Hey guys, if you're here, chances are you've got a Polaris Sportsman 700 Twin and you're either having some issues or just want to learn more about keeping your ATV running smoothly. Well, you've come to the right place! This guide is packed with info, tips, and tricks to help you diagnose, repair, and maintain your machine. We're going to dive deep, covering everything from common problems to detailed repair steps. Let's get started!

Common Issues and Troubleshooting

Alright, let's talk about the common issues you might run into with your Polaris Sportsman 700 Twin. Knowing what to look out for is half the battle. We'll break down the most frequent problems and how to troubleshoot them. Now, your ATV can experience a variety of issues, from minor hiccups to more serious problems. The good news is, most of these can be fixed with a little know-how and elbow grease.

One of the most frequent complaints is starting problems. If your ATV cranks but doesn’t start, or if it struggles to start, you'll want to check a few things. First, inspect the battery and ensure it’s fully charged and has a good connection. Next, check the spark plugs; worn or fouled spark plugs can prevent the engine from firing correctly. Fuel delivery is another crucial area, so examine the fuel filter and fuel pump. A clogged fuel filter or a failing fuel pump can starve the engine of fuel. Also, remember to check for any vacuum leaks, which can disrupt the air-fuel mixture. And finally, don’t forget to check the choke mechanism, which can be problematic in colder temperatures.

Another very common issue is performance problems. If your Sportsman 700 Twin is losing power, running rough, or experiencing poor acceleration, then something is off. Start by checking the air filter and fuel filter. A dirty air filter will restrict airflow, and a clogged fuel filter will limit fuel delivery. Next, inspect the carburetor. Carburetor problems can range from a simple adjustment to a complete rebuild. Then, examine the ignition system, including the spark plugs, ignition coil, and stator. Also, ensure the exhaust system isn't blocked.

Engine overheating is another issue. Overheating can lead to serious engine damage. First, check the coolant level and ensure the radiator is free of debris. Then, inspect the water pump and thermostat. The water pump circulates the coolant, and the thermostat regulates the engine temperature. If you frequently ride in muddy conditions, you'll want to pay close attention to the cooling system, as mud and debris can easily clog the radiator. Also, make sure the fan is working properly.

Finally, electrical issues are also pretty common. These can range from a dead battery to faulty wiring. Start by checking the battery connections for corrosion. Then, inspect the fuses and relays, and replace any that are blown. Also, examine the wiring harness for any damage or loose connections. If you're dealing with electrical issues, a multimeter can be your best friend.

Engine Repair and Maintenance

Now, let's get into the heart of your ATV: the engine. This section covers everything from basic maintenance to more involved repairs. Keeping your engine in tip-top shape is crucial for both performance and longevity.

Oil Changes

Regular oil changes are the cornerstone of engine maintenance. The frequency of oil changes depends on how you use your ATV, but as a general rule, aim for every 50-100 hours of riding or at least once a year. Make sure you use the right type of oil – check your owner's manual for the recommended viscosity and specifications. The oil filter should be replaced with every oil change. To perform an oil change, start by warming up the engine. This helps the oil flow more easily. Then, locate the oil drain plug, place a drain pan underneath, and remove the plug. Once the oil has drained completely, replace the drain plug and tighten it to the specified torque. Next, remove the oil filter and replace it with a new one. Finally, add the correct amount of new oil, check the oil level with the dipstick, and start the engine. Let the engine run for a few minutes and then check for any leaks.

Spark Plugs

Spark plugs play a vital role in engine performance. Inspect your spark plugs regularly (every 100-200 hours) for wear and tear, and replace them when necessary. The gap between the electrodes should be within the specified range, as indicated in your owner’s manual. When replacing spark plugs, make sure to use the correct type. Refer to your owner’s manual for the correct part number. Use a spark plug socket to remove the old plugs, and install the new ones, tightening them to the recommended torque.

Air Filter

A clean air filter is essential for optimal engine performance. The air filter should be cleaned or replaced regularly. The frequency depends on your riding conditions. In dusty or muddy environments, you will want to clean it more often. To clean the air filter, remove it from the airbox. For foam filters, you can wash them with a filter cleaner and then re-oil them with a filter oil. For paper filters, you can gently tap them to remove dirt or use compressed air. However, don't use compressed air on a foam filter. Be very gentle. When installing a new air filter, make sure it seals properly to prevent any dirt or debris from entering the engine.

Valve Adjustment

Valve adjustment is an important maintenance task that ensures proper engine performance and prevents valve damage. The valves control the flow of air and fuel into and out of the engine. Over time, the valve clearance can change, leading to reduced performance or engine damage. Valve adjustment typically involves measuring the valve clearance and adjusting it to the specified range, as described in your service manual.

