2003 Polaris Sportsman 600 Owners Manual

2003 Polaris Sportsman 600 Manual

Get 2003 Polaris Sportsman 600 PDF manuals and user guides View all 2003 Polaris Sportsman 600 manuals

2003 Polaris Sportsman 600 manual content summary:

  • 2003 Polaris Sportsman 600 | Owners Manual - Page 1
    2003 Sportsman 600 Sportsman 700 Owner's Manual for Vehicle Maintenance and Safety Read this manual carefully. It contains important safety information. This is an adult vehicle only. Operation is prohibited for those under 16 years of age.
  • 2003 Polaris Sportsman 600 | Owners Manual - Page 2
    WARNING The engine exhaust from this product contains chemicals known to cause cancer, birth defects or other reproductive harm.
  • 2003 Polaris Sportsman 600 | Owners Manual - Page 3
    We've created a web site just for YOU! S S S S S Technical tips New product introductions Event schedules Parts and Service Manual information Exciting details about The Way Out Check it out...www.polarisindustries.com/owner 1
  • 2003 Polaris Sportsman 600 | Owners Manual - Page 4
    Industries Inc. reserves the right to make product changes and improvements that may affect illustrations or explanations. No part of this manual shall be reproduced or used without the written permission of Polaris Industries Inc. Copyright 2002 Polaris Industries Inc. All Rights Reserved Printed
  • 2003 Polaris Sportsman 600 | Owners Manual - Page 5
    operation of your vehicle, be sure to follow the instructions and recommendations in this owner's manual. Your manual contains instructions for minor maintenance, but information about major repairs is outlined in the Polaris Service Manual and should be performed only by a Factory Certified Master
  • 2003 Polaris Sportsman 600 | Owners Manual - Page 6
    VEHICLE IDENTIFICATION NUMBERS The frame vehicle identification number (VIN)(1) and engine serial number (2) are important for model identification when registering your vehicle, when obtaining insurance, and when ordering replacement parts. In the event your vehicle is stolen, these numbers are
  • 2003 Polaris Sportsman 600 | Owners Manual - Page 7
    VEHICLE IDENTIFICATION NUMBERS ...4 TABLE OF CONTENTS ...5 SAFETY ...6 CONTROLS ...36 FEATURES ...44 OPERATION ...50 NOISE EMISSION CONTROL SYSTEM REGULATION ...68 MAINTENANCE AND LUBRICATION ...69 TROUBLESHOOTING ...113 POLARIS-RECOMMENDED PRODUCTS ...117 SPECIFICATIONS ...118 WARRANTY ...122 5
  • 2003 Polaris Sportsman 600 | Owners Manual - Page 8
    been placed on the ATV for your protection. Read and follow the instructions on each decal carefully. If a decal becomes illegible or comes off, charge. The part number is printed on the decal. WARNING IF OWNER'S MANUAL IS MISSING, CONTACT A POLARIS DEALER FOR A REPLACEMENT. E1997, 2000 7079083
  • 2003 Polaris Sportsman 600 | Owners Manual - Page 9
    rough or hilly terrain, reduce speed and cargo. Do not block headlight. Be careful if load extends over the side of the rack. Read Owner's Manual for more detailed loading information 7170732 7
  • 2003 Polaris Sportsman 600 | Owners Manual - Page 10
    conditions. Do not operate vehicle without pre-filter. S Operation of this vehicle without engine breather filter(s) can cause engine damage. Consult owner's manual or dealer for details. S Specific carburetor jetting and adjustments are required depending on temperature and altitude. See your Owner
  • 2003 Polaris Sportsman 600 | Owners Manual - Page 11
    control or forward flipover may result, especially in AWD. See Owner's Manual. 7079604 PRINTED IN U.S.A. ALL WHEEL DRIVE SWITCH Do not push switch . This may cause severe drive shaft and clutch damage. See your Owner's Manual. 7079780 MANUFACTURED BY: POLARIS IND INC. DATE: VIN: THIS VEHICLE IS
  • 2003 Polaris Sportsman 600 | Owners Manual - Page 12
    SAFETY Safe Riding Gear Always wear clothing suited to the type of riding. ATV riding requires special protective clothing for comfort and to reduce the chance of injury. 1. Helmet Your helmet is the most important piece of protective gear for safe riding. A helmet can prevent a severe head injury.
