Hey there, fellow ATV enthusiasts! If you're here, chances are you're wrestling with your i2002 Polaris Sportsman 700 Twin. Don't worry, you're in good company! These machines are legendary for their ruggedness, but even the toughest ATVs need a little TLC from time to time. This guide is designed to be your go-to resource for troubleshooting and repairing your Polaris Sportsman 700 Twin. We'll dive into common issues, provide practical solutions, and get you back on the trails in no time. Whether you're a seasoned mechanic or a weekend warrior, this should help. Let's get started!

Common Issues and Diagnostic Tips for the Polaris Sportsman 700 Twin

Alright, let's talk about the problems that tend to pop up with the Polaris Sportsman 700 Twin. Knowing what to look for is half the battle, right? Here's a rundown of the usual suspects, along with some diagnostic tips to help you pinpoint the issue. Remember, safety first! Always disconnect the battery before performing any repairs, and make sure your ATV is stable.

Starting and Running Problems

One of the most frequent complaints is a reluctant starter or an engine that won't fire up. Let's break down the common causes:

• Dead Battery: This seems obvious, but it's often the culprit! Check the battery voltage with a multimeter. It should be around 12.6 volts when fully charged. If it's low, try charging it or jump-starting the ATV. If it won't hold a charge, you'll need a new battery.
• Faulty Starter Relay: The starter relay is a small electrical switch that sends power to the starter motor. If it's bad, the starter won't engage. You can test the relay by swapping it with a known good one (if you have one) or by using a multimeter to check for continuity.
• Fuel Issues: No fuel, no start! Make sure the fuel tank has gas, and the fuel valve is open. Also, inspect the fuel filter for clogs. A clogged filter can restrict fuel flow, preventing the engine from starting or running smoothly. Next, check the fuel pump. You should be able to hear it running when you turn the key on. If not, check the fuse, wiring, and the pump itself.
• Spark Plug Problems: A fouled or faulty spark plug can prevent the engine from firing. Remove the spark plugs and inspect them. They should be clean and dry. Replace them if they're wet, fouled, or damaged. Also, make sure the spark plug wires are connected securely.
• Ignition System: The ignition coil, stator, and other components in the ignition system can fail. If you suspect an ignition problem, use a spark tester to check for a strong spark at the spark plugs. If there's no spark, you'll need to troubleshoot the ignition system further, which could involve checking the wiring, the ignition coil, and the stator.

Engine Performance Issues

Even when your Polaris Sportsman 700 Twin starts, it might not run as well as it should. Here are some problems that can affect engine performance:

• Carburetor Problems: Carburetors can be finicky. Clogs in the jets, a stuck float, or other issues can affect fuel delivery, leading to poor performance. You may need to clean and adjust the carburetor or rebuild it. This often involves taking it apart, cleaning all the jets and passages with carburetor cleaner, and reassembling it carefully.
• Air Filter Problems: A dirty air filter restricts airflow, which can reduce engine power. Replace the air filter regularly, especially if you ride in dusty conditions.
• Exhaust System Problems: Restrictions in the exhaust system can also reduce engine power. Check for any blockages, such as a clogged spark arrestor or a damaged exhaust pipe.
• Compression Issues: Low compression can indicate worn piston rings, valves, or other internal engine problems. Perform a compression test to check the engine's health. The compression should be within the manufacturer's specified range. If it's low, you may need to rebuild the top end or the engine.
• Belt Problems: The CVT belt can break, or crack over time and usage. Make sure you get a proper replacement belt to avoid further performance issues.

Electrical Problems

Electrical gremlins can cause all sorts of headaches. Here are some common electrical issues:

• Fuses: Always check the fuses first! A blown fuse is a common cause of electrical problems. Replace any blown fuses with the correct amperage.
• Wiring Problems: Check the wiring harness for any damage, such as frayed wires or loose connections. Pay close attention to the connections at the battery, the starter, and the ignition switch.
• Charging System Problems: If the battery isn't charging, the charging system may be at fault. Check the voltage regulator, stator, and wiring.
• Lights and Accessories: Problems with the lights or accessories are usually related to wiring or blown fuses. Inspect the wiring and replace any blown fuses.

