POLARIS SPORTSMAN 600 700 800 Series 2002-2010 Repair Manual PDF Download

Models Covered: Sportsman 600 (2003-2005) Sportsman 700 (2002-2006) Sportsman 700 EFI (2004-2007) Sportsman 700 EFI X2 (2008) Sportsman MV7 (2005-2006) Sportsman 800 EFI (2005-2010) Sportsman 800 EFI X2 (2007-2009) Sportsman 800 EFI Touring (2008-2009) This manual can be used by anyone from a first time owner/amateur to a professional technician.Easy to read type,And give you all the information needed to do the procedure correctly. Keep this service manual handy and use it often. Performing routine,preventive maintenance will save you time & money by helping to prevent premature failure and unnecessary repairs. Manual Contents: INDEX QUICK REFERENCE DATA CHAPTER ONE / GENERAL INFORMATION Manual organization / Warnings, cautions and notes / Safety / Serial numbers / Model identification (2004 models) / Fasteners / Shop supplies / Tools / Measuring tools / Electrical system fundamentals / Service methods / Storage / Specifications CHAPTER TWO / TROUBLESHOOTING Warning light system / Starting the engine / Engine will not start / Starting difficulties / Poor engine performance / Fuel system / Engine / Engine lubrication / Cylinder leakdown test / Clutch system / Electrical testing / Electrical troubleshooting / Meter assembly / Front gearcase / Steering / Brake system / Specifications CHAPTER THREE / LUBRICATION, MAINTENANCE and TUNE-UP Maintenance schedule / Pre-ride inspection / Tune-up / Engine compression test / Engine oil and filter / Oil pressure test / Clutch / Transmission oil / Shift linkage / Air filter / Inline breather filter / Air intake ducts / Idle speed (carbureted models) / Control cables / Fuel system / Exhaust system / Ignition timing (2002-2004 carbureted models) / Spark plugs / Cooling system / Front gearcase oil / Rear gearcase oil (all models except X2 and Touring models) / Tires and wheels / Steering system / Suspension / Brake system / Lighting system / Recoil starter / Lubrication service / Fasteners / Wires, hoses and control cables / Specifications CHAPTER FOUR / ENGINE TOP END Component identification / Rocker cover / Rocker arms and pushrods / Cylinder head / Cylinder block and pistons / Valve lifter / Specifications CHAPTER FIVE / ENGINE LOWER END Engine service / Oil system priming / Engine removal / Engine installation / Recoil starter (MV7 models) / Alternator covers (all models except MV7) / Flywheel, bendix and stator / Water pump cover / Stator housing / Timing gears / Water/oil pump / Camshaft thrust plate / Crankcase / Engine break-in / Specifications CHAPTER SIX / CLUTCH AND DRIVE BELT Clutch system operation / Clutch tools / Clutch drying / Drive belt / Clutch outer cover / Clutch inner cover / Drive clutch / Driven clutch / Specifications CHAPTER SEVEN / TRANSMISSION AND SHIFT MECHANISM (ALL MODELS EXCEPT X2 AND TOURING MODELS) Gearshift selector / Transmission case / Transmission / Specifications EIGHT / TRANSMISSION AND SHIFT MECHANISM (X2 AND TOURING MODELS) Gearshift selector / Transmission case / Transmission shafts / Differential gear assembly / Snorkel shaft / Specifications CHAPTER NINE / AIR/FUEL AND EXHAUST SYSTEMS (CARBURETED MODELS) Air box / Exhaust system / Intake manifold / Carburetor / Carburetor tests and adjustments / Pilot screw / Throttle cable / Throttle lever housing / Choke (starter) cable / Fuel draining / Fuel valve / Fuel tank / Rear tank (2005-on MV7 models) / Fuel sender (late 2004-on 600 and 700 models, 2005-on MV7 models) / Fuel pump / Specifications CHAPTER TEN / AIR/FUEL SYSTEM (FUEL INJECTED MODELS) Air box / Exhaust system / Exhaust manifold / Intake manifold / Priming the fuel system / Depressurizing the fuel system / Fuel tank / Fuel pump / Fuel sender / Pressure regulator / Throttle lever housing / Throttle cable / Throttle body / Fuel injectors / Crankshaft position (CKP) sensor / Temperature and barometric air pressure / (T-BAP) sensor / Throttle position sensor (TPS) / Electronic control unit (ECU) / Self diagnosis / Specifications CHAPTER ELEVEN / ELECTRICAL SYSTEM Electrical component replacement / Electrical connectors / Battery / Charging system / Stator / Voltage regulator/rectifier / Logic box (2005-on carbureted models) / Relays / Ignition system identification / CDI unit / Trigger coil / Ignition coil / Electronic control unit (ECU) / Starting system / Starter / Starter solenoid / Electronic throttle control (ETC) switch / Headlight pod / Headlight / Taillight assembly / Work light (models so equipped) / Switches / All wheel drive (AWD) coil / Active descent control (ADC) coil / Speed sensor / Transmission switch / Resistor module (2004-on models) / Shift indicator circuit / Differential solenoid (X2 and Touring models) / Differential controller relay (X2 and Touring models) / Meter assembly / On-board diagnostics / Fuses / Wiring and connectors / Wiring diagrams / Specifications CHAPTER TWELVE / COOLING SYSTEM Hoses and hose clamps / Cooling system inspection / Coolant reservoir / Radiator / Radiator fan / Fan switch (2002-2004 600 and 700 models) / Coolant temperature sensor / Coolant temperature sensor (carbureted models) / Thermostat / Water pump / Specifications CHAPTER THIRTEEN / WHEELS, TIRES AND HUBS Wheels / Front hub / Front bearing carrier / Rear hub / Rear bearing carrier / Tires / Specifications CHAPTER FOURTEEN / FRONT SUSPENSION, STEERING AND FRONT DRIVE SYSTEM Hubstrut / Front strut / A-arm / Tie rod / Steering post / Handlebar / Handlebar grip / Front drive axle / Front drive shaft / Universal joint / Front gearcase / Specifications CHAPTER FIFTEEN / REAR SUSPENSION AND REAR DRIVE SYSTEM Shock absorber / Upper control arm / Lower control arm / Control arm inspection / Stabilizer linkage assembly / Stabilizer support / Rear drive axle / Rear gearcase (all models except X2 and Touring / models) / Rear drive shaft (all models except X2 and / Touring models) / Specifications CHAPTER SIXTEEN / BRAKES Brake operation / Brake service notes / Brake bleeding / Brake fluid draining / Brake pad inspection / Front brake caliper / Rear brake caliper / Front brake master cylinder / Rear brake master cylinder / Brake pedal / Brake disc / Brake hoses / Specifications CHAPTER SEVENTEEN / BODY AND FRAME Quick release inserts / Rider¿s seat / Rider¿s backrest and passenger seat (X2 models) / Passenger seat (Touring models) / Side panel / Fender cover / Front fender / Front rack / Front bumper (all models except MV7) / Front brush guard / Grill and radiator shield (all models except / MV7 models) / Rear rack (all models except MV7, X2 and Touring models) / Rear rack (Touring models) / Rear rack and brush guard assembly / (MV7 models) / Rear fender (all models except X2 and MV7 models) / Rear quarter panel (X2 models) / Footwell / Rear storage box (all models except X2 models) / Cargo box (X2 models) / Winch / Winch contactor / Specifications COLOR WIRING DIAGRAMS File Format: PDF Compatible: All Versions of Windows & Mac Language: English Requirements: Adobe PDF Reader