Category:
High-performance All-Terrain Vehicle (ATV)
Target Audience:
Recreational riders, hunters, farmers, and utility users seeking a robust and capable ATV.
Competitors:
Other premium ATVs from brands like Can-Am, Yamaha, Arctic Cat, and Kawasaki during the mid-2000s era.
Powertrain:
Powerful liquid-cooled V-twin engines (600cc and 700cc variants) offering strong torque and horsepower.
Drivetrain:
True On-Demand All-Wheel Drive (AWD) system for superior traction in challenging conditions.
Suspension:
Independent front and rear suspension providing excellent ride comfort and ground clearance.
Utility:
Heavy-duty racks for cargo hauling, robust chassis for demanding work and recreational use.
Primary Coverage:
Complete repair, maintenance, rebuilding, and restoration procedures for 2004 Polaris Sportsman 600 and 700 models.
Secondary Coverage:
Troubleshooting, diagnostics, specifications, torque values, wiring diagrams, component identification, and adjustments.
Estimated Pages:
Likely in the range of 300-600 pages, typical for a comprehensive service manual.
Type:
Service Repair Manual / Workshop Manual
Format:
PDF (Digital Download)
Engine:
Detailed coverage of the Polaris Twin cylinders, including disassembly, inspection, assembly, timing, cooling system (liquid-cooled), lubrication system, and fuel delivery.
Transmission:
Coverage of the automatic PVT (Polaris Variable Transmission) system, including belt inspection and replacement, clutch service, and gearbox maintenance.
Drivetrain:
Comprehensive information on the AWD (All-Wheel Drive) system, front differential, rear differential, drive shafts, CV joints, and wheel hubs.
Suspension:
Front and rear suspension systems, including independent suspension components, shock absorbers, springs, bushings, and alignment procedures.
Brakes:
Hydraulic braking system, including front and rear brake calipers, master cylinder, brake lines, brake pads, rotor maintenance, and bleeding procedures.
Electrical:
Complete electrical system coverage, including battery, charging system (stator, rectifier/regulator), ignition system, lighting, starter motor, and wiring diagrams.
Fuel System:
Carburetor (likely Mikuni BST series for 600, potentially Keihin for 700) or fuel injection system, fuel pump, fuel filter, and fuel tank service.
Cooling System:
Radiator, fan, coolant, water pump, and related hoses and thermostat service.
Frame And Body:
Chassis components, front and rear racks, fenders, seat, handlebars, and body panel removal/installation.
Routine Maintenance:
Oil changes, filter replacements, spark plug service, air filter cleaning/replacement, battery checks, brake fluid checks, coolant flushes, and drive belt inspection.
Troubleshooting:
Systematic diagnostic procedures for common and uncommon issues, symptom-based troubleshooting guides.
Engine Repair:
Top-end rebuilds (cylinder head, piston), bottom-end rebuilds (crankshaft, connecting rods), valve adjustments, carburetor/fuel injection tuning.
Transmission Overhaul:
PVT belt replacement, clutch inspection and service, gearbox lubrication and seals.
Electrical Diagnostics:
Component testing (stator, CDI, etc.), troubleshooting wiring harness issues, starter system repair.
Brake System Repair:
Caliper rebuild, master cylinder replacement, brake line bleeding, pad and rotor replacement.
Suspension Rebuild:
Shock absorber replacement, bushing replacement, wheel bearing service.
Bodywork Repair:
Panel removal and installation, rack repair, seat mounting.
Torque Specifications:
Precise torque values for all critical fasteners and components.
Depth:
Comprehensive. Covers basic maintenance to complete engine and transmission overhauls, detailed electrical troubleshooting, and chassis component repairs.
Diagnostic Tools:
Information on using standard automotive tools and potential specialized diagnostic procedures relevant to the vehicle's systems.
Type:
Liquid-cooled, 4-stroke, SOHC, V-twin
Horsepower 600:
Estimated 45-50 HP (advertised figures may vary)
Horsepower 700:
Estimated 50-55 HP (advertised figures may vary)
Torque:
Significant low-end torque suitable for towing and climbing.
Fuel Delivery 600:
Likely Twin Mikuni BST40 carburetors
Fuel Delivery 700:
Likely Twin Keihin carburetors (specific model may vary)
Type:
Electronic Ignition (CDI)
Type:
Wet sump lubrication system
Type:
Liquid Cooling with fan assist
Length:
Approx. 83 inches (210.8 cm)
Width:
Approx. 46 inches (116.8 cm)
Height:
Approx. 45 inches (114.3 cm)
Wheelbase:
Approx. 50.5 inches (128.3 cm)
Ground Clearance:
Approx. 10.5 inches (26.7 cm)
Front Rack Capacity:
Approx. 100 lbs (45.4 kg)
Rear Rack Capacity:
Approx. 200 lbs (90.7 kg)
Dry Weight:
Approx. 600-650 lbs (272-295 kg) depending on model
Towing Capacity:
Approx. 1,500 lbs (680 kg)
Hitch Type:
Standard 1.25-inch receiver hitch
Engine Oil Change:
Every 100 hours or 12 months, whichever comes first.
Spark Plug Service:
Inspect every 100 hours, replace as needed.
Air Filter Cleaning:
Clean every 50 hours or more frequently in dusty conditions.
Pvt Belt Inspection:
Inspect every 100 hours for wear and damage; replace as needed.
Brake Fluid Check:
Check level every 50 hours, flush and replace every 24 months.
Engine Oil Type:
SAE 20W-50 API-SG rated oil (specific Polaris recommendation may vary).
Engine Oil Capacity:
Approx. 2.5 US quarts (2.3 liters) with filter change.
Coolant Type:
Ethylene glycol-based coolant with corrosion inhibitors (50/50 mix with distilled water recommended).
Brake Fluid Type:
DOT 3 or DOT 4 hydraulic brake fluid.
Gearcase Fluid Type:
Polaris Demand Drive Fluid (front differential) and SAE 80W-90 Gear Oil (rear differential).
Pvt Belt Wear:
Drive belt wear and slippage can occur with heavy use or improper maintenance, affecting acceleration and power delivery. Regular inspection is crucial.
Electrical Connections:
Corrosion or loose connections in electrical connectors can lead to intermittent issues or component failure. Keeping connections clean and protected is important.
Carburetor Tuning:
Carburetors may require periodic adjustment for optimal performance, especially after significant mileage or if experiencing rough idling or performance issues.
