Product Category:
High-performance utility ATV
Target Audience:
Outdoor enthusiasts, hunters, farmers, recreational riders, professional mechanics
Competitors:
Yamaha Grizzly, Can-Am Outlander, Arctic Cat 500/700, Honda Foreman/Rancher
Key Differentiators:
Polaris's focus on powerful engines, independent rear suspension (IRS) on many models, and robust chassis design for challenging terrain.
Manual Value Proposition:
Empowers owners to perform professional-grade maintenance and repairs, saving time and money.
Manual Utility:
Essential tool for diagnosing and resolving issues, ensuring optimal performance and longevity of the ATV.
Overall Coverage:
Comprehensive repair and maintenance for all major ATV systems
Engine Coverage:
Engine overhaul, top-end rebuild, bottom-end rebuild, cooling system, lubrication system, fuel system, ignition system
Transmission Coverage:
PVT (Polaris Variable Transmission) belt replacement, clutch service, gearcase service, driveline components
Chassis Coverage:
Frame, suspension (front and rear), steering, brakes, wheels, tires
Electrical Coverage:
Wiring diagrams, lighting, ignition system, starting system, charging system, instruments, accessories
Estimated Page Count:
Likely 400-600 pages (typical for factory service manuals of this era and complexity)
Manual Type:
Factory Service Manual / Workshop Manual
Powertrain Systems:
Engine, cooling, fuel delivery, exhaust, PVT transmission, differentials, driveshafts, axles
Chassis And Body:
Frame, plastics, seating, handlebars, racks, fenders, skid plates
Suspension And Steering:
Front and rear suspension components (shocks, arms, bushings), steering linkage, tie rods, wheel bearings
Braking System:
Hydraulic brake system (master cylinders, calipers, lines, levers), parking brake
Electrical System:
Battery, starter, alternator, ignition coil, CDI unit, lighting (headlights, taillight, brake light), instrumentation cluster, fan control, winch wiring (if applicable)
Routine Maintenance:
Oil changes, filter replacements (oil, air), spark plug service, lubrication points, coolant checks, brake adjustments, tire pressure checks, PVT belt inspection/replacement
Repair Procedures:
Engine rebuilds (top-end and bottom-end), transmission overhauls, suspension component replacement, brake system repairs, electrical diagnostics and repair, steering system servicing
Troubleshooting:
Systematic diagnostic guides for common issues (e.g., starting problems, poor performance, braking issues, electrical faults)
Technical Specifications:
Torque specifications for all fasteners, fluid capacities and types, clearances, timing specifications, electrical component testing values
Depth Of Coverage:
Factory-level detail, suitable for complete disassembly and reassembly of all major components. Includes diagnostic flowcharts and troubleshooting trees.
Print Quality:
High-resolution scans of original factory manual pages, ensuring clarity of text and diagrams.
Binding Type:
Not applicable (digital download)
Paper Type:
Not applicable (digital download)
Text Searchability:
Likely searchable PDF, allowing for quick location of specific topics or keywords.
Engine Type 600:
Liquid-cooled, 2-stroke, parallel-twin cylinder (common for this era's Polaris 600 engine)
Engine Displacement 600:
Approximately 580cc (typical for Polaris 600 twin)
Engine Type 700:
Liquid-cooled, 4-stroke, SOHC, parallel-twin cylinder (common for this era's Polaris 700 engine)
Engine Displacement 700:
Approximately 698cc (typical for Polaris 700 twin)
Horsepower 600:
Estimated 50-60 HP (typical for 2-stroke twins of this size)
Horsepower 700:
Estimated 50-60 HP (typical for 4-stroke twins of this size, though torque is often higher)
Torque 700:
Expected to be significantly higher than the 600, providing better low-end grunt.
