Polaris 700 Sportsman: Troubleshooting & Repair Guide

Hey guys, if you're here, chances are you're either a proud owner of a Polaris 700 Twin Sportsman or you're considering becoming one. Either way, welcome! This guide is designed to be your go-to resource for everything related to the Polaris 700 Sportsman repair, troubleshooting, and general maintenance. We'll dive deep into common issues, how to diagnose them, and, most importantly, how to get your ATV back in tip-top shape. This guide will specifically focus on the i2005 Polaris 700 Twin Sportsman, but much of the information here is applicable to other years and models as well. So, grab your tools, and let's get started!

Understanding Your Polaris 700 Sportsman

Before we jump into the nitty-gritty of Polaris 700 Sportsman repair, let's take a moment to appreciate what makes this ATV a classic. The Polaris 700 Twin Sportsman is known for its robust performance, powerful engine, and go-anywhere capabilities. The 700cc twin-cylinder engine provides plenty of power for both work and play, making it a favorite among riders of all skill levels. The Sportsman series is famous for its independent rear suspension (IRS), which provides a smooth ride over rough terrain, enhancing comfort and handling. The i2005 model, in particular, has several features that set it apart. The fuel injection system ensures optimal performance and fuel efficiency, while the automatic transmission makes it easy to operate, even for beginners. Understanding the basic components and how they work together is the first step in successful troubleshooting. Familiarize yourself with the engine, transmission, suspension, and electrical systems. Knowing where things are located and what they do will save you time and headaches down the road. Regular maintenance, such as oil changes, filter replacements, and spark plug checks, is crucial for keeping your ATV running smoothly. By taking care of your Polaris 700 Sportsman, you can ensure it provides years of reliable service and enjoyment.

Key Components and Systems

Let's break down the main components of your Polaris 700 Twin Sportsman. The engine is the heart of your ATV, and the 700cc twin-cylinder engine is a powerhouse. The fuel injection system ensures the engine gets the precise amount of fuel it needs for optimal performance. The transmission is an automatic PVT (Polaris Variable Transmission), which uses a belt-driven system to transfer power to the wheels. The suspension system, as mentioned earlier, is an independent rear suspension (IRS), which provides a smooth ride over bumpy terrain. The electrical system includes the battery, starter, charging system, and various sensors and switches. The cooling system is also essential, keeping the engine from overheating. Make sure you understand how each component functions and interacts with each other. This knowledge is important when it comes to troubleshooting any issues that may arise. For example, if your ATV won't start, the problem could be with the battery, starter, or fuel system. Likewise, if your engine is overheating, the issue could be with the cooling system.

Common Issues and Troubleshooting

Alright, let's get down to business. Every ATV, including the Polaris 700 Sportsman, can experience problems from time to time. Here, we'll cover some of the most common issues you might encounter and provide you with troubleshooting tips to get you back on the trail ASAP. Remember, safety first! Always disconnect the negative battery cable before performing any repairs.

Engine Starting Problems

One of the most frustrating problems is when your ATV won't start. Here's a breakdown of possible causes and how to troubleshoot them:

Dead Battery: Check the battery voltage with a multimeter. If it's below 12 volts, it's likely dead and needs charging or replacing.
Faulty Starter: Listen for a clicking sound when you turn the key. If you hear it, the starter might be bad. Check the starter relay and fuses.
Fuel System Issues: Check for fuel by smelling the exhaust. If it smells like gas, then the problem is probably not fuel. However, if there is no fuel smell, check the fuel pump, fuel filter, and fuel injectors.
Spark Plug Problems: Remove the spark plug and check for spark. If there is no spark, replace the spark plug or check the ignition system.

Engine Performance Problems

Does your engine feel sluggish or run rough? Here's what to check:

Dirty Fuel Injectors: Over time, fuel injectors can become clogged. Use a fuel injector cleaner or have them professionally cleaned.
Air Filter Problems: A clogged air filter restricts airflow, reducing performance. Replace or clean the air filter regularly.
Compression Issues: Low compression can cause poor engine performance. Perform a compression test to check the engine's health.
Fuel Pump Issues: Check for proper fuel flow to the engine. A weak fuel pump can cause issues like hesitation and poor acceleration.

Electrical System Issues

Electrical problems can be tricky, but here are some troubleshooting tips:

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Check Fuses: Blown fuses are a common cause of electrical problems. Check all fuses and replace any that are blown.
Wiring Problems: Look for damaged or corroded wires. Repair or replace any damaged wiring.
Sensor Failures: Sensors such as the crank position sensor (CPS) can fail, causing the engine to run poorly or not at all. Test or replace the suspect sensors.

