Polaris Sportsman 700 EFI Owner's Manual
Polaris Sportsman 700 EFI Owner's Manual

Polaris Sportsman 700 EFI Owner's Manual

Polaris 2004 atv owner's manual
Hide thumbs Also See for Sportsman 700 EFI:
Table of Contents

Advertisement

Advertisement

Table of Contents
loading

Summary of Contents for Polaris Sportsman 700 EFI

  • Page 3 WARNING The engine exhaust from this product contains chemicals known to cause cancer, birth defects or other reproductive harm. A card containing important ATV safety information should be attached to the owner’s manual on the next page. If you cannot locate this card, or if it has been removed, please call 1-800-342-3764 for assistance.
  • Page 4 We’ve created a web site just for YOU! Check it out... www.polarisindustries.com/owner Technical tips New product introductions Event schedules Parts and Service Manual information Exciting details about The Way Out...
  • Page 5 Copyright 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 6: Welcome

    S Personal Task Vehiclest (PTVs) S All-Surface Loaders (ASLs) We believe Polaris sets a standard of excellence for all utility and recreational vehicles manufactured in the world today. Many years of experience have gone into the engineering, design, and development of your Polaris vehicle, making it the finest machine we’ve ever...
  • Page 7: Vehicle Identification Numbers

    Remove the spare key and store it in a safe place. Your key can be duplicated only by mating a Polaris key blank with one of your existing keys. If both keys are lost, the ignition switch must be replaced.
  • Page 8: Table Of Contents

    EMISSION CONTROL SYSTEMS MAINTENANCE AND LUBRICATION TROUBLESHOOTING POLARIS PRODUCTS SPECIFICATIONS WARRANTY ........
  • Page 9: Safety

    ATV, always read and follow the instructions of the decals on the ATV. If any decal becomes illegible or comes off, contact your Polaris dealer to purchase a replacement. Replacement safety decals are provided by Polaris at no charge.
  • Page 10: Safety Decals And Locations

    Safety Decals and Locations WARNING IMPROPER TIRE PRESSURE OR OVERLOADING can cause loss of control resulting in SEVERE INJURY OR DEATH. TIRE PRESSURE IN PSI (KPa): FRONT 5 (34,5) REAR 5 (34,5) MAXIMUM WEIGHT CAPACITY (Gross Vehicle Weight) INCLUDING MACHINE, DRIVER AND CARGO IS 1200 LBS. (545 kg). Reduce speed and allow greater distance for braking when carrying cargo.
  • Page 11 SAFETY Safety Decals and Locations Moving parts hazard under belt-clutch guard. To prevent serious injury, do not operate vehicle with guard removed. Do not modify engine or clutch. Doing so can cause part failure, possible imbalance, and excessive engine RPM which can result in serious injury or death. S DO NOT TOW FROM RACK OR BUMPER.
  • Page 12: All Wheel Drive

    THIS VEHICLE IS AN ALL TERRAIN VEHICLE AND IS NOT INTENDED FOR USE ON PUBLIC ROADS. CE VÉHICULE EST UN VÉHICULE TOUT TERRAIN QUI NiEST PAS DESTINÉ À ÊTRE UTILISÉ SUR LES CHEMINS PUBLICS. 7079780 Canadian Certification Decal SAFETY MANUFACTURED BY: POLARIS IND. INC. DATE: VIN: 7171492 7170509...
  • Page 13: Safe Riding Gear

    SAFETY Safe Riding Gear Always wear clothing suited to the type of riding. ATV riding requires special protective clothing for comfort and to reduce the chance of injury. 1. Helmet Your helmet is the most important piece of protective gear for safe riding. A helmet can prevent a severe head injury.
  • Page 14: Operator Safety

    Failure to follow the warnings contained in this manual can result in severe injury or death. A Polaris ATV is not a toy and can be hazardous to operate. This vehicle handles differently than other vehicles, such as motorcycles and cars. A collision or rollover can occur quickly, even during routine maneuvers like turning, or driving on hills or over obstacles, if you fail to take proper precautions.
  • Page 15 SAFETY Operator Safety The following signal words and symbols appear throughout this manual and on your vehicle. Your safety is involved when these words and symbols are used. Become familiar with their meanings before reading the manual. The safety alert symbol, on your vehicle or in this manual, alerts you to the potential for personal injury.
  • Page 16 S Never operate an ATV without proper instruction. Take a training course. Beginners should receive training from a certified instructor. Contact an authorized Polaris ATV dealer or call Polaris at 1-800-342-3764 to find out about the training courses nearest you.
  • Page 17 SAFETY Operator Safety S Always have the ATV inspected by an authorized Polaris dealer if it’s been involved in an accident. S Never operate on hills too steep for the ATV or for your abilities. Practice on smaller hills before attempting larger hills.
  • Page 18: Equipment Modifications

