User Manuals: Polaris Sportsman 700 ATV

Manuals and User Guides for Polaris Sportsman 700 ATV. We have 3 Polaris Sportsman 700 ATV manuals available for free PDF download: Service Manual, Owner's Manual

Polaris Sportsman 700 Service Manual (308 pages)

Brand: Polaris | Category: Motorcycle | Size: 30 MB

General Information

5
- Table of Contents
  5
- Model Identification
  6
- Serial Number Location
  6
- Sportsman Models Identification
  7
  - U 1/2
    10
- Publication Numbers
  14
- Paint Codes
  14
- Replacement Keys
  14
- Standard Torque Specifications
  15
- Conversion Table
  16
- Glossary of Terms
  18
Maintenance

19
- Periodic Maintenance Chart
  20
- Pre-Ride Inspection
  22
- Special Tools
  24
- Front & Rear Gearcase Lubrication
  27
- Transmission Lubrication
  29
  - Throttle Inspection
    31
  - Idle Speed Adjustment
    32
  - Throttle Cable
    32
- Fuel System
  33
- Compression Test
  34
  - Fuel Filter
    34
  - Carburetor Draining
    34
- Battery Maintenance
  35
- Ignition Timing
  36
  - Spark Plug
    36
- Radiator Screen Removal
  38
  - Coolant Level Inspection
    38
- Air Box Sediment Tube Service
  39
- Breather Filter
  40
- PVT Drying & PVT Drain Plug
  40
- Oil Change/Filter
  41
  - Engine Oil Level
    41
  - Wheel Alignment
    44
  - Brake Pad Inspection
    46
  - Front Suspension
    47
  - Rear Suspension
    47
- Controls
  48
- Tire Inspection
  48
- Wheel Removal/Installation
  48
  - Wheel Installation
    48
  - Tire Pressure
    48
  - Torque Table
    48
- Warn Winch Operation
  49
Table of Contents

51
- Engine Exploded Views
  52
  - Top End
    55
- Piston Identification
  57
- Special Tools
  57
- Torque Specifications
  58
- Engine Fastener Torque Patterns
  59
- 600 Engine Service Data
  60
- Cooling System Specifications
  64
- Cooling System Test
  64
- Engine Installation Notes
  66
- Oil Flow
  68
- Rocker Arm/Pushrod Inspection
  69
  - Cylinder Head Removal
    69
- Cylinder Head Disassembly/Inspection
  70
  - Cylinder Head Inspection
    70
- Valve Inspection
  72
- Combustion Chamber
  73
- Valve Seat Reconditioning
  73
- Cylinder Head Assembly
  75
- Valve Sealing Test
  76
- Valve Train Exploded View
  76
- Engine Head Reassembly
  77
- Cylinder Removal
  79
- Piston Removal
  79
- Valve Lifter Removal/Inspection
  79
- Cylinder Inspection
  80
  - Piston Ring Installed Gap
    83
- Starter Bendix Removal/Inspection
  84
- Flywheel/Stator Installation
  85
- Flywheel/Stator Removal/Inspection
  85
- Engine Crankcase Disassembly/Inspection
  86
- Camshaft Inspection
  94
- Engine Crankcase Assembly
  95
- Troubleshooting
  106
Fuel System/Carburetion

109
- Fuel Flow Diagram
  111
- Carburetor Jetting
  112
- Assembly, CV Carburetor
  113
  - Float System
    115
  - Main System
    115
  - Carburetor Inspection
    117
  - Carburetor Cleaning
    117
  - Carburetor Assembly
    118
- CV Carburetor System Function (4 Cycle)
  113
- Needle & Seat Leakage Test
  119
- Fuel Level
  120
- Fuel Pump Service
  120
  - Fuel Pump Disassembly
    120
- Fuel Sender Service
  121
- Troubleshooting
  121
Table of Contents

123
- Cover/Panel Removal
  124
- Side Panel Removal
  125
- Body Assembly Exploded View
  127
- Body Rack Assembly, Exploded View
  128
- Headlight Pod Exploded View
  130
- Steering/A--Arm Exploded View
  131
- Rear Suspension Exploded View
  132
- A-Arm Replacement
  133
- Steering Post Assembly
  134
- Front Strut Assembly Exploded View
  135
- Front Strut Cartridge Replacement
  136
- Decal Replacement
  137
Clutch

139
- Drive Clutch Exploded View
  140
- PVT Sealing and Ducting Components
  140
- PVT Operation Overview
  142
- PVT Overheating/Diagnosis
  144
- PVT Disassembly
  145
- PVT Assembly/Inspection
  146
- Drive Clutch Spring Specifications
  147
- Shift Weights /Inspection
  148
- Drive Clutch Disassembly/Inspection
  149
  - Clearance Inspection
    149
- Drive Clutch Reassembly
  151
- Drive Belt Removal/Inspection
  152
- Clutch Alignment/Offset
  154
- Drive Belt Installation
  154
- Late 2004 Driven Clutch Inspection
  166
- Troubleshooting
  171
Table of Contents

