2004 Polaris Sportsman 700 EFI Owners Manual

2004 Polaris Sportsman 700 EFI Manual

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2004 Polaris Sportsman 700 EFI manual content summary:

  • 2004 Polaris Sportsman 700 EFI | Owners Manual - Page 1
  • 2004 Polaris Sportsman 700 EFI | Owners Manual - Page 2
  • 2004 Polaris Sportsman 700 EFI | Owners Manual - Page 3
    contains chemicals known to cause cancer, birth defects or other reproductive harm. A card containing important ATV safety information should be attached to the owner's manual on the next page. If you cannot locate this card, or if it has been removed, please call 1-800-342-3764 for assistance.
  • 2004 Polaris Sportsman 700 EFI | Owners Manual - Page 4
    We've created a web site just for YOU! S S S S S Technical tips New product introductions Event schedules Parts and Service Manual information Exciting details about The Way Out Check it out...www.polarisindustries.com/owner 1
  • 2004 Polaris Sportsman 700 EFI | Owners Manual - Page 5
    Copyright 2003 Polaris Sales Inc. 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
  • 2004 Polaris Sportsman 700 EFI | Owners Manual - Page 6
    operation of your vehicle, be sure to follow the instructions and recommendations in this owner's manual. Your manual contains instructions for minor maintenance, but information about major repairs is outlined in the Polaris Service Manual and should be performed only by a Factory Certified Master
  • 2004 Polaris Sportsman 700 EFI | Owners Manual - Page 7
    VEHICLE IDENTIFICATION NUMBERS The frame vehicle identification number (VIN) and engine serial number are important for model identification when registering your vehicle, when obtaining insurance, and when ordering replacement parts. In the event your vehicle is stolen, these numbers are essential
  • 2004 Polaris Sportsman 700 EFI | Owners Manual - Page 8
    TABLE OF CONTENTS WELCOME ...3 VEHICLE IDENTIFICATION NUMBERS ...4 SAFETY ...6 FEATURES AND CONTROLS ...32 OPERATION ...47 EMISSION CONTROL SYSTEMS ...64 MAINTENANCE AND LUBRICATION ...65 TROUBLESHOOTING ...103 POLARIS PRODUCTS ...105 SPECIFICATIONS ...109 WARRANTY ...110 INDEX ...117 5
  • 2004 Polaris Sportsman 700 EFI | Owners Manual - Page 9
    of the decals on the ATV carefully. If any of the decals depicted in this manual differ from the decals on your ATV, always read and follow the instructions of the decals on the ATV. If any decal becomes illegible or comes off, contact your Polaris dealer to purchase a replacement. Replacement
  • 2004 Polaris Sportsman 700 EFI | Owners Manual - Page 10
    or hilly terrain, reduce speed and cargo. Do not block headlight. Be careful if load extends over the side of the rack. Read Owner's Manual for more detailed loading information 7079084 ATTENTION S Operation of this vehicle without the air filter element will severely damage the engine. S Clean pre
  • 2004 Polaris Sportsman 700 EFI | Owners Manual - Page 11
    SAFETY Safety Decals and Locations WARNING Moving parts hazard under belt-clutch guard. To prevent serious injury, do not operate vehicle with guard removed. Do not modify engine or clutch. Doing so can cause part failure, possible imbalance, and excessive engine RPM which can result in serious
  • 2004 Polaris Sportsman 700 EFI | Owners Manual - Page 12
    sudden increases in power and traction if too much throttle is applied. Loss of control or forward flipover may result, especially in AWD. See Owner's Manual. 7079604 SAFETY ALL WHEEL DRIVE SWITCH Do not push switch to engage AWD if the rear wheels are spinning. This may cause severe drive shaft
  • 2004 Polaris Sportsman 700 EFI | Owners Manual - Page 13
    SAFETY Safe Riding Gear Always wear clothing suited to the type of riding. ATV riding requires special protective clothing for comfort and to reduce the chance of injury. 1. Helmet Your helmet is the most important piece of protective gear for safe riding. A helmet can prevent a severe head injury
  • 2004 Polaris Sportsman 700 EFI | Owners Manual - Page 14
    routine maneuvers like turning, or driving on hills or over obstacles, if you fail to take proper precautions. Read and understand your owner's manual and all warnings before operating a Polaris ATV. Age Restrictions This vehicle is an ADULT VEHICLE ONLY. Operation is prohibited for anyone under 16
  • 2004 Polaris Sportsman 700 EFI | Owners Manual - Page 15
    used. Become familiar with their meanings before reading the manual. The safety alert symbol, on your vehicle or in this manual, alerts you to the potential for personal injury. IMPORTANT will alert you to important information or instructions. NOTE: A note will alert you to key information or
  • 2004 Polaris Sportsman 700 EFI | Owners Manual - Page 16
    Safety SAFETY WARNING Serious injury or death can result if you do not follow these instructions and procedures, which are outlined in further detail within your owner's manual. S Read this manual and all labels carefully, and follow the operating procedures described. S Never operate an ATV
  • 2004 Polaris Sportsman 700 EFI | Owners Manual - Page 17
    . To avoid stalling, maintain a steady speed when climbing a hill. If you stall or roll backwards, follow the special procedure for braking described in this manual. Always dismount on the uphill side, or to either side if the ATV is pointed straight uphill. Turn the ATV around and remount following
  • 2004 Polaris Sportsman 700 EFI | Owners Manual - Page 18
