2003 Polaris Sportsman 700 Twin

[CuriousG]

Wondering if anyone happens to know where I can download the service manual for this beast? I just bought one today here in Costa Rica and the speedo doesn't work but the rest of the gauges do. Is it true that the 4x4 wont engage without the speedo working?

Also this is my fourth quad however I've always had Yamaha's in the past and to be honest when I first started this thing up it sure sounds rough. It is EFI right? I recall seeing a V-twin one time and it sounded rough also because of the basically two motors running in unison which sounds a little rougher than say a 660 Grizzly or 450 Kodiak.

Anyways, those are my ???'s and hopefully I can meet some fellow SP owners to exchange ideas and advice.

[jack whelen]

Ihad the same problem with my 03 600 I replaced my wheel sensor and worked fine hope that helps...

[CuriousG]

Thanks for the tip I will keep that in mind however it turns out I have another problem after taking the quad for a short ride I discovered that the cooling fan is not engaging and the machine is overheating. Have to fix that first before moving on to the other issues.

Any tips on problems with fans on the Sportsman?

[Ken]

Yup.

There's a few reasons.

1) The sensor isn't working

2) You have a short

3) The battery isn't charging...a low battery will not turn on the fan

[CuriousG]

And would a low battery affect my speedo also? If so then this might be the majority of problems right there?

[Ken]

Low battery would cause your POD to go whacky...you'll see strange characters....jibberish.

[CuriousG]

Nope no jibberish. I will be looking at it today with a mechanic friend of mine. Albeit he works on cars I think together we should be able to figure out the fan problem at least. Thanks for the help.

[CuriousG]

I just know that me and this forum are going to have a lasting relationship. What a resource for me while I'm in the middle of the Costa Rican jungle with my Polaris and not many options like you have back in NA.

[Ken]

No worries. Glad to help out. I had same issue plaguing me for a long time. Found out it was a short charging the battery. The low battery, would cause it to overheat.

That's amazing you are in costa rica. At first I thought the Nigerian scammers had migrated to CR! Then you posted a real question.

[Ken]

Btw

Here's a list of all the things that need to be working for the fan.

Wiring- no shorts
Temp sensor
The speed POD (it's the brains of the quad)
A rusted fuse relating to fan or pod
The fan is functional

At idol, the fan will pop on pretty quickly. No more than 10 min, usually 5-8. It doesn't take much to get all that aluminum hot. It's amazing how effective and nessesary that fan is to the cooling.

[CuriousG]

Better believe it. Yeah, I am still waiting for my buddy to show up before getting to it. One thing I dont know much about is the POD. Why would Polaris make it so that if anything happens to that thing then things like the 4X4 wont work and crap like that. Kind of a poor engineering effort there dont you agree? All your eggs in one POD per se! lol

Do you happen to have a service manual for this thing? Could be tough troubleshooting without it but I'm sure we may have to make due.

[MrBill]

I have a complete service manual for this rig.
Send me your email address and the section you need. I will scan the pages and email the to you. all 262 pages will not email well..

[Ken]

The computer has to be somewhere I guess.

Search this forum(Polaris ). A few manuals have been posted. Just not sure what year.

[jack whelen]

My polaris 500 temp sensor went out once @radiator .bypass the sensor to see if fan comes on . I replaced my sensor and was good to go...

[GrizzlyGuy]

You can buy a service manual for the 2004 model here:

http://www.repairmanual.com/motorcycles/2004/54/0/15219