  • 2003 Polaris Sportsman 600 | Owners Manual - Page 13
    routine maneuvers like turning, or driving on hills or over obstacles, if you fail to take proper precautions. Read and understand your owner's manual and all warnings before operating a Polaris ATV. Age Restrictions This vehicle is an ADULT VEHICLE ONLY. Operation is prohibited for anyone under 16
  • 2003 Polaris Sportsman 600 | Owners Manual - Page 14
    symbols are used. Become familiar with their meanings before reading the manual. The safety alert symbol, on your vehicle or in this manual, alerts you to the potential for personal injury. WARNING The the vehicle. CAUTION NOTE: A note will alert you to important information or instructions. 12
  • 2003 Polaris Sportsman 600 | Owners Manual - Page 15
    Operator Safety WARNING Serious injury or death can result if you do not follow these instructions and procedures, which are outlined in further detail within your owner's manual. S Read this manual and all labels carefully, and follow the operating procedures described. S Never operate an ATV
  • 2003 Polaris Sportsman 600 | Owners Manual - Page 16
    . To avoid stalling, maintain a steady speed when climbing a hill. If you stall or roll backwards, follow the special procedure for braking described in this manual. Always dismount on the uphill side, or to either side if the ATV is pointed straight uphill. Turn the ATV around and remount following
  • 2003 Polaris Sportsman 600 | Owners Manual - Page 17
    exceed the stated load capacity for your ATV. Cargo must be properly distributed and securely attached. Reduce speed and follow the instructions in this manual for carrying cargo or towing. Allow a greater distance for braking. FOR MORE INFORMATION ABOUT ATV SAFETY, call the Consumer Product Safety
  • 2003 Polaris Sportsman 600 | Owners Manual - Page 18
    Safety WARNING POTENTIAL HAZARD Operating this ATV without proper instruction. WHAT CAN HAPPEN The risk of an accident the skills learned in the course and the operating techniques described in the owner's manual. For more information about the training course, contact an authorized ATV dealer or
  • 2003 Polaris Sportsman 600 | Owners Manual - Page 19
    SAFETY Operator Safety WARNING POTENTIAL HAZARD Carrying a passenger on an ATV. WHAT CAN HAPPEN Carrying a passenger greatly reduces the operator's ability to balance and control the ATV, which could cause an accident and injury to the operator and/or passenger. HOW TO AVOID THE HAZARD Never carry
  • 2003 Polaris Sportsman 600 | Owners Manual - Page 20
    SAFETY Operator Safety WARNING POTENTIAL HAZARD Operating an ATV on paved surfaces, including sidewalks, paths, parking lots, and driveways. WHAT CAN HAPPEN ATV tires are designed for off-road use. Operating on paved surfaces may adversely affect the handling of the ATV and could result in loss of
  • 2003 Polaris Sportsman 600 | Owners Manual - Page 21
    SAFETY Operator Safety WARNING POTENTIAL HAZARD Operating this ATV on public streets, roads or highways. WHAT CAN HAPPEN The ATV could collide with another vehicle. HOW TO AVOID THE HAZARD Never operate the ATV on any public street, road or highway, including dirt and gravel roads. In many states
  • 2003 Polaris Sportsman 600 | Owners Manual - Page 22
    SAFETY Operator Safety WARNING POTENTIAL HAZARD Operating this ATV without wearing an approved helmet, eye protection and protective clothing. WHAT CAN HAPPEN Operating an ATV without an approved helmet increases the risk of a severe head injury or death in the event of an accident. Operating
  • 2003 Polaris Sportsman 600 | Owners Manual - Page 23
    SAFETY Operator Safety WARNING POTENTIAL HAZARD Operating the ATV after consuming alcohol or drugs. WHAT CAN HAPPEN Consumption of alcohol and/or drugs could seriously affect operator judgment. Reaction time may be slower and operator balance and perception could be affected. Consuming alcohol and/
  • 2003 Polaris Sportsman 600 | Owners Manual - Page 24
    SAFETY Operator Safety WARNING POTENTIAL HAZARD Attempting wheelies, jumps and other stunts. WHAT CAN HAPPEN Attempting stunts increases the chance of an accident, including an overturn. HOW TO AVOID THE HAZARD Never attempt wheelies, jumps, or other stunts. Avoid exhibition driving. 22
  • 2003 Polaris Sportsman 600 | Owners Manual - Page 25
    use to make sure it's in safe operating condition. Always follow the inspection and maintenance procedures and schedules described in the owner's manual. WARNING POTENTIAL HAZARD Removing hands from the handlebars or feet from the footrests during operation. WHAT CAN HAPPEN Removing even one hand
  • 2003 Polaris Sportsman 600 | Owners Manual - Page 26
    SAFETY Operator Safety WARNING POTENTIAL HAZARD Failure to use extra caution when operating the ATV on unfamiliar terrain. WHAT CAN HAPPEN Unfamiliar terrain may contain hidden rocks, bumps, or holes that could cause loss of control or overturn. HOW TO AVOID THE HAZARD Travel slowly and use extra
  • 2003 Polaris Sportsman 600 | Owners Manual - Page 27
    SAFETY Operator Safety WARNING POTENTIAL HAZARD Failure to use extra caution when operating on excessively rough, slippery or loose terrain. WHAT CAN HAPPEN Operating on excessively rough, slippery or loose terrain could cause loss of traction or loss of control, which could result in an accident
  • 2003 Polaris Sportsman 600 | Owners Manual - Page 28
    and lead to a collision or overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for turning as described in the owner's manual. Practice turning at slow speeds before attempting to turn at faster speeds. Never turn at excessive speed. WARNING POTENTIAL HAZARD Operating on excessively
  • 2003 Polaris Sportsman 600 | Owners Manual - Page 29
    could cause loss of control or overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for climbing hills as described in the owner's manual. Always check the terrain carefully before ascending any hill. Never operate the ATV on hills steeper than 25_. Never climb hills with excessively
  • 2003 Polaris Sportsman 600 | Owners Manual - Page 30
    of control or overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for traveling down hills as described in the owner's manual. NOTE: A special technique is required when braking while traveling downhill. See page 62. Always check the terrain carefully before descending a hill. Shift
  • 2003 Polaris Sportsman 600 | Owners Manual - Page 31
