Polaris Sportsman 600 / 700 ATV 2004 Service & Repair Manual (P/N 9918540, 9918724)

• Covers early and late 2004 Polaris Sportsman 600 and 700 ATV models, including standard and Hunter Edition variants
• Contains 56 exploded-view diagrams, 16 maintenance/torque tables, and 2 detailed jetting charts
• This 304-page manual (P/N 9918540 and 9918724) serves as the primary technical reference for the 2004 production cycle, detailing the specific differences between early- and late-build engines, clutches, and cooling systems
• Delivers detailed PDF troubleshooting guides, complete wiring diagrams, and essential repair procedures for the independent mechanic
• Highlights the Mikuni BST 34mm carburetor, Engine Braking System (EBS), Centralized Hilliard front gearcase, Warn winch, and MacPherson struts

What the Manual Documents

This service publication provides detailed technical information for maintenance and engine overhauls on both the 597cc and 683cc liquid-cooled powerplants. Chapters are structured logically by mechanical system. The manual starts with general identification and serial number locations, then moves into extensive sections on the drivetrain, transmission, and brakes. Having these factory specifications on the bench significantly reduces diagnostic bay time and prevents parts mismatches during the mid-year production changes.

Instead of subletting expensive jobs to the dealership, DIYers and independent shops can utilize the step-by-step instructions to perform complete CV joint boot replacements, water pump mechanical seal installations, and valve seat reconditioning. To further streamline these procedures, the document features a coolant flow diagram, an ignition system testing flow chart, a starter system testing flow chart, clutch charts, and tap drill charts. You will find documentation on critical PVT system procedures, such as drying and drain plug management. The text also covers exhaust pipe carbon purging and cooling system pressure testing. As a full factory workshop manual, it outlines engine top-end disassembly, cylinder head inspection, valve train reassembly, and replacement protocols for the crankshaft gear and oil pump.

When working on the 2004 platform, technicians must carefully navigate specific diagnostic pitfalls. For instance, Polaris transitioned from Ducati to Kokusan DC/CDI ignition systems on February 20, 2003, making flywheel and electrical component identification critical to resolving no-spark conditions. Furthermore, when servicing the EBS driven clutch, the unit must be disassembled exclusively from the helix end; attempting to remove the outer snap ring first will permanently destroy the internal one-way clutch seals. Please note that all technical data provided here serves strictly as a reference point; professional mechanics relying on OEM documentation should always be the final authority for safe vehicle service.

Specification Highlights

Engine displacement stands at 597cc for the 600 model and 683cc for the 700. Transmission fluid capacity ranges from 13.5 to 15.2 oz., heavily dependent on whether you are working on an early or late build. Ground clearance for these units is 11.25 inches.

Inside the engine service section, crankcase drain plug torque is specified at 20 to 22 ft. lbs. The cooling system holds exactly 3.2 quarts (3 liters). When handling the cylinder head, bolt torque follows a strict multi-stage sequence. This process finishes with a 90-degree turn after the initial tightening pass.