service repair manual

1. 




2.     
             
           

                 
    

                
     

                


       

        
     
      
     
     
      
       
       
      
    
     

3.   
 

                
                  
           
               
                 
               
     
            
             
                

       
E                   
                 
                 
                    
                

4.   
  
  
   
  
   
   
  
  
  

8. 46 in
116.84 cm
85 in
215.90 cm
50.75 in
128.90 cm

9. 46 in
116.84 cm
47 in
119.38 cm
11 in
27.94 cm
46 in
116.84 cm

 

 

10.  

   
         
  

  
 
 
 
    _  
   
  
   
_  
 
   



  

 
 
 
   
 
    
     



 

 



    
 
    





 

 


    



 

 

    
                      
  
              
 I  
                      
 I  
                    
   I   
      
    
         
 
                   
    
           
    
        
      
    
   
      

   
               
  
           
  
            
  
          
  
          
  
       
    
         
   
         
  
          
   I 
        
     

 

 
                   
 
                    
   I 
    
    
     
   I
   
   I 
         
  I 
           
  
       
   
            
   
   
   
 

11.  
 

   
           
  
  
  
   
   
        
               
        
                   
       
             
           
    
      I         
    
          
                 
        
          
      
               
  
     
       
 
         
      
        
 
     
    
        
       
      
  
        
      
  I     
    
  II      
              
  I      
     
   I        
      
        
  
  I     
       
  I  
       
  
 

        
   
        
   
     

  I  
       
  I  
      
  I  
       
  I  
      
      
      
 
    
    
    
     
   
   
   

12. 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)

14. 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
. .

15. 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.

16.  

 
    



 

 

        
           
 
  





   
          
         
 
       
         
          
        
      
  
   
 
 
 
 
 
 
 
 
 
 

 


17.  

  
                 
                
    
        
   
        
                                           
        
                                           
   
        
                                               
        
                                             
        
                                           
        
                                           
        
                                           
        
                                           
        
                                           
        
                                           
        
                                          
        
                                          

     
     
     
          
         
    
       

18.  

 
 
                        
     
                                  
 
                        
 
             
     
                                        
 
                  
     
                                      
  
       
 
                        
     
                                  
 
                       
     
                             
 
                       
 
                  
     
                                       
 
         
     
                                       
 
                  
 
                       
     
                             
 
                       
     
                                 
 
                       
 
         
     
                                       
 
                 
     
                                       
 
             
 
                       
     
                                 
 
                       
     
                            
 
                       
 
                 
     
                                       
 
             
     
                                       
 
                 
 
                       
     
                          
 
                       
     
                                 
 
                      
 
            
     
                                       
 
                 
     
                                       
 
         
 
                       
     
                                 
 
                       
     
                            
 
                       
 
                 
     
                                       
 
         
     
                                       
 
                 
 
                      
     
                            
 
                       
     
                                 
 
                       
 
           

19.  

 
      
      
      
     
     
    
     
     
    
   
    
    
     
     
      
         
         
      
    
    
         
         
        
        
        
        
          
          
        
        
       
        
           
           
          
          
       
            
            

20.  

   
       
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
  
   
   
   
   
   
   
   
   
  
    
   
   
  
   
       
  
  
  
  
  
  
  
  
  
  
  
  
  
  
  
  
  




















































21.  

  
    
   
      
    
    
   
    
  
            
                    

  
                  

                   

                   
  
      
               
                
   
                
    
         
                
      
         
                
 
                       
        
 
 
  
 
          


    
  
                    
   


    
            

22.  

  
 
 
                  
          
 
             
  
  
        
 
        
    
   
      
 
              

         
            

            
   
       
                     
              
 
              
         
                  

         
   

23. 


 

   
              
  
                     
    
  
     
  
                           
  
                       
     
        
  
                 
   
          
  
                  
  
                            
  
                       
  
                     
 
                               
   
             
   
                
   
                        
     
           
  
                          
      
             
  
                        
    
              
   
            
   
                   
  
                     
 
                                
  
               
  
                          

24. 

  
             
               
        
               
         
H               
    
"               
            
               
               
         
     
   
  
  

  

"              
    
            
"        
        
"        
     
"     
  
    
"             
       
   
H                 
              
               
                
H                  
       
H           
         
    

        
   
           
         
        
          

             
           
        
           
      
   
    
     t
      
     
     t
      

25. 

   

  
  

  

"              
"             
             
           
           
"            
          
H          
H       
    
  
"           
"           
   
     
H            
"      
     
"      
     
H          
       
    
    
   
   
   
      
   
   
              
G      
G                 
G          
G      
G          
G        
G                   
 
G          
G             
G               
G           

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