2003 Polaris Sportsman 600 Twin Service Repair Manual by 16326108

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

                              



                       

                                                  

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

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

        E                                                                                             

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 

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 

 

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

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 

 



 



 



46 in 116.84 cm

85 in 215.90 cm

50.75 in 128.90 cm

 

 

46 in 116.84 cm

47 in 119.38 cm



11 in 27.94 cm

46 in 116.84 cm



                       



   

 

                                                                                                                                       

              I      

 

     

_    _  

 

  

  

   





      



                                                                                                                                 

  I     I  I  I      

 

   

                                                                                                                                                                              



      I   I   I                

 

  

  

 

   

 





   

 





                             

                                                                                   

 

         I              





                                                                                                                                     

  

 

                                                                             

                                                   

        I   II   I   I      I   I   

                                                                     

              I   I   I   I      

                                



GENERAL INFORMATION MODEL: . . . . . . . . . . 2003 SPORTSMAN MODEL NUMBER: . A03CH59 ENGINE MODEL: . . EH059OLE

600

JETTING CHART

CARBURETION Type . . . . . . . . . . . . . . . . Main Jet . . . . . . . . . . . . Pilot Jet . . . . . . . . . . . . . Jet Needle . . . . . . . . . . . Needle Jet . . . . . . . . . . . Throttle Valve . . . . . . . . Pilot Screw . . . . . . . . . . Pilot Air Jet . . . . . . . . . . Valve Seat . . . . . . . . . . . Float Height . . . . . . . . . Fuel Octane (R+M/2) .

BST 34 Mikuni 155 45 J8--4FA01--3 P-4 #100 1.5 Turns Out 160 1.5 14.7mm (.58I) 1mm 87 Non-Oxygenated or 89 Oxygenated

Type . . . . . . . . . . . . . . . . . . . . Belt . . . . . . . . . . . . . . . . . . . . . Belt Width (Projected) . . . . . Side Angle (Overall) . . . . . . Outside Circumference . . . . Center Distance . . . . . . . . . . Clutch Offset . . . . . . . . . . . . Secondary Spring . . . . . . . . Driven Helix . . . . . . . . . . . . . Spring Position (Helix) . . . . Spring Position (Sheave) . .

Meters (Feet)

Below 40 F Below +5 C

+40 F and above +40_F +5_C and above

0-1800 (0-6000)

162 5 162.5

155

Above 1800 Above (6000)

150

145

CLUTCH CHART *EBS require no helix/spring adjustment

Altitude

CLUTCH PVT 3211091 1.188I (30.18mm) 28 2 40.875 .188I 10 .12I (254.5mm) 0.5I (12.7mm) White/Yellow Compound (EBS) N/A N/A

ENGINE Type . . . . . . . . . . . . . . . . . . . . . . . Displacement . . . . . . . . . . . . . . . Bore . . . . . . . . . . . . . . . . . . . . . . . Stroke . . . . . . . . . . . . . . . . . . . . . Compression Ratio . . . . . . . . . . Cooling . . . . . . . . . . . . . . . . . . . . Lubrication Type . . . . . . . . . . . . Operating RPM 200 . . . . . . . . . Idle RPM 100 (lights off) . . . . Compression Pressure . . . . . . .

1.8

AMBIENT TEMPERATURE

Altitude

4 Cycle, Twin Cyl. 597 cc 3.012I (76.5 mm) 2.559I (65 mm) 9.35/1 Full Stroke Liquid Pressurized Wet Sump 6000 RPM 1100 RPM 150--170psi 15%

Meters (Feet)

0-1800 (0-6000) 1800-3700 (6000-12000)

Shift Weight

Drive Clutch Spring

Driven Clutch Spring

Driven Helix

10 MH

Blue/Green (5631215)

White/Yellow

EBS

10 WH

Blue/Green (5631214)

White/Yellow

EBS

GENERAL INFORMATION MODEL: . . . . . . . . . . . . 2003 SPORTSMAN MODEL NUMBER: . . . A03CH59 ENGINE MODEL: . . . . EH059OLE

ELECTRICAL Flywheel I.D. . . . . . . CDI Marking . . . . . . . Alternator Output . . . Ignition Timing . . . . . Spark Plug / Gap . . . Lights: Head . . . . . . Grill (2) . . . . Tail . . . . . . . . Brake . . . . . . Voltage Regulator . . Electric Start . . . . . . . Instrument Cluster . .

