Polaris 2003 SPORTSMAN 600, 2003 SPORTSMAN 700, 2002 SPORTSMAN 700, SPORTSMAN 600, SPORTSMAN 700 Service Manual

2003 SPORTSMAN 600

2002 - 2003 SPORTSMAN 700

SERVICE MANUAL

PN 9918066

UNDERSTANDING SAFETY LABELS AND INSTRUCTIONS

Throughout these instructions, important information is brought to your attention by the following symbols:

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!

DANGER

Failure to follow DANGER instructions will result in severe injury or death to the operator, bystander orperson
inspecting or servicing the ATV.

WARNING

Failure to follow WARNING instructions could result in severe injury or death to the operator, bystander or
person inspecting or servicing the ATV.

CAUTION:

A CAUTION indicates special precautions that must be taken to avoid personal injury, or ATV or property
damage.

NOTE:

A NOTE provides key information to clarify instructions.

Trademarks

Polaris acknowledges the following products mentioned in this manual:

FLEXLOC, Registered Trademark of SPS Technologies
Loctite, Registered Trademark of the Loctite Corporation
STA-BIL, Registered Trademark of Gold Eagle
FOX, Registered Trademark of Fox Shox
Nyogel, Trademark of Wm. F. Nye Co.
Fluke, Registered Trademark of John Fluke Mfg. Co.
Mity Vac, Registered Trademark of Neward Enterprises, Inc.
Ammco, Registered Trademark of Ammco Tools, Inc.
Torx, Registered Trademark of Textron
Hilliard, Trademark of the Hilliard Corporation

2003 SPORTSMAN 600/700

SERVICE MANUAL

Foreword

This manual is designed primarily for use by certified Polaris Master Service Dealer technicians in a properly
equipped shop and should be kept available for reference. All references to left and right side of the vehicle
are from the operator’s perspective when seated in a normal riding position.

Some procedures outlined inthis manual require a sound knowledge of mechanical theory, tool use, and shop
procedures in order to perform the work safely and correctly. Technicians should read the text and be familiar
with service procedures before starting the work. Certain procedures require the use of special tools. Use
only the proper tools as specified.

This manual includes procedures for maintenance operations, component identification and unit repair, along
with service specifications for 2003 Polaris Sportsman 600/700 ATVs. Comments or suggestions about this
manual may be directed to: Service Publications Dept. @ Polaris