Step-by-Step Repair Guides for Your Polaris Sportsman 700 Twin

Okay, now that we've covered the common issues, let's get into some specific repair guides. We'll walk you through the steps to fix some of the most common problems. Remember, if you're not comfortable working on your ATV, it's always a good idea to consult a qualified mechanic.

Battery and Charging System Repair

Troubleshooting the Battery:

1. Check the Voltage: Use a multimeter to measure the battery voltage. It should be around 12.6 volts when fully charged. If it's low (below 12 volts), charge the battery.
2. Load Test: If the battery won't hold a charge, it may be bad. Take the battery to an auto parts store for a load test.
3. Inspect Terminals: Make sure the battery terminals are clean and free of corrosion. Clean them with a wire brush if necessary.

Charging System Diagnosis:

1. Check the Voltage Regulator: The voltage regulator controls the charging voltage. Test it with a multimeter. With the engine running, the voltage across the battery terminals should be between 13.5 and 14.5 volts.
2. Inspect the Stator: The stator generates the electrical current for charging. Check the stator's output voltage with a multimeter. Disconnect the stator from the voltage regulator and measure the AC voltage. The voltage should increase with engine speed.
3. Check Wiring: Inspect all wiring connections in the charging system for damage or corrosion.

Repairing the Charging System:

1. Replace the Voltage Regulator: If the voltage regulator is faulty, replace it.
2. Replace the Stator: If the stator is not generating enough voltage, replace it. This typically requires removing the engine cover to access the stator.
3. Repair Wiring: Repair any damaged wiring or replace any corroded connectors.

Carburetor Cleaning and Adjustment

Tools You'll Need:

• Screwdrivers (Phillips and flathead)
• Wrench set
• Carburetor cleaner
• Compressed air
• Small brushes
• Gloves and eye protection

Procedure:

1. Remove the Carburetor: Disconnect the fuel line, throttle cable, and any other connections. Unscrew the carburetor from the intake manifold and the airbox.
2. Disassemble the Carburetor: Carefully disassemble the carburetor, taking note of the order of the parts. Remove the float bowl, jets, float, needle valve, and other components.
3. Clean the Carburetor: Spray all the carburetor parts with carburetor cleaner. Use compressed air to blow out all the jets, passages, and orifices. Use small brushes to clean stubborn deposits.
4. Inspect and Replace Parts: Inspect the jets, float, and needle valve for damage. Replace any damaged parts. Pay special attention to the condition of the float needle valve as it is a common issue.
5. Reassemble the Carburetor: Reassemble the carburetor, making sure all the parts are in their correct order. Ensure that the float is set to the correct height (consult your service manual).
6. Adjust the Carburetor: Once the carburetor is reassembled, you may need to adjust the idle speed and the air/fuel mixture. Consult your service manual for the correct settings.

Spark Plug Replacement

Tools You'll Need:

• Spark plug socket
• Wrench or ratchet
• New spark plugs

Procedure:

1. Locate the Spark Plugs: The spark plugs are usually located on the cylinder heads. Consult your service manual for their exact location.
2. Remove the Spark Plug Wires: Disconnect the spark plug wires from the spark plugs. It is best to label the wires so you can return them to the correct location.
3. Remove the Spark Plugs: Use a spark plug socket to remove the old spark plugs. Be careful not to cross-thread the spark plugs when removing or installing them.
4. Inspect the Old Spark Plugs: Inspect the old spark plugs for any signs of fouling, damage, or wear. Check the gap of the old spark plugs with a gap tool to compare them to the new ones.
5. Install the New Spark Plugs: Install the new spark plugs, tightening them to the torque specification in your service manual.
6. Reconnect the Spark Plug Wires: Reconnect the spark plug wires to the new spark plugs.

