2002-2003 Polaris Sportsman 700 Service & Repair Manual

CHAPTER INDEX CHAPTER 1 GENERAL CHAPTER 2 MAINTENANCE CHAPTER 3 ENGINE CHAPTER 4 FUEL SYSTEM CHAPTER 5 BODY/SUSPENSION CHAPTER 6 PVT SYSTEM CHAPTER 7 FINAL DRIVE CHAPTER 8 TRANSMISSION CHAPTER 9 BRAKES CHAPTER 10 ELECTRICAL

1 GENERAL INFORMATION 1.1 CHAPTER 1 GENERAL INFORMATION Model Identification 1.2 ....................... Serial Number Location 1.2 ................... 2003 Sportsman Models 1.3 .................. Machine Dimensions 1.4-1.5 ..................... Specifications - 2002 Sportsman 700 1.6-1.7 ....... Specifications - 2003 Sportsman 600 1.8-1.9 ....... Specifications - 2003 Sportsman 700 1.10-1.11 ....... Publication Numbers 1.12 ..................... Paint Codes 1.12 ............................. Replacement Keys 1.12 ....................... Standard Torque Specifications 1.13 ............ Decimal Equivalent Chart 1.14 ................. Conversion Table 1.15 ........................ Tap Drill Charts 1.16 .......................... Glossary of Terms 1.17-1.18 ........................

GENERAL INFORMATION 1.2 MODEL IDENTIFICA TION The machine model number must be used with any correspondence regarding warranty or service. Machine Model Number Identification Year Designation Basic Chassis Designation Engine Designation A 03 CH 68 AA Emissions & Model Option ENGINE DESIGNATION NUMBERS EH068OLE11 Twin cylinder, Liquid Cooled, 4 Stroke, Electric Start ............... EH059OLE11 Twin cylinder, Liquid Cooled, 4 Stroke, Electric Start ............... VIN IDENTIFICA TION 1 2 3 4 5 6 7 8 9 10 1 1 12 13 14 15 16 17 4 X A C H 6 8 A * 2 P 0 0 0 0 0 0 Vehicle Description Vehicle Identifier Powertrain Engine Emissions Model Year Plant No. Individual Serial No. Body Style Check Digit World Mfg. ID * This could be either a number or a letter ENGINE SERIAL NUMBER LOCA TION Whenever corresponding about an engine, be sure to refer to the engine model number and serial number. This information can be found on the sticker applied to the top side of the crankcase (A). An additional number is stamped on the side of the crankcase beneath the cylinder coolant elbow. MACHINE MODEL NUMBER AND SERIAL NUMBER LOCA TION The machine model number and serial number are important for vehicle identification. The machine serial number is stamped on the lower left side of the frame tube.(B) TRANSMISSION I.D. NUMBER LOCA TION A B Front The transmission I.D. number is located on the right side of machine.

SPORTSMAN 600 SPORTSMAN 700 NOTE: MODELS WILL VARY IN COLOR. GENERAL INFORMATION 1.3 2003 SPRORTSMAN 600 & 700 MODELS

46 in 116.84 cm 85 in 215.90 cm 50.75 in 128.90 cm FRONT SIDE GENERAL INFORMATION 1.4 MACHINE DIMENSIONS

46 in 116.84 cm 47 in 119.38 cm 11 in 27.94 cm 46 in 116.84 cm REAR GENERAL INFORMATION 1.5 MACHINE DIMENSIONS

