This service repair workshop manual covers the 2004 Sportsman 600 and 700 models, high-performance All-Terrain Vehicles renowned for their powerful liquid-cooled V-twin engines and True On-Demand All-Wheel Drive systems. Engineered for robust performance and durability, these ATVs are designed for recreational riders, hunters, farmers, and utility users tackling challenging terrain. Key features include independent front and rear suspension for superior comfort and ground clearance, heavy-duty racks for substantial cargo hauling, and a towing capacity of approximately 1,500 lbs, making them versatile for both work and play. The 600 model boasts a 597cc engine, while the 700 features a 699cc engine, both delivering significant low-end torque for demanding tasks. This comprehensive manual provides detailed procedures for complete repair, maintenance, rebuilding, and restoration of your 2004 Sportsman. It encompasses all major systems, including in-depth coverage of the engine, transmission, drivetrain, suspension, brakes, and electrical systems. You will find systematic troubleshooting guides, diagnostics, precise specifications, torque values, and essential wiring diagrams. The manual is structured to assist owners, mechanics, and technicians in performing routine maintenance, addressing known issues, and executing complex repairs, ensuring the longevity and optimal performance of your vehicle. 🏷️ 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...