2003 Polaris Sportsman 6x6 Service Manual

2003 Polaris Sportsman 6x6 ATV with detailed service procedures for carburetor, engine, PVT system, transmission, final drive, brakes, and more. Publication C38968.

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Document Details

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Document Number / Seller:
31959 / Donald Peterson
File Size:
6.85 MB
File Type:
PDF
Language:
English
Printable:
Yes
Category:
6x6
Last updated / verified
Sep 12, 2025

Models Covered & Key Technical Specifications

2003 Polaris Sportsman 6x6 Service Manual: Complete Repair Guide for 6x6 Utility ATV - Official Service & Repair Manual for 6x6 Utility ATV, 2003 edition Engine-Compendium Polaris Sportsman 6x6 (2003) | Service Manual.

  • Calibrated Footprint Data: 104.5 in. length contributes to overall vehicle Stability Framework.
  • Specific Imaging Specs: 498 cc displacement defines the engine's core operational Capacity Topology.
  • Critical Tightening Data: 40 ft. lbs. (55 Nm) signifies the drive clutch bolt torque Protocol.
  • Universal Gap Specs: .036" (0.9 mm) specifies the recommended spark plug gap Parameter.
  • Core Power Draw: 16 L capacity provides ample fuel storage for extended operation Norms.
  • Standard Component Weight: 406.4 kg dry weight allows for manageable vehicle operation Bounds.

Professional Workshop Service Manual & Technical Specifications

Factory-Level Service Repair Manual: 6x6 Polaris Sportsman 6x6 - Official Service & Repair Manual for 6x6 Utility ATV, 2003 edition Engine-Compendium

Specification-Class: Polaris Sportsman 6x6 // Asset-ID: 2003 // Specification-Class: Service Manual

Specification Operational-Logic Calibration-Data
Model Number A03CL50AA Engine EH50PLE10
Engine Type 4 Cycle, Single Cyl. Cooling Liquid
Drive Clutch Type PVT Belt Width 1.188" (30.18 mm)

Providing a structural breakdown of the manual's content, this document details various systems and procedures critical for the upkeep and repair of your Polaris Sportsman 6x6. The manual is organized to provide a clear understanding of the machine's components and their functions. It covers everything from basic maintenance to in-depth system overhauls. You'll find information on the engine, transmission, and drive systems, along with guidance on the body, steering, and suspension. Finally, the manual provides detailed insights into the brake and fuel systems, ensuring you have a comprehensive resource for all your service needs. This integrated approach to documentation aims to simplify complex repair tasks and promote a better understanding of the vehicle's mechanical aspects.

Completely requiring an understanding of torque specifications, this manual details appropriate values for various fasteners to ensure proper assembly and prevent component damage. This ensures that all reassembly and adjustments are performed to factory standards, guaranteeing optimal performance and longevity of the vehicle's components.

FAQ

What specifications are essential for testing the Polaris Sportsman 6x6? keyboard_arrow_down

14 ft. lbs. (19 Nm) is the specified torque for the oil filter wrench, critical for maintaining proper oil flow.

Check the correct diagnostic procedures for the Polaris Sportsman 6x6. keyboard_arrow_down

The manual details that 150 ft. lbs. (207 Nm) is the torque specification for the swing arm pivot bolts, ensuring structural integrity.

What does the documented fluid capacity requirements indicate for the Polaris Sportsman 6x6? keyboard_arrow_down

2.25 Quarts is the specified system capacity for the liquid cooling system, essential for maintaining optimal operating temperatures.

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I loved the detailed diagrams. Customer support was quick to respond when I had questions about the download. Highly recommend!
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This manual is thorough and easy to understand. The download process was smooth and I received my link almost immediately! Great service!
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Rated 4 out of 5 stars