2004-2005 Polaris Sportsman 6x6 Workshop Service Repair Manu

2004-2005 SPORTSMAN 600/700 SERVICE MANUAL PN 9918803

2004 SPORTSMAN 600/700 SERVICE MANUAL Foreword ThismanualisdesignedprimarilyforusebycertifiedPolarisMasterServiceDealertechniciansinaproperly equipped shop and should be kept available for reference. All references to left and right side of the vehicle are from the operator’s perspective when seated in a normal riding position. Someproceduresoutlinedinthismanualrequireasoundknowledgeofmechanicaltheory,tooluse,andshop proceduresinordertoperformtheworksafelyandcorrectly. Techniciansshouldreadthetextandbefamiliar with service procedures before starting the work. Certain procedures require the use of special tools. Use only the proper tools as specified. Thismanualincludesproceduresformaintenanceoperations,componentidentificationandunitrepair,along withservicespecificationsfor 2004PolarisSportsman600/700ATVs. Commentsorsuggestionsaboutthis manualmaybedirectedto: ServicePublicationsDept.@PolarisSalesInc.2100Hwy55MedinaMinnesota 55340. 2004 Sportsman 600/700 ATV Service Manual (PN 9918803) ECopyright 2003 Polaris Sales Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this publication. Depictions and/or procedures in this publication are intended for reference use only. No liability can be accepted for omissions or inaccuracies. Any reprinting or reuse of the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited. Printed in U.S.A.

UNDERSTANDING SAFETY LABELS AND INSTRUCTIONS Throughout these instructions, important information is brought to your attention by the following symbols: The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOURSAFETY ISINVOLVED! DANGER FailuretofollowDANGERinstructionswillresultinsevereinjuryordeathtotheoperator,bystanderorperson inspecting or servicing the ATV. WARNING Failure to follow WARNING instructions could result in severe injury or death to the operator, bystander or person inspecting or servicing the ATV. CAUTION: A CAUTION indicates special precautions that must be taken to avoid personal injury, or ATV or property damage. NOTE: A NOTE provides key information to clarify instructions. Trademarks Polaris acknowledges the following products mentioned in this manual: FLEXLOC, Registered Trademark of SPS Technologies Loctite, Registered Trademark of the Loctite Corporation STA-BIL, Registered Trademark of Gold Eagle FOX, Registered Trademark of Fox Shox Nyogel, Trademark of Wm. F. Nye Co. Fluke, Registered Trademark of John Fluke Mfg. Co. Mity Vac, Registered Trademark of Neward Enterprises, Inc. Ammco, Registered Trademark of Ammco Tools, Inc. Torx, Registered Trademark of Textron Hilliard, Trademark of the Hilliard Corporation Warn, Trademark of the Warn Industries

GENERAL MAINTENANCE ENGINE CARBURETION CLUTCHING FINAL DRIVE BODY AND STEERING TRANSMISSION BRAKES ELECTRICAL

GENERAL INFORMATION 1.1 Model Identification 1.2 ....................... Serial Number Location 1.2 ................... 2004 Sportsman Models Identification 1.3 ...... 2004 Sportsman Models / Dimensions 1.4--1.5 ...... Specifications - Early 2004 Sportsman 600 1.6 .. Specifications - Late 2004 Sportsman 600 1.7 .. Specifications - Early 2004 Sportsman 700 1.8 .. Specifications - Late 2004 Sportsman 700 1.9 ... Publication Numbers 1.10 ..................... Paint Codes 1.10 ............................. Replacement Keys 1.10 ....................... Standard Torque Specifications 1.11 ............ Conversion Table 1.12 ........................ Tap Drill Charts 1.13 .......................... Decimal Equivalent Chart 1.13 ................. Glossary of Terms 1.14 ........................ Specs

