POLARIS SPORTSMAN ATV 600 and 700 FULL SERVICE REPAIR MANUAL

700 EFI FEATURES




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* Powerful liquid-cooled, electronic fuel-injected, twin-cylinder Polaris Liberty 700 engine
* Selectable 2WD/AWD with on-demand AWD
* IRS w/ 9.5"/24.1 cm of wheel travel & 11.25"/28.6 cm of ground clearance
* Towing capability: 1500 lb./680.4 kg
* 300 lb./136.1 kg rack capacity (100 lb./45.4 kg front, 200 lb./90.7 kg rear)
* Industry-leading Polaris Variable Transmission
* Integrated front storage compartment
* Tough composite body components
* Long-Travel MacPherson front suspension
* PXT radial tires
* Receiver hitch
* Rear toolbox
* Lock & Ride accessory compatible
* Colors: Red/Black, Black/Silver, Green/Black

This is the COMPLETE official full factory service repair manual for the POLARIS SPORTSMAN ATV 600 and 700. Production model years 2007 BUT SHOULD COVER OTHERS AS WELL. HUNDREDS of pages allow you to print it out in its entirety or just the pages you need!!

These manuals are your number one source for repair and service information. They are specifically written for the do-it-yourselfer as well as the experienced mechanic. Using this repair manual is an inexpensive way to keep your equipment working properly. Each manual provides step-by-step instructions based on the complete disassembly of the machine. It is this level of detail, along with hundreds of photos and illustrations, that guide the reader through each service and repair procedure.

* Detailed substeps expand on repair procedure information
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Numbered instructions guide you through every repair procedure step by step.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
* Numbered table of contents easy to use so that you can find the information you need fast.
* This manual also makes it easy to diagnose and repair problems with your machines electrical system. Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.

Complete download comes in pdf format which can work under all PC based windows operating system and Mac also. It saves to your hard-drive and can be burned to CD-ROM. All pages are printable. No need to pay for shipping and wait for the overpriced paper textbook or CD-ROM to arrive via snail mail.

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RELATED ATV SERVICE MANUAL SEARCHES:

FRAME/BODY PANELS/EXHAUST SYSTEM TROUBLESHOOTING

Excessive exhaust noise

* Deformed exhaust system
* Exhaust gas leaks

Poor performance

* Clogged muffler
* Broken exhaust system
* Exhaust gas leaks

LUBRICATION SYSTEM TROUBLESHOOTING

Oil level too low - high oil consumption

* Oil consumption
* External oil leak
* Worn piston rings or incorrect piston ring installation
* Worn cylinder
* Worn valve guide or stem seals
* Oil pump worn or damaged

Oil contamination

* Oil or filter not changed often enough
* Worn piston rings or incorrect piston ring installation
* Worn valve guide or stem seals

FUEL SYSTEM TROUBLESHOOTING

Engine cranks but wont start

* No fuel in tank
* No fuel to carburetor
* Clogged fuel strainer
* Clogged fuel line
* Clogged fuel tank breather tube
* Misadjusted fuel level
* Too much fuel getting to the engine
* Clogged air cleaner
* Flooded carburetor
* Intake air leak
* Contaminated/deteriorated fuel
* Clogged jets
* Clogged starting enrichment valve circuit
* Improper starting enrichment valve operation
* Improper throttle operation
* No spark at plug (faulty ignition system)

Lean mixture

* Clogged fuel jets
* Faulty float valve
* Float level too low
* Restricted fuel line
* Clogged carburetor air vent tube
* Restricted fuel tank breather tube
* Intake air leak
* Faulty vacuum piston
* Faulty throttle valve

Rich mixture

* Starting enrichment valve open (ON)
* Clogged air jets
* Faulty float valve
* Float level too high
* Dirty air cleaner
* Worn jet needle or needle jet
* Faulty vacuum piston

