Locked2002 Polaris Sportsman 700 fluid capacities?

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SouthernSuzuki
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2011/01/10 21:37:32 (permalink)

2002 Polaris Sportsman 700 fluid capacities?

I just got this 02 Sportsman 700 and wanna go over it and service it. I've searched around and haven't had very good luck on finding the oil capacities for this model. Maybe someone on here has a service manual. Is the oil capacity two quarts like on the new ones and can I use a cheap thick oil thats not Polaris? What kind of oil and how much does the Front Diff hold? Can i used some cheap gear oil for the rear diff and how much does it hold? What is the transmission oil capacity? Also what type of spark plugs should I put in it?
 
thanks for any input

2012 Sunset Red Polaris Sportsman 850 EPS,
3" CATVOS with 2.5" Rake,
Cobra Axles,
27" Itp XTR's,
6000K HID's, 
Big Gun Slip on,
Uni Air Filter,
Soon to have much bigger tires 

       
 
#1

11 Replies Related Threads

    Po_700_Po
    Mud Master
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    Re:2002 Polaris Sportsman 700 fluid capacities? 2011/01/11 00:30:20 (permalink)
    Use this manual.....
    http://www.megaupload.com/?d=Y1A3JT0Z
     
    Oil capacity 2 qts use 0w40 synthetic.
    Front diff 5 oz MUST use Polaris demand drive fluid.
    Rear diff 5 oz use 85w90 synthetic recommended.
    Trans 13.5 oz Use Polaris fluid.

    04.5 SP 700 Twin
    27" Bi/Tri's on black SS 212's 
    '06 800 primary clutch with stock 700 spring
    Team rapid reaction roller secondary clutch with 800 spring and helix
    Heelclicker weights set 5.5/5.5/0.0
    #2
    Razrback
    Trail Rider
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    Re:2002 Polaris Sportsman 700 fluid capacities? 2011/01/11 01:20:03 (permalink)
    +1
     
    Front: Demand Drive
    Engine: Either 2 qts of PS4 or a good synthetic 0w40, might need a tad more to top it off.
    Trans: 1 qt AGL
    Rear: Angle Drive or 85w90
     
    In the diffs and trans, just fill them till you get to the bottom of the fill plug.

    2006 Sportsman 450
    27" Vampires on ITP steel wheels

    HD front springs
    3 Headlight Mod
    55w driving lights
    Front brushguard
    Rear metal flat rack/basket
    Home made Fuel Can racks

    #3
    SouthernSuzuki
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    Re:2002 Polaris Sportsman 700 fluid capacities? 2011/01/11 10:17:59 (permalink)
    Do I have to use synthetic oil? Because theres no telling what kind of oil has been ran in it. So I can use just some 85w-90 gear oil for the rear.
     
    thanks for the replys 

    2012 Sunset Red Polaris Sportsman 850 EPS,
    3" CATVOS with 2.5" Rake,
    Cobra Axles,
    27" Itp XTR's,
    6000K HID's, 
    Big Gun Slip on,
    Uni Air Filter,
    Soon to have much bigger tires 

           
     
    #4
    SouthernSuzuki
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    Re:2002 Polaris Sportsman 700 fluid capacities? 2011/01/11 10:22:13 (permalink)
    Also where is the cheapest place to get Tie Rod ends, u-joints, and bearings and stuff like that for this bike at?

    2012 Sunset Red Polaris Sportsman 850 EPS,
    3" CATVOS with 2.5" Rake,
    Cobra Axles,
    27" Itp XTR's,
    6000K HID's, 
    Big Gun Slip on,
    Uni Air Filter,
    Soon to have much bigger tires 

           
     
    #5
    Razrback
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    Re:2002 Polaris Sportsman 700 fluid capacities? 2011/01/11 13:38:14 (permalink)
    U-joints and bearings can be picked up at napa, or other auto parts stores. Somebody on ebay is selling full bearing sets really cheap, but I doubt they're very good quality. As far as tie rod ends, I can't help you there. I haven't had to replace mine.
     