    exceed the stated load capacity for your ATV. Cargo must be properly distributed and securely attached. Reduce speed and follow the instructions in this manual for carrying cargo or towing. Allow a greater distance for braking. FOR MORE INFORMATION ABOUT ATV SAFETY, call the Consumer Product Safety
  • 2004 Polaris Sportsman 700 EFI | Owners Manual - Page 19
    Safety WARNING POTENTIAL HAZARD Operating this ATV without proper instruction. WHAT CAN HAPPEN The risk of an accident the skills learned in the course and the operating techniques described in the owner's manual. For more information about the training course, contact an authorized ATV dealer or
  • 2004 Polaris Sportsman 700 EFI | Owners Manual - Page 20
    Operator Safety SAFETY WARNING POTENTIAL HAZARD Carrying a passenger on an ATV. WHAT CAN HAPPEN Carrying a passenger greatly reduces the operator's ability to balance and control the ATV, which could cause an accident and injury to the operator and/or passenger. HOW TO AVOID THE HAZARD Never carry
  • 2004 Polaris Sportsman 700 EFI | Owners Manual - Page 21
    SAFETY Operator Safety WARNING POTENTIAL HAZARD Operating this ATV on public streets, roads or highways. WHAT CAN HAPPEN The ATV could collide with another vehicle. HOW TO AVOID THE HAZARD Never operate the ATV on any public street, road or highway, including dirt and gravel roads. In many states
  • 2004 Polaris Sportsman 700 EFI | Owners Manual - Page 22
    Operator Safety SAFETY WARNING POTENTIAL HAZARD Operating the ATV after consuming alcohol or drugs. WHAT CAN HAPPEN Consumption of alcohol and/or drugs could seriously affect operator judgment. Reaction time may be slower and operator balance and perception could be affected. Consuming alcohol and
  • 2004 Polaris Sportsman 700 EFI | Owners Manual - Page 23
    use to make sure it's in safe operating condition. Always follow the inspection and maintenance procedures and schedules described in the owner's manual. WARNING POTENTIAL HAZARD Removing hands from the handlebars or feet from the footrests during operation. WHAT CAN HAPPEN Removing even one hand
  • 2004 Polaris Sportsman 700 EFI | Owners Manual - Page 24
    Operator Safety SAFETY WARNING POTENTIAL HAZARD Failure to use extra caution when operating the ATV on unfamiliar terrain. WHAT CAN HAPPEN Unfamiliar terrain may contain hidden rocks, bumps, or holes that could cause loss of control or overturn. HOW TO AVOID THE HAZARD Travel slowly and use extra
  • 2004 Polaris Sportsman 700 EFI | Owners Manual - Page 25
    and lead to a collision or overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for turning as described in the owner's manual. Practice turning at slow speeds before attempting to turn at faster speeds. Never turn at excessive speed. WARNING POTENTIAL HAZARD Operating on excessively
  • 2004 Polaris Sportsman 700 EFI | Owners Manual - Page 26
    could cause loss of control or overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for climbing hills as described in the owner's manual. Always check the terrain carefully before ascending any hill. Never operate the ATV on hills steeper than 25_. Never climb hills with excessively
  • 2004 Polaris Sportsman 700 EFI | Owners Manual - Page 27
    of control or overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for traveling down hills as described in the owner's manual. NOTE: A special technique is required when braking while traveling downhill. See page 58. Always check the terrain carefully before descending a hill. Shift
  • 2004 Polaris Sportsman 700 EFI | Owners Manual - Page 28
    Never attempt to turn the ATV around on any hill until you've mastered the turning technique (on level ground) as described in the owner's manual. See page 59. Use extra caution when turning on any hill. Avoid crossing the side of a steep hill. When crossing the side of a hill: Always
  • 2004 Polaris Sportsman 700 EFI | Owners Manual - Page 29
    uphill side, or to either side if ATV is pointed straight uphill. Turn the ATV around and remount, following the procedure described in the owner's manual. See page 59. 26
  • 2004 Polaris Sportsman 700 EFI | Owners Manual - Page 30
    such as rocks and fallen trees when possible. If unavoidable, use extreme caution and always follow proper procedures as outlined in the owner's manual. WARNING POTENTIAL HAZARD Skidding or sliding. WHAT CAN HAPPEN Skidding or sliding can cause loss of control. If the tires regain traction
  • 2004 Polaris Sportsman 700 EFI | Owners Manual - Page 31
    SAFETY Operator Safety WARNING POTENTIAL HAZARD Operating the ATV through deep or fast-flowing water. WHAT CAN HAPPEN Tires may float, causing loss of traction and loss of control, which could lead to an accident or overturn. HOW TO AVOID THE HAZARD Avoid operating the ATV through deep or fast-
  • 2004 Polaris Sportsman 700 EFI | Owners Manual - Page 32
    tires specified for the ATV in the owner's manual. Always maintain proper tire pressure as described in the owner's manual and on safety decals. WARNING POTENTIAL HAZARD Operating installed and used according to approved instructions. See your authorized Polaris ATV dealer for more information. 29
  • 2004 Polaris Sportsman 700 EFI | Owners Manual - Page 33
    . Allow a greater distance for braking. Always follow the instructions in the owner's manual for carrying cargo or pulling a trailer. WARNING POTENTIAL HAZARD ice is thick enough and sound enough to support the machine and its operator, as well as the force created by a moving vehicle,
