2004 Polaris Sportsman 700 Owners Manual

2004 Polaris Sportsman 700 Manual

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2004 Polaris Sportsman 700 manual content summary:

  • 2004 Polaris Sportsman 700 | Owners Manual - Page 1
  • 2004 Polaris Sportsman 700 | Owners Manual - Page 2
    NEVER USE WITH DRUGS OR ALCOHOL NEVER: Operate without proper training or instruction. Operate on public roads. A collision can occur with another vehicle. Operate and protective apparel. READ OWNER'S MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS. Part No. 9918724 Rev 06 PRINTED IN THE USA
  • 2004 Polaris Sportsman 700 | 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 | 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 | 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 | 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 | Owners Manual - Page 7
    VEHICLE IDENTIFICATION NUMBERS The frame vehicle identification number (VIN)(1) and engine serial number (2) 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
  • 2004 Polaris Sportsman 700 | Owners Manual - Page 8
    CONTENTS WELCOME ...3 VEHICLE IDENTIFICATION NUMBERS ...4 SAFETY ...6 CONTROLS ...36 FEATURES ...44 OPERATION ...50 EMISSION CONTROL SYSTEMS ...68 MAINTENANCE AND LUBRICATION ...69 ADJUSTMENTS ...112 POLARIS PRODUCTS ...115 TROUBLESHOOTING ...116 SPECIFICATIONS ...120 WARRANTY ...128 INDEX ...133 5
  • 2004 Polaris Sportsman 700 | 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 | 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 | 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 | 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 | 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 | 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 | Owners Manual - Page 15
    symbols are 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. WARNING The the vehicle. CAUTION NOTE: A note will alert you to important information or instructions. 12
  • 2004 Polaris Sportsman 700 | 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 | 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 | 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 | 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 | 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
  • 2004 Polaris Sportsman 700 | Owners Manual - Page 21
    SAFETY Operator Safety WARNING POTENTIAL HAZARD Operating an ATV on paved surfaces, including sidewalks, paths, parking lots, and driveways. WHAT CAN HAPPEN ATV tires are designed for off-road use. Operating on paved surfaces may adversely affect the handling of the ATV and could result in loss
  • 2004 Polaris Sportsman 700 | Owners Manual - Page 22
    Operator Safety 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 | Owners Manual - Page 23
    SAFETY Operator Safety WARNING POTENTIAL HAZARD Operating this ATV without wearing an approved helmet, eye protection and protective clothing. WHAT CAN HAPPEN Operating an ATV without an approved helmet increases the risk of a severe head injury or death in the event of an accident. Operating
  • 2004 Polaris Sportsman 700 | Owners Manual - Page 24
    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 | Owners Manual - Page 25
    SAFETY Operator Safety WARNING POTENTIAL HAZARD Attempting wheelies, jumps and other stunts. WHAT CAN HAPPEN Attempting stunts increases the chance of an accident, including an overturn. HOW TO AVOID THE HAZARD Never attempt wheelies, jumps, or other stunts. Avoid exhibition driving. 22
  • 2004 Polaris Sportsman 700 | Owners Manual - Page 26
    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 | Owners Manual - Page 27
    SAFETY Operator 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 | Owners Manual - Page 28
    Operator Safety SAFETY WARNING POTENTIAL HAZARD Failure to use extra caution when operating on excessively rough, slippery or loose terrain. WHAT CAN HAPPEN Operating on excessively rough, slippery or loose terrain could cause loss of traction or loss of control, which could result in an accident
  • 2004 Polaris Sportsman 700 | Owners Manual - Page 29
    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 | Owners Manual - Page 30
    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 | Owners Manual - Page 31
    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 62. Always check the terrain carefully before descending a hill. Shift
  • 2004 Polaris Sportsman 700 | Owners Manual - Page 32
    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 63. 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 | Owners Manual - Page 33
