Polaris 500/600/700/800 XC SP Snowmobile Service Manual, 2004 (P/N 9918586)

This 2004 Polaris XC SP Performance Service Manual covers factory maintenance, diagnosis, and repair for the 500, 600, 700, and 800 XC SP snowmobiles, including the listed M-10 variants. P/N 9918586, copyright 2003, includes separate service procedures for Liberty small-block and large-block engines.

PDF Text Search, Bookmarks and Wiring Detail

Finding procedures and diagrams: The main text supports keyword searches, and embedded bookmarks link to chapters and individual service topics. Labels within the ACE wiring diagram, the main wiring schematic, and some other illustrations are not searchable. Small wiring labels are readable with magnification; rotating the sideways diagrams also makes them easier to follow.

One printable, English-language 294-page PDF includes the front and back covers, three introductory pages, and two unnumbered chapter-divider pages within that total.

Liberty Engine, Clutch and Chassis Service

The overview below highlights selected service topics. Other covered work includes headlight adjustment and exhaust-system inspection.

• Engine repair: Step-by-step engine removal, small-block and large-block disassembly and assembly, piston and cylinder inspection, crankshaft truing and indexing, and VES service.

• Fuel and carburetion: Mikuni TM carburetor overhaul, throttle synchronization, choke adjustment, fuel-pump checks, and model-specific jetting charts for temperature and altitude.

• Clutch and belt service: P-85 drive-clutch and TEAM roller driven-clutch procedures, spider indexing, belt inspection, deflection adjustment, and clutch offset and alignment checks.

• Steering and suspension: EDGE camber and toe adjustment, M-10 and M-10 ACE setup, suspension lubrication diagrams, and Fox and Ryde FX shock rebuilding.

• Brakes and final drive: Hayes master-cylinder service, brake bleeding and pad replacement, chaincase bearing work, jackshaft and driveshaft removal, and track installation.

• Electrical diagnosis: Ignition timing, no-spark troubleshooting, charging and starting-system tests, wiring schematics, and Detonation Elimination Technology operation and fault interpretation.

Written primarily for Polaris snowmobile service technicians in a properly equipped shop, this manual assumes sound knowledge of mechanical theory, tool use, and shop procedures.

Engine Inspection, Lubrication and Cooling

Cylinder inspection covers head warpage, bore taper, and out-of-round measurements. Engine assembly instructions include tightening sequences for cylinder-head, cylinder-base, and crankcase fasteners, with separate procedures for the two Liberty engine families.

Oil-injection coverage extends to pump-output checks, bleeding, and cable adjustment. Separate cooling-system diagrams identify the 500/600 and 700/800 layouts, alongside coolant-level and air-bleeding procedures.

Mikuni TM Carburetion and Fuel Diagnosis

The model-specific jetting tables pair main-jet sizes with needle positions for different operating conditions. Troubleshooting charts distinguish rich and lean symptoms by throttle opening, helping relate plug fouling or poor acceleration to the relevant carburetor circuit.

The TM service section explains that the float, inlet needle, and seat are replaced as an assembly and that float level is preset. It also warns that pressurizing the fuel tank can damage this assembly.

P-85 Balance and Driven-Clutch Setup

P-85 drive-clutch exploded views accompany spring and weight data, roller inspection, and spider-shimming procedures. Sheave reference marks and the recorded spider-washer thickness are critical to preserving clutch balance; losing those references can leave the clutch out of balance and require replacement.

Polaris restricts drive-clutch servicing to appropriately trained, authorized dealer personnel using the specified tools and procedures.

Suspension Setup, Shock Rebuilding and Brake Service

The M-10 FRA initial setup reference chart relates rider weight to suspension settings. M-10 ACE coverage adds motor, switch, controller, rectifier, and potentiometer tests, plus potentiometer timing and use of service harness PA-46355.

Suspension setup decals and typical shock-valving arrangement drawings supplement shock-specific IFP-depth, nitrogen-charge, and valve-stack data. When servicing rebuildable shocks, follow the manual’s depressurization precautions: trapped nitrogen can eject components.

Hayes master-cylinder procedures extend to cartridge, lever, pivot-pin, and parking-brake spring replacement. Final-drive coverage includes bearing installation and gearing/chain compatibility charts.

Starting, Ignition and D.E.T. Troubleshooting

The dynamic starting-system test chart separates battery, cable, solenoid, and starter faults. Electrical coverage also includes six-pulse alternator information, lighting and switch tests, and a shared wiring schematic with optional equipment identified.

D.E.T. coverage explains system operation, indicator flash patterns, fail-safe behavior, and troubleshooting for equipped models.

Examples of Fuel-System Pressure Checks

The Mikuni TM needle-and-seat inspection specifies a 5 psi pressure test with a one-minute observation period; the assembly should hold pressure indefinitely. The section identifies pressure tester 2870975.

For the impulse-operated fuel pump, the diaphragm inspection specifies 4–6 psi applied at the impulse fitting or line, with pressure held indefinitely. These are separate component checks, rather than a single fuel-system operating-pressure specification.