    Never attempt to turn the ATV around on any hill until you've mastered the turning technique (on level ground) as described in the owner's manual. See page 63. Use extra caution when turning on any hill. Avoid crossing the side of a steep hill. When crossing the side of a hill: Always
  • 2003 Polaris Sportsman 600 | Owners Manual - Page 32
    uphill side, or to either side if ATV is pointed straight uphill. Turn the ATV around and remount, following the procedure described in the owner's manual. See page 63. 30
  • 2003 Polaris Sportsman 600 | Owners Manual - Page 33
    such as rocks and fallen trees when possible. If unavoidable, use extreme caution and always follow proper procedures as outlined in the owner's manual. WARNING POTENTIAL HAZARD Skidding or sliding. WHAT CAN HAPPEN Skidding or sliding can cause loss of control. If the tires regain traction
  • 2003 Polaris Sportsman 600 | Owners Manual - Page 34
    SAFETY Operator Safety WARNING POTENTIAL HAZARD Operating the ATV through deep or fast-flowing water. WHAT CAN HAPPEN Tires may float, causing loss of traction and loss of control, which could lead to an accident or overturn. HOW TO AVOID THE HAZARD Avoid operating the ATV through deep or fast-
  • 2003 Polaris Sportsman 600 | Owners Manual - Page 35
    tires specified for the ATV in the owner's manual. Always maintain proper tire pressure as described in the owner's manual and on safety decals. WARNING POTENTIAL HAZARD Operating installed and used according to approved instructions. See your authorized Polaris ATV dealer for more information. 33
  • 2003 Polaris Sportsman 600 | Owners Manual - Page 36
    . Allow a greater distance for braking. Always follow the instructions in the owner's manual for carrying cargo or pulling a trailer. WARNING POTENTIAL HAZARD ice is thick enough and sound enough to support the machine and its operator, as well as the force created by a moving vehicle,
  • 2003 Polaris Sportsman 600 | Owners Manual - Page 37
    WARNING Operating a damaged ATV can result in an accident with serious injury or death. After any overturn or accident, have a qualified service dealer inspect the entire machine for possible damage, including (but not limited to) brakes, throttle and steering systems. WARNING Safe operation of
  • 2003 Polaris Sportsman 600 | Owners Manual - Page 38
    CONTROLS Engine Electrical Switches WARNING Activating the override switch while the throttle is open can cause loss of control, resulting in severe injury or death. Do not activate the override switch while the throttle is open. 2 1 3 Override Switch (1) (Reverse Speed Limiter) - This vehicle is
  • 2003 Polaris Sportsman 600 | Owners Manual - Page 39
    to severe injury or death. Never start or operate an ATV with a sticking or improperly operating throttle. Always contact your dealer for service if throttle problems arise. Failure to check or maintain proper operation of the throttle system can result in an accident if the throttle lever sticks
  • 2003 Polaris Sportsman 600 | Owners Manual - Page 40
    CONTROLS Light Switches The light switch is located on the left handlebar. It's used to turn the lights on and off and to switch the lights from HI to LO. NOTE: The lights won't work unless the key is in the on position and the shut-off switch is in the run position. WARNING Operating the ATV on
  • 2003 Polaris Sportsman 600 | Owners Manual - Page 41
    CONTROLS Master Cylinder 1 The brake fluid in the master 2 cylinder (1), which is located on the left handlebar, should be checked before each ride. The fluid level can be seen through an indicator window (2) on the top of the master cylinder. This eye will appear dark when the fluid level is full.
  • 2003 Polaris Sportsman 600 | Owners Manual - Page 42
    CONTROLS Parking Brake WARNING Operating the ATV while the parking brake is engaged could result in an accident and serious injury or death. Always check to be sure the parking brake is disengaged before operating. Setting the Parking Brake 1 1. Squeeze and release the brake lever (1) two or three
  • 2003 Polaris Sportsman 600 | Owners Manual - Page 43
    CONTROLS Auxiliary Brake WARNING Aggressively applying the auxiliary brake when backing down a hill may cause rear tipover, which could result in serious injury or death. Use caution when applying the auxiliary brake. Do not aggressively apply the auxiliary brake when going forward. The rear wheels
  • 2003 Polaris Sportsman 600 | Owners Manual - Page 44
    CONTROLS Choke The choke assists in starting a cold engine. Refer to the engine starting procedure on page 53 for correct choke and throttle settings during starting. Fuel Valve The fuel valve (1) is located on the left side panel. It has three positions: OFF: For vehicle storage and when
  • 2003 Polaris Sportsman 600 | Owners Manual - Page 45
    lock the parking brake. Maintaining shift linkage adjustment is important to assure proper transmission function. See your dealer if you experience any shifting problems. Belt Life To extend belt life, use low forward gear in heavy pulling situations and when operating at less than seven miles per
  • 2003 Polaris Sportsman 600 | Owners Manual - Page 46
    FEATURES All Wheel Drive (AWD) System Polaris 4-wheel drive ATVs are equipped with a unique, Polaris-exclusive, Demand 4 Drive (AWD) system activated by a switch (1) on the right handlebar. When the switch is off, the ATV is in 2 wheel drive at all times. When the 1 switch is on, the ATV is in
  • 2003 Polaris Sportsman 600 | Owners Manual - Page 47
    FEATURES Instrument Cluster Your ATV is equipped with an instrument cluster that senses vehicle speed from the right front wheel. The instrument cluster measures distance in miles as well as hours of operation. It also includes a reverse speed limiter function that limits the ATV's speed to
  • 2003 Polaris Sportsman 600 | Owners Manual - Page 48
    Coolant Temperature - Do not continue to operate the ATV is this warning appears or serious engine damage could result. 3. Hour Meter 4. Service Interval/Miscellaneous Service Warnings 5. Low Battery and Over Voltage - This warning usually indicates that the ATV is being operated at an RPM too low
  • 2003 Polaris Sportsman 600 | Owners Manual - Page 49
    Instrument Cluster Rider Information Center The rider information center has 4 standard modes: Mode 1 - Odometer Mode 2 - Tripmeter Mode 3 - Total Service Hours Mode 4 - Programmable service interval The reverse override button on the left handlebar is also the mode button. NOTE: If using the mode
  • 2003 Polaris Sportsman 600 | Owners Manual - Page 50