  • 2004 Polaris Sportsman 700 EFI | Owners Manual - Page 34
    WARNING Operating a damaged ATV can result in an accident with serious injury or death. After any overturn or accident, have a qualified service dealer inspect the entire machine for possible damage, including (but not limited to) brakes, throttle and steering systems. WARNING Safe operation of
  • 2004 Polaris Sportsman 700 EFI | Owners Manual - Page 35
    FEATURES AND CONTROLS Engine Electrical Switches WARNING Activating the override switch while the throttle is open can cause loss of control, resulting in severe injury or death. Do not activate the override switch while the throttle is open. 2 1 3 Mode/Reverse Override Switch (1) - This vehicle
  • 2004 Polaris Sportsman 700 EFI | Owners Manual - Page 36
    to severe injury or death. Never start or operate an ATV with a sticking or improperly operating throttle. Always contact your dealer for service if throttle problems arise. Failure to check or maintain proper operation of the throttle system can result in an accident if the throttle lever sticks
  • 2004 Polaris Sportsman 700 EFI | Owners Manual - Page 37
    FEATURES AND CONTROLS Light Switches The light switch is located on the left handlebar. It's used to turn the lights on and off and to switch the lights from HI to LO. NOTE: The lights won't work unless the key is in the ON position and the auxiliary shut-off switch is in the RUN position. WARNING
  • 2004 Polaris Sportsman 700 EFI | Owners Manual - Page 38
    Master Cylinder FEATURES AND CONTROLS 1 The brake fluid in the master 2 cylinder (1), which is located on the left handlebar, should be checked before each ride. The fluid level can be seen through an indicator window (2) on the top of the master cylinder. This eye will appear dark when the fluid
  • 2004 Polaris Sportsman 700 EFI | Owners Manual - Page 39
    FEATURES AND CONTROLS Parking Brake WARNING Operating the ATV while the parking brake is engaged could result in an accident and serious injury or death. Always check to be sure the parking brake is disengaged before operating. Setting the Parking Brake 1 1. Place the transmission in park. 2.
  • 2004 Polaris Sportsman 700 EFI | Owners Manual - Page 40
    Auxiliary Brake FEATURES AND CONTROLS WARNING Aggressively applying the auxiliary brake when backing down a hill may cause rear tipover, which could result in serious injury or death. Use caution when applying the auxiliary brake. Do not aggressively apply the auxiliary brake when going forward.
  • 2004 Polaris Sportsman 700 EFI | Owners Manual - Page 41
    FEATURES AND CONTROLS Fuel Tank The fuel tank filler cap (1) is located directly below the handlebar. Use either leaded or unleaded gasoline with a minimum pump octane number of 87=(R+ M/2) octane. 1 Fuel Filter The in-line fuel filter should be replaced by your dealer after every 200 hours of
  • 2004 Polaris Sportsman 700 EFI | Owners Manual - Page 42
    Automatic Transmission Gear Selector FEATURES AND CONTROLS The transmission gear selector (1) is located on the right side of the vehicle. H: High Gear L: Low Gear N: Neutral R: Reverse P: Park To shift into HIGH or PARK, you must first apply the auxiliary brake to activate the high/park lock-out
  • 2004 Polaris Sportsman 700 EFI | Owners Manual - Page 43
    FEATURES AND CONTROLS All Wheel Drive (AWD) System Polaris 4-wheel drive ATVs are equipped with a unique, Polaris-exclusive, On-Demand All Wheel Drive system, which is activated by the AWD switch (1) on 1 the right handlebar. When the switch is off, the ATV is in two-wheel drive at all times. When
  • 2004 Polaris Sportsman 700 EFI | Owners Manual - Page 44
    Instrument Cluster FEATURES AND CONTROLS Your ATV is equipped with an instrument cluster that senses vehicle speed from the right front wheel. The instrument cluster measures distance in miles as well as hours of operation. It also includes a reverse speed limiter function that limits the ATV's
  • 2004 Polaris Sportsman 700 EFI | Owners Manual - Page 45
    = Park 2. AWD Indicator - This indicator illuminates when the electrical portion of the AWD system is enabled. 3. Engine Hour Display Indicator 9 1 4. Service Interval/Diagnostic Mode Indicator 5. Low Battery and Over Voltage - This warning usually indicates that the ATV is operating at an RPM too
  • 2004 Polaris Sportsman 700 EFI | Owners Manual - Page 46
    Cluster FEATURES AND CONTROLS Rider Information Center The rider information center has 4 standard modes: Mode 1 - Odometer Mode 2 - Tripmeter Mode 3 - Total Service Hours Mode 4 - Tachometer The reverse override button on the left handlebar is also the mode button. NOTE: If using the mode button
  • 2004 Polaris Sportsman 700 EFI | Owners Manual - Page 47
    FEATURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode The diagnostic mode is for informational purposes only. Please return your ATV to your dealer for all major repairs. As long as the gauge is in the diagnostic mode, the wrench icon will remain lit. To leave the
  • 2004 Polaris Sportsman 700 EFI | Owners Manual - Page 48
    faster. When the desired time increment is displayed, release the button and wait for the wrench to stop flashing. When the wrench stops blinking, your service hours are set. NOTE: If you scroll past the intended number, hold the button down until the count turns over to 0. You can then reset