Fuel Delivery 600:
Carbureted (likely Mikuni or Keihin twin carburetors)
Fuel Delivery 700:
Fuel Injection (EFI) or Carbureted (depending on specific sub-model/region, but EFI was becoming prevalent)
Transmission Type:
Polaris Variable Transmission (PVT) with Engine Braking
Drive System:
Shaft Drive with On-Demand All-Wheel Drive (AWD)
Gear Selection:
High (H), Low (L), Neutral (N), Reverse (R), Park (P)
Pvt Fluid Type:
Polaris AGL Premium Gearcase Lubricant (or equivalent SAE 80W-90 gear oil for the gearcase)
Length:
Approximately 83 inches (210.8 cm) - Typical for Sportsman models
Width:
Approximately 46 inches (116.8 cm) - Typical for Sportsman models
Height:
Approximately 47 inches (119.4 cm) - Typical for Sportsman models
Dry Weight:
Approximately 600-650 lbs (272-295 kg) - Varies by model and year
Ground Clearance:
Approximately 10.5 inches (26.7 cm)
Front Rack Capacity:
Typically 50 lbs (22.7 kg)
Rear Rack Capacity:
Typically 100 lbs (45.4 kg)
Towing Capacity:
Typically 1500 lbs (680 kg)
Front Tire Size:
25x8-12 or 26x8-12 (common)
Rear Tire Size:
25x11-12 or 26x11-12 (common)
Wheel Bolt Pattern:
4x110mm (common for Polaris ATVs)
Atv Safety Standards:
Compliant with ANSI/SVIA-1-2010 and B71.4-2004 standards where applicable.
Braking System Type:
Hydraulic disc brakes, front and rear
Parking Brake:
Hand-lever activated
Rollover Protection:
N/A for ATV design; rider responsibility
Lighting Package:
Dual headlights, taillight, brake light
Instrumentation:
Digital/analog instrument cluster typically includes speedometer, tachometer, odometer, trip meter, fuel gauge, neutral/reverse indicators, and warning lights.
Engine Braking:
Standard feature of the Polaris Variable Transmission (PVT), providing engine braking on descents.
Accessory Charging:
Typically includes a DC power outlet for charging accessories.
Engine Oil Change Interval:
Typically every 25 hours or annually, whichever comes first.
Pvt Belt Inspection Interval:
Every 25 hours or annually.
Air Filter Cleaning:
As needed, depending on operating conditions (frequently recommended for dusty environments).
Engine Oil 600 2Stroke:
Polaris 2-Stroke Synthetic Oil or equivalent premium 2-stroke oil suitable for liquid-cooled engines.
Engine Oil 700 4Stroke:
Polaris 4-Stroke Synthetic Oil or equivalent SAE 10W-40 motorcycle/ATV engine oil meeting API SG or higher specifications.
Coolant Type:
Permanent type antifreeze/coolant (ethylene glycol based) with corrosion inhibitors. Typically a 50/50 mix with distilled water.
Brake Fluid Type:
DOT 3 or DOT 4 Hydraulic Brake Fluid.
Common Wear Items:
PVT belts (wear and tear), ball joints, tie rod ends, wheel bearings, brake pads.
Potential Engine Issues:
For 2-stroke 600: carbon buildup, potential for overheating if cooling system isn't maintained. For 4-stroke 700: valve adjustment, potential for cam chain tensioner issues.
Electrical Concerns:
Wiring harness integrity, stator or regulator/rectifier failures can occur with age and vibration.
Polaris History:
Polaris Industries Inc. has been a leading manufacturer of powersports vehicles since its founding in 1954, known for innovation in snowmobiles, ATVs, and motorcycles.
Sportsman Lineage:
The Sportsman line has been a cornerstone of Polaris's ATV offerings, evolving from basic utility models to feature-rich recreational and work platforms. The 600 and 700 models represent a significant step up in power and performance in the early 2000s.
Manufacturing Location:
Typically manufactured in Roseau, Minnesota, USA.
Production Period:
Models covered are from the early 2000s, a period of significant growth and technological advancement for Polaris ATVs.
