2005 Polaris 340/600/800 Edge Touring, Trail Touring, Trail Touring Deluxe & Widetrak LX Snowmobile Service Manual (P/N 9919304)

Polaris service manual P/N 9919304 covers the 2005 340 Edge Touring, Trail Touring, Trail Touring Deluxe, 600 Edge Touring, 800 Edge Touring, and Widetrak LX snowmobiles.

Finding Procedures and Reading Wiring Diagrams

Search and diagram detail: Most service text is searchable, but labels embedded in some charts and wiring diagrams are not. Bookmarks provide navigation, although some labels do not match their destinations. Small connector and wire labels are readable with enlargement.

Supplied as one printable, 300-page PDF, including the front and back covers and four notes pages.

Engine, Clutch and Chassis Service Coverage

The selected service topics below are supplemented by headlight aiming and seasonal storage procedures.

• Engine and cooling: Engine removal, internal inspection, recoil service, lubrication-system adjustment, thermostat testing, and variable exhaust valve maintenance.

• Fuel delivery: Mikuni VM and TM carburetor service, fuel-pump repair, jetting charts, and troubleshooting for starting and running problems.

• Clutching and final drive: P-85 and TEAM roller clutch service, belt and alignment checks, HYVO gearing, and Widetrak transmission overhaul.

• Steering and suspension: Front-end alignment, ski service, EDGE Touring ACE diagnostics, rear-suspension setup, and Ryde FX shock rebuilding.

• Brakes: Hydraulic bleeding and master-cylinder service, plus separate mechanical-brake procedures for Widetrak LX.

• Electrical systems: Ignition, electric-start and charging tests, detonation protection, throttle-safety checks, wiring diagrams, and troubleshooting charts.

Written for Polaris snowmobile service technicians working in a properly equipped shop, this manual assumes familiarity with mechanical theory, tool use, and standard service procedures.

Fuji and Liberty Engine Repair

Maintenance schedules address brake inspection, belt service, and track tensioning. Fuel, oil, and chaincase capacity tables accompany torque specifications for cylinder heads, crankcases, and engine mounts.

Engine procedures cover Fuji assemblies and distinguish the Liberty small-block and big-block designs, including stator removal and installation for the 600 and 800 engines. Crankcase assembly, cooling-system bleeding, oil-pump service, and exhaust-valve maintenance receive separate treatment.

The Liberty sections distinguish the 600 cross-shaft-driven water pump from the 800 belt-driven arrangement. The big-block water-pump belt warning identifies belt failure as a potential cause of serious engine damage.

Mikuni VM and TM Carburetor Work

Mikuni TM flatslide carburetor synchronization is presented as a step-by-step procedure. VM and TM exploded views identify internal parts, while altitude and ambient-temperature jetting charts provide model-specific setup references.

Clutches and Widetrak Transmission Repair

Drive-clutch work is specified for authorized Polaris technicians with current service training and factory tools. The P-85 instructions warn that unmarked sheaves combined with changed or misplaced spider shims can alter clutch balance and require replacement.

TEAM roller driven-clutch procedures cover internal disassembly and inspection. HYVO gearing charts and Widetrak transmission cross-sectional views document drive-system arrangements, including low, high, and reverse power flow. Widetrak procedures extend through transmission removal, disassembly, assembly, and installation.

EDGE Touring ACE, Ryde FX Shocks and Brakes

EDGE Touring ACE coverage includes controller, motor, and potentiometer diagnosis. Its wiring diagram and test procedure for the specified service harness support troubleshooting with the engine stopped.

Ryde FX rebuild instructions distinguish IFP (Internal Floating Piston) and emulsion designs, with production shock valving charts and special-tool references.

Hydraulic-brake procedures include bleeding and master-cylinder service; Widetrak mechanical brakes have separate inspection and adjustment procedures.

Observe the manual's safety precautions for rotating clutches and tracks, brake work, and pressurized shock absorbers.

DET Protection and Electrical Fault Tracing

DET coverage explains warning-light behavior and engine fail-safe responses. Electric-start diagnostic charts distinguish dynamic checks from static motor tests, while model-specific wiring pages support circuit tracing.

TPS-equipped circuits appear in the wiring material, but this PDF does not provide a dedicated TPS testing or adjustment procedure.

Sample Water Pump and Coolant Sensor Specifications

For the 800 Liberty big-block water-pump drive, the belt replacement threshold is a width below 0.250 in. (6.35 mm). For the coolant-temperature thermistor used on TPS-equipped models, the specified resistance is 2,189–2,675 ohms at 68°F (20°C).