Polaris SPORTSMAN 600 Service Manual
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Polaris SPORTSMAN 600 Service Manual

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2004 SPORTSMAN 600/700
SERVICE MANUAL
PN 9918803

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Summary of Contents for Polaris SPORTSMAN 600

  • Page 1 2004 SPORTSMAN 600/700 SERVICE MANUAL PN 9918803...
  • Page 2 2004 Sportsman 600/700 ATV Service Manual (PN 9918803) ECopyright 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 and the information presented in this publication.
  • Page 3 NOTE: A NOTE provides key information to clarify instructions. Trademarks Polaris acknowledges the following products mentioned in this manual: FLEXLOC, Registered Trademark of SPS Technologies Loctite, Registered Trademark of the Loctite Corporation STA-BIL, Registered Trademark of Gold Eagle FOX, Registered Trademark of Fox Shox Nyogel, Trademark of Wm.
  • Page 4 GENERAL MAINTENANCE ENGINE CARBURETION BODY AND STEERING CLUTCHING FINAL DRIVE TRANSMISSION BRAKES ELECTRICAL...

  • Page 5: Table Of Contents

    ..2004 Sportsman Models / Dimensions ..1.4--1.5 Specifications - Early 2004 Sportsman 600 Specifications - Late 2004 Sportsman 600 Specifications - Early 2004 Sportsman 700 Specifications - Late 2004 Sportsman 700 .

  • Page 6: Model Identification

    GENERAL INFORMATION MODEL IDENTIFICATION The machine model number must be used with any correspondence regarding warranty or service. Machine Model Number Identification A 0 4 C H 6 8 A A Emissions & Model Option Year Designation Basic Chassis Designation Engine Designation ENGINE DESIGNATION NUMBERS EH068OLE...

  • Page 7: Sportsman Models Identification

    2004 SPORTSMAN MODEL IDENTIFICATION - - EARLY/LATE MODELS Mid--year changes were made to the 2004 Sportsman 600 & 700 models. When servicing your 2004 Sportsman it is important to identify which model you are working on. Throughout this service manual the different procedures (titles) are identified as “EARLY 2004”...
  • Page 8 GENERAL INFORMATION 2004 EARLY/LATE SPORTSMAN 600 MODEL: ..MODEL NUMBER: A04CH59 ENGINE MODEL: EH059OLE Category Dimension / Capacity Length 81 in./205.7 cm Width 46 in./116.8 cm Height 47 in./119.38 cm Wheel Base 50.75 in./128.9 cm...
  • Page 9 GENERAL INFORMATION LATE 2004 SPORTSMAN 600 HUNTER EDITION MODEL: ..MODEL NUMBER: A04CH59 ENGINE MODEL: EH059LE Category Dimension / Capacity Length 81 in./205.7 cm Width 46 in./116.8 cm Height 47 in./119.38 cm Wheel Base 50.75 in./128.9 cm...

  • Page 10: U 1/2

    Lubrication Pressurized Wet Sump Front Suspension / Shock A- -arm / MacPherson Strut Oil Requirements / Capacity Polaris 0W- -40 2 qt. / 1.9 ltr Front Travel 6.7 in. / 17.02 cm Exhaust System Single Pipe Rear Suspension / Shock...
  • Page 11 GENERAL INFORMATION LATE 2004 SPORTSMAN 600 & HUNTER EDITION MODEL: ..MODEL NUMBER: A04CH59 EH059OLE ENGINE MODEL: Engine Drivetrain Platform Polaris Twin Cylinder Transmission Type Drumshift - - H/L/N/Rev/Park Engine Model Number...
  • Page 12 Lubrication Pressurized Wet Sump Front Suspension / Shock A- -arm / MacPherson Strut Oil Requirements / Capacity Polaris 0W- -40 2 qt. / 1.9 ltr Front Travel 6.7 in. / 17.02 cm Exhaust System Single Pipe Rear Suspension / Shock...
  • Page 13 Lubrication Pressurized Dry Sump Front Suspension / Shock A- -arm / MacPherson Strut Oil Requirements / Capacity Polaris 0W- -40 2 qt. / 1.9 ltr Front Travel 6.7 in. / 17.02 cm Exhaust System Single Pipe Rear Suspension / Shock...

  • Page 14: Publication Numbers

    GENERAL INFORMATION PUBLICATION NUMBERS Year Model Model No. Owner’s Parts Parts Manual Manual PN Micro Fiche 2004 Early Sportsman 600 A04CH59 9918540 9918610 9918611 2004 Early Sportsman 700 A04CH68 9918540 9918612 9918613 2004 Late Sportsman 600 A04CH59 9918724 9918731 9918732...

  • Page 15: Standard Torque Specifications

    GENERAL INFORMATION STANDARD TORQUE SPECIFICATIONS The following torque specifications are to be used as a general guideline. There are exceptions in the steering, suspension, and engine areas. Always consult the exploded views in each manual section for torque values of fasteners before using standard torque.

  • Page 16: Conversion Table

    GENERAL INFORMATION CONVERSION TABLE Unit of Measure Multiplied by Converts to ft. lbs. x 12 = in. lbs. in. lbs. x .0833 = ft. lbs. ft. lbs. x 1.356 = Nm in. lbs. x .0115 = kg-m x .7376 = ft.lbs. kg-m x 7.233 = ft.
  • Page 17 GENERAL INFORMATION SAE TAP DRILL SIZES DECIMAL EQUIVALENTS 1/64 ....0156 Thread Size/Drill Size Thread Size/Drill Size 1/32 ... .0312 .

  • Page 18: Glossary Of Terms

    Center Distance: Distance between center of crankshaft and center of driven clutch shaft. Chain Pitch: Distance between chain link pins (No. 35 = 3/8″ or 1 cm). Polaris measures chain length in number of pitches. Crankshaft Run-Out: Run-out or “bend” of crankshaft measured with a dial indicator while crankshaft is supported between centers on V blocks or resting in crankcase.
  • Page 19 MAINTENANCE Periodic Maintenance Chart ....2.2-2.3 Pre-Ride Inspection ..... . Recommended Lubricants and Capacities .

  • Page 20: Periodic Maintenance Chart

    Change oil immediately and monitor level. If oil level begins to rise, discontinue use and determine cause.) E= Emission Control System Service (California). NOTE: Inspection may reveal the need for replacement parts. Always use genuine Polaris parts. ENGINE / COOLING / CONTROLS Item...
  • Page 21 MAINTENANCE PERIODIC MAINTENANCE CHART CONT’D ELECTRICAL Item Maintenance Interval Remarks (Whichever comes first) Spark Plug 100 hrs 12 months 1000 (1600) Inspect - Replace if necessary Wiring 100 hrs 12 months 1000 (1600) Inspect for abrasion, routing, security. " Apply Dielectric grease to connectors that are subjected to water, mud, etc.

  • Page 22: Pre-Ride Inspection

    MAINTENANCE PRE-RIDE / DAILY INSPECTION Perform the following pre-ride inspection daily, and when servicing the vehicle at each scheduled maintenance. Tires - check condition and pressures Fuel and oil tanks - fill both tanks to their proper level; Do not overfill oil tank All brakes - check operation and adjustment (includes auxiliary brake) Throttle - check for free operation Headlight/Taillight/Brakelight - check operation of all indicator lights and switches...
  • Page 23 MAINTENANCE POLARIS LUBRICANTS,MAINTENANCE AND SERVICE PRODUCTS Part No. Description Part No. Description Engine Lubricant Additives / Sealants / Thread Locking Agents / Misc. 2870791 Fogging Oil (12 oz. Aerosol) 2870585 Loctitet Primer N, Aerosol, 25 g 2871098 Premium 2 Cycle Engine Oil (Quart) (12...

  • Page 24: Special Tools

    MAINTENANCE SPECIAL TOOLS PART NUMBER TOOL DESCRIPTION CHAPTER TOOL USED IN PV- -43527 Oil Filter Wrench 2870872 Shock Spanner Wrench 2, 5 8712100 or 8712500 Tachometer 2,10 2200634 Valve Seat Reconditioning Kit PU- -45257 Valve Spring Compressor PU- -45652 Valve Pressure Hose 2871043 Flywheel Puller PU- -44693...
  • Page 25 Annually or 100 hours of operation (refer to Maintenance Schedule for additional information) © More often under severe conditions (operating in water or hauling heavy loads) Grease conforming to NLGI No. 2, such as Polaris Premium All Season Grease, Conoco Superlube M or ¢ Mobilegrease Special Ill.
  • Page 26 Annually or 100 hours of operation (refer to Maintenance Schedule for additional information) © More often under severe conditions (operating in water or hauling heavy loads) Grease conforming to NLGI No. 2, such as Polaris Premium All Season Grease, Conoco Superlube M or ¢ Mobilegrease Special...

  • Page 27: Front & Rear Gearcase Lubrication

    Catch and discard used oil properly. G The correct front gearcase lubricant to use is 2. Clean and reinstall drain plug using a new sealing Polaris Premium Demand Hub Fluid. washer. The Late 2004 front gearcase has a NOTE: 3.
  • Page 28 G Be sure vehicle is level before proceeding. G Check vent hose to be sure it is routed properly and unobstructed. G The correct rear gearcase lubricant to use is Polaris ATV Angle Drive Fluid. REAR GEARCASE SPECIFICATIONS Specified Lubricant:...

  • Page 29: Transmission Lubrication

    Catch and discard used oil properly. 3. Clean and reinstall the drain plug with a new sealing washer. Torque to specification. 4. Remove fill plug. 5. Add Polaris AGL Gearcase Lubricant to proper View From Front level as described above. 6. Check for leaks.
  • Page 30 Fill Plug specification. 3. Remove fill plug. 4. Add 13.5 oz. of Polaris AGL Gearcase Lubricant or fill to top of the fill plug hole threads. 5. Check for leaks. 6. Reinstall fill plug and torque to 14 ft.lbs. (19.4 Nm).

  • Page 31: Throttle Inspection

    MAINTENANCE SHIFT LINKAGE INSPECTION be smooth and lever must return freely without binding. 1. Place the gear selector in neutral. NOTE: Shift rod is preset at time of manufacture. 2. Set parking brake. 3. Start the engine and let it idle. Shift Linkage Rod 4.

  • Page 32: Idle Speed Adjustment

    MAINTENANCE PILOT SCREW Illustration of choke may vary with models. The pilot system supplies fuel during engine operation with the throttle valve closed or slightly opened. The fuel/air mixture is metered by pilot screw and discharged into the main bore through the pilot outlet. CAUTION: The pilot screw is calibrated at the factory to meet PEA / CRAB regulations for air quality standards and is sealed with a brass...

  • Page 33: Fuel System

    MAINTENANCE FUEL SYSTEM THROTTLE CABLE / ELECTRONIC THROTTLE CONTROL (ETC SWITCH) ADJUSTMENT CONTEND WARNING 3. Start engine and set idle to specified RPM. Gasoline is extremely flammable and explosive under certain conditions. Always stop the engine and refuel outdoors or in a well ventilated area. Adjuster Boot Lock-...

  • Page 34: Compression Test

    MAINTENANCE VENT LINES 3. Turn drain screw out two turns and allow fuel in the float bowl and fuel line to drain completely. Check fuel tank, oil tank, carburetor, battery and 4. Inspect the drained fuel for water or sediment. transmission vent lines...

  • Page 35: Battery Maintenance

    MAINTENANCE BATTERY MAINTENANCE COMPRESSION TEST CONT’D A cylinder leakdown test is the best indication of engine condition. Follow manufacturer’s instructions to perform a cylinder leakage test. (Never use high WARNING pressure leakage testers, as crankshaft seals may dislodge and leak). Battery electrolyte is poisonous.

  • Page 36: Ignition Timing

    MAINTENANCE To remove the battery: 5. Measure gap with a wire gauge. Refer to specifications for proper spark plug type and gap. 1. Disconnect holder strap and remove cover. Adjust gap if necessary by bending the side 2. Disconnect battery negative (-) (black) cable first, electrode carefully.
  • Page 37 Do not add straight antifreeze or straight water to the system. Straight water or antifreeze may cause the system to freeze, corrode, or overheat. Polaris 60/40 Anti-Freeze / Coolant (PN 2871323) 2.19...

  • Page 38: Radiator Screen Removal

    Cover 1. Remove reservoir cap. Verify the inner splash cap vent hole is clear and open. 2. Fill reservoir to upper mark with Polaris Premium 60/40 Anti Freeze / Coolant (PN 2871323) or a Rack mixture of antifreeze and distilled water as required for freeze protection in your area.

  • Page 39: Air Box Sediment Tube Service

    MAINTENANCE AIR FILTER/PRE-FILTER NOTE: Apply a small amount of general purpose SERVICE grease to the sealing edges of the filter before reinstalling. It is recommended that the air filter and pre filter be replaced annually. When riding in extremely dusty conditions, replacement is required more often.

