Polaris Sportsman 600-700 02-03

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2003 SPORTSMAN 600
2002 - 2003 SPORTSMAN 700
SERVICE MANUAL
PN 9918066
UNDERSTANDING SAFETY LABELS AND INSTRUCTIONS
Throughout these instructions, important information is brought to your attention by the following symbols:
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!
DANGER
Failure to follow DANGER instructions will result in severe injury or death to the operator, bystander or person
inspecting or servicing the ATV.
WARNING
Failure to follow WARNING instructions could result in severe injury or death to the operator, bystander or
person inspecting or servicing the ATV.
CAUTION:
A CAUTION indicates special precautions that must be taken to avoid personal injury, or ATV or property
damage.
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. F. Nye Co.
Fluke, Registered Trademark of John Fluke Mfg. Co.
Mity Vac, Registered Trademark of Neward Enterprises, Inc.
Ammco, Registered Trademark of Ammco Tools, Inc.
Torx, Registered Trademark of Textron
Hilliard, Trademark of the Hilliard Corporation
2003 SPORTSMAN 600/700
SERVICE MANUAL
Foreword
This manual is designed primarily for use by certified Polaris Master Service Dealer technicians in a properly
equipped shop and should be kept available for reference. All references to left and right side of the vehicle
are from the operator’s perspective when seated in a normal riding position.
Some procedures outlined in this manual require a sound knowledge of mechanical theory, tool use, and shop
procedures in order to perform the work safely and correctly. Technicians should read the text and be familiar
with service procedures before starting the work. Certain procedures require the use of special tools. Use
only the proper tools as specified.
This manual includes procedures for maintenance operations, component identification and unit repair, along
with service specifications for 2003 Polaris Sportsman 600/700 ATVs. Comments or suggestions about this
manual may be directed to: Service Publications Dept. @ Polaris Sales Inc. 2100 Hwy 55 Medina Minnesota
55340.
2002 Sportsman 600/700 ATV Service Manual (PN 9918066)
E
Copyright 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. Depictions and/or procedures in this
publication are intended for reference use only. No liability can be accepted for omissions or inaccuracies. Any reprinting or reuse of
the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited. Printed in U.S.A.
CHAPTERINDEX
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
 GENERAL INFORMATION
CHAPTER1
GENERALINFORMATION
1
.......................
Serial Number Location
1.2
...................
1.2
2003 Sportsman Models
..................
1.3
.....................
Specifications - 2002 Sportsman 700
1.4-1.5
.......
1.6-1.7
Specifications - 2003 Sportsman 600
.......
1.8-1.9
Specifications - 2003 Sportsman 700
.......
1.10-1.11
Publication Numbers
.....................
1.12
.............................
Replacement Keys
1.12
.......................
Standard Torque Specifications
1.12
............
1.13
Decimal Equivalent Chart
.................
1.14
Conversion Table
........................
1.15
..........................
Glossary of Terms
1.16
........................
1.17-1.18
1.1
Model Identification
Machine Dimensions
Paint Codes
Tap Drill Charts
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