    faster. When the desired time increment is displayed, release the button and wait for the wrench to stop flashing. When the wrench stops blinking, your service hours are set. NOTE: If you scroll past the intended number, hold the button down until the count turns over to 0. You can then reset
  • 2003 Polaris Sportsman 600 | Owners Manual - Page 51
    FEATURES Instrument Cluster Rider Information Center Diagnostic Mode The diagnostic mode is for informational purposes only. Please return your ATV to your dealer for all major repairs. To enter the diagnostics mode: 1. Turn the key switch off and wait 20 seconds. 2. Set the park brake and shift the
  • 2003 Polaris Sportsman 600 | Owners Manual - Page 52
    OPERATION Fuel Safety WARNING Gasoline is highly flammable and explosive under certain conditions. S Always exercise extreme caution whenever handling gasoline. S Always refuel with the engine stopped, and outdoors or in a well ventilated area. S Do not smoke or allow open flames or sparks in or
  • 2003 Polaris Sportsman 600 | Owners Manual - Page 53
    OPERATION Break-In Period The break-in period for your new Polaris ATV is defined as the first ten hours of operation, or the time it takes to use the first two full tanks of gasoline. No single action on your part is as important as following the procedures for a proper break-in. Careful treatment
  • 2003 Polaris Sportsman 600 | Owners Manual - Page 54
    OPERATION Pre-Ride Inspection WARNING If a proper inspection is not done before each use, severe injury or death could result. Always inspect the vehicle before each use to ensure it's in proper operating condition. Use the following checklist to verify that your vehicle is in proper working
  • 2003 Polaris Sportsman 600 | Owners Manual - Page 55
    OPERATION Starting the Engine Starting a Cold Engine WARNING Engine exhaust contains poisonous carbon monoxide and can cause loss of consciousness resulting in severe injury or death. Never run an engine in an enclosed area. 1. Place the transmission in neutral and lock the parking brake. 2. Turn
  • 2003 Polaris Sportsman 600 | Owners Manual - Page 56
    OPERATION Starting the Engine Starting a Warm Engine Warm engines do not normally require the use of the choke. Using the choke can cause the spark plug to become wet fouled. 1. Position the vehicle on a level surface with the transmission in neutral. 2. Lock the parking brake, turn the fuel tank
  • 2003 Polaris Sportsman 600 | Owners Manual - Page 57
    of load. Always read and understand the load distribution warning labels on the vehicle, and never exceed the weight capacities specified in your owner's manual and on safety decals. Cargo weight should be evenly distributed (1/3 on the front rack and 2/3 on the rear rack) and mounted as low as
  • 2003 Polaris Sportsman 600 | Owners Manual - Page 58
    extra caution. Always attach the tow load to the hitch point designated for your vehicle. S HEAVY LOADS CAN CAUSE BRAKING AND CONTROL PROBLEMS. Use extreme caution when applying brakes with a loaded vehicle. Avoid terrain or situations that may require backing downhill. S USE EXTREME CAUTION when
  • 2003 Polaris Sportsman 600 | Owners Manual - Page 59
    OPERATION Driving Safely Driving Procedures 1. Sit upright with both feet on the footrests and both hands on the handlebars. 2. Start the engine and allow it to warm up, then shift the transmission into gear. 3. Check your surroundings and determine your path of travel. 4. Release the parking brake
  • 2003 Polaris Sportsman 600 | Owners Manual - Page 60
    tire must slip traction slightly. To turn, steer in the direction of the turn, leaning your upper body to the inside of the turn while supporting your weight on the outer footrest. This technique alters the balance of traction between the rear wheels, allowing the turn to be made smoothly. The
  • 2003 Polaris Sportsman 600 | Owners Manual - Page 61
    OPERATION Driving Safely Driving on Slippery Surfaces Whenever riding on slippery surfaces such as wet trails or loose gravel, or during freezing weather, follow these precautions: 1. Slow down when entering slippery areas. 2. Maintain a high level of alertness, reading the trail and avoiding quick
  • 2003 Polaris Sportsman 600 | Owners Manual - Page 62
    injury or death. Avoid climbing steep hills (25_ maximum). Use extreme caution when operating on hills, and follow proper operating procedures outlined in the owner's manual. 60
  • 2003 Polaris Sportsman 600 | Owners Manual - Page 63
    overturn, resulting in severe injury or death. Avoid crossing the side of a hill when possible. Follow proper procedures as outlined in the owner's manual. Sidehilling can be a dangerous type of driving and should be avoided if at all possible. If you do enter into a situation where sidehilling
  • 2003 Polaris Sportsman 600 | Owners Manual - Page 64
    down. 4. Apply the brakes slightly to aid in slowing. Familiarize yourself with operation of the auxiliary brake in the event loss of normal service brakes occurs. WARNING Excessive speed can cause loss of control and lead to serious injury or death. Always operate slowly when traveling downhill
  • 2003 Polaris Sportsman 600 | Owners Manual - Page 65
    on hills, and follow proper operating procedures outlined in the owner's manual. If the vehicle stalls while climbing a hill, never back it of the vehicle, turn the handlebars full left. 5. While holding the service brake, release the parking brake lock and slowly allow the vehicle to roll
  • 2003 Polaris Sportsman 600 | Owners Manual - Page 66
    brakes by applying light pressure to the lever until braking action is normal. After running the vehicle in water, it's critical to have it serviced as outlined in the maintenance chart. See page 69. The following areas need special attention: engine oil, transmission oil, front and rear gearcases
  • 2003 Polaris Sportsman 600 | Owners Manual - Page 67
    OPERATION Driving Safely Driving Over Obstacles Be alert! Look ahead and learn to read the terrain you're traveling on. Be constantly alert for hazards such as logs, rocks and low hanging branches. WARNING Severe injury or death can result if your vehicle comes in contact with a hidden obstacle.
  • 2003 Polaris Sportsman 600 | Owners Manual - Page 68
    OPERATION Driving Safely Driving in Reverse Follow these precautions when operating in reverse: 1. Always avoid backing downhill. 2. Back slowly. 3. When in reverse, apply the brakes lightly for stopping. 4. Avoid turning at sharp angles in reverse. 5. Never open the throttle suddenly while backing.