  • Page 40: Breather Filter

    MAINTENANCE BREATHER HOSE 3. Reinstall drain plug. 1. Be sure breather line is routed properly and secured in place. CAUTION: Make sure lines are not kinked or pinched. PVT DRYING & PVT DRAIN PLUG NOTE: If operating the ATV in or through water, be sure to check the PVT cover and other components Sediment Tube for water ingestion.

  • Page 41: Oil Change/Filter

    MAINTENANCE ENGINE OIL LEVEL crankcase, the oil level will read higher on the bottom side of the dipstick. Proper level indication is determined on the upper surface of the dipstick as it The 600/700 engine is a wet--sump engine, meaning is being removed, regardless of the level marks being the oil is contained in the bottom of the crankcase.
  • Page 42 12. Remove dipstick and fill sump with 2 quarts (1.9 l) damage. Also check to make sure all cotter pins are of Polaris Premium 4 Synthetic Oil (PN 2871281). in place. If cotter pins are removed, they must not be re-used.
  • Page 43 ( possible performed by an authorized Polaris MSD- -certi- loose wheel nuts or loose front hub fied technician when replacing worn or dam- components).

  • Page 44: Wheel Alignment

    MAINTENANCE WHEEL ALIGNMENT WHEEL ALIGNMENT METHOD 1: METHOD 2: CHALK STRAIGHTEDGE OR STRING 1. Place machine on a smooth level surface. 2. Set handlebars in a straight ahead position and Be sure to keep handlebars centered. See notes secure handlebars in this position. NOTE: The below.
  • Page 45 MAINTENANCE TOE ALIGNMENT EXHAUST PIPE ADJUSTMENT WARNING If toe alignment is incorrect, measure the distance between vehicle center and each wheel. This will tell G Do not perform clean out immediately after the engine has been run, as the ex- you which tie rod needs adjusting.

  • Page 46: Brake Pad Inspection

    HOSE/FITTING INSPECTION reservoir to the indicated level inside reservoir. Check brake system hoses and fittings for cracks, Use Polaris DOT 3 Brake Fluid (PN deterioration, abrasion, and leaks. Tighten any loose 2870990). fittings and replace any worn or damaged parts.

  • Page 47: Front Suspension

    MAINTENANCE SUSPENSION: SPRING PRELOAD ADJUSTMENT Auxiliary Foot Brake Pedal Full Full Height Operator weight and vehicle loading affect Engagement suspensionspringpreloadrequirements. Adjustas necessary. Shock Spanner Wrench Floor (PN 2870872) Board Surface AUXILIARY BRAKE ADJUSTMENT (HYDRAULIC) FRONT SUSPENSION Use the following procedure to inspect the hydraulic Compress and release front suspension.

  • Page 48: Controls

    MAINTENANCE CONTROLS WHEEL INSTALLATION Check controls for proper operation, positioning 1. With the transmission in gear and the parking and adjustment. brake locked, place the wheel in the correct position on the wheel hub. Be sure the valve stem is toward the outside and rotation arrows on the tire point toward forward rotation.

  • Page 49: Warn Winch Operation

    MAINTENANCE The use of non-standard size or type The winch is located in the front bumper area. tires may affect ATV handling. Tire Tread Depth Always replace tires when tread depth is worn to 1/8″ (3 mm) or less. Tread Depth 1/8I (3 mm) The mini--rocker (IN/OUT) control controls the direction of the cable for the winch.
  • Page 50 MAINTENANCE When the winch is FREESPOOL, the winch allows the cable to be pulled out freely. NOTE: The switch on the handlebar does not have to be in the OUT position. FREESPOOL Thumb Warmer The hand warmer switch is located on the left side of the headlight pod.
  • Page 51 ENGINE Engine Exploded Views ..... . 3.2--3.6 Special Tools ....... Piston Identification .

  • Page 52: Engine Exploded Views

    ENGINE ENGINE EXPLODED VIEW CRANKCASE Camshaftt Thrust Plate Journal Bearings Ball Bearing 115 ± 12 in. lbs. Balance Shaft (13 ± 1.35 Nm) Flange Seal 60 ± 6 in. lbs. (6.8 ± .68 Nm) Bushing Woodruff Key Crankshaft Oil Pickup Journal Bearings Baffle 60 ±...
  • Page 53 ± (10.85 .35 Nm) ± 108 ± 12 in. lbs. (6.8 ± .68 Nm) Oil Pump Bolt Tighten Sequence TIMING MARKS Mag Cover Bolt Tighten Sequence Apply Polaris 0W--40 oil to component. Apply White GEAR TIMING AT TDC Lithium Grease.
  • Page 54 ENGINE ENGINE EXPLODED VIEW Apply Polaris MAG SIDE Starter Grease. Apply Polaris 0W--40 oil to seal. Loctitet Pipe Sealant (PN 2871956) Bolts Water Pump Cover Bolt Gasket (Tighten Top Bolt First) Tighten Sequence (NO Grease or Oil!) 8 ft. lbs.

  • Page 55: Top End

    Apply 0W--40 to lifters. Pushrods Bushing Do not expansion plug install more than 1.5 mm inward. Expansion 1.5 mm Plug Cylinder Side View Piston Assembly Circlip UP for Install Gasket Hydraulic Lifter Apply Polaris 0W--40 oil. Apply Moly Lube Grease.
  • Page 56 ENGINE ENGINE EXPLODED VIEW OUTER COMPONENTS Screws 8 in. lbs. ± (9.5 0.9 Nm) ± Rocker Cover Breather O--ring Seal 5 in. lbs. ± Breather Bolts (2.5 0.55 Nm) ± Spark Plugs 24 in. lbs. ± (24.5 2.7 Nm) ± Carburetor Boot 24 in.

  • Page 57: Special Tools

    ENGINE SPECIAL TOOLS PART NUMBER TOOL DESCRIPTION PV- -43527 Oil Filter Wrench 2200634 Valve Seat Reconditioning Kit PU- -45257 Valve Spring Compressor PU- -45652 Valve Pressure Hose 2871043 Flywheel Puller 2870390 Piston Support Block PU- -45497- -2 Cam Gear Tooth Alignment Tool PU- -45497- -1 Cam Gear Spring Installation Kit (Tapered Pins) PU- -45498...

  • Page 58: Torque Specifications

    ENGINE TORQUE SPECIFICATIONS TORQUE SPECIFICATIONS Fastener Size 600/700 600/700 in. Lbs. (Nm) ft.lbs. (Nm) Camshaft Gear 8 mm 22 ± 2 (30 ± 3) Camshaft Thrust Plate 6 mm 115-± 12 (13 ± 1.35) Carburetor Adaptor Bolts 8 mm 216 ± 24 (24.5-± 2.7) Counterbalance Gear 8 mm 22 ±...

  • Page 59: Engine Fastener Torque Patterns

    ENGINE ENGINE FASTENER TORQUE PATTERNS Tighten cylinder head/cylinder base, and crankcase fasteners in the following sequence outlined below. CRANKCASE BOLT TIGHTEN SEQUENCE 2 ft. lbs. ± 3 Nm) ± CYLINDER HEAD BOLT TIGHTEN SEQUENCE Lubricate threads and between washer and underside of bolt with engine oil. Torque in sequence to spec provided, allow the gasket to set for 1 minute, then tighten in sequence 90°...

  • Page 60: 600 Engine Service Data

    ENGINE 600 ENGINE SERVICE DATA Cylinder Head / Valve Engine No. - - EH059OLE Camshaft Cam lobe height In 0 .2170” ± 0.00236” (5.5118 ± 0.060 mm) 0 .2170” ± 0.00236” (5.5118 ± 0.060 mm) Camshaft journal OD 1.654” ± 0.00039” (42 ± 0.010 mm) Center 1.634”...
  • Page 61 ENGINE 600 ENGINE SERVICE DATA Cylinder / Piston / Connecting Rod Engine No. - - EH590ALOE Cylinder Surface warpage limit (mating with cyl- 0.004” (0.10 mm) inder head) Cylinder bore 3.0118” (76.5mm) Taper limit 0.00031” (0.008 mm) Out of round limit 0.00030”...
  • Page 62 ENGINE 700 ENGINE SERVICE DATA Cylinder Head / Valve Engine No. - - EH68ALOE / EH068OLE Camshaft Cam lobe height In 0 .2170” ± 0.00236” (5.5118 ± 0.060 mm) 0 .2170” ± 0.00236” (5.5118 ± 0.060 mm) Camshaft journal OD 1.654”...
  • Page 63 ENGINE 700 ENGINE SERVICE DATA Cylinder / Piston / Connecting Rod Engine No. - - EH68ALOE / EH068OLE Cylinder Surface warpage limit (mating with cyl- 0.004” (0.10 mm) inder head) Cylinder bore 3.1495” (80 mm) Taper limit 0.00031” (0.008 mm) Out of round limit 0.00030”...

  • Page 64: Cooling System Specifications

    2. The radiator cap relief pressure is 13 lbs. Replace damage. Polaris Premium 60/40 Antifreeze/Coolant is cap if it does not meet this specification. recommended for use in all cooling systems and comes Surge Tank pre-mixed, ready to use.
  • Page 65 ENGINE ENGINE REMOVE & INSTALL 12. Disconnect the coolant hoses. Properly dispose of any antifreeze from the engine or hoses. 1. Clean work area. 13. Refer to PVT System Chapter 6 to remove outer clutch cover, drive belt, drive clutch, driven clutch, 2.

  • Page 66: Engine Installation Notes

    ENGINE INSTALLATION NOTES Engine Break In Period The break in period for a Polaris ATV engine is defined After the engine is installed in the frame, review this as the first ten hours of operation, or the time it takes checklist and perform all steps that apply: to use two full tanks of gasoline.
  • Page 67 Rinse thoroughly, dry with compressed air, A finished cylinder should have a cross-hatch pattern and oil the bore immediately with Polaris 4 Cycle to ensure piston ring seating and to aid in the retention Lubricant to prevent the formation of surface rust.

  • Page 68: Oil Flow

    ENGINE OIL FLOW This chart describes the flow of oil through the EH68 and the EH059 engine. Beginning in the crankcase sump, the oil is drawn through an oil galley to the feed side of the oil pump. The oil is then pumped through the oil filter. If the oil filter is obstructed, a bypass valve contained in the filter allows oil to bypass the filter element.

  • Page 69: Rocker Arm/Pushrod Inspection

    ENGINE ROCKER ARM INSPECTION 5. If the push rod (A) is visibly bent, it should be replaced. 1. Mark or tag rocker arms in order of disassembly to keep them in order for reassembly. CYLINDER HEAD REMOVAL 2. Inspect the wear pad at the valve end of the rocker arm for indications of scuffing or abnormal wear.

  • Page 70: Cylinder Head Disassembly/Inspection

    ENGINE CYLINDER HEAD INSPECTION WARNING 1. Thoroughly clean cylinder head surface to Wear eye protection or a face shield during remove all traces of gasket material and carbon. cylinder head disassembly and reassembly. CAUTION: Use care not to damage sealing surface. 1.
  • Page 71 ENGINE CYLINDER HEAD DISASSEMBLY, CONT. Valve Spring Length: NOTE: Carefully remove the cylinder components. Place the hydraulic lifters (C), pushrods (D), and Std: 1.827I (46.40 mm) rocker arms (E) in a safe, clean area. Installed Height: 1.47” (37.34 mm) 6. Remove valve guide seals. IMPORTANT: It is recommended to replace seals whenever the cylinder head is disassembled.

  • Page 72: Valve Inspection

    ENGINE VALVE INSPECTION Valve Stem Diameter: 1. Remove all carbon from valves with a soft wire Intake: 0.2356” ± 0.00039” wheel or brush. (5.985 ± 0.01 mm) 2. Check valve face for runout, pitting, and burnt Exhaust: 0.2346” ± 0.00039” spots.

  • Page 73: Combustion Chamber

    1. Install pilot into valve guide. VALVE SEAT RECONDITIONING Cylinder Head Reconditioning NOTE: Polaris recommends that the work be done by a local machine shop that specializes in this area. NOTE: The cylinder head valve guides cannot be replaced. WARNING Wear eye protection or a face shield during cylinder head disassembly and reassembly.
  • Page 74 ENGINE VALVE SEAT RECONDITIONING CONT’D If the seat is too narrow, widen using the 45° cutter and re-check contact If the contact area of the cutter is in point on the valve face and seat width the same place, the valve guide is after each cut.

  • Page 75: Cylinder Head Assembly

    ENGINE VALVE SEAT RECONDITIONING CONT”D 8. Clean all filings from the area with hot soapy water, rinse, and dry with compressed air. WARNING Wear eye protection or a face shield when working with compressed air during cylinder head disassembly and reassembly. 9.

  • Page 76: Valve Sealing Test

    ENGINE VALVE SEALING TEST 1. Clean and dry the combustion chamber area (A). Refer to Page 3.23 for cleaning tips. 2. Pour a small amount of clean solvent onto the intake port and check for leakage around each intake valve. The valve seats should hold fluid with no seepage.

