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Polaris Sportsman 700 User Manual
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2004 SPOR
TSMAN 600/700
SER
VICE MANU
AL
PN 9918803
2004 SPORTSMAN 600/700 SER
VICE MANU
AL PN 9918803
PN 9918803
Printed in USA
61446 Cover 8/22/03 2:02 PM Page 1
2
Table of Contents
General Information
5
Table of Contents
5
Model Identification
6
Serial Number Location
6
Sportsman Models Identification
7
U 1/2
10
Publication Numbers
14
Paint Codes
14
Replacement Keys
14
Standard Torque Specifications
15
Conversion Table
16
Glossary of Terms
18
Maintenance
19
Periodic Maintenance Chart
20
Pre-Ride Inspection
22
Special Tools
24
Front & Rear Gearcase Lubrication
27
Transmission Lubrication
29
Throttle Inspection
31
Idle Speed Adjustment
32
Throttle Cable
32
Fuel System
33
Compression Test
34
Fuel Filter
34
Carburetor Draining
34
Battery Maintenance
35
Ignition Timing
36
Spark Plug
36
Radiator Screen Removal
38
Coolant Level Inspection
38
Air Box Sediment Tube Service
39
Breather Filter
40
PVT Drying & PVT Drain Plug
40
Oil Change/Filter
41
Engine Oil Level
41
Wheel Alignment
44
Brake Pad Inspection
46
Front Suspension
47
Rear Suspension
47
Controls
48
Tire Inspection
48
Wheel Removal/Installation
48
Wheel Installation
48
Tire Pressure
48
Torque Table
48
Warn Winch Operation
49
Table of Contents
51
Engine Exploded Views
52
Top End
55
Piston Identification
57
Special Tools
57
Torque Specifications
58
Engine Fastener Torque Patterns
59
600 Engine Service Data
60
Cooling System Specifications
64
Cooling System Test
64
Engine Installation Notes
66
Oil Flow
68
Rocker Arm/Pushrod Inspection
69
Cylinder Head Removal
69
Cylinder Head Disassembly/Inspection
70
Cylinder Head Inspection
70
Valve Inspection
72
Combustion Chamber
73
Valve Seat Reconditioning
73
Cylinder Head Assembly
75
Valve Sealing Test
76
Valve Train Exploded View
76
Engine Head Reassembly
77
Cylinder Removal
79
Piston Removal
79
Valve Lifter Removal/Inspection
79
Cylinder Inspection
80
Piston Ring Installed Gap
83
Starter Bendix Removal/Inspection
84
Flywheel/Stator Installation
85
Flywheel/Stator Removal/Inspection
85
Engine Crankcase Disassembly/Inspection
86
Camshaft Inspection
94
Engine Crankcase Assembly
95
Troubleshooting
106
Fuel System/Carburetion
109
Fuel Flow Diagram
111
Carburetor Jetting
112
Assembly, CV Carburetor
113
Float System
115
Main System
115
Carburetor Inspection
117
Carburetor Cleaning
117
Carburetor Assembly
118
CV Carburetor System Function (4 Cycle)
113
Needle & Seat Leakage Test
119
Fuel Level
120
Fuel Pump Service
120
Fuel Pump Disassembly
120
Fuel Sender Service
121
Troubleshooting
121
Table of Contents
123
Cover/Panel Removal
124
Side Panel Removal
125
Body Assembly Exploded View
127
Body Rack Assembly, Exploded View
128
Headlight Pod Exploded View
130
Steering/A--Arm Exploded View
131
Rear Suspension Exploded View
132
A-Arm Replacement
133
Steering Post Assembly
134
Front Strut Assembly Exploded View
135
Front Strut Cartridge Replacement
136
Decal Replacement
137
Clutch
139
Drive Clutch Exploded View
140
PVT Sealing and Ducting Components
140
PVT Operation Overview
142
PVT Overheating/Diagnosis
144
PVT Disassembly
145
PVT Assembly/Inspection
146
Drive Clutch Spring Specifications
147
Shift Weights /Inspection
148
Drive Clutch Disassembly/Inspection
149
Clearance Inspection
149
Drive Clutch Reassembly
151
Drive Belt Removal/Inspection
152
Clutch Alignment/Offset
154
Drive Belt Installation
154
Late 2004 Driven Clutch Inspection
166
Troubleshooting
171
Table of Contents
173
Final Drive
174
Front Drive Axle Removal
175
Front Hub Inspection
175
Driveshaft & CV Joint Handling Tips
176
Front Drive Axle Installation
176
Front Hub Disassembly & Assembly
178
U--Joint Assembly
179
U-Joint Disassembly
179
Front Gearcase Removal/Install
180
Early 2004 Front Gearcase Exploded View
188
Late 2004 Front Gearcase Information
189
Rear Hub Removal
198
Rear Hub Installation
199
Rear Hub Assembly
200
Rear Hub Disassembly
200
Rear Driveshaft Removal
201
Driveshaft and CV Joint Tips
202
Rear Driveshaft Installation
202
Rear Driveshaft Service
203
Rear Gearcase Removal
205
Rear Gearcase Assembly
206
Rear Gearcase Disassembly
206
Rear Gearcase Installation
206
Rear Gearcase Exploded View
209
Transmission
211
Transmission, Exploded View
212
Gear Shift Selector Removal
216
Torque Specifications/Lubrication
216
Transmission Removal
216
Transmission Installation
217
Transmission Disassembly
218
Transmission Reassembly
223
Brakes
229
2004 Brake Line Identification
231
Brake Noise Troubleshooting
231
Brake System Service Notes
231
Hydraulic Brake System Overview
232
Brake Bleeding / Fluid Change
233
Hydraulic Caliper Bleeding
233
Master Cylinder Installation
235
Master Cylinder Removal
235
Front Pad Removal
236
Front Pad Installation
237
Brake Burnishing
238
Front Disc Inspection
238
Front Disc Removal/Replacement
238
Front Caliper Disassembly
239
Front Caliper Removal
239
Front Caliper Inspection
240
Front Caliper Installation
241
Front Caliper Reassembly
241
Front Caliper Exploded View
243
Rear Pad Removal
244
Rear Pad Installation
245
Rear Caliper Reassembly
246
Rear Caliper Assembly
247
Rear Caliper Removal/Inspection
246
Rear Disc Inspection
248
Rear Caliper Exploded View
250
Troubleshooting
250
Table of Contents
251
Timing Check Procedure
252
Gear Position Switch Test
254
Instrument Cluster Overview
254
Diagnostic Mode
256
Speedometer Removal/Installation
258
Speedometer Operation Troubleshooting
260
Fan Control Switch Tests
265
Coolant Temperature
265
Fan Motor Tests
265
Flywheel Identification
267
Ignition System Testing Flow Chart
269
Ignition System Troubleshooting
270
Battery Identification
273
Conventional Battery Installation
274
Conventional Battery Testing
274
Battery Check
276
Battery Charging
277
Battery Inspection
278
Battery Testing
278
Battery Installation
278
Bulb Replacement
280
Headlamp Switch
282
Fuel Sender Service
283
Hand / Thumb Warmer Switches
283
Starter System Troubleshooting
286
Starter Motor Removal
286
Starter Drive
290
Starter System Testing Flow Chart
292
4
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Polaris Sportsman 700 Specifications
General
Starting System
Electric
Rear Brakes
Hydraulic Disc
Cooling
Liquid
Front Suspension
MacPherson Strut
Front Brakes
hydraulic disc
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