2002-2010 Polaris Sportsman 600, 700, 800 manual

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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