Polaris 2003 SPORTSMAN 600 User manual

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)
ECopyright 2002 Polaris Sales Inc. All information contained within this publication is based on the latest product information at the
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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1
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
A
B
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
GENERAL INFORMATIONGENERAL 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
GENERAL INFORMATIONGENERAL INFORMATION
1.5
MACHINE DIMENSIONS
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GENERAL INFORMATION
GENERAL INFORMATIONGENERAL 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
l
t
i
t
u
d
e
B
e
l
o
w
4
0
F
Below +5°C
+
4
0
F
a
n
d
a
b
o
v
e
+5_C and above
Meters 0-1800
1
6
7
5
1
6
2
5
M
e
t
e
r
s
(Feet)
0
-
1
8
0
0
(0-6000) 167.5 162.5
(
F
e
e
t
)
Above 1800
1
6
0
1
5
5
A
b
o
v
e
1
8
0
0
Above (6000) 160 155
CLUTCH CHART
*EBS require no helix/spring adjustment
S
h
i
f
t
D
r
i
v
e
C
l
u
t
c
h
D
r
i
v
e
n
C
l
u
t
c
h
D
r
i
v
e
n
A
l
t
i
t
u
d
e
Shift
W
e
i
g
h
t
Drive Clutch
S
p
r
i
n
g
Driven Clutch
S
p
r
i
n
g
Driven
H
e
l
i
x
A
l
t
i
t
u
d
e
Weight Spring Spring Helix
Meters 0-1800
2
0
5
6
Bl
u
e
/
G
r
e
e
n
W
h
i
t
e
/
Y
e
l
l
o
w
E
B
S
M
e
t
e
r
s
(Feet)
0
-
1
8
0
0
(0-6000) 20--56
B
l
u
e
/
G
r
e
e
n
(5631215) White/Yellow EBS
(
F
e
e
t
)
1800-3700
2
0
5
4
Bl
u
e
/
G
r
e
e
n
W
h
i
t
e
/
Y
e
l
l
o
w
E
B
S
1
8
0
0
-
3
7
0
0
(6000-12000) 20--54
B
l
u
e
/
G
r
e
e
n
(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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Lubricant Key
GENERAL INFORMATION
GENERAL INFORMATIONGENERAL INFORMATION
1.7
MODEL: 2002 SPORTSMAN 700 ............
MODEL NUMBER: A02CH68AA/CA...
ENGINE MODEL: EH68ALOE1....
ELECTRICAL FLUID Capacity Type
Flywheel I.D. 4060152 Fuel Tank 4.75 gals. (17.9 L)...... ..........
CDI Marking 4010364 Coolant 3.2 qts. (3 L) *PP6....... ............ .
Alternator Output 300 Watts Transmission 13.50 oz. *PPS... ....... ....
Ignition Timing 25°BTDC@3000±500RPM Gearcase Oil (Front).. 5 oz. (150 ml)...*PDD.....
Spark Plug / Gap RC7YC -- 0.036I(0.9mm) Gearcase Oil (Rear) 5oz. (150 ml) 80--90 GL5... . .
Lights: Head 50 Watt Quartz Engine Oil 2 qts. (1.9L) *PP4...... .......... ..
Grill (2) 27 Watts Quartz Brake (Hand) Dot 3.... .......
Tail 8.26 watts Brake (Foot) Dot 3........ ........
Brake 26.9 watts......
Voltage Regulator LR39 *PP6 Polaris Premium 60/40 Antifreeze/Coolant..
Electric Start Standard *PPS Polaris Premium Synthetic Gear Case Oi.......
Instrument Cluster LCD *PP4 Polaris 0W--40 Synthetic Engine Lubricant..
*PDD Premium Demand Drive Hub Fluid
SUSPENSION / CHASSIS DRIVE TRAIN
Body Style Gen IV 4 Wheel Independent Shaft Drive........
Front Suspension MacPherson Strut Gear Reduction-Low 7.5/1.. .