  • 2004 Polaris Sportsman 700 EFI | Owners Manual - Page 49
    FEATURES AND CONTROLS Instrument Cluster Rider Information Center Special EFI Diagnostic Mode The EFI diagnostic mode is for informational purposes only. Please see your Polaris dealer for all major repairs. To download blink codes (failure codes) from the EFI module: 1. Place the transmission in
  • 2004 Polaris Sportsman 700 EFI | Owners Manual - Page 50
    Fuel Safety OPERATION WARNING Gasoline is highly flammable and explosive under certain conditions. Always exercise extreme caution whenever handling gasoline. Always refuel with the engine stopped, and outdoors or in a well ventilated area. Do not smoke or allow open flames or sparks in or near
  • 2004 Polaris Sportsman 700 EFI | Owners Manual - Page 51
    OPERATION Break-In Period The break-in period for your new Polaris ATV is defined as the first ten hours of operation, or the time it takes to use the first two full tanks of gasoline. No single action on your part is as important as following the procedures for a proper break-in. Careful treatment
  • 2004 Polaris Sportsman 700 EFI | Owners Manual - Page 52
    Pre-Ride Inspection OPERATION WARNING If a proper inspection is not done before each use, severe injury or death could result. Always inspect the vehicle before each use to ensure it's in proper operating condition. Use the following checklist to verify that your vehicle is in proper working
  • 2004 Polaris Sportsman 700 EFI | Owners Manual - Page 53
    OPERATION Starting the Engine WARNING Engine exhaust contains poisonous carbon monoxide and can cause loss of consciousness resulting in severe injury or death. Never run an engine in an enclosed area. 1. Position the vehicle on a level surface with the transmission in PARK. 2. Lock the park
  • 2004 Polaris Sportsman 700 EFI | Owners Manual - Page 54
    and understand the load distribution warning labels on the vehicle, and never exceed the weight capacities outlined in the specifications section of the owner's manual and on the safety decals. Cargo weight should be evenly distributed (1/3 on the front rack and 2/3 on the rear rack) and mounted as
  • 2004 Polaris Sportsman 700 EFI | Owners Manual - Page 55
    with extra caution. Always attach the tow load to the hitch point designated for your vehicle. HEAVY LOADS CAN CAUSE BRAKING AND CONTROL PROBLEMS. Use extreme caution when applying brakes with a loaded vehicle. Avoid terrain or situations that may require backing downhill. USE EXTREME CAUTION when
  • 2004 Polaris Sportsman 700 EFI | Owners Manual - Page 56
    Driving Safely Driving Procedures OPERATION 1. Sit upright with both feet on the footrests and both hands on the handlebars. 2. Start the engine and allow it to warm up, then shift the transmission into gear. 3. Check your surroundings and determine your path of travel. 4. Release the parking
  • 2004 Polaris Sportsman 700 EFI | Owners Manual - Page 57
    tire must slip traction slightly. To turn, steer in the direction of the turn, leaning your upper body to the inside of the turn while supporting your weight on the outer footrest. This technique alters the balance of traction between the rear wheels, allowing the turn to be made smoothly. The
  • 2004 Polaris Sportsman 700 EFI | Owners Manual - Page 58
    Driving Safely Driving on Slippery Surfaces OPERATION Whenever riding on slippery surfaces such as wet trails or loose gravel, or during freezing weather, follow these precautions: 1. Slow down when entering slippery areas. 2. Engage AWD before wheels begin to lose traction. 3. Maintain a high
  • 2004 Polaris Sportsman 700 EFI | Owners Manual - Page 59
    injury or death. Avoid climbing steep hills (25_ maximum). Use extreme caution when operating on hills, and follow proper operating procedures outlined in the owner's manual. 56
  • 2004 Polaris Sportsman 700 EFI | Owners Manual - Page 60
    overturn, resulting in severe injury or death. Avoid crossing the side of a hill when possible. Follow proper procedures as outlined in the owner's manual. Sidehilling can be the most dangerous type of driving encountered and should be avoided if at all possible. If you do enter into a situation
  • 2004 Polaris Sportsman 700 EFI | Owners Manual - Page 61
    to lock, which could result in loss of control. Before operating your ATV, learn how the auxiliary brake works in case you lose your normal service brakes. 58
  • 2004 Polaris Sportsman 700 EFI | Owners Manual - Page 62
    on hills, and follow proper operating procedures outlined in the owner's manual. If the vehicle stalls while climbing a hill, never back it of the vehicle, turn the handlebars full left. 5. While holding the service brake, release the parking brake lock and slowly allow the vehicle to roll
  • 2004 Polaris Sportsman 700 EFI | Owners Manual - Page 63
    brakes by applying light pressure to the lever until braking action is normal. After running the vehicle in water, it's critical to have it serviced as outlined in the maintenance chart. See page 65. The following areas need special attention: engine oil, transmission oil, front and rear gearcases
  • 2004 Polaris Sportsman 700 EFI | Owners Manual - Page 64
    Driving Safely Driving Over Obstacles OPERATION Be alert! Look ahead and learn to read the terrain you're traveling on. Be constantly alert for hazards such as logs, rocks and low hanging branches. WARNING Severe injury or death can result if your vehicle comes in contact with a hidden obstacle.