  • Page 77: Engine Head Reassembly

    ENGINE ENGINE HEAD REASSEMBLY 4. Lubricate push rods (D) and install into lifters. Before reassembly, clean the bolts and bolt holes with Primer N (PN 2870585) to remove any debris. This will ensure proper sealing when installing bolts. 1. Install the head gasket (A) on the cylinder (B). 5.
  • Page 78 ENGINE ENGINE HEAD REASSEMBLY CONT’D 11. Install thermostat (J), O--ring, thermostat housing. Torque thermostat housing 8. Install breather reed (G) into rocker cover (H). bolts to 84 ± 8 in.lbs. (9.5 ± 0.9 Nm). Lightly apply black RTV sealant to the outer edges of the breather reed.

  • Page 79: Cylinder Removal

    ENGINE CYLINDER REMOVAL 4. Check the lifters for wear or scores. 5. Check the bottom end of lifter to make sure that it 1. Follow engine disassembly procedures to has a slight convex. remove rocker cover and cylinder head. 6. If the bottom surface has worn flat, it may be used 2.

  • Page 80: Cylinder Inspection

    ENGINE apply heat to the piston rings. The ring may lose b) Remove the expander. radial tension. 3. Remove top compression ring: *Using a piston ring pliers: Carefully expand ring and lift it off the piston. CAUTION: Do not expand the Compression Rings ring more than the amount necessary to remove it...
  • Page 81 Cylinder Out of Round Limit: .002I (.05mm)Max. Standard Bore Size (Both Cylinders): Sportsman 700 : 3.1496I (80 mm) Sportsman 600: 3.0018” (76.50 mm) PISTON-TO-CYLINDER CLEARANCE 4. Inspect cylinder for taper and out of round with a telescoping gauge or a dial bore gauge. Measure...
  • Page 82 ENGINE 2. Measure piston pin O.D. Replace piston and/or piston pin if out of tolerance. 5 mm Piston Piston Pin Piston Pin Measurement Locations Piston to Cylinder Clearance 600: .0022” ± .00067” (.055 ± .017 mm) Piston Pin O.D. 700: .0016” ± .00063” (.041 ± .016 mm) 0.7874”...

  • Page 83: Piston Ring Installed Gap

    ENGINE Piston Ring Installed Gap Piston Top Ring: 0.01181” ± 0.00393” (0.30 ± 0.10 mm) Ring Second Ring Limit: 0.01476” ± 0.00492” (0.375 ± 0.125 mm) Oil Ring Limit: 0.00984” ± .00393” (0.25 ± 0.10 mm) Top Ring Limit: 0.01083” ± 0.00295” Feeler Gauge (0.275 ±...

  • Page 84: Starter Bendix Removal/Inspection

    ENGINE STARTER DRIVE/BENDIX 7. Inspect the bendix bushing (C) in the mag cover for wear. Replace as needed. REMOVAL/INSPECTION 1. Remove stator housing bolts and remove housing. 2. Remove the flywheel nut and washer. Install Flywheel Puller (PN 2871043) and remove flywheel.

  • Page 85: Flywheel/Stator Removal/Inspection

    ENGINE FLYWHEEL/STATOR REMOVAL/INSPECTION 1. Remove stator housing bolts and remove housing. 5. Remove the bendix (E) if necessary. FLYWHEEL/STATOR INSTALLATION Remove Stator Cover NOTE: Before assembly, clean the bolts and bolt holes with Primer N (PN 2870585) to remove any 2.

  • Page 86: Engine Crankcase Disassembly/Inspection

    ENGINE Stator Housing Bolt Torque: Flywheel Nut Torque: 96 ± 12 in.lbs. (1.85 ± 1.35 Nm) 65 ± 7 ft. lbs. (88 ± 9.50 Nm) *Torque Bolts In Sequence (Pg. 3.4) 5. Inspect the mating surface around the gear/stator housing cover and the crankcase for oil seepage. ENGINE CRANKCASE If there is seepage between the mating surfaces, DISASSEMBLY/INSPECTION...
  • Page 87 ENGINE bolts into the flywheel more than 1/4″ or stator coils may be damaged. 2871043 7. Note the positions of the gears in the photo. 5. Remove the starter bendix (G), wire holddown plate (H), and the woodruff key (I) from the Camshaft Gear crankshaft.
  • Page 88 ENGINE NOTE: If replacing one of the gears, it is 11. The cam gear assembly contains three loaded recommended that all of the gears be replaced. A springs. To open the cam gear assembly: gear kit is available in the parts book. Place the cam gear on a flat surface with the timing mark side facing up.
  • Page 89 ENGINE Inspect Teeth & Tabs PU- -45497- -1 Replace Three Springs To assemble: Cam Gear Reassembly Hold the spring with one finger. 15. Install the new springs into the grooves of the cam Start the pointed end of the tapered gear.
  • Page 90 ENGINE (R) to align the teeth of the cam gears, as shown in the picture. Cam Gear Spring Installation Tool Kit: NOTE: Install the Cam Gear Alignment Tool (PU- -45497) (PU- -45497- -2) into one assembly hole counter clockwise from the timing mark. Tapered Pins: (PU- -45497- -1) Cam Gear Tooth Align Tool:...
  • Page 91 ENGINE balance shaft gear. 2871043 2871043 23. Inspect the crankshaft gear (Q) for broken or worn Water/Oil Pump Removal/Disassembly teeth. If the crankshaft gear does not need to be replaced, it does not need to be removed. If the crankshaft gear is damaged, remove the 26.
  • Page 92 ENGINE 28. Remove the oil pressure relief. The oil pressure DISASSEMBLY OF WATER/OIL PUMP SHAFT relief consists of a bolt, washer, spring, and valve (dowel). Inspect the the valve (dowel) for signs of WARNING Wear appropriate safety gear possible obstructions. Use compressed air to during this procedure.
  • Page 93 ENGINE WATER/OIL PUMP REASSEMBLY CRANKCASE DISASSEMBLY CONT’D 33. Press new bearing onto the shaft. 36. Remove thrust plate (U). Bearing 34. Press the bearing/shaft assembly using the 37. Remove PTO end engine mount. Remove bearing’s outer race. Do not use the shaft to press crankcase bolts.

  • Page 94: Camshaft Inspection

    ENGINE CAMSHAFT INSPECTION 1. Thoroughly clean the cam shaft. 2. Visually inspect each cam lobe for wear, chafing or damage. 39. Remove balance shaft and crankshaft. Lobe height 3. Measure height of each cam lobe using a micrometer. Compare to specifications. Cam Lobe Height (Intake &...

  • Page 95: Engine Crankcase Assembly

    ENGINE 1. Install oil pick up (A), if removed. Torque bolt to 60 ± 6 in. lbs. (6.8 ± 0.68 Nm). Camshaft Journal O.D. : A. (Mag): 1.654” ± .00039” (42 ± .010 mm) B. (Ctr.): 1.634” ± .00039” (41.50 ± .010 mm) C.
  • Page 96 ENGINE 4. Apply Moly Lube Grease to cam journals and 7. Assemble the crankcase halves. Apply LocTitet balance shaft bearing surfaces of the MAG case 242 (PN 2871949)to the threads and pipe sealant halve. Install cam and balance shafts. to the bolt flanges. Torque bolts to 22 ± 2 ft. lbs. (30 ±...
  • Page 97 ENGINE 10. Lubricate connecting rods with 0W--40 engine oil. 13. Install piston assemblies into cylinder aligning the piston pin holes, to ensure proper alignment of the pistons to the connecting rods upon assembly. Partially install the piston pins into the pistons. Cylinder Installation 11.
  • Page 98 ENGINE NOTE: While installing in piston pins, cover all engine passages. The clip could fall into the engine during installation. Line Up Marks 18. Apply moly lube, lubriplate, or oil to the rotors on the oil pump shaft. NOTE: The application of oil or lubriplate aids in priming the oil pump during initial engine start up.
  • Page 99 ENGINE debris. This will ensure proper sealing when installing bolts and new Loctitet. 20. Install oil pump housing bolts (H). The new bolts contain patch lock, so Loctitet is not needed on the new bolts. Torque bolts to 84 ± 8 in.lbs. (9.50 ± 0.90 Nm) and follow the torque sequence on Pg.
  • Page 100 ENGINE (PU- -45838). Torque to 22 ± 2 ft. lbs.(30 ± 3 Nm). PU- -45498 PU- -45838 27. Reinstall the camshaft gear; so the timing marks are properly aligned. Install the washer and bolt. Balance Shaft Gear Bolt Torque: Torque to 22 ± 2 ft. lbs.(30 ± 3 Nm). 22 ±...
  • Page 101 ENGINE (no lubricant) during assembly. Use of lubricants (oil, soapy water, etc.) will not allow the seal to PU- -45543 wear- -in and seal properly. Do not touch seal surface or allow seal surface to come in contact with contaminates during installation.
  • Page 102 ENGINE Important: Set PA- -45401 the direction of the paper seal lip PA- -45658 31. Carefully install the tapered end of the 33. Install the new gasket to the gear/stator housing Crankshaft Seal Protection Tool (PA- -45658) cover and crankcase. With the tools installed, through the paper side of the crankshaft seal.
  • Page 103 ENGINE Gear/Stator Housing Bolt Torque: 96 ± 12 in. lbs. (10.85 ± 0.35 Nm) *Torque in Proper Sequence (Pg. 3.3) NOTE: Before assembly, clean the bolts and bolt holes with Primer N (PN 2870585) to remove any debris. This will ensure proper sealing when installing bolts.
  • Page 104 ENGINE 39. Install water pump cover (R) with new O-ring seal. grommet (U) with Nyogelt Grease (PN Torque bolts to 96 ± 12 in. lbs. (10.85 ± 0.35 Nm) 2871329). in proper sequence (See Pg. 3.4). NOTE: Be sure the stator wires are routed properly under the wire hold down bracket.
  • Page 105 46. Remove primer plug from the engine. Install the Oil System Priming Adapter (PU- -45778) into the oil plug hole. Push 3--5 oz. (approx.) of Polaris 0W--40 into the adapter until resistance is felt. Remove the adapter. Apply pipe dope or Teflon tape to the plug threads.

  • Page 106: Troubleshooting

    ENGINE TROUBLESHOOTING Spark Plug Fouling Spark plug cap loose or faulty Engine flooded Low compression (high cylinder Choke cable adjustment or leakage) plunger/cable sticking No spark (Spark plug fouled) Foreign material on choke plunger ignition component failure seat or plunger Engine Does Not Turn Over Incorrect spark plug heat range or Dead battery...
  • Page 107 ENGINE TROUBLESHOOTING, CONT Valve sticking Air leaks in intake Piston Failure - Scoring Lean condition Lack of lubrication COOLING SYSTEM Dirt entering engine through cracks in air filter or ducts TROUBLESHOOTING Engine oil dirty or contaminated Overheating Excessive Smoke and Carbon Buildup Low coolant level Excessive piston-to-cylinder clearance...
  • Page 108 3. Always add coolant to the radiator first, filling to the top of the neck to replace air that has been purged from the system. Polaris Premium Antifreeze Fill the reservoir only after you have completely filled the cool- 2871534 Quart ing system at the radiator filler neck.
  • Page 109 FUEL SYSTEM/CARBURETION Exploded View, Mikuni BST 34 Carburetor . . . Fuel Tank Asm. Exploded View ... . Fuel Flow Diagram ..... . . Special Tool &...
  • Page 110 FUEL SYSTEM/CARBURETION BST 34 CARBURETOR EXPLODED VIEW 1. Ring 2. E--Ring 3. Jet Needle 4. Ring 5. Diaphragm 6. Needle Jet 7. Screw 8. Spring Washer 9. Jet Block 10. Washer 11. Main Jet 12. Cap 13. Seal 14. Packing 15.

  • Page 111: Fuel Flow Diagram

    FUEL SYSTEM/CARBURETION FUEL TANK ASSEMBLY NOTE: Late--build 2004 Models equipped with a fuel sender have NO reserve feature. Gas Cap Early 2004 Models are NOT equipped with a sender Seal and have the reserve feature on fuel valve. Foam Fuel Sender Gasket On/Off Valve Tank...

  • Page 112: Carburetor Jetting

    3130571 dense with reduced oxygen. 157.5 3130572 3131141 Polaris ATV Carburetors are calibrated for an altitude 162.5 3131142 0-6000 ft. (0-1800 meters) and ambient 3131143 temperatures between +40 and +80° F (+5° to +26°...

  • Page 113: Cv Carburetor System Function (4 Cycle)

    FUEL SYSTEM/CARBURETION CV CARBURETOR SYSTEM VENT SYSTEMS - CV FUNCTION CARBURETOR The carburetor float bowl vent lines supply atmospheric pressure to the float bowl. The lines Carburetor Component Function must be free of kinks, restrictions and be properly System Main Main Main routed.
  • Page 114 FUEL SYSTEM/CARBURETION CARBURETOR OPERATION CONT’D When the throttle plate is opened and engine speed begins to increase, the pressure in the venturi (and therefore in the chamber above the diaphragm) becomes significantly lower than atmospheric. Atmospheric pressure in the chamber below the diaphragm forces the diaphragm upward, raising the slide against spring pressure.