Engine stalls, hard to start, rough idling

* Restricted fuel line
* Fuel mixture too lean/rich
* Contaminated/deteriorated fuel
* Clogged jets
* Intake air leak
* Misadjusted idle speed
* Misadjusted pilot screw
* Misadjusted float level
* Restricted fuel tank breather tube
* Clogged air cleaner
* Clogged slow circuit
* Clogged starting enrichment valve circuit
* Faulty ignition system

Afterburn when engine braking is used

* Leanmixture in slow circuit
* Faulty air cut-off valve
* Faulty ignition system

Backfiring or misfiring during acceleration

* Leanmixture
* Faulty ignition system

Poor performance (driveability) and poor fuel economy

* Clogged fuel system
* Faulty ignition system

CYLINDER HEAD/VALVE TROUBLESHOOTING

Engine top-end problems usually affect engine performance. These can be diagnosed by a compression test, or by tracing top-end noise with a sounding rod or stethoscope. If the performance is poor at low speeds, check for a white smoke in the crankcase breather tube. If the tube is smoky, check for seized piston ring

Compression too low, hard starting or poor performance at low speed

Valves

Incorrect valve adjustment
Burned or bent valves
Incorrect valve timing
Broken valve spring
Uneven valve seating
Valve stuck open

Cylinder head

Leaking or damaged cylinder head gasket
Warped or cracked cylinder head
Loose spark plug

Compression too high

Excessive carbon build-up on piston head or
combustion chamber
Worn or damaged decompressor system

Excessive smoke

Worn valve stem or valve guide
Damaged stemseal
Cylinder/piston problem

Excessive noise

Incorrect valve clearance
Sticking valve or broken valve spring
Excessive worn valve seat
Worn or damaged camshaft
Worn rocker arm and/or shaft
Worn rocker arm follower or valve stem end
Worn or damaged push rod and/or cam follower
Worn cam chain
Worn or damaged cam chain tensioner
Worn cam sprocket teeth
Cylinder/piston problem

Rough idle

Low cylinder compression

CYLINDER/PISTON TROUBLESHOOTING

Compression too low, hard starting or poor performance at low speed

* Leaking cylinder head gasket
* Worn, stuck or broken piston ring
* Worn or damaged cylinder and piston
* Bent connecting rod

Compression too high, overheating or knocking

* Excessive carbon built-up on piston head or combustion chamber

Excessive smoke

* Worn cylinder, piston or piston rings
* Improper installation of piston rings
* Scored or scratched piston or cylinder wall

Abnormal noise

* Worn piston pin or piston pin hole
* Worn connecting rod small end
* Worn cylinder, piston or piston rings

CLUTCH/GEARSHIFT LINKAGE TROUBLESHOOTING

Clutch slips when accelerating

* Incorrect clutch adjustment
* Worn clutch discs
* Weak clutch springs
* Faulty clutch lifter
* Improper oil viscosity or oil additive used

Clutch will not disengage

* Faulty clutch lifter
* Warped clutch plates

The vehicle creeps

* Faulty centrifugal clutch

Clutch operating feels rough

* Worn clutch outer and center grooves
* Warped clutch plates
* Loose clutch lock nut
* Faulty clutch lifter
* Improper oil viscosity or oil level

Hard to shift

* Incorrect clutch adjustment
* Worn or damaged gearshift cam and stopper arm
* Faulty clutch lifter
* Improper engine oil viscosity
* Bent fork shaft and gearshift spindle or damaged shift forks and shift drum

Transmission jumps out of gear

* Broken shift drum stopper arm
* Weak or broken shift linkage return springs
* Worn or damaged gearshift cam
* Bent fork shaft or worn shift forks and shift drum
* Worn gear dogs or slots

ALTERNATOR/STARTER CLUTCH TROUBLESHOOTING

Starter motor turns, but engine does not turn

* Faulty starter clutch
* Damaged starter reduction gear

CRANKCASE/TRANSMISSION/CRANKSHAFT TROUBLESHOOTING

Excessive engine noise

* Worn, seized or chipped transmission gears
* Worn transmission bearings
* Worn or damaged connecting rod bearing
* Worn crankshaftmain journal bearing
* Worn connecting rod small end
* Worn balancer bearing
* Improper balancer installation

