2004 Polaris Sportsman 700 EFI ATV Service Manual
Original Polaris service manual covers 700 EFI models for the year 2004.
PN: 9918774
This high quality with hi-resolution diagrams and illustrations. Manual is deeply indexed and searchable for easy access to information it contains.
Manual chapters:
- General Information
- Engine
- Fuel Injection
- Body and Steering
- Clutching
- Final Drive
- Transmission
- Brakes
- Electrical
- Wiring Diagrams
- Index
This is a complete official full workshop service repair manual used by Polaris dealer's shops.
To find information in PDF file please use "Ctrl+F" or "Command+F" for Mac and enter keywords you need to find in a manual.
File will be available for download in minutes!
This Manual PDF file is:
- + Printable: Yes
- + Viewable on: MS Windows, Mac, Android, iOS, Linux
- + Requires: Adobe Acrobat/Preview
Once manual is downloaded any number of pages could be printed or it could be printed in whole.
Manual could be opened in Adobe Acrobat on any mobile device (like iPad, iPhone or Android device etc.) any computer capable of viewing a PDF files including IBM compatible computers running Windows, Linux (or any other flavor of UNIX). Apple Computers have native support for PDF files.
Reviews - Write a Review
Rated: 5 by: Daniel Posted: Wednesday, July 19, 2023 at 11:32AM
Full list of manual chapters:
TABLE OF CONTENTS
CHAPTER 1-GENERAL
MODEL IDENTIFICATION
SERIAL NUMBER LOCATION
2004 SPORTSMAN DIMENSIONS
SPECIFICATIONS-SPORTSMAN 700 EFI
PUBLICATION NUMBERS
PAINT CODES
REPLACEMENT KEYS
STANDARD TORQUE SPECIFICATIONS
CONVERSION TABLE
TAP DRILL CHARTS
DECIMAL EQUIVALENT CHART
GLOSSARY OF TERMS
CHAPTER 2-MAINTENANCE
PERIODIC MAINTENANCE CHART
PRE-RIDE INSPECTION
RECOMMENDED LUBRICANTS AND CAPACITIES
LUBRICANT AND MAINTENANCE PRODUCT NUMBERS
SPECIAL TOOLS
LUBRICATION CHARTS
FRONT AND REAR GEARCASE LUBRICATION
THROTTLE CABLE ADJUSTMENT
TRANSMISSION LUBRICATION
TRANSMISSION LINKAGE INSPECTION
FUEL SYSTEM
COMPRESSION TEST
BATTERY MAINTENANCE
IGNITION
COOLANT SYSTEM MAINTENANCE
RADIATOR SCREEN REMOVAL
AIR FILTER SERVICE
AIR BOX SEDIMENT TUBE SERVICE
BREATHER FILTER
PVT DRYING and PVT DRAIN PLUG
OIL CHANGE FILTER
STEERING AND TOE ALIGNMENT
EXHAUST SYSTEM MAINTENANCE
BRAKE SYSTEM SERVICE
SUSPENSION SERVICE
CONTROLS
WHEEL REMOVAL/INSTALLATION
TIRE INSPECTION
WARN WINCH OPERATION (IF EQUIPPED)
CHAPTER 3-ENGINE
ENGINE EXPLODED VIEWS
SPECIAL TOOLS
PISTON IDENTIFICATION
TORQUE SPECIFICATIONS