Tow Capacity 1225 lbs. (555.6 kg) Gear Reduction-Rev 5.11/1...... .
Turning Radius 76I(181.61 cm) Gear Reduction-High 3.09/1.....
Toe Out 1/8I-1/4I(3-6.35 mm) Front Drive Ratio 3.82/1........... ....
Ground Clearance 11I(27.94 cm) Final Drive Ratio 3.10/1.. ....
Front Vertical Travel 6.7I(17.02 cm) Brake (Hand) Single Lever, Hyd. Disc.......
Rear Suspension Progressive Rate Independent Brake (Auxiliary Foot) Hydraulic...
Rear Travel 9.5I(24.13 cm) Transmission Park Lock........
Rear Shock 2ITwin Tube........
Shock Adjustment Cam..
TIRES
TireSize-Front 25x8-12....
Tire Size - Rear 25 x 11 - 12....
Tire Pressure - F/R 5/5 lbs.
Total Width 46I(116.84 cm)........
Total Length 85I(215.90 cm).......
Total Height 47I(119.38 cm)........
Wheel Base 50.75I(128.90 cm).......
Weight - Dry 740 lbs. (335.60 kg).......
LOAD CAPACITY
Front Rack (Std) 90 lbs......
Rear Rack (Std) 180 lbs.......
Tongue Weight 150 lbs.....
Hitch Towing Capacity...1500 lbs.
Enfocus Software - Customer Support

GENERAL INFORMATION
1.8
MODEL: 2003 SPORTSMAN 600 ..........
MODEL NUMBER: A03CH59.
ENGINE MODEL: EH059OLE..
JETTING CHART
AMBIENT TEMPERATURE
Altitude Below 40qF+40_F and above
A
l
t
i
t
u
d
e
B
e
l
o
w
4
0
F
Below +5qC
+
4
0
F
a
n
d
a
b
o
v
e
+5_C and above
Meters 0-1800
1
6
2
5
1
5
5
M
e
t
e
r
s
(Feet)
0
-
1
8
0
0
(0-6000) 162.5 155
(
F
e
e
t
)
Above 1800
1
5
0
1
4
5
A
b
o
v
e
1
8
0
0
Above (6000) 150 145
CLUTCH CHART
*EBS require no helix/spring adjustment
S
h
i
f
t
D
r
i
v
e
C
l
u
t
c
h
D
r
i
v
e
n
C
l
u
t
c
h
D
r
i
v
e
n
A
l
t
i
t
u
d
e
Shift
W
e
i
g
h
t
Drive Clutch
S
p
r
i
n
g
Driven Clutch
S
p
r
i
n
g
Driven
H
e
l
i
x
A
l
t
i
t
u
d
e
Weight Spring Spring Helix
Meters 0-1800
1
0
M
H
Bl
u
e
/
G
r
e
e
n
W
h
i
t
e
/
Y
e
l
l
o
w
E
B
S
M
e
t
e
r
s
(Feet)
0
-
1
8
0
0
(0-6000) 10 MH
B
l
u
e
/
G
r
e
e
n
(5631215) White/Yellow EBS
(
F
e
e
t
)
1800-3700
1
0
W
H
Bl
u
e
/
G
r
e
e
n
W
h
i
t
e
/
Y
e
l
l
o
w
E
B
S
1
8
0
0
-
3
7
0
0
(6000-12000) 10 WH
B
l
u
e
/
G
r
e
e
n
(5631214) White/Yellow EBS
ENGINE
Type 4 Cycle, Twin Cyl........................
Displacement 597 cc...............
Bore 3.012I(76.5 mm).......................
Stroke 2.559I(65 mm).....................
Compression Ratio 9.35/1 Full Stroke..........
Cooling Liquid....................
Lubrication Type Pressurized Wet Sump............
Operating RPMr200 6000 RPM.........
Idle RPM r100 (lights off) 1100 RPM....
Compression Pressure 150--170psi r15%.......
CARBURETION
Type BST 34 Mikuni................