  • 2004 Polaris Sportsman 700 EFI | Owners Manual - Page 65
    OPERATION Driving Safely Driving in Reverse Follow these precautions when operating in reverse: 1. Always avoid backing downhill. 2. Back slowly. 3. When in reverse, apply the brakes lightly for stopping. 4. Avoid turning at sharp angles in reverse. 5. Never open the throttle suddenly while backing.
  • 2004 Polaris Sportsman 700 EFI | Owners Manual - Page 66
    Driving Safely Parking on an Incline OPERATION Avoid parking on an incline if possible. If it's unavoidable, follow these precautions: 1. Turn the engine off. 2. Place the transmission in park. 3. Set the parking brake. 4. Always block the rear wheels on the downhill side as shown. 63
  • 2004 Polaris Sportsman 700 EFI | Owners Manual - Page 67
    level requirements. Spark Arrestor Your Polaris ATV has a spark arrestor that was tested and approved in accordance with the USDA Forestry Service Standard 5100-1C. Exhaust Emission Control System Exhaust emissions are controlled by engine design. An electronic fuel injection (EFI) system controls
  • 2004 Polaris Sportsman 700 EFI | Owners Manual - Page 68
    components are explained in the periodic maintenance schedule. Use the instrument cluster's programmable service interval mode to help determine when maintenance service is due. See page 45 for instructions. Maintenance intervals are based upon average riding conditions and an average vehicle speed
  • 2004 Polaris Sportsman 700 EFI | Owners Manual - Page 69
    marked with a J could result in component failure and lead to serious injury or death. Have an authorized Polaris dealer perform these services. Item Brake System Auxiliary Brake Tires Wheels Frame nuts, bolts, fasteners " Air filter, Hours/ Miles Frequency Remarks Inspect Inspect Inspect Inspect
  • 2004 Polaris Sportsman 700 EFI | Owners Manual - Page 70
    Periodic Maintenance Schedule Item " Air box sediment MAINTENANCE AND LUBRICATION Hours/ Miles Frequency Remarks Drain deposits whenever visible Check operation daily; apply Polaris dielectric grease to connector when replaced Check operation daily; apply Polaris dielectric grease to socket when
  • 2004 Polaris Sportsman 700 EFI | Owners Manual - Page 71
    failure and lead to serious injury or death. Have an authorized Polaris dealer perform these services. Item " Engine oil level/oil Hours/ Miles Frequency Remarks Check level daily; break-in service at one month; change oil more often in cold weather Replace with oil change Inspect Inspect
  • 2004 Polaris Sportsman 700 EFI | Owners Manual - Page 72
    Periodic Maintenance Schedule Item Coolant strength Hours/ Miles 100 hrs. 12 months MAINTENANCE AND LUBRICATION Frequency Remarks Inspect strength seasonally; pressure test system annually Inspect; replace as needed Inspect; adjust as needed Check for leaks at tank cap, lines; replace lines and
  • 2004 Polaris Sportsman 700 EFI | Owners Manual - Page 73
    MAINTENANCE AND LUBRICATION Periodic Maintenance Record Maintenance Interval Performed 10 hrs. 20 hrs. 50 hrs. 100 hrs. Servicing Servicing Date Dealer or Person Use the following chart to record periodic maintenance. Remarks 70
  • 2004 Polaris Sportsman 700 EFI | Owners Manual - Page 74
    is due at 20 hours, the equivalent odometer reading would be 200 miles. Perform all services at whichever reading is reached first. Lubrication Guide Key " L Polaris Premium All Season Grease or grease conforming to NLGI F More often under severe use, such as wet or dusty conditions No. 2, such
  • 2004 Polaris Sportsman 700 EFI | Owners Manual - Page 75
    MAINTENANCE AND LUBRICATION Premium 4 Synthetic Lubricant Polaris Premium 4 All Season synthetic engine oil has been specially formulated for use in Polaris 4-cycle engines. It's a fully synthetic, high performance, multi-viscosity oil designed to provide the ultimate in lubrication performance and
  • 2004 Polaris Sportsman 700 EFI | Owners Manual - Page 76
    Oil Check MAINTENANCE AND LUBRICATION The oil dipstick and fill tube (1) are located on the left side of the vehicle. 1. Position the ATV on a level surface. 2. Start the engine and let it idle for 20-30 seconds, then stop the engine. 3. Lift the lever lock (2) to remove the dipstick. Wipe it dry
  • 2004 Polaris Sportsman 700 EFI | Owners Manual - Page 77
    first. Suggested break-in oil change is at 20 hours, 200 miles, or one month, whichever comes first. Severe use operation requires more frequent service. Severe use includes continuous duty in dusty or wet conditions and cold weather riding. NOTE: Severe use cold weather riding is all riding below
  • 2004 Polaris Sportsman 700 EFI | Owners Manual - Page 78
    Transmission Oil MAINTENANCE AND LUBRICATION The transmission oil level should be checked every six months or 1000 miles (1600 km), whichever comes first. Transmission oil should be changed annually. We recommend the use of Polaris AGL Synthetic Gearcase Lubricant. See page 109 for the part
  • 2004 Polaris Sportsman 700 EFI | Owners Manual - Page 79
