2003 Sportsman Models - Polaris SPORTSMAN 600 2003 Service Manual

2003 SPORTSMAN 600
MODEL: . . . . . . . . . .
MODEL NUMBER: . A03CH59
ENGINE MODEL: . . EH059OLE
CARBURETION
Type . . . . . . . . . . . . . . . . BST 34 Mikuni
Main Jet . . . . . . . . . . . . 155
Pilot Jet . . . . . . . . . . . . . 45
Jet Needle . . . . . . . . . . . J8--4FA01--3
Needle Jet . . . . . . . . . . . P-4
Throttle Valve . . . . . . . . #100
Pilot Screw . . . . . . . . . . 1.5 Turns Out
Pilot Air Jet . . . . . . . . . . 160
Valve Seat . . . . . . . . . . . 1.5
Float Height . . . . . . . . . 14.7mm (.58I) 1mm
Fuel Octane (R+M/2) . 87 Non-Oxygenated or
89 Oxygenated
CLUTCH
Type . . . . . . . . . . . . . . . . . . . .
Belt . . . . . . . . . . . . . . . . . . . . .
Belt Width (Projected) . . . . .
Side Angle (Overall) . . . . . .
Outside Circumference . . . .
Center Distance . . . . . . . . . .
Clutch Offset . . . . . . . . . . . .
Secondary Spring . . . . . . . .
Driven Helix . . . . . . . . . . . . .
Spring Position (Helix) . . . .
Spring Position (Sheave)
ENGINE
Type . . . . . . . . . . . . . . . . . . . . . . .
Displacement . . . . . . . . . . . . . . .
Bore . . . . . . . . . . . . . . . . . . . . . . .
Stroke . . . . . . . . . . . . . . . . . . . . .
Compression Ratio . . . . . . . . . .
Cooling . . . . . . . . . . . . . . . . . . . .
Lubrication Type . . . . . . . . . . . .
Operating RPM 200 . . . . . . . . .
Idle RPM 100 (lights off)
Compression Pressure . . . . . . .
1.8
PVT
3211091
1.188I (30.18mm)
28 2
40.875 .188I
10 .12I (254.5mm)
0.5I (12.7mm)
White/Yellow
Compound (EBS)
N/A
. . N/A
4 Cycle, Twin Cyl.
597 cc
3.012I (76.5 mm)
2.559I (65 mm)
9.35/1 Full Stroke
Liquid
Pressurized Wet Sump
6000 RPM
. . . . 1100 RPM
150--170psi 15%
GENERAL INFORMATION
JETTING CHART
AMBIENT TEMPERATURE
Altitude Altitude
Below 40 F Below 40 F
Below +5 C
Meters Meters 0-1800 0-1800
162 5 162.5
(0-6000)
(Feet) (Feet)
Above 1800 Above 1800
150 150
Above (6000)
CLUTCH CHART
*EBS require no helix/spring adjustment
Shift Shift
Altitude Altitude
Weight Weight
Meters Meters
0-1800 0-1800
10 MH 10 MH
(Feet) (Feet) (0-6000)
1800-3700 1800-3700
10 WH 10 WH
(6000-12000)
+40_F and above +40 F and above
+5_C and above
155 155
145 145
Drive Clutch Drive Clutch Driven Clutch Driven Clutch Driven Driven
Spring Spring Spring Spring Helix Helix
Blue/Green Blue/Green
White/Yellow White/Yellow EBS EBS
(5631215)
Blue/Green Blue/Green
White/Yellow White/Yellow EBS EBS
(5631214)