    We are concerned for the safety of our customers and for the general public. Therefore, we strongly recommend that consumers do not install on a Polaris ATV any equipment that may increase the speed or power of the vehicle, or make any other modifications to the vehicle for these purposes.
  • Page 19 ATVs, he/she may not have the skills, abilities, or judgment needed to operate an ATV safely and could be susceptible to accident or injury. HOW TO AVOID THE HAZARD No one under the age of 16 should operate a Polaris ATV.
  • Page 20 SAFETY Operator Safety WARNING POTENTIAL HAZARD Carrying a passenger on an ATV. WHAT CAN HAPPEN Carrying a passenger greatly reduces the operator’s ability to balance and control the ATV, which could cause an accident and injury to the operator and/or passenger. HOW TO AVOID THE HAZARD Never carry a passenger.
  • Page 21 SAFETY Operator Safety WARNING POTENTIAL HAZARD Operating this ATV on public streets, roads or highways. WHAT CAN HAPPEN The ATV could collide with another vehicle. HOW TO AVOID THE HAZARD Never operate the ATV on any public street, road or highway, including dirt and gravel roads.
  • Page 22 SAFETY Operator Safety WARNING POTENTIAL HAZARD Operating the ATV after consuming alcohol or drugs. WHAT CAN HAPPEN Consumption of alcohol and/or drugs could seriously affect operator judgment. Reaction time may be slower and operator balance and perception could be affected. Consuming alcohol and/or drugs before or while operating an ATV could result in an accident causing severe injury or death.
  • Page 23 SAFETY Operator Safety WARNING POTENTIAL HAZARD Failure to inspect the ATV before operating. Failure to properly maintain the ATV. WHAT CAN HAPPEN Poor maintenance increases the possibility of an accident or equipment damage. HOW TO AVOID THE HAZARD Always inspect your ATV before each use to make sure it’s in safe operating condition.
  • Page 24 SAFETY Operator Safety WARNING POTENTIAL HAZARD Failure to use extra caution when operating the ATV on unfamiliar terrain. WHAT CAN HAPPEN Unfamiliar terrain may contain hidden rocks, bumps, or holes that could cause loss of control or overturn. HOW TO AVOID THE HAZARD Travel slowly and use extra caution when operating on unfamiliar terrain.
  • Page 25 SAFETY Operator Safety WARNING POTENTIAL HAZARD Turning improperly. WHAT CAN HAPPEN Improper turns could cause loss of control and lead to a collision or overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for turning as described in the owner’s manual.
  • Page 26 SAFETY Operator Safety WARNING POTENTIAL HAZARD Climbing hills improperly. WHAT CAN HAPPEN Improper hill climbing could cause loss of control or overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for climbing hills as described in the owner’s manual. Always check the terrain carefully before ascending any hill.
  • Page 27 SAFETY Operator Safety WARNING POTENTIAL HAZARD Traveling downhill improperly. WHAT CAN HAPPEN Improperly descending a hill could cause loss of control or overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for traveling down hills as described in the owner’s manual.
  • Page 28 SAFETY Operator Safety WARNING POTENTIAL HAZARD Improperly crossing hills and turning on hills. WHAT CAN HAPPEN Improperly crossing or turning as hills could cause loss of control or overturn. HOW TO AVOID THE HAZARD Never attempt to turn the ATV around on any hill until you’ve mastered the turning technique (on level ground) as described in...
  • Page 29 SAFETY Operator Safety WARNING POTENTIAL HAZARD Stalling, rolling backwards or improperly dismounting while climbing a hill. WHAT CAN HAPPEN The vehicle could overturn. HOW TO AVOID THE HAZARD Maintain steady speed when climbing a hill. If all forward speed is lost: Keep your weight uphill.
  • Page 30 SAFETY Operator Safety WARNING POTENTIAL HAZARD Improperly operating over obstacles. WHAT CAN HAPPEN Operating over obstacles could cause loss of control or overturn. HOW TO AVOID THE HAZARD Before operating in a new area, check for obstacles. Avoid operating over large obstacles such as rocks and fallen trees when possible.
  • Page 31 SAFETY Operator Safety WARNING POTENTIAL HAZARD Operating the ATV through deep or fast-flowing water. WHAT CAN HAPPEN Tires may float, causing loss of traction and loss of control, which could lead to an accident or overturn. HOW TO AVOID THE HAZARD Avoid operating the ATV through deep or fast-flowing water.
  • Page 32 Never modify the ATV through improper installation or use of accessories. All parts and accessories added to the vehicle must be genuine Polaris Industries Inc. or equivalent components designed for use on this ATV and should be installed and used according to approved instructions.
  • Page 33 SAFETY Operator Safety WARNING POTENTIAL HAZARD Overloading the ATV or carrying/towing cargo improperly. WHAT CAN HAPPEN Overloading and towing can cause changes in vehicle handling, which could lead to loss of control or an accident. HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this ATV.
  • Page 34 SAFETY Operator Safety WARNING Operating a damaged ATV can result in an accident with serious injury or death. After any overturn or accident, have a qualified service dealer inspect the entire machine for possible damage, including (but not limited to) brakes, throttle and steering systems.
  • Page 35: Features And Controls

