2002-2003 Polaris Sportsman 600 & 700 Service & Repair Manual (P/N 9918066)

• Covers 2002–2003 Polaris Sportsman 600 and 700 ATVs, including all engine, chassis, and transmission variants
• Official OEM publication P/N 9918066, published in 2002
• Contains over 70 exploded-view diagrams, 15+ torque specification tables, and comprehensive maintenance procedures for the EH-series engine build
• Serves as the factory-authorized reference originally used for the 2002–2003 Sportsman initial production release

Service Documentation and Manual Structure

This 262-page factory manual delivers the precise technical data and maintenance procedures required to effectively service these ATVs. Segmented into ten primary chapters, the document outlines general vehicle identification, fluid specifications, and periodic maintenance schedules. Working on the top end? The engine section details piston removal, cylinder head inspection, and rocker arm specifications. For undercarriage work, dedicated chassis and suspension chapters provide exact wear limits for strut cartridges, bushings, and tie-rod ends. Prior to initiating any mechanical teardown or fluid exchange, technicians must review the integrated safety protocols to prevent component damage or personal injury.

Engine and Technical Specifications Preview

Beyond mechanical overhauls, the documentation lists specific reference values for electrical systems, fuel delivery, and drivetrain maintenance. Accurate torque application is critical. Cylinder head bolts require 60–64 ft. lbs. (81–87 Nm), while the oil filter housing torque sits at 33–37 ft. lbs. (45–50 Nm). The manual also documents hot engine oil pressure at 25–34 PSI at 5500 RPM. Cooling system capacity for these models is 2.25 quarts. Intake valve stem diameter measures 0.2356 inches. You will also find comprehensive data tables covering clutch spring rates, altitude-adjusted jetting guidelines, and standard hardware torque values.