The Unparalleled 2003 Polaris Sportsman 600 & 2002-2003 Polaris Sportsman 700: Unveiling a Legacy of Unmatched Performance
At the pinnacle of all-terrain prowess, the 2003 Polaris Sportsman 600 and its formidable 2002-2003 Polaris Sportsman 700 sibling stand as true paragons of off-roading excellence. These legendary machines embody the very essence of innovation, engineering brilliance, and unwavering reliability, meticulously engineered to conquer the most unforgiving terrain with unmatched versatility and adrenaline-pumping performance.
2003 Polaris Sportsman 600: A Symphony of Power and Precision
With its potent, liquid-cooled, single-cylinder engine displacing 598 cubic centimeters, the 2003 Polaris Sportsman 600 unleashes a symphony of raw power and precision. This indomitable powerhouse delivers an exhilarating surge of acceleration and effortlessly tackles obstacles that would leave lesser ATVs struggling. Whether traversing treacherous mud bogs or ascending steep inclines, the 600's unwavering torque and responsive handling inspire confidence in every maneuver.
Its advanced suspension system, featuring a robust independent front suspension and a robust rear suspension with adjustable preload, ensures an unparalleled ride quality. The 600 glides over rough terrain with remarkable stability, soaking up bumps and obstacles with ease while maintaining exceptional control. This meticulous attention to suspension design empowers riders to tackle even the most demanding trails with both precision and comfort.
2002-2003 Polaris Sportsman 700: Dominating the Off-Road Realm
The 2002-2003 Polaris Sportsman 700 takes all-terrain performance to new heights with its formidable 695 cubic centimeter, liquid-cooled, single-cylinder engine. This unstoppable force delivers staggering torque and effortless acceleration, propelling the 700 forward with incredible authority. Its advanced electronic fuel injection system ensures precise fuel delivery, resulting in optimal performance and efficiency in all conditions.
Fortified with a heavy-duty suspension system that seamlessly harmonizes independent front suspension with a robust rear suspension with an adjustable preload and sway bar, the 700 conquers the most extreme terrain with unwavering composure. This meticulously engineered suspension system absorbs the harshest impacts with aplomb, providing riders with an unparalleled level of control and comfort. The 700's exceptional ground clearance and aggressive tires further enhance its off-road capability, empowering riders to navigate rugged landscapes with newfound confidence.
Unveiling the Technological Edge
The 2003 Polaris Sportsman 600 and 2002-2003 Polaris Sportsman 700 are not merely all-terrain vehicles; they represent a fusion of cutting-edge technology and innovative engineering. These machines are endowed with an array of advanced features that elevate their performance and functionality to unparalleled levels.
The 600's intuitive digital instrument panel relays vital information at a glance, including speedometer, odometer, trip meter, hour meter, and fuel level. This comprehensive display empowers riders with real-time insights into their vehicle's performance, enabling them to make informed decisions while navigating the most challenging trails.
The 700, with its advanced electronic fuel injection system, ensures optimal fuel delivery under all conditions. This sophisticated system continuously monitors engine parameters and adjusts the fuel mixture accordingly, resulting in enhanced performance, improved fuel economy, and reduced emissions. The 700's front-mounted radiator and fan optimize cooling efficiency, ensuring consistent performance even in the most demanding off-road environments.
A Legacy of Rugged Durability
The 2003 Polaris Sportsman 600 and 2002-2003 Polaris Sportsman 700 are not simply high-performance all-terrain vehicles; they are built to endure the most extreme conditions and withstand the rigors of off-road adventure. Their durable construction and meticulous attention to detail ensure years of unwavering reliability and unmatched longevity.
The 600's rugged chassis and resilient components withstand the relentless pounding of rough terrain, providing a solid foundation for its exceptional performance. Its robust front and rear cargo racks provide ample storage capacity for essential gear and accessories, empowering riders to venture into the wilderness with confidence.
The 700's heavy-duty frame and suspension components have been meticulously engineered to withstand the demands of off-road abuse. Its durable polycarbonate body panels resist scratches and dents, maintaining the 700's pristine appearance even after countless expeditions.
Unleashing the Adventure Spirit
The 2003 Polaris Sportsman 600 and 2002-2003 Polaris Sportsman 700 are more than mere machines; they are the embodiment of the adventurous spirit. They empower riders to explore uncharted territories, conquer challenging landscapes, and experience the exhilarating freedom of off-road exploration.
Whether traversing dense forests, tackling rocky trails, or navigating muddy bogs, the 600 and 700 offer riders an unforgettable experience
2003 Polaris Sportsman 600 & 2002 - 2003 Polaris Sportsman 700 ATV Factory Service / Repair/ Workshop Manual
Modell Year: 2002 2003
Languages: English
File Format: PDF
DELIVERED Format IN: PDF
ZOOM IN/OUT: Yes
Printable: Yes
QUALITY OF MANUAL: Factory
* INSTANT DOWNLOAD
* NO SHIPPING COST
* NO NEED TO WAIT FOR A CD-ROM
SERVICE MANUAL COVERS:
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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
Numbers
2003 Sportsman 600/700 Models, 1.3
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 Lubrication, 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 Lubrication, 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
Lubrication Charts, 2.7, 2.8
Lubrication, 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
TAGS:
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