Table of Contents
Advertisement
Quick Links
Advertisement
Table of Contents
Related Manuals for Polaris 2003 SPORTSMAN 600
Summary of Contents for Polaris 2003 SPORTSMAN 600
- Page 1 2003 SPORTSMAN 600 2002 - 2003 SPORTSMAN 700 SERVICE MANUAL PN 9918066...
- Page 2 NOTE: A NOTE provides key information to clarify instructions. Trademarks Polaris acknowledges the following products mentioned in this manual: FLEXLOC, Registered Trademark of SPS Technologies Loctite, Registered Trademark of the Loctite Corporation STA-BIL, Registered Trademark of Gold Eagle FOX, Registered Trademark of Fox Shox Nyogel, Trademark of Wm.
- Page 3 2002 Sportsman 600/700 ATV Service Manual (PN 9918066) ECopyright 2002 Polaris Sales Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant improvements in the design and quality of production components, some minor descrepancies may result between the actual vehicle and the information presented in this publication.
- Page 4 CHAPTER INDEX CHAPTER 1 GENERAL CHAPTER 2 MAINTENANCE CHAPTER 3 ENGINE CHAPTER 4 FUEL SYSTEM CHAPTER 5 BODY/SUSPENSION CHAPTER 6 PVT SYSTEM CHAPTER 7 FINAL DRIVE CHAPTER 8 TRANSMISSION CHAPTER 9 BRAKES CHAPTER 10 ELECTRICAL...
-
Page 5: Table Of Contents
..... 1.4-1.5 Specifications - 2002 Sportsman 700 ..1.6-1.7 Specifications - 2003 Sportsman 600 ..1.8-1.9 Specifications - 2003 Sportsman 700 .. -
Page 6: General Information
GENERAL INFORMATION MODEL IDENTIFICA TION The machine model number must be used with any correspondence regarding warranty or service. Machine Model Number Identification A 0 3 C H 6 8 A A Emissions & Model Option Year Designation Basic Chassis Designation Engine Designation ENGINE DESIGNATION NUMBERS... - Page 7 GENERAL INFORMATION GENERAL INFORMATION 2003 SPRORTSMAN 600 & 700 MODELS SPORTSMAN 600 SPORTSMAN 700 NOTE: MODELS WILL VARY IN COLOR.
-
Page 8: Machine Dimensions
GENERAL INFORMATION MACHINE DIMENSIONS FRONT 46 in 116.84 cm 85 in 215.90 cm SIDE 50.75 in 128.90 cm... - Page 9 GENERAL INFORMATION GENERAL INFORMATION MACHINE DIMENSIONS 46 in 116.84 cm 47 in 119.38 cm 11 in 27.94 cm REAR 46 in 116.84 cm...
- Page 10 GENERAL INFORMATION GENERAL INFORMATION 2002 SPORTSMAN 700 MODEL: ..MODEL NUMBER: A02CH68AA/CA ENGINE MODEL: EH68ALOE1 JETTING CHART AMBIENT TEMPERATURE Altitude ltitude CARBURETION Below 40°F Below 40 F +40_F and above +40 F and above Below +5°C +5_C and above Type...
-
Page 11: Final Drive
LR39 *PP6 Polaris Premium 60/40 Antifreeze/Coolant Electric Start ..Standard *PPS Polaris Premium Synthetic Gear Case Oi Instrument Cluster *PP4 Polaris 0W--40 Synthetic Engine Lubricant *PDD Premium Demand Drive Hub Fluid SUSPENSION / CHASSIS... - Page 12 GENERAL INFORMATION 2003 SPORTSMAN 600 MODEL: ..MODEL NUMBER: A03CH59 ENGINE MODEL: EH059OLE JETTING CHART AMBIENT TEMPERATURE CARBURETION Altitude Altitude Below 40 F Below 40 F +40_F and above +40 F and above...
- Page 13 LR39 *PP6 Polaris Premium 60/40 Antifreeze/Coolant Electric Start ..Standard *PPS Polaris Premium Synthetic Gear Case Lube Instrument Cluster *PP4 Polaris 0W--40 Synthetic Engine Lubricant *PDD Premium Demand Drive Hub Fluid SUSPENSION / CHASSIS...
- Page 14 GENERAL INFORMATION 2003 SPORTSMAN 700 MODEL: ..MODEL NUMBER: A03CH68 ENGINE MODEL: EH068OLE JETTING CHART AMBIENT TEMPERATURE CARBURETION Altitude Altitude Below 40 F Below 40 F +40_F and above +40 F and above Below +5 C +5_C and above Type...
- Page 15 LR39 *PP6 Polaris Premium 60/40 Antifreeze/Coolant Electric Start ..Standard *PPS Polaris Premium Synthetic Gear Case Lube Instrument Cluster *PP4 Polaris 0W--40 Synthetic Engine Lubricant *PDD Premium Demand Drive Hub Fluid SUSPENSION / CHASSIS...
-
Page 16: Publication Numbers
9918213 9917718 9917719 When ordering service parts be sure to use the correct parts manual. PAINT CODES PAINTED PART COLOR DITZLER POLARIS DESCRIPTION NUMBER NUMBER Springs Black 9440 P-067 FRAME COLOR - (All) P067 Medium Gloss Black 9440 / 8520147. -
Page 17: Standard Torque Specifications
GENERAL INFORMATION GENERAL INFORMATION STANDARD TORQUE SPECIFICATIONS The following torque specifications are to be used as a general guideline. There are exceptions in the steering, suspension, and engine areas. Always consult the exploded views in each manual section for torque values of fasteners before using standard torque. -
Page 18: Decimal Equivalents
GENERAL INFORMATION GENERAL INFORMATION DECIMAL EQUIVALENTS 1/64 ......0156 1/32 ....0312 . - Page 19 GENERAL INFORMATION GENERAL INFORMATION CONVERSION TABLE Unit of Measure Multiplied by Converts to ft. lbs. x 12 = in. lbs. in. lbs. x .0833 = ft. lbs. ft. lbs. x 1.356 = Nm in. lbs. x .0115 = kg-m x .7376 = ft.lbs.
-
Page 20: Decimal Equivalent Chart
GENERAL INFORMATION GENERAL INFORMATION SAE TAP DRILL SIZES Thread Size Drill Size Thread Size Drill Size #0-80 3/64 1/2-13 27/64 #1-64 1/2-20 29/64 #1-72 9/16-12 31/64 #2-56 9/16-18 33/64 #2-64 5/8-11 17/32 #3-48 5/64 5/8-18 37/64 #3-56 3/4-10 21/32 #4-40 3/4-16 11/16 #4-48... -
Page 21: Glossary Of Terms
CC: Cubic centimeters. Center Distance: Distance between center of crankshaft and center of driven clutch shaft. Chain Pitch: Distance between chain link pins (No. 35 = 3/8² or 1 cm). Polaris measures chain length in number of pitches. CI: Cubic inches. - Page 22 Piston Clearance: Total distance between piston and cylinder wall. psi.: Pounds per square inch. PTO: Power take off. PVT: Polaris Variable Transmission (Drive Clutch System) qt.: Quart/quarts. Regulator: Voltage regulator. Regulates battery charging system output at approx. 14.5 DCV as engine RPM increases.