and identifies the kit as unsuitable for ISR-sanctioned racing; using lower-octane fuel with the stock heads can damage the engine.

P-85 Clutches, Chaincases, and Track Service

Exploded-view clutch diagrams support the P-85 and TEAM service sections. The Belt Wear / Burn Diagnosis Chart connects belt symptoms with possible causes, while Clutch Offset Adjustment drawings support alignment checks.

The P-85 instructions address matching component positions and retaining the original shim arrangement. Incorrect reassembly can leave the clutch out of balance and require replacement of the complete assembly.

Final-drive coverage includes HYVO chaincases, chaincase oil service, shaft and bearing work, and track removal and installation. Maintenance procedures also cover drive-belt replacement, track tension, and track alignment.

Shock Rebuilding, CRC Steering, and Hayes Brakes

Front and rear suspension sections combine model-specific shock data with torsion-spring selection, weight-transfer adjustments, and suspension lubrication points. The 440 rear-suspension material includes shock-travel and motion-ratio information.

Walker Evans, Ryde FX, and Arvin rebuilding procedures cover shock disassembly, inspection, and assembly. Walker Evans tooling includes IFP bleed tool P/N PS-45908.

CRC steering procedures address camber and toe alignment. Hayes brake coverage extends to hydraulic bleeding, pad replacement, and master-cylinder cartridge servicing; chassis sections include seat-cover and nosepan replacement.

Follow the manual’s safety precautions when working around rotating clutches, pressurized shocks, hot coolant, and hydraulic brake components.

DET Fault Signals, TPS Tests, and Wiring

Detonation Elimination Technology troubleshooting distinguishes detonation indications from sensor faults and high coolant temperature. This helps technicians interpret the warning signal before selecting the relevant diagnostic checks.

Electrical sections include ignition timing curves, no-spark troubleshooting, starter testing, alternator checks, and TPS procedures using test kit P/N 2201519. The wiring section contains a separate 440 schematic and a schematic for the 600/700/800 PRO X and PRO X2 models.

A Preview of Fuel Capacities and TPS Test Data

Fuel-capacity tables list 5 gallons for the 440 PRO XR and 11.8 gallons for the other covered models. The liquid-cooled 700/800 models list a coolant capacity of 4.5 quarts.

For TPS-equipped Polaris domestic engines, the electrical section specifies 4.0–4.2 volts at wide-open throttle. This value appears with the sensor testing and adjustment procedures, alongside the test-equipment requirements.

PDF Navigation and Wiring-Diagram Readability

Search and navigation: The main text is searchable, and embedded bookmarks provide access to the chapters and index. Wiring diagrams and some embedded charts are not text-searchable; small wiring labels are readable when enlarged.

One printable, 326-page PDF in English, including both covers, introductory pages, chapter dividers, the index, and eight notes pages.