Polaris SPORTSMAN 600 2003 Manuals

Manuals and User Guides for Polaris SPORTSMAN 600 2003. We have 1 Polaris SPORTSMAN 600 2003 manual available for free PDF download: Service Manual

Polaris SPORTSMAN 600 2003 Service Manual

Polaris SPORTSMAN 600 2003 Service Manual (262 pages)

Brand: Polaris | Category: Offroad Vehicle | Size: 117.81 MB

Table of Contents

Chapter Index

4
- Table of Contents
  4
- General Information
  6
- Model Identification
  6
- Serial Number Location
  6
- 2003 Sportsman Models
  12
- Paint Codes
  16
- Publication Numbers
  16
- Replacement Keys
  16
- Standard Torque Specifications
  17
  - Decimal Equivalents
    18
  - Conversion Table
    19
- Decimal Equivalent Chart
  20
- Glossary of Terms
  21
Chapter 2 Maintenance

23
- Periodic Maintenance Chart
  24
- General
  25
- Pre-Ride Inspection
  25
- Engine
  27
  - Special Tools
    28
  - Transmission Lubrication
    32
- Chapter 8 Brakes
  
  33
  - Idle Speed Adjustment
    34
  - Fuel System
    35
  - Carburetor Draining
    36
  - Compression Test
    36
    
    Fuel Filter
    36
    
    Vent Lines
    36
  - Battery Maintenance
    37
  - Electrical
    38
    
    Coolant Level Inspection
    40
    
    Radiator Coolant Level Inspection
    40
    
    Radiator Screen Removal
    40
    
    Air Box Sediment Tube Service
    41
    
    Breather Filter
    42
    
    PVT Drying & PVT Drain Plug
    42
- Chapter 1 Chapter 4
  
  42
- Chapter 5
  
  42
  - Pvt System
    42
    
    Engine Oil Level
    43
    
    Oil and Filter Change
    43
  - Final Drive
    45
    
    Brake System Inspection
    48
    
    Exhaust Pipe
    48
    
    Auxiliary Brake Testing
    49
    
    Brake Pad Inspection
    49
    
    Controls
    50
    
    Front Suspension
    50
    
    Rear Suspension
    50
    
    Wheel Removal/Installation
    50
    
    Tire Inspection
    51
    
    Tire Pressure
    51
Chapter 3 Engine

53
- Engine Exploded Views
  54
- Special Tools
  59
  - Accessible Components
    59
- Torque Specifications
  60
- Engine Fastener Torque Patterns
  61
- Piston Identification
  61
- 600 Engine Service Data
  62
- Cooling System Specifications
  66
- Engine Installation Notes
  68
  - Cylinder Hone Selection and Honing Procedure
    69
- Oil Flow
  70
- Rocker Arm/Pushrod Inspection
  71
  - Cylinder Head Removal
    71
- Cylinder Head Disassembly/Inspection
  72
  - Cylinder Head Inspection
    72
  - Cylinder Head Warpage
    72
- Valve Inspection
  74
- Combustion Chamber
  75
- Valve Seat Reconditioning
  75
- Cylinder Head Reassembly
  77
- Valve Sealing Test
  78
- Valve Train Exploded View
  78
- Engine Head Reassembly
  79
- Cylinder Removal
  81
- Piston Removal
  81
- Valve Lifter Removal/Inspection
  81
- Cylinder Inspection
  82
- Starter Bendix Removal/Inspection
  85
  - Piston Ring Installed Gap
    85
- Flywheel/Stator Removal/Inspection
  86
- Flywheel/Stator Installation
  87
- Engine Lower Disassembly/Inspection
  88
- Camshaft Inspection
  96
- Engine Lower Assembly
  97
- Troubleshooting
  108
Chapter 4 Fuel System/Carburetion

111
- Fuel Flow Diagram
  113
- Carburetor Jetting
  114
  - Mikuni Jet Part Numbers
    114
  - Jetting Guidelines
    114
- Assembly, CV Carburetor
  115
  - Mikuni CV Carb Operation
    115
  - Float System
    117
  - Main System
    117
  - Carburetor Cleaning
    118
  - Carburetor Inspection
    119
  - Carburetor Assembly
    119
  - Float Height Adjustment
    120
- CV Carburetor System Function (4 Cycle)
  115
- Needle and Seat Leakage Test
  120
- Fuel Level
  121
- Fuel Pump Service
  121
  - Fuel Pump Disassembly
    121
- Troubleshooting
  122
Chapter 5 Body / Steering / Suspension