Main Jet 155............
Pilot Jet 45.............
Jet Needle J8--4FA01--3...........
Needle Jet P-4...........
Throttle Valve #100........
Pilot Screw 1.5 Turns Out..........
Pilot Air Jet 160..........
Valve Seat 1.5...........
Float Height 14.7mm (.58I)r1mm.........
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) 28qr2q......
Outside Circumference 40.875 r.188I....
Center Distance 10r.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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Lubricant Key
GENERAL INFORMATION
1.9
MODEL: 2003 SPORTSMAN 600 ............
MODEL NUMBER: A03CH59...
ENGINE MODEL: EH059OLE....
ELECTRICAL FLUID Capacity Type
Flywheel I.D. 4060152 Fuel Tank 4.75 gals. (17.9 L)...... ..........
CDI Marking 4010785 Coolant 3.2 qts. (3 L) *PP6....... ............ .
Alternator Output 300Watts Transmission 13.50 oz. *PPS... ....... ....
Ignition Timing 25qBTDC@3000RPMr500 Gearcase Oil (Front).. 5 oz. (150 ml)...*PDD.....
Spark Plug / Gap RC7YC -- 0.035I(0.9mm) Gearcase Oil (Rear) 5oz. (150 ml) 80--90 GL5... . .
Lights: Head 50 Watt Quartz Engine Oil 2 qts. (1.9L) *PP4...... .......... ..
Grill (2) 27 Watts Quartz Brake (Hand) Dot 3.... .......
Tail 8.26 watts Brake (Foot) Dot 3........ ........
Brake 26.9 watts......
Voltage Regulator LR39 *PP6 Polaris Premium 60/40 Antifreeze/Coolant..
Electric Start Standard *PPS Polaris Premium Synthetic Gear Case Lube.......
Instrument Cluster LCD *PP4 Polaris 0W--40 Synthetic Engine Lubricant..
*PDD Premium Demand Drive Hub Fluid
SUSPENSION / CHASSIS DRIVE TRAIN
Body Style Gen IV 4 Wheel Independent Shaft Drive........
Front Suspension MacPherson Strut Gear Reduction-Low 7.49:1.. .
Tow Capacity 1225 lbs. (555.6 kg) Gear Reduction-Rev 5.11:1...... .
Turning Radius 76I(181.61 cm) Gear Reduction-High 2.89:1.....
Toe O ut 1/ 8I-1/4I(3-6.35 mm) Front Drive Ratio 3.82:1........... ....
Ground Clearance 11I(27.94 cm) Final Drive Ratio 3.10:1.. ....
Front Vertical Travel 6.7I(17.02 cm) Brake (Hand) Single Lever, Hyd. Disc.......
Rear Suspension Progressive Rate Independent Brake (Auxiliary Foot) Hydraulic...
Rear Travel 9.5I(24.13 cm) Transmission Park Lock........
Rear Shock 2ITwin Tube........
Shock Adjustment Cam..
TIRES
TireSize-Front 25x8-12....
Tire Size - Rear 25 x 11 - 12....
Tire Pressure - F/R 5/5 lbs.
Total Width 46I(116.84 cm)........
Total Length 85I(215.90 cm).......
Total Height 47I(119.38 cm)........
Wheel Base 50.75I(128.90 cm).......
Weight - Dry 740 lbs. (335.60 kg).......
LOAD CAPACITY
Front Rack (Std) 90 lbs. (41 kg).....
Rear Rack (Std) 200 lbs. (91 kg)......
Tongue Weight 150 lbs. (68 kg)....
Hitch Towing Capacity...1500 lbs. (681)
Enfocus Software - Customer Support

GENERAL INFORMATION
1.10
MODEL: 2003 SPORTSMAN 700 ..........
MODEL NUMBER: A03CH68.
ENGINE MODEL: EH068OLE..