173
- Final Drive
  174
- Front Drive Axle Removal
  175
- Front Hub Inspection
  175
- Driveshaft & CV Joint Handling Tips
  176
- Front Drive Axle Installation
  176
- Front Hub Disassembly & Assembly
  178
- U--Joint Assembly
  179
- U-Joint Disassembly
  179
- Front Gearcase Removal/Install
  180
- Early 2004 Front Gearcase Exploded View
  188
- Late 2004 Front Gearcase Information
  189
- Rear Hub Removal
  198
- Rear Hub Installation
  199
- Rear Hub Assembly
  200
- Rear Hub Disassembly
  200
- Rear Driveshaft Removal
  201
- Driveshaft and CV Joint Tips
  202
- Rear Driveshaft Installation
  202
- Rear Driveshaft Service
  203
- Rear Gearcase Removal
  205
- Rear Gearcase Assembly
  206
- Rear Gearcase Disassembly
  206
- Rear Gearcase Installation
  206
- Rear Gearcase Exploded View
  209
Transmission

211
- Transmission, Exploded View
  212
- Gear Shift Selector Removal
  216
- Torque Specifications/Lubrication
  216
- Transmission Removal
  216
- Transmission Installation
  217
- Transmission Disassembly
  218
- Transmission Reassembly
  223
Brakes

229
- 2004 Brake Line Identification
  231
- Brake Noise Troubleshooting
  231
- Brake System Service Notes
  231
- Hydraulic Brake System Overview
  232
- Brake Bleeding / Fluid Change
  233
- Hydraulic Caliper Bleeding
  233
- Master Cylinder Installation
  235
- Master Cylinder Removal
  235
- Front Pad Removal
  236
- Front Pad Installation
  237
- Brake Burnishing
  238
- Front Disc Inspection
  238
- Front Disc Removal/Replacement
  238
- Front Caliper Disassembly
  239
- Front Caliper Removal
  239
- Front Caliper Inspection
  240
- Front Caliper Installation
  241
- Front Caliper Reassembly
  241
- Front Caliper Exploded View
  243
- Rear Pad Removal
  244
- Rear Pad Installation
  245
- Rear Caliper Reassembly
  246
  - Rear Caliper Assembly
    247
- Rear Caliper Removal/Inspection
  246
- Rear Disc Inspection
  248
- Rear Caliper Exploded View
  250
- Troubleshooting
  250
Table of Contents

251
- Timing Check Procedure
  252
- Gear Position Switch Test
  254
- Instrument Cluster Overview
  254
  - Diagnostic Mode
    256
- Speedometer Removal/Installation
  258
- Speedometer Operation Troubleshooting
  260
- Fan Control Switch Tests
  265
  - Coolant Temperature
    265
- Fan Motor Tests
  265
- Flywheel Identification
  267
- Ignition System Testing Flow Chart
  269
- Ignition System Troubleshooting
  270
- Battery Identification
  273
  - Conventional Battery Installation
    274
  - Conventional Battery Testing
    274
  - Battery Check
    276
  - Battery Charging
    277
  - Battery Inspection
    278
  - Battery Testing
    278
  - Battery Installation
    278
  - Bulb Replacement
    280
  - Headlamp Switch
    282
- Fuel Sender Service
  283
- Hand / Thumb Warmer Switches
  283
- Starter System Troubleshooting
  286
  - Starter Motor Removal
    286
- Starter Drive
  290
- Starter System Testing Flow Chart
  292

Polaris Sportsman 700 Owner's Manual (153 pages)