    MAINTENANCE AND LUBRICATION Front Gearcase Oil The front gearcase lubricant level should be checked every six months or 1000 miles (1600 km), whichever comes first. Front gearcase oil should be changed annually. We recommend the use of Polaris Premium Hub Drive Fluid. See page 109 for the part
  • 2004 Polaris Sportsman 700 EFI | Owners Manual - Page 80
    Rear Gearcase Oil MAINTENANCE AND LUBRICATION The rear gearcase lubricant level should be checked every six months or 1000 miles (1600 km), whichever comes first. Rear gearcase oil should be changed annually. Use Polaris AGL Synthetic Gearcase Lube (or GL5 80-90 weight gear lube). NOTE: See page
  • 2004 Polaris Sportsman 700 EFI | Owners Manual - Page 81
    MAINTENANCE AND LUBRICATION Engine Cooling System Coolant Level The recovery bottle (1) is located on the left side of the machine. To access the recovery bottle, remove the left side panel as outlined on page 83. 1 The fluid level must be maintained between the minimum and maximum marks on the
  • 2004 Polaris Sportsman 700 EFI | Owners Manual - Page 82
    Engine Cooling System MAINTENANCE AND LUBRICATION WARNING Escaping steam can cause severe burns. Never remove the pressure cap while the engine is warm or hot. Always allow the engine to cool before removing the pressure cap. Radiator Coolant Level 2 NOTE: This procedure is required only if the
  • 2004 Polaris Sportsman 700 EFI | Owners Manual - Page 83
    MAINTENANCE AND LUBRICATION Brakes The front and rear brakes are hydraulic disc brakes, activated by moving the single brake lever toward the handlebar. These brakes are self-adjusting. The following checks are recommended to keep the brake system in good operating condition. Check more often if
  • 2004 Polaris Sportsman 700 EFI | Owners Manual - Page 84
    Brakes MAINTENANCE AND LUBRICATION 2. Check the brake system for fluid leaks. 3. Check the brakes for excessive travel or spongy feel. 4. Check the friction pads for wear, damage and looseness. 5. Check the security and surface condition of the disc. NOTE: Pads should be changed when worn to 3/64″
  • 2004 Polaris Sportsman 700 EFI | Owners Manual - Page 85
    measurement should be 1/16″ - 1/8″ (.2 to .3 cm) more than the front measurement. NOTE: If you discover improper alignment, see your Polaris dealer for service. Steering Assembly The steering assembly of the ATV should be checked periodically for loose nuts and bolts. If loose nuts and bolts are
  • 2004 Polaris Sportsman 700 EFI | Owners Manual - Page 86
    Side Panel Removal MAINTENANCE AND LUBRICATION NOTE: Side panel removal may be difficult until the locking tabs and receivers have been snapped and unsnapped a few times. 1. Remove the seat. Step 2 2. Grasp the rear of the side panel near the rear cab. With a quick and firm motion, pull the panel
  • 2004 Polaris Sportsman 700 EFI | Owners Manual - Page 87
    an accident resulting in serious injury or death. Maintain proper tire pressure as described on the decal on your ATV and in the owner's manual. Always use original equipment size and type when replacing tires. Make sure the wheels are installed properly. Always replace tires when the tread depth
  • 2004 Polaris Sportsman 700 EFI | Owners Manual - Page 88
    by an authorized Polaris dealer. Wheel Nut Torque Specifications Check the wheel nut torques occasionally and when they've been loosened for maintenance service. Bolt Size Front 3/8″ Rear 3/8″ Sportsman 700 30 ft. lbs. (41 Nm) 30 ft. lbs. (41 Nm) Front Wheel Hub Tightening Front wheel bearing
  • 2004 Polaris Sportsman 700 EFI | Owners Manual - Page 89
    MAINTENANCE AND LUBRICATION Filter Systems Air Filter Service 1 1. Remove the seat, release the air box cover clips, and 2 remove the air box cover. 2. Loosen the clamp your vehicle without a breather filter can cause engine damage. Always reinstall the breather filter after removing for service. 86
  • 2004 Polaris Sportsman 700 EFI | Owners Manual - Page 90
    dirty during normal operation. Wash the headlights frequently to maintain lighting quality. Hot components can cause serious burns to skin. Do not service the headlamps until they've cooled sufficiently. Headlight Lamp Replacement 1. Remove the two screws on the lower front corners of the headlight
  • 2004 Polaris Sportsman 700 EFI | Owners Manual - Page 91
    MAINTENANCE AND LUBRICATION Lights The headlight beam can be adjusted to any position desired by turning the adjusting knob on the bottom right side of the headlight pod. 1. Position the vehicle on a level surface with the headlight approximately 25 ft. (7.6 m) from a wall. 2. Measure the distance
  • 2004 Polaris Sportsman 700 EFI | Owners Manual - Page 92
    Lights MAINTENANCE AND LUBRICATION Headlight Housing Replacement 1. Remove the two screws on the lower front corners of the headlight pod. 2. Using a small flat-blade screwdriver, push in on the lock tab through the two small openings at the front of the headlight pod. 3. Lift the pod slightly
  • 2004 Polaris Sportsman 700 EFI | Owners Manual - Page 93
