2002-05 Polaris Sportsman 600/700 overview and issues they have.

[@Caseusfette]

When I got my 2004 700 I replaced all of these things right away, also had to do all the CV driveshafts and the Gear select lever and an ignition coil. It runs great now!

[@slowhand1000ca]

me too, everything was worn beyond

[@cartonvera]

I bought one that needed belt. Replace intake booth and belt now it shakes so bad, i cleaned carb to. Yes i still have the ducati coil should i replace? It was running fine months ago before i got to turn it back on

[@sheagraham116]

You think this 600 engine is a pretty solid engine long term? I just picked one up for really really cheap. Should be a fun project but just wanted to know your opinion on the actually 600 engine reliability before I put some money into the Polaris 600 twin project. (Mines an 04 with only 800 original miles)

[@shanekerry9530]

Maybe some rubber motor mounts it reminds me of the Liberty Twin 900 Fuzion Polaris. Shake the holy hell outta the rig….. changed Mounts and it made HUGE DIFFERENCE

[@aaron2k2]

Thank god for these videos 😮😊

[@jimryan8102]

Hi I have a hopeless 2004 700 that was beaten its whole life replaced bearing u joints whole shafts once I saw the extent of the ware if I grab the inner axle shafts there is play like a wobble I already have my suspicions but I figured I would put it out there with hopes that someone will tell me it's not the diffs that's right both Tha ks

[@maxwell6504]

i had one with low miles that i got cheap and it was BEAT. it was never once maintained. all drive shaft joints were junk, cracked exhaust manifold y pipe, oil seal leaking oil into the coolant, air filter was all chewed up and was all metal, had no filter material left, carb boot and car boots were junk, all bushings were gone, low power, sticky brakes, rad completely clogged up, small crack in frame, missing bolts everywhere, looked like the front end was once on fire and so was the wiring, oil was complete junk, faded plastics, etc. never ever seen one so beat.

[@TheTechGuider]

just picked up a 600 project. does 700 cranks fit in the 600s

[@TitaniummanGarage]

Yes. They are pretty identical .

[@SamDemontigny]

Where do I find where the transmission to fill

[@rbljackson]

thanks for this. Ive got an 2004 Polaris 600 Sportsman. wanted to add a receiver hitch and do some food plot work with one. Two issues...i need a replacement gas tank, and the upper bushing on the steering hub must be shot because the handlebars have too much slop in them. How hard would these be to change out? How would this unit do for pulling a small cultivator? Any chance you got an extra gas tank for one? the threads on the cap on mine are cracked. My guess is previous owner set a heavy gas can on it in cold weather while filling it and cracked the cap threads. The cap still goes on, but it leaks gas if anywhere near full, or on a hill, etc.

[@TitaniummanGarage]

I think it would do fine. it has the power. They are great for plowing snow too. The top bushing isnt bad. But you have to take the headlight pod off and front hood. 2 bolts and nuts hold handlebar bushing on with a u bracket. Its easier with the tank off. I have several tanks. I'm not positive If I have one for a 600. I'll look. where are you located?

[@rbljackson]

@@TitaniummanGarage im in Snyder Texas, 79549

[@riverfallscory]

Will you do those prop shafts or just the u joints/bearings?

[@lookoutmountaingarockhunte1300]

Thank you!!

[@riverfallscory]

I’ve got an 05 700 twin efi. There’s two lines leading to the rear brake caliper. I know the one goes to the rear master cylinder, where does the other one go?

[@cem7936]

One for foot (spare) one for hand break (main)

[@coreytarducci36]

Nice video. Did you get new rear hubs or used ones

[@TitaniummanGarage]

I had some already. they were used.

[@heavenlysheephugshuggingfo1505]

Correct me if I'm wrong but can't some of those why pipes be tagged or soldered are plasma welded or just take that one towards saying that melts metal onto their

[@TitaniummanGarage]

The one I had was welded. It warped. didnt seal correctly.

