2002 2003 2004 2005_POLARIS_SPORTSMAN_600_700_800_MV7_ATV_REPAIR_SHOP_MANUAL

THE COMPLETE, LARGEST & EASY-TO-USE REPAIR & SERVICE MANUAL FOR

POLARIS SPORTSMAN ATV

2002 ~ 2010

Polaris Repair Manual Sportsman 600, Sportsman 700, Sportsman MV7, Sportsman 800 2002-2010

THIS ESSENTIAL 484 PAGE REPAIR & SERVICE MANUAL IS A MUST FOR OWNERS & MECHANICS

This new Clymer polaris Sportsman title is a Black & Gold Series book that includes 484 pages, 41 pages of color wiring diagrams and hundreds of illustrations and original photographs developed from the complete disassembly of the machine.

This manual covers the following models:

Sportsman 600 (2003-2005)

Sportsman 700 (2002-2006)

Sportsman 700 EFI (2004-2007)

Sportsman 700 EFI X2 (2008)

Sportsman MV7 (2005-2006)

Sportsman 800 EFI (2005-2010)

Sportsman 800 EFI X2 (2007-2009)

Sportsman 800 EFI Touring (2008-2009)

The chapter breakdown for the new M366 is as follows:

FONT COLOR=YELLOW>Table of Contents

Quick Reference Data

Chapter One/General Information

Manual organization/Warnings, cautions and note/Safety/Serial numbers/Model identification (2004 models)/Fasteners/Shop supplies/Tools/Measuring tools/Electrical system fundamentals/Service methods/Storage/Specifications

Chapter Two/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/Steering/Brake system/Specifications

Chapter Three/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 models 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 Four/Engine Top End

Component identification/Rocker cover/Rocker arms and pushrods/Cylinder head/Cylinder block and pistons/Valve lifter/Specifications

Chapter Five/Engine Lower End

Engine service/Oil system priming/Engine removal/Engine installation/Recoil starter (MV7 models)/Alternator covers (all models 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 Six/Clutch and Drive Belt System

Clutch system operation/Clutch tools/Clutch drying/Drive belt/Clutch outer cover/Clutch inner cover/Drive clutch/Driven clutch/Specifications

Chapter Seven/Transmission and Shift Mechanism (All Models Except X2 and Touring Models)

Gearshift selector/Transmission case/Transmission/Specifications

Chapter Eight/Transmission and Shift Mechanism (X2 and Touring Models)

Gearshift selector/Transmission case/Transmission shafts/Differential gear assembly/Snorkel shaft/Specifications

Chapter Nine/Air-Fuel and Exhaust System (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 (later 2004-on 600 and 700 models, 2005-on MV7 models)/Fuel pump/Specifications

Chapter Ten/Air-Fuel System (Fuel-Injected Models)

Air box/Exhaust system/Exhaust 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 Eleven/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 (models 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 diagnosis/Fuses/Wiring and connectors/Wiring diagrams/Specifications

Chapter Twelve/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/Thermostat/Water pump/Specifications

Chapter Thirteen/Wheels, Tires and Hubs

Wheels/Front hub/Front bearing carrier/Rear hub/Rear bearing carrier/Tires/Specifications

Chapter Fourteen/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 Fifteen/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 models except X2 and Touring models)/Rear drive shaft (all models except X2 and Touring models)/Specifications

Chapter Sixteen/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 Seventeen/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 models except MV7)/Front brush guard/Grill and radiator shield (all models except MV7 models)/Rear rack (all models except MV7, X2 and Touring models)/Rear rack (Touring models)/Rear rack and brush guard assembly (MV7 models)/Rear quarter panel (X2 models)/Footwell/Rear storage box (all models except M2 models)/Cargo box (X2 models)/Winch/Winch contactor/Specifications

Index

Wiring Diagrams

INDEX | COLOR WIRING DIAGRAMS

Clymer motorcycle repair manuals can save you money on maintenance and repair bills. Step-by-step procedures and detailed illustrations guide you through every job, from maintenance and troubleshooting, all the way to complete teardown and rebuild.

CONDITION: NEW

SIZE: 8 1/2 x 11

FORMAT: GLOSSY HEAVY PAPER STOCK COVER

NUMBER OF PAGES: 484

PROFUSELY ILLUSTRATED WITH HUNDREDS OF ORIGINAL PHOTOS & DRAWINGS