GENERAL INFORMATION 1.6 MODEL: 2002 SPORTSMAN 700 .......... MODEL NUMBER: A02CH68AA/CA . ENGINE MODEL: EH68ALOE1 .. JETTING CHART AMBIENT TEMPERATURE Altitude Below 40F +40_F and above ltitude Below 40 F Below +5C +40 F and above +5_C and above Meters 0-1800 167 5 162 5 Meters (Feet) 0-1800 (0-6000) 167.5 162.5 (Feet) Above 1800 Above 1800 Above (6000) 160 155 CLUTCH CHART *EBS require no helix/spring adjustment Shift Drive Clutch Driven Clutch Driven Altitude Shift Weight Drive Clutch Spring Driven Clutch Spring Driven Helix Altitude Weight Spring Spring Helix Meters 0-1800 20 56 Blue/Green White/Yellow EBS Meters (Feet) 0-1800 (0-6000) 20--56 Blue/Green (5631215) White/Yellow EBS (Feet) 1800-3700 20 54 Blue/Green White/Yellow EBS 1800-3700 (6000-12000) 20--54 Blue/Green (5631214) White/Yellow EBS ENGINE Type 4 Cycle, Twin Cyl. ....................... Displacement 683 cc ............... Bore 3.149I (80 mm) ....................... Stroke 2.677I (68 mm) ..................... Valve Clearance In/Ex 0.006/0.006I@ TDC on compression ....... Compression Ratio 9.78/1 Full Stroke .......... Cooling Liquid .................... Lubrication Type Pressurized Wet Sump ............ Operating RPM200 6000 RPM ......... Idle RPM200 (lights off) 1100 RPM ..... Compression Pressure (Std) 15% ....... CARBURETION Type BST 34 Mikuni ................ Main Jet 162.5 ............ Pilot Jet 45 ............. Jet Needle 4BH41--4 ........... Needle Jet P-6 ........... Throttle Valve #100 ........ Pilot Screw 1.5 Turns Out .......... Pilot Air Jet 160 .......... Valve Seat 1.5 ........... Float Height 14.7mm (.58I)1mm ......... Fuel Octane (R+M/2) 87 Non-Oxygenated or . 89 Oxygenated CLUTCH Type PVT .................... Belt 3211091 ..................... Belt Width (Projected) 1.188I (30.18mm) ..... Side Angle (Overall) 28 2 ...... Outside Circumference 40.875 .188I .... Center Distance 10.12I (254.5mm) .......... Clutch Offset 0.5I (12.7mm) ............ Secondary Spring White/Yellow ........ Driven Helix Compound (EBS) ............. Spring Position (Helix) N/A .... Spring Position (Sheave) N/A ..

Lubricant Key GENERAL INFORMATION 1.7 MODEL: 2002 SPORTSMAN 700 ............ MODEL NUMBER: A02CH68AA/CA ... ENGINE MODEL: EH68ALOE1 .... ELECTRICAL FLUID Capacity Type Flywheel I.D. 4060152 Fuel Tank 4.75 gals. (17.9 L) ...... .......... CDI Marking 4010364 Coolant 3.2 qts. (3 L) *PP6 ....... ............ . Alternator Output 300 Watts Transmission 13.50 oz. *PPS ... ....... .... Ignition Timing 25 BTDC@3000500RPM Gearcase Oil (Front).. 5 oz. (150 ml)...*PDD ..... Spark Plug / Gap RC7YC -- 0.036I (0.9mm) Gearcase Oil (Rear) 5oz. (150 ml) 80--90 GL5 ... . . Lights: Head 50 Watt Quartz Engine Oil 2 qts. (1.9L) *PP4 ...... .......... .. Grill (2) 27 Watts Quartz Brake (Hand) Dot 3 .... ....... Tail 8.26 watts Brake (Foot) Dot 3 ........ ........ Brake 26.9 watts ...... Voltage Regulator LR39 *PP6 Polaris Premium 60/40 Antifreeze/Coolant .. Electric Start Standard *PPS Polaris Premium Synthetic Gear Case Oi ....... Instrument Cluster LCD *PP4 Polaris 0W--40 Synthetic Engine Lubricant .. *PDD Premium Demand Drive Hub Fluid SUSPENSION / CHASSIS DRIVE TRAIN Body Style Gen IV 4 Wheel Independent Shaft Drive ........ Front Suspension MacPherson Strut Gear Reduction-Low 7.5/1 .. . Tow Capacity 1225 lbs. (555.6 kg) Gear Reduction-Rev 5.11/1 ...... . Turning Radius 76I (181.61 cm) Gear Reduction-High 3.09/1 ..... Toe Out 1/8I-1/4I (3-6.35 mm) Front Drive Ratio 3.82/1 ........... .... Ground Clearance 11I (27.94 cm) Final Drive Ratio 3.10/1 .. .... Front Vertical Travel 6.7I (17.02 cm) Brake (Hand) Single Lever, Hyd. Disc ....... Rear Suspension Progressive Rate Independent Brake (Auxiliary Foot) Hydraulic ... Rear Travel 9.5I (24.13 cm) Transmission Park Lock ........ Rear Shock 2I Twin Tube ........ Shock Adjustment Cam .. TIRES Tire Size - Front 25 x 8 - 12 .... Tire Size - Rear 25 x 11 - 12 .... Tire Pressure - F/R 5/5 lbs . Total Width 46I (116.84 cm) ........ Total Length 85I (215.90 cm) ....... Total Height 47I (119.38 cm) ........ Wheel Base 50.75I (128.90 cm) ....... Weight - Dry 740 lbs. (335.60 kg) ....... LOAD CAPACITY Front Rack (Std) 90 lbs. ..... Rear Rack (Std) 180 lbs. ...... Tongue Weight 150 lbs. .... Hitch Towing Capacity...1500 lbs.