Polaris 2003 ATV Owner's Manual

Brand: Polaris | Category: Offroad Vehicle | Size: 2 MB

Welcome
5
Table of Contents
7
Vehicle Identification Numbers
8
- Age Restrictions
  9
- Operator Safety
  9
- Know Your Vehicle
  9
- Safety Training
  9
Safety
9
- Equipment Modifications
  13
- Safety Decals and Locations
  34
- Safe Riding Gear
  38
Electrical Switches
39
Controls
39
- Throttle Lever
  40
  - Light Switches
    41
  - Brake Lever
    42
  - Important Safeguards
    43
- Setting the Parking Brake
  43
  - Auxiliary Brake
    44
  - Fuel Filter
    45
  - Fuel Tank
    45
  - Fuel Valve
    45
  - Fuel Safety
    46
  - Automatic Transmission Gear Selector
    48
  - Belt Life
    48
- Recoil Starter
  49
- All-Wheel Drive (Awd) System
  50
- Engaging Wheel Hubs
  50
Features
50
- Disengaging Wheel Hubs
  51
- Indicator Lights
  52
- Instrument Cluster
  53
- Rider Information Center
  54
- Diagnostic Mode
  57
- Break-In Period
  58
Operation
58
- Pre-Ride Inspection
  60
- Starting a Cold Engine
  61
- Starting the Engine
  61
- Starting a Warm Engine
  62
  - Hauling Cargo
    63
  - Driving Procedures
    65
  - Driving Safely
    65
  - Making Turns
    66
  - Driving on Slippery Surfaces
    67
  - Driving Uphill
    68
  - Driving Downhill
    70
- Turning Around on a Hill
  71
  - Driving through Water
    72
  - Driving over Obstacles
    73
  - Driving in Reverse
    74
- Parking on an Incline
  75
Noise Emission Control System Regulation
76
- Usfs Approved Spark Arrestor
  76
Maintenance Chart Key
77
Maintenance and Lubrication
77
- Periodic Maintenance Schedule
  77
- Lubrication Recommendations
  82
- Premium 2-Cycle Oil
  87
- Premium Gold Synthetic 2-Cycle Oil
  87
- Premium 4 Synthetic Oil
  88
- Transmission Oil Change - Sportsman
  96
  - Front Gearcase Oil Change
    97
  - Front Gearcase Oil Check
    97
- Rear Gearcase Oil Change
  98
- Rear Gearcase Oil Check
  98
  - Engine Oil Check
    100
  - Coolant Level
    101
  - Engine Cooling System
    101
- Radiator Coolant Level
  102
- Oil Pump Bleeding - 2-Cycle Engines
  103
- Front Brake
  106
- Rear Brake
  107
- Toe Alignment
  108
- Camber and Caster
  109
- Rear Spring
  109
- Steering Assembly
  109
  - Adjusting Carburetor/2-Cycle Engines
    111
  - Adjustments
    111
- Throttle Cable Freeplay
  112
- Side Panel Removal - Gen IV
  113
- Wheel Removal
  114
- Wheel Installation
  115
- Wheel Nut Torque Specifications
  115
- Front Wheel Hub Tightening
  116
- Tire Tread Depth
  116
  - Drive Chain
    117
  - Filter Systems
    120
  - Headlight Lamp Replacement - Scrambler
    122
  - High Beam Adjustment - Scrambler
    122
  - Headlight Adjustment - Trail Blazer
    123
  - Headlight Lamp Replacement - Trail Blazer
    123
  - Headlight Lamp Replacement - Gen IV
    124
  - High Beam Adjustment - Gen IV
    125
  - Headlight Housing Replacement - Gen IV
    126
  - Indicator Lamp Replacement
    127
- Taillight/Brakelight Lamp Replacement
  127
- Spark Plug Removal and Replacement
  128
- Spark Plugs
  128
- Vehicle Immersion
  129
- Spark Arrestor
  130
- Drain Locations
  132
- Recoil Housing
  132
  - High Range
    133
  - Low Range
    133
- Pvt System
  133
- Pvt Drying
  134
  - Battery (Conventional)
    135
  - Battery Removal
    136
  - Battery Charging (Sealed Battery)
    137
  - Battery Installation
    137
  - Battery Storage
    137
  - Cleaning and Storage
    139
  - Cleaning the Atv
    139
- Washing the Atv
  139
- Waxing the Atv
  139
- Fluid Levels
  140
- Storage Tips
  141
- Transporting the Atv
  142
Polaris Recommended Products
143
Troubleshooting
144
- Engine Turns Over, Fails to Start
  145
- Engine Pings or Knocks
  145
- Engine Backfires
  146
- Engine Runs Irregularly, Stalls or Misfires
  146
- Engine Stops or Loses Power
  147
Warranty
148
Engine Oil
150
Index
151

Polaris Sportsman 700 Service Manual (22 pages)

ATV

Brand: Polaris | Category: Offroad Vehicle | Size: 38 MB

Table of Contents
5
Model Identification
6
Serial Number Location
6
Machine Dimensions
8
Chapter 1

11
Chapter 2

11
Chapter 3

11
Chapter 4

11
Chapter 5

11
Chapter 6

11
Final Drive

11
- Publication Numbers
  16
- Paint Codes
  16
- Replacement Keys
  16
- Standard Torque Specifications
  17
- Decimal Equivalents
  18
- Decimal Equivalent Chart
  20
- Sae Tap Drill Sizes
  20
- Glossary of Terms
  21

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User Manuals: Polaris Sportsman 700 ATV

Polaris Sportsman 700 Service Manual (308 pages)

Table of Contents

General Information

Maintenance

Table of Contents

Fuel System/Carburetion

Table of Contents

Clutch

Table of Contents

Transmission

Brakes

Table of Contents

Polaris Sportsman 700 Owner's Manual (153 pages)

Table of Contents

Polaris Sportsman 700 Service Manual (22 pages)

Table of Contents

Chapter 1

Chapter 2

Chapter 3

Chapter 4

Chapter 5

Chapter 6

Final Drive

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