Name: Polaris SPORTSMAN 600 Service Manual
Brand: Polaris
Rating: 5 (1 reviews)

5. Table of Contents
6. Model Identification
7. Sportsman Models Identification
10. U 1/2
14. Publication Numbers
15. Standard Torque Specifications
16. Conversion Table
18. Glossary of Terms
20. Periodic Maintenance Chart
22. Pre-Ride Inspection
24. Special Tools
27. Front & Rear Gearcase Lubrication
29. Transmission Lubrication
31. Throttle inspection
32. Idle speed adjustment
33. Fuel System
34. Compression Test
35. Battery Maintenance
36. IGNITION TIMING
38. Radiator Screen Removal
39. Air Box Sediment Tube Service
40. Breather Filter
41. Oil Change/Filter
44. Wheel alignment
46. Brake pad inspection
47. Front suspension
48. Controls
49. Warn Winch Operation
52. Engine Exploded Views
55. Top end
57. Special Tools
58. Torque Specifications
59. Engine Fastener Torque Patterns
60. 600 ENGINE SERVICE DATA
64. Cooling System Specifications
66. Engine Installation Notes
68. Oil Flow
69. Rocker Arm/Pushrod Inspection
70. Cylinder Head Disassembly/Inspection
72. Valve Inspection
73. Combustion Chamber
75. Cylinder Head Assembly
76. Valve Sealing Test
77. Engine Head Reassembly
80. Cylinder Inspection
83. Piston ring installed gap
84. Starter Bendix Removal/Inspection
85. Flywheel/Stator Removal/Inspection
86. Engine Crankcase Disassembly/Inspection
94. Camshaft Inspection
95. Engine Crankcase Assembly
106. Troubleshooting
111. Fuel Flow Diagram
112. Carburetor Jetting
113. CV Carburetor System Function (4 Cycle)
115. Float system
117. Carburetor inspection
118. Carburetor assembly
119. Needle & Seat Leakage Test
120. Fuel Level
121. Fuel Sender Service
124. Cover/Panel Removal
125. Side Panel Removal
127. BODY ASSEMBLY EXPLODED VIEW
128. Body Rack Assembly, Exploded View
130. Headlight Pod Exploded View
131. Steering/A--Arm Exploded View
132. Rear Suspension Exploded View
133. A-Arm Replacement
134. Steering Post Assembly
135. Front Strut Assembly Exploded View
136. Front Strut Cartridge Replacement
137. Decal Replacement
140. Drive Clutch Exploded View
142. PVT Operation Overview
144. PVT Overheating/Diagnosis
145. PVT Disassembly
146. PVT Assembly/Inspection
147. Drive Clutch Spring Specifications
148. Shift Weights /Inspection
149. Drive Clutch Disassembly/Inspection
151. Drive Clutch Reassembly
152. Drive Belt Removal/Inspection
154. Drive Belt Installation
166. Late 2004 Driven Clutch Inspection
171. Troubleshooting
174. Final drive
175. Front Hub Inspection
176. Front Drive Axle Installation
178. Front Hub Disassembly & Assembly
179. U-Joint Disassembly
180. Front Gearcase Removal/Install
188. Early 2004 Front Gearcase Exploded View
189. Late 2004 Front Gearcase Information
198. Rear Hub Removal
199. Rear Hub Installation
200. Rear Hub Disassembly
201. Rear Driveshaft Removal
202. Driveshaft and CV Joint Tips
203. Rear Driveshaft Service
205. Rear Gearcase Removal
206. Rear Gearcase Installation
209. Rear Gearcase Exploded View
212. Transmission, Exploded View
216. Torque Specifications/Lubrication
217. Transmission Installation
218. Transmission Disassembly
223. Transmission Reassembly
231. 2004 Brake Line Identification
232. Hydraulic Brake System Overview
233. Hydraulic Caliper Bleeding
235. Master Cylinder Removal
236. Front Pad Removal
237. Front Pad Installation
238. Brake Burnishing
239. Front Caliper Removal
240. Front Caliper Inspection
241. Front Caliper Reassembly
243. Front Caliper Exploded View
244. Rear Pad Removal
245. Rear Pad Installation
246. Rear Caliper Removal/Inspection
247. Rear caliper assembly
248. Rear Disc Inspection
250. Rear Caliper Exploded View
252. Timing Check Procedure
254. Gear Position Switch Test
256. Diagnostic mode
258. Speedometer Removal/Installation
260. Speedometer Operation Troubleshooting
265. Fan Motor Tests
267. Flywheel Identification
269. Ignition System Testing Flow Chart
270. Ignition System Troubleshooting
273. Battery Identification
274. Conventional battery installation
276. Battery check
277. Battery charging
278. Battery inspection
280. Bulb replacement
282. Headlamp switch
283. Fuel Sender Service
286. Starter System Troubleshooting
290. Starter Drive
292. Starter System Testing Flow Chart

Description

The Service Manual of the Polaris SPORTSMAN 600 and SPORTSMAN 700 Motorcycle is essential for efficient maintenance and repair of the motorcycles. It includes a detailed model identification, list of publication numbers and a table of contents. The manual also provides detailed technical information related to the engine, transmission, suspension and other components. It also provides step by step instructions for all service and repair operations. The Polaris SPORTSMAN 600 and 700 motorcycles are designed for riders who demand performance and durability. They feature powerful engines, lightweight alloy frames and advanced suspension systems. The manual is a reliable source of information when it comes to servicing and maintaining the motorcycle. It also contains troubleshooting tips and diagrams that help to identify and solve potential problems. The Service Manual of the Polaris SPORTSMAN 600 and SPORTSMAN 700 Motorcycle is an invaluable resource for any rider.

Also for: SPORTSMAN 700

File size: 29.13 MB

Created: January 30, 2023

Last updated: March 22, 2023