    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 63. 30
  • 2004 Polaris Sportsman 700 | Owners Manual - Page 34
    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 | Owners Manual - Page 35
    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 | Owners Manual - Page 36
    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. 33
  • 2004 Polaris Sportsman 700 | Owners Manual - Page 37
    . 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 | Owners Manual - Page 38
    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 | Owners Manual - Page 39
    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 is equipped
  • 2004 Polaris Sportsman 700 | Owners Manual - Page 40
    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 | Owners Manual - Page 41
    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 shut-off switch is in the RUN position. WARNING Operating the ATV on
  • 2004 Polaris Sportsman 700 | Owners Manual - Page 42
    Master Cylinder 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 level is full
  • 2004 Polaris Sportsman 700 | Owners Manual - Page 43
    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. Squeeze and
  • 2004 Polaris Sportsman 700 | Owners Manual - Page 44
    Auxiliary Brake 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. The rear
  • 2004 Polaris Sportsman 700 | Owners Manual - Page 45
    CONTROLS Choke The choke assists in starting a cold engine. Refer to the engine starting procedure on page 53 for correct choke and throttle settings during starting. Fuel Valve The fuel valve (1) is located on the left side panel. It has two positions: OFF: For vehicle storage and when
  • 2004 Polaris Sportsman 700 | Owners Manual - Page 46
    Automatic Transmission Gear Selector CONTROLS The transmission gear selector (1) is located on the right side of the vehicle. Shift patterns vary, depending on your model. 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
  • 2004 Polaris Sportsman 700 | Owners Manual - Page 47
    FEATURES All Wheel Drive (AWD) System Polaris 4-wheel drive ATVs are equipped with a unique, Polaris-exclusive, All Wheel Drive (AWD) system, which is activated by a switch (1) on the right handlebar. When the switch is off, the ATV is in 2 wheel drive at all 1 times. When the switch is on, the ATV
  • 2004 Polaris Sportsman 700 | Owners Manual - Page 48
    Instrument Cluster FEATURES Your ATV is equipped with an instrument cluster that senses vehicle speed from the right front wheel. The instrument cluster measures distance in miles or kilometers as well as hours of operation. It also includes a reverse speed limiter function that limits the ATV's
  • 2004 Polaris Sportsman 700 | Owners Manual - Page 49
    = Park 2. AWD Indicator - This indicator illuminates when the electrical portion of the AWD system is enabled. 9 1 3. Engine Hour Display Indicator 4. Service Interval/Diagnostic Mode Indicator 5. Low Battery and Over Voltage - This warning usually indicates that the ATV is being operated at an RPM
  • 2004 Polaris Sportsman 700 | Owners Manual - Page 50
    Instrument Cluster Rider Information Center FEATURES 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 to
  • 2004 Polaris Sportsman 700 | Owners Manual - Page 51
    FEATURES 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 diagnostic mode,
  • 2004 Polaris Sportsman 700 | Owners Manual - Page 52
    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 | Owners Manual - Page 53
    OPERATION Fuel Safety WARNING Gasoline is highly flammable and explosive under certain conditions. S Always exercise extreme caution whenever handling gasoline. S Always refuel with the engine stopped, and outdoors or in a S S S S S well ventilated area. Do not smoke or allow open flames or
  • 2004 Polaris Sportsman 700 | Owners Manual - Page 54
    Break-In Period OPERATION 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
  • 2004 Polaris Sportsman 700 | Owners Manual - Page 55
    OPERATION Pre-Ride Inspection 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 | Owners Manual - Page 56
    Starting the Engine Starting a Cold Engine OPERATION 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. Place the transmission in PARK and lock the parking brake. 2. Turn
  • 2004 Polaris Sportsman 700 | Owners Manual - Page 57
    OPERATION Starting the Engine Starting a Warm Engine Warm engines do not normally require the use of the choke. Using the choke can cause the spark plug to become wet fouled. 1. Position the vehicle on a level surface with the transmission in PARK. 2. Lock the parking brake, turn the fuel tank