GENERAL INFORMATION 1.2 MODEL IDENTIFICA TION The machine model number must be used with any correspondence regarding warranty or service. Machine Model Number Identification YearDesignation Basic Chassis Designation Engine Designation A 04 CH 68 AA Emissions & Model Option ENGINE DESIGNATION NUMBERS EH068OLE Twin cylinder, Liquid Cooled, 4 Stroke, Electric Start ................. EH059OLE Twin cylinder, Liquid Cooled, 4 Stroke, Electric Start ................. VIN IDENTIFICA TION 1 2 3 4 5 6 7 8 9 10 1 1 12 13 14 15 16 17 4XACH68A*4P000000 Vehicle Description Vehicle Identifier Powertrain Engine Emissions Model Year Plant No. Individual Serial No. Body Style Check Digit World Mfg. ID * This could be either a number or a letter ENGINE SERIAL NUMBER LOCA TION Besuretorefertotheenginemodelnumberandserialnumber whenever corresponding about an engine. This information can be found on the sticker applied to the top side of the crankcase(A). Anadditionalnumberisstampedonthesideof the crankcase beneath the cylinder coolant elbow. MACHINE MODEL NUMBER AND SERIAL NUMBER LOCA TION The machine model number and serial number are importantforvehicleidentification. Themachineserial number is stamped on the lower left side of the frame tube.(B) TRANSMISSION I.D. NUMBER LOCA TION A B Front The transmission I.D. number is located on the right side of machine.

GENERAL INFORMATION 1.3 Mid--year changes were made to the 2004 Sportsman 600 & 700 models. When servicing your 2004 Sportsman it is important to identify which model you are working on. Throughout this service manual the different procedures (titles) are identified as “EARLY 2004” or “LATE 2004”, use the correct procedure according to the model you are working on. If the procedure (title) does not specify a “EARLY 2004 ” or “LATE 2004 ”, then the procedure pertains to both models. To identify which model Sportsman you have, refer to the identification illustration below. Late 2004 Early 2004 INSTRUMENT CLUSTER Fuel Level Indicator 2004 SPORTSMAN MODEL IDENTIFICATION -- EARLY/LATE MODELS Early 2004 Late 2004 Fill Plug in Rear of Case Fill Plug on Right Side of Case

GENERAL INFORMATION 1.4 MODEL: 2004 EARLY/LATE SPORTSMAN 600 .......... MODEL NUMBER: A04CH59 . ENGINE MODEL: EH059OLE .. Category Dimension / Capacity Length 81 in./205.7 cm Width 46 in./116.8 cm Height 47 in./119.38 cm Wheel Base 50.75 in./128.9 cm Dry Weight 740 lbs./335.6 kg Gross Vehicle Weight 1240 lbs. / 562.45 kg Front Rack Capacity 100 lbs./45.4 kg Rear Rack Capacity 200 lbs./90.8 kg Towing Capacity 1500 lbs./681 kg Hitch Tongue Capacity 150 lbs./68 kg Body Style Gen VI MODEL: 2004 EARLY/LATE SPORTSMAN 700 .......... MODEL NUMBER: A04CH68 . ENGINE MODEL: EH068OLE .. Category Dimension / Capacity Length 81 in./205.7 cm Width 46 in./116.8 cm Height 47 in./119.4 cm Wheel Base 50.75 in./128.9 cm Dry Weight 740 lbs./335.6 kg Gross Vehicle Weight 1240 lbs. / 562.45 kg Front Rack Capacity 100 lbs./45.4 kg Rear Rack Capacity 200 lbs./90.7 kg Towing Capacity 1500 lbs./454 kg Hitch Tongue Capacity 150 lbs./68 kg Body Style Gen VI

GENERAL INFORMATION 1.5 MODEL: LATE 2004 SPORTSMAN 600 HUNTER EDITION .......... MODEL NUMBER: A04CH59 . ENGINE MODEL: EH059LE .. Category Dimension / Capacity Length 81 in./205.7 cm Width 46 in./116.8 cm Height 47 in./119.38 cm Wheel Base 50.75 in./128.9 cm Dry Weight 782 lbs./355 kg Gross Vehicle Weight 1240 lbs. / 562.45 kg Front Rack Capacity 100 lbs./45.4 kg Rear Rack Capacity 200 lbs./90.8 kg TowingCapacity 1500 lbs./681 kg Hitch Tongue Capacity 150 lbs./68 kg Body Style Gen VI Warn Winch Standard Hand/Thumb Warmer Standard MODEL: LATE 2004 SPORTSMAN 700 HUNTER EDITION .......... MODEL NUMBER: A04CH68 . ENGINE MODEL: EH068OLE .. Category Dimension / Capacity Length 81 in./205.7 cm Width 46 in./116.8 cm Height 47 in./119.4 cm Wheel Base 50.75 in./128.9 cm Dry Weight 740 lbs./335.6 kg Gross Vehicle Weight 1240 lbs. / 562.45 kg Front Rack Capacity 100 lbs./45.4 kg Rear Rack Capacity 200 lbs./90.7 kg TowingCapacity 1500 lbs./454 kg Hitch Tongue Capacity 150 lbs./68 kg Body Style Gen VI Warn Winch Standard Hand/Thumb Warmer Standard

