2003 Polaris Sportsman 600 and 2002-2003 Polaris Sportsman 700 DIY Factory Service Repair Maintena


(2003 Polaris Sportsman 600) & (2002 - 2003 Polaris Sportsman 700) - DIY Factory Service / Repair / Maintenance Manual ! - 02 03 Download !!



( VERY HIGH QUALITY FACTORY SERVICE MANUAL - 251 MB !! )



1. Language: English

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Description:





COVERS ALL MODELS & ALL REPAIRS A-Z



THIS IS NOT GENERIC REPAIR INFORMATION! IT IS VEHICLE SPECIFIC. THIS IS THE EXACT SAME MANUAL USED BY TECHNICIANS AT THE DEALERSHIPS TO MAINTAIN, SERVICE, DIAGNOSE AND REPAIR YOUR VEHICLE.



COMPLETE STEP-BY-STEP INSTRUCTIONS, DIAGRAMS, ILLUSTRATIONS, WIRING SCHEMATICS, AND SPECIFICATIONS TO COMPLETELY REPAIR YOUR VEHICLE WITH EASE!



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FACTORY HIGHLY DETAILED REPAIR MANUALS, WITH COMPLETE INSTRUCTIONS AND ILLUSTRATIONS, WIRING SCHEMATICS AND DIAGRAMS TO COMPLETELY SERVICE AND REPAIR YOUR VEHICLE.



ALL MANUALS ARE WINDOWS VISTA32 and 64, XP, ME, 98, NT, 2000 COMPATIBLE AND WORK WITH MAC!







SERVICE MANUAL COVERS:





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



DETAILED INDEX WITH ACTUAL PAGE/SECTION NUMBERS:



