2002-2010 Polaris Sportsman 600, 700 & 800 Service Manual
Complete workshop manual for Polaris Sportsman 600, 700, and 800 models from 2002-2010. Documents engine, drivetrain, and body components. Part number A04CH59.
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Models Covered & Key Technical Specifications
Polaris Sportsman 600, 700 & 800 (A04CH59) - 2002-2010
Complete Reference Suite | Owner's Manual
- Nominal Cooling Specs: 2.25 Quarts establishes the system fluid capacity Requirements.
- Principal Throughput Data: 330 w @ 3000 RPM limits the alternator charging output Threshold.
- Rated Dimensional Limits: 50.75 in. / 128.9 cm defines the standard wheel base Measurement.
- Calibrated Torque Data: The front hub retaining nut requires 70 ft. lbs. (95 Nm) for proper torque Configuration.
- Documented Containment Volume: 4.25 gal. US signifies the fuel tank capacity Benchmarks.
- Design Environmental Range: -40° F to 120° F provides the engine oil ambient temperature Range.
Professional Workshop Service Manual & Technical Specifications
Authoritative Quality Repair Manual: Polaris Sportsman 600, 700 & 800 Repair Manual, covers 2002-2010 Field-Reference
Assembly-Group: Sportsman 600/700/800 // Asset-ID: A04CH59 / category ATV // Assembly-Group: Motorcycle Logic.
| Metric | System-Path | Calibration-Data |
|---|---|---|
| Engine | Specifications | 3.2-3.17 |
| Fuel System | Carburetor | 4.2-4.15 |
| Clutch | PVT System | 6.2-6.34 |
| Final Drive | AWD Components | 7.2-7.36 |
| Body/Steering/Suspension | Maintenance | 5.2-5.15 |
| Electrical | System Checks | Section 2 |
Documentation sections include Engine, Fuel System, Clutch, Final Drive, Body/Steering/Suspension, and Electrical components. Thorough procedures are provided for all systems and sub-systems. Comprehensive specifications are included to ensure proper assembly and maintenance. This manual documents torque specifications for fasteners to ensure proper clamp load consistency.
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