GENERAL INFORMATION 1.6 MODEL: EARLY 2004 SPORTSMAN 600 .......... MODEL NUMBER: A04CH59 . ENGINE MODEL: EH059OLE .. Engine Platform Polaris Twin Cylinder Engine Model Number EH0590PLE024 Engine Displacement 597cc Number of Cylinders 2 Bore & Stroke (mm) 76.5 x 65 mm Compression Ratio 9.35:1 Compression Pressure 150--170psi Engine Idle Speed 1100 ± 50 Rpm Engine Max Operating Rpm 6500 Rpm ± 200 Rpm Cooling System / Capacity Liquid -- 3.2 qt / 3 ltr Overheat Warning HOT on Instrument Cluster Lubrication Pressurized Wet Sump Oil Requirements / Capacity Polaris 0W--40 2 qt. / 1.9 ltr Exhaust System Single Pipe Carburetion Carburetor model Mikuni BST 34mm Main Jet 155 Pilot Jet 45 Pilot Air Jet 160 Jet Needle -- Clip Position J8--4FA01--3 Needle Jet P--4 Pilot Screw Initial Setting 21/2 Turns Out (Set at factory, non--adjustable) Float Height 13 -- 14 mm / 0.51 -- 0.55 in Fuel Delivery Fuel Pump Fuel Capacity / Requirement 4.25galUS/16L 87 Octane (minimum) 89 Oxygenated Electrical Alternator Output 330 w @ 3000 RPM Voltage Regulator 3--Phase-- LR--390 Lights : Pod 50 watts Grill Two x 27 watts Brake 8.26 watts Tail 26.9 watts Ignition System CDI Ignition Operating RPM 6000 RPM Ignition Timing 13° BTDC @ 1200 RPM± 250 Spark plug / Gap RC7YC/ .035 in./ 0.9 mm Battery / Model / Amp Hr YuasaYB30L--B 30AmpHr Circuit Breakers Fan 10 amp / Harness 20 amp Starting Electric Instrument Cluster LCD Drivetrain Transmission Type Drumshift -- H/L/N/Rev/Park Transmission Capacity 13.5 oz. / 400ml Rear Gearcase Capacity 5 oz. / 150ml Front Gearcase Capacity 5 oz. / 150ml Gear Ratio : Low Rev High Front Drive Rear Drive 7.5:1 5.11:1 3.09:1 3.82:1 3.10:1 Clutch Type PVT w/EBS Belt 3211091 Steering / Suspension Front Suspension / Shock A--arm / MacPherson Strut Front Travel 6.7 in. / 17.02 cm Rear Suspension / Shock Progressive Rate Independent /Two x 2” Coil--over Shock Rear Travel 9.5 in. / 24.13 cm Ground Clearance 11.25 in. / 28.6 cm Shock Preload Adjustment Front / Rear Front --Non Adjustable. Rear -- RatchetStyle-- Std. Turning Radius 71.5 in. / 181.6 cm unloaded Toe Out 0 -- 1/16 in / .0 -- .159 mm Wheels / Brakes Wheel Size / Pattern -- Front Steel25x8--12/4--156 Wheel Size / Pattern -- Rear Steel25x11--12/4--156 Front Tire Size 25x8--12 Rear Tire Size 25x11--12 Recommended Air Pressure F/R 5 psi Front 5 psi Rear Brake -- Front Dual Hydraulic Disc Brake -- Rear Dual Hydraulic Disc JETTING CHART Altitude Meters (Feet) AMBIENT TEMPERATURE 0--1800 (0--6000) above 1800 (above 6000) Below 40°F Below 5°C Above +40°F Above +5°C 162.5 155 150 145 CLUTCH CHART EBS Models have no helix/spring adjustment Altitude Meters (Feet) 0--1800 (0--6000) 1800--3700 (6000--12000) Shift Drive Spring Driven Helix Weight 10--MH 10--WH 41--37 Blu/Grn Blu/Grn Driven Spring Wht/ Yel Wht/ Yel 41--37 (7041157) (7041157) (7041635) (5132751) (5630513) (5630710) (7041635) (5132751)

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2004-2005 Polaris Sportsman 6x6 Workshop Service Repair Manu

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