  • 2004 Polaris Sportsman 700 | Owners Manual - Page 58
    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 | Owners Manual - Page 59
    extra caution. Always attach the tow load to the hitch point designated for your vehicle. S 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. S USE EXTREME CAUTION when
  • 2004 Polaris Sportsman 700 | Owners Manual - Page 60
    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 | Owners Manual - Page 61
    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 | Owners Manual - Page 62
    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 | Owners Manual - Page 63
    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. 60
  • 2004 Polaris Sportsman 700 | Owners Manual - Page 64
    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 | Owners Manual - Page 65
    down. 4. Apply the brakes slightly to aid in slowing. Familiarize yourself with operation of the auxiliary brake in the event loss of normal service brakes occurs. WARNING Excessive speed can cause loss of control and lead to serious injury or death. Always operate slowly when traveling downhill
  • 2004 Polaris Sportsman 700 | Owners Manual - Page 66
    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 | Owners Manual - Page 67
    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 69. The following areas need special attention: engine oil, transmission oil, front and rear gearcases
  • 2004 Polaris Sportsman 700 | Owners Manual - Page 68
    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 | Owners Manual - Page 69
    OPERATION Driving Safely 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. Driving in
  • 2004 Polaris Sportsman 700 | Owners Manual - Page 70
    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 in the
  • 2004 Polaris Sportsman 700 | Owners Manual - Page 71
    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 The exhaust emission control system is composed of efficient carburetor settings with an optimum
  • 2004 Polaris Sportsman 700 | Owners Manual - Page 72
    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 49 for instructions. Maintenance intervals are based upon average riding conditions and an average vehicle speed
  • 2004 Polaris Sportsman 700 | Owners Manual - Page 73
    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 Hours/ Miles Frequency Remarks Inspect Inspect Inspect Inspect Inspect Inspect; clean Replace coolant every
  • 2004 Polaris Sportsman 700 | Owners Manual - Page 74
    replace annually and as needed Inspect periodically Check monthly; change annually Lubricate all fittings, pivots, cables, etc. Check level daily; break-in service at one month; change oil more often in cold weather Replace with oil change Inspect Drain bowl periodically and prior to storage Inspect
  • 2004 Polaris Sportsman 700 | Owners Manual - Page 75
    the procedures 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 " Drive chain(s) Hours/ Miles 50 hrs. 100 hrs. 50 hrs. 100 hrs. 100 hours Frequency Remarks 6 months 12 months 6 months 12 months
  • 2004 Polaris Sportsman 700 | Owners Manual - Page 76
    Periodic Maintenance Record Maintenance Interval Performed 10 hrs. 20 hrs. 50 hrs. 100 hrs. Servicing Servicing Date Dealer or Person MAINTENANCE AND LUBRICATION Remarks Use the following chart to record periodic maintenance. 73
  • 2004 Polaris Sportsman 700 | Owners Manual - Page 77
    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 | Owners Manual - Page 78
    Lubrication Guide MAINTENANCE AND LUBRICATION (Fig. 1) (Fig. 2) (Fig. 3) 75
  • 2004 Polaris Sportsman 700 | Owners Manual - Page 79
    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 | Owners Manual - Page 80
    The oil dipstick and fill tube (1) are located on the left side of the vehicle. NOTE: A rising oil level between checks in cool weather driving can indicate contaminants such as gas or moisture collecting in the crankcase. If the oil level is over the full/safe mark, change the oil immediately. 1.
  • 2004 Polaris Sportsman 700 | Owners Manual - Page 81
    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 | Owners Manual - Page 82
    Oil Change (400/500) MAINTENANCE AND LUBRICATION 7. Place shop towels beneath the oil filter. Using an oil filter wrench, turn the filter (1) counterclockwise and remove. 8. Lubricate the gasket on the new filter with a film of new engine oil. Check to make sure the gasket is in good condition.