A

A--Arm Replacement, 5.9

Air Filter Service, 2.19

Alternator Output Test, 10.16

B

Battery Charging, 10.20

Battery Installation, 10.19

Battery Maintenance, 2.15

Battery Service, 10.18, 10.19, 10.20

Battery Terminal Bolts, 10.18

Battery Testing, 10.19

Battery, Off Season Storage, 10.20

Body Assembly Exploded View, 5.3

Brake Bleeding/Fluid Change, 9.5, 9.6, 9.9, 9.15

Brake Caliper Disassembly, Front, 9.11

Brake Caliper Exploded View, Front, 9.14

Brake Caliper Exploded View, Rear, 9.20

Brake Caliper Inspection, Front, 9.12

Brake Caliper Installation, Front, 9.13

Brake Caliper Removal, Front, 9.10

Brake Caliper Removal/Inspection, Rear, 9.17

Brake Disc Inspection, Front, 9.9

Brake Disc Inspection, Rear, 9.19

Brake Disc Removal/Replacement, Front, 9.10

Brake Fluid Level, 2.26

Brake Hose/Fitting Inspection, 2.27

Brake Light Switch Testing, 10.22

Brake Master Cylinder Exploded View, Rear, 9.20

Brake Noise, 9.3

Brake Pad Assembly, Front, 9.8

Brake Pad Inspection, 2.27

Brake Pad Installation, Rear, 9.16

Brake Pad Removal, Front, 9.8

Brake Pad Removal, Rear, 9.15, 9.16

Brake System Inspection, 2.26

Brake System Operation, 9.4

Brake, Auxiliary, Hydraulic, 2.27

Brake, Auxiliary, Testing, 2.27

Brakelight Lamp Replacement, 10.22

Breather Filter Maintenance, 2.20

Breather Hose Inspection, 2.20

Brush Replacement, Starter Motor, 10.24

C

Cam Gear Assembly, 3.38

Cam Gear Disassembly , 3.37

Cam Gear Removal, 3.37

Camber & Caster, 2.23

Camshaft Inspection, 3.44

Carburetor Assembly, 4.9

Carburetor Disassembly, 4.7

Carburetor Exploded View, BST34, 4.2

Carburetor Float Bowl Draining, 2.14

Carburetor Float Height Adjustment, 4.10

Carburetor Float System, 4.7

Carburetor Fuel Level Testing, 4.11

Carburetor Inspection, 4.8, 4.9

Carburetor Main System, 4.7

Carburetor Needle and Seat Testing, 4.10

Carburetor Operation, 4.5

Carburetor Pilot System, 4.6

Carburetor Starter System, 4.6

Carburetor System Function, 4.5

CDI Output Test, 10.15

Charging System Break Even Test, 10.16

Charging System Testing, 10.17

Choke Adjustment, 2.11

Clutch Alignment, 6.16

Clutch Offset, 6.16

Combustion Chamber, 3.23

Compression Test, 2.14

Controls Inspection, 2.28

Coolant Level Inspection , 2.18

Coolant Strength, 2.17

Coolant Temperature Sensor, 10.12

Cooling System Hoses, 2.17

Cooling System Overview , 2.17

Cooling System Test, 2.17

Cover/Panel Removal, 5.8

Cranking Output Test, 10.15

Current Draw, 10.15

CV Joint Handling Tips, 7.4, 7.21

Cylinder Head Assembly, 3.25

Cylinder Head Disassembly, 3.20, 3.21

Cylinder Head Inspection, 3.20

Cylinder Head Reconditioning, 3.23

Cylinder Head Removal, 3.19, 3.26

Cylinder Head Warpage, 3.20

Cylinder Honing, 3.17

Cylinder Inspection, 3.30

Cylinder Removal/Inspection, 3.29

D

Decal Replacement, 5.12

Decimal Equivalent Chart, 1.14

Diagnostic Mode, 10.5, 10.6

Drive Belt Installation, 6.16

Drive Belt Removal/Inspection, 6.14

Drive Clutch Assembly, 6.13, 6.14

Drive Clutch Disassembly, 6.11, 6.12, 6.13

Drive Clutch Exploded View, 6.2

Drive Clutch Inspection, 6.11

Drive Clutch Operation, 6.4

Drive Shaft Boot Replacement, 7.5

Driven Clutch Operation, 6.4, 6.5

Dual Hydraulic Caliper Bleeding, 9.4

E

EBS Drive Clutch Bushing Service, 6.20

EBS Drive Clutch Inspection, 6.17

EBS Driven Clutch Bushing Service, 6.22

EBS Driven Clutch Disassembly, 6.18, 6.20

EBS Exploded View, 6.3

EBS Moveable Sheave Bushing Inspection, 6.18

EBS One Way Drive Clutch Inspection, 6.17, 6.18

