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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Polaris 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.
Technical Specifications
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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

Polaris Manual Features & Content 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.

Manual FAQ, Purchase & Download Details

What fluid capacity and lubricant information is included in the general specifications tables? keyboard_arrow_down

Manual includes detailed specification tables that list fluid capacities for the cooling system, transmission, and gearcases. These tables also provide recommendations for engine oil and other specialized service lubricants.

Is there a reference for standard torque values included in the general information section? keyboard_arrow_down

Document contains a standard torque specifications table that provides a general guideline for fastener torque values based on bolt size and grade.

Are the major mechanical and electrical systems covered in the manual's chapter structure? keyboard_arrow_down

Manual is organized into chapters that cover the engine, carburetion, body and steering, clutching, final drive, transmission, brakes, and electrical systems. Each of these chapters provides relevant technical information and specification data for the Polaris Sportsman 600, 700, and 800 models.

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