    FEATURES AND CONTROLS Engine Electrical Switches WARNING Activating the override switch while the throttle is open can cause loss of control, resulting in severe injury or death. Do not activate the override switch while the throttle is open. Mode/Reverse Override Switch (1) - This vehicle is equipped with a reverse speed limiter system.
  • Page 36: Throttle Lever

    This ATV is equipped with Polaris Electronic Throttle Control (ETC), which is designed to reduce the risk of a frozen or stuck throttle. If the throttle cable should stick in an open position when the operator releases the throttle lever, the engine will stop, and power to the rear wheels will cease.
  • Page 37: Brake Lever

    FEATURES AND CONTROLS Light Switches The light switch is located on the left handlebar. It’s used to turn the lights on and off and to switch the lights from HI to LO. NOTE: The lights won’t work unless the key is in the ON position and the auxiliary shut-off switch is in the RUN position.
  • Page 38: Master Cylinder

    NOTE: When checking the fluid level, the ATV must be on level ground with the handlebars straight. If the fluid level is low add DOT 3 brake fluid only. See page 109 for the part numbers of Polaris products. WARNING After opening a bottle of brake fluid, always discard any unused portion.
  • Page 39: Parking Brake

    FEATURES AND CONTROLS Parking Brake WARNING Operating the ATV while the parking brake is engaged could result in an accident and serious injury or death. Always check to be sure the parking brake is disengaged before operating. Setting the Parking Brake 1.
  • Page 40: Auxiliary Brake

    The rear wheels may skid and slide sideways, causing loss of control and serious injury or death. Your Polaris ATV has an auxiliary brake (1) for added safety. It’s located on the...
  • Page 41: Fuel Tank

    FEATURES AND CONTROLS Fuel Tank The fuel tank filler cap (1) is located directly below the handlebar. Use either leaded or unleaded gasoline with a minimum pump octane number of 87=(R+ M/2) octane. Fuel Filter The in-line fuel filter should be replaced by your dealer after every 200 hours of operation and any time the fuel becomes contaminated with dirt or debris.
  • Page 42: Belt Life

    Automatic Transmission Gear Selector The transmission gear selector (1) is located on the right side of the vehicle. H: High Gear L: Low Gear N: Neutral R: Reverse P: Park To shift into HIGH or PARK, you must first apply the auxiliary brake to activate the high/park lock-out mechanism.
  • Page 43: Engaging The Front Gearcase

    FEATURES AND CONTROLS All Wheel Drive (AWD) System Polaris 4-wheel drive ATVs are equipped with a unique, Polaris-exclusive, On-Demand All Wheel Drive system, which is activated by the AWD switch (1) on the right handlebar. When the switch is off, the ATV is in two-wheel drive at all times.
  • Page 44: Instrument Cluster

    Instrument Cluster Your ATV is equipped with an instrument cluster that senses vehicle speed from the right front wheel. The instrument cluster measures distance in miles as well as hours of operation. It also includes a reverse speed limiter function that limits the ATV’s speed to approximately 7-9 mph.
  • Page 45: Rider Information Center

    If this occurs, take the ATV to your Polaris dealer for proper diagnosis. 1. Gear Indicator - As the shift lever is moved, this indicates the...
  • Page 46 FEATURES AND CONTROLS Instrument Cluster Rider Information Center The rider information center has 4 standard modes: Mode 1 - Odometer Mode 2 - Tripmeter Mode 3 - Total Service Hours Mode 4 - Tachometer The reverse override button on the left handlebar is also the mode button.
  • Page 47: Diagnostic Mode

    FEATURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode The diagnostic mode is for informational purposes only. Please return your ATV to your dealer for all major repairs. As long as the gauge is in the diagnostic mode, the wrench icon will remain lit.
  • Page 48 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode 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. When your vehicle leaves the factory, this feature is set at 50 hours.
  • Page 49: Special Efi Diagnostic Mode

    Special EFI Diagnostic Mode The EFI diagnostic mode is for informational purposes only. Please see your Polaris dealer for all major repairs. To download blink codes (failure codes) from the EFI module: 1. Place the transmission in PARK, turn the engine off and turn the key switch to the ON position.
  • Page 50: Operation

    OPERATION Fuel Safety WARNING Gasoline is highly flammable and explosive under certain conditions. Always exercise extreme caution whenever handling gasoline. Always refuel with the engine stopped, and outdoors or in a well ventilated area. Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored.
  • Page 51: Break-In Period

    OPERATION Break-In Period The break-in period for your new Polaris ATV is defined as the first ten hours of operation, or the time it takes to use the first two full tanks of gasoline. No single action on your part is as important as following the procedures for a proper break-in.
  • Page 52 Pre-Ride Inspection WARNING If a proper inspection is not done before each use, severe injury or death could result. Always inspect the vehicle before each use to ensure it’s in proper operating condition. Use the following checklist to verify that your vehicle is in proper working condition before each use.
  • Page 53: Starting The Engine

    Water in the bottom of the crankcase can lead to engine damage and must be drained. Water accumulation increases as outside temperature decreases. See your Polaris dealer for engine heater kits, which provide quicker warm-ups and easier starting in colder weather.
  • Page 54: Hauling Cargo

    OPERATION Hauling Cargo Your ATV has been designed to carry or tow a certain amount of load. Always read and understand the load distribution warning labels on the vehicle, and never exceed the weight capacities outlined in the specifications section of the owner’s manual and on the safety decals. Cargo weight should be evenly distributed (1/3 on the front rack and 2/3 on the rear rack) and mounted as low as possible.
  • Page 55 OPERATION Hauling Cargo WARNING Hauling cargo improperly can alter vehicle handling and may cause loss of control or brake instability and result in serious injury or death. Always follow these precautions when hauling cargo: REDUCE SPEED AND ALLOW GREATER DISTANCES FOR BRAKING WHEN HAULING CARGO.
  • Page 56: Driving Safely

    Driving Safely Driving Procedures 1. Sit upright with both feet on the footrests and both hands on the handlebars. 2. Start the engine and allow it to warm up, then shift the transmission into gear. 3. Check your surroundings and determine your path of travel. 4.
  • Page 57: Making Turns

    OPERATION Driving Safely Making Turns Your ATV is equipped with a solid rear axle, which drives both rear wheels equally at all times. This means that the wheel on the outside of the turn must travel a greater distance than the inside wheel when turning and the inside tire must slip traction slightly.
  • Page 58: Driving On Slippery Surfaces

    Driving Safely Driving on Slippery Surfaces Whenever riding on slippery surfaces such as wet trails or loose gravel, or during freezing weather, follow these precautions: 1. Slow down when entering slippery areas. 2. Engage AWD before wheels begin to lose traction.
  • Page 59: Traveling Uphill

    OPERATION Driving Safely Traveling Uphill Whenever traveling uphill, follow these precautions: 1. Always travel straight uphill. 2. Avoid steep hills (25_ maximum). 3. Keep both feet on the footrests. 4. Transfer your weight forward. 5. Proceed at a steady rate of speed and throttle opening. 6.
  • Page 60 Driving Safely Sidehilling WARNING Improperly crossing hills or turning on hills can result in loss of control or vehicle overturn, resulting in severe injury or death. Avoid crossing the side of a hill when possible. Follow proper procedures as outlined in the owner’s manual. Sidehilling can be the most dangerous type of driving encountered and should be avoided if at all possible.
  • Page 61: Traveling Downhill

    OPERATION Driving Safely Traveling Downhill WARNING Excessive speed when traveling downhill can cause loss of control and serious injury or death. When traveling downhill, follow these precautions: 1. Transfer your weight to the rear. 2. Drive straight down the hill. 3.
  • Page 62: Turning Around On A Hill

    Driving Safely Turning Around on a Hill WARNING Improper hill climbing procedures could cause loss of control or overturn and result in serious injury or death. Avoid climbing steep hills (25_ maximum). Use extreme caution when operating on hills, and follow proper operating procedures outlined in the owner’s manual.
  • Page 63: Driving Through Water

    OPERATION Driving Safely Driving Through Water Your ATV can operate through water with a maximum recommended depth equal to the bottom of the footrests (1). Follow these procedures when operating through water: 1. Determine water depths and current before crossing. 2.
  • Page 64: Driving Over Obstacles

