2004 POLARIS SPORTSMAN 700 MANUAL PDF

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All information contained within this publication is based on the latest product information at the time of publication.

Due to constant improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this publication. A NOTE provides key information to clarify instructions. Trademarks Polaris acknowledges the following products mentioned in this manual: When servicing your Sportsman it is important to identify which model you are working on.

There are exceptions in the steering, suspension, and engine areas. Always consult the exploded views in each manual section for torque values of fasteners before using standard torque. Distance between center of crankshaft and center of driven clutch shaft.

Distance between chain link pins No. Polaris polarus chain length in number of pitches. Recommended Lubricants and Capacities. Change oil immediately and monitor level. If oil level begins to rise, discontinue use and determine cause.

Inspection may reveal the need for replacement parts. Always use genuine Polaris parts. Catch and discard used oil properly. G The correct front gearcase lubricant to use is sportsmxn. G Be sure vehicle is level before proceeding. G Check vent hose to be sure it is routed properly and unobstructed. Clean and reinstall the drain plug with a new sealing washer.

Reinstall fill plug and torque to 14 ft. Place the gear selector in neutral. Shift rod is preset at time of manufacture. Start the engine and let it idle. Shift Linkage Rod 4. The pilot system supplies fuel during engine operation with the throttle valve closed or slightly opened.

Start engine and set idle to specified RPM.

Polaris Sportsman 700

Gasoline is extremely flammable and explosive under certain conditions. Always stop the engine and manial outdoors or in a well ventilated area.

Turn drain screw out two turns and allow fuel in the float bowl and fuel line to drain completely. Check fuel tank, oil tank, carburetor, battery and 4. Inspect the drained fuel for water or sediment. Battery electrolyte is poisonous. Measure gap with a wire gauge.

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Polaris Sportsman 700 Efi 2005 Service Manual

Refer to specifications for proper spark plug type and gap. Disconnect holder strap and remove cover. Adjust gap if necessary by bending the side 2. Disconnect sportsmzn negative – black cable first, electrode carefully. Do not add straight antifreeze or straight water to the system. Straight water or antifreeze may cause the system to freeze, corrode, or overheat.

Verify the inner splash cap vent hole is clear and open.

Owner’s Manuals | Polaris

It is recommended that the air filter and pre filter be replaced annually. When riding in extremely dusty conditions, replacement is required more often. Be sure breather line is routed properly and secured in place. Make sure lines are not kinked or pinched. Remove dipstick and fill sump with 2 quarts 1.

If cotter pins are removed, they must not be re-used. Place machine on a smooth level surface. Set handlebars in a straight ahead position and Be sure to keep handlebars centered. See notes secure sportdman in this position. This will tell G Do not perform clean out immediately after the engine has been spoortsman, as the ex- you which tie rod needs adjusting. Tighten any loose With the transmission in gear and the parking and adjustment.

Be sure the valve stem is toward the outside and rotation arrows on the tire point toward forward rotation. The switch on the handlebar does not have soprtsman be in the OUT position. Apply Polaris 0W oil to seal. Apply 0W to lifters.

Pushrods Bushing Do not expansion plug install more than 1. Apply Moly Lube Grease. The radiator cap relief pressure is 13 lbs. Disconnect the coolant hoses. Properly dispose of any antifreeze from the engine or hoses. Refer to PVT System Chapter 6 to remove outer clutch cover, drive belt, drive clutch, driven clutch, 2.

Rinse thoroughly, dry with compressed air, A finished cylinder should have a cross-hatch pattern and oil the bore immediately with Polaris 4 Cycle to ensure piston ring seating and to aid in the retention Lubricant to prevent the formation of surface rust. Beginning in the crankcase sump, the oil is drawn through an oil galley to the feed side of the oil pump. The oil is then pumped through the oil filter.

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If the oil filter is obstructed, a bypass valve contained in the filter allows oil to bypass the filter element. If the push rod A is visibly bent, it should be replaced. Mark or tag rocker arms in order of disassembly to keep them in order for reassembly.

Inspect the wear pad at the valve end of the rocker arm for indications of scuffing or abnormal wear. Thoroughly clean cylinder head surface to Wear eye protection or a face shield during remove all traces of gasket material and carbon. Use care not to damage sealing surface. Carefully remove the cylinder components. Place the hydraulic lifters Cpushrods Dand Std: Remove valve guide seals. It is recommended to replace seals whenever the cylinder head is disassembled.

Remove all carbon from valves with a soft wire Intake: Check valve face for runout, pitting, and burnt Exhaust: Install pilot into valve guide. Polaris recommends that the work be done by a local machine shop that specializes in this area.

The cylinder head valve guides cannot be replaced. Clean all filings from the area with hot soapy water, rinse, and dry with compressed air. Clean and dry the combustion chamber area A. Refer to Page 3. Pour a small amount of clean solvent onto the intake port and check for leakage around each intake valve. The valve seats should hold fluid with no seepage. Lubricate push rods D and install into lifters.

Before reassembly, clean the bolts and bolt holes with Primer N PN to remove any debris.

POLARIS SPORTSMAN EFI SERVICE MANUAL Pdf Download.

This will ensure proper sealing when installing bolts. Install the head gasket A on the cylinder B. Install thermostat JO–ring, thermostat housing. Torque thermostat housing 8. Install breather reed G into rocker cover H. Lightly apply black RTV sealant to the outer edges of the breather reed.

Check the lifters for wear or scores. Check the bottom end of lifter to make sure that it 1. Follow engine disassembly procedures to has a slight convex.

If the bottom surface has worn flat, it may be used 2.

The ring may lose b Remove the expander.