Polaris Sportsman 600, 700 & 800 Series ATV (2002-2010) Service Repair Manual
Description
Clymer ATV repair manuals are written specifically for the do-it-yourself enthusiast. From basic maintenance to troubleshooting to complete overhaul, Clymer manuals provide the information you need. The most important tool in your tool box may be your Clymer manual, get one today.Every Clymer manual contains hundreds of original photographs and illustrations developed from a complete disassembly and assembly of a motorcycle. This, in addition to extensive research, allows Clymer to achieve an unmatched level of detail, accuracy and clarity.The step-by-step instructions and two-column text with large print are user-friendly. Bold figure numbers make it easy to quickly match instructions with illustrations and photos. Thumb-tabbed chapters, numbered table of contents and an extensive index make it possible to locate the desired section quickly.
Contents
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 /…
- Step-by-step procedures
- Easy-to-follow photos
- Complete troubleshooting section
- Valuable short cuts