  • 2004 Polaris Sportsman 700 | Owners Manual - Page 83
    MAINTENANCE AND LUBRICATION Oil Change (600/700) 1. Place the vehicle on a level surface. 2. Run the engine for two to three minutes until warm. Stop the engine. 3. Clean the area around the drain plug. 4. Place a drain pan beneath engine crankcase and remove the drain plug. CAUTION Hot oil can
  • 2004 Polaris Sportsman 700 | Owners Manual - Page 84
    Transmission Oil (400/500) 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 Premium Synthetic Gearcase Lubricant. See page 115 for
  • 2004 Polaris Sportsman 700 | Owners Manual - Page 85
    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 Drive Hub Fluid. Use of non-recommended oils may
  • 2004 Polaris Sportsman 700 | Owners Manual - Page 86
    Transmission Oil (600/700) 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 Premium Synthetic Gearcase Lubricant. See page 115 for
  • 2004 Polaris Sportsman 700 | Owners Manual - Page 87
    MAINTENANCE AND LUBRICATION Rear Gearcase Oil (600/700) 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 Premium Synthetic Gearcase Lube (or GL5 80-90 weight gear lube). NOTE
  • 2004 Polaris Sportsman 700 | Owners Manual - Page 88
    Engine Cooling System Coolant Level MAINTENANCE AND LUBRICATION 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 90. 1 The fluid level must be maintained between the minimum and maximum marks on the
  • 2004 Polaris Sportsman 700 | Owners Manual - Page 89
    MAINTENANCE AND LUBRICATION Engine Cooling System 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 | Owners Manual - Page 90
    Brakes MAINTENANCE AND LUBRICATION 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 | Owners Manual - Page 91
    MAINTENANCE AND LUBRICATION Brakes 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 | Owners Manual - Page 92
    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 | Owners Manual - Page 93
    MAINTENANCE AND LUBRICATION Side Panel Removal 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 | Owners Manual - Page 94
    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 | Owners Manual - Page 95
    All nuts that have a cotter pin installed must be serviced 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 400/500 20 ft. lbs. (27
  • 2004 Polaris Sportsman 700 | Owners Manual - Page 96
    Filter Systems MAINTENANCE AND LUBRICATION 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 vehicle without a breather filter can cause engine damage. Always reinstall the breather filter after removing for service. 93
  • 2004 Polaris Sportsman 700 | Owners Manual - Page 97
    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 | Owners Manual - Page 98
    Lights MAINTENANCE AND LUBRICATION High Beam Adjustment 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.
  • 2004 Polaris Sportsman 700 | Owners Manual - Page 99
    MAINTENANCE AND LUBRICATION Lights 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 while
  • 2004 Polaris Sportsman 700 | Owners Manual - Page 100
    Lights MAINTENANCE AND LUBRICATION Lower Headlamp Removal / Installation 1. Turn the back of the headlight harness (1) in a clockwise 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 and
  • 2004 Polaris Sportsman 700 | Owners Manual - Page 101
    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 white. A white insulator tip indicates overheating, caused by use of an improper spark plug or incorrect carburetion
  • 2004 Polaris Sportsman 700 | Owners Manual - Page 102
    . 9. Turn the fuel valve on. 10. Attempt to start the engine. If necessary, repeat the drying procedure. 11. 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 | Owners Manual - Page 103
