Positioning:
Essential resource for Polaris Sportsman 600/700 owners and technicians seeking to perform their own maintenance and repairs.
Value Proposition:
Offers significant cost savings compared to dealership or independent shop labor charges by empowering DIY repairs and maintenance.
Feature Highlight:
This manual is designed to cover all aspects of the vehicle's operation, maintenance, and repair, providing professional-level guidance.
Engine:
Engine overhaul, disassembly, assembly, lubrication, cooling system, exhaust system
Transmission:
Drive clutch, driven clutch, final drive, gearbox, maintenance, repair
Brakes:
Hydraulic brake system, calipers, master cylinder, brake fluid, bleeding procedures
Electrical:
Ignition system, starter, charging system (stator, regulator/rectifier), battery, lighting, wiring diagrams, electrical troubleshooting
Suspension:
Front and rear suspension, shocks, A-arms, bushings, wheel bearings
Steering:
Steering system, tie rods, steering shaft, adjustments
Fuel System:
Carburetor(s), fuel pump, fuel lines, fuel filter, maintenance and adjustments
Body Chassis:
Frame inspection, body panels, fenders, racks, seat, graphics
Maintenance:
Scheduled maintenance, oil changes, filter replacements, lubrication points, valve adjustments
Troubleshooting:
Diagnostic charts, symptom-based troubleshooting, common problems and solutions
Repair:
Step-by-step repair instructions for all major components and systems
Rebuild:
Complete engine and transmission rebuild procedures
Assembly Disassembly:
Detailed instructions for component removal and installation
Depth Level:
Comprehensive: from basic owner maintenance to advanced mechanical and electrical repair
Detail Level:
Includes torque specifications, clearances, timing marks, and detailed diagrams
Engine Type:
4-stroke, liquid-cooled, SOHC, V-Twin (for both 600 and 700 models, displacement varies)
Engine 600 Displacement:
597cc
Engine 700 Displacement:
683cc
Horsepower Estimate 600:
Approx. 45-50 HP (model dependent)
Horsepower Estimate 700:
Approx. 50-55 HP (model dependent)
Carburetor Type:
Mikuni (specific models vary, e.g., VM34 or dual carburetors)
Fuel Type:
Unleaded Gasoline
Cooling System:
Liquid Cooling with fan assist
Ignition System:
Electronic Ignition (CDI)
Transmission Type:
Automatic (CVT - Continuously Variable Transmission)
Drive System:
On-Demand All-Wheel Drive (AWD) with 2WD option
Clutch System:
Polaris Variable Transmission (PVT) with High/Low range and Reverse
Transmission Fluid:
Polaris AGL Premium Synthetic Gearcase Lubricant or equivalent SAE 30 premium quality oil
Length:
Approx. 81 inches (205.7 cm)
Width:
Approx. 46 inches (116.8 cm)
Height:
Approx. 45 inches (114.3 cm)
Dry Weight:
Approx. 575-590 lbs (261-268 kg)
Ground Clearance:
Approx. 10.25 inches (26 cm)
Front Rack Capacity:
300 lbs (136 kg)
Rear Rack Capacity:
600 lbs (272 kg)
Towing Capacity:
1500 lbs (680 kg)
Wheelbase:
50.5 inches (128.3 cm)
Oil Change Interval:
Every 100 hours or annually (whichever comes first)
Air Filter Cleaning:
Every 25 hours or every 6 months
Spark Plug Replacement:
Every 100 hours or annually
Valve Adjustment Interval:
Every 100 hours or annually
Engine Oil Type:
Polaris PS-4 4-stroke synthetic engine oil (or SAE 0W-40 or 5W-40 synthetic motorcycle oil)
Engine Oil Capacity:
Approx. 2.5 US quarts (2.4 liters) with filter change
Coolant Type:
Polaris Engineered Coolant or a premium quality ethylene glycol-based antifreeze with corrosion inhibitors (e.g., 50/50 mix)
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid
Common Wear Items:
CV joint boots, suspension bushings, drive belt, brake pads, wheel bearings
Electrical Common Failures:
Stator, regulator/rectifier failures, CDI unit issues reported on some models.
Engine Common Issues:
Carburetor tuning and adjustment, occasional starter motor issues.
Polaris Heritage:
Polaris Industries, founded in 1954, is a major American manufacturer known for its snowmobiles, ATVs, UTVs, and motorcycles.
Sportsman Lineage:
The Sportsman line has been a cornerstone of Polaris's ATV offerings, evolving from utility-focused machines to more versatile and powerful platforms. The 600 and 700 models represented a significant step up in power and capability for their time.
Production Period:
2002-2003 model years
Industry Recognition:
The Polaris Sportsman line has consistently received positive reviews and recognition for its performance, comfort, and utility in the ATV market.
Consumer Ratings:
Owners generally praise the power and off-road capability of the 600 and 700 models, particularly for trail riding and utility tasks.
Certification:
Meets relevant safety and emissions standards for ATVs of its era.