CVT Belt Replacement

Tools You'll Need:

• Wrench or socket set
• Torque wrench
• New CVT belt

Procedure:

1. Access the CVT: The CVT (Continuously Variable Transmission) is usually located under a cover on the side of the ATV. Consult your service manual for access procedures.
2. Remove the CVT Cover: Remove the bolts securing the CVT cover.
3. Remove the Old Belt: Remove the old belt by squeezing the secondary clutch sheaves together to release the belt.
4. Install the New Belt: Install the new belt, ensuring it's properly seated on the primary and secondary clutches. Follow the belt's direction arrow if applicable. A correctly installed CVT belt will rest at the top of the primary clutch sheaves.
5. Reassemble the CVT: Reinstall the CVT cover and tighten the bolts to the torque specification in your service manual. Make sure the belt is aligned properly before closing.

Preventative Maintenance Tips for Your Polaris Sportsman 700 Twin

Preventative maintenance is the key to keeping your Polaris Sportsman 700 Twin running smoothly for years to come. Here are some key maintenance tips:

Regular Oil Changes

Changing the oil and filter regularly is crucial for engine longevity. Follow the manufacturer's recommended oil change intervals, and use the correct type of oil for your ATV. This will remove any built-up dirt and debris.

Air Filter Maintenance

Keep the air filter clean! A dirty air filter can restrict airflow and damage the engine. Clean or replace the air filter regularly, especially if you ride in dusty conditions. Inspect the air filter after every ride.

Check Fluids

Check all fluids regularly, including coolant, brake fluid, and differential fluid. Top them off as needed, and replace them at the recommended intervals.

Inspect the Belt and Clutches

Regularly inspect the CVT belt and clutches for wear and damage. Replace the belt as needed, and clean the clutches to ensure they operate properly. Inspect the belt after every ride.

Grease Fittings

Grease the fittings on the suspension and steering components regularly to prevent wear and corrosion. Use a grease gun to apply grease to the fittings. Consult your service manual for the location of the grease fittings.

General Inspection

• Tires: Ensure the tires have the right air pressure.
• Brakes: Check the brake pads and brake lines.
• Suspension: Inspect the shocks and struts.

Troubleshooting Resources and Where to Find Parts for Your Polaris Sportsman 700 Twin

So, you've got your ATV, and now you want to be able to make some repairs. Here are some of the resources you can use to help you do it.

Service Manuals

A service manual is your best friend when it comes to repairing your ATV. It provides detailed instructions, diagrams, and specifications for your specific model. You can usually find a service manual online or at your local Polaris dealer.

Online Forums and Communities

Online forums and communities are a great resource for getting advice and troubleshooting tips. You can often find answers to your questions and connect with other ATV enthusiasts. Some popular Polaris ATV forums include ATV Connection and Highlifter.

Polaris Dealers and Repair Shops

If you're not comfortable performing a repair yourself, you can take your ATV to a Polaris dealer or a reputable repair shop. They can diagnose the problem and perform the repairs for you.

Parts Suppliers

You'll need parts to repair your ATV. There are several places to buy parts, including:

• Polaris Dealers: They carry genuine Polaris parts.
• Online Parts Suppliers: Websites like eBay, Amazon, and Rocky Mountain ATV/MC offer a wide selection of parts.
• Local Auto Parts Stores: Some auto parts stores carry ATV parts.

Final Thoughts and Next Steps

Alright, guys, you've made it through! Hopefully, this guide has given you a solid foundation for troubleshooting and repairing your i2002 Polaris Sportsman 700 Twin. Remember that the key is to take things one step at a time, be patient, and don't be afraid to ask for help if you need it. By using these guides, you will be able to perform these repairs with ease.

Now, get out there, enjoy the trails, and keep your Polaris running strong! Ride safe!