JETTING CHART
AMBIENT TEMPERATURE
Altitude Below 40qF+40_F and above
A
l
t
i
t
u
d
e
B
e
l
o
w
4
0
F
Below +5qC
+
4
0
F
a
n
d
a
b
o
v
e
+5_C and above
Meters 0-1800
1
6
0
1
5
5
M
e
t
e
r
s
(Feet)
0
-
1
8
0
0
(0-6000) 160 155
(
F
e
e
t
)
Above 1800
1
4
7
5
1
4
2
5
A
b
o
v
e
1
8
0
0
Above (6000) 147.5 142.5
CLUTCH CHART
*EBS require no helix/spring adjustment
S
h
i
f
t
D
r
i
v
e
C
l
u
t
c
h
D
r
i
v
e
n
C
l
u
t
c
h
D
r
i
v
e
n
A
l
t
i
t
u
d
e
Shift
W
e
i
g
h
t
Drive Clutch
S
p
r
i
n
g
Driven Clutch
S
p
r
i
n
g
Driven
H
e
l
i
x
A
l
t
i
t
u
d
e
Weight Spring Spring Helix
Meters 0-1800
2
0
5
6
Bl
u
e
/
G
r
e
e
n
W
h
i
t
e
/
Y
e
l
l
o
w
E
B
S
M
e
t
e
r
s
(Feet)
0
-
1
8
0
0
(0-6000) 20--56
B
l
u
e
/
G
r
e
e
n
(5631215) White/Yellow EBS
(
F
e
e
t
)
1800-3700
2
0
5
4
Bl
u
e
/
G
r
e
e
n
W
h
i
t
e
/
Y
e
l
l
o
w
E
B
S
1
8
0
0
-
3
7
0
0
(6000-12000) 20--54
B
l
u
e
/
G
r
e
e
n
(5631214) White/Yellow EBS
ENGINE
Type 4 Cycle, Twin Cyl........................
Displacement 683 cc...............
Bore 3.149I(80 mm).......................
Stroke 2.677I(68 mm).....................
Compression Ratio 9.78/1 Full Stroke..........
Cooling Liquid....................
Lubrication Type Pressurized Wet Sump............
Operating RPMr200 6000 RPM.........
Idle RPMr100 (lights off) 1100 RPM.....
Compression Pressure 150--170psi r15%.......
CARBURETION
Type BST 34 Mikuni................
Main Jet 155............
Pilot Jet 47.5.............
Jet Needle J8--4FA01--3...........
Needle Jet P-6M (829)...........
Throttle Valve #100........
Pilot Screw 1.5 Turns Out..........
Pilot Air Jet 160..........
Valve Seat 1.5...........
Float Height 14.7mm (.58I)r1mm.........
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) 28qr2q......
Outside Circumference 40.875 r.188I....
Center Distance 10r.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..
Enfocus Software - Customer Support

Lubricant Key
GENERAL INFORMATION
1.11
MODEL: 2003 SPORTSMAN 700 ............
MODEL NUMBER: A03CH68...
ENGINE MODEL: EH068OLE....
ELECTRICAL FLUID Capacity Type
Flywheel I.D. 4060152 Fuel Tank 4.75 gals. (17.9 L)...... ..........
CDI Marking 4010364 Coolant 3.2 qts. (3 L) *PP6....... ............ .
Alternator Output 300 Watts Transmission 13.50 oz. *PPS... ....... ....
Ignition Timing 32qBTDC@5760RPMr200 Gearcase Oil (Front).. 5 oz. (150 ml)...*PDD.....
Spark Plug / Gap RC7YC -- 0.036I(0.9mm) Gearcase Oil (Rear) 5oz. (150 ml) 80--90 GL5... . .
Lights: Head 50 Watt Quartz Engine Oil 2 qts. (1.9L) *PP4...... .......... ..
Grill (2) 27 Watts Quartz Brake (Hand) Dot 3.... .......
Tail 8.26 watts Brake (Foot) Dot 3........ ........
Brake 26.9 watts......
