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

Polaris service manual P/N 9918066, published in 2002, covers 2003 Sportsman 600 and 2002–2003 Sportsman 700 ATVs. Its ten chapters cover scheduled maintenance, diagnosis, and component repair.

PDF Search, Chapter Bookmarks and Wiring Detail

Text access and diagram detail: The main text is searchable, with embedded bookmarks for the chapter index and all ten chapters. The two wiring diagrams have searchable titles, but their internal labels are not searchable. Small wiring labels require zooming.

One printable English PDF contains 262 pages, including the original front and back covers, safety and foreword pages, chapter index, five-page alphabetical index, and four notes/blank pages.

Engine Overhaul, PVT Service and AWD Diagnosis

The topics below are a selection of the manual’s contents. Other examples include air-filter service and headlight aiming.

• Engine repair: Step-by-step engine removal, piston removal, cylinder-head inspection, valve-seat work, rocker-arm specifications, hydraulic lifter inspection, and bottom-end disassembly and reassembly.

• Fuel system: Mikuni BST 34 carburetor overhaul, float adjustment, needle-and-seat leakage tests, and fuel-pump service.

• PVT and EBS: Clutch overhaul, one-way clutch inspection, bushing replacement, belt inspection, and clutch alignment for the Engine Braking System.

• AWD and final drive: Centralized Hilliard diagnosis, front and rear gearcase repair, and CV-joint and U-joint service.

• Transmission: Removal, teardown and reassembly, including the silent-chain drive, gear clusters, shift-drum timing, and park-lockout assembly.

• Chassis and brakes: Strut cartridge and ball-joint replacement, A-arm service, brake caliper rebuilding, and hydraulic bleeding.

• Electrical diagnosis: Separate model-year wiring diagrams accompany ignition, charging, starter, speedometer, and AWD diagnostic charts.

It was written primarily for certified Polaris Master Service Dealer technicians working in a properly equipped shop.

Model-Specific Service Data

The specification sheets pair A02CH68AA/CA with the EH68ALOE1 engine, A03CH59 with EH059OLE, and A03CH68 with EH068OLE. Model-specific charts distinguish carburetor calibration, clutch setups, ignition specifications, and drivetrain ratios, helping match service data to the correct vehicle.

EH-Series Engine Repair and Cooling

Job planning: The Accessible Components guide separates in-frame cylinder-head and piston service from crankshaft and counterbalance-bearing jobs that require engine removal.

Timing and lubrication: Cam-gear timing uses the Cam Gear Tooth Alignment Tool PU-45497-2; post-rebuild oil priming is documented with Oil System Priming Adapter PU-45778. The Oil Flow chart traces the pressurized wet-sump system alongside oil-pressure testing.

The honing section describes deglazing the nicasil coating; excessive cylinder wear or damage calls for cylinder replacement.

Cooling procedures address pressure testing and air purging. Water-pump seal service carries a specific caution: attempting the job with the gear/stator housing still attached can damage the pump shaft.

Carburetor Circuits and PVT Setup

The BST 34 Carburetor Exploded View and circuit descriptions separate the float, pilot, main, and enrichment systems. Altitude- and temperature-adjusted jetting charts supplement lean/rich mixture and poor-idle troubleshooting.

Spring-rate charts and shift-weight references accompany the Engine Braking System (EBS) Exploded View. Polaris specifies certified MSD technicians and factory-authorized special tools for PVT repairs. The driven-clutch instructions warn that disassembly from the wrong end can damage the one-way clutch seals.

Hilliard AWD Fault Tracing

AWD diagnosis addresses coil resistance, armature wear, and pole gap, supported by the Side Cutaway View of Centralized Hilliard Cover. Instrument-cluster test charts distinguish electrical control faults from mechanical AWD problems before gearcase work is considered.

Suspension, Steering and Hydraulic Brakes

MacPherson front struts and independent rear suspension are covered with rear control-arm bushing orientation drawings. Steering work includes tie-rod inspection and string or chalk toe-alignment methods. Camber and caster are nonadjustable.

Brake procedures distinguish the rear caliper’s separate hand- and foot-brake circuits. The front master cylinder is treated as a replacement assembly, not a rebuildable unit.

Electrical Tests and Repair References

The Wiring Diagram 2002 Sportsman 700 and Wiring Diagram 2003 Sportsman 600/700 show connector identification and component test specifications. Instrument-cluster diagnostics address missing speed readings, reverse-limiter faults, and loss of AWD.

CDI peak-output, charging-system “break even,” wheel-speed sensor, and starter voltage-drop tests support electrical fault isolation. Starter coverage extends to brush replacement, armature testing, and motor reassembly.

Component-specific torque tables supplement standard hardware torques. Separate engine service-data tables distinguish intake valve-stem dimensions, piston clearances, and wear limits for the two engine sizes.

Before any mechanical teardown or fluid exchange, review the manual’s safety precautions for vehicle support, hot coolant, and rotating PVT components.

Examples of Oil-Pressure and AWD Test Specifications

For the EH-series engines, the oil-pressure test lists 34 psi standard and 25 psi minimum at 5,500 rpm with the engine hot and Polaris 0W-40 Synthetic oil.

The Centralized Hilliard front-gearcase diagnosis specifies coil resistance of 22.8–25.2 ohms across the grey and brown/white harness wires.