[@Hammerback0]

I sprayed my carb boot and it died, ordered a new carb boot, put it on, sprayed it and it died (again) is it common for the Chinesium boots to be warped or could the head be warped?

[@TitaniummanGarage]

On a 6/700? That I can't answer. I haven't bought a china boot for that model. Maybe try black rtv on the base of the boot and see if it stops.

[@heavenlysheephugshuggingfo1505]

How much did that all cost to fix yourself

[@TitaniummanGarage]

I had all the parts except the intake boot from another machine. otherwise it would have cost 200 bucks maybe.

[@aldobeltran3898]

I have a 04 Polaris 700 sportsman twin when I turn the machine on, the manifold exhaust gets really hot and glowing red. The fan is working correctly, does not show over heating light and the air filter is new. It used to idle at 1500 rpms now it idles at 2000 or more while the choke is in regular position. Any help works thank you

[@carter.coleman]

Mine used to do that and it would burn up exhaust gaskets, I got a full big gun exhaust and it doesn't glow red anymore

[@sammacin4082]

Replace your intake carb boot

[@Aa-sy9qw]

lol bro i want one of those..

[@GearHardoffRoad]

What a arm bushing are you using on these sportsman the cheap ebay amaizons aint doing it!!

[@TitaniummanGarage]

Try Partzilla

[@andrewinsinga2993]

Would you say the 500ho of the same year has less issues 🤔

[@TitaniummanGarage]

Less depending on how well maintained it was.

[@GaryToland]

Just bought one like that one tonight. $800 because he thought it is seized up.

[@GaryToland]

Are there any rebuild kits for the 600? I'm having a hard time finding anything.

[@TitaniummanGarage]

6 and 700's are the same. The connecting rod is a different length. pistons, head and gaskets are the same.

[@GaryToland]

@@TitaniummanGarage thanks

[@grandcrappy]

TiGeorge For '24.

[@TitaniummanGarage]

Vote for me. Everyone gets a 4 wheeler. Haha.

[@2StrokeSmoke544]

I have an 03’ sportsman 700 with new intake boots and manifold. Rebuilt the carb and took it back out 3 times to recheck it to make sure its cleaned good and it is.. i just looked again and i dont see a 300$ kit that includes the stator.. i have the rm stator kit that allows it to run off the other side of the stator or whatever. So this idles good but wont rev out.. sounds like it runs on 1 cylinder when ya throttle it.. also new plugs, wires.. kill switch is new. Checked grounds. Wish i could send this to ya to work on.. im very mechanically inclined but this has me stumped. Also a new voltage regulator.. im lost ha

[@Caseusfette]

I had this issue and it made me pull my hair out until I realised that one side of my ignition coil was only working intermittently. so i was effectively running on 1 cylinder.. I don't know if your RM kit came with a new coil but i would double check that both sides are firing.

[@Caseusfette]

i ended up not using the coil from the RM kit and purchased one from Polaris, solved my problem.

[@2StrokeSmoke544]

Well looks like an intermittent spark but hard to check by myself. I went and bought a stator although its not a polaris part being thats around 700$. We will see. So close to just selling this machine, what a shame the line of issues this has given me..

[@TitaniummanGarage]

@@2StrokeSmoke544 It's unfortunate all the issues these have. When they run good they are a lot of fun. That $300 buck price I said was from years ago. Prices probably went up. I haven't had the pleasure of dealing with any stator or coil issues yet. Out of the 5 I've owned and sold the only one was the stator I had to replace because the wires on the back of the stator burned. I bought a used Polaris stator for 90 bucks and that did the trick.

[@2StrokeSmoke544]

Well the stator wasnt my problem.. i can only guess.. maybe a bad vacuum line? Or the camshaft is smoked.. still idles great and will not rev out. Falls on its face, backfires out the carb and sounds like it runs on one cylinder. Thanks for the help tho it was definitely worth a shot!

[@donhuffenberger9471]

How much is the rear diff

[@TitaniummanGarage]

They are pricey if you go on ebay. 3 to 500.