2004 POLARIS SPORTSMAN ATV 600 700 Service Repair Manual

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UGS: 104405

Mots clés: 2004 ATV Misc Polaris Powersports SPORTSMAN 600 SPORTSMAN 700

Variantes de produits

Description

The 2004 Sportsman 600 and 700 All-Terrain Vehicles (ATVs) represent a robust and capable line of utility ATVs, engineered for demanding off-road use. These models are characterized by their powerful liquid-cooled V-twin engines, offering significant torque and horsepower for tasks such as hauling, towing, and navigating challenging terrain. Key features include an independent front and rear suspension system for enhanced comfort and handling, and the Variable Transmission with On-Demand All-Wheel Drive for superior traction. The Sportsman series is recognized for its rugged build quality and versatility, making it a reliable choice for both work and recreational pursuits. This comprehensive factory service manual provides detailed information essential for the maintenance, repair, and troubleshooting of the 2004 Sportsman 600/700 ATVs. It covers a wide array of systems, including full engine and transmission service, electrical systems, suspension, steering, and braking systems, along with body and frame components. The manual includes routine maintenance schedules, in-depth engine and component rebuild procedures, carburetor adjustments, and electrical system diagnostics with wiring diagrams. Its purpose is to serve as an authoritative resource for owners, mechanics, and technicians, ensuring the optimal performance and longevity of the vehicle through clear, factory-level technical guidance.

🏷️ Basic Information

Identification

Make:

Polaris

Model:

Sportsman 600 / 700

Year:

Vehicle Type:

All-Terrain Vehicle (ATV)

Codes

Chassis Code:

A04CH61AA (600), A04CH70AA (700)

👋 Introduction

Market Position

Positioning:

The 2004 Polaris Sportsman 600/700 was positioned as a premium, heavy-duty utility ATV, known for its powerful V-twin engine and rugged capability.

Competitive Analysis

Competitors:

Competed directly with models from Yamaha (Grizzly), Can-Am (Outlander), and Arctic Cat (4x4).

Key Features

Engine:

Powerful liquid-cooled V-twin engines offering substantial torque and horsepower for hauling and towing.

Suspension:

Independent front and rear suspension provided a comfortable ride and excellent handling over varied terrain.

Drivetrain:

On-Demand All-Wheel Drive (AWD) system for superior traction.

Utility:

Heavy-duty racks and towing capacity for work and recreational use.

📋 Manual Details

Coverage Areas

Engine Service:

Transmission Service:

Electrical System:

Suspension Steering:

Braking System:

Body Frame:

Maintenance Schedule:

Included

Troubleshooting:

Comprehensive

Page Count

Estimated Pages:

Manual Type

Type:

Factory Service Manual / Repair Manual

Language

Primary Language:

English

Format

File Type:

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Complete disassembly, inspection, assembly, and tuning of 4-stroke liquid-cooled V-twin engines (600cc and 700cc).

Fuel System:

Carburetor identification, adjustment, overhaul, fuel pump, fuel tank, and fuel lines.

Ignition System:

CDI unit, ignition coils, spark plugs, timing adjustments, and troubleshooting.

Cooling System:

Radiator, coolant, thermostat, water pump, fan operation, and bleeding procedures.

Exhaust System:

Muffler, pipes, heat shields, and inspection.

Transmission Drivetrain:

CVT (Continuously Variable Transmission) operation, belt inspection and replacement, clutch service, gearcase inspection, fluid changes, and rear differential.

Electrical System:

Battery, starter motor, charging system (stator, regulator/rectifier), lighting system, wiring diagrams, switches, and diagnostic procedures.

Chassis Frame:

Frame inspection, welds, mounting points, and protective coatings.

Suspension System:

Front and rear suspension components, shock absorbers, springs, bushings, and adjustments.

Steering System:

Handlebars, steering column, tie rods, ball joints, and steering linkage.

Braking System:

Hydraulic brake system, brake levers, master cylinders, calipers, brake pads, brake lines, and bleeding procedures.

Wheels Tires:

Wheel specifications, tire pressure, and mounting.

Bodywork Plastics:

Fenders, body panels, seat removal, and rack systems.

Special Tools:

Identification and usage of specialized tools required for repairs.

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, spark plug checks, air filter cleaning, lubrication points, and general inspection.

Engine Overhaul:

Detailed steps for piston removal, cylinder head service, valve adjustments, timing chain, and crankshaft assembly.

Carburetor Rebuild:

Step-by-step instructions for disassembling, cleaning, inspecting, and reassembling carburetors.

Cvt Belt Replacement:

Proper procedures for accessing and replacing the drive belt.

Brake System Maintenance:

Brake pad replacement, caliper servicing, and bleeding the hydraulic system.

Electrical Troubleshooting:

Diagnostic charts, common electrical faults, and testing procedures for components.

Suspension Adjustment:

Instructions for adjusting pre-load and damping (if applicable).

Torque Specifications:

Precise torque values for all critical fasteners.

Wiring Diagrams:

Detailed electrical schematics for easy diagnosis.

Technical Depth

Depth:

Comprehensive factory-level technical information suitable for professional technicians and experienced DIY mechanics.

