2002-2010 Polaris Sportsman 600, 700, 800 manual

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Polaris 2002-2010 Polaris Sportsman 600, 700, 800 manual - Technical Specifications

  • File Size: 322.72 MB
  • File Type: ZIP
  • Language: English
  • Printable: Yes
  • Estimated Download Time: 6.61 Minutes
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Polaris Models and Parts Covered in this Diesel Engine Manual

Polaris Sportsman

  • 2002

    • 700 Twin

  • 2003

    • 600 Twin
    • 700 Twin

  • 2004

    • 600 Twin
    • 700 Twin
    • 700 EFI (introduced mid-year)

  • 2005

    • 700 Twin
    • 700 EFI
    • 800 Twin EFI

  • 2006

    • 700 Twin
    • 700 EFI
    • 800 Twin EFI

  • 2007

    • 700 EFI
    • 800 EFI

  • 2008

    • 800 EFI

  • 2009

    • 800 EFI

  • 2010

    • 800 EFI

  • Production/model years: 2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009, 2010

Polaris 2002-2010 Polaris Sportsman 600, 700, 800 manual - Complete Manual Information

Table of Contents

General

  • Model Identification
  • Serial Number Location
  • 2004 Sportsman Models Identification
  • 2004 Sportsman Models Dimensions
  • Specifications - Early 2004 Sportsman 600
  • Specifications - Late 2004 Sportsman 600
  • Specifications - Early 2004 Sportsman 700
  • Specifications - Late 2004 Sportsman 700
  • Publication Numbers
  • Paint Codes
  • Replacement Keys
  • Standard Torque Specifications
  • Conversion Table
  • Tap Drill Charts
  • Decimal Equivalent Chart
  • Glossary of Terms

Maintenance

  • Routine Maintenance Schedule
  • Lubrication and Fluids
  • Periodic Inspections
  • Maintenance Procedures

Engine

  • Engine Removal and Installation
  • Engine Overhaul Procedures
  • Cylinder Head and Valves
  • Piston and Crankshaft
  • Lubrication System
  • Cooling System

Carburetion

  • Carburetor Adjustment
  • Carburetor Overhaul
  • Fuel System Components

Body and Steering

  • Frame
  • Subframe
  • Footrests and Handlebars
  • Steering Mechanism
  • Suspension Adjustment

Clutching

  • Clutch Removal and Installation
  • Clutch Adjustment
  • Clutch Overhaul

Final Drive

  • Drive Chain
  • Drive Shaft
  • Differential

Transmission

  • Transmission Removal and Installation
  • Transmission Overhaul Procedures

Brakes

  • Brake System Overview
  • Hydraulic Brake System
  • Brake Pads and Discs
  • Brake Fluid Replacement
  • Parking Brake

Electrical

  • Electrical Components Overview
  • Wiring Diagrams
  • Battery and Charging System
  • Ignition System
  • Lighting System
  • Instrumentation
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Sarah P.says...
The manual covers all aspects of the Sportsman models. Downloading was a breeze, and I got the link almost instantly!
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This manual has everything you need for proper maintenance and repairs. The download was smooth and I received a quick email with the link!
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James R.says...
I found this manual incredibly useful. Customer support was very responsive when I had a question about the download process. Highly professional!
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Tom H.says...
This guide has helped me troubleshoot issues effectively. The email support was impressive; they answered my queries promptly!