    Driving Safely Driving Over Obstacles Be alert! Look ahead and learn to read the terrain you’re traveling on. Be constantly alert for hazards such as logs, rocks and low hanging branches. WARNING Severe injury or death can result if your vehicle comes in contact with a hidden obstacle.
  • Page 65: Driving In Reverse

    Use with caution. Avoid backing on inclines, and avoid turning at sharp angles. NOTE: Your Polaris ATV is equipped with a reverse speed limiter. The override button should be used with caution as rearward vehicle speed is greatly increased. Do not operate at wide open throttle. Open the throttle just enough to maintain a desired speed.
  • Page 66: Parking On An Incline

    OPERATION Driving Safely Parking on an Incline Avoid parking on an incline if possible. If it’s unavoidable, follow these precautions: 1. Turn the engine off. 2. Place the transmission in park. 3. Set the parking brake. 4. Always block the rear wheels on the downhill side as shown.
  • Page 67: Emission Control Systems

    Do not modify the engine, intake or exhaust components, as doing so may affect compliance with state and local noise level requirements. Spark Arrestor Your Polaris ATV has a spark arrestor that was tested and approved in accordance with the USDA Forestry Service Standard 5100-1C. Exhaust Emission Control System Exhaust emissions are controlled by engine design.
  • Page 68: Maintenance And Lubrication

    Inspect, clean, lubricate, adjust and replace parts as necessary. When inspection reveals the need for replacement parts, use genuine Polaris parts available from your Polaris dealer. NOTE: Service and adjustments are critical. If you’re not familiar with safe service and adjustment procedures, have a qualified dealer perform these operations.
  • Page 69: Periodic Maintenance Schedule

    Perform all services at whichever reading is reached first. WARNING Improperly performing the procedures marked with a result in component failure and lead to serious injury or death. Have an authorized Polaris dealer perform these services. Item Brake System Auxiliary Brake...
  • Page 70 Monthly 50 hrs. 3 months Drain deposits whenever visible Check operation daily; ap- ply Polaris dielectric grease to connector when replaced Check operation daily; ap- ply Polaris dielectric grease to socket when replaced Inspect; replace as needed Inspect monthly; change annually Check monthly;...
  • Page 71 MAINTENANCE AND LUBRICATION Periodic Maintenance Schedule WARNING Improperly performing the procedures marked with a result in component failure and lead to serious injury or death. Have an authorized Polaris dealer perform these services. Item Engine oil level/oil " change Oil Filter "...
  • Page 72 MAINTENANCE AND LUBRICATION Periodic Maintenance Schedule Item Coolant strength Spark plugs Ignition Timing Fuel system Radiator Cooling system hoses Clutches (drive and driven) Engine mounts Brake fluid Fuel filter Spark arrestor Front wheel bear- ings Idle speed Toe adjustment Headlight aim Hours/ Frequency Remarks Miles...
  • Page 73 MAINTENANCE AND LUBRICATION Periodic Maintenance Record Use the following chart to record periodic maintenance. Maintenance Servicing Interval Performed 10 hrs. 20 hrs. 50 hrs. 100 hrs. Servicing Date Dealer or Person Remarks...
  • Page 74: Lubrication Guide

    More often under severe use, such as wet or dusty conditions " Polaris Premium All Season Grease or grease conforming to NLGI No. 2, such as Conoco Superlube M or Mobilegrease Special Use Polaris Premium U-Joint Lube every 500 miles, before long periods of storage, or after pressure washing or submerging.
  • Page 75: Premium 4 Synthetic Lubricant

    +49° C.) Its exceptional frictional properties result in more efficient operation, more power output and lower fuel consumption. Although Polaris Premium 4 is the only oil recommended for use in this engine, use of any API certified SH oil is allowable as long as it’s 0W-40.
  • Page 76: Oil Check

    MAINTENANCE AND LUBRICATION Oil Check The oil dipstick and fill tube (1) are located on the left side of the vehicle. 1. Position the ATV on a level surface. 2. Start the engine and let it idle for 20-30 seconds, then stop the engine.
  • Page 77: Oil And Filter Change

    MAINTENANCE AND LUBRICATION Oil and Filter Change The recommended oil change interval is 100 hours, 1000 miles, or every six months, whichever comes first. Suggested break-in oil change is at 20 hours, 200 miles, or one month, whichever comes first. Severe use operation requires more frequent service.
  • Page 78: Transmission Oil

