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

• Covers 2003 Polaris Sportsman 600 and 2002–2003 Sportsman 700 ATVs; OEM service publication P/N 9918066, published in 2002.
• EH-series engine repair covers removal, cylinder-head and valve-seat work, and bottom-end disassembly and reassembly for the liquid-cooled twins.
• Mikuni BST 34 carburetor overhaul, float adjustment, needle-and-seat leakage tests, and fuel-pump service.
• PVT / Engine Braking System (EBS) procedures include clutch overhaul, one-way clutch inspection, bushing replacement, belt inspection, and clutch alignment.
• Centralized Hilliard AWD diagnosis, front and rear gearcase repair, CV joint and U-joint service, and transmission teardown.
• Chassis procedures cover strut cartridge and ball-joint replacement, A-arm service, brake caliper rebuilding, and hydraulic bleeding.
• Separate model-year wiring diagrams accompany ignition, charging, starter, speedometer, and AWD diagnostic charts.

Service Documentation and Model Coverage

This 262-page PDF is organized into ten primary chapters, beginning with general vehicle identification, fluid specifications, and periodic maintenance schedules. It was written primarily for certified Polaris Master Service Dealer technicians working in a properly equipped shop.

The 2002 700 specification sheets identify model A02CH68AA/CA with the EH68ALOE1 engine. The 2003 sheets pair A03CH59 with EH059OLE for the 600, and A03CH68 with EH068OLE for the 700. Model-specific charts distinguish carburetor calibration, clutch setups, ignition specifications, and drivetrain ratios.

EH-Series Engine Repair and Cooling

Working on the top end? The engine section details piston removal, cylinder head inspection, and rocker arm specifications. Hydraulic lifter inspection, crankshaft bearings, and counterbalance-shaft work extend coverage below the cylinder.

The Accessible Components guide separates in-frame cylinder-head and piston service from crankshaft and counterbalance-bearing jobs that require engine removal. 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 honing section describes deglazing the nicasil coating and cylinder replacement for excessive wear or damage.

Oil-pressure testing and the Oil Flow chart cover the pressurized wet-sump system; 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.

Fuel Metering and Drivetrain Diagnosis

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.

For clutch setup, spring-rate charts and shift-weight references accompany the Engine Braking System (EBS) Exploded View. The EBS instructions specifically warn that taking the driven clutch apart from the wrong end can damage its one-way clutch seals.

AWD fault tracing checks coil resistance, armature wear, and pole gap, supported by the Side Cutaway View of Centralized Hilliard Cover. Transmission repair coverage extends to the silent-chain drive, gear clusters, shift-drum timing, and park-lockout assembly.

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 Diagnosis and Factory Reference Data

The Wiring Diagram 2002 Sportsman 700 and Wiring Diagram 2003 Sportsman 600/700 include 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.

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.