EBS One Way Driven Clutch Inspection, 6.18

Electrical Service Notes, 10.3

Electrical Special tools, 10.3

Engine Accessible Components, 3.7

Engine Bottom End Disassembly, 3.29, 3.30, 3.32

Engine Bottom End Disassembly/Inspection, 3.44

Engine Break in Period, 3.16

Engine Designation Numbers, 1.2

Engine Exploded View, 3.2, 3.3, 3.4, 3.5, 3.6

Engine Eploded View, 2002, Sportsman 700, 3.58

Engine Fastener Torque Patterns, 3.9

Engine Head Assembly, 3.27, 3.28

Engine Lower Disassembly/Inspection, 3.36, 3.37

Engine Lower Reassembly, 3.45

Engine Lubricatin, 3.17

Engine Removal, 3.15

Engine Serial Number Location, 1.2

Engine Service Data, 600 Engine, 3.10, 3.11

Engine Service Data, 700 Engine, 3.12, 3.13

Engine to Frame Ground, 2.16

Engine Top End Disassembly, 3.19, 3.22, 3.26

ETC Operation Test, 10.13

ETC Switch Adjustment, 2.12

ETC Switch Testing, 10.13

Exhaust System, Maintenance, 2.26

F

Fan Control Circuit Testing, 10.12

Fan Control Switch Bypass Test, 10.12

Fan Control Switch Testing, 10.13

Fan Motor Current Draw Test, 10.12

Flywheel Identification, 10.2

Frame, Nuts, Bolts, Fasteners, 2.29

Front Axle Exploded View, 7.2

Front Axle Installation, 7.4

Front Axle Removal, 7.3

Front Hub Assembly, 7.6

Front Hub Disassembly, 7.6

Front Hub Inspection, 7.3

Front Prop Shaft Removal, 7.6

Front Strut Assembly, 5.7

Front Strut Ball Joint Replacement, 5.11

Fuel Filter Maintenance, 2.14

Fuel Pump Service, 4.11

Fuel System, 2.13

Fuel Tank Assembly, Exploded View, 4.3

G

Gear Position Switch Test, 10.4

Gear Shift Selector Removal, 8.4

Gearcase Assembly, Rear , 7.26

Gearcase Assembly/Inspection, Front, 7.12

Gearcase Coil Resistance, Front, 7.10

Gearcase Diagnosis -- Centralized Hilliard, Front,

7.14

Gearcase Disassembly, Front, 7.10

Gearcase Disassembly, Rear , 7.25

Gearcase Exploded View, Front, 7.16

Gearcase Exploded View, Rear , 7.28

Gearcase Installation, Front, 7.15

Gearcase Installation, Rear , 7.24

Gearcase Lubricatin, Front/Rear, 2.9

Gearcase Operation (4X4), Front, 7.9

Gearcase Removal, Front, 7.8

Gearcase Removal, Rear , 7.24

Glossary of Terms, 1.17, 1.18

H

Headlamp Service, 10.21, 10.22

Headlamp Switch Testing, 10.22

Headlight Adjustment, 10.21

High Engine Coolant Temperature, 10.5

High/Low Battery Voltage, 10.5

Honing to Oversize, 3.17

Hour Meter, 10.5

Hub Installation, Rear, 7.18

Hub Removal, Rear, 7.17

I

Idle Speed Adjustment, 2.12

Ignition System Components, 10.2

Ignition System Testing, 10.14

Ignition Timing Curve, 10.4

Instrument Cluster Troubleshooting, 10.5

J

Jetting Guidelines, 4.4

K

Keys, Replacement, 1.12

L

Load Test, 10.20

Low Oil Pressure, 10.5

Lubricants, 2.5

Lubricants, Recommended, 2.4

Lubricatin Charts, 2.7, 2.8

Lubricatin, Transmission, 2.10, 8.4

M

Machine Dimensions, 1.4, 1.5

Mag Cover Seal Replacement, 3.51

Maintenance Chart, Periodic, 2.2, 2.3

Master Cylinder Installation, 9.7

Master Cylinder Removal, 9.6

Model & Serial Number Location, 1.2

Model Identification, 1.2

O

Oil Check , Engine, 2.21

Oil Filter Change, 2.21

Oil Flow, 3.18

Oil Pressure Test, 3.17

P

Paint Codes, 1.12

Pilot Screw Adjustment, 2.12

Piston Identification, 3.9

Piston Removal, 3.29

Piston Ring Installed Gap, 3.33, 3.34

Piston to Cylinder Clearance, 3.31

Piston/Rod Inspection, 3.32

Pre-Ride Inspection, 2.3

Progammable Service Interval, 10.5

Programmable Service Interval, 10.5, 10.6

Publication Numbers, 1.12

Push Rod Inspection, 3.19

PVT Assembly, 6.8