Top End Rebuild

A top-end rebuild may be necessary if your engine is experiencing a loss of compression, excessive oil consumption, or other performance issues. This involves removing the cylinder head and cylinder, inspecting the pistons, rings, and valves, and replacing any worn parts. This is a more advanced repair and may require special tools and experience. When performing a top-end rebuild, make sure to follow the torque specifications. Also, pay close attention to the alignment of the parts.

Bottom End Rebuild

A bottom-end rebuild is a more extensive repair that involves removing the engine from the ATV and disassembling it completely. This may be necessary if the crankshaft, connecting rods, or bearings are damaged. This type of repair requires advanced knowledge and tools and is often best left to a professional mechanic unless you have experience.

Fuel System Troubleshooting and Repairs

Let’s dive into the fuel system because, let's face it, without fuel, your ATV isn't going anywhere. This section provides a guide to diagnosing and fixing fuel-related issues.

Carburetor

The carburetor mixes air and fuel to create the mixture that powers the engine. Carburetor problems can often lead to a variety of issues, such as poor starting, rough idling, or a loss of power. If you're experiencing these issues, then start by inspecting the carburetor for any obvious issues. Check the fuel lines for leaks or cracks. Make sure the fuel is flowing freely to the carburetor. You can also clean the carburetor, remove the float bowl, and spray carb cleaner through the jets and passages. If cleaning doesn’t fix the problem, you might need to rebuild the carburetor, replacing worn parts like jets, floats, and gaskets. Carburetor rebuilding can be challenging and requires careful attention to detail.

Fuel Pump

The fuel pump is responsible for delivering fuel from the fuel tank to the carburetor. A failing fuel pump can cause starting issues or a loss of power. To check the fuel pump, you can test its output pressure and flow rate, using a fuel pressure gauge. If the pump is not delivering the correct pressure or flow, you might need to replace it. Be sure to disconnect the battery and work in a well-ventilated area when working with the fuel system, as fuel fumes can be dangerous.

Fuel Tank

The fuel tank stores the fuel for your ATV. Fuel tank problems can include leaks, clogs, or contamination. Inspect the fuel tank for any leaks, cracks, or other damage. Check the fuel tank vent to ensure that it isn't blocked. If you suspect that your fuel tank is contaminated, then you can drain and flush it. Make sure to use the proper fuel storage containers and dispose of used fuel properly.

Fuel Filter

The fuel filter is designed to remove debris from the fuel, protecting the carburetor and fuel pump. A clogged fuel filter can restrict fuel flow and cause performance issues. Locate the fuel filter and inspect it for any signs of clogs or debris. Replace the fuel filter if it is dirty or clogged. It is best to replace the fuel filter every year or so, especially if you ride in dirty or dusty conditions.

Electrical System Diagnostics and Repairs

Let's get into the electrical system of your Polaris Sportsman 700 Twin. This area can seem intimidating, but understanding the basics can help you diagnose and repair many common electrical issues.

Battery

The battery is the heart of your electrical system. It provides the power needed to start the engine and run the various electrical components on your ATV. Make sure the battery terminals are clean and free of corrosion. Check the battery voltage with a multimeter. A fully charged battery should read around 12.6 volts. If the battery voltage is low, then try charging the battery with a battery charger. If the battery won't hold a charge or if it's old, it might be time for a replacement. Always disconnect the negative battery terminal before working on the electrical system.

Charging System

The charging system is responsible for recharging the battery while the engine is running. A faulty charging system can lead to a dead battery. Start by checking the voltage regulator and stator. You can test the voltage regulator using a multimeter. The stator generates the electricity. Then, inspect the wiring harness for any damaged wires or loose connections. If the charging system isn't working properly, then you might need to replace the voltage regulator, stator, or other components.

Ignition System

The ignition system is responsible for generating the spark that ignites the air-fuel mixture in the engine cylinders. Components include the ignition coil, spark plugs, and the electronic control unit (ECU). Check the spark plugs and replace them if they are worn or fouled. Test the ignition coil with a multimeter to ensure it's functioning correctly. Inspect the wiring and connections related to the ignition system for any damage or corrosion. If the engine is misfiring or not starting, the ignition system could be the culprit.

Wiring

Electrical wiring can cause a lot of problems if it's damaged or corroded. Start by inspecting the wiring harness for any signs of damage, such as frayed wires or loose connections. Clean any corroded connections with a wire brush or contact cleaner. Use a multimeter to check for continuity in the wiring. Repair any damaged wires by either replacing the entire wire or using wire connectors and electrical tape. If you’re not comfortable working with wiring, consider seeking help from a professional mechanic.