Voltage Regulator LR39 *PP6 Polaris Premium 60/40 Antifreeze/Coolant..
Electric Start Standard *PPS Polaris Premium Synthetic Gear Case Lube.......
Instrument Cluster LCD *PP4 Polaris 0W--40 Synthetic Engine Lubricant..
*PDD Premium Demand Drive Hub Fluid
SUSPENSION / CHASSIS DRIVE TRAIN
Body Style Gen IV 4 Wheel Independent Shaft Drive........
Front Suspension MacPherson Strut Gear Reduction-Low 7.49:1.. .
Tow Capacity 1225 lbs. (555.6 kg) Gear Reduction-Rev 5.1:1...... .
Turning Radius 76I(181.61 cm) Gear Reduction-High 2.89:1.....
Toe O ut 1/ 8I-1/4I(3-6.35 mm) Front Drive Ratio 3.82:1........... ....
Ground Clearance 11I(27.94 cm) Final Drive Ratio 3.10:1.. ....
Front Vertical Travel 6.7I(17.02 cm) Brake (Hand) Single Lever, Hyd. Disc.......
Rear Suspension Progressive Rate Independent Brake (Auxiliary Foot) Hydraulic...
Rear Travel 9.5I(24.13 cm) Transmission Park Lock........
Rear Shock 2ITwin Tube........
Shock Adjustment Cam..
TIRES
TireSize-Front 25x8-12....
Tire Size - Rear 25 x 11 - 12....
Tire Pressure - F/R 5/5 lbs.
Total Width 46I(116.84 cm)........
Total Length 85I(215.9 cm).......
Total Height 47I(119.38 cm)........
Wheel Base 50.75I(128.90 cm).......
Weight - Dry 740 lbs. (335.60 kg).......
LOAD CAPACITY
Front Rack (Std) 90 lbs......
Rear Rack (Std) 180 lbs.......
Tongue Weight 150 lbs.....
Hitch Towing Capacity...1500 lbs.
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1.12
PUBLICATION NUMBERS
Year Model Model No. Owner’s
Manual
PN
Parts
Manual PN
Parts
Micro Fiche
PN
2003 Sportsman 600/700 A03CH59 / A03CH68 9918213 9917718 9917719
When ordering service parts be sure to use the correct parts manual.
PAINT CODES
PAINTED PART COLOR
DESCRIPTION
DITZLER
NUMBER
POLARIS
NUMBER
Springs Black 9440 P-067
FRAME COLOR - (All) P067 Medium Gloss Black 9440 / 8520147.
Order direct from Midwest Industrial Coatings (952-942-1840). Mix as directed.
REPLACEMENT KEYS
Replacement keys can be made from the original
key. To identify which series the key is, take the
first two digits on the original key and refer to the
chart to the right for the proper part number.
Should both keys become lost, ignition switch
replacement is required.
Series # Part Number
20 4010278
21 4010278
22 4010321
23 4010321
27 4010321
28 4010321
31 4110141
32 4110148
67 4010278
68 4010278
31XX
Key Series
Number
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1.13
STANDARD TORQUE SPECIFICATIONS
The following torque specifications are to be used as a general guideline. There are exceptions in the steering,
suspension, and engine areas. Always consult the exploded views in each manual section for torque values of
fasteners before using standard torque.
Bolt Size Threads/In Grade 2 Grade 5 Grade 8
Torque in. lbs. (Nm)
#10 - 24 27 (3.1) 43 (5.0) 60 (6.9).............. ................ ..............
#10 - 32 31 (3.6) 49 (5.6) 68 (7.8).............. ................ ..............
Torque ft. lbs. (Nm)*
1/4 - 20 5 (7) 8 (11) 12 (16).............. .................. ................
1/4 - 28 6 (8) 10 (14) 14 (19).............. .................. ..............
5/16 - 18 11 (15) 17 (23) 25 (35).............. ................ ..............
5/16 - 24 12 (16) 19 (26) 29 (40).............. ................ ..............
