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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Sample pages from the 2002-2010 Polaris Sportsman 600, 700 & 800 Service Manual manual
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Polaris Models Covered & Key Technical Specifications
Models: Polaris Sportsman 600, Polaris Sportsman 700, Polaris Sportsman 800
Sub-models / Variants: Early 2004, Late 2004, Hunter Edition, A04CH59, A04CH68
Build Years: 2002–2010
Technical Data:
- Engine Displacement: 597 cc (600), 683 cc (700)
- Engine Configuration: Polaris Twin Cylinder, 4-Stroke, Liquid Cooled, Electric Start
- Engine Oil Capacity: 2 quarts (1.9 liters)
- Fuel Capacity: 4.25 gallons US (16 liters)
- Transmission Type: Drumshift (H/L/N/Rev/Park)
- Final Drive System: 4WD with PVT w/EBS clutch
- Cooling System Capacity: 3.2 quarts (3 liters)
- Alternator Output: 330 W @ 3000 RPM
- Front/Rear Tire Size: 25x8-12 / 25x11-12
- Brake System: Dual Hydraulic Disc (Front and Rear)
Polaris Manual Features & Content Preview
Technical Scope for the Polaris Sportsman 600, 700 & 800
- Built for owners and technicians servicing the 2002–2010 Polaris Sportsman 600, 700, and 800 series, including early and late 2004 variants.
- Original OEM publication, Polaris RepairPro Service Manual.
- Contains 47 pages of technical data, including engine rebuild specifications, cooling system schematics, and torque requirement tables.
- File link appears in your order confirmation straight away.
- Indexed PDF search covers every chapter and appendix.
- Suitable for printing individual sections for shop-floor use.
- Includes 9 exploded-view diagrams for engine and transmission assembly.
- Documents the specific differences between early and late 2004 production builds, including transmission fill-plug locations and jetting charts.
- This manual remains the authoritative reference for internal engine clearances, valve train settings, and cooling system maintenance for the A04CH59 and A04CH68 chassis types.
Component and System Documentation
The 2002–2010 Polaris Sportsman 600, 700 & 800 service manual details the technical parameters for engine, cooling, and drivetrain systems. Documentation covers the teardown and reassembly of the liquid-cooled twin-cylinder powerplants, specifically noting tolerances for camshaft journals, piston-to-cylinder clearance, and valve stem diameters. The content includes guidance on transmission lubrication, gearcase maintenance, and clutch system adjustments essential for maintaining power delivery. The text describes the proper procedures for engine service and internal component inspections using manufacturer-specified special tools.
Specification Highlights
The engine oil capacity is specified at 2 quarts (1.9 L) using 0W-40 synthetic oil, with an ambient temperature range of -40° F to 120° F. Cooling system capacity is documented at 3.2 quarts (3 L). Torque values for critical fasteners, such as the front hub retaining nut, are listed at 70 ft. lbs. (95 Nm) to ensure safe operation. The manual provides reference data for the 330W alternator output, CDI ignition timing of 13° BTDC at 1200 RPM, and standard piston diameters for the 600 and 700 engine models. All service data shown here is for reference only — qualified technicians and the original OEM documentation remain the authoritative source for any hands-on work.
Document Reference: Original OEM manufacturer publication, Polaris RepairPro Service Manual
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