  • Page 115: Float System

    FUEL SYSTEM/CARBURETION FLOAT SYSTEM Fuel enters the float chamber (3) by means of the inlet pipe and passage, through a screen on the back of the inlet needle seat (4), and around the inlet needle (2). As the fuel fills the float chamber, the float (1) rises and forces the inlet needle against the seat, shutting off the orifice in the seat.
  • Page 116 FUEL SYSTEM/CARBURETION PILOT SCREW may be permanently damaged. The pilot system supplies fuel during engine operation with the throttle valve closed or slightly opened. The fuel/air mixture is metered by pilot screw and discharged into the main bore through the pilot outlet. CAUTION: The pilot screw is calibrated at the factory to meet EPA / CARB regulations for air quality standards and is sealed with a brass...

  • Page 117: Carburetor Inspection

    FUEL SYSTEM/CARBURETION installed over the pilot screw cavity, it must be 1. Thoroughly clean the carburetor body, jets, and removed for access. all passages with carburetor cleaner or electrical contact cleaner. 2. If carburetor extremely dirty contaminated with fuel residue and varnish, soak for short periods only in carburetor cleaner, and rinse in hot water.

  • Page 118: Carburetor Assembly

    FUEL SYSTEM/CARBURETION CARBURETOR ASSEMBLY pressure tested after assembly. Inspect the diaphragm (A) for holes, deterioration, or damage. Make sure the diaphragm is pliable but not Worn, Deposits Good Condition swollen. The diaphragm should fit properly in the carburetor body. Replace diaphragm assembly if diaphragm is damaged.

  • Page 119: Needle & Seat Leakage Test

    FUEL SYSTEM/CARBURETION CARBURETOR ASSEMBLY CONT’D 3. If adjustment is necessary, bend the tongue slightly. Be sure float measurement is even on left 5. Install the pilot mixture screw, spring, washer, and and right side. O-ring as an assembly. Lubricate the O-Ring with oil or light grease before installation.

  • Page 120: Fuel Level

    Remove the valve and wash with soap and water. Carburetor cleaner may be The Polaris Sportsman 600/700 is equipped with a used to clean the pump body when the check pressure regulated fuel pump (1-3 PSI). The pump is valves are removed.

  • Page 121: Fuel Sender Service

    FUEL SYSTEM/CARBURETION LATE 2004 FUEL SENDER REMOVAL/INSTALL Fuel Sender Removal 1. Disconnect the negative battery cable. 2. Remove the side panels and front cab assembly. Refer to “COVER PANEL REMOVAL” in Chapter 5 for details. 3. Remove the gas tank cover vent hose. Be sure to properly route the vent hose upon reassembly.
  • Page 122 FUEL SYSTEM/CARBURETION TROUBLESHOOTING Loose jets Worn jet needle/needle jet or other FUEL STARVATION/LEAN MIXTURE carburetor parts Dirty carburetor (air bleed Symptoms: Hard start or no start, bog, backfire, passages or jets) popping through intake / exhaust, hesitation, Weak or damaged vacuum piston detonation, low power, spark plug erosion, engine return spring runs hot, surging, high idle, idle speed erratic.
  • Page 123 BODY / STEERING / SUSPENSION Special Tools & Torque Specifications ..Cover/Panel Removal ..... . . Side Panel Removal .

  • Page 124: Cover/Panel Removal

    BODY / STEERING / SUSPENSION SPECIAL TOOLS COVER/PANEL REMOVAL To Remove: Seat TOOL PART NUMBER DESCRIPTION Pull release lever at the rear of the Ball Joint 2870871 seat Lift and pull seat rearward, Replacement Tool disengaging seat from tabs at the Shock Spanner 2870872 rear of the fuel tank...

  • Page 125: Side Panel Removal

    BODY / STEERING / SUSPENSION SIDE PANEL REMOVAL NOTE:Side panel removal may be difficult until the Step 3. locking tabs and receivers have been snapped and unsnapped a few times. 1. Remove seat. Grasp rear of side panel near rear cab.
  • Page 126 BODY / STEERING / SUSPENSION FRONT RACK/BUMPER REAR RACK REMOVAL REMOVAL 1. Remove the four bolts that secure the rear rack to rear rack support. 1. Remove the four bolts from the top rack. Remove Bolts FRONT GRILL REMOVAL 2. Remove the bolt that secures the panel located in 1.

  • Page 127: Body Assembly Exploded View

    BODY / STEERING / SUSPENSION BODY ASSEMBLY EXPLODED VIEW Rear Cab Assembly Pull UP on rear of seat and back Seat Latch to disengage tabs at front of seat Release Seat Latch Storage Rear Cab Rear Mud Guard Frame Front Housing Wheelwell Front Cab Assembly Front Cover...

  • Page 128: Body Rack Assembly, Exploded View

    BODY / STEERING / SUSPENSION BODY RACK EXPLODED VIEW Rear Rack Extender Rear Rack Rear Rack Support Front Rack Extender Front Rack Front Bumper Front Rack Support Panel Brush Guard Radiator Screen Side Shield Grill...
  • Page 129 BODY / STEERING / SUSPENSION WARN WINCH ASSEMBLY COMPONENTS (SPORTSMAN  HUNTER PACKAGE) NOTE: The Warn Winch Assembly is only standard on the Hunter Package Sportsman ATV Winch Contactor Winch Switch Assembly Main Harness Front Harness Rack Support Mount Plate Winch Front Bumper Headlight...

  • Page 130: Headlight Pod Exploded View

    BODY / STEERING / SUSPENSION HEADLIGHT POD **Hand Warmer Switch EXPLODED VIEW Torque bolts evenly so gap is equal at front and rear of handlebar block **Thumb Warmer Switch 11-13 ft. lbs. (15-18 Nm) Clean knurling when repositioning handlebars Adjuster ** Models w/ thumb warmer and hand warmer standard.

  • Page 131: Steering/A--Arm Exploded View

    BODY / STEERING / SUSPENSION STEERING/A- -ARM NOTE: To avoid damage to tie rods and other steering EXPLODED VIEW components, be sure to install tie rod end bolts in the proper direction. The steering post arm bolt (B) points up; the rod end bolts (A) point down.

  • Page 132: Rear Suspension Exploded View

    BODY / STEERING / SUSPENSION REAR SUSPENSION EXPLODED VIEW 17 ft. lbs. (24 Nm) Stabilizer Support 17 ft. lbs. (24 Nm) 35 ft. lbs. (48 Nm) Forward Upper Control Skid Plate Strap Stabilizer Bar Arm 35 ft. lbs. (48 Nm) 30 ft.

  • Page 133: A-Arm Replacement

    BODY / STEERING / SUSPENSION A-ARM REPLACEMENT 9. Attach A-arm to hub strut assembly. Tighten ball joint nut to 25 ft. lbs. (35 Nm). If cotter pin holes are not aligned, tighten nut slightly to align. Install 1. Elevate and safely support vehicle with weight a new cotter pin with open ends toward rear of removed from front wheel(s).

  • Page 134: Steering Post Assembly

    BODY / STEERING / SUSPENSION STEERING POST ASSEMBLY 1. Torque to 75 ft. lbs. (101 Nm) 2. Align cotter pin hole. 3. Install cotter pin. 12 ft. lbs. (16 Nm) Bend both ends of cot- ter pin around nut in op- posite directions.

  • Page 135: Front Strut Assembly Exploded View

    BODY / STEERING / SUSPENSION FRONT STRUT ASSEMBLY EXPLODED VIEW 15 ft. lbs. (21 Nm) Strut Bumper Spacer Rubber Washer Upper Pivot Ball Strut Washer Clamp 18 ft. lbs. Spacer (25 Nm) 15 ft. lbs. Bolt Lower Pivot Ball (21 Nm) Spring Retainer Lubrication Fitting Spring...

  • Page 136: Front Strut Cartridge Replacement

    BODY / STEERING / SUSPENSION FRONT STRUT CARTRIDGE REPLACEMENT REFER TO ILLUSTRATION ON PAGE 5.13 1. Compress spring using strut spring compressor tools. Strut Spring Compressor Tools (PN 2871573) and (PN 2871574) 2. Hold strut rod and remove top nut. 7.

  • Page 137: Decal Replacement

    BODY / STEERING / SUSPENSION DECAL REPLACEMENT BALL JOINT REPLACEMENT CONT’D 8. To install new ball joint: WARNING Remove extension cap and attach puller guide using short bolts The following procedure involves the use of an provided in the kit. open flame.
  • Page 138 BODY / STEERING / SUSPENSION NOTES 5.16...
  • Page 139 CLUTCH Drive Clutch Exploded View ....PVT Sealing and Ducting Components ..EBS System Exploded View ....Special Tools, Supplies &...

  • Page 140: Drive Clutch Exploded View

    CLUTCH DRIVE CLUTCH EXPLODED VIEW Mark with permanent marker before disassembly One way clutch EBS Drive Clutch PVT SEALING AND DUCTING COMPONENTS Clutch Inlet Duct Transmission Cover Seal Inner Clutch Cover Clamps Boot Duct Clutch Cover Seal Inner Cover Seal Seal Retainer Bracket Clutch Cover...
  • Page 141 CLUTCH ENGINE BRAKING SYSTEM (EBS) EXPLODED VIEW Flat Spacer Drive Clutch Assembly Retaining Ring Ramp 2.25″ PTFE Washer One Way Clutch Drive Ramp Bushing Washer Brass Washer Shift Weights Compression Torque to Coil Spring 200 Ft. Lbs. Spring Bushing (271 Nm) Screw Spacer Sleeve Cover...

  • Page 142: Pvt Operation Overview

    2871226 control engagement (initial vehicle movement), clutch Replacement Tool upshift and backshift. During the development of a Polaris ATV, the PVT system is matched first to the Piston Pin Puller 2870386 engine power curve; then to average riding conditions EBS Clutch 2872292 and the vehicle’s intended usage.
  • Page 143 CLUTCH DRIVEN CLUTCH OPERATION CONT’D air ducts, as well as the inner and outer covers, must be properly sealed to ensure clean air is As engine RPM and horsepower increase, the load being used for cooling the PVT system. This also from the drive belt increases, resulting in the belt will prevent water and other contaminants from rotating up toward the outer diameter of the drive...

  • Page 144: Pvt Overheating/Diagnosis

    10 seconds. PVT seals should be inspected for damage if repeated leaking occurs. Clutch malfunction. Inspection/repair of clutch components should be performed by a certified Polaris MSD techinician.

  • Page 145: Pvt Disassembly

    CLUTCH PVT DISASSEMBLY NOTE: Some fasteners and procedures will vary. Driven Clutch Puller (PN 2870913) Refer to the appropriate parts manual for proper fasteners and fastener placement. 1. Remove seat. 2. Remove or loosen rear cab fasteners as 8. Remove driven clutch offset spacers from the necessary to gain access to PVT outer cover.

  • Page 146: Pvt Assembly/Inspection

    CLUTCH PVT ASSEMBLY/INSPECTION 7. Install clutch offset spacer(s) on transmission input shaft. 1. Inspect PVT inner cover-to-engine seal. Replace if cracked or damaged. Align the alignment mark on the cover with the mark on the engine seal. Seal this edge to cover on engine side Offset Spacer 8.

  • Page 147: Drive Clutch Spring Specifications

    CLUTCH DRIVE CLUTCH SPRING SPECIFICATIONS The drive clutch spring has two NEUTRAL FULL UPSHIFT primary functions: ATV TRAVEL 1. Controls clutch engagement RPM. The springs which have a higher rate when the clutch is in neutral will increase clutch engagement RPM. 2.

  • Page 148: Shift Weights /Inspection

    CLUTCH SHIFT WEIGHTS Shown below are optional shift weights which may be used in the PVT system. These shift weights have many different factors designed into them for controlling engagement RPM and shifting patterns. Shift weights should not be changed or altered without first having a thorough understanding the effects they have on belt to sheave clearance, clutch balance, engagement and shifting characteristics.

  • Page 149: Drive Clutch Disassembly/Inspection

    Never replace parts with used parts from another clutch assembly! All PVT maintenance or repairs should be performed only by a certified Polaris Master Service Dealer (MSD) technician who has received the proper training and understands the procedures outlined in this manual.
  • Page 150 CLUTCH SPIDER REMOVAL DRIVE CLUTCH DISASSEMBLY CONT’D 2. Remove cover bolts evenly in a cross pattern and 1. Remove the limiter nut using the Clutch Spider remove cover plate. Nut Socket (PN 2870338). Install clutch in 3. Inspect cover bushing (A). The outer cover holding fixture...

  • Page 151: Drive Clutch Reassembly

    CLUTCH Moveable Sheave Bushing Inspection button is positioned toward the solid roller pin. It is recommended to switch all buttons to the rubber 2. Inspect the Teflont coating on the moveable version during service (if needed). sheave bushing. Moveable Sheave Bushing Inspection: DRIVE CLUTCH REASSEMBLY Replace the cover bushing if more brass NOTE: It is important that the same number and...