PVT Disassembly, 6.7

PVT Drying, 2.20, 6.5

PVT Maintenance, 6.5

PVT Operation, 6.4

PVT Overheating, 6.6

PVT System Sealing/Ducting Components, 6.2

PVT Troubleshooting, 6.24, 6.25

R

Radiator Coolant Level Inspection, 2.18

Radiator Front Cover Removal, 2.18

Radiator, Maintenance, 2.17

Rear Caliper Assembly, 9.18

Rear Drive Shaft Installation, 7.21

Rear Drive Shaft Removal, 7.20

Rear Drive Shaft Service, 7.22

Hub Assembly, Rear , 7.20

Hub Disassembly, Rear , 7.19

Rear Suspension Exploded View, 5.6

Rocker Arm Inspection, 3.19

S

Sediment Tube, Maintenance, 2.19

Shift Linkage Adjustment, 2.11

Shift Weights, 6.10

Side Panel Removal, 5.9

Spark Plug Maintenance, 2.16

Special Tools, 2.6, 4.4, 7.3, 9.2

Special Tools, CH 3, 3.7

Special Tools, PVT, 6.4

Specifications, Brake, 9.2

Specifications, Cooling System, 3.14

Specifications, Drive Clutch Spring, 6.9

Specifications, Model, 1.6, 1.7, 1.8, 1.9, 1.10,

1.11

Specifications, Torque, Brakes, 9.2

Specifications, Torque, Engine, 3.8

Specifications, Torque, Final Drive, 7.3

Specifications, Torque, PVT, 6.4

Specifications, Torque, Standard, 1.13

Specifications, Torque, Steering, 5.8

Specifications, Torque, Suspension, 5.8

Specifications, Torque, Transmission, 8.4

Speedometer Installation, 10.7

Speedometer Troubleshooting, 10.8, 10.9, 10.10,

10.11, 10.12

Speedometer Removal, 10.7

Speedometer/Odometer, 10.5

Spider Removal, 6.12

Starter Assembly, 10.26, 10.28

Starter Disassembly, 10.23

Starter Drive, 10.27

Starter Drive Removal/Inspection, 3.33

Starter Motor Armature Testing, 10.25

Starter Motor Brush Inspection/Replacement,

10.24

Starter Motor Cleaning, 10.25

Starter Solenoid Bench Test, 10.26

Starter System Test, 10.29

Stator Removal/Inspection, 3.34, 3.35

Steering Maintenance, 2.22

Steering Post Assembly, 5.10

Suspension Preload Adjustment, 2.28

Suspension, Front, Inspection, 2.28

Suspension, Rear, Inspection, 2.28

T

Taillight Lamp Replacement, 10.22

Tap Drill Chart, 1.16

Throttle Cable Adjustment, 2.12

Throttle Operation, 2.11

Tie Rod Inspection, 2.23

Timing Check Procedure, 10.3, 10.4

Tire Inspection, 2.29

Tire Pressure, 2.29

Tire Tread Depth, 2.29

Toe Alignment, 2.25

Torque Patterns, Engine, 3.9

Transmission Disassembly, 8.5, 8.6, 8.7, 8.8, 8.9,

8.10, 8.11

Transmission I.D. Location, 1.2

Transmission Installation, 8.5

Transmission Reassembly, 8.11, 8.12, 8.13, 8.14,

8.15

Transmission Removal, 8.4, 8.5

Transmission, Exploded View, 8.2, 8.3

Trigger Coil Gap, 10.4

Troubleshooting, Brakes, 9.19

Troubleshooting, Cooling System, 3.57

Troubleshooting, Engine, 3.56, 3.57

Troubleshooting, Fuel System/Carb, 4.12

Troubleshooting, Ignition System, 10.15

Troubleshooting, Spark Plug, 3.56

Troubleshooting, Starter System, 10.23

U

U--Joint Assembly, 7.7

U--Joint Disassembly, 7.7

Unit of Measure Conversion Table, 1.15

V

Valve Inspection, 3.22

Valve Lifter Removal/Inspection, 3.29

Valve Seal Testing, 3.26

Valve Seat Inspection, 3.23

Valve Seat Reconditioning, 3.23, 3.24, 3.25

Vent Line Maintenance, 2.14

VIN Identification, 1.2

Voltage Drop Test, 10.23

Voltage Test Open Circuit, 10.19

W

Warning Indications for Rider Information Center,

10.6

Water/Oil Pump Removal, 3.41

Wheel Inspection, 2.28

Wheel Installation, 2.29

Wheel Removal Front or Rear, 2.28

Wheel, Hub, Spindle Torque, 2.28

Wiring Diagram, 2002, Sportsman 700, 10.31

Wiring Diagram, 2003, Sportsman 600/700, 10.32



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