    The transmission oil level should be checked every six months or 1000 miles (1600 km), whichever comes first. Transmission oil should be changed annually. We recommend the use of Polaris AGL Synthetic Gearcase Lubricant. See page 109 for the part numbers of Polaris products. Oil Check The transmission oil fill plug (1) is located on the right side of the ATV behind the footwell.
  • Page 79: Front Gearcase Oil

    The front gearcase lubricant level should be checked every six months or 1000 miles (1600 km), whichever comes first. Front gearcase oil should be changed annually. We recommend the use of Polaris Premium Hub Drive Fluid. See page 109 for the part numbers of Polaris products. Oil Check 1.
  • Page 80: Rear Gearcase Oil

    The rear gearcase lubricant level should be checked every six months or 1000 miles (1600 km), whichever comes first. Rear gearcase oil should be changed annually. Use Polaris AGL Synthetic Gearcase Lube (or GL5 80-90 weight gear lube). NOTE: See page 109 for the part numbers of Polaris products.
  • Page 81: Engine Cooling System

    50/50 mixture of high quality aluminum compatible anti-freeze/coolant and distilled water. See page 109 for the part numbers of Polaris products. NOTE: Polaris Premium 60/40 is already premixed and ready to use. Do not dilute with water. NOTE: Always follow the manufacturer’s mixing recommendations...
  • Page 82: Radiator Coolant Level

    NOTE: To ensure that the coolant maintains its ability to protect the engine, we recommend that the system be completely drained every two years and a fresh mixture of antifreeze and water added. Polaris recommends the use of Polaris Premium 60/40 anti-freeze/coolant or a 50/50 mixture of high quality aluminum compatible anti-freeze/coolant and distilled water.
  • Page 83: Brakes

    Always fill the reservoir as needed whenever the cover is loosened or removed to ensure proper diaphragm operation. Use Polaris DOT 3 brake fluid. Do not overfill.
  • Page 84 MAINTENANCE AND LUBRICATION Brakes 2. Check the brake system for fluid leaks. 3. Check the brakes for excessive travel or spongy feel. 4. Check the friction pads for wear, damage and looseness. 5. Check the security and surface condition of the disc. NOTE: Pads should be changed when worn to 3/64″...
  • Page 85: Toe Alignment

    NOTE: If you discover improper alignment, see your Polaris dealer for service. Steering Assembly The steering assembly of the ATV should be checked periodically for loose nuts and bolts. If loose nuts and bolts are found, see your Polaris dealer for service before operating the vehicle.
  • Page 86: Side Panel Removal

    MAINTENANCE AND LUBRICATION Side Panel Removal NOTE: Side panel removal may be difficult until the locking tabs and receivers have been snapped and unsnapped a few times. 1. Remove the seat. 2. Grasp the rear of the side panel near the rear cab. With a quick and firm motion, pull the panel forward and outward to disengage the two rear tabs.
  • Page 87: Wheel Removal

    MAINTENANCE AND LUBRICATION WARNING Operating your ATV with worn tires, improperly inflated tires, non-standard tires or improperly installed tires will affect vehicle handling and could cause an accident resulting in serious injury or death. Maintain proper tire pressure as described on the decal on your ATV and in the owner’s manual.
  • Page 88: Wheel Installation

    5. Torque the wheel nuts according to the wheel nut torque specifications chart. NOTE: All nuts that have a cotter pin installed must be serviced by an authorized Polaris dealer. Wheel Nut Torque Specifications Check the wheel nut torques occasionally and when they’ve been loosened for maintenance service.
  • Page 89: Filter Systems

    MAINTENANCE AND LUBRICATION Filter Systems Air Filter Service 1. Remove the seat, release the air box cover clips, and remove the air box cover. 2. Loosen the clamp and remove the filter. 3. Remove the fabric type pre-filter (1) from the main filter (2).
  • Page 90: Headlight Lamp Replacement

    MAINTENANCE AND LUBRICATION Lights When servicing a halogen lamp, don’t touch the lamp with bare fingers. Oil from your skin leaves a residue, causing a hot spot that will shorten the life of the lamp. WARNING Poor lighting while driving can result in severe injury or death. Headlight and taillight lenses become dirty during normal operation.
  • Page 91: High Beam Adjustment

    MAINTENANCE AND LUBRICATION Lights High Beam Adjustment The headlight beam can be adjusted to any position desired by turning the adjusting knob on the bottom right side of the headlight pod. 1. Position the vehicle on a level surface with the headlight approximately 25 ft.
  • Page 92: Headlight Housing Replacement

