POLARIS SPORTMAN 600 700 2002 2003 Service Repair Manual + Wiring

POLARIS SPORTMAN 600 700 2002 2003 Service Repair Manual + Wiring

Loaded with illustrations, instructions, photos, and diagrams, complete to service and repair your POLARIS. Read and print pages, or copy the entire manual to your hard drive.

262  Pages

Models Covered :  

2002 SPORTMAN 700

2003 SPORTMAN 700

2003 SPORTMAN 600

Model Year:

2002, 2003

Manual Covers :

• General Information
• Maintenance
• Engine
• Fuel System/Carburetion
• Body
• Steering
• Suspension
• PVT System
• Clutch
• Final Drive
• Transmission Service
• Brakes
• Starter
• Electrical
• Wiring Diagram

This manual is the same as the manual used by workshops. Service Manual contains detailed instructions and step by step diagrams for all workshop procedures.

 Language: English 
Format: PDF – Indexed and Searchable

COMPATIBLE WITH ALL WINDOWS & MAC COMPUTERS 
(WINDOWS 11, WINDOWS 10, WINDOWS 8 ETC.) 

Windows/Mac/Tablet/Phone Friendly

• Engine: The 2003 Sportsman 600 was equipped with a 597cc liquid-cooled, 4-stroke V-twin, while the 2002 and 2003 Sportsman 700 models had a 683cc liquid-cooled, 4-stroke V-twin. Both used a carburetor for fuel delivery.
• Transmission: Both models featured an automatic Continuously Variable Transmission (CVT).
• Drivetrain: Like most Sportsman models, they came with selectable all-wheel drive (AWD) and 2WD.
• Suspension: The ATVs were built with MacPherson strut front suspension and independent rear suspension (IRS).
• Towing: According to a user manual from Polaris, the maximum trailer weight for the 2003 Sportsman 600/700 was 1,500 pounds on level ground. 

• Carburetor and Y-pipe leaks: Vibrations from the twin-cylinder engine often cause the Y-pipe and carburetor boots to crack. This can create an engine lean condition, leading to poor performance, backfiring, and potential engine damage. A clogged or dirty carburetor can also cause starting and idling issues.
• Exhaust leaks: Exhaust leaks, particularly at the exhaust manifold’s “donut gasket,” are also a result of engine vibrations and can cause poor engine performance.
• Ignition system: Many of these models came originally equipped with a unreliable Ducati ignition system. If the ignition fails, it can cause starting issues and poor engine operation.
• Starting and shifting problems: The stock starter motor can be a common point of failure. Some owners have also reported issues with the shift indicator or a spring related to the brake pedal, which can prevent the ATV from shifting properly.
• Fuel system problems: The fuel pump can fail, or the fuel tank vent can become plugged, causing fuel delivery issues.
• Recalls: The 2003 Predator ATV was recalled for improperly torqued brake calipers, but the carbureted 600 and 700 models were not listed in the recall notice from the U.S. Consumer Product Safety Commission (CPSC). However, the 2003 and later Sportsman 700 EFI models were recalled in 2004 for separate fuel and throttle issues. 

• Service manuals: PDF versions of the official 2002–2003 Polaris Sportsman 600/700 Twin Factory Service Manual are available from sellers on eBay.
• Carburetor repair: Replacement carburetors or rebuild kits are available from online retailers. However, some owners recommend rebuilding the OEM Mikuni carburetor rather than purchasing a cheaper, lower-quality replacement.
• Ignition coils: Aftermarket ignition coils with longer leads are available from sellers on Amazon, which can help avoid issues with cracked wires due to vibration.
• Engine parts: For engine components like gaskets and pistons, online retailers like wideworldofindoorsports.com offer kits for the Sportsman 700.
• Aftermarket parts and upgrades: Many accessories and upgrades are available from retailers like RevZilla, including winch mounts, wheel bearings, suspension springs, and exhaust systems.