  • Page 152: Drive Belt Removal/Inspection

    CLUTCH DRIVE CLUTCH REASSEMBLY CONT’D 8. Reinstall cover, aligning bosses on the tower and cover. Torque cover bolts evenly to specification 2. Install moveable sheave onto fixed sheave. 3. Install spider spacers. Use same quantity and thickness as were removed. 4.
  • Page 153 CLUTCH Place a straight edge on each side of the drive belt. Place another straight edge on top of belt. Measure the distance where the side straight edges intersect the top, as shown in the illustration. Projected Belt Width Belt Width: New 1.174 - 1.188″...

  • Page 154: Drive Belt Installation

    CLUTCH end of this chapter for possible causes. Offset Alignment Tool (PN 2872292) - EBS 1/8I +0 / -- 1/16 Center 3.2mm +0 / -- 1.6 mm) Distance Clutch Center Distance - 10″ +.1 / -.05 (254 +2.5 / -1.3mm) Belt Nominal Length - 40.875″±...
  • Page 155 CLUTCH shaft without slipping. If problems are noted in either direction, continue with disassembly. Shim Kit (PN 2200126) CLUTCH OFFSET Important: Inspect clutch alignment and center distance before adjusting offset. Offset is correct when rear of tool contacts rear of inner sheave with driven clutch pushed completely inward on shaft and bolt torqued.
  • Page 156 CLUTCH MOVEABLE SHEAVE noted. BUSHING INSPECTION 1. Inspect the Teflont coating on the moveable sheave bushing. Inspect BOTH sheaves for signs of wear, grooving or cracking. Clean surfaces with a 3Mt pad if needed Moveable Sheave Bushing Inspection: Replace the cover bushing if more brass than Teflont is visible on the bushing.
  • Page 157 CLUTCH compression spring only and has no torsional wind. Move Freely 2. When rotated clockwise, the outer sheave should lock to the shaft and inner sheave without NOTE: Rotating the moveable sheave so that the slipping. rollers are not in contact with either helix ramp surfaces will lessen the effort needed to push the helix inward.
  • Page 158 CLUTCH contact the inside of the rollers. Do not lubricate the roller or roller pin. Heat Area Roller Lightly Apply Loctitet 680 To Tapered Portion Of Screw Dry Locking Agent Applied To New Screws 7. Inspect moveable sheave bushing for wear. Inspect BOTH sheaves for signs of wear, grooving or cracking.
  • Page 159 CLUTCH EARLY 2004 - - EBS DRIVE 6. With towers pointing toward the vise, slide sheave onto puller rod. BUSHING SERVICE 7. Install removal tool (Item A/B) into center of sheave with “A side” toward sheave. EBS CLUTCH BUSHING REMOVAL AND 8.
  • Page 160 CLUTCH EARLY 2004 - - EBS DRIVEN EBS Drive Clutch Cover Bushing Removal BUSHING SERVICE 1. Install main adapter (Item 8) on puller. EBS Driven - Bushing Removal Nut (C) Removal Tool (3) 1. Install puller adapter (Item 10) onto puller. Adapter Reducer (9) Main Adapter...
  • Page 161 CLUTCH 8. Remove nut (C) (left hand thread) from puller rod 7. Turn clutch sheave counterclockwise until and set aside. bushing is removed and sheave comes free. 9. Remove adapters from puller. 8. Remove nut (C) (left hand thread) from puller rod and set aside.
  • Page 162 CLUTCH 8. Remove nut (C) (left hand thread) from puller rod the moveable sheave as the rollers move to the other and set aside. side of the ramp, providing instant EBS braking. Engine braking (EBS) continues until the drive clutch 9.
  • Page 163 CLUTCH Mark Components Before Disassembly Mark Components Before Disassembly NOTE: Rotating the moveable sheave so that the rollers are not in contact with either helix ramp surfaces will lessen the effort needed to push the helix inward. 4. Remove helix (C), spring (D), and spring seat washer (E) and inspect for wear or damage.
  • Page 164 CLUTCH Heat Area Roller Lightly Apply Loctitet 680 To Tapered Portion Of Screw Dry Locking Agent Applied To New Screws Roller 5. Inspect surface of rollers for flat spots and wear. Retaining Screw Rollers must rotate freely on pins without excessive clearance.
  • Page 165 CLUTCH 7. Check for movement of the shaft in the stationary 9. Remove the snap ring (F). sheave. The shaft should rotate freely until the stop plate makes contact with the sheave casting. Some lateral movement is allowable. amount of movement shall be limited to prevent the plate from raising out of the sheave pocket.

  • Page 166: Late 2004 Driven Clutch Inspection

    CLUTCH LATE 2004 - - DRIVEN CLUTCH DRIVEN BUSHING SERVICE” later in this chapter for replacement of driven bushings . REASSEMBLY 2. Be sure to use the alignment marks for reassembly. 1. Simply reverse the steps of the disassembly process. Replace any parts needed. See “EBS LATE 2004 EBS DRIVEN CLUTCH EXPLODED VIEW 1.
  • Page 167 CLUTCH LATE 2004 - - EBS DRIVE 6. With towers pointing toward the vise, slide sheave onto puller rod. BUSHING SERVICE 7. Install removal tool (Item A/B) into center of sheave with “A side” toward sheave. EBS CLUTCH BUSHING REMOVAL AND 8.
  • Page 168 CLUTCH LATE 2004 - - EBS DRIVEN EBS Drive Clutch Cover Bushing Removal BUSHING SERVICE 1. Install main adapter (Item 8) on puller. EBS Driven - Bushing Removal Nut (C) Removal Tool (3) 1. Install puller adapter (Item 10) onto puller. Adapter Reducer (9) Main Adapter...
  • Page 169 CLUTCH 8. Remove nut (C) (left hand thread) from puller rod 7. Turn clutch sheave counterclockwise until and set aside. bushing is removed and sheave comes free. 9. Remove adapters from puller. 8. Remove nut (C) (left hand thread) from puller rod and set aside.
  • Page 170 CLUTCH 8. Remove nut (C) (left hand thread) from puller rod and set aside. 9. Remove installation tool and clutch sheave from puller. EBS Driven - Stationary Sheave (Inner) Bushing Removal 1. Install puller adapter onto puller. 2. Install adapter reducer. Bushing Tool (2) 3.

  • Page 171: Troubleshooting

    CLUTCH TROUBLESHOOTING Situation Probable Cause Remedy Engine RPM -Wrong or broken drive clutch spring. -Replace with recommended spring. below specified operating range -Drive clutch shift weight too heavy. -Install correct shift weight kit to match engine application. although engine is properly -Driven clutch spring broken or installed -Replace spring;...
  • Page 172 CLUTCH TROUBLESHOOTING Situation Probable Cause Remedy Belt slippage -Belt worn out -Replace belt. -Water ingestion -Inspect and seal PVT system. -Belt contaminated with oil or grease -Inspect and clean. Belt burnt, thin -Abuse (continued throttle application when -Caution operator to operate machine within guidelines. spots vehicle is stationary, excess load) -Dragging brake...
  • Page 173 FINAL DRIVE AWD Axle/Propshaft Exploded Views ..Special Tools & Torque Specifications ..Front Hub Inspection ..... Front Drive Axle Removal .

  • Page 174: Final Drive

    FINAL DRIVE AWD FRONT DRIVE AXLE EXPLODED VIEW Front Drive Axle Components Circlip Boot CV Joint Assy Drive Axle U--Joint and Yoke Clamps Front Prop Shaft Components Propshaft Assembly O-Ring Prop Shaft Cross and Bearing Kit Yoke, Propshaft to Transmission Yoke, Front Gearcase Spring Pin...

  • Page 175: Front Hub Inspection

    FINAL DRIVE SPECIAL TOOLS 7. Remove the two brake caliper attaching bolts. CAUTION: Do not hang the caliper by the brake PART NUMBER TOOL line. Use wire to hang the caliper to prevent DESCRIPTION possible damage to the brake line. 2872608 Roller Pin Removal Tool...

  • Page 176: Front Drive Axle Installation

    FINAL DRIVE New Cotter Key Front Hub Retaining Nut Torque 11. With short, sharp jerks, remove drive shaft from front gearcase. 70 ft. lbs. (95 Nm) DRIVESHAFT AND CV JOINT HANDLING TIPS Care should be exercised during driveshaft removal or when servicing CV joints. Driveshaft components are precision parts.
  • Page 177 FINAL DRIVE FRONT DRIVE SHAFT CV JOINT BOOT REPLACEMENT Retaining ring 1. Remove wheel, brake caliper and wheel hub. Refer to Front Drive Axle Removal Page 7.3 for procedure. 2. Remove cotter pin and castle nut from A-arm ball joint. Pull shaft to remove from CV joint 7.

  • Page 178: Front Hub Disassembly & Assembly

    FINAL DRIVE bell, lift one edge of boot to let out excess air NOTE: Drive bearing out evenly by tapping on outer Secure with clamp. race only. Once bearing is at bottom of casting, support casting on outer edges so bearing can be removed.

  • Page 179: U-Joint Disassembly

    FINAL DRIVE Roll Pin Remover Tool (PN 2872608) NOTE: If removing front housing, use roll pin removal tool to remove the pins from both front drive axles. U-JOINT DISASSEMBLY CAUTION: Wear eye protection at all times. 1. Remove internal or external snap ring from all bearing caps.

  • Page 180: Front Gearcase Removal/Install

    FINAL DRIVE 2. Using a suitable arbor or vise, fully seat bearing cap in one side. Continually check for free movement of bearing cross as bearing caps are assembled. 7. When installation is complete, Yokes must pivot freely in all directions without binding. If the joint is stiff or binding, tap the yoke lightly to center the joint until it pivots freely in all directions.
  • Page 181 FINAL DRIVE CAUTION: Do not hang the caliper by the brake line. Use wire to hang the caliper to prevent possible Frame damage to the brake line. 6. Remove the front hub from the drive shaft. 7. Remove cotter pin, lower ball joint nut and A-arm from ball joint.
  • Page 182 FINAL DRIVE EARLY 2004 - - FRONT Disengagement: As the front and rear wheels gain GEARCASE OPERATION - - traction, rotating very close to the same speed, the front wheels “overdrive” the output hubs and the CENTRALIZED HILLIARD) rollers are forced outward, disengaging the AWD. The vehicle is now back to rear wheel drive until the next loss of traction.
  • Page 183 FINAL DRIVE Front Gearcase Coil Resistance: 22.8- -25.2 Ohms Gearcase Coil Resistance NOTE: To test the gearcase coils resistance, use the coil harness. The gearcase coils should measure between 22.8 ohms and 25.2 ohms. 3. Remove output shaft assembly. 7. Inspect the ring gear (C) for consistent wear patterns.
  • Page 184 FINAL DRIVE 10. Inspect the armature plate (F) for a consistent wear pattern. Uneven wear of the armature plate (F) indicates a warped plate, which may cause intermittent operation. 11. Remove the thrust bearing (G) from the output hub (D). Inspect the thrust bearing (G) and the dowel (H).
  • Page 185 FINAL DRIVE EARLY 2004 - - FRONT GEARCASE REASSEMBLY/INSPECTION 1. Replace O--rings, seals, worn components. 2. Press the pinion shaft seal into the pinion cover, until the seal is flush with the sealing surface. 3. Inspect bearings on output and pinion shafts. To replace, press new bearing on to shaft.
  • Page 186 FINAL DRIVE 8. Install the shim onto the ring gear. 11. Install output cover with new o-ring and torque bolts to 14 ft. lbs. (19 Nm). 9. Install the armature plate onto the ring gear. Cover Bolts Torque 14 ft. lbs. (19 Nm) 12.
  • Page 187 FINAL DRIVE present for proper operation. ILL. 1 Possible Wear Ring on Armature Plate OK Condition 3. Inspect the armature plate for a consistent wear Bad Condition pattern. There should one or two distinct wear (Wear from Coil bands (one band inside the other). If only one On Armature Plate) band of wear is present (or if there is wear between the two bands, inspect the coil area as...

  • Page 188: Early 2004 Front Gearcase Exploded View

    FINAL DRIVE EARLY 2004 - - FRONT GEARCASE EXPLODED VIEW Ref. Qty. Description Ref. Qty. Description 1 Asm., Mid Gearcase 1 O- - Ring 1 Cover, Output 1 Seal 1 O- - Ring 11 Kit, Bolt 1 Insert 1 Cover, Input 1 Coil 1 Bearing, Roller Ball 1 Kit, Shim Set (Incl.

