MANUEL D'ENTRETIEN POUR VTT

MODELS COVERED:

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)

This Polaris Sportsman ATV manual is 504 pages.

QUICK REFERENCE DATA

CHAPTER ONE / 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 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 / 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
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

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 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 TEN / 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 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 diagnostics / 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 / Coolant temperature sensor (carbureted models) / 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 fender (all models except X2 and MV7 models) / Rear quarter panel (X2 models) / Footwell / Rear storage box (all models except X2 models) / Cargo box (X2 models) / Winch / Winch contactor / Specifications

INDEX

COLOR WIRING DIAGRAMS