    MAINTENANCE AND LUBRICATION Lights Headlight Housing Replacement 1. Remove the two screws on the lower front corners of the headlight pod. 2. Using a small flat-blade screwdriver, push in on the lock tab through the two small openings at the front of the headlight pod. 3.
  • Page 93 MAINTENANCE AND LUBRICATION Lights Lower Headlamp Removal / Installation 1. Turn the back of the headlight harness (1) in a counterclockwise direction. 2. Pull the harness assembly out from the headlight assembly. 3. Remove the headlamp and replace with a new headlamp.
  • Page 94: Spark Plugs

    S Spark plug torque is 18 ft. lbs. (24 Nm). CAUTION Using non-recommended spark plugs can result in serious engine damage. Always use Polaris-recommended spark plugs. Spark plug condition is indicative of engine operation. The spark plug firing end condition should be read after the engine has been warmed up and the vehicle has been driven at higher speeds.
  • Page 95: Vehicle Immersion

    MAINTENANCE AND LUBRICATION Vehicle Immersion CAUTION If your vehicle becomes immersed, major engine damage can result if the machine is not thoroughly inspected. Take the vehicle to your dealer before starting the engine. If it’s impossible to take your ATV to a dealer before starting it, follow the steps outlined below.
  • Page 96: Spark Arrestor

    MAINTENANCE AND LUBRICATION Spark Arrestor WARNING Failure to heed the following warnings while servicing the spark arrestor could result in serious injury or death. Do not perform service on the spark arrestor while the system is hot. Exhaust system temperatures can reach 1000° F. Allow components to cool sufficiently before proceeding.
  • Page 97: Pvt System

    MAINTENANCE AND LUBRICATION PVT System The basic operation of the Polaris PVT system is dependent on engine speed and vehicle torque requirements. As engine speed increases, the force exerted on the movable drive sheave by the flyweights also increases. This, in turn, increases the amount of pinch applied to the drive belt.
  • Page 98: Pvt Drying

    Always follow all recommended maintenance procedures. See your dealer as outlined in the owner’s manual. This PVT system is intended for use on Polaris products only. Do not install it in any other product. Always make sure the PVT housing is securely in place during operation.
  • Page 99: Battery Removal

    MAINTENANCE AND LUBRICATION Battery WARNING Improperly connecting or disconnecting battery cables can result in an explosion and cause serious injury or death. When removing the battery, always disconnect the negative (black) cable first. When reinstalling the battery, always connect the negative (black) cable last.
  • Page 100: Battery Charging

    Check battery voltage each month during storage and recharge as needed to maintain a full charge. NOTE: Battery charge can be maintained by using a Polaris Battery Tendert charger (PN 2871076) or by charging about once a month to make up for normal self-discharge.
  • Page 101 MAINTENANCE AND LUBRICATION Battery Battery Charging NOTE: Always verify battery condition before and 1-2 hours after the end of charging. State of Voltage Charge 100% 12.8-13.0 volts 75%-100% 12.5-12.8 volts 50%-75% 12.0-12.5 volts 25%-50% 11.5-12.0 volts 0%-25% 11.5 volts or less Action charger @ standard amps specified on top of battery)
  • Page 102: Cleaning And Storage

    Rinse with water frequently and dry with a chamois to prevent water spots. NOTE: If warning and safety labels are damaged, contact your a Polaris dealer for free replacement. CAUTION High water pressure may damage ATV components.
  • Page 103: Fluid Levels

    Use dish soap type cleaners only. High pressure washers may force water past seals. Stabilize the Fuel Fill the fuel tank. Add Polaris Carbon Clean Fuel Treatment or Polaris Fuel Stabilizer. Follow the instructions on the container for the recommended amount. (Carbon clean will also reduce the possibility of bacterial growth in the fuel system.) Allow 15-20 minutes of operation...
  • Page 104: Storage Tips

    6. If Polaris fuel system additive is not used, fuel tank, fuel lines, and injectors should be completely drained of gasoline. Inspect and Lubricate Inspect all cables and lubricate.
  • Page 105: Battery Maintenance

    Set the tire pressure and safely support the ATV with the tires 1-2” off the ground. Be sure the storage area is well ventilated, and cover the machine with a genuine Polaris ATV cover. NOTE: Do not use plastic or coated materials. They do not allow enough ventilation to prevent condensation, and may promote corrosion and oxidation.
  • Page 106: Camber And Caster

    Follow the adjustment procedures exactly, or see your Polaris dealer for service. The handlebars can be adjusted for rider preference.
  • Page 107: Throttle Cable Freeplay