  • Page 189: Late 2004 Front Gearcase Information

    FINAL DRIVE LATE 2004 - - FRONT Roller Cage and Roller’s Rotate Inward and Grip the Output Hub for AWD Engagement GEARCASE OPERATION - - CENTRALIZED HILLIARD) Output Rollers Normal Operation: With the AWD switch off the vehicle drives only the rear wheels (2 wheel drive). When the AWD switch is activated it engages the Hilliard, locking both front axles into All Wheel Drive.
  • Page 190 FINAL DRIVE 7. Inspect the ring gear (C) for consistent wear patterns. The surfaces should be free of nicks Front Gearcase Coil Resistance: and scratches. 22.8- -25.2 Ohms Gearcase Coil Resistance NOTE: To test the gearcase coils resistance, use the coil harness.
  • Page 191 FINAL DRIVE 10. Remove the spacer washer (D), armature plate (E), and rubber O--ring from the output cover. O--ring 13. Inspect the magnetic coil (I) in the output housing. 11. Inspect the armature plate (E) for a consistent NOTE: See “FRONT GEARCASE DIAGNOSIS” wear pattern.
  • Page 192 FINAL DRIVE 18. Remove and replace the O--rings and seals from the assembly. 16. Remove the input cover (M), bearing (N), and the pinion gear (O). Inspect the pinion gear (O) for chipped, broken, or missing teeth. Replace the input cover O--ring. 17.
  • Page 193 FINAL DRIVE LATE 2004 - - FRONT GEARCASE REASSEMBLY/INSPECTION 1. Replace O--rings, seals, worn components. 2. Press the pinion shaft seal into the pinion cover, until the seal is flush with the sealing surface. 3. Inspect bearings on output and pinion shafts. To replace, press new bearing on to shaft.
  • Page 194 FINAL DRIVE 7. Install the armature plate (D) and spacer washer (E) into the output cover. NOTE: Be sure backlash plate is in place. Backlash Plate 11. Install the output cover assembly onto the main gearcase. 8. Install the retaining ring (F) into the output cover. NOTE: Be sure armature plate tabs are placed into Be sure the retaining ring is properly seated into the slots on roll cage.
  • Page 195 FINAL DRIVE NOTE: Be sure the square O--ring is placed flat on the cover surface, if the O--ring is twisted fluid leakage may occur. 3. Inspect the armature plate for a consistent wear pattern. There should one or two distinct wear bands (one band inside the other).
  • Page 196 FINAL DRIVE ILL. 1 Possible Wear Ring on Armature Plate Rollers OK Condition Bad Condition (Wear from Coil On Armature Plate) 4. Check to make sure the coil is seated in the U--shaped insert that is pressed into the gearcase cover.
  • Page 197 FINAL DRIVE LATE 2004 FRONT GEARCASE - - CENTRALIZED HILLIARD EXPLODED VIEW Ref. Qty. Description Ref. Qty. Description 1 Asm., Mid Gearcase 1 O- - Ring 1 Cover, Output 1 Seal 1 O- - Ring 11 Kit, Bolt 1 Insert 1 Cover, Input 1 Coil 1 Bearing, Roller Ball...

  • Page 198: Rear Hub Removal

    FINAL DRIVE REAR HUB REMOVAL 1. Place the ATV in Park and lock the parking brake. Remove rear hub cap. 9. Remove hub. 2. Remove cotter pin. 3. Loosen the hub retaining nut. 4. Loosen the wheel nuts. 5. Safely support the rear of the ATV. CAUTION: Secure the machine.

  • Page 199: Rear Hub Installation

    FINAL DRIVE 11. Remove both lower control arm bolts. Rear Hub Nut Torque: 80 ft. lbs. (109 Nm) 12. Remove bearing carrier. Rear Wheel Nut Torque 30 ft. lbs. (41 Nm) REAR HUB INSTALLATION 1. Insert bearing carrier on drive shaft. 5.

  • Page 200: Rear Hub Disassembly

    FINAL DRIVE REAR HUB DISASSEMBLY REAR HUB ASSEMBLY 1. Support bottom of bearing carrier housing. 1. Remove outer snap ring. 2. Start bearing in housing. 2. From the back side, tap on the outer bearing race with a drift punch in the reliefs as shown. 3.

  • Page 201: Rear Driveshaft Removal

    FINAL DRIVE CAUTION: Use an arbor press only on the outer race, as bearing damage may occur. 4. Install snap ring into groove. REAR DRIVE SHAFT REMOVAL 1. Remove rear hub and bearing carrier. (See Pages 7.26). 2. Tip hub outward and remove shaft from hub. 3.

  • Page 202: Driveshaft And Cv Joint Tips

    FINAL DRIVE DRIVESHAFT AND CV JOINT 2. Apply anti-seize compound to splines of shaft. 3. Install a new lock ring and install the shaft. HANDLING TIPS 4. Lift bearing carrier into place and install bolt to upper control arm. Torque bolt to 35 ft. lbs. (48 Care should be exercised during driveshaft removal Nm).

  • Page 203: Rear Driveshaft Service

    FINAL DRIVE REAR DRIVE SHAFT SERVICE Spread ends of snap ring to remove joint from shaft 1. Remove clamps from rubber boot(s) using the proper boot clamp pliers. Tap CV Housing Off Shaft 4. Place a new snap ring in the groove of the CV joint inner hub, with tabs facing the shaft as shown.
  • Page 204 FINAL DRIVE 5. Refit CV joint on interconnecting shaft by tapping NOTE: When replacing a damaged boot, check the with a plastic hammer on the joint housing. Take grease for contamination by rubbing it between two care not to damage threads on the outboard CV fingers.

  • Page 205: Rear Gearcase Removal

    FINAL DRIVE Tighten the rear gearcase as shown in illustration 1. Joint Capacity Joint Capacity 50 Grams 50 Grams 30 ft. lbs. (41 Nm) (2 bolts) INBOARD OUTBOARD 100g Total 80g Total Remove Propshaft Boot Capacity Boot Capacity 30 Grams 50 Grams NOTE: CV Joint Grease Capacity: 30 ft.

  • Page 206: Rear Gearcase Installation

    2. Torque the installation bolts and nuts to the torques specified in Ill. 1 on previous page. 3. Refill the rear gearcase with 5 oz. (150 ml) of Polaris Premium Gearcase Lubricant (PN 2871653). Torque the fill plug to 14 ft. lbs. (19 Nm).
  • Page 207 FINAL DRIVE 6. Remove the input shaft cover and the pinion shaft from the gearcase housing. See next page. 2. Replace O--rings, seals, worn components. 7. Inspect the ring gear for abnormal wear, broken, or chipped teeth. Spin the bearing to check the ball bearings for smoothness.
  • Page 208 FINAL DRIVE Pinion Shaft Cover Bolt Torque: 25 ft. lbs. (34 Nm) 4. Install the original shim(s), thrust button, and thrust button shims into the gearcase cover. 5. Apply Crankcase Sealant (PN 2871557) to surface of case and install cover bolts. Install the gearcase cover onto the gearcase housing.

  • Page 209: Rear Gearcase Exploded View

    FINAL DRIVE REAR GEARCASE EXPLODED VIEW Ref. Qty. Description Ref. Qty. Description 1 Asm., Rear Gearcase 1 10T Pinion Shaft 1 Cover, Output, LH 1 Ball Bearing 8 Screw 1 O- - ring 1 Tube Vent 1 Cover, Input 2 Washer 1 Seal 2 Plug 1 Rear Gearcase Housing...
  • Page 210 FINAL DRIVE NOTES 7.38...
  • Page 211 TRANSMISSION Transmission, Exploded View ....8.2--8.5 Torque Specifications/Lubrication ... Gear Shift Selector Removal ....Transmission Removal .

  • Page 212: Transmission, Exploded View

    14- -18 ft.lbs. (19- -24 Nm) FOR REASSEMBLY 27- -34 ft.lbs. (37- -46 Nm) Apply White Lithium 6- -12 ft.lbs. (8- -16 Nm) Based Grease. 14- -18 ft.lbs. (19- -24 Nm) Apply Polaris Crankcase Sealant Apply Loctitet 262 to the bolt threads.
  • Page 213 TRANSMISSION EARLY 2004 TRANSMISSION EXPLODED VIEW, CONT. Ref. Qty. Description Ref. Qty. Description 1 Asm., 4x4 Transmission 1 28T Gear 1 Nut 1 40T Gear 1 Washer 1 44T Gear 8 Screw 4 Screw 1 Cover 1 Cover Bearing 1 Detent Pawl 1 Ring 1 O- - ring 1 Ball Bearing...
  • Page 214 Torque 12- - 18 fl.lbs. (16- - 24 Nm) Apply White Lithium Based Grease. 7- -9 ft.lbs. (9.5- -12 Nm) Apply Polaris 15- -19 ft.lbs. (20- -26 Nm) Crankcase Sealant 27- -34 ft.lbs. (37- -46 Nm) Apply Loctitet 262 to the bolt threads.
  • Page 215 TRANSMISSION LATE 2004 TRANSMISSION EXPLODED VIEW, CONT. Ref. Qty. Description Ref. Qty. Description 1 22T Sprocket 1 Nut 1 19T Sprocket 1 Shift Drum Bellcrank 1 Silent Chain 5 Sector Cover Screws 1 Front Main Output Shaft 1 Sector Cover 1 10T Spiral Pinion Shaft 1 Sector Cover Gasket 1 Ball Bearing...

  • Page 216: Torque Specifications/Lubrication

    TRANSMISSION 2004 TRANSMISSION Transmission Mounting INFORAMTION The Early 2004 transmission is the same as the Late 2004 transmission, except for the location of the fill plug. Refer to Chapter 2 for fill plug locations. Front TORQUE SPECIFICATIONS COMPONENT FT. LBS. (IN.LBS.) Transmission Case Bolts 27--34...

  • Page 217: Transmission Installation

    TRANSMISSION 7. Remove PVT outer cover, both drive and driven 10. Remove the park lock spring. clutch, and inner PVT cover (refer to Clutch Chapter 6). 8. Use the Roll Pin Removal Tool (PN 2872608) to Park Lock Spring remove the roll pins from the front prop shaft and the rear prop shaft.

  • Page 218: Transmission Disassembly

    TRANSMISSION 4. Remove the five bolts that secure the cover. Remove the detent spring. Spring 5. Mark the detent gear with a white pen. Remove the detent gear from the case. Tighten Bolts In Sequence A through E TRANSMISSION DISASSEMBLY 1.
  • Page 219 TRANSMISSION NOTE: It may be helpful to place a mark just above the keyed spline for reference. 7. Remove the shift shaft and detent lever. 10. Lift shift rail 0.5--1” (12.70--25.40 mm). Then rotate the shift rail/forks and shift drum, so the the forks’...
  • Page 220 TRANSMISSION 13. Set the upper gear cluster on a flat surface and inspect the components. 16. Remove the park lock engagement dog. Remove the wave spring and reverse engagement dog. Engagement Dogs 14. Remove the shift forks from the assembly. Note the correct position of each fork.
  • Page 221 TRANSMISSION 18. Remove the snap ring and washer from the 22. Use a press to remove the gear from the shaft. reverse shaft. 23. Make note of the direction of the gear and hub 19. Remove low gear (33T) and the needle bearing. location.
  • Page 222 TRANSMISSION 25. Slide off the shift dogs and wave springs. 29. Remove the front housing cover screws. 26. Remove the snap ring, washer, gear, and split bearing. 27. Remove bearing and the helical gear. 28. Remove the pinion shaft retainer plate and the pinion shaft.

  • Page 223: Transmission Reassembly

    TRANSMISSION 30. Remove the front housing cover, shim, thrust 34. Inspect engagement dogs of gears and replace if button, and thrust button shim. edges are rounded. 35. Inspect gear teeth for wear, cracks, chips or broken teeth. Note the location of the hubs on the gear.
  • Page 224 TRANSMISSION 3. Before installing the cover make sure the sealing 8. Apply Loctitet 262 (Red) (PN 2871951) to screw surfaces are clean and dry, and shafts are fully threads and torque screws to 6--12 ft. lbs. (8--16 seated in the transmission case. Apply Nm).
  • Page 225 TRANSMISSION NOTE: Install a new snap ring at this time. When installing the new snap ring, open the the snap ring just far enough to go over the shaft, to avoid stressing the snap ring. If the snap ring is over--stressed, it could come off the shaft and cause internal damage to the transmission.
  • Page 226 TRANSMISSION 16. Position the shift forks up and so the the pins point 19. Lift the shift rail slightly and rotate the rail/fork toward the 9 o’clock position, before installing the assembly so it meshes with the tracks on the shift drum assembly.
  • Page 227 TRANSMISSION 24. Place a small amount of grease (PN 2871551) into the pocket before installing the sector gear. Install the shift gear (16T) on the shift drum shaft. Install the sector gear in the bushing pocket on the left side. Aligning the timing marks on the gears. 28.
  • Page 228 NOTE: Rotate the bellcrank to line the flat side of the switch up to the flat side of the shaft. 34. Install transmission and add Polaris AGL Gearcase Lubricant (PN 2873602) in the recommended amount. Refer to Maintenance Chapter 2 for more information.
  • Page 229 BRAKES Special Tools/Specifications/Torques ... 2004 Brake Line Identification ....Brake System Service Notes ....Brake Noise Troubleshooting .
  • Page 230 BRAKES SPECIAL TOOLS PART NUMBER TOOL DESCRIPTION 2870975 Mity Vact Pressure Test Tool SPECIFICATIONS Front Brake Caliper Item Standard Service Limit Brake Pad Thickness .298″ / 7.6mm .180″ / 4.6mm Brake Disc Thickness .150-.164″ / 3.810-4.166mm .140″ / 3.556mm Brake Disc Thickness Variance Between .002″...