3/8 - 16 20 (27) 30 (40) 45 (62).............. ................ ..............
3/8 - 24 23 (32) 35 (48) 50 (69).............. ................ ..............
7/16 - 14 30 (40) 50 (69) 70 (97).............. ................ ..............
7/16 - 20 35 (48) 55 (76) 80 (110).............. ................ ..............
1/2 - 13 50 (69) 75 (104) 110 (152).............. ................ .............
1/2 - 20 55 (76) 90 (124) 120 (166).............. ................ .............
Metric
6 x 1.0 72-78 In. lbs.
8 x 1.25 14-18 ft. lbs.
10 x 1.25 26-30 ft. lbs.
*To convert ft. lbs. to Nm multiply foot pounds by .1.382
*To convert Nm to ft. lbs. multiply Nm by .7376.
SPECIFIC TORQUE VALUES OF FASTENERS
Refer to exploded views in the appropriate section.
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1.14
DECIMAL EQUIVALENTS
1/64 .0156.........................
1/32 .0312 1 mm = .0394²................... ................
3/64 .0469.........................
1/16 .0625..............
5/64 .0781 2 mm = .0787²......................... ................
3/32 .0938...................
7/64 .1094 3 mm = .1181²....................... ................
1/8 . 1250. .......
9/64 .1406.........................
5/32 .1563 4 mm = .1575²................... ................
11/64 .1719........................
3/16 .1875 5 mm = .1969².............. ................
13/64 .2031........................
7/32 .2188...................
15/64 .2344 6 mm = .2362²........................ ................
1/4 .25..........
17/64 .2656 7 mm = .2756²........................ ................
9/32 .2813...................
19/64 .2969........................
5/16 .3125 8 mm = .3150².............. ................
21/64 .3281........................
11/32 .3438 9 mm = .3543².................. ................
23/64 .3594........................
3/8 .375..........
25/64 .3906 10 mm = .3937²........................ ................
13/32 .4063..................
27/64 .4219 11 mm = .4331²........................ ................
7/16 .4375..............
29/64 .4531........................
15/32 .4688 12 mm = .4724².................. ................
31/64 .4844........................
1/2 .5 13 mm = .5118.......... ...................
33/64 .5156........................
17/32 .5313..................
35/64 .5469 14 mm = .5512²........................ ................
9/16 .5625..............
37/64 .5781 15 mm = .5906²........................ ................
19/32 .5938..................
39/64 .6094........................
5/8 .625 16 mm = .6299².......... .................
41/64 .6406........................
21/32 .6563 17 mm = .6693².................. ................
43/64 .6719.......................
11/16 .6875.............
45/64 .7031 18 mm = .7087²........................ ................
23/32 .7188..................
47/64 .7344 19 mm = .7480²........................ ................
3/4 .75..........
49/64 .7656........................
25/32 .7813 20 mm = .7874².................. ................
51/64 .7969........................
13/16 .8125 21 mm = .8268²............. ................
53/64 .8281........................
27/32 .8438..................
55/64 .8594 22 mm = .8661²........................ ................
7/8 .875..........
57/64 .8906 23 mm = .9055²........................ ................
29/32 .9063..................
59/64 .9219.......................
15/16 .9375 24 mm = .9449²............. ................
61/64 .9531........................
31/32 .9688 25 mm = .9843.................. ................
63/64 .9844........................
11.0............
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GENERAL INFORMATION
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1.15
CONVERSION TABLE
Unit of Measure Multiplied by Converts to
ft. lbs. x12 =in.lbs.
in. lbs. x .0833 = ft. lbs.
ft. lbs. x 1.356 =Nm
in. lbs. x .0115 =kg-m
Nm x .7376 = ft.lbs.
kg-m x 7.233 = ft. lbs.
kg-m x 86.796 =in.lbs.
kg-m x10 =Nm
in. x 25.4 =mm
mm x .03937 =in.
in. x2.54 =cm
mile (mi.) x1.6 =km
km x .6214 = mile (mi.)