    ADJUSTMENTS Throttle Body/Idle RPM Idle RPM is preset by the manufacturer. If the engine idle speed is not satisfactory, please see your Polaris dealer for adjustment. Throttle Cable Freeplay Throttle cable freeplay is adjusted at the handlebar. 1. Slide the boots (1) off the inline cable adjuster sleeve (2). Loosen the adjuster locknut (3).
  • Page 108: Troubleshooting

    10 seconds. Clutch seals should be inspected for damage if repeated leaking occurs. Contact your Polaris dealer for inspection of clutch com- ponents. Replace old or off-season fuel with fresh fuel. Check for fouled plugs or foreign material in gas tank, fuel lines or fuel filter.
  • Page 109 TROUBLESHOOTING Contact your Polaris dealer for service if you’re unable to identify solutions using the following charts. Engine Doesn’t Turn Over Possible Cause Tripped circuit breaker Low battery voltage Loose battery connections Loose solenoid connections Engine Turns Over, Fails to Start...
  • Page 110 TROUBLESHOOTING Solution Inspect, clean and/or replace spark plugs Set gap to specs or replace plugs Replace with new fuel See your Polaris dealer See your Polaris dealer See your Polaris dealer Solution Inspect, clean and/or replace spark plugs See your Polaris dealer...
  • Page 111: Engine Overheating

    5 seconds each, then start Inspect and replace Replace with new fuel Inspect, clean and/or replace spark plugs See your Polaris dealer Set gap to specs or replace plugs Check all connections and tighten Recharge battery to 12.8 VDC...
  • Page 112: Polaris Products

    AGL Synthetic Gearcase Lubricant (qt.) 2873603 AGL Synthetic Gearcase Lubricant (gal.) 2873604 AGL Synthetic Gearcase Lubricant (2.5 gal.) 2871653 Polaris ATV Angle Drive Fluid (8 oz.) 2872276 Polaris ATV Angle Drive Fluid (2.5 gal.) 2870465 Oil Pump for Gearcase Oil 2871654 Premium Hub Drive Fluid (8 oz.)
  • Page 113: Specifications

    Ignition Timing Spark Plug / Gap Lubrication System Driving System Type * Based on EU Directive 76/432/EC SPORTSMAN 700 EFI 1240 lbs. (563 kg) 4.25 gal. (16 l) 2 qts. (1.9 l) 3.2 qts. (3 l) 1500 lbs. (681 kg) 1914 lbs.
  • Page 114: Clutching Chart

    Brake Light Instrument Cluster Clutching Chart Altitude Meters 0-1800 (Feet) (0-6000) 1800-3700 (6000-12000) SPECIFICATIONS SPORTSMAN 700 EFI Side Lever (H/L/N/R/P) 7.5:1 5.11:1 2.89:1 3.82:1 3.10:1 25 x 8 - 12 25 x 11 - 12 Hydraulic Disc Hydraulic Hydraulic lock, all wheel...
  • Page 115: Warranty

    MONTH LIMITED WARRANTY on all components of the Polaris All Terrain Vehicle (ATV) against defects in material or workmanship. Polaris also gives a one year limited warranty on the final drive chain for failure due to defects. This warranty covers the parts and labor charges for repair or replacement of defective parts which are covered by this warranty.
  • Page 116 WARRANTY COVERAGE AND EXCLUSIONS: LIMITATIONS OF WARRANTIES AND REMEDIES The Polaris limited warranty excludes any failures that are not caused by a defect in material or workmanship. This warranty does not cover accidental damage, normal wear and tear, abuse or improper handling.
  • Page 117: Engine Oil

    HOW TO OBTAIN WARRANTY SERVICE If your ATV requires warranty service, you must take it to a Polaris dealer authorized to repair Polaris ATVs. When requesting warranty service you must present your copy of the Warranty Registration form to the dealer.
  • Page 118 In the Country where your vehicle was purchased: Warranty or Service Bulletin repairs must be done by an authorized Polaris dealer. If you move or are traveling within the country where your vehicle was purchased, Warranty or Service Bulletin repairs may be requested from any authorized Polaris dealer who sells the same line as your vehicle.
  • Page 119 Exported Vehicles How to Get Service If Purchased From A Private Party: If you purchase a Polaris product from a private citizen outside of the country in which the vehicle was originally purchased, all warranty coverage will be denied. Notice...
  • Page 120: Index

    Accessories ....ADJUSTMENTS ..Age Restrictions ....Air Filter Service .
  • Page 121 Parking on an Incline ... Periodic Maintenance Schedule POLARIS PRODUCTS ..Pre-Ride Inspection ... . .

This manual is also suitable for:

2004 sportsman 700 efi

Table of Contents