The Polaris Sportsman 600, 700, and 800 models, produced between 2002 and 2010, represent a robust line of all-terrain vehicles engineered for versatility and off-road capability. These ATVs are known for their durable construction and reliable performance across various terrains, making them suitable for both work and recreational activities. This generation of Sportsman vehicles showcases a commitment to innovation, offering a range of engine options, including potent 2-stroke and efficient 4-stroke powertrains, and features like the Variable Transmission system with engine braking for enhanced control. With their strong utility focus, including ample cargo capacity and towing capabilities, these models have earned a reputation for being dependable companions for demanding tasks and adventurous outings. This comprehensive Repair Service Manual provides detailed guidance for the maintenance, repair, and troubleshooting of your 2002-2010 Sportsman 600/700/800. It covers all major mechanical, electrical, and structural systems, offering in-depth information on engine overhauls, transmission service, brake system maintenance, suspension and steering repairs, and electrical diagnostics. The manual includes essential maintenance schedules, diagnostic procedures for common issues, and technical specifications, all presented with clear diagrams and step-by-step instructions. Designed for DIY enthusiasts, independent repair shops, and dealerships alike, this resource empowers users to effectively maintain their vehicles, ensuring optimal performance and longevity while potentially reducing repair costs. 🏷️ Basic Information Identification Make: Polaris Model: Sportsman 600/700/800 Model Years Covered: 2002-2010 Product Name: 2002-2010 Polaris Sportsman 600 700 800 Repair Service MANUAL Product Description: 2002-2010 Polaris Sportsman 600 700 800 REPAIR SERVICE MANUAL. This covers all systems, maintenance and repairs. Codes Chassis Codes Common: A02CH57AA, A03CH57AA, A04CH57AA, A05CH57AA, A02CH67AA, A03CH67AA, A04CH67AA, A05CH67AA, A04CH67AB, A05CH67AB, A06CH67AA, A06CH67AB, A06CH67AC, A07CH67AA, A07CH67AB, A08CH67AC, A09CH67AA, A09CH73AA, A10CH73AA 👋 Introduction Market Position Target User: DIY enthusiasts, independent repair shops, and Polaris dealerships. Value Proposition: Provides in-depth, manufacturer-level repair information enabling owners to perform maintenance and repairs, saving time and money. Competitive Analysis Uniqueness: Covers a broad range of model years and engine displacements (600cc, 700cc, 800cc) within a single, comprehensive manual, including both carbureted and EFI variants. Key Features Coverage Scope: Holistic coverage from routine maintenance to complex engine and drivetrain overhauls. Detail Level: Extensive use of diagrams, exploded views, and step-by-step instructions. 📋 Manual Details Coverage Areas Engine: Complete coverage: engine overhaul, component diagnostics, tuning, cooling system, lubrication system. Transmission Drivetrain: Automatic transmission (PVT) service, drive clutch, driven clutch, final drive, axles, CV joints, driveline maintenance. Brakes: Hydraulic brake system inspection, service, bleeding, component replacement (master cylinder, calipers, lines). Suspension Steering: Front and rear suspension service (struts, shocks, control arms), steering system maintenance and repair, wheel alignment. Electrical System: Ignition system, starting system, charging system (alternator, battery), lighting, wiring diagrams, diagnostic procedures. Fuel System: Carburetor troubleshooting and adjustment (for non-EFI models), fuel injection system diagnostics and service (for EFI models), fuel pump, fuel filter. Body Chassis: Body panel removal and installation, frame inspection and repair, plastic components, seat service, rack systems. Maintenance Schedule: Comprehensive recommended maintenance schedules based on operating hours or mileage. Troubleshooting: Diagnostic charts and procedures for common issues across all systems. Page Count Estimated Pages: 700+ Manual Type Type: Repair Service Manual Language Language: English Format Format: Digital (PDF) 📖 Manual Coverage Systems Covered All Major Systems: Yes, covers all major mechanical, electrical, and structural systems of the specified Polaris Sportsman models. Procedures Included Maintenance Routines: Oil changes, filter replacements, spark plug service, chain/belt tensioning, lubrication points, air filter cleaning/replacement. Repair Tasks: Engine rebuilds, transmission overhauls, suspension component replacement, brake caliper rebuilds, electrical component diagnosis and replacement. Diagnostics: Detailed troubleshooting guides, symptom-based diagnostics, electrical circuit analysis, EFI fault code interpretation. Special Tool Requirements: Identification and usage instructions for specialized tools required for specific procedures. Technical Depth Depth: Comprehensive: includes detailed diagrams, torque specifications, clearances, assembly instructions, and diagnostic flowcharts. 📊 Manual Specifications File Format File Type: PDF (Portable Document Format) Searchability: Fully searchable text for quick information retrieval. Print Quality: High-resolution, suitable for printing individual pages or the entire manual. Binding Type Binding Format: N/A (Digital Download) Paper Type Paper Recommendation: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Families: Polaris 2-stroke twin-cylinder (600, 700) and Polaris ProStar 4-stroke twin-cylinder (800). 600Cc Engine Type: Liquid-cooled, 2-stroke, parallel-twin 700Cc Engine Type: Liquid-cooled, 2-stroke, parallel-twin 800Cc Engine Type: Liquid-cooled, 4-stroke, parallel-twin (ProStar) Performance Displacement 600Cc: 597cc Displacement 700Cc: 698cc Displacement 800Cc: 775cc (approx.) Horsepower Range Approx: 50-70 HP (varies by engine and year) Torque Range Approx: 45-60 lb-ft (varies by engine and year) Fuel System Carbureted Models: Mikuni or Keihin carburetors (specific sizes vary by model/year) Efi Models: Electronic Fuel Injection (EFI) system, Bosch or similar components Fuel Type Required: Unleaded gasoline (minimum 87 octane) Lubrication Oil Type 2 Stroke: 2-stroke engine oil, specifically formulated for liquid-cooled, oil-injected engines. Oil Type 4 Stroke: SAE 0W-40 or 5W-50 Synthetic 4-stroke engine oil (refer to manual for exact specifications). 🔧 Transmission Standard...