    These machines were intended to be run with synthetic, so even if you don't use popo fluids, I'd say to at least use something that's as close as possible to it.
    post edited by Razrback - 2011/01/11 13:40:46

    2006 Sportsman 450
    27" Vampires on ITP steel wheels

    HD front springs
    3 Headlight Mod
    55w driving lights
    Front brushguard
    Rear metal flat rack/basket
    Home made Fuel Can racks

    #6
    Po_700_Po
    Mud Master
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    Re:2002 Polaris Sportsman 700 fluid capacities? 2011/01/11 20:43:25 (permalink)


    Wheel Bearings
    Sp700 Rear wheel bearings Federal-Mogul Bearings 510013 
    Sp700 Front wheel bearings BCA 510014 
    Rear - Napa # FW143 
    Polaris front strut Bearings replaced by: John Deer JD8935 About $5.00 each 
    Polaris front wheel hillard hub bearings replaced by: John Deer JD8933 about $5.00 
    SP500 with the hubs that lock. Front wheel bearings that go inside hub - Timken L44649 & L44643  
      
    Oil Filters
    Sp400&500 Oil Filter STP SMO17 
    sp600 or sp700 oil filter Super Tech ST7317 at Wallmart 
    Wix filter – 51357 
    K&N- 196 
    Amsoil- # EaOM103 (chrome filter is EaOM103C) 
    Fram oil filter for single cylinder is PH6017A  

    Air Filter: 
    K&N- 1003 
    Precharger- 1003PK 

    Front Diff
    2 Federal Mogul 108 (output bearing) 
    2 CR# 15801 (output seals) 
    1 Federal Mogul 306 (input bearing) 
    1 Federal Mogul 9748 (input seal) 
    1 CR Speedi-Sleeve 99098 (for input shaft seal) 
    1 NTA 815 (needle bearing) 
    Chicago Rawhide oil seal that works for the (output seal) on front diff. CR# 15801(SP700) 
    Chicago Rawhide Front axle seal- 692461 @ $4.53 and Front shaft- 692321 @ $ 4.04 

    Rear Diff: 
    2) Bearings - 6010-2RSC3 SRI-2 The brand is KYK 
    1) Bearing - 6306-2RSC3 SRI-2 The brand is KYK 
    2) Seals - Polaris PN 3233878 
    1) Seal - Polaris PN 3233785 
    1) Bushing - Polaris PN 3233577 
    Chicago Rawhide Rear axle seal- 19630 @ $7.14  

    John Deere front diff replacement parts: 
    JD part # Roller Kit #MIA 10666 
    Cage Kit #MIA 10667 
    Seal Kit #MIA 10654 

    U-joints
    NAPA u-joint(338) works on the inner joint of front stock c.v. axle. (SP700) 
    U-joint for 2002 700 sp rear prop shaft - 1-0170 this is a SFK brand 
    Sp700 Rear drive shaft u-joints NAPA#338 
    Napa equivalent, with grease zerk # 1501 
     
    Boots
    CV Boot kit for the front of 05 model sportsmans - 8409 this is a Precision brand 
    CV Boot kit for the rear of all 600-800 model sportsmans that I'm aware of - 7427 this is a Precision brand (or # 4445) 
    Stock CV boot (front) for 02 700: Discount Auto Parts P/N 6-1052 Fits Dodge Neon, not sure what year. 
    stock cv boot for 03 sp700 car quest part# 85-0904 
    86-96 ford escort c.v. boot to replace a gorilla 

    Fans: 
    Sp?? Fan www.offroadwarehouse.com 
    Sp500 Fan p/n 30100515 800-341-7757 
    Spal fan (factory fan)- Spal VA07-AP12/C-58A Fan (30100452). Number to order is 1-800-345-0327 or
    www.spalusa.com    
    Spal # is 30100411 fits- 
       2004 Sportsman 400 
       2004 Sportsman 500 
       2005 ATP 500 4X4 
       2005 Sportsman 400 
       2006-07 Sportsman 450 
       2005-07 Sportsman 500 H.O. and EFI 
       2006-07 Sportsman X2 500  
      
    Thermal fan switch: 
    fan switch to replace a 2000-2003 Polaris  4010161, for a Nissan 84-88 Maxima or 86-89  Nissan Stanasa. (Blue Streak TS-127, Nappa FS147, Wells SW526). ?? Thermal sensor - tells fan when to come on - Wells SW526 less than $30  

    Exhaust seals
    NAPA part # 31360  
      
    Fuel pumps
    Sportsman 800 fuel pump- Airtex E8198   $79.97 (89-92 hyundai sonata 4 cyl) 
    Carter fuel pump # E7000 is the same as a 05 700 efi 
    NAPA fuel pump, part # 72118  works perfect on a 800 EFI 
    Airtex fuel pump for a 700 efi- fits a 93-04 hyundai elantra or sonata 4cyl. 

