🏷️ Basic Information Identification Make: Polaris Model: Sportsman 600/700 Year: 2004 Product Type: Service Repair Workshop Manual Codes Model Codes: Likely includes A04CHxxxx variations for 600 Twin and A04CNxxxx variations for 700 Twin, specific codes depend on sub-model/trim 👋 Introduction Market Position Category: High-performance All-Terrain Vehicle (ATV) Target Audience: Recreational riders, hunters, farmers, and utility users seeking a robust and capable ATV. Competitive Analysis Competitors: Other premium ATVs from brands like Can-Am, Yamaha, Arctic Cat, and Kawasaki during the mid-2000s era. Key Features Powertrain: Powerful liquid-cooled V-twin engines (600cc and 700cc variants) offering strong torque and horsepower. Drivetrain: True On-Demand All-Wheel Drive (AWD) system for superior traction in challenging conditions. Suspension: Independent front and rear suspension providing excellent ride comfort and ground clearance. Utility: Heavy-duty racks for cargo hauling, robust chassis for demanding work and recreational use. 📋 Manual Details Coverage Areas Primary Coverage: Complete repair, maintenance, rebuilding, and restoration procedures for 2004 Polaris Sportsman 600 and 700 models. Secondary Coverage: Troubleshooting, diagnostics, specifications, torque values, wiring diagrams, component identification, and adjustments. Page Count Estimated Pages: Likely in the range of 300-600 pages, typical for a comprehensive service manual. Manual Type Type: Service Repair Manual / Workshop Manual Language Language: English Format Format: PDF (Digital Download) 📖 Manual Coverage Systems Covered Engine: Detailed coverage of the Polaris Twin cylinders, including disassembly, inspection, assembly, timing, cooling system (liquid-cooled), lubrication system, and fuel delivery. Transmission: Coverage of the automatic PVT (Polaris Variable Transmission) system, including belt inspection and replacement, clutch service, and gearbox maintenance. Drivetrain: Comprehensive information on the AWD (All-Wheel Drive) system, front differential, rear differential, drive shafts, CV joints, and wheel hubs. Suspension: Front and rear suspension systems, including independent suspension components, shock absorbers, springs, bushings, and alignment procedures. Brakes: Hydraulic braking system, including front and rear brake calipers, master cylinder, brake lines, brake pads, rotor maintenance, and bleeding procedures. Electrical: Complete electrical system coverage, including battery, charging system (stator, rectifier/regulator), ignition system, lighting, starter motor, and wiring diagrams. Fuel System: Carburetor (likely Mikuni BST series for 600, potentially Keihin for 700) or fuel injection system, fuel pump, fuel filter, and fuel tank service. Cooling System: Radiator, fan, coolant, water pump, and related hoses and thermostat service. Frame And Body: Chassis components, front and rear racks, fenders, seat, handlebars, and body panel removal/installation. Procedures Included Routine Maintenance: Oil changes, filter replacements, spark plug service, air filter cleaning/replacement, battery checks, brake fluid checks, coolant flushes, and drive belt inspection. Troubleshooting: Systematic diagnostic procedures for common and uncommon issues, symptom-based troubleshooting guides. Engine Repair: Top-end rebuilds (cylinder head, piston), bottom-end rebuilds (crankshaft, connecting rods), valve adjustments, carburetor/fuel injection tuning. Transmission Overhaul: PVT belt replacement, clutch inspection and service, gearbox lubrication and seals. Electrical Diagnostics: Component testing (stator, CDI, etc.), troubleshooting wiring harness issues, starter system repair. Brake System Repair: Caliper rebuild, master cylinder replacement, brake line bleeding, pad and rotor replacement. Suspension Rebuild: Shock absorber replacement, bushing replacement, wheel bearing service. Bodywork Repair: Panel removal and installation, rack repair, seat mounting. Torque Specifications: Precise torque values for all critical fasteners and components. Technical Depth Depth: Comprehensive. Covers basic maintenance to complete engine and transmission overhauls, detailed electrical troubleshooting, and chassis component repairs. Diagnostic Tools: Information on using standard automotive tools and potential specialized diagnostic procedures relevant to the vehicle's systems. 📊 Manual Specifications File Format Format: PDF Searchability: Typically searchable text within PDF for quick information retrieval. Print Quality Quality: High resolution, suitable for printing individual pages or the entire manual. Binding Type Binding: Not applicable (digital download). Paper Type Paper Type: Not applicable (digital download). ⚙️ Engine Specifications Primary Engine Type: Liquid-cooled, 4-stroke, SOHC, V-twin Displacement 600: 597cc Displacement 700: 699cc Performance Horsepower 600: Estimated 45-50 HP (advertised figures may vary) Horsepower 700: Estimated 50-55 HP (advertised figures may vary) Torque: Significant low-end torque suitable for towing and climbing. Fuel System Fuel Delivery 600: Likely Twin Mikuni BST40 carburetors Fuel Delivery 700: Likely Twin Keihin carburetors (specific model may vary) Ignition Type: Electronic Ignition (CDI) Lubrication Type: Wet sump lubrication system Cooling Type: Liquid Cooling with fan assist 🔧 Transmission Standard Type: Automatic Polaris Variable Transmission (PVT) with engine braking Optional Gears: Forward, Neutral, Reverse Features Drive Modes: 2WD/AWD On-Demand system 📐 Dimensions Exterior Length: Approx. 83 inches (210.8 cm) Width: Approx. 46 inches (116.8 cm) Height: Approx. 45 inches (114.3 cm) Wheelbase: Approx. 50.5 inches (128.3 cm) Ground Clearance: Approx. 10.5 inches (26.7 cm) Cargo Front Rack Capacity: Approx. 100 lbs (45.4 kg) Rear Rack Capacity: Approx. 200 lbs (90.7 kg) Weights Dry Weight: Approx. 600-650 lbs (272-295 kg) depending on model Towing Towing Capacity: Approx. 1,500 lbs (680 kg) Hitch Type: Standard 1.25-inch receiver hitch 🛡️ Safety Features Ratings Crash Tests: Not typically rated by NHTSA or IIHS; safety relies on design and operator care. Active Features Braking System:...