  • 2003 Polaris Sportsman 600 | Owners Manual - Page 69
    OPERATION Driving Safely Parking on an Incline Avoid parking on an incline if possible. If it's unavoidable, follow these precautions: 1. Turn the engine off. 2. Place the transmission in park. 3. Set the parking brake. 4. Always block the rear wheels on the downhill side. See illustration. 5. Shut
  • 2003 Polaris Sportsman 600 | Owners Manual - Page 70
    tall grass, especially dry grass. USFS Approved Spark Arrestor Your Polaris ATV has a muffler that was tested and approved in accordance with the USFS Forest Service Standard 5100-1A. 68
  • 2003 Polaris Sportsman 600 | Owners Manual - Page 71
    components are explained in the periodic maintenance schedule. Use the speedometer's programmable service interval mode to help determine when maintenance service is due. See page 48 for instructions. Maintenance intervals are based upon average riding conditions and an average vehicle speed
  • 2003 Polaris Sportsman 600 | Owners Manual - Page 72
    marked with a J could result in component failure and lead to serious injury or death. Have an authorized Polaris dealer perform these services. Item Brake System Auxiliary Brake Tires Wheels Frame nuts, bolts, fasteners " Air filter, Hours/ Miles Frequency Remarks Inspect Inspect Inspect Inspect
  • 2003 Polaris Sportsman 600 | Owners Manual - Page 73
    Inspect; replace annually and as needed Inspect periodically Check monthly; change annually Lubricate all fittings, pivots, cables, etc. Check level daily; break-in service at one month; change oil more often in cold weather Replace with oil change Inspect tube Pre-Ride Pre-Ride Pre-Ride Pre-Ride
  • 2003 Polaris Sportsman 600 | Owners Manual - Page 74
    the procedures marked with a J could result in component failure and lead to serious injury or death. Have an authorized Polaris dealer perform these services. Item Carburetor float bowl J Throttle Cable/ETC Hours/ Miles 50 hrs. 50 hrs. 50 hrs. 100 hrs. Frequency Remarks 6 months 6 months 6 months
  • 2003 Polaris Sportsman 600 | Owners Manual - Page 75
    when parts are replaced As required Adjust as needed Headlight aim " More often under severe use, such as dirty or wet conditions L Emission Control System Service (California) J Dealer service item 73
  • 2003 Polaris Sportsman 600 | Owners Manual - Page 76
    MAINTENANCE AND LUBRICATION Periodic Maintenance Record Use the following chart to record periodic maintenance. Maintenance Interval Performed 10 hrs. 20 hrs. 50 hrs. 100 hrs. Servicing Servicing Date Dealer or Person Remarks 74
  • 2003 Polaris Sportsman 600 | Owners Manual - Page 77
    - NOTES - 75
  • 2003 Polaris Sportsman 600 | Owners Manual - Page 78
    MAINTENANCE AND LUBRICATION Lubrication Recommendations NOTE: Hours are based on 10 mph average. If service is due at 20 hours, the equivalent odometer reading would be 200 miles. Perform all services at whichever reading is reached first. Lubrication Chart Key " L Polaris Premium All Season
  • 2003 Polaris Sportsman 600 | Owners Manual - Page 79
    MAINTENANCE AND LUBRICATION Lubrication Recommendations (1) (2) (3) (4) (5) (6) 77
  • 2003 Polaris Sportsman 600 | Owners Manual - Page 80
    MAINTENANCE AND LUBRICATION Lubrication Recommendations Premium 4 Synthetic Lubricant Polaris Premium 4 All Season synthetic engine oil has been specially formulated for use in Polaris 4-cycle engines. It's a fully synthetic, high performance, multi-viscosity oil designed to provide the ultimate in
  • 2003 Polaris Sportsman 600 | Owners Manual - Page 81
    first. Suggested break-in oil change is at 20 hours, 200 miles, or one month, whichever comes first. Severe use operation requires more frequent service. Severe use includes continuous duty in dusty or wet conditions and cold weather riding. NOTE: Severe use cold weather riding is all riding below
  • 2003 Polaris Sportsman 600 | Owners Manual - Page 82
    MAINTENANCE AND LUBRICATION Lubrication Recommendations Oil and Filter Change 1. Place the vehicle on a level surface. 2. Run the engine for two to three minutes until warm. Stop the engine. 3. Clean the area around the drain plug. 4. Place a drain pan beneath engine crankcase and remove the drain
  • 2003 Polaris Sportsman 600 | Owners Manual - Page 83
    the oil level. The oil should be maintained 1 5/8" from the top of the fill plug hole. See the specifications section of the owner's manual for oil capacities. 1 5/8" Transmission Oil Change 1. Remove the four screws on the footwell and gently pull outward to remove the footwell. 2. Remove the
  • 2003 Polaris Sportsman 600 | Owners Manual - Page 84
    MAINTENANCE AND LUBRICATION Lubrication Recommendations Front Gearcase Oil Check The front gearcase lubricant level should be checked every six months or 1000 miles (1600 km), whichever comes first. Front gearcase oil should be changed annually. 1. Position the ATV on a level surface. 2. Remove the
  • 2003 Polaris Sportsman 600 | Owners Manual - Page 85
    MAINTENANCE AND LUBRICATION Lubrication Recommendations Rear Gearcase Oil Check With the ATV on a level surface, remove the fill plug and visually inspect the lubricant level through the fill hole (1). Maintain the oil level with the bottom of the fill plug hole. Rear Gearcase Oil Change 1. Remove
