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
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B
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w
4
0
F
Below +5°C
+
4
0
F
a
n
d
a
b
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v
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+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
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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
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D
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C
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D
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C
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D
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A
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Shift
W
e
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g
h
t
Drive Clutch
S
p
r
i
n
g
Driven Clutch
S
p
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i
n
g
Driven
H
e
l
i
x
A
l
t
i
t
u
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Weight Spring Spring Helix
Meters 0-1800
2
0
5
6
Bl
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/
G
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n
W
h
i
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/
Y
e
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E
B
S
M
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t
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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
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/
G
r
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e
n
W
h
i
t
e
/
Y
e
l
l
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w
E
B
S
1
8
0
0
-
3
7
0
0
(6000-12000) 20--54
B
l
u
e
/
G
r
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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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