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2003 Polaris Sportsman 600 Twin Service Repair Manual.pdf
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46 in 116.84 cm 85
in 215.90 cm 50.75 in 128.90 cm
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46 in 116.84 cm 47
in 119.38 cm 11 in 27.94 cm 46 in 116.84 cm
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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 150 145 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 . .
13.
Lubricant Key GENERAL INFORMATION 1.9 MODEL:
2003 SPORTSMAN 600 . . . . . . . . . . . . MODEL NUMBER: A03CH59 . . . ENGINE MODEL: EH059OLE . . . . ELECTRICAL FLUID Capacity Type Flywheel I.D. 4060152 Fuel Tank 4.75 gals. (17.9 L) . . . . . . . . . . . . . . . . CDI Marking 4010785 Coolant 3.2 qts. (3 L) *PP6 . . . . . . . . . . . . . . . . . . . . Alternator Output 300Watts Transmission 13.50 oz. *PPS . . . . . . . . . . . . . . Ignition Timing 25 BTDC@3000RPM 500 Gearcase Oil (Front).. 5 oz. (150 ml)...*PDD . . . . . Spark Plug / Gap RC7YC -- 0.035I (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 Lube . . . . . . . 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 7.49:1 . . . Tow Capacity 1225 lbs. (555.6 kg) Gear Reduction-Rev 5.11:1 . . . . . . . Turning Radius 76I (181.61 cm) Gear Reduction-High 2.89:1 . . . . . 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. (41 kg) . . . . . Rear Rack (Std) 200 lbs. (91 kg) . . . . . . Tongue Weight 150 lbs. (68 kg) . . . . Hitch Towing Capacity...1500 lbs. (681)
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GENERAL INFORMATION 1.10 MODEL: 2003
SPORTSMAN 700 . . . . . . . . . . MODEL NUMBER: A03CH68 . ENGINE MODEL: EH068OLE . . 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 160 155 Meters (Feet) 0-1800 (0-6000) 160 155 (Feet) Above 1800 147 5 142 5 Above 1800 Above (6000) 147.5 142.5 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) . . . . . . . . . . . . . . . . . . . . . Compression Ratio 9.78/1 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 47.5 . . . . . . . . . . . . . Jet Needle J8--4FA01--3 . . . . . . . . . . . Needle Jet P-6M (829) . . . . . . . . . . . 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 . .
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Lubricant Key GENERAL INFORMATION 1.11 MODEL:
2003 SPORTSMAN 700 . . . . . . . . . . . . MODEL NUMBER: A03CH68 . . . ENGINE MODEL: EH068OLE . . . . 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 32 BTDC@5760RPM 200 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 Lube . . . . . . . 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 7.49:1 . . . Tow Capacity 1225 lbs. (555.6 kg) Gear Reduction-Rev 5.1:1 . . . . . . . Turning Radius 76I (181.61 cm) Gear Reduction-High 2.89:1 . . . . . 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 (215.9 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.
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