2002-2010 Polaris Sportsman 600 700 800 Repair Service MANUA

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🏷️ 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 Type: Automatic Polaris Variable Transmission (PVT) with Engine Braking Optional Gearbox: CVT transmission with High, Low, Neutral, and Reverse gears. Features Clutch System: Primary (Drive) Clutch and Secondary (Driven) Clutch, roller or belt system. Drive System: Shaft Drive, AWD (on-demand) or 2WD system. Transmission Fluid: Polaris PVT Fluid or equivalent (e.g., AGL Gearcase Lubricant for final drive). 📐 Dimensions Exterior Length Typical: Approx. 83-85 inches Width Typical: Approx. 46-48 inches Height Typical: Approx. 48-50 inches Weights Dry Weight Typical: Approx. 550-650 lbs (varies by model) Ground Clearance Typical: Approx. 8-11 inches Towing Capacity: 1500 lbs (typical) Cargo Rack Capacity Front Rear: Front: ~100 lbs, Rear: ~200 lbs (approximate, check specific model) 🛡️ Safety Features Ratings Atv Safety Standards: Meets ANSI/SVIA 1-2010 and SAE J1903 standards. Active Features Braking System: Hydraulic disc brakes (front and rear), engineered for reliable stopping power. Engine Braking: PVT system provides significant engine braking for controlled descents. Passive Features Rollover Protection: Not standard; proper ATV operation and safety gear are crucial. Lighting: Dual headlights, taillight/brake light combination. 💡 Technology Features Infotainment Display Features: Digital gauge clusters providing speed, RPM, fuel level, gear indicator, trip meter, and warning lights. Some models may have basic odometer readings. Driver Assistance Efi Systems: For EFI models, advanced engine control units...

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Type: Atv

Säljare:

Sku: 49306

Collections: ALL ATV Powersports

Availability: In stock

Tags: 2002 2003 2004 2005 2006 2007 2008 2009 2010 ATV Misc Polaris Powersports Sportsman 600 Sportsman 700 Sportsman 800

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Description

🏷️ 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:

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

Type:

Automatic Polaris Variable Transmission (PVT) with Engine Braking

Optional

Gearbox:

CVT transmission with High, Low, Neutral, and Reverse gears.

Features

Clutch System:

Primary (Drive) Clutch and Secondary (Driven) Clutch, roller or belt system.

Drive System:

Shaft Drive, AWD (on-demand) or 2WD system.

Transmission Fluid:

Polaris PVT Fluid or equivalent (e.g., AGL Gearcase Lubricant for final drive).

📐 Dimensions

Exterior

Length Typical:

Approx. 83-85 inches

Width Typical:

Approx. 46-48 inches

Height Typical:

Approx. 48-50 inches

Weights

Dry Weight Typical:

Approx. 550-650 lbs (varies by model)

Ground Clearance Typical:

Approx. 8-11 inches

Towing Capacity:

1500 lbs (typical)

Cargo

Rack Capacity Front Rear:

Front: ~100 lbs, Rear: ~200 lbs (approximate, check specific model)

🛡️ Safety Features

Ratings

Atv Safety Standards:

Meets ANSI/SVIA 1-2010 and SAE J1903 standards.

Active Features

Braking System:

Hydraulic disc brakes (front and rear), engineered for reliable stopping power.

Engine Braking:

PVT system provides significant engine braking for controlled descents.

Passive Features

Rollover Protection:

Not standard; proper ATV operation and safety gear are crucial.

Lighting:

Dual headlights, taillight/brake light combination.

💡 Technology Features

Infotainment

Display Features:

Digital gauge clusters providing speed, RPM, fuel level, gear indicator, trip meter, and warning lights. Some models may have basic odometer readings.

Driver Assistance

Efi Systems:

For EFI models, advanced engine control units (ECUs) manage fuel delivery, ignition timing, and emissions for optimal performance and efficiency.

Connectivity

Diagnostic Ports:

On-board diagnostic ports for EFI models allowing connection to diagnostic tools for error code retrieval and live data monitoring.

🔧 Maintenance

Service Intervals

Oil Change Engine:

Every 100 hours or annually for 4-stroke; 2-stroke requires oil injection system maintenance.

Air Filter Service:

Every 50 hours or more frequently in dusty conditions.

Spark Plug Replacement:

Refer to manual; typically every 100-200 hours or as needed for diagnosis.

Clutch Inspection:

Every 100 hours or annually.

Fluid Specifications

Brake Fluid:

DOT 3 or DOT 4; refer to specific model manual.

Coolant:

Ethylene glycol-based antifreeze with corrosion inhibitors, typically a 50/50 mix with distilled water.

Gearcase Lubricant:

Polaris AGL Gearcase Lubricant or SAE 80W-90 Hypoid gear oil.

Known Issues

2 Stroke Specific:

Carburetor clogging, power valve issues, crank seal leaks, piston ring wear.

4 Stroke Specific:

EFI sensor issues (TPS, MAP), starter drive failures, fuel pump issues, occasional oil leaks from seals.

Common Atv Issues:

CV joint boot tears, suspension component wear, drive belt wear, electrical connector corrosion.

📚 Vehicle History

Brand Heritage

Polaris History:

Polaris Industries Inc. is a long-standing American manufacturer known for its snowmobiles, ATVs, and UTVs.

Model Evolution

Sportsman Lineage:

The Sportsman line has been a flagship ATV offering from Polaris, focusing on utility, comfort, and off-road capability. This generation represents a significant update and platform consolidation.

Production

Manufacturing Location:

Primarily manufactured in the United States (e.g., Roseau, Minnesota; Spirit Lake, Iowa).

Engine Progression:

This period saw the transition from Polaris's dominant 2-stroke engines (600, 700) to the more modern and efficient 4-stroke ProStar engines (800), reflecting industry trends.

🏆 Awards & Recognition

Recognitions

Industry Reputation:

Polaris Sportsman models are consistently recognized for their utility, comfort, and ruggedness in the ATV market.

Ratings

Consumer Reviews:

Generally positive consumer reviews highlighting performance and versatility, though specific issues can arise depending on model year and maintenance.