  • Page 231: 2004 Brake Line Identification

    IDENTIFICATION NOTES NOTE: 2004 Sportsman ATVs have two different Polaris disc brake systems are light weight, low styles of brake lines. The two styles of brake lines maintenance and perform well in the conditions ATVs are “pipe fit” style and “banjo” style. Be sure to routinely encounter.

  • Page 232: Hydraulic Brake System Overview

    Pad G compensating port restricted Educate operator Master cylinder pis- The Polaris disc brake system consists of the ton not returning com- following components or assemblies: brake lever; pletely master cylinder; hydraulic hose; brake calipers (slave cylinder); brake pads; and brake discs, which are Caliper piston(s) not secured to the drive line.

  • Page 233: Hydraulic Caliper Bleeding

    BRAKE BLEEDING - FLUID When servicing Polaris ATV brake systems, use only Polaris DOT 3 Brake Fluid (PN 2870990). CHANGE WARNING: Once a bottle is opened, use what is...
  • Page 234 (PN 2870990) 11. Repeat procedure Steps 5-9 for the remaining caliper(s). 12. Add Polaris Dot 3 Brake Fluid (PN 2870990) to 6. Begin bleeding procedure with the caliper that is MAX level inside reservoir. farthest from the master cylinder. Install a box end wrench on caliper bleeder screw.

  • Page 235: Master Cylinder Removal

    Reservoir Cover Torque - parts. There are different brake master cylinders for the different Polaris ATV models. Refer to your parts 5 in. lbs. (0.56 Nm) manual or guide for the correct parts. The master cylinder is not serviceable and is replaced as a unit.

  • Page 236: Front Pad Removal

    2-3 turns. 3. Remove caliper mounting bolts. 4. Push caliper piston into caliper bore slowly using a C-clamp or locking pliers with pads installed. Polaris DOT 3 Brake Fluid (PN 2870990) NOTE: Brake fluid will be forced through 4. Follow bleeding procedure on Pages 9.7-9.8.

  • Page 237: Front Pad Installation

    5. Install the adjuster screw and turn clockwise until stationary pad contacts disc, then back off 1/2 FRONT PAD INSTALLATION turn (counterclockwise). 1. Lubricate mounting bracket pins with a light film of Polaris Premium All Season Grease, and install rubber dust boots.

  • Page 238: Brake Burnishing

    BRAKES 6. Verify fluid level in reservoir is up to MAX line Brake Disc Thickness inside reservoir and install reservoir cap. .150-.164″ (3.810-4.166 mm) Service Limit .140″ / 3.556 mm Master Cylinder Fluid Up to MAX line inside reservoir Brake Disc Thickness Variance Service Limit: .002″...

  • Page 239: Front Caliper Removal

    BRAKES FRONT CALIPER 2. Remove bolts and disc. 3. Clean mating surface of disc and hub. DISASSEMBLY 4. Install disc on hub. 5. Install new bolts and tighten to specified torque. 1. Remove brake pad adjuster screw. Front Brake Disc Mounting Bolt Torque 18 ft.

  • Page 240: Front Caliper Inspection

    BRAKES FRONT CALIPER INSPECTION Remove Mounting Bracket 1. Inspect caliper body for nicks, scratches or wear. Measure bore size and compare to specifications. Replace if damage is evident or if worn beyond service limit. Front Caliper Piston Bore I.D. Std. 1.191-1.192″ (30.25-30.28 mm) Service Limit 1.193″...

  • Page 241: Front Caliper Reassembly

    INSTALLATION 1. Install caliper on hub strut, and torque mounting bolts. 2. Coat piston with clean Polaris DOT 3 Brake Fluid (C). Install piston (D) with a twisting motion while pushing inward. Piston should slide in and out of bore smoothly, with light resistance.
  • Page 242 BRAKES NOTES 3. Install the adjuster screw and turn until stationary pad contacts disc, then back off 1/2 turn. 4. Follow brake bleeding procedure outlined on Pages 9.5-9.6. 5. Install wheels and torque wheel nuts to specification. Front Wheel Nut Torque 20 ft.

  • Page 243: Front Caliper Exploded View

    BRAKES FRONT BRAKE CALIPER EXPLODED VIEW APPLY POLARIS DOT 3 BRAKE FLUID TO COMPONENT APPLY POLARIS ALL PURPOSE GREASE Socket Set Screw Bushing Boot Square Piston O--Rings Bleeder Screw Brake Pads 35--60 IN. LBS. (4--6.5 NM) Caliper Assembly Boot Bushing...

  • Page 244: Rear Pad Removal

    BRAKES REAR BRAKE PAD REMOVAL 5. Remove a slide bolt with a hex wrench. 1. Support the machine. Remove the rear tire. 6. Remove the brake pads from the caliper. 2. Remove caliper mounting bolts and lift caliper off Remove of disc.

  • Page 245: Rear Pad Installation

    BRAKES REAR BRAKE PAD INSTALLATION 1. Install new brake pads in caliper body. Torque Mounting Install Pads Bolts Rear Brake Caliper Torque: 18 ft. lbs. (25 Nm) 2. Tighten the slide pin with a hex wrench. 5. Slowly pump the brake lever until pressure has 3.

  • Page 246: Rear Caliper Removal/Inspection

    BRAKES REAR CALIPER 5. Remove the anvil bolts and separate caliper halves and remove pistons with piston pliers. REMOVAL/INSPECTION Caliper 1. Clean caliper area before removal. 2. Using a flare nut wrench, remove hand brake (inner) and auxiliary brake (outer) lines. Place a container to catch brake fluid draining from brake lines.

  • Page 247: Rear Caliper Assembly

    BRAKES REAR CALIPER ASSEMBLY 3. Install brake pads in caliper body with friction material facing each other. Install the slide pins and the slide pin retaining ring. Torque the slide 1. Install new O-rings in the slide bolt bushing holes. pins to 30--35 ft.lbs.

  • Page 248: Rear Disc Inspection

    BRAKES 5. Install brake line and tighten securely with a line 2. Use a 0-1″ micrometer and measure disc wrench. Torque the brake lines to the proper thickness at 8 different points around perimeter of torque specification. disc. Replace disc if worn beyond service limit. NOTE: See Page 9.3 to identify which style brake line your ATV has installed.
  • Page 249 BRAKES AUXILIARY BRAKE Remove the washers, bushings, and tension spring REMOVAL / INSTALL 2. Reverse the steps for installation, use a new cotter key during installation. Rear Brake Master Cylinder Removal / Install 1. If necessary, remove the rear brake line from the master cylinder.

  • Page 250: Rear Caliper Exploded View

    BRAKES REAR BRAKE CALIPER EXPLODED VIEW Anvil Bolts APPLY POLARIS DOT 3 BRAKE FLUID TO COMPONENT Torque 16--18 ft.lbs. Washers (22--25 Nm) Rear Caliper Bleed Piston Screws Torque 25--30 in. lbs. Bracket O--rings (2.80--3.40) Nm Seals Pads Slide Pins Torque Bushings 30--35 ft.lbs.
  • Page 251 ELECTRICAL Timing Check Procedure ..... 10.2 Gear Position Switch Test ....10.4 Instrument Cluster Overview .

  • Page 252: Timing Check Procedure

    The timing tag on the flywheel indicates the direction NOTE: 2004 Sportsman 600/700 ATVs were built of rotation and the scale for ignition timing. with either a Ducati ignition system or a Kokusan ignition system.
  • Page 253 ELECTRICAL TRIGGER COIL GAP 2004 Model Flywheel Identification Ducati Measure trigger coil gap with a feeler gauge. The gap Flywheel should be .022--.028 inch (.56--.71 mm). Timing Marks Measure Trigger Coil Gap Built Before Feb- ruary 20, 2003 Kokusan Flywheel Timing Marks Trigger Coil Gap: .022- -.028 inch (.56- -.71 mm)

  • Page 254: Gear Position Switch Test

    ELECTRICAL GEAR POSITION INDICATOR INSTRUMENT CLUSTER OVERVIEW SWITCH TEST NOTE: Also see “INSTRUMENT CLUSTER EARLY 2004 TROUBLESHOOTING” for gear switch re- (A) Speedo Needle (also flashes sistance. during warning condition) (B) Speedometer TRANSMISSION SWITCH in MPH/KPH High/Low/Neutral/Reverse/Park Switch High Range Low Range Neutral Reverse...
  • Page 255 “Cooling System Troubleshooting” for help with Refer to Illustration 1: diagnosis of overheating. The Polaris ATV Instrument Cluster is powered by battery voltage (12 VDC) and requires inputs from the engine RPM, transmission gear, and wheel speed sensor for proper operation. Two harnesses plug into the cluster head;...

  • Page 256: Diagnostic Mode

    ELECTRICAL Screen 1: The first screen indicates battery voltage. 6. AWD Indicator Refer to Ill. 2. Illuminates when the electrical portion of the AWD system is enabled. 7. Gear Indicator Specifies what position shift lever and transmission are in. This area is blank if a fault occurs. 8.
  • Page 257 ELECTRICAL Screen 4: Gear circuit diagnostic. This screen displays the resistance value (in ohms) being read at the gear switch input of the gauge. NOTE: 10- -20% variance from these readings is within normal parameters. 628 Ohms in High Screen 5: Programmable service interval. The purpose of the programmable service interval is to provide the consumer and dealer with a convenient reminder for routine maintenance.

  • Page 258: Speedometer Removal/Installation

    ELECTRICAL NOTE: If you scroll past the intended number, hold the button down until the count turns over to 0. You can then reset the number. Turn Service Interval OFF: 1. If the service interval is enabled (functioning) on your ATV and you wish to turn it off, toggle to the service interval mode.
  • Page 259 ELECTRICAL SPEEDOMETER INSTALLATION 2. Push the instrument cluster out from the backside of the pod, while securely holding the pod. 1. Spray a soap and water mixture onto the outer surface area of the instrument cluster. This will help the instrument cluster slide into the pod assembly more easily.

  • Page 260: Speedometer Operation Troubleshooting

    ELECTRICAL SPEEDOMETER TROUBLESHOOTING TEST 1 - - NO ALL WHEEL DRIVE Note: If AWD icon comes on, instru- START HERE - - ment cluster is O.K. Proceed to me- ENGINE OFF chanical tests (in Service Manual). - - KEY SWITCH ON Check the AWD icon on instrument clus- - - TRANSMISSION IN LOW ter to verify it’s operation.
  • Page 261 ELECTRICAL SPEEDOMETER TROUBLESHOOTING TEST 2 - - NO SPEEDOMETER AND/OR ODOMETER DISPLAY CHECK FOR REPLACE START HERE MINIMUM 6VDC SPEEDO ON PIN B TO PIN C KEY & STOP 3 Pin Connector SWITCHES ON REPLACE MEASURE SPEEDO BACK OF A: D.C. Power SPEEDO WITH B: Signal CONNECTORS...
  • Page 262 ELECTRICAL SPEEDOMETER TROUBLESHOOTING TEST 4 - - NO AWD HUB SAFETY LIMIT NOTE: IF THE AWD ICON DOES NOT COME ON OR IF 12 VDC IS NOT REGISTERING AND AWD IS ENGAGING START HERE ABOVE 3100 RPM,IT MAY BE A MECHANICAL PROBLEM. SPEEDO ATV IN NEUTRAL CHECK...
  • Page 263 ELECTRICAL SPEEDOMETER TROUBLESHOOTING TEST 5 REVERSE SPEED LIMITER ACTIVATED IN FORWARD GEAR (Engine loses spark when vehicle speed is above 7-9 mph.) START HERE 16 Pin Connector 1. Red- - 12V Ignition Switch 9. Blue White- - Engine Overheat Switch CHECK 2.
  • Page 264 ELECTRICAL SPEEDOMETER TROUBLESHOOTING TEST 7 FUEL GAUGE DISPLAY NOT WORKING 16 Pin Connector START HERE 1. Red- - 12V Ignition Switch 9. Blue White- - Engine Overheat Switch 2. Red/White- - 12V ETC and AWD Switch 10. N/C 11. N/C 3.

  • Page 265: Fan Motor Tests

    1. Disconnect harness from fan switch on radiator. Fan Motor Current Draw: 2. Place a jumper wire between the Red/Blk and Org/Blk wires in the connector. Should Be Less Than 15 Amps NOTE: This fan motor current draw specification only applies to Sportsman 600/700. 10.15...
  • Page 266 ELECTRICAL FAN CONTROL SWITCH ETC OPERATION TEST OPERATION TEST Remove throttle block cover by carefully releasing all tabs around edge of cover. 1. Place switch in a water bath and submerse it to Place transmission in neutral and apply parking the base of the threads.