    MAINTENANCE AND LUBRICATION Lights Lower Headlamp Removal / Installation 1. Turn the back of the headlight harness (1) in a counterclockwise direction. 2. Pull the harness assembly out from the headlight assembly. 3. Remove the headlamp and replace with a 1 new headlamp. 4. Install the new headlamp
  • 2004 Polaris Sportsman 700 EFI | Owners Manual - Page 94
    will be few combustion deposits. The electrodes are not burned or eroded. This indicates the proper type and heat range for the engine and the service. NOTE: The tip should not be flaky and white. A white insulator tip indicates overheating, caused by use of an improper spark plug or incorrect fuel
  • 2004 Polaris Sportsman 700 EFI | Owners Manual - Page 95
    and reinstall, or replace with new plugs. 6. Attempt to start the engine. If necessary, repeat the drying procedure. 7. Take the ATV to your dealer for service as soon as possible, whether you succeed in starting it or not. NOTE: If water has been ingested into the PVT, follow the procedure on
  • 2004 Polaris Sportsman 700 EFI | Owners Manual - Page 96
    Spark Arrestor MAINTENANCE AND LUBRICATION WARNING Failure to heed the following warnings while servicing the spark arrestor could result in serious injury or death. Do not perform service on the spark arrestor while the system is hot. Exhaust system temperatures can reach 1000° F. Allow
  • 2004 Polaris Sportsman 700 EFI | Owners Manual - Page 97
    MAINTENANCE AND LUBRICATION PVT System The basic operation of the Polaris PVT system is dependent on engine speed and vehicle torque requirements. As engine speed increases, the force exerted on the movable drive sheave by the flyweights also increases. This, in turn, increases the amount of pinch
  • 2004 Polaris Sportsman 700 EFI | Owners Manual - Page 98
    procedures. See your dealer as outlined in the owner's manual. This PVT system is intended for use on Polaris products when water is accidently ingested into the PVT system. Use the following instructions to dry it out before operating: 1. Remove the drain plug and service as soon as possible. 95
  • 2004 Polaris Sportsman 700 EFI | Owners Manual - Page 99
    not been fully charged can damage the battery and result in a shorter life. It can also hinder vehicle performance. Follow the battery charging instructions on page 97 before installing the battery. 1. Ensure that the battery is fully charged. 2. Set the battery in the battery holder. 3. Connect and
  • 2004 Polaris Sportsman 700 EFI | Owners Manual - Page 100
    and the sealing strip cannot be removed, you must use a voltmeter or multimeter to measure DC voltage. For a refresh charge, follow all instructions carefully. 1. Check the battery voltage with a voltmeter or multimeter. A fully charged battery will register 12.8 V or higher. 2. If the voltage is
  • 2004 Polaris Sportsman 700 EFI | Owners Manual - Page 101
    MAINTENANCE AND LUBRICATION Battery Battery Charging NOTE: Always verify battery condition before and 1-2 hours after the end of charging. State of Charge 100% Voltage Action Charge Time* (Using constant current charger @ standard amps specified on top of battery) 12.8-13.0 volts None, check at 3
  • 2004 Polaris Sportsman 700 EFI | Owners Manual - Page 102
    Accessories MAINTENANCE AND LUBRICATION Auxiliary power outlets provide 12V power for operating accessories such as hand held spot lights. Accessory outlets are available for all models. Polaris also has a wide range of additional accessories available for your ATV. See your Polaris dealer.
  • 2004 Polaris Sportsman 700 EFI | Owners Manual - Page 103
    may force water past seals. Stabilize the Fuel Fill the fuel tank. Add Polaris Carbon Clean Fuel Treatment or Polaris Fuel Stabilizer. Follow the instructions on the container for the recommended amount. (Carbon clean will also reduce the possibility of bacterial growth in the fuel system.) Allow 15
  • 2004 Polaris Sportsman 700 EFI | Owners Manual - Page 104
    the Engine 1. Treat the fuel system with Polaris Carbon Clean, following the instructions on the can. Run the engine for several minutes so the Carbon Follow lubrication guidelines in the Maintenance Section of the service or owner's manual to completely grease and lubricate the entire vehicle with
  • 2004 Polaris Sportsman 700 EFI | Owners Manual - Page 105
    Test engine coolant strength and change if necessary. Coolant should be replaced every two years. Storage Area/Covers Set the tire pressure and safely support the ATV with the tires 1-2" off the ground. Be sure the storage area is well ventilated, and cover the machine with a genuine Polaris ATV
  • 2004 Polaris Sportsman 700 EFI | Owners Manual - Page 106
    in loss of control and possible serious personal injury or death. Follow the adjustment procedures exactly, or see your Polaris dealer for service. The handlebars can be adjusted for 1 rider preference. 1. Locate handlebar bolts (1) by removing the upper headlight pod. 2. Loosen the four bolts
  • 2004 Polaris Sportsman 700 EFI | Owners Manual - Page 107