    MAINTENANCE AND LUBRICATION Spark Arrestor 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 components
  • 2004 Polaris Sportsman 700 | Owners Manual - Page 104
    PVT System MAINTENANCE AND LUBRICATION 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 | Owners Manual - Page 105
    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. 102
  • 2004 Polaris Sportsman 700 | Owners Manual - Page 106
    Battery MAINTENANCE AND LUBRICATION Your ATV may have either a sealed battery, which requires little maintenance, or a conventional battery. A sealed battery can be identified by its flat covers on the top of the battery. A conventional battery has six filler caps on the top of the battery. Always
  • 2004 Polaris Sportsman 700 | Owners Manual - Page 107
    MAINTENANCE AND LUBRICATION Battery Battery Removal 1. Disconnect the hold-down strap holding the battery in position, and remove battery cover. 2. On conventional batteries, remove the battery vent tube. 3. Disconnect the black (negative) battery cable first. 4. Disconnect the red (positive)
  • 2004 Polaris Sportsman 700 | Owners Manual - Page 108
    negative (black) cable last. WARNING Battery Charging (Sealed Battery) The following battery charging instructions apply only to the installation of a YUASA activated, sealed battery. Read all instructions before proceeding with the installation of this battery. The YUASA activated, sealed battery
  • 2004 Polaris Sportsman 700 | Owners Manual - Page 109
    the voltage is less than 12.8 volts, recharge the battery. NOTE: When using an automatic charger, refer to the charger manufacturer's instructions for recharging. When using a constant current charger, use the following guidelines for recharging. WARNING An overheated battery could explode, causing
  • 2004 Polaris Sportsman 700 | Owners Manual - Page 110
    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 | Owners Manual - Page 111
    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 | Owners Manual - Page 112
    following the instructions on the can. Run the engine for several minutes so the Carbon Clean reaches the carburetor. Turn the engine off. 2. Support the front 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 | Owners Manual - Page 113
    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 | Owners Manual - Page 114
    Transporting the ATV MAINTENANCE AND LUBRICATION Follow these procedures when transporting the vehicle. 1. Turn off the engine and remove the key to prevent loss during transporting. 2. Place the transmission in PARK and lock the parking brake. 3. Turn the fuel valve off and be sure the fuel cap,
  • 2004 Polaris Sportsman 700 | Owners Manual - Page 115
    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 | Owners Manual - Page 116
    Carburetor/Idle RPM ADJUSTMENTS If the engine idle speed is not satisfactory, and all other conditions are favorable, the carburetor can be adjusted. 1. Warm up the engine by running the vehicle for approximately five minutes. 2. Place the transmission in gear with the parking brake applied. 3.
  • 2004 Polaris Sportsman 700 | Owners Manual - Page 117
    ADJUSTMENTS Throttle Cable Freeplay Throttle cable freeplay is adjusted at the handlebar. 1. Slide the boots (1) off the inline cable adjuster sleeve (2). Loosen the adjuster locknut (3). 2. Turn the adjuster until 1/16″ to 1/8″ freeplay is achieved at the thumb lever. NOTE: While adjusting
  • 2004 Polaris Sportsman 700 | Owners Manual - Page 118
    POLARIS PRODUCTS Part No. 2870791 2871281 2871844 2871477 2871478 2871653 2872276 2870465 2871654 2872277 2871322 2871423 2871460 2871515 2871551 2871312 2871329 2872073 2872348 2871323 2871534 2871326 2870652 2870990 2872893 Description Engine Lubricant Fogging Oil (12 oz. Aerosol) Engine Oil (qt.)
