🏷️ Basic Information Identification Make: Polaris Model: Sportsman 600 / 700 Model Years Covered: 2002, 2003 Product Type: Factory Service/Repair/Workshop Manual Codes Engine Code 600: Not explicitly stated, but typically a Polaris 580cc or similar twin cylinder Engine Code 700: Not explicitly stated, but typically a Polaris 698cc or similar twin cylinder 👋 Introduction Market Position Product Category: High-performance utility ATV Target Audience: Outdoor enthusiasts, hunters, farmers, recreational riders, professional mechanics Competitive Analysis Competitors: Yamaha Grizzly, Can-Am Outlander, Arctic Cat 500/700, Honda Foreman/Rancher Key Differentiators: Polaris's focus on powerful engines, independent rear suspension (IRS) on many models, and robust chassis design for challenging terrain. Key Features Manual Value Proposition: Empowers owners to perform professional-grade maintenance and repairs, saving time and money. Manual Utility: Essential tool for diagnosing and resolving issues, ensuring optimal performance and longevity of the ATV. 📋 Manual Details Coverage Areas Overall Coverage: Comprehensive repair and maintenance for all major ATV systems Engine Coverage: Engine overhaul, top-end rebuild, bottom-end rebuild, cooling system, lubrication system, fuel system, ignition system Transmission Coverage: PVT (Polaris Variable Transmission) belt replacement, clutch service, gearcase service, driveline components Chassis Coverage: Frame, suspension (front and rear), steering, brakes, wheels, tires Electrical Coverage: Wiring diagrams, lighting, ignition system, starting system, charging system, instruments, accessories Page Count Estimated Page Count: Likely 400-600 pages (typical for factory service manuals of this era and complexity) Manual Type Manual Type: Factory Service Manual / Workshop Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Powertrain Systems: Engine, cooling, fuel delivery, exhaust, PVT transmission, differentials, driveshafts, axles Chassis And Body: Frame, plastics, seating, handlebars, racks, fenders, skid plates Suspension And Steering: Front and rear suspension components (shocks, arms, bushings), steering linkage, tie rods, wheel bearings Braking System: Hydraulic brake system (master cylinders, calipers, lines, levers), parking brake Electrical System: Battery, starter, alternator, ignition coil, CDI unit, lighting (headlights, taillight, brake light), instrumentation cluster, fan control, winch wiring (if applicable) Procedures Included Routine Maintenance: Oil changes, filter replacements (oil, air), spark plug service, lubrication points, coolant checks, brake adjustments, tire pressure checks, PVT belt inspection/replacement Repair Procedures: Engine rebuilds (top-end and bottom-end), transmission overhauls, suspension component replacement, brake system repairs, electrical diagnostics and repair, steering system servicing Troubleshooting: Systematic diagnostic guides for common issues (e.g., starting problems, poor performance, braking issues, electrical faults) Technical Specifications: Torque specifications for all fasteners, fluid capacities and types, clearances, timing specifications, electrical component testing values Technical Depth Depth Of Coverage: Factory-level detail, suitable for complete disassembly and reassembly of all major components. Includes diagnostic flowcharts and troubleshooting trees. 📊 Manual Specifications File Format File Format: PDF Print Quality Print Quality: High-resolution scans of original factory manual pages, ensuring clarity of text and diagrams. Binding Type Binding Type: Not applicable (digital download) Paper Type Paper Type: Not applicable (digital download) Searchability Text Searchability: Likely searchable PDF, allowing for quick location of specific topics or keywords. ⚙️ Engine Specifications Primary Engine Engine Type 600: Liquid-cooled, 2-stroke, parallel-twin cylinder (common for this era's Polaris 600 engine) Engine Displacement 600: Approximately 580cc (typical for Polaris 600 twin) Engine Type 700: Liquid-cooled, 4-stroke, SOHC, parallel-twin cylinder (common for this era's Polaris 700 engine) Engine Displacement 700: Approximately 698cc (typical for Polaris 700 twin) Performance Horsepower 600: Estimated 50-60 HP (typical for 2-stroke twins of this size) Horsepower 700: Estimated 50-60 HP (typical for 4-stroke twins of this size, though torque is often higher) Torque 700: Expected to be significantly higher than the 600, providing better low-end grunt. Fuel System Fuel Delivery 600: Carbureted (likely Mikuni or Keihin twin carburetors) Fuel Delivery 700: Fuel Injection (EFI) or Carbureted (depending on specific sub-model/region, but EFI was becoming prevalent) 🔧 Transmission Standard Transmission Type: Polaris Variable Transmission (PVT) with Engine Braking Drive System: Shaft Drive with On-Demand All-Wheel Drive (AWD) Features Gear Selection: High (H), Low (L), Neutral (N), Reverse (R), Park (P) Fluid Specifications Pvt Fluid Type: Polaris AGL Premium Gearcase Lubricant (or equivalent SAE 80W-90 gear oil for the gearcase) 📐 Dimensions Exterior Length: Approximately 83 inches (210.8 cm) - Typical for Sportsman models Width: Approximately 46 inches (116.8 cm) - Typical for Sportsman models Height: Approximately 47 inches (119.4 cm) - Typical for Sportsman models Weights Dry Weight: Approximately 600-650 lbs (272-295 kg) - Varies by model and year Ground Clearance: Approximately 10.5 inches (26.7 cm) Cargo Front Rack Capacity: Typically 50 lbs (22.7 kg) Rear Rack Capacity: Typically 100 lbs (45.4 kg) Towing Towing Capacity: Typically 1500 lbs (680 kg) Wheels And Tires Front Tire Size: 25x8-12 or 26x8-12 (common) Rear Tire Size: 25x11-12 or 26x11-12 (common) Wheel Bolt Pattern: 4x110mm (common for Polaris ATVs) 🛡️ Safety Features Ratings Atv Safety Standards: Compliant with ANSI/SVIA-1-2010 and B71.4-2004 standards where applicable. Active Features Braking System Type: Hydraulic disc brakes, front and rear Parking Brake: Hand-lever activated Passive...