🏷️ Basic Information Identification Make: Polaris Model: Sportsman 600, Sportsman 700 Model Year 600: 2003 Model Number 600: A03CH59 Engine Model 600: EH059OLE Model Year 700: 2002, 2003 Model Number 700: A02CH68AA/CA Engine Model 700: EH68ALOE1 Generation Generation Overview: This manual covers the initial generations of the Polaris Sportsman 600 and 700 models, known for their robust utility and off-road capabilities. Codes Vin Decoder Reference: Manual may contain VIN decoding information relevant to the specified model years for accurate identification of specific components and configurations. 👋 Introduction Market Position Segment: High-performance utility ATVs for recreational and work applications. Competitive Analysis Competitors: Competes with similar offerings from manufacturers like Arctic Cat, Can-Am, and Honda in the utility ATV market. Key Features Versatility: Known for their versatility in various terrains and applications, from trail riding to hauling and towing. Engine Power: The 600cc and 700cc engines provide ample power for demanding tasks and spirited riding. Manual Benefit: Provides comprehensive technical guidance essential for maintaining and repairing these capable machines, ensuring longevity and optimal performance. 📋 Manual Details Coverage Areas Comprehensive Coverage: This manual covers all major mechanical, electrical, and body systems for the specified Polaris Sportsman models. It is designed for technicians and owners performing all levels of service and repair. Page Count Total Pages: 262 Manual Type Type: Official Factory Service/Repair/Workshop Manual Language Primary Language: English Format Digital Format: PDF 📖 Manual Coverage Systems Covered Engine: Detailed coverage of engine disassembly, assembly, diagnosis, and repair, including cylinder heads, pistons, rings, crankshaft, camshaft, valve train, oil pump, and lubrication system. Fuel System: Includes carburetor system, fuel pump, fuel filter, fuel lines, and troubleshooting for fuel delivery issues. Ignition System: Coverage of spark plugs, wiring, ignition coil, timing, and diagnostic procedures. Transmission Drivetrain: Information on transmission maintenance, fluid changes, and drivetrain components. Brakes: Detailed procedures for brake pad replacement, rotor service, brake lines, and hydraulic system maintenance. Electrical System: Extensive coverage including wiring diagrams, sensor diagnostics, battery, starter, alternator, lighting systems, and switches. Chassis Suspension: Includes information on suspension components, steering system, wheel bearings, and axle assemblies. Body Panels Trim: Details on body panel removal, installation, and trim components, including fenders, hoods, and bumpers. Cooling System: Radiator, fan, coolant hoses, and oil cooling systems are covered. Tire Wheel Service: Information on tire rotation, wheel bearing maintenance, and tire replacement procedures. Procedures Included Routine Maintenance: Oil changes, transmission fluid changes, fluid level checks, tire rotation, and filter replacements. Engine Rebuild: Comprehensive guide for complete engine teardown, inspection, machining, and reassembly. Troubleshooting: Diagnostic charts and procedures for identifying and resolving common mechanical and electrical issues. Component Replacement: Step-by-step instructions for replacing specific parts such as brake pads, spark plugs, fuel pumps, alternators, and wiring harnesses. Wiring Repair: Detailed wiring diagrams for tracing electrical faults and performing repairs. Technical Specifications: Includes torque specifications, fluid capacities, clearances, and electrical values essential for accurate repairs. Fastener Management: Guidance on proper fastener selection, torque values, and usage of gaskets and seals. Technical Depth Depth: Factory level depth, covering everything from basic maintenance to complete engine and transmission overhauls. Includes diagnostic procedures and specifications for professional technicians. 📊 Manual Specifications File Format Format: PDF Download Interactivity: Supports zoom in/out functionality for detailed viewing of diagrams and text. Print Quality Printability: Yes, printable Binding Type Delivery Format: Instant Download (Digital) Paper Type Digital Quality: Factory quality, ensuring clarity and accuracy of all illustrations and text. ⚙️ Engine Specifications Primary Engine Engine Type 600: Liquid-cooled, 4-stroke, 4-valve SOHC, 600cc Engine Type 700: Liquid-cooled, 4-stroke, 4-valve SOHC, 700cc Performance Horsepower Estimated 600: Approximately 50 HP (exact figures may vary by source) Horsepower Estimated 700: Approximately 55-60 HP (exact figures may vary by source) Fuel System Carburetor Type: CV-type Carburetor(s) Fuel Capacity Recommendation: Uses standard unleaded gasoline (refer to manual for specific octane rating) Engine Components Pistons Rings: Covers specifications for piston and ring installation and clearances. Crankshaft Bearings: Includes procedures for crankshaft and bearing inspection and replacement. 🔧 Transmission Standard Type: Automatic PVT (Polaris Variable Transmission) with Engine Braking Optional Gearing: Includes High and Low range, Reverse, and Park settings. Features Drive System: On-Demand AWD (All-Wheel Drive) with 2WD/4WD selector. Fluid Type: Specific Automatic Transmission Fluid (ATF) or proprietary Polaris fluid required (refer to manual for exact specification and capacity). 📐 Dimensions Exterior Length Approx: 81 inches (approximate, may vary slightly) Width Approx: 46 inches (approximate) Height Approx: 45 inches (approximate) Weights Dry Weight Approx: 600 lbs - 650 lbs (approximate) Towing Capacity: 1500 lbs Rack Capacity Front: 200 lbs Rack Capacity Rear: 400 lbs 🛡️ Safety Features Ratings Atv Safety Considerations: Manual emphasizes safe operating practices, protective gear, and rider training, common for ATVs of this era. Active Features Braking System: Hydraulic disc brakes on all wheels for reliable stopping power. Engine Braking: Variable transmission provides engine braking for controlled descents. Passive...