2004 Polaris Sportsman 600 700 Twin ATV Service Manual

Description

This Official 2004 Polaris Sportsman 600 / 700cc Twin Utility ATV Service Manual provides detailed service information, step-by-step repair instruction and maintenance specifications for both early and late 2004 models of Sportsman 700 Twin and Sportsman 600 Twin Cylinder ATVs.

Covers model year 2004 Sportsman 600, 2004.5 Sportsman 600 , 2004 Sportsman 700, and 2004.5 Sportsman 700

This manual is the same publication used by your local Polaris service department.

Table of Contents
General Information

Introduction
Model Identification
Safety Information
Specifications
Maintenance

Maintenance Schedule
Lubrication
Fluids and Lubricants
Engine

Engine Removal and Installation
Cylinder Head and Cylinder
Piston and Crankshaft
Engine Reassembly
Fuel System

Fuel Pump
Carburetor
Fuel Tank
Cooling System

Radiator
Coolant Replacement
Electrical System

Battery
Charging System
Ignition System
Electrical Components
Transmission

Transmission Removal
Gearbox Disassembly and Reassembly
Drive System

Drive Belt
Drive Chain
Differential
Suspension

Front Suspension
Rear Suspension
Shock Absorbers
Steering and Frame

Steering Components
Frame and Subframe
Brakes

Brake System Overview
Brake Pad Replacement
Brake Bleeding
Wheels and Tires

Wheel Removal
Tire Replacement
Body and Seat

Body Panels
Seat Removal and Installation
Troubleshooting

Diagnostic Procedures
Common Issues and Solutions
Appendix

Torque Specifications
Wiring Diagrams
Special Tools