  • 2004 Polaris Sportsman 700 | Owners Manual - Page 119
    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. performance. Check for fouled plugs or foreign material in gas tank, fuel lines, or carburetor. Contact your dealer for service. 116
  • 2004 Polaris Sportsman 700 | Owners Manual - Page 120
    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 | Owners Manual - Page 121
    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 | Owners Manual - Page 122
    TROUBLESHOOTING Engine Stops or Loses Power Possible Cause Out of fuel Kinked or plugged fuel vent line Water present in fuel Overuse of choke Fouled or
  • 2004 Polaris Sportsman 700 | Owners Manual - Page 123
    SPECIFICATIONS SPORTSMAN 400 Gross Vehicle Weight Towing Capacity Hitch Tongue Capacity Front Rack Capacity Rear Rack Capacity Overall Length Overall Width Overall Height Wheelbase Ground Clearance Dry Weight Minimum Turning Radius Fuel Capacity Engine Oil Capacity Coolant Capacity Engine
  • 2004 Polaris Sportsman 700 | Owners Manual - Page 124
    SPECIFICATIONS SPORTSMAN 400 Shift Type Gear Reduction - Low Gear Reduction - Reverse Gear Reduction - Forward Drive Ratio - Front Tire, Front Tire, Rear Front Brake Rear Brake Auxiliary Brake Parking Brake Front Suspension Rear Suspension Shock Adjustment Headlight Taillights Brakelight Instrument
  • 2004 Polaris Sportsman 700 | Owners Manual - Page 125
    SPECIFICATIONS SPORTSMAN 500 Gross Vehicle Weight Hitch Towing Rating Unbraked Trailer Towing Capacity* Hitch Tongue Capacity Front Rack Capacity Rear Rack Capacity Overall Length Overall Width Overall Height Wheelbase Ground Clearance Dry Weight Minimum Turning Radius Fuel Capacity Engine Oil
  • 2004 Polaris Sportsman 700 | Owners Manual - Page 126
    SPECIFICATIONS SPORTSMAN 500 Shift Type Gear Reduction - Low Gear Reduction - Reverse Gear Reduction - Forward Drive Ratio - Front Tire, Front Tire, Rear Front Brake Rear Brake Auxiliary Brake Parking Brake Front Suspension Rear Suspension Shock Adjustment Headlight Taillights Brakelight Instrument
  • 2004 Polaris Sportsman 700 | Owners Manual - Page 127
    SPECIFICATIONS SPORTSMAN 600 Gross Vehicle Weight Fuel Capacity Towing Capacity Hitch Tongue Capacity Front Rack Capacity Rear Rack Capacity Overall Length Overall Width Overall Height Wheelbase Ground Clearance Dry Weight Minimum Turning Radius Engine Oil Capacity Coolant Capacity Engine
  • 2004 Polaris Sportsman 700 | Owners Manual - Page 128
    SPECIFICATIONS SPORTSMAN 600 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 Front Suspension Rear Suspension Shock Adjustment Headlight (watts) Taillights
  • 2004 Polaris Sportsman 700 | Owners Manual - Page 129
    SPECIFICATIONS SPORTSMAN 700 Gross Vehicle Weight Fuel Capacity Towing Rating Unbraked Trailer 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 Oil Capacity
  • 2004 Polaris Sportsman 700 | Owners Manual - Page 130
    SPECIFICATIONS SPORTSMAN 700 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 Front Suspension Rear Suspension Shock Adjustment Headlight Taillights Brake
  • 2004 Polaris Sportsman 700 | Owners Manual - Page 131
    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. 128
  • 2004 Polaris Sportsman 700 | Owners Manual - Page 132
    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 | Owners Manual - Page 133
    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 | Owners Manual - Page 134
    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 | Owners Manual - Page 135
    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 | Owners Manual - Page 136
    INDEX A Accessories ...107 ADJUSTMENTS ...112-114 Age Restrictions ...11 Air Filter Service ...93 All Wheel Drive ...44 Automatic Transmission ...43 Auxiliary Brake ...88 AWD ...44 E Electrical K K-Turn ...63 L Light Switches ...38 Lights ...94-97 Low Range ...101 Lubrication Guide ...74-75 133
  • 2004 Polaris Sportsman 700 | Owners Manual - Page 137
    (400/500) ...81 Transmission Oil (600/700) ...83 Transporting the ATV ...111 Traveling Downhill ...62 Traveling Uphill ...60 Trip Meter ...47 TROUBLESHOOTING ...116-119 Turning Around on a Hill ...63 P Parking Brake ...40 Parking on an Incline ...67 Periodic Maintenance Schedule . . 69-72 POLARIS
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