Welcome to the comprehensive service and repair manual for the Polaris Sportsman 600 and 700 All-Terrain Vehicles (ATVs) from the 2002-2003 model years. Engineered for robust performance and versatility, these ATVs are renowned for their capable 4-stroke, liquid-cooled V-twin engines, available in 597cc and 683cc displacements, respectively. With features like on-demand all-wheel drive, automatic CVT transmissions, and substantial rack capacities, the Sportsman models are designed for demanding trail riding and utility tasks. This manual serves as an essential resource for owners and technicians, providing in-depth guidance to ensure optimal performance and longevity. This extensive service manual offers complete coverage for all aspects of maintenance, repair, rebuilding, and restoration for your Polaris Sportsman. Inside, you will find detailed procedures for engine overhaul, transmission servicing, brake system maintenance, electrical system diagnostics, suspension and steering adjustments, and fuel system care. It includes step-by-step instructions, torque specifications, clearances, and high-resolution diagrams to facilitate accurate work. Whether performing routine scheduled maintenance, troubleshooting complex issues, or undertaking major component repairs, this manual provides the professional-level expertise needed to keep your ATV in peak condition. 🏷️ 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...