The Polaris Sportsman 600, produced for the 2003 and 2004 model years, is a robust All-Terrain Vehicle (ATV) designed for a wide range of applications, from demanding utility tasks to spirited off-road exploration. This model features a powerful 597cc liquid-cooled, 2-stroke parallel-twin engine with Electronic Fuel Injection (EFI), delivering approximately 70-75 horsepower for strong performance. Key engineering highlights include an Independent Front and Rear Suspension (IRS) for enhanced ride comfort and traction, along with an On-Demand All-Wheel Drive (AWD) system. Its sturdy construction, considerable towing capacity, and impressive ground clearance make it a reliable choice for ATV enthusiasts, farmers, hunters, and professional mechanics seeking a capable and versatile machine. This comprehensive English-language workshop service manual provides detailed guidance for maintaining and repairing the Polaris Sportsman 600 ATVs from 2003 and 2004. The manual covers all essential systems, including in-depth engine service, transmission (PVT) operation, chassis and suspension, braking systems, and the electrical system. It offers step-by-step procedures for routine maintenance, troubleshooting common and complex issues, and complete repair instructions for all major components. Technical specifications, wiring diagrams, and fluid recommendations are also included, ensuring owners and technicians have the necessary information to keep the Sportsman 600 operating at peak performance and reliability. 🏷️ Basic Information Identification Make: Polaris Model: Sportsman 600 Years Covered: 2003, 2004 Vehicle Type: ATV (All-Terrain Vehicle) Codes Engine Code General: 600 Twin EFI 👋 Introduction Market Position Product Segment: High-performance utility/sport ATV segment. Target Audience: ATV enthusiasts, off-road riders, farmers, hunters, and professional mechanics. Competitive Analysis Key Competitors Era: Yamaha Kodiak/Grizzly, Honda Foreman/Rancher, Arctic Cat 500/650. Key Features Vehicle Engine Configuration: Liquid-cooled, 2-stroke, parallel-twin engine with Electronic Fuel Injection (EFI). Suspension Type: Independent front and rear suspension (IRS) for superior ride comfort and traction. Drivetrain Features: On-Demand All-Wheel Drive (AWD) with unlockable front differential. 📋 Manual Details Coverage Areas Language: English Format: PDF Manual Type: Workshop Service Manual Page Count Estimated Page Count: Refer to specific manual for exact count, typically 500+ pages for comprehensive coverage 📖 Manual Coverage Systems Covered Engine Systems: Engine disassembly, assembly, lubrication, cooling system, fuel system (EFI), ignition system, exhaust system, piston and cylinder service, crankshaft and connecting rod service, valve train Transmission Drivetrain: PVT (Polaris Variable Transmission) clutch operation and service, drive belt inspection and replacement, final drive (gearcase), front and rear driveshaft, differential service Chassis Suspension: Frame inspection and repair, front and rear suspension geometry, shock absorber service, A-arm inspection and replacement, wheel bearing service Brakes: Hydraulic brake system diagnosis, caliper service, master cylinder overhaul, brake pad replacement, fluid bleeding, parking brake adjustment Electrical System: Wiring diagrams, battery maintenance, charging system (stator, rectifier/regulator), starter system, lighting system (headlights, taillights, brake lights), instrumentation, ignition system components, EFI sensor diagnosis Fuel System Efi: Fuel pump testing, fuel injectors, throttle body service, ECM (Engine Control Module) troubleshooting, sensor testing (MAP, TPS, IAT) Cooling System: Radiator service, fan operation, thermostat replacement, coolant type and capacity Procedures Included Maintenance: Routine inspections, oil change intervals and specifications, filter replacements (oil, air), spark plug recommendations, lubrication points Troubleshooting: Diagnostic procedures for common and uncommon issues, symptom-based troubleshooting guides, electrical system diagnostics Repair: Step-by-step repair instructions for all major vehicle components, including engine overhaul, transmission rebuild, suspension repair, electrical component replacement Installation: Instructions for accessory installation, component replacement procedures Technical Depth Depth Level: Comprehensive; covers from basic owner maintenance to complete engine and transmission rebuilds, including advanced electrical diagnostics. 📊 Manual Specifications File Format File Type: PDF Searchability: Likely searchable text due to PDF format, facilitating quick information retrieval. Print Quality: High-resolution scans or digital creation, ensuring clarity of diagrams and text. Binding Type Binding For Physical Copy: N/A (Digital PDF) Paper Type Paper Type For Physical Copy: N/A (Digital PDF) ⚙️ Engine Specifications Primary Engine Engine Displacement: 597cc (36.4 cu. in.) Engine Type: Liquid-cooled, 2-stroke, parallel-twin Bore X Stroke: 68.0 mm x 53.0 mm (approx.) Cooling System: Liquid-cooled with fan assist Performance Horsepower Estimated: Approx. 70-75 HP (Performance figures can vary slightly based on specific tuning and testing). Torque Estimated: Not officially published, but significant low-end torque for pulling and climbing. Fuel System Fuel Induction: Electronic Fuel Injection (EFI) with Mikuni throttle body. Fuel Type Required: Unleaded gasoline, minimum 87 octane Lubrication Oil Type Recommended: Polaris Synthetic 2-stroke Oil or equivalent meeting API TC specifications. Ignition Ignition System: CDI (Capacitor Discharge Ignition) with electronic advance Spark Plug Type: NGK R CR9EK (Check manual for specific gap and exact part number) 🔧 Transmission Standard Transmission Type: Polaris Variable Transmission (PVT) with engine braking Gears: High, Low, Neutral, Reverse, Park Features Clutch System: Dual centrifugal clutch system (primary and secondary) Drive Belt: 3211077 (Primary Clutch Sheave to Secondary Clutch) - Always verify with manual. 📐 Dimensions Exterior Length: 81.0 in. (2057 mm) Width: 46.0 in. (1168 mm) Height: 47.5 in. (1207 mm) Wheelbase: 50.5 in. (1283 mm) Weights...