Fuses and Relays

Fuses and relays protect the electrical components from damage. Check the fuses for any blown ones. Replace any blown fuses with the correct amperage. Inspect the relays for any signs of damage. If any of the relays are faulty, you should replace them.

Suspension and Steering Repairs

Let’s move on to the suspension and steering system. This is crucial for a smooth and safe ride. Let's delve into how to diagnose and repair issues in this area.

Shocks

Shocks absorb bumps and vibrations, providing a comfortable ride and improving handling. Inspect your shocks for any signs of leaks, damage, or wear. If your shocks are leaking oil, then they might need to be replaced. Also, check the shock mounts and bushings for wear and tear. If your shocks are worn, then the ride will be rough, and handling will be reduced. You can often replace the shocks with aftermarket shocks that provide better performance and a smoother ride.

A-Arms and Bushings

A-arms connect the wheels to the frame, and bushings allow the A-arms to move smoothly. Check the A-arms for any signs of damage or bending. Inspect the bushings for wear. Worn bushings can cause excessive play in the suspension and affect handling. If the A-arms are damaged, then replace them. Replace the bushings if they are worn. You can usually replace the bushings without replacing the entire A-arm.

Ball Joints

Ball joints allow the wheels to pivot for steering. Check the ball joints for any play or looseness. If the ball joints are worn, then they can cause excessive wear on the tires and affect handling. To check the ball joints, you can try to move the wheel up and down and side to side. Excessive play indicates worn ball joints. Replace the ball joints if they are worn or damaged.

Tie Rods

Tie rods connect the steering rack to the wheels. They are crucial for steering. Inspect the tie rods for any damage, bending, or looseness. If the tie rods are damaged, then the steering may be affected. Replace the tie rods if they are damaged. Ensure the tie rod ends are lubricated to prevent excessive wear.

Transmission and Drive Train

Now, let's talk about the transmission and drivetrain of your Polaris Sportsman 700 Twin. The drivetrain delivers power from the engine to the wheels, so keeping it in good shape is essential for performance.

Belt

The drive belt is a critical component of the transmission. It transfers power from the engine to the transmission. Inspect the drive belt for wear, cracks, or glazing. A worn or damaged drive belt can cause slippage and loss of power. If the belt is worn or damaged, then replace it. When installing a new belt, make sure that it's the correct type. Refer to your owner's manual for the correct part number. Follow the recommended break-in procedure for your new belt.

Clutch

The clutch engages and disengages the drive belt. Check the clutch components for wear, damage, or contamination. Check the clutch sheaves for wear. Inspect the clutch rollers and weights. Clean the clutch components with a suitable cleaner. Replace the clutch components if they are worn or damaged.

Gearcase

The gearcase houses the gears that transfer power to the wheels. Check the gearcase for leaks or damage. Inspect the gear oil level and add oil if necessary. Replace the gear oil according to the manufacturer's recommendations. Look for metal shavings in the gear oil, which can indicate internal damage.

Axles

Axles transfer power from the gearcase to the wheels. Inspect the axles for any damage or play. Check the axle boots for tears or cracks. Damaged axle boots can allow dirt and water to contaminate the axle joints. Replace the axle boots if they are torn or cracked. If you hear clicking noises while turning, then it can indicate a worn axle joint. Replace the axles if they are worn or damaged.

Final Tips and Prevention

Alright, you've made it this far, so I know you're serious about keeping your Polaris Sportsman 700 Twin running strong. Here are some final tips and preventive measures to help keep your ATV in top condition.

Regular Maintenance

As you have seen, regular maintenance is key. Following the maintenance schedule in your owner's manual is crucial. It covers things like oil changes, spark plug replacements, and air filter cleaning. A little bit of preventative maintenance can save you a lot of headaches and money down the road.

Storage

Proper storage is critical, especially if you won’t be using your ATV for extended periods. When storing your ATV, make sure to stabilize the fuel to prevent it from going bad. Disconnect the battery. Store your ATV in a dry, covered area.

Cleaning

Cleaning your ATV regularly can help prevent the buildup of dirt, mud, and debris, which can damage the components. After each ride, clean your ATV with soap and water. Pay special attention to the areas where dirt and mud accumulate.

Lubrication

Lubricate your ATV regularly, as per the owner's manual. This includes lubricating the suspension components, steering components, and drive components. Lubrication helps to prevent wear and tear.

Safety

Safety always comes first. Wear appropriate safety gear, including a helmet, gloves, and eye protection. Make sure your ATV is in good working condition before each ride. Ride within your skill level, and always be aware of your surroundings.

That's it, folks! I hope this guide helps you keep your Polaris Sportsman 700 Twin running strong for many years to come. Remember, regular maintenance and a little bit of care go a long way. Happy riding!