    Fuel Filters (EFI’s): 
    EFI fuel filter- NAPA #3199 will work, but is some smaller.  
    Bosch: 045905273 
    FRAM: G7143 
    ACDELCO: GF561F 
    WIX: 33199 

    Iridium Spark Plugs
    Sportsman 600/700/800 is BKR7EIX 
      
    Spark Plugs for Sportsman twins
    NGK BKR7E(all) 
    Autolite 3922 
    Denso K22PR-U  
      
    Spark Plugs for Sportsman 500
    NGK BKR5ES (96-04) 
    BKR6ES (00-05 H.O. and 05-06) 
    Champion RC12YC (all) 
    Denso K20PR-U (all) 
    Autolite 3923 (all)  
      
    Spark Plugs for Sportsman 400: 
    NGK BKR5E(02-up) 
    NGK BKR5ES(02-up) 
    Champion RC12YC(02-up) 
    Denso K20PR-U(02-up) 
    Autolite 3923(02-up) 
    NGK BR8ES(94-97) 
    Denso W24ESR-U(94-97) 
    Autolite 4063(94-97)  

    Solenoids: 
    2005 700 efi solenoid Napa# 18-5817 (Mercury/mariner 89-96158 vertical post) 
    Starter solenoid Napa part SME 7016841, I used this one on my 99 Sportsman 500 
    Starter solenoid - local lawnmower-small engine parts house mtd part number 435435  

    20 amp circuit breaker
    Advanced Auto parts- Buss 20 amp 12v circuit breaker 

    Tools: 
    Polaris specialty tools- 
    www.victorspecialtytools.com 

    Great sites: 
    www.goallballs.com 
    www.erlandsonperformance.com 
    www.polarispartshouse.com 
    www.cheapcycleparts.com 
    <message edited by subforeman on Monday, January 11, 2010 11:29 PM>



    04.5 SP 700 Twin
    27" Bi/Tri's on black SS 212's 
    '06 800 primary clutch with stock 700 spring
    Team rapid reaction roller secondary clutch with 800 spring and helix
    Heelclicker weights set 5.5/5.5/0.0
    #7
    SouthernSuzuki
    Mud Master
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    Re:2002 Polaris Sportsman 700 fluid capacities? 2011/01/12 00:47:35 (permalink)
    Which one of those spark plugs is the is the best spark plug to run? 

    2012 Sunset Red Polaris Sportsman 850 EPS,
    3" CATVOS with 2.5" Rake,
    Cobra Axles,
    27" Itp XTR's,
    6000K HID's, 
    Big Gun Slip on,
    Uni Air Filter,
    Soon to have much bigger tires 

           
     
    #8
    Po_700_Po
    Mud Master
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    Re:2002 Polaris Sportsman 700 fluid capacities? 2011/01/12 19:55:59 (permalink)
    Everyone is saying the NGK iridium give a little more power. I haven't tried them but will soon.

    04.5 SP 700 Twin
    27" Bi/Tri's on black SS 212's 
    '06 800 primary clutch with stock 700 spring
    Team rapid reaction roller secondary clutch with 800 spring and helix
    Heelclicker weights set 5.5/5.5/0.0
    #9
    SouthernSuzuki
    Mud Master
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    Re:2002 Polaris Sportsman 700 fluid capacities? 2011/01/14 12:01:54 (permalink)
    Also the plastic water pump cover is leaking on it. I know there was a recall on it so I had my dealer run the VIN and it came back nothing about it. I've searched all morning for the recall or the service bulletin number with no luck. He told me if I could find that we may could find out more about it. The recall was replacing the plastic one with a aluminum one or putting a metal bracket over the plastic cover to keep it from leaking. Can somebody please help me out here or post a picture of what he updated cover looks like.
     
    thanks

    2012 Sunset Red Polaris Sportsman 850 EPS,
    3" CATVOS with 2.5" Rake,
    Cobra Axles,
    27" Itp XTR's,
    6000K HID's, 
    Big Gun Slip on,
    Uni Air Filter,
    Soon to have much bigger tires 

           
     
    #10
    jimmypsp700
    Dirt Monster
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    Re:2002 Polaris Sportsman 700 fluid capacities? 2011/01/14 20:20:09 (permalink)
    I been there and done that on most of the above. ..