  • 2003 Polaris Sportsman 600 | Owners Manual - Page 86
    MAINTENANCE AND LUBRICATION Engine Cooling System Coolant Level The recovery bottle (1) is located on the left side of the machine. To access the recovery bottle, remove the left side panel as outlined on page 93. 1 The fluid level must be maintained between the minimum and maximum marks on the
  • 2003 Polaris Sportsman 600 | Owners Manual - Page 87
    MAINTENANCE AND LUBRICATION Engine Cooling System WARNING Escaping steam can cause severe burns. Never remove the pressure cap while the engine is warm or hot. Always allow the engine to cool before removing the pressure cap. Radiator Coolant Level NOTE: This procedure is required only if the
  • 2003 Polaris Sportsman 600 | Owners Manual - Page 88
    MAINTENANCE AND LUBRICATION Adjustments Front Brake WARNING After opening a bottle of brake fluid, always discard any unused portion. Never store or use a partial bottle. Brake fluid is hygroscopic, meaning it rapidly absorbs moisture from the air. The moisture causes the boiling temperature of the
  • 2003 Polaris Sportsman 600 | Owners Manual - Page 89
    MAINTENANCE AND LUBRICATION Adjustments Rear Brake The rear brake is a hydraulic disc brake and is activated by the same lever that activates the front brake system. The rear brake system is self-adjusting and requires no maintenance other than periodic checks of the pads for wear. Pads should be
  • 2003 Polaris Sportsman 600 | Owners Manual - Page 90
    front rim (3). Rear measurement should be 1/16″ - 1/8″ (.2 to .3 cm) more than the front measurement. NOTE: If you discover improper alignment, see your Polaris dealer for service. 88
  • 2003 Polaris Sportsman 600 | Owners Manual - Page 91
    assembly of the ATV should be checked periodically for loose nuts and bolts. If loose nuts and bolts are found, see your Polaris dealer for service before operating the vehicle. Camber and Caster The camber and caster are non-adjustable. Rear Spring The rear shock absorber spring is adjusted by
  • 2003 Polaris Sportsman 600 | Owners Manual - Page 92
    in loss of control and possible serious personal injury or death. Follow the adjustment procedures exactly, or see your Polaris dealer for service. Handlebars The handlebars can be adjusted for 1 rider preference. 1. Locate handlebar bolts (1) by removing the upper headlight pod. 2. Loosen the four
  • 2003 Polaris Sportsman 600 | Owners Manual - Page 93
    MAINTENANCE AND LUBRICATION Adjustments Carburetor/Idle RPM If the engine idle speed is not satisfactory, and all other conditions are favorable, the carburetor can be adjusted. 1. Warm up the engine by running the vehicle for approximately five minutes. 2. Place the transmission in gear with the
  • 2003 Polaris Sportsman 600 | Owners Manual - Page 94
    MAINTENANCE AND LUBRICATION Adjustments Throttle Cable Freeplay Throttle cable freeplay is adjusted at the handlebar. 1. Slide the boots (1) off the inline cable adjuster sleeve (2). Loosen the adjuster locknut (3). 2. Turn the adjuster until 1/16″ to 1/8″ freeplay is achieved at the thumb lever.
  • 2003 Polaris Sportsman 600 | Owners Manual - Page 95
    MAINTENANCE AND LUBRICATION Adjustments Side Panel Removal NOTE: Side panel removal may be difficult until the locking tabs and receivers have been snapped and unsnapped a few times. 1. Remove the seat. Step 2. 2. Grasp the rear of the side panel near the rear cab. With a quick and firm motion, pull
  • 2003 Polaris Sportsman 600 | Owners Manual - Page 96
    an accident resulting in serious injury or death. Maintain proper tire pressure as described on the decal on your ATV and in the owner's manual. Always use original equipment size and type when replacing tires. Make sure the wheels are installed properly. Always replace tires when the tread depth
  • 2003 Polaris Sportsman 600 | Owners Manual - Page 97
    6. Torque the wheel nuts according to the wheel nut torque specifications chart. NOTE: All nuts that have a cotter pin installed must be serviced by an authorized Polaris dealer. Wheel Nut Torque Specifications Check the wheel nut torques occasionally and when they've been loosened for maintenance
  • 2003 Polaris Sportsman 600 | Owners Manual - Page 98
    MAINTENANCE AND LUBRICATION Filter Systems Air Filter Service 1. Remove the seat, release the clips, and remove the air box cover. 2. Loosen the clamp and remove the filter vehicle without a breather filter can cause engine damage. Always reinstall the breather filter after removing for service. 96
  • 2003 Polaris Sportsman 600 | Owners Manual - Page 99
    dirty during normal operation. Wash the headlights frequently to maintain lighting quality. Hot components can cause serious burns to skin. Do not service the headlamps until they've cooled sufficiently. Headlight Lamp Replacement 1. Remove the two screws on the lower front corners of the headlight
  • 2003 Polaris Sportsman 600 | Owners Manual - Page 100
    MAINTENANCE AND LUBRICATION Lights High Beam Adjustment The headlight beam can be adjusted to any position desired by turning the adjusting knob on the bottom right side of the headlight pod. 1. Position the vehicle on a level surface with the headlight approximately 25 ft. (7.6 m) from a wall. 2.