Detailed Repair Procedures

Now, let's get into some specific repair procedures you can do at home. Remember to consult your service manual for detailed instructions and torque specifications. It's the bible when it comes to your Polaris 700 Sportsman repair.

Replacing the Spark Plugs

Safety First: Disconnect the negative battery cable.
Locate the Spark Plugs: They are usually located under the seat or in an easily accessible area on the engine.
Remove the Spark Plug Wires: Carefully disconnect the spark plug wires from the spark plugs.
Remove the Spark Plugs: Use a spark plug socket to remove the old spark plugs.
Inspect the Old Spark Plugs: Look for wear, fouling, or damage.
Install New Spark Plugs: Install the new spark plugs, tightening them to the manufacturer's specifications.
Reconnect the Spark Plug Wires: Reconnect the spark plug wires.
Reconnect the Battery: Reconnect the negative battery cable.

Cleaning or Replacing the Air Filter

Locate the Airbox: The airbox is usually located under the seat or in an easily accessible area.
Remove the Air Filter Cover: Remove the cover to access the air filter.
Remove the Air Filter: Carefully remove the air filter.
Inspect the Air Filter: If it's dirty, you can try cleaning it (foam filters) or replace it (paper filters).
Clean or Replace: Clean the foam filter with a special air filter cleaner and oil it, or replace the paper filter.
Install the Air Filter: Reinstall the clean or new air filter.
Replace the Air Filter Cover: Replace the cover.

Checking and Replacing the Oil

Warm Up the Engine: Run the engine for a few minutes to warm up the oil.
Locate the Drain Plug: The drain plug is usually located on the bottom of the engine.
Place a Drain Pan: Place a drain pan under the drain plug.
Remove the Drain Plug: Remove the drain plug to drain the oil.
Locate the Oil Filter: The oil filter is usually located near the engine.
Remove the Oil Filter: Remove the oil filter.
Install the New Oil Filter: Install the new oil filter.
Replace the Drain Plug: Replace the drain plug, tightening it to the manufacturer's specifications.
Locate the Oil Fill Cap: It's usually located on the engine or crankcase.
Add New Oil: Add the correct amount of oil, as specified in your service manual.
Check the Oil Level: Use the dipstick to check the oil level.

Preventive Maintenance

Preventive maintenance is key to keeping your Polaris 700 Sportsman in top condition and preventing costly repairs. Here are some essential maintenance tasks:

Regular Oil Changes

Frequency: Change the oil and filter every 50-100 hours of use, or as recommended in your service manual.
Why: Clean oil lubricates the engine, reduces friction, and extends engine life.

Air Filter Maintenance

Frequency: Clean or replace the air filter regularly, especially if you ride in dusty conditions.
Why: A clean air filter ensures proper airflow to the engine, improving performance and preventing engine damage.

Spark Plug Inspection

Frequency: Inspect the spark plugs regularly (every 100-200 hours) and replace them as needed.
Why: Properly functioning spark plugs ensure efficient combustion and optimal engine performance.

Tire and Wheel Inspection

Frequency: Check tire pressure before each ride and inspect tires for damage or wear.
Why: Proper tire pressure and tire condition improve handling, ride comfort, and safety.

Checking the Coolant

Frequency: Check the coolant level and condition regularly (every 50-100 hours) and change it as recommended.
Why: Proper coolant levels and condition prevent overheating and engine damage.

Resources and Further Help

Service Manuals

The most important resource for any Polaris 700 Sportsman repair is the service manual. It provides detailed diagrams, specifications, and repair procedures. You can find service manuals online or at your local Polaris dealer.

Online Forums and Communities

Online forums and communities are a great resource for getting advice, troubleshooting problems, and sharing experiences. Here are a few popular forums:

Polaris ATV Forums: These forums have active members who can assist with any type of repair.
ATV Connection: Another great place to find troubleshooting and repair guides.

Local Mechanics

If you're not comfortable performing the repairs yourself, don't hesitate to take your ATV to a qualified mechanic. Make sure to find a mechanic with experience working on Polaris ATVs.

Conclusion

So, there you have it, a comprehensive guide to Polaris 700 Sportsman repair, troubleshooting, and maintenance. By following these tips and procedures, you can keep your ATV running smoothly for years to come. Remember, regular maintenance is the key to preventing major problems. Don't be afraid to get your hands dirty and learn about your machine. Happy riding, and stay safe out there! We hope this guide helps you enjoy your Polaris 700 Sportsman for many years to come! Now go out there and have some fun!