    Make sure you only use PPDD 5 oz in the front diff., the others have alternatives.  I used Mobil 1 oil 0w40.. and Mobil 1 gear oil in rear diff.
     
    I've had relatively good luck with my first year model 2002 Sportsman 700 and was (sold)  very happy with it.  The engine ran great (and strong).  Compression is still very good at 160 and 164 psi.   Maintenance is key.  The lifters are hydraulic and do not require adjustment.
     
    The 20 amp resettable breakers in plastic pouches under the hood (front rack) can corrode and cause the headlights to blink and/or go out and the speedo to act up and/or blink and go out.  Also some 2002 models were installed with 10 amp breakers in error.
     
    My Thermal sensor went out, check fan by jumping it with a wire.  The Thermal sensor # 4010161 is $63, a Wells SW526 auto replacement will work.
    The front exhaust donut (NAPA part # 31360) at the Y-pipe exhaust manifold wears and may leak.
     
    I have replaced the carb boot/adaptor (p/n 1253415), the rubber gets weathered/dry rotted bad on some and may crack through.
     
    And If you have 4,000 miles or more on the quad it is a good chance the float needle valve (p/n 3131360 VALVE-NEEDLE, 1.5(PUSH IN)) needs replacement soon.  The bore will wear with marks in it from the needles vertical ribs (very much like the service manual shows) and it will not seat proberly and allow the bowl to overflow and leak out the tube.  Replace the O-ring also while you're at it.
     
    And the Speedo Hall sensors sometimes go out ($50 part, p/n 4010298), its at the right front wheel rotor and has a wire going up to the pod.
     
    Replaced the battery with a Deka/ Extreme #EXT30L
    30 amp battery (sp700 OEM YB30L-B (Polaris #4010630)) maintenance free AGM.  Put a strap under the battery for easy removal.

    AGM batteries for the Twins

    Deka/ Extreme #EXT30L www.eastpenn-deka.com
    Odyssey number PC925L
    BikeMaster Platinum #49-9069
    YAUSA #YIX30L-BS
     
     
    The water pump cover should be a metal replacement of the leaky original plastic cover on '02-03 models.
    This was a Tech Service Bulletin for  models in '02 and some early '03's.
     
    The crank breather filter should be omitted for colder climates, this was also a Tech Service Bulletin (TSB).   It added an insulated hose (w/1" slot).
    The TSB is #S-03-05 and the part # is 2202744
     
    Also some machines, mostly '03's have cold weather start jetting updates, both of the TSB's and the jetting should have been taken care of under warranty.
     
    Overall I would say the suspension and driveline parts (bearings, bushings, ball-joints and u-joints) are the most important to check for wear and may need replacement over time or if the machine wasn’t greased and maintained properly.  This could be due to the extra weight of the machine and possibly how hard it was driven.
     
    Jim
    post edited by jimmypsp700 - 2011/01/14 20:21:28

    2010 Sportsman 850XP EPS

    2000 Scrambler 400 2x4
    -Trail ported & modded
    -Wiseco .040 over
    -RcR /HPD clutched & Piped
     
    2002 Sportsman 700 (SOLD)
    -800 mods
    #11
    SouthernSuzuki
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    Re:2002 Polaris Sportsman 700 fluid capacities? 2011/01/15 00:25:42 (permalink)
    Can anybody tell me the bulletin number for this or help me get the information on that bulletin?

    2012 Sunset Red Polaris Sportsman 850 EPS,
    3" CATVOS with 2.5" Rake,
    Cobra Axles,
    27" Itp XTR's,
    6000K HID's, 
    Big Gun Slip on,
    Uni Air Filter,
    Soon to have much bigger tires 

           
     
    #12
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