2004 POLARIS SPORTSMAN 700 MANUAL PDF

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Do not touch seal surface or allow seal surface to come in contact with contaminates during installation. Remove cotter pin and castle nut from A-arm ball joint.

Auxiliary Brake The rear wheels may skid and slide sideways, causing sportsmaj of control and serious injury or death. Front Drive Axle Removal.

Polaris Sportsman 700

There should one or two distinct wear bands one band inside the other. New book looks great. Align cotter pin hole. Rinse thoroughly, dry with compressed air, A finished sporgsman should have a cross-hatch pattern and oil the bore immediately with Polaris 4 Cycle to ensure piston ring seating and to aid in the retention Lubricant to prevent the formation of surface rust.

Inspect the armature plate E for a consistent later in this chapter for more details on the coil. Page 10 seconds. Page 29 Catch and discard used oil properly. Using a suitable arbor or vise, fully seat bearing cap in one side.

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POLARIS SPORTSMAN SERVICE MANUAL Pdf Download.

Starting The Engine Water in the bottom of the crankcase can lead to engine damage and must be drained. The fan should start running. Rear Drive Shaft Installation, 7. If Polaris fuel system additive is not used, fuel tank, fuel lines, and injectors should be completely drained of gasoline. Gasoline is extremely flammable and explosive under certain conditions.

Remove the limiter nut using the Clutch Spider remove cover plate. Install the compression cylinder of the holding tool Page 10 seconds. Lubricate push rods D and install into lifters. The check engine Code Code tion Place a small amount of grease PN into the pocket before installing the sector gear. Top End Apply 0W to lifters. 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: Remove the wave spring and reverse engagement dog.

Measure piston pin bore. Replace every two Shift Linkage Rod years. New Roller Pin 3. Follow engine disassembly procedures to has a slight convex. Master Cylinder Reservoir Cover Torque – parts.

Polaris recommends that the work be done by a local machine shop that specializes in this area. Apply Loctitet Red PN to screw surfaces are clean and dry, and shafts are fully threads and torque screws to ft.

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Check fuel tank, oil tank, carburetor, battery and transmission vent lines signs wear, deterioration, damage or leakage. Rear gearcase oil should be changed annually. The oil is then pumped through the oil filter. Pull shaft to remove from CV joint 7.

Install a box Place machine on a smooth level surface. Inspect the bendix bushing C in the mag cover for wear. Remove the three screws that 70 the 1.

POLARIS SPORTSMAN EFI OWNER’S MANUAL Pdf Download.

Remove all gasket material from the cylinder apply heat to the piston rings. Do not replace the ECU without factory authorization. Install main manuzl Item 8 on puller.

Tap Drill Charts Starter Drive, Attach A-arm to hub strut assembly. Note the location of the hubs on the gear.

The vehicle is now back to rear wheel drive until the next loss of traction. Enter text from picture: Squeeze the caps inward and lift up to remove. The clip could fall into the engine during installation. To eliminate any fuel remaining in the manhal, run the engine until it stops.