Polaris Sportsman 600 700 800 Series 2002-2010 Repair Manual (PS015615)

Polaris Sportsman 600 700 800 Series 2002-2010 Repair Manual (PS015615)

• This manual presented for you in electronic format you can just print out the page you need then dispose of it when you have completed your task. This manual has detailed illustrations as well as step by step written instructions with the necessary diagrams or pictures. These manuals are your number one source for repair and service information, specifically written for the do-it-yourself as well as the experienced mechanics worldwide used to use this factory manual to fix your vehicle. Using this repair manual is an inexpensive way to keep your car working properly. it is this level of detail, along with illustrations, that guide the reader through each service, repairs, maintenance procedure.
• 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
  
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  Language: English
  
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