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SPORTSMAN 700 2002
Polaris SPORTSMAN 700 2002 User Manual
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PN 9918066
Printed in USA
2002-2003 SPORTSMAN 600/700 SER
VICE MANU
AL PN 9918066
2003 SPOR
TSMAN 600
2002
-
2003 SPOR
TSMAN 700
SER
VICE MANU
AL
PN 9918066
223336_coverB 9/17/02 10:22 PM Page 1
2
Table of Contents
Chapter Index
4
Table of Contents
4
General Information
6
Model Identification
6
Serial Number Location
6
2003 Sportsman Models
12
Paint Codes
16
Publication Numbers
16
Replacement Keys
16
Standard Torque Specifications
17
Decimal Equivalents
18
Conversion Table
19
Decimal Equivalent Chart
20
Glossary of Terms
21
Chapter 2 Maintenance
23
Default Chapter
24
Periodic Maintenance Chart
24
General
25
Pre-Ride Inspection
25
Engine
27
Special Tools
28
Transmission Lubrication
32
Chapter 8 Brakes
33
Idle Speed Adjustment
34
Fuel System
35
Carburetor Draining
36
Compression Test
36
Fuel Filter
36
Vent Lines
36
Battery Maintenance
37
Electrical
38
Coolant Level Inspection
40
Radiator Coolant Level Inspection
40
Radiator Screen Removal
40
Air Box Sediment Tube Service
41
Breather Filter
42
PVT Drying & PVT Drain Plug
42
Chapter 1 Chapter 4
42
Chapter 5
42
Pvt System
42
Engine Oil Level
43
Oil and Filter Change
43
Final Drive
45
Brake System Inspection
48
Exhaust Pipe
48
Auxiliary Brake Testing
49
Brake Pad Inspection
49
Controls
50
Front Suspension
50
Rear Suspension
50
Wheel Removal/Installation
50
Tire Inspection
51
Tire Pressure
51
Chapter 3 Engine
53
Engine Exploded Views
54
Special Tools
59
Accessible Components
59
Torque Specifications
60
Engine Fastener Torque Patterns
61
Piston Identification
61
600 Engine Service Data
62
Cooling System Specifications
66
Engine Installation Notes
68
Cylinder Hone Selection and Honing Procedure
69
Oil Flow
70
Rocker Arm/Pushrod Inspection
71
Cylinder Head Removal
71
Cylinder Head Disassembly/Inspection
72
Cylinder Head Inspection
72
Cylinder Head Warpage
72
Valve Inspection
74
Combustion Chamber
75
Valve Seat Reconditioning
75
Cylinder Head Reassembly
77
Valve Sealing Test
78
Valve Train Exploded View
78
Engine Head Reassembly
79
Cylinder Removal
81
Piston Removal
81
Valve Lifter Removal/Inspection
81
Cylinder Inspection
82
Starter Bendix Removal/Inspection
85
Piston Ring Installed Gap
85
Flywheel/Stator Removal/Inspection
86
Flywheel/Stator Installation
87
Engine Lower Disassembly/Inspection
88
Camshaft Inspection
96
Engine Lower Assembly
97
Troubleshooting
108
Chapter 4 Fuel System/Carburetion
111
Fuel Flow Diagram
113
Carburetor Jetting
114
Mikuni Jet Part Numbers
114
Jetting Guidelines
114
Assembly, CV Carburetor
115
Mikuni CV Carb Operation
115
Float System
117
Main System
117
Carburetor Cleaning
118
Carburetor Inspection
119
Carburetor Assembly
119
Float Height Adjustment
120
CV Carburetor System Function (4 Cycle)
115
Needle and Seat Leakage Test
120
Fuel Level
121
Fuel Pump Service
121
Fuel Pump Disassembly
121
Troubleshooting
122
Chapter 5 Body / Steering / Suspension
123
Headlight Pod Exploded View
126
Steering/A--Arm Exploded View
127
Rear Suspension Exploded View
128
Front Strut Assembly Exploded View
129
Cover/Panel Removal
130
A-Arm Replacement
131
Side Panel Removal
131
Steering Post Assembly
132
Front Strut Cartridge Replacement
133
Ball Joint Replacement
133
Decal Replacement
134
Chapter 6 Pvt System
135
Drive Clutch Exploded View
136
PVT Sealing and Ducting Components
136
PVT Operation Overview
138
Drive Clutch Operation
138
Pvt System Fastener Torques
138
Driven Clutch Operation
138
Pvt Drying
139
PVT Overheating/Diagnosis
140
PVT Disassembly
141
PVT Assembly/Inspection
142
Drive Clutch Spring Specifications
143
Shift Weights /Inspection
144
Drive Clutch Disassembly/Inspection
145
Shift Weight Inspection
145
Button to Tower Clearance Inspection
145
Spider Removal
146
Drive Clutch Reassembly
147
Drive Belt Removal/Inspection
148
Clutch Alignment/Offset
150
Clutch Offset
150
Drive Belt Installation
150
Troubleshooting
158
Chapter 7 Final Drive 7
161
Awd Front Drive Axle Exploded View
162
Front Drive Axle Removal
163
Front Hub Inspection
163
Driveshaft & CV Joint Handling Tips
164
Front Drive Axle Installation
164
U--Joint Assembly
167
U-Joint Disassembly
167
Front Gearcase Removal
168
Front Gearcase Operation
169
Front Gearcase Diagnosis
174
Front Gearcase Exploded View
176
Rear Hub Removal
177
Rear Hub Installation
178
Rear Hub Disassembly
179
Rear Driveshaft Removal
180
Rear Hub Assembly
180
Rear Driveshaft Installation
181
Rear Driveshaft Service
182
Rear Gearcase Installation
184
Rear Gearcase Removal
184
Rear Gearcase Disassembly
185
Rear Gearcase Assembly
186
Rear Gearcase Exploded View
188
Transmission Exploded View
190
Transmission Removal
192
Transmission Disassembly
193
Transmission Installation
193
Chapter 9 Brakes
205
Brake Noise Troubleshooting
207
Brake System Service Notes
207
Hydraulic Caliper Bleeding
208
Brake Bleeding / Fluid Change
209
Master Cylinder Removal
210
Master Cylinder Installation
211
Front Pad Assembly
212
Front Pad Removal
212
Brake Burnishing
213
Front Disc Inspection
213
Front Caliper Removal
214
Front Caliper Disassembly
215
Front Caliper Inspection
216
Front Caliper Reassembly
216
Front Caliper Installation
217
Rear Caliper Removal/Inspection
221
Rear Caliper Assembly
222
Troubleshooting
223
Chapter 10 Electrical
225
Flywheel Identification
226
Timing Check Procedure
227
Electrical Service Notes
227
Trigger Coil Gap
228
Instrument Cluster Troubleshooting
229
Speedometer Removal/Installation
231
Speedometer Troubleshooting
232
Fan Motor Current Draw
236
Ignition System Testing Flow Chart
238
Ignition System Troubleshooting
239
Alternator Output Test
240
Charging System Testing Flow Chart
241
Battery Installation
243
Battery Testing
243
High Beam Headlight Adjustment
245
Headlight Housing Replacement
245
Starter System Troubleshooting
247
Starter Motor Disassembly
247
Voltage Drop Test
247
Armature Testing
249
Starter Drive
251
Starter System Testing Flow Chart
253
Paint Codes
260
Conversion Table
261
5
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Polaris SPORTSMAN 700 2002 Specifications
General
Brand
Polaris
Model
SPORTSMAN 700 2002
Category
Offroad Vehicle
Language
English
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