Polaris Sportsman 600/700 ATV 2004 Service & Repair Manual (P/N 9918803)

The 2004 Polaris Sportsman 600/700 Service Manual (P/N 9918803) covers maintenance, troubleshooting, and workshop repair for early and late models, including Hunter Edition variants.

Searchable Workshop Text and Wiring Appendix

Search and navigation: Workshop text is searchable, with PDF bookmarks for chapters, individual procedures, wiring diagrams, and the index. Wiring-image labels are not searchable, and small circuit labels require enlargement. The file begins with the contents; the original cover and introductory pages are absent, and their bookmarks have no usable destination.

One printable English PDF contains 304 pages, including a seven-page wiring appendix, six index pages, and three notes pages.

Engine, EBS Clutch, and AWD Repair Coverage

The following are selected topics from the manual. Additional reference material includes tap drill charts and exhaust pipe carbon-purging instructions.

• Engine overhaul: Top-end disassembly, cylinder head inspection, valve train reassembly, crankcase inspection, crankshaft gear replacement, and oil pump service.
• Fuel and cooling: Mikuni carburetor overhaul, float and inlet-needle checks, fuel pump testing, coolant circulation, and cooling-system pressure testing.
• PVT and EBS: Belt inspection, clutch alignment, driven-clutch service, bushing inspection, clutch charts, and PVT drying and drain-plug procedures.
• Drivetrain: CV joint boot replacement, universal-joint service, Centralized Hilliard front gearcase repair, rear gearcase overhaul, and transmission disassembly.
• Chassis and brakes: MacPherson strut service, steering and suspension inspection, hydraulic brake diagnosis, caliper rebuilding, and pad and disc replacement.
• Electrical diagnosis: Instrument-cluster diagnostics, ignition and charging tests, starter overhaul, fuel-sender testing, and variant-specific wiring diagrams with wire termination tables.

The material suits experienced ATV technicians and independent workshops equipped for mechanical measurement and electrical testing. The manual specifically reserves PVT service for a certified Polaris Master Service Dealer technician trained in the procedures and equipped with the required tools.

Early and Late Component Identification

Identification illustrations distinguish early and late configurations through features such as the instrument display and transmission fill-plug arrangement. Matching these details to the vehicle helps select the applicable service section before choosing component references or diagnostic procedures.

Separate early and late coverage addresses driven clutches and front gearcases. Transmission material includes exploded views, shift-selector service, gears, shift forks, bearings, and chain inspection.

Engine Rebuilding and Water Pump Seal Work

Step-by-step coverage includes cylinder head disassembly, valve seat reconditioning, water pump mechanical seal installation, and crankcase assembly. Tool listings identify equipment for valve work, seal installation, camshaft alignment, and oil-system priming.

Cylinder head instructions include hydraulic lifter inspection, rocker and pushrod checks, and staged bolt tightening. The cylinder section distinguishes deglazing from damage that requires cylinder replacement; valve seat work includes a recommendation for specialist machine-shop assistance.

The water pump section explains the shaft-damage risk associated with removing the mechanical seal while its housing remains attached. Oil pump replacement and crankshaft gear work receive separate procedures.

Mikuni Carburetion and Coolant Circulation

The Mikuni BST 34 mm carburetor section explains circuit operation alongside overhaul, needle-and-seat leakage testing, float adjustment, and vacuum-operated fuel pump service. Jetting charts relate settings to temperature and altitude.

A coolant flow diagram accompanies cooling-system inspection, pressure testing, thermostat checks, and pump service. These sections connect system operation with the checks used to investigate fuel-delivery and cooling faults.

EBS Clutches, Hilliard AWD, and Hydraulic Brakes

Driven-clutch procedures distinguish early and late assemblies and explain the risk of damaging one-way clutch seals through disassembly from the wrong end. Clutch charts and alignment information accompany belt and bushing inspection.

Centralized Hilliard AWD troubleshooting separates electrical checks from internal gearcase inspection. Step-by-step CV joint boot replacement and driveshaft service complement this coverage.

Brake instructions distinguish the hand-operated and auxiliary circuits, with bleeding, caliper rebuilding, and disc inspection. The master cylinder is treated as a replacement assembly rather than an internally rebuildable component.

Ignition Identification and Hunter Edition Equipment

Electrical identification distinguishes Ducati systems used before February 20, 2003, from Kokusan systems used from that date. Flywheel illustrations and component identification address ignition parts that are not interchangeable.

The Ignition System Testing Flow Chart, Charging System Testing Flow Chart, and Starter System Testing Flow Chart organize fault checks. Instrument-cluster diagnostics and fuel-gauge wiring supplement these procedures. Hunter Edition material covers Warn winch operation and wiring, plus hand and thumb warmer switches.

Selected Oil-Pressure and Carburetor Specifications

The engine section gives a standard oil pressure of 39 psi and a minimum of 35 psi at 5,500 rpm, with the engine at operating temperature and Polaris 0W-40 synthetic oil.

For the Mikuni carburetor, specified float height is 13–14 mm. The illustrated measurement references the float-bowl mating surface and the step on the float, with the inlet-needle spring uncompressed; both sides of the float are checked for alignment.