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2004 Polaris Sportsman 700 EFI ATV Service Manual

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Number of pages: 277
File Size: 25.36 Mb
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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.

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Rated: 5 by: Daniel Posted: Wednesday, July 19, 2023 at 11:32AM

Good quality download. Genuine and accurate. Very fast download without any issues.

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

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