This comprehensive repair manual covers a wide range of Polaris Sportsman models from 2002 to 2010, providing detailed instructions and guidance for maintenance, repair, and troubleshooting. The manual is designed for both novice and professional mechanics, offering clear and easy-to-understand language. It is an essential tool for anyone who wants to keep their Sportsman ATV running smoothly and efficiently. This manual covers models including the 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), and Sportsman 800 EFI Touring (2008-2009). The manual begins with essential general information, including safety precautions, serial number identification, model identification, fastener information, shop supplies, tools, measuring tools, electrical system fundamentals, service methods, storage, and specifications. It then delves into troubleshooting, covering various areas such as warning light systems, engine starting problems, poor engine performance, fuel systems, engine lubrication, clutch systems, electrical testing, and more. The next section focuses on lubrication, maintenance, and tune-up procedures, providing a comprehensive maintenance schedule, pre-ride inspection guidelines, tune-up instructions, engine compression testing, oil and filter changes, clutch maintenance, transmission oil checks, air filter cleaning, idle speed adjustments, fuel system checks, exhaust system maintenance, spark plug replacement, cooling system checks, tire and wheel maintenance, steering system adjustments, suspension checks, braking system maintenance, and lighting system inspection. The manual further explores specific components of the ATV, starting with the engine top end. Detailed information is provided on the rocker cover, rocker arms, pushrods, cylinder head, cylinder block, pistons, valve lifter, and specifications. The engine lower end section covers engine service procedures, oil system priming, engine removal and installation, recoil starter maintenance, alternator cover inspection, flywheel, bendix, and stator checks, water pump cover maintenance, stator housing inspection, timing gear inspection, water/oil pump maintenance, camshaft thrust plate inspection, crankcase inspection, and engine break-in procedures. The clutch and drive belt section explains the operation of the clutch system, provides guidance on using clutch tools, covers drive belt replacement, and provides detailed information on the clutch outer cover, clutch inner cover, drive clutch, and driven clutch. The transmission and shift mechanism section is broken down into two chapters, one for all models except X2 and Touring models and another for X2 and Touring models. The air/fuel and exhaust systems section covers components such as the airbox, exhaust system, intake manifold, carburetor, fuel draining, fuel valve, fuel tank, fuel sender, fuel pump, and specifications. The fuel-injected models are discussed in a separate chapter, covering the airbox, exhaust system, intake manifold, fuel tank, fuel pump, fuel sender, pressure regulator, throttle lever housing, throttle cable, throttle body, fuel injectors, crankshaft position sensor, temperature and barometric air pressure sensor, throttle position sensor, electronic control unit, self-diagnosis, and specifications. The electrical system is comprehensively addressed, covering electrical component replacement, electrical connectors, battery maintenance, charging system checks, stator inspection, voltage regulator/rectifier inspection, relays, ignition system identification, CDI unit inspection, trigger coil inspection, ignition coil inspection, electronic control unit, starting system components, headlight pod, headlight, taillight assembly, switches, wiring diagrams, and specifications. The manual dedicates a dedicated section to the cooling system, covering hoses and hose clamps, coolant reservoir, radiator, radiator fan, fan switch, coolant temperature sensor, thermostat, water pump, and specifications. Information on wheels, tires, and hubs is provided, including specifications and maintenance procedures. The front suspension, steering, and front drive system are discussed in detail, covering components like the hubstrut, front strut, A-arm, tie rod, steering post, handlebar, front drive axle, front drive shaft, universal joint, and front gearcase. The rear suspension and rear drive system section explores components such as the shock absorber, upper control arm, lower control arm, stabilizer linkage assembly, rear drive axle, rear gearcase, and rear drive shaft. The braking system section provides detailed instructions on brake operation, brake service notes, brake bleeding procedures, brake fluid draining, brake pad inspection, caliper maintenance, master cylinder inspection, brake pedal inspection, brake disc inspection, brake hose inspection, and specifications. Finally, the body and frame section covers components such as the rider's seat, passenger seat, side panels, fender cover, front fender, front rack, front bumper, grill and radiator shield, rear rack, rear fender, footwell, storage box, winch, and winch contactor. The manual concludes with color wiring diagrams.

The Polaris Sportsman, a stalwart in the ATV world, has been a popular choice for riders seeking a blend of versatility and performance. The 2002-2010 models, specifically the 600, 700, and 800 series, represent a significant era in the Sportsman's lineage. These ATVs boasted a robust design, capable of tackling demanding terrain with ease. Featuring a reliable single-cylinder engine, the Sportsman delivered ample power for both recreational riding and utility tasks. The 600cc, 700cc, and 800cc variants offered a range of power options to suit different rider preferences and riding styles. Whether navigating trails, hauling cargo, or tackling chores around the farm, the Sportsman proved its mettle as a capable and dependable companion. Beyond its powerful engine, the Sportsman's appeal lay in its well-balanced handling and comfortable ride. A sturdy frame and independent suspension system ensured a smooth ride over uneven terrain, while the ergonomics were designed to provide a comfortable and controlled experience. The Sportsman incorporated a range of features that enhanced its versatility, including a convenient cargo bed, optional accessories such as winches and plows, and a selection of color options to personalize the ride. Over the years, the Sportsman's reputation for reliability, performance, and ease of use has solidified its position as a frontrunner in the ATV market. Its ability to tackle a variety of tasks, from recreational riding to utilitarian work, has made it a trusted choice for riders seeking a versatile and capable machine.