2002-2010 Polaris Sportsman 600, 700, 800 ATV Repair Manual by Clymer

Description

This 2002-2010 Polaris Sportsman 600, 700 & 800 ATV Repair Manual by Clymer provides detailed service information, step-by-step repair instruction and maintenance specifications for 2002-2010 Polaris Sportsman 600, 700 & 800 ATVs including:

2003-2005 POLARIS Sportsman 600 ATVs
2002-2006 POLARIS Sportsman 700 ATVs
2004-2007 POLARIS Sportsman 700 EFI ATVs
2008 Polaris Sportsman 700 EFI X2 ATVs
2005-2010 POLARIS Sportsman 800 EFI ATVs
2008-2009 POLARIS Sportsman 800 EFI Touring ATVs
2007-2009 POLARIS Sportsman 800 EFI X2 ATVs
2005-2006 POLARIS Sportsman MV7 ATVs

This manual contains the following repair topics to help you fix your own ATV:

Chapter 1 – 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 2 – 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 3 – 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 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 4 – ENGINE TOP END
Component identification, Rocker cover, Rocker arms and pushrods, Cylinder head, Cylinder block and pistons, Valve lifter, Specifications

Chapter 5 – ENGINE LOWER END
Engine service, Oil system priming, Engine removal, Engine installation, Recoil starter (MV7 models), Alternator covers (all 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 6 – 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 7 – TRANSMISSION AND SHIFT MECHANISM (ALL MODELS EXCEPT X2 AND TOURING MODELS)
Gearshift selector, Transmission case, Transmission, Specifications

Chapter 8 – TRANSMISSION AND SHIFT MECHANISM (X2 AND TOURING MODELS)
Gearshift selector, Transmission case, Transmission shafts, Differential gear assembly, Snorkel shaft, Specifications

Chapter 9 – 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 10 – 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 11 – 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 (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 12 – 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 13 – WHEELS, TIRES AND HUBS
Wheels, Front hub, Front bearing carrier, Rear hub, Rear bearing carrier, Tires, Specifications

Chapter 14 – 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 15 – 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 except X2 and Touring, models), Rear drive shaft (all except X2 and, Touring models), Specifications

Chapter 16 – 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 17 – 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 except MV7), Front brush guard, Grill and radiator shield (all except, MV7 models), Rear rack (all except MV7, X2 and Touring models), Rear rack (Touring models), Rear rack and brush guard assembly, (MV7 models), Rear fender (all except X2 and MV7 models), Rear quarter panel (X2 models), Footwell, Rear storage box (all except X2 models), Cargo box (X2 models), Winch, Winch contactor, Specifications

INDEX

COLOR WIRING DIAGRAMS