Diagnostic Capabilities:

In-depth troubleshooting guides, symptom-to-cause analysis, and diagnostic procedures for all major systems.

Rebuild Procedures:

Detailed, step-by-step instructions for complete engine and transmission rebuilds.

📊 Manual Specifications

File Format

Format:

Searchability:

Searchable text allows for quick access to information.

Print Quality

Quality:

High-resolution scans of original factory documentation, ensuring clarity of text and diagrams.

Binding Type

Binding:

N/A (Digital PDF Format)

Paper Type

Paper:

N/A (Digital PDF Format)

⚙️ Engine Specifications

Primary Engine

Engine Type 600:

4-stroke, SOHC, V-twin, liquid-cooled

Engine Displacement 600:

587 cc (35.8 cu in)

Engine Type 700:

4-stroke, SOHC, V-twin, liquid-cooled

Engine Displacement 700:

695 cc (42.4 cu in)

Performance

Horsepower 600 Est:

Approximately 45-50 HP

Torque 600 Est:

Approximately 40-45 lb-ft

Horsepower 700 Est:

Approximately 50-55 HP

Torque 700 Est:

Approximately 50-55 lb-ft

Fuel System

Carburetor Type:

Dual Mikuni BSR34 carburetors (typical)

Fuel Type:

Unleaded gasoline (87 octane or higher recommended)

Fuel Capacity:

4.0 gallons (15.1 L)

🔧 Transmission

Standard

Transmission Type:

Automatic (CVT - Continuously Variable Transmission)

Optional

Gear Selection:

High, Low, Neutral, Reverse, Park

Features

Drive System:

Shaft Drive with Polaris Variable Transmission (PVT) and Engine Braking

Final Drive:

Sealed drive shaft with front and rear differentials

Gear Reduction:

Specific ratios detailed in manual for high/low ranges

📐 Dimensions

Exterior

Length:

81 in (205.7 cm)

Width:

46 in (116.8 cm)

Height:

47 in (119.4 cm)

Wheelbase:

50.5 in (128.3 cm)

Ground Clearance:

11.5 in (29.2 cm)

Weights

Dry Weight:

617 lbs (279.9 kg)

Cargo

Front Rack Capacity:

150 lbs (68 kg)

Rear Rack Capacity:

300 lbs (136 kg)

Towing Capacity:

1500 lbs (680.4 kg)

🛡️ Safety Features

Ratings

Atv Safety:

All ATVs carry risks. Always wear a helmet and appropriate protective gear. Ride responsibly and follow all safety guidelines.

Active Features

Braking System:

Hydraulic disc brakes front and rear, sealed hydraulic rear brake pedal.

Engine Braking:

Standard feature of the PVT system for downhill control.

Passive Features

Lighting:

Dual 35W headlights, 35W taillight/brakelight.

Throttle Limiter:

Often implemented via throttle stop screw or cam profile for beginner modes (check specific model configuration).

Rollover Protection:

Not equipped with roll cage or seatbelts; rider position is critical.

💡 Technology Features

Infotainment

Features:

No integrated infotainment system; focus is on utility and off-road performance.

Driver Assistance

Features:

No electronic driver assistance features typical of modern vehicles. Relies on rider skill and terrain awareness.

Connectivity

Features:

No connectivity features. Basic electrical system for starting, lighting, and ignition.

🔧 Maintenance

Service Intervals

Engine Oil Change:

Every 100 hours or annually, whichever comes first.

Air Filter Cleaning:

Every 50 hours or more frequently in dusty conditions.

Spark Plug Check:

Every 100 hours.

Transmission Oil Change:

Every 200 hours or annually.

Fluid Specifications

Engine Oil Type:

SAE 10W-40 Synthetic Motorcycle Oil (meeting API SG or higher)

Engine Oil Capacity:

Refer to manual for exact capacity, typically around 2.5-3.0 quarts (2.37-2.84 L)

Transmission Gearcase Oil:

Polaris Premium Synthetic Gearcase Oil or equivalent SAE 75W-90

Transmission Gearcase Capacity:

Refer to manual, typically around 1 pint (0.47 L)

Coolant Type:

Ethylene glycol-based antifreeze (50/50 mix with distilled water)

Known Issues

Common Wear Items:

CVT belt wear, suspension bushings, ball joints, and steering tie rods.

Potential Electrical:

Stator failures, regulator/rectifier issues, and connector corrosion can occur with age and exposure.

Engine Performance:

Carburetor synchronization and adjustment are critical for optimal performance. V-twin engines can be sensitive to proper tuning.

📚 Vehicle History

Brand Heritage

Polaris Legacy:

Polaris has a long history of innovation in recreational vehicles, starting with snowmobiles and expanding into ATVs and UTVs.

Model Evolution

Sportsman Line:

The Sportsman line is Polaris's flagship ATV series, known for its comfort, power, and utility features, evolving significantly throughout the early 2000s.

Production

Manufacturing Location:

Polaris ATVs are primarily manufactured in the United States.

🏆 Awards & Recognition

Recognitions

Industry Standing:

The Polaris Sportsman line consistently received positive reviews for its combination of power, comfort, and utility, making it a benchmark in the ATV market during its production era.