ENGINE FASTENER TORQUE PATTERNS
ENGINE SERVICE DATA
COOLING SYSTEM SPECIFICATIONS
COOLING SYSTEM TEST
4-STROKE COOLANT SYSTEM BLEEDING PROCEDURE
ENGINE REMOVAL/INSTALLATION
ENGINE INSTALLATION NOTES
CYLINDER HONING
OIL PRESSURE TEST/FLOW
ROCKER ARM/PUSHROD INSPECTION
VALVE INSPECTION
COMBUSTION CHAMBER
VALVE SEAT RECONDITIONING
CYLINDER HEAD ASSEMBLY
VALVE SEALING TEST
VALVE TRAIN EXPLODED VIEW
ENGINE HEAD REASSEMBLY
CYCLINDER REMOVAL
VALVE LIFTER REMOVAL/INSPECTION
PISTON REMOVAL
CYLINDER INSPECTION
PISTON/ROD/RING SERVICE
STARTER BENDIX REMOVAL/INSPECTION
FLYWHEEL/STATOR REMOVAL/INSPECTION
FLYWHEEL/STATOR INSTALLATION
ENGINE CRANKSHAFT DISASSEMBLY/INSPECTION
CAMSHAFT INSPECTION
ENGINE CRANKCASE ASSEMBLY
TROUBLESHOOTING
CHAPTER 4-FUEL INJECTION
SPECIAL TOOLS
SERVICE NOTES
700 EFI SYSTEM EXPLODED VIEW
FUEL TANK EXPLODED VIEW
ELECTRONIC FUEL INJECTION SYSTEM
OPERATION OVERVIEW
INITIAL START/PRIMING PROCEDURE
ELECTRONIC CONTROL UNIT
SERVICE
REPLACEMENT
FUEL PUMP/TANK ASSEMBLY
TEST
REPLACEMENT
FUEL PRESSURE REGULATOR
TEST
REPLACEMENT
FUEL FILTERS
SERVICE
REPLACEMENT
FUEL INJECTORS
SERVICE
REPLACEMENT
CRANKSHAFT POSITION SENSOR
TEST
REPLACEMENT
TEMPERATURE/BAROMETRIC AIR PRESSURE SENSOR
TEST (REFER TO DIAGNOSTIC SOFTWARE)
REPLACEMENT
THROTTLE POSITION SENSOR
TEST
REPLACEMENT
TPS INSTALLATION
ENGINE TEMPERATURE SENSOR
TEST (REFER TO DIAGNOSTIC SOFTWARE)
REPLACEMENT
DIAGNOSTICS USING "BLINK CODES"
TROUBLESHOOTING
CHAPTER 5-BODY AND STEERING
SPECIAL TOOLS AND TORQUE SPECIFICATIONS
COVER AND PANEL REMOVAL
SIDE PANEL REMOVAL
FRONT-REAR RACK/GRILL REMOVAL
BODY ASSEMBLY, EXPLODED VIEW
BODY RACK ASSEMBLY, EXPLODED VIEW
HEADLIGHT POD EXPLODED VIEW
STEERING/A-ARM EXPLODED VIEW
REAR SUSPENSION EXPLODED VIEW
A-ARM REPLACEMENT
STEERING POST ASSEMBLY
FRONT STRUT ASSEMBLY EXPLODED VIEW
FRONT STRUT CARTRIDGE REPLACEMENT
FRONT STRUT BALL JOINT REPLACEMENT
DECAL REPLACEMENT
CHAPTER 6-CLUTCHING
DRIVE CLUTCH EXPLODED VIEW
PVT SEALING AND DUCTING COMPONENTS
EBS SYSTEM EXPLODED SYSTEM
SPECIAL TOOLS, SUPPLIES and TORQUES
PVT OPERATION OVERVIEW
PVT MAINENTANCE/INSPECTION/DRYING
PVT OVERHEATING/DIAGNOSIS
PVT DISASSEMBLY
PVT ASSEMBLY/INSPECTION
DRIVE CLUTCH SPRING SPECIFICATIONS
SHIFT WEIGHTS/INSPECTION
DRIVE CLUTCH DISASSEMBLY/INSPECTION
DRIVE CLUTCH REASSEMBLY
DRIVE BELT REMOVAL/INSPECTION
DRIVE BELT INSTALLATION
CLUTCH ALIGNMENT/OFFSET
DRIVE CLUTCH BUSHING SERVICE
DRIVEN CLUTCH SERVICE
DRIVEN CLUTCH EXPLODED VIEW
TROUBLESHOOTING