600 FLUID

4060152 4010785 300Watts 25 BTDC@3000RPM 500 RC7YC -- 0.035I (0.9mm) 50 Watt Quartz 27 Watts Quartz 8.26 watts 26.9 watts LR39 Standard LCD

Capacity

Type

Fuel Tank . . . . . . . . . . 4.75 gals. (17.9 L) Coolant . . . . . . . . . . . . 3.2 qts. (3 L) . *PP6 Transmission . . . . . . . 13.50 oz. . . . . *PPS Gearcase Oil (Front).. 5 oz. (150 ml)...*PDD Gearcase Oil (Rear) . 5oz. (150 ml) . 80--90 GL5 Engine Oil . . . . . . . . . . 2 qts. (1.9L) . . *PP4 Brake (Hand) . . . . . . . Dot 3 Brake (Foot) . . . . . . . . Dot 3 Lubricant Key *PP6 Polaris Premium 60/40 Antifreeze/Coolant *PPS Polaris Premium Synthetic Gear Case Lube *PP4 Polaris 0W--40 Synthetic Engine Lubricant *PDD Premium Demand Drive Hub Fluid

SUSPENSION / CHASSIS

DRIVE TRAIN

Body Style . . . . . . . . Front Suspension . . Tow Capacity . . . . . . Turning Radius . . . . . Toe Out . . . . . . . . . . . Ground Clearance . . Front Vertical Travel Rear Suspension . . . Rear Travel . . . . . . . . Rear Shock . . . . . . . . Shock Adjustment . .

4 Wheel Independent Shaft Drive Gear Reduction-Low . 7.49:1 Gear Reduction-Rev . 5.11:1 Gear Reduction-High 2.89:1 Front Drive Ratio . . . . 3.82:1 Final Drive Ratio . . . . 3.10:1 Brake (Hand) . . . . . . . Single Lever, Hyd. Disc Brake (Auxiliary Foot) Hydraulic Transmission Park Lock

TIRES

Tire Size - Front . . . . Tire Size - Rear . . . . Tire Pressure - F/R . Total Width . . . . . . . . Total Length . . . . . . . Total Height . . . . . . . . Wheel Base . . . . . . . Weight - Dry . . . . . . .

Gen IV MacPherson Strut 1225 lbs. (555.6 kg) 76I (181.61 cm) 1/8I-1/4I (3-6.35 mm) 11I (27.94 cm) 6.7I (17.02 cm) Progressive Rate Independent 9.5I (24.13 cm) 2I Twin Tube Cam

25 x 8 - 12 25 x 11 - 12 5/5 lbs 46I (116.84 cm) 85I (215.90 cm) 47I (119.38 cm) 50.75I (128.90 cm) 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)

1.9

GENERAL INFORMATION MODEL: . . . . . . . . . . 2003 SPORTSMAN MODEL NUMBER: . A03CH68 ENGINE MODEL: . . EH068OLE

700

JETTING CHART

BST 34 Mikuni 155 47.5 J8--4FA01--3 P-6M (829) #100 1.5 Turns Out 160 1.5 14.7mm (.58I) 1mm 87 Non-Oxygenated or 89 Oxygenated

Meters (Feet)

Below 40 F Below +5 C

+40 F and above +40_F +5_C and above

0-1800 (0-6000)

160

155

Above 1800 Above (6000)

147 5 147.5

142 5 142.5

CLUTCH CHART *EBS require no helix/spring adjustment

Altitude

CLUTCH PVT 3211091 1.188I (30.18mm) 28 2 40.875 .188I 10 .12I (254.5mm) 0.5I (12.7mm) White/Yellow Compound (EBS) N/A N/A