    ADJUSTMENTS Throttle Body/Idle RPM Idle RPM is preset by the manufacturer. If the engine idle speed is not satisfactory, please see your Polaris dealer for adjustment. Throttle Cable Freeplay Throttle cable freeplay is adjusted at the handlebar. 1. Slide the boots (1) off the inline cable adjuster
  • 2004 Polaris Sportsman 700 EFI | Owners Manual - Page 108
    TROUBLESHOOTING Drive Belt and Cover Problems Possible Cause Driving the ATV onto a pickup or tall trailer in high range Starting out going up a steep incline Driving at fresh fuel. Check for fouled plugs or foreign material in gas tank, fuel lines or fuel filter. See your dealer for service. 105
  • 2004 Polaris Sportsman 700 EFI | Owners Manual - Page 109
    TROUBLESHOOTING Contact your Polaris dealer for service if you're unable to identify solutions using the following charts. Engine Doesn't Turn Over Possible Cause Tripped circuit breaker Low battery voltage Loose battery
  • 2004 Polaris Sportsman 700 EFI | Owners Manual - Page 110
    TROUBLESHOOTING Engine Backfires Possible Cause Weak spark from spark plugs Incorrect spark plug gap or heat range Old or non-recommended fuel Incorrectly installed spark plug
  • 2004 Polaris Sportsman 700 EFI | Owners Manual - Page 111
    TROUBLESHOOTING Engine Stops or Loses Power Possible Cause Out of fuel Kinked or plugged fuel vent line Water present in fuel Fouled or defective spark plugs
  • 2004 Polaris Sportsman 700 EFI | Owners Manual - Page 112
    POLARIS PRODUCTS Part No. 2870791 2871281 2871844 2871567 2873602 2873603 2873604 2871653 2872276 2870465 2871654 2872277 2871322 2871423 2871460 2871515 2871551 2871312 2871329 2872073 2872348 2871323 2871534 2872113 2871326 2870652 2870990 2872893 Description Engine Lubricant Fogging Oil (12 oz.
  • 2004 Polaris Sportsman 700 EFI | Owners Manual - Page 113
    SPECIFICATIONS SPORTSMAN 700 EFI Gross Vehicle Weight Fuel Capacity Engine Oil Capacity Coolant Capacity Towing Capacity Front Rack Capacity Rear Rack Capacity Hitch Tongue Capacity Overall Length Overall Width Overall Height Wheelbase Ground Clearance Dry Weight Minimum Turning Radius Engine
  • 2004 Polaris Sportsman 700 EFI | Owners Manual - Page 114
    SPECIFICATIONS SPORTSMAN 700 EFI Shift Type Gear Reduction - Low Gear Reduction - Reverse Gear Reduction - High Drive Ratio - Front: Drive Ratio - Final Tire Size - Front Tire Size - Rear Front Brake Rear Brake Parking Brake Headlight Taillights Brake Light Instrument Cluster Side Lever (H/L/N/R/P)
  • 2004 Polaris Sportsman 700 EFI | Owners Manual - Page 115
    COVERAGE WILL BE ALLOWED UNLESS YOUR ATV IS REGISTERED WITH POLARIS. Initial dealer preparation and set-up of your ATV is very important in ensuring trouble-free operation. Purchasing a machine in the crate or without proper dealer set-up will void your warranty coverage. 112
  • 2004 Polaris Sportsman 700 EFI | Owners Manual - Page 116
    for purposes other than for which it was manufactured, or for any damages which occur during trailer transit or as a result of unauthorized service or the use of unauthorized parts. In addition, this warranty does not cover physical damage to paint or finish, stress cracks, tearing or puncturing
  • 2004 Polaris Sportsman 700 EFI | Owners Manual - Page 117
    THE DEALER IS YOUR RESPONSIBILITY). Polaris suggests that you use your original selling dealer; however, you may use any Polaris Servicing Dealer to perform warranty service. Please work with your dealer to resolve any warranty issues. Should your dealer require any additional assistance they will
  • 2004 Polaris Sportsman 700 EFI | Owners Manual - Page 118
    must be done by an authorized Polaris dealer. If you move or are traveling within the country where your vehicle was purchased, Warranty or Service Bulletin repairs may be requested from any authorized Polaris dealer who sells the same line as your vehicle. Outside the Country where your vehicle
  • 2004 Polaris Sportsman 700 EFI | Owners Manual - Page 119
    where it was purchased, and you have not followed the procedure set out above, your vehicle will no longer be eligible for warranty or service bulletin coverage of any kind. (Vehicles registered to Government officials or military personnel on assignment outside of the country where the vehicle was
  • 2004 Polaris Sportsman 700 EFI | Owners Manual - Page 120
    Accessories ...99 ADJUSTMENTS ...103-104 Age Restrictions ...11 Air Filter Service ...86 All Wheel Drive ...40 Automatic Transmission ...39 Auxiliary ...59 L Light Switches ...34 Lights ...87-90 Low Range ...94 Lubrication Guide ...71 D Diagnostic Mode ...44-46 Driving in Reverse ...62 Driving on
  • 2004 Polaris Sportsman 700 EFI | Owners Manual - Page 121
    Tires ...84 Toe Alignment ...82 Transmission Oil ...75 Transporting the ATV ...102 Traveling Downhill ...58 Traveling Uphill ...56 Trip Meter ...43 TROUBLESHOOTING ...105-108 Turning Around on a Hill ...59 R Radiator Coolant Level ...79 Rear Gearcase Oil ...77 Rear Spring ...103 Rider Information
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