123
- Headlight Pod Exploded View
  126
- Steering/A--Arm Exploded View
  127
- Rear Suspension Exploded View
  128
- Front Strut Assembly Exploded View
  129
- Cover/Panel Removal
  130
- A-Arm Replacement
  131
- Side Panel Removal
  131
- Steering Post Assembly
  132
- Front Strut Cartridge Replacement
  133
  - Ball Joint Replacement
    133
- Decal Replacement
  134
Chapter 6 Pvt System

135
- Drive Clutch Exploded View
  136
- PVT Sealing and Ducting Components
  136
- PVT Operation Overview
  138
  - Drive Clutch Operation
    138
  - Pvt System Fastener Torques
    138
  - Driven Clutch Operation
    138
  - Pvt Drying
    139
- PVT Overheating/Diagnosis
  140
- PVT Disassembly
  141
- PVT Assembly/Inspection
  142
  - Drive Clutch Spring Specifications
    143
- Shift Weights /Inspection
  144
- Drive Clutch Disassembly/Inspection
  145
  - Shift Weight Inspection
    145
  - Button to Tower Clearance Inspection
    145
  - Spider Removal
    146
- Drive Clutch Reassembly
  147
- Drive Belt Removal/Inspection
  148
- Clutch Alignment/Offset
  150
  - Clutch Offset
    150
- Drive Belt Installation
  150
- Troubleshooting
  158
Chapter 7 Final Drive 7

161
- Awd Front Drive Axle Exploded View
  162
- Front Drive Axle Removal
  163
- Front Hub Inspection
  163
- Driveshaft & CV Joint Handling Tips
  164
- Front Drive Axle Installation
  164
- U--Joint Assembly
  167
- U-Joint Disassembly
  167
- Front Gearcase Removal
  168
- Front Gearcase Operation
  169
- Front Gearcase Diagnosis
  174
- Front Gearcase Exploded View
  176
- Rear Hub Removal
  177
- Rear Hub Installation
  178
- Rear Hub Disassembly
  179
- Rear Driveshaft Removal
  180
- Rear Hub Assembly
  180
- Rear Driveshaft Installation
  181
- Rear Driveshaft Service
  182
- Rear Gearcase Installation
  184
- Rear Gearcase Removal
  184
- Rear Gearcase Disassembly
  185
- Rear Gearcase Assembly
  186
- Rear Gearcase Exploded View
  188
  - Transmission Exploded View
    190
  - Transmission Removal
    192
  - Transmission Disassembly
    193
  - Transmission Installation
    193
Chapter 9 Brakes

205
- Brake Noise Troubleshooting
  207
- Brake System Service Notes
  207
- Hydraulic Caliper Bleeding
  208
- Brake Bleeding / Fluid Change
  209
- Master Cylinder Removal
  210
- Master Cylinder Installation
  211
- Front Pad Assembly
  212
- Front Pad Removal
  212
- Brake Burnishing
  213
- Front Disc Inspection
  213
- Front Caliper Removal
  214
- Front Caliper Disassembly
  215
- Front Caliper Inspection
  216
- Front Caliper Reassembly
  216
- Front Caliper Installation
  217
- Rear Caliper Removal/Inspection
  221
  - Rear Caliper Assembly
    222
- Troubleshooting
  223
Chapter 10 Electrical

225
- Flywheel Identification
  226
- Timing Check Procedure
  227
  - Electrical Service Notes
    227
- Trigger Coil Gap
  228
- Instrument Cluster Troubleshooting
  229
- Speedometer Removal/Installation
  231
- Speedometer Troubleshooting
  232
  - Fan Motor Current Draw
    236
- Ignition System Testing Flow Chart
  238
- Ignition System Troubleshooting
  239
  - Alternator Output Test
    240
- Charging System Testing Flow Chart
  241
  - Battery Installation
    243
  - Battery Testing
    243
  - High Beam Headlight Adjustment
    245
  - Headlight Housing Replacement
    245
- Starter System Troubleshooting
  247
  - Starter Motor Disassembly
    247
  - Voltage Drop Test
    247
  - Armature Testing
    249
- Starter Drive
  251
- Starter System Testing Flow Chart
  253
  - Paint Codes
    260
  - Conversion Table
    261

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