Transmission jumps out of gear

* Worn gear dogs or dog holes
* Worn shift drum guide groove
* Worn shift fork guide pin
* Worn gear shifter groove
* Worn shift fork
* Bent shift fork shaft

Hard to shift

* Damaged shift fork
* Bent shift fork shaft
* Damaged shift fork guide pin
* Damaged shift drum guide groove

Abnormal vibration

* Improper balancer timing

FRONT WHEEL/SUSPENSION/STEERING TROUBLESHOOTING

Hard steering

* Steering shaft holder too tight
* Damaged steering shaft bearing/bushing
* Insufficient tire pressure

Steers one side or does not track straight

* Incorrect wheel alignment
* Unequal tire pressure
* Bent tie-rod, suspension arm or frame
* Worn or damaged knuckle bearing or brake drum bearing
* Weak shock absorber

Front wheel wobbling

* Bent rim
* Worn or damaged knuckle bearing or brake drum bearing
* Faulty tire
* Axle nut not tightened properly

Soft suspension

* Weak shock absorber spring
* Faulty shock absorber damper

Hard suspension

* Bent shock absorber damper rod
* Improperly installed suspension arms
* Faulty suspension arm bushings

Front suspension noise

* Loose front suspension fasteners
* Damaged suspension components

REAR WHEEL/SUSPENSION TROUBLESHOOTING

Rear wheel wobbling

* Bent rim
* Worn or damaged rear axle bearings
* Faulty rear tire
* Axle fastener not tightened properly
* Faulty swingarm pivot bearings

Rear wheel turns hard

* Faulty rear axle bearings
* Bent rear axle
* Rear brake drag

Soft suspension

* Weak shock absorber spring
* Oil leakage fromdamper unit

Hard suspension

* Damaged rear suspension pivot bearing or bushing
* Damaged swingarm pivot bearing
* Improperly tightened swingarm pivot

Rear suspension noise

* Faulty rear shock absorber
* Loose rear suspension fasteners
* Worn rear suspension pivot bearing or bushing

BRAKE SYSTEM TROUBLE SHOOTING

Front wheel wobbling and noise

* Worn brake shoes

Poor brake performance

* Brake not adjusted properly
* Worn brake shoes and drum
* Water in brake drum
* Contaminated brake shoes and drum
* Air in hydraulic system
* Leaking hydraulic system
* Clogged/restricted fluid passage
* Incorrectly installed rear brake arm
* Worn rear brake cam

FRONT DRIVING MECHANISM TROUBLE SHOOTING

Consistent noise during cruising

* Oil level too low
* Foreignmatter contaminating gear oil
* Worn or damaged bearing
* Worn or damaged ring gear and pinion gear
* Deformed ring gear or differential case
* Improper tooth contact between ring gear and pinion gear

Gear noises while running

* Oil level too low
* Foreignmatter contaminating gear oil
* Chipped or damaged gears
* Improper tooth contact between ring gear and pinion gear

Gear noises while coasting

* Damage or chipped gears

Abnormal noises when turning

* Worn or damaged ring gear bearing
* Worn or damaged face cam and cam follower
* Worn or damaged differential housing groove
* Worn cone spring or shim

Abnormal noises at start or during acceleration

* Excessive backlash between ring gear and pinion gear
* Worn differential splines
* Loose fasteners
* Worn cone spring or shim

Oil leak

* Oil level too high
* Clogged breather
* Damaged seals
* Loose case cover bolt

Over heating

* Oil level too low
* Insufficient backlash between ring gear and pinion gear

REAR DRIVING MECHANISM TROUBLE SHOOTING

Excessive noise

* Worn or scored ring gear shaft and axle
* Worn or scored pinion and splines
* Worn pinion and ring gears
* Excessive backlash between pinion and ring gears
* Oil level too low

Wobble or vibration in vehicle

* Axle not tightened properly
* Bent axle

Oil leak

* Oil level too high
* Clogged breather
* Damaged seals
* Loose case cover bolt