Polaris SPORTSMAN 600 2003 Bedienungsanleitung

PN 9918066

Printed in USA

2002-2003 SPORTSMAN 600/700 SERVICE MANUAL PN 9918066

2003 SPORTSMAN 600

2002-2003 SPORTSMAN 700

SERVICE MANUAL

PN 9918066

223336_coverB 9/17/02 10:22 PM Page 1

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

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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)

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.

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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

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GENERAL INFORMATION

1.1

CHAPTER 1

GENERAL INFORMATION

Model Identification 1.2.......................

Serial Number Location 1.2...................

2003 Sportsman Models 1.3..................

Machine Dimensions 1.4-1.5.....................

Specifications - 2002 Sportsman 00 1.6-1........

Specifications - 2003 Sportsman 600 1.8-1.9.......

Specifications - 2003 Sportsman 00 1.10-1.11.......

Publication Numbers 1.12.....................

Paint Codes 1.12.............................

Replacement Keys 1.12.......................

Standard Torque Specifications 1.13............

Decimal Equivalent Chart 1.14.................

Conversion Table 1.15........................

Tap Drill Charts 1.16..........................

Glossary of Terms 1.1 -1.18........................

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GENERAL INFORMATION

1.2

MODEL IDENTIFICATION

The machine model number must be used with any correspondence regarding warranty or service.

Machine Model Number Identification

Year Designation Basic Chassis

Designation Engine Designation

A03CH68AA

Emissions &

Model Option

ENGINE DESIGNATION NUMBERS

EH068OLE11 Twin cylinder, Liquid Cooled, 4 Stroke, Electric Start...............

EH059OLE11 Twin cylinder, Liquid Cooled, 4 Stroke, Electric Start...............

VIN IDENTIFICATION

1234568910 1112 13 14 15 16 1

4XA C H 68A* 2P0 00 000

Vehicle Description Vehicle Identifier

Powertrain

Engine

Emissions Model

Year

Plant No.

Individual Serial No.

Body Style

Check Digit

World Mfg. ID

* This could be either

a number or a letter

ENGINE SERIAL NUMBER LOCATION

Whenever corresponding about an engine, be sure to refer to

the engine model number and serial number. This information

can be found on the sticker applied to the top side of the

crankcase (A). An additional number is stamped on the side of

the crankcase beneath the cylinder coolant elbow.

MACHINE MODEL NUMBER AND

SERIAL NUMBER LOCATION

The machine model number and serial number are

important for vehicle identification. The machine serial

number is stamped on the lower left side of the frame

tube.(B)

TRANSMISSION I.D. NUMBER

LOCATION

Front

The transmission I.D. number is located on

the right side of machine.

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SPORTSMAN 600

SPORTSMAN 700

NOTE: MODELS WILL VARY IN COLOR.

GENERAL INFORMATION

1.3

2003 SPRORTSMAN 600 & 700 MODELS

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46 in

116.84 cm

85 in

215.90 cm

50.75 in

128.90 cm

FRONT

SIDE

GENERAL INFORMATION

1.4

MACHINE DIMENSIONS

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46 in

116.84 cm

47 in

119.38 cm

11 in

27.94 cm

46 in

116.84 cm

REAR

GENERAL INFORMATION

1.5

MACHINE DIMENSIONS

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GENERAL INFORMATION

1.6

MODEL: 2002 SPORTSMAN 700..........

MODEL NUMBER: A02CH68AA/CA.

ENGINE MODEL: EH68ALOE1..

JETTING CHART

AMBIENT TEMPERATURE

Altitude Below 40°F+40_F and above

Below +5°C

+5_C and above

Meters 0-1800

(Feet)

(0-6000) 167.5 162.5

(

)

Above 1800

Above (6000) 160 155

CLUTCH CHART

*EBS require no helix/spring adjustment

Shift

Drive Clutch

Driven Clutch

Driven

Weight Spring Spring Helix

Meters 0-1800

(Feet)

(0-6000) 20--56

(5631215) White/Yellow EBS

(

)

1800-3700

(6000-12000) 20--54

(5631214) White/Yellow EBS

ENGINE

Type 4 Cycle, Twin Cyl........................

Displacement 683 cc...............

Bore 3.149I(80 mm).......................

Stroke 2.677I(68 mm).....................

Valve Clearance In/Ex 0.006/0.006I@ TDC on compression.......

Compression Ratio 9.78/1 Full Stroke..........

Cooling Liquid....................

Lubrication Type Pressurized Wet Sump............

Operating RPM±200 6000 RPM.........

Idle RPM±200 (lights off) 1100 RPM.....

Compression Pressure (Std) ±15%.......

CARBURETION

Type BST 34 Mikuni................

Main Jet 162.5............

Pilot Jet 45.............

Jet Needle 4BH41--4...........

Needle Jet P-6...........

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 PVT....................

Belt 3211091.....................

Belt Width (Projected) 1.188I(30.18mm).....

Side Angle (Overall) 28°±2°......

Outside Circumference 40.875 ±.188I....

Center Distance 10±.12I(254.5mm)..........

Clutch Offset 0.5I(12.7mm)............

Secondary Spring White/Yellow........

Driven Helix Compound (EBS).............

Spring Position (Helix) N/A....

Spring Position (Sheave) N/A..

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