CHAPTER 7-FINAL DRIVE
AWD AXLE/PROPSHAFT EXPLODED VIEWS
SPECIAL TOOLS and TORQUE SPECIFICATIONS
FRONT HUB INSPECTION
FRONT DRIVE AXLE REMOVAL
FRONT DRIVE AXLE INSTALLATION
DRIVESHAFT and CV JOINT HANDLING TIPS
FRONT DRIVESHAFT CV BOOT REPLACEMENT
FRONT HUB DISASSEMBLY and ASSEMBLY
AWD FRONT PROP SHAFT REMOVAL
U-JOINT DISASSEMBLY
U-JOINT ASSEMBLY
FRONT GEARCASE REMOVAL/INSTALL
FRONT GEARCASE INFORMATION
FRONT GEARCASE EXPLODED VIEW
REAR HUB REMOVAL
REAR HUB INSTALLATION
REAR HUB DISASSEMBLY
REAR HUB ASSEMBLY
REAR DRIVESHAFT REMOVAL
DRIVESHAFT AND CV JOINT TIPS
REAR DRIVESHAFT INSTALLATION
REAR DRIVESHAFT SERVICE
REAR GEARCASE REMOVAL
REAR GEARCASE INSTALLATION
REAR GEARCASE DISASSEMBLY
REAR GEARCASE ASSEMBLY
REAR GEARCASE EXPLODED VIEW
CHAPTER 8-TRANSMISSION
TRANSMISSION, EXPLODED VIEW
TORQUE SPECIFICATIONS/LUBRICATION
GEAR SHIFT SELECTOR REMOVAL
TRANSMISSION REMOVAL
TRANSMISSION INSTALLATION
TRANSMISSION DISASSEMBLY
TRANSMISSION REASSEMBLY
CHAPTER 9-BRAKES
SPECIAL TOOLS/SPECIFICATIONS/TORQUES
2004 BRAKE LINE IDENTIFICATION
BRAKE SYSTEM SERVICE NOTES
BRAKE NOISE TROUBLESHOOTING
HYDRAULIC BRAKE SYSTEM OVERVIEW
HYDRAULIC CALIPER BLEEDING
BRAKE BLEEDING/FLUID CHANGE
MASTER CYLINDER REMOVAL
MASTER CYLINDER INSTALLATION
FRONT PAD REMOVAL
FRONT PAD INSTALLATION
BRAKE BURNISHING
FRONT DISC INSPECTION
FRONT DISC REMOVAL/REPLACEMENT
FRONT CALIPER REMOVAL
FRONT CALIPER DISASSEMBLY
FRONT CALIPER INSPECTION
FRONT CALIPER REASSEMBLY
FRONT CALIPER INSTALLATION
FRONT CALIPER EXPLODED VIEW
REAR PAD REMOVAL
RAR PAD INSTALLATION
REAR CALIPER REMOVAL/INSPECTION
REAR CALIPER REASSEMBLY
RAR DISC INSPECTION
AUXILIARY MASTER CYLINDER REMOVE/INSTALL
REAR CALIPER EXPLODED VIEW
TROUBLESHOOTING
CHAPTER 10-ELECTRICAL
CRANKSHAFT POSITION SENSOR GAP
GEAR POSITION SWITCH TEST
INSTRUMENT CLUSTER OVERVIEW
SPEEDOMETER REMOVAL/INSTALLATION
SPEEDOMETER OPERATION TROUBLESHOOTING
COOLANT SENSOR TESTS
FAN MOTOR TESTS
FAN CONTROL SWITCH TESTS
ELECTRONIC THROTTLE CIRCIUIT SYSTEM OPERATION
FLYWHEEL IDENTIFICATION
IGNITION SYSTEM OPERATION
IGNITION COMPONENTS
IGNITION SYSTEM TESTING FLOW CHART
IGNITION SYSTEM TROUBLESHOOTING
CHARGING SYSTEM TESTING/LOAD SHED RELAY
BATTERY IDENTIFICATION
CONVENTIONAL BATTERY ACTIVATION/SERVICE
LOW MAINT. BATTERY ACTIVATION /SERVICE
HEAD LIGHT/BRAKE LIGHT LAMP SERVICE
STARTER SYSTEM TROUBLESHOOTING
STARTER MOTOR SERVICE
STARTER DRIVE
STARTER ASSEMBLY EXPLODED VIEW
STARTER SYSTEM TESTING FLOW CHART
Wiring Diagrams
Index