GENERAL INFORMATION 1.8 MODEL: 2003 SPORTSMAN 600 .......... MODEL NUMBER: A03CH59 . ENGINE MODEL: EH059OLE .. JETTING CHART AMBIENT TEMPERATURE Altitude Below 40 F +40_F and above Altitude Below 40 F Below +5 C +40 F and above +5_C and above Meters 0-1800 162 5 155 Meters (Feet) 0-1800 (0-6000) 162.5 155 (Feet) Above 1800 Above 1800 Above (6000) 150 145 CLUTCH CHART *EBS require no helix/spring adjustment Shift Drive Clutch Driven Clutch Driven Altitude Shift Weight Drive Clutch Spring Driven Clutch Spring Driven Helix Altitude Weight Spring Spring Helix Meters 0-1800 10 MH Blue/Green White/Yellow EBS Meters (Feet) 0-1800 (0-6000) 10 MH Blue/Green (5631215) White/Yellow EBS (Feet) 1800-3700 10 WH Blue/Green White/Yellow EBS 1800-3700 (6000-12000) 10 WH Blue/Green (5631214) White/Yellow EBS ENGINE Type 4 Cycle, Twin Cyl. ....................... Displacement 597 cc ............... Bore 3.012I (76.5 mm) ....................... Stroke 2.559I (65 mm) ..................... Compression Ratio 9.35/1 Full Stroke .......... Cooling Liquid .................... Lubrication Type Pressurized Wet Sump ............ Operating RPM 200 6000 RPM ......... Idle RPM 100 (lights off) 1100 RPM .... Compression Pressure 150--170psi 15% ....... CARBURETION Type BST 34 Mikuni ................ Main Jet 155 ............ Pilot Jet 45 ............. Jet Needle J8--4FA01--3 ........... Needle Jet P-4 ........... Throttle Valve #100 ........ Pilot Screw 1.5 Turns Out .......... Pilot Air Jet 160 .......... Valve Seat 1.5 ........... Float Height 14.7mm (.58I) 1mm ......... Fuel Octane (R+M/2) 87 Non-Oxygenated or . 89 Oxygenated CLUTCH Type PVT .................... Belt 3211091 ..................... Belt Width (Projected) 1.188I (30.18mm) ..... Side Angle (Overall) 28 2 ...... Outside Circumference 40.875 .188I .... Center Distance 10 .12I (254.5mm) .......... Clutch Offset 0.5I (12.7mm) ............ Secondary Spring White/Yellow ........ Driven Helix Compound (EBS) ............. Spring Position (Helix) N/A .... Spring Position (Sheave) N/A ..

2002-2003 Polaris Sportsman 700 Service & Repair Manual

You're Reading a Preview

Recently Viewed