🏷️ Basic Information Identification Make: Polaris Model: Sportsman Year: 2002-2003 Sub Model: 600 / 700 Vehicle Type: All-Terrain Vehicle (ATV) Codes Oem Manual Code Example: P-SM600700-2002-2003 👋 Introduction Market Position Positioning: Essential resource for Polaris Sportsman 600/700 owners and technicians seeking to perform their own maintenance and repairs. Competitive Analysis Value Proposition: Offers significant cost savings compared to dealership or independent shop labor charges by empowering DIY repairs and maintenance. Key Features Feature Highlight: This manual is designed to cover all aspects of the vehicle's operation, maintenance, and repair, providing professional-level guidance. 📋 Manual Details Coverage Areas Primary Coverage: Complete service, repair, maintenance, rebuilding, and restoration Page Count Estimated Page Count: 500+ Manual Type Manual Format: Service Repair Workshop Manual Language Language: English Format Digital Format: PDF Download 📖 Manual Coverage Systems Covered Engine: Engine overhaul, disassembly, assembly, lubrication, cooling system, exhaust system Transmission: Drive clutch, driven clutch, final drive, gearbox, maintenance, repair Brakes: Hydraulic brake system, calipers, master cylinder, brake fluid, bleeding procedures Electrical: Ignition system, starter, charging system (stator, regulator/rectifier), battery, lighting, wiring diagrams, electrical troubleshooting Suspension: Front and rear suspension, shocks, A-arms, bushings, wheel bearings Steering: Steering system, tie rods, steering shaft, adjustments Fuel System: Carburetor(s), fuel pump, fuel lines, fuel filter, maintenance and adjustments Body Chassis: Frame inspection, body panels, fenders, racks, seat, graphics Procedures Included Maintenance: Scheduled maintenance, oil changes, filter replacements, lubrication points, valve adjustments Troubleshooting: Diagnostic charts, symptom-based troubleshooting, common problems and solutions Repair: Step-by-step repair instructions for all major components and systems Rebuild: Complete engine and transmission rebuild procedures Assembly Disassembly: Detailed instructions for component removal and installation Technical Depth Depth Level: Comprehensive: from basic owner maintenance to advanced mechanical and electrical repair Detail Level: Includes torque specifications, clearances, timing marks, and detailed diagrams 📊 Manual Specifications File Format File Type: PDF Searchability: Searchable text for quick information retrieval Print Quality Image Resolution: High-resolution images and diagrams for clarity Printable: Printable pages for workshop use Binding Type Binding: N/A (Digital Download) Paper Type Paper: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: 4-stroke, liquid-cooled, SOHC, V-Twin (for both 600 and 700 models, displacement varies) Engine 600 Displacement: 597cc Engine 700 Displacement: 683cc Performance Horsepower Estimate 600: Approx. 45-50 HP (model dependent) Horsepower Estimate 700: Approx. 50-55 HP (model dependent) Fuel System Carburetor Type: Mikuni (specific models vary, e.g., VM34 or dual carburetors) Fuel Type: Unleaded Gasoline Engine Features Cooling System: Liquid Cooling with fan assist Ignition System: Electronic Ignition (CDI) 🔧 Transmission Standard Transmission Type: Automatic (CVT - Continuously Variable Transmission) Drive System: On-Demand All-Wheel Drive (AWD) with 2WD option Features Clutch System: Polaris Variable Transmission (PVT) with High/Low range and Reverse Fluid Requirements Transmission Fluid: Polaris AGL Premium Synthetic Gearcase Lubricant or equivalent SAE 30 premium quality oil 📐 Dimensions Exterior Length: Approx. 81 inches (205.7 cm) Width: Approx. 46 inches (116.8 cm) Height: Approx. 45 inches (114.3 cm) Weights Dry Weight: Approx. 575-590 lbs (261-268 kg) Ground Clearance: Approx. 10.25 inches (26 cm) Cargo Front Rack Capacity: 300 lbs (136 kg) Rear Rack Capacity: 600 lbs (272 kg) Towing Towing Capacity: 1500 lbs (680 kg) Wheelbase Wheelbase: 50.5 inches (128.3 cm) 🛡️ Safety Features Ratings Atv Safety Standards: Designed to meet ANSI/SVIA standards for ATVs. Active Features Braking System: Hydraulic disc brakes front and rear Passive Features Roll Over Protection: Not equipped with a roll cage or seatbelts (standard ATV design). Helmets and protective gear are mandatory. 💡 Technology Features Infotainment Infotainment Features: N/A (Basic ATV functionality, no integrated infotainment system) Driver Assistance Assistance Features: N/A (Standard ATV design, no electronic driver assistance features) Connectivity Connectivity Options: N/A 🔧 Maintenance Service Intervals Oil Change Interval: Every 100 hours or annually (whichever comes first) Air Filter Cleaning: Every 25 hours or every 6 months Spark Plug Replacement: Every 100 hours or annually Valve Adjustment Interval: Every 100 hours or annually Fluid Specifications Engine Oil Type: Polaris PS-4 4-stroke synthetic engine oil (or SAE 0W-40 or 5W-40 synthetic motorcycle oil) Engine Oil Capacity: Approx. 2.5 US quarts (2.4 liters) with filter change Coolant Type: Polaris Engineered Coolant or a premium quality ethylene glycol-based antifreeze with corrosion inhibitors (e.g., 50/50 mix) Brake Fluid Type: DOT 3 or DOT 4 brake fluid Known Issues Common Wear Items: CV joint boots, suspension bushings, drive belt, brake pads, wheel bearings Electrical Common Failures: Stator, regulator/rectifier failures, CDI unit issues reported on some models. Engine Common Issues: Carburetor tuning and adjustment, occasional starter motor issues. 📚 Vehicle History Brand Heritage Polaris Heritage: Polaris Industries, founded in 1954, is a major American manufacturer known for its snowmobiles, ATVs, UTVs, and motorcycles. Model Evolution Sportsman Lineage: The Sportsman line has been a cornerstone of Polaris's ATV offerings, evolving from utility-focused machines to more versatile and powerful platforms. The 600 and 700 models represented a significant step up...