  • Page 267: Flywheel Identification

    Kokusan Flywheel EH059OLE24, EH068OLE15 4010899 300 W 600/700 - - DC / CDI IGNITION The Sportsman 600/700 has incorporated into it’s Operation Overview: design a DC/ CDI ignition system. The DC/CDI system relies on battery power for ignition. Some of the advantages of DC ignition are:...
  • Page 268 ELECTRICAL COMPONENTS OF 600/700 330 WATT ALTERNATOR IGNITION SYSTEM Ignition Controller (If Built After 2/20/03) NOTE: CDI boxes may look the Ignition Controller same but have different internal cir- (If Built Before to 2/20/03) cuitry. Be sure to always use the correct CDI box part number.

  • Page 269: Ignition System Testing Flow Chart

    ELECTRICAL IGNITION SYSTEM TESTING FLOW CHART Whenever troubleshooting an electrical problem, first check all terminal connections to be sure they are clean and tight. Also be sure that colors match when wires are connected. Use the following pages as a guide for troubleshooting.

  • Page 270: Ignition System Troubleshooting

    Pulse Black and 3.3 DCV (Trigger) Excessive crankshaft runout on magneto (RH) end - should not exceed .0024″ 330 Watt 4 Stroke (Sportsman 600/700 Built After Faulty CDI module February 20, 2003) CDI OUTPUT TEST USING Coil Connect Meter Reading...
  • Page 271 ELECTRICAL Connect an ammeter in series with the negative amps (battery discharge). Reverse meter leads if battery cable. Check for current draw with the key off. a positive reading is indicated. If the draw is excessive, loads should be 4. Shift transmission into neutral and start the disconnected from the system one by one until the engine.
  • Page 272 ELECTRICAL CHARGING SYSTEM TESTING FLOW CHART Whenever charging system problems are suspected, proceed with the following system check after verifying that all wires are in good condition, connected and not kinked or pinched. Using a multitester set on D.C. volts, mea- sure the battery open circuit voltage (See Remove the battery and properly ser- earlier test).

  • Page 273: Battery Identification

    ELECTRICAL BATTERY IDENTIFICATION BATTERY ACTIVATION (CONVENTIONAL) NOTICE: It is important to identify what type of battery you have installed in your ATV. Different types WARNING of batteries require different service procedures. Proper servicing and upkeep of your battery is very important for maintaining long battery life.

  • Page 274: Conventional Battery Installation

    4. Remove the filler caps and add distilled water only as needed to bring each cell to the proper level. Do not overfill the battery. Use Polaris corrosion resistant Nyogelt grease (PN 2871329) on battery bolts. See Battery Installation on Refill using only distilled water.
  • Page 275 ELECTRICAL Following are three tests which can easily be made on OPEN CIRCUIT VOLTAGE a battery to determine its condition: OCV Test, State of Conventional YuMicront Specific Gravity Test and Load Test. charge Lead-acid Type 100% 12.60V 12.70V CONVENTIONAL BATTERY Charged 12.40V 12.50V...

  • Page 276: Battery Check

    ELECTRICAL Remove battery from 3. Install battery in vehicle with positive terminal machine and wash the case and toward the front. Coat threads of battery bolt with battery tray with a mild solution of a corrosion resistant dielectric grease. baking soda and water. Rinse with lots of fresh water after cleaning.

  • Page 277: Battery Charging

    ELECTRICAL To service a Low Maintenance battery: 1. Remove battery from the vehicle 2. Test battery with a voltage meter or load tester to determine battery condition. This will determine the length of time required to charge the battery to full capacity.

  • Page 278: Battery Inspection

    ELECTRICAL LOW MAINTENANCE LOW MAINTENANCE BATTERY INSPECTION/ BATTERY TESTING REMOVAL Whenever a service complaint is related to either the starting or charging systems, the battery should be The battery is located under the seat. checked first. Following are three tests which can easily be made on a battery to determine its condition: OCV Test, Specific Gravity Test and Load Test.
  • Page 279 ELECTRICAL NOTE: This test can only be performed on machines The chart below indicates freezing points by specific with electric starters. This test cannot be performed gravity. with an engine or starting system that is not working properly. Electrolyte Freezing Points A battery may indicate a full charge condition in the OCV Specific Gravity Freezing...

  • Page 280: Bulb Replacement

    ELECTRICAL 1. Place the vehicle on a level surface with the headlight approximately 25’ (7.6 m) from a wall. Remove 3 screws 25’ (7.6 m) Lamp Center Height 2″ (5.1 cm) 2. Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height.
  • Page 281 ELECTRICAL 5. Pull the headlight housing up to release from the 9. Adjust the headlight aim by turning the adjusting locking tabs. knob. Position Snap pins LOWER HEADLAMP knob in into tabs REMOVAL/INSTALLATION slot and secure in lock- ing tabs Lower Headlamps Route Adjustment...

  • Page 282: Headlamp Switch

    ELECTRICAL Brake Switch Locations: Un- der front cover close to CDI Lens Cover box. Bulb 1. From the rear of the taillight remove two screws holding lens cover in place and remove lens cover. 2. Remove lamp and replace it with recommended 2.

  • Page 283: Fuel Sender Service

    ELECTRICAL FUEL SENDER TEST HAND/THUMB WARMER SWITCHES (SPORTSMAN 1. Remove the fuel sender from the fuel tank. Refer Chapter “FUEL SENDER HUNTER EDITION) REMOVAL/INSTALLATION”. 2. Stand the fuel sender on a flat surface. Button Removal / Installation 3. Hook up an ohm meter to the fuel sender harness 1.
  • Page 284 ELECTRICAL mounting bracket and the master cylinder clamp, next to the front spacer. 3. Reposition the spacers between the mini--rocker switch mounting bracket and the master cylinder clamp and reinstall the bolts to secure the switch. Torque the rear bolt first, then torque the front bolt. Torque to 25 in./lbs.
  • Page 285 ELECTRICAL BASIC WARN WINCH WIRING (SPORTSMAN HUNTER  EDITION) Cable Boot Blue Cable (6 ga.) Battery (20 ga.) Rocker Switch (IN/OUT) Black (6 ga.) Green Yellow Black Cable (6 ga.) Winch Contactor -- Located under left rear fender. 12V Contact Red Cable (6 ga.) Mounting Hardware Fairlead Roller...

  • Page 286: Starter System Troubleshooting

    ELECTRICAL STARTER SYSTEM drop tests on the starter system. TROUBLESHOOTING Voltage should not exceed .1 DC volts per connection Starter Motor Does Not Turn Battery discharged. Low specific STARTER MOTOR REMOVAL/ gravity Loose or faulty battery cables or DISASSEMBLY corroded connections (see Voltage Drop Tests) NOTE: Use electrical contact cleaner to clean starter Related wiring loose, disconnected,...
  • Page 287 ELECTRICAL O--rings Shims NOTE: The shims will be replaced during 3. Slide positive brush springs to the side, pull reassembly. brushes out of their guides and remove brush plate. Slide brush end frame off end of starter. BRUSH NOTE: The electrical input post must stay with the field coil housing.
  • Page 288 ELECTRICAL Brush Length Limit 5/16″ (8mm) Brush Replacement 1. Remove terminal nut with lock washer, flat washer, large phenolic washer, the small phenolic spacers, and sealing O-ring. Inspect O-ring and replace if damaged. 2. Inspect surface of commutator. Replace if excessively worn or damaged.
  • Page 289 ELECTRICAL 6. Place armature in a growler. Turn growler on and position a hacksaw blade or feeler gauge lengthwise 1/8″ (.3 cm) above armature coil Roller Bearing laminates. Rotate armature 360°. If hacksaw blade is drawn to armature on any pole, the Seal armature is shorted and must be replaced.

  • Page 290: Starter Drive

    Washer To measure the resistance of the pull-in coil, connect one meter lead to the solenoid lead wire and the other Polaris Premium Starter Drive Grease to ground. The resistance should be 2.8-3.6 ohms. (PN 2871460) Refer to Electric Starter System Testing in this section to further test the solenoid.
  • Page 291 ELECTRICAL STARTER ASSEMBLY Ref. Ref. Description Description 1. Rubber Ring* Gear Assembly 2. Brush Spring Though Bolt 3. Thrust Washer Cover 4. Gear Assembly Stopper 5. O-Ring* Snap Ring 6. Brush Complete Washer 7. O-Ring* Flange Bolt 8. Thrust Washer Thrust Washer 9.

  • Page 292: Starter System Testing Flow Chart

    ELECTRICAL STARTER SYSTEM TESTING FLOW CHART Condition: Starter fails to turn motor. NOTE: Make sure engine crankshaft is free to turn before proceeding with dynamic testing of starter system. A digital multitester must be used for this test. With the tester on the VDC position, place the tes- ter’s black lead on the battery negative and the red Remove battery and properly service.
  • Page 293 ELECTRICAL WIRING DIAGRAM - - HAND AND THUMB WARMERS / WINCH (HUNTER EDITION) 10.43...
  • Page 294 ELECTRICAL NOTES 10.44...
  • Page 295 ELECTRICAL WIRING DIAGRAM EARLY 2004 SPORTSMAN 600/700 (BUILT BEFORE FEB. 20, 2003)
  • Page 296 ELECTRICAL WIRING DIAGRAM EARLY 2004 SPORTSMAN 600/700 (BUILT BEFORE FEB. 20, 2003)
  • Page 297 ELECTRICAL WIRING DIAGRAM LATE 2004 SPORTSMAN 600/700 (BUILT AFTER FEB. 20, 2003)
  • Page 298 ELECTRICAL WIRING DIAGRAM LATE 2004 SPORTSMAN 600/700 (BUILT AFTER FEB. 20, 2003)
  • Page 299 ELECTRICAL WIRING DIAGRAM LATE 2004 SPORTSMAN 600/700 (MODELS WITH FUEL GAUGE)
  • Page 300 ELECTRICAL WIRING DIAGRAM LATE 2004 SPORTSMAN 600/700 (MODELS WITH FUEL GAUGE)
  • Page 301 ELECTRICAL WIRING DIAGRAM 2004 SPORTSMAN 600/700 HUNTER EDT. (HAND WARM/WINCH)
  • Page 302 Brake Pad Installation, Rear, 9.17 Brake Pad Removal, Front, A--Arm Replacement, 5.11 Brake Pad Removal, Rear, 9.16 Air Filter Service, 2.21 Brake System Inspection, 2.28 Alternator Output Test, 10.21 Brake System Operation, Auxiliary Brake Removal, 9.21 Brake, Auxiliary, Hydraulic, 2.29 Brake, Auxiliary, Testing, 2.28 Brakelight Lamp Replacement,...
  • Page 303 Compression Test, 2.16 Controls Inspection, 2.30 EBS Drive Clutch Bushing Service, Early 2004, Coolant Level Inspection , 2.20 6.21 Coolant Strength, 2.19 EBS Drive Clutch Bushing Service, Late 2004, 6.29 Coolant Temperature Sensor, 10.15 EBS Drive Clutch Inspection, 6.17 Cooling System Hoses, 2.19 EBS Driven Clutch Bushing Service, Early 2004, Cooling System Overview ,...
  • Page 304 Fan Control Switch Bypass Test, 10.15 Gear Position Switch Test, 10.4 Fan Control Switch Testing, 10.16 Gear Shift Selector Removal, Gearcase Assembly, Rear , 7.35 Fan Motor Current Draw Test, 10.15 Gearcase Coil Resistance, Front, 7.11, 7.18 Flywheel Identification, 10.17 Gearcase Disassembly, Rear , 7.34 Frame, Nuts, Bolts, Fasteners,...
  • Page 305 PVT Assembly, PVT Disassembly, Load Test, 10.25, 10.28 PVT Drying, 2.22, Lubricants, PVT Maintenance, Lubrication Charts, 2.7, 2.8 PVT Operation, Lubrication, Transmission, PVT Overheating, Lubrication, Transmission, Early 2004, 2.11 PVT System Sealing/Ducting Components, Lubrication, Transmission, Late 2004, 2.12 PVT Troubleshooting, 6.33, 6.34 Mag Cover Seal Replacement, 3.50...
  • Page 306 Specifications, Torque, Steering, Transmission Information, Specifications, Torque, Suspension, Transmission Installation, Transmission Reassembly, 8.13 Specifications, Torque, Transmission, Transmission Removal, Speedometer Installation, 10.9 Transmission, Exploded View, Early 2004, 8.2, Speedometer Troubleshooting, 10.10, 10.11, 10.12, 10.13, 10.14 Transmission, Exploded View, Late 2004, 8.4, 8.5 Speedometer Removal, 10.8 Trigger Coil Gap,...
  • Page 307 Winch Switch Installation, 10.34 Winch Wiring, 10.35 Wiring Diagram, Hand / Thumb Warmer / Winch, 10.43...
  • Page 308 PN 9918803 Printed in USA...

This manual is also suitable for:

Sportsman 700

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