1.10

AMBIENT TEMPERATURE

Altitude

4 Cycle, Twin Cyl. 683 cc 3.149I (80 mm) 2.677I (68 mm) 9.78/1 Full Stroke Liquid Pressurized Wet Sump 6000 RPM 1100 RPM 150--170psi 15%

Meters (Feet)

0-1800 (0-6000) 1800-3700 (6000-12000)

Shift Weight

Drive Clutch Spring

Driven Clutch Spring

Driven Helix

20 -56 2056

Blue/Green (5631215)

White/Yellow

EBS

20 -54 2054

Blue/Green (5631214)

White/Yellow

EBS

GENERAL INFORMATION MODEL: . . . . . . . . . . . . 2003 SPORTSMAN MODEL NUMBER: . . . A03CH68 ENGINE MODEL: . . . . EH068OLE

700 FLUID

4060152 4010364 300 Watts 32 BTDC@5760RPM 200 RC7YC -- 0.036I (0.9mm) 50 Watt Quartz 27 Watts Quartz 8.26 watts 26.9 watts LR39 Standard LCD

Capacity

Type

SUSPENSION / CHASSIS

DRIVE TRAIN

4 Wheel Independent Shaft Drive Gear Reduction-Low . 7.49:1 Gear Reduction-Rev . 5.1:1 Gear Reduction-High 2.89:1 Front Drive Ratio . . . . 3.82:1 Final Drive Ratio . . . . 3.10:1 Brake (Hand) . . . . . . . Single Lever, Hyd. Disc Brake (Auxiliary Foot) Hydraulic Transmission Park Lock

TIRES

Gen IV MacPherson Strut 1225 lbs. (555.6 kg) 76I (181.61 cm) 1/8I-1/4I (3-6.35 mm) 11I (27.94 cm) 6.7I (17.02 cm) Progressive Rate Independent 9.5I (24.13 cm) 2I Twin Tube Cam

25 x 8 - 12 25 x 11 - 12 5/5 lbs 46I (116.84 cm) 85I (215.9 cm) 47I (119.38 cm) 50.75I (128.90 cm) 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.

1.11

 

  





 

    

  

  

   







           

   

 

 

 









                    

                                                 

   



 

 









































 

                                          

 



 

 

                             

         

         

                                                                                                                                                     

         

                                                                                                                                                                                                                                     

 

 

                                                                                                                                                                                                   

                   

        

                    

            



 

                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                          



                                                                                                                                                                                                                                                                                                                                                                                                                                                                                   

                                                                                                   

 

    

 

 

 

 

  

 

 

  

 

 

 

 

 

 



 

 



 

  



 

  



 

 



 





 

 



 

 

 

 

 



 

  

 

 

  

   

 

   

  

 

    

 

 

  



 

 



 

 

   

 

   

  

 

    

   

 

  

 

 

    

   

 

  

 

 

    

   

 

    

   

 

    

   

 

  

 

 

    

   

 

 

 

 

    

      

 

  

 

 

       

 

 

      

     

 

  

                    

  

         



 

     

 

 

 

                          

                          

                                      

                                      

                                                        



                  

                  

                  

 

  

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

                                  

                  



 

  

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





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

                           







                                                                    H                     "                                                                             

     



  

" 





 

   

 

 

 

       

 

 

 

 

   





       

"

    

"

    





    

   







   

  



 

    



 



  

    

 

 

 

     

  

 

 

 

     

  

 

 

 

      

   

 

   

 

 

 

      

H

 

 

 

 

                 

H

 

 

 

 

  

 



     

 

 

 

            



 

 

 

    

  

 

 

 



 

 

 

 



   

 

 

 



 

 

 

 

    



 

 

 

    

 

 

 

 

      

 



 



 

 



  

 





    t       

  





    t       

 





     

 



  





 

 

 

 

 

     

  

 

 

 

   

 

 

 

 

     

   

 

 

 

  



  

 



 

   

 

 

 

 

  



 

" "

        

 

 

 

  

 



      

 

 

 

 

  

 

 

 

 

  







    

 

 

 

 

   

  





    

  





    

  

 



 

 

  

 



   

 





  







  

   

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  

                   G       G                  G           G       G           G         G                      G           G              G                G           

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