Ounces (oz) x 28.35 = Grams (g)
Fluid Ounces (fl. oz.) x 29.57 = Cubic Centimeters (cc)
Cubic Centimeters (cc) x .03381 = Fluid Ounces (fl. oz.)
Grams (g) x 0.035 = Ounces (oz)
lb. x .454 =kg
kg x 2.2046 =lb.
Cubic inches (cu in) x 16.387 = Cubic centimeters (cc)
Cubic centimeters (cc) x 0.061 = Cubic inches (cu in)
Imperial pints (Imp pt) x 0.568 = Liters (l)
Liters (l) x1.76 = Imperial pints (Imp pt)
Imperial quarts (Imp qt) x 1.137 = Liters (l)
Liters (l) x0.88 = Imperial quarts (Imp qt)
Imperial quarts (Imp qt) x 1.201 = US quarts (US qt)
US quarts (US qt) x 0.833 = Imperial quarts (Imp qt)
US quarts (US qt) x 0.946 = Liters (l)
Liters (l) x 1.057 = US quarts (US qt)
US gallons (US gal) x 3.785 =Liters (l)
Liters (l) x 0.264 = US gallons (US gal)
Pounds - force per square inch (psi) x 6.895 = Kilopascals (kPa)
Kilopascals (kPa) x 0.145 = Pounds - force per square inch (psi)
Kilopascals (kPa) x0.01 = Kilograms - force per square cm
Kilograms - force per square cm x 98.1 = Kilopascals (kPa)
p (3.14) xR
2x H (height) = Cylinder Volume
°Cto°F: 9 (°C + 40) ¸5-40=°F
°Fto°C: 5 (°F + 40) ¸9-40=°C
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1.16
SAE TAP DRILL SIZES
Thread Size Drill Size Thread Size Drill Size
#0-80 3/64
#1-64 53
#1-72 53
#2-56 51
#2-64 50
#3-48 5/64
#3-56 45
#4-40 43
#4-48 42
#5-40 38
#5-44 37
#6-32 36
#6-40 33
#8-32 29
#8-36 29
#10-24 24
#10-32 21
#12-24 17
#12-28 4.6mm
1/4-20 7
1/4-28 3
5/16-18 F
5/16-24 I
3/8-16 O
3/8-24 Q
7/16-14 U
7/16-20 25/64
1/2-13 27/64
1/2-20 29/64
9/16-12 31/64
9/16-18 33/64
5/8-11 17/32
5/8-18 37/64
3/4-10 21/32
3/4-16 11/16
7/8-9 49/64
7/8-14 13/16
1-8 7/8
1-12 59/64
1 1/8-7 63/64
1 1/8-12 1 3/64
11/4-7 17/64
1 1/4-12 1 11/64
11/2-6 111/32
1 1/2-12 1 27/64
13/4-5 19/16
1 3/4-12 1 43/64
2-4 1/2 1 25/32
2-12 1 59/64
2 1/4-4 1/2 2 1/32
21/2-4 21/4
23/4-4 21/2
3-4 2 3/4
METRIC TAP DRILL SIZES
Tap Size Drill Size Decimal Equivalent Nearest Fraction
3x.50
3x.60
4x.70
4x.75
5x.80
5x.90
6 x 1.00
7 x 1.00
8 x 1.00
8 x 1.25
9 x 1.00
9 x 1.25
10 x 1.25
10 x 1.50
11 x 1.50
12 x 1.50
12 x 1.75
#39
3/32
#30
1/8
#19
#20
#9
16/64
J
17/64
5/16
5/16
11/32
R
3/8
13/32
13/32
0.0995
0.0937
0.1285
0.125
0.166
0.161
0.196
0.234
0.277
0.265
0.3125
0.3125
0.3437
0.339
0.375
0.406
0.406
3/32
3/32
1/8
1/8
11/64
5/32
13/64
15/64
9/32
17/64
5/16
5/16
11/32
11/32
3/8
13/32
13/32
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