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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Document Details

keyboard_arrow_down
Document Number / Seller:
32130 / Daniel Davis
File Size:
322.72 MB
File Type:
ZIP
Language:
English
Printable:
Yes
Category:
ATV
Last updated / verified
Jun 21, 2025

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.

Manual Description & Preview

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.

FAQ

Identify the **correct** service interval parameters for regular maintenance. keyboard_arrow_down

100 hours is the recommended interval for Engine Oil changes and the Fuel System/Filter, with annual checks for cooling system hoses and mounts.

What procedures are **documented** for the system architecture related to the drivetrain? keyboard_arrow_down

Chapter 6 details the Drive Clutch and Driven Clutch disassembly and reassembly, including PVT system sealing and ducting components.

Determine the **precise** tool requirements for front hub and steering components. keyboard_arrow_down

2870871 is listed for Ball Joint Replacement Tool, and 2871572 is listed for the Strut Rod Wrench for steering component service.

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