  • 2003 Polaris Sportsman 600 | Owners Manual - Page 101
    MAINTENANCE AND LUBRICATION Lights Headlight Housing Replacement 1. Remove the two screws on the lower front corners of the headlight pod. 2. Using a small flat-blade screwdriver, push in on the lock tab through the two small openings at the front of the headlight pod. 3. Lift the pod slightly while
  • 2003 Polaris Sportsman 600 | Owners Manual - Page 102
    MAINTENANCE AND LUBRICATION Lights Lower Headlamp Removal / Installation 1. Turn the back of the headlight harness (1) in a clockwise direction. 2. Pull the harness assembly out from the headlight assembly. 3. Remove the headlamp and replace with a 1 new headlamp. 4. Install the new headlamp and
  • 2003 Polaris Sportsman 600 | Owners Manual - Page 103
    will be few combustion deposits. The electrodes are not burned or eroded. This indicates the proper type and heat range for the engine and the service. NOTE: The tip should not be white. A white insulator tip indicates overheating, caused by use of an improper spark plug or incorrect carburetion
  • 2003 Polaris Sportsman 600 | Owners Manual - Page 104
    . 9. Turn the fuel valve on. 10. Attempt to start the engine. If necessary, repeat the drying procedure. 11. Take the ATV to your dealer for service as soon as possible, whether you succeed in starting it or not. NOTE: If water has been ingested into the PVT, follow the procedure on
  • 2003 Polaris Sportsman 600 | Owners Manual - Page 105
    MAINTENANCE AND LUBRICATION Spark Arrestor WARNING Failure to heed the following warnings while servicing the spark arrestor could result in serious injury or death. Do not perform service on the spark arrestor while the system is hot. Exhaust system temperatures can reach 1000° F. Allow components
  • 2003 Polaris Sportsman 600 | Owners Manual - Page 106
    MAINTENANCE AND LUBRICATION PVT System The basic operation of the Polaris PVT system is dependent on engine speed and vehicle torque requirements. As engine speed increases, the force exerted on the movable drive sheave by the flyweights also increases. This, in turn, increases the amount of pinch
  • 2003 Polaris Sportsman 600 | Owners Manual - Page 107
    procedures. See your dealer as outlined in the owner's manual. This PVT system is intended for use on Polaris products when water is accidently ingested into the PVT system. Use the following instructions to dry it out before operating: 1. Remove the drain plug and service as soon as possible. 105
  • 2003 Polaris Sportsman 600 | Owners Manual - Page 108
    MAINTENANCE AND LUBRICATION Battery Keep the battery terminals and connections free of corrosion. If cleaning is necessary, remove the corrosion with a stiff wire brush. Wash with a solution of one tablespoon baking soda and one cup water. Rinse well with tap water and dry off with clean shop towels
  • 2003 Polaris Sportsman 600 | Owners Manual - Page 109
    MAINTENANCE AND LUBRICATION Battery Improperly connecting or disconnecting battery cables can result in an explosion and cause serious injury or death. When removing the battery, always disconnect the negative (black) cable first. When reinstalling the battery, always connect the negative (black)
  • 2003 Polaris Sportsman 600 | Owners Manual - Page 110
    MAINTENANCE AND LUBRICATION Battery Battery Installation and Connections 1. Set the battery in the battery holder. 2. Install the battery vent tube. NOTE: It must be free of obstructions and securely installed. If not, battery gases could accumulate and cause an explosion. The tube should be routed
  • 2003 Polaris Sportsman 600 | Owners Manual - Page 111
    MAINTENANCE AND LUBRICATION Cleaning and Storage See page 117 for the part numbers of Polaris-recommended products. Cleaning the ATV Keeping your ATV clean will not only improve its appearance but it can also extend the life of various components. With a few precautions, your ATV can be cleaned
  • 2003 Polaris Sportsman 600 | Owners Manual - Page 112
    may force water past seals. Stabilize the Fuel Fill the fuel tank. Add Polaris Carbon Clean Fuel Treatment or Polaris Fuel Stabilizer. Follow the instructions on the container for the recommended amount. (Carbon clean will also reduce the possibility of bacterial growth in the fuel system.) Allow 15
  • 2003 Polaris Sportsman 600 | Owners Manual - Page 113
    you choose not to use Polaris Fogging Oil, perform the following procedure. 1. Support the front end of the machine so the engine is level or tilted slightly lubrication guidelines in the Maintenance Section of the service or owner's manual to completely grease and lubricate the entire vehicle with
  • 2003 Polaris Sportsman 600 | Owners Manual - Page 114
    Test engine coolant strength and change if necessary. Coolant should be replaced every two years. Storage Area/Covers Set the tire pressure and safely support the ATV with the tires 1-2" off the ground. Be sure the storage area is well ventilated, and cover the machine with a genuine Polaris ATV
  • 2003 Polaris Sportsman 600 | Owners Manual - Page 115
    TROUBLESHOOTING Drive Belt and Cover Problems Possible Cause Driving the ATV onto a pickup or tall trailer in high range. Starting out going up a steep incline. performance. Check for fouled plugs or foreign material in gas tank, fuel lines, or carburetor. Contact your dealer for service. 113
  • 2003 Polaris Sportsman 600 | Owners Manual - Page 116
    TROUBLESHOOTING Contact your Polaris dealer for service if you're unable to identify solutions using the following charts. Engine Doesn't Turn Over Possible Cause Tripped circuit breaker Low battery voltage Loose battery
  • 2003 Polaris Sportsman 600 | Owners Manual - Page 117
    TROUBLESHOOTING Engine Backfires Possible Cause Weak spark from spark plugs Incorrect spark plug gap or heat range Old or non-recommended fuel Incorrectly installed spark plug
  • 2003 Polaris Sportsman 600 | Owners Manual - Page 118
    TROUBLESHOOTING Engine Stops or Loses Power Possible Cause Out of fuel Kinked or plugged fuel vent line Water present in fuel Overuse of choke Fouled or
  • 2003 Polaris Sportsman 600 | Owners Manual - Page 119
    POLARIS RECOMMENDED PRODUCTS Part No. 2870791 2871721 2871240 2872927 2871098 2871281 2871844 2871477 2871478 2871653 2872276 2870465 2871654 2872277 2871322 2871423 2871460 2871515 2871551 2871312 2871329 2871323 2871534 2871326 2870652 2870990 2872893 Description Engine Lubricant Fogging Oil (12
  • 2003 Polaris Sportsman 600 | Owners Manual - Page 120
    SPECIFICATIONS SPORTSMAN 600 Gross Vehicle Weight Fuel Capacity Hitch Towing Capacity Hitch Tongue Capacity Front Rack Capacity Rear Rack Capacity Overall Length Overall Width Overall Height Wheelbase Ground Clearance Dry Weight Minimum Turning Radius Engine Oil Capacity Coolant Capacity Engine
  • 2003 Polaris Sportsman 600 | Owners Manual - Page 121
    SPECIFICATIONS SPORTSMAN 600 Shift Type Gear Reduction - Low Gear Reduction - Reverse Gear Reduction - High Drive Ratio - Front: Drive Ratio - Final Tire Size - Front Tire Size - Rear Front Brake Rear Brake Parking Brake Headlight (watts) Taillights (watts) Brake Light (watts) Instrument Cluster
  • 2003 Polaris Sportsman 600 | Owners Manual - Page 122
    SPECIFICATIONS SPORTSMAN 700 Gross Vehicle Weight Fuel Capacity Towing Rating Unbraked Trailer Towing Capacity* Front Rack Capacity Rear Rack Capacity Hitch Tongue Capacity Overall Length Overall Width Overall Height Wheelbase Ground Clearance Dry Weight Minimum Turning Radius Engine Oil Capacity
  • 2003 Polaris Sportsman 600 | Owners Manual - Page 123
    SPECIFICATIONS SPORTSMAN 700 Shift Type Gear Reduction - Low Gear Reduction - Reverse Gear Reduction - High Drive Ratio - Front: Drive Ratio - Final Tire Size - Front Tire Size - Rear Front Brake Rear Brake Parking Brake Headlight (watts) Taillights (watts) Brake Light (watts) Instrument Cluster
  • 2003 Polaris Sportsman 600 | Owners Manual - Page 124
    COVERAGE WILL BE ALLOWED UNLESS YOUR ATV IS REGISTERED WITH POLARIS. Initial dealer preparation and set-up of your ATV is very important in ensuring trouble-free operation. Purchasing a machine in the crate or without proper dealer set-up will void your warranty coverage. 122
  • 2003 Polaris Sportsman 600 | Owners Manual - Page 125
    for purposes other than for which it was manufactured, or for any damages which occur during trailer transit or as a result of unauthorized service or the use of unauthorized parts. In addition, this warranty does not cover physical damage to paint or finish, stress cracks, tearing or puncturing
  • 2003 Polaris Sportsman 600 | Owners Manual - Page 126
    THE DEALER IS YOUR RESPONSIBILITY). Polaris suggests that you use your original selling dealer; however, you may use any Polaris Servicing Dealer to perform warranty service. Please work with your dealer to resolve any warranty issues. Should your dealer require any additional assistance they will
  • 2003 Polaris Sportsman 600 | Owners Manual - Page 127
    INDEX A Accessories ...69 Adjustments ...86-95 Age Restrictions ...11 Air Filter Service ...96 All Wheel Drive ...44 Automatic Transmission ...43 Auxiliary Brake ...87 AWD ...44 E Electrical Switches ...Engaging Front Gearcase ...Engine Cooling System ...Engine Oil Check ...Engine
  • 2003 Polaris Sportsman 600 | Owners Manual - Page 128
    ...62 Traveling Uphill ...60 Trip Meter ...47 TROUBLESHOOTING ...113-116 Turning Around on a Hill ... 52 Premium 4 Synthetic Lubricant ...78 Programmable Service Interval ...48 PVT Drying ...105 PVT Vehicle Immersion ...102 W Warning, Read Owner's Manual ...11 WARRANTY ...122-124 WELCOME ...3 Wheel
  • 2003 Polaris Sportsman 600 | Owners Manual - Page 129
    NEVER USE WITH DRUGS OR ALCOHOL NEVER: Operate without proper training or instruction. Operate on public roads. A collision can occur with another vehicle. Operate and protective apparel. READ OWNER'S MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS. Part No. 9918213 Rev 03 PRINTED IN THE USA
  • 1
  • 2
  • 3
  • 4
  • 5
  • 6
  • 7
  • 8
  • 9
  • 10
  • 11
  • 12
  • 13
  • 14
  • 15
  • 16
  • 17
  • 18
  • 19
  • 20
  • 21
  • 22
  • 23
  • 24
  • 25
  • 26
  • 27
  • 28
  • 29
  • 30
  • 31
  • 32
  • 33
  • 34
  • 35
  • 36
  • 37
  • 38
  • 39
  • 40
  • 41
  • 42
  • 43
  • 44
  • 45
  • 46
  • 47
  • 48
  • 49
  • 50
  • 51
  • 52
  • 53
  • 54
  • 55
  • 56
  • 57
  • 58
  • 59
  • 60
  • 61
  • 62
  • 63
  • 64
  • 65
  • 66
  • 67
  • 68
  • 69
  • 70
  • 71
  • 72
  • 73
  • 74
  • 75
  • 76
  • 77
  • 78
  • 79
  • 80
  • 81
  • 82
  • 83
  • 84
  • 85
  • 86
  • 87
  • 88
  • 89
  • 90
  • 91
  • 92
  • 93
  • 94
  • 95
  • 96
  • 97
  • 98
  • 99
  • 100
  • 101
  • 102
  • 103
  • 104
  • 105
  • 106
  • 107
  • 108
  • 109
  • 110
  • 111
  • 112
  • 113
  • 114
  • 115
  • 116
  • 117
  • 118
  • 119
  • 120
  • 121
  • 122
  • 123
  • 124
  • 125
  • 126
  • 127
  • 128
  • 129
Owner's Manual
Vehicle Maintenance and Safety
2003
Sportsman 600
Sportsman 700
for
Read this manual carefully. It contains important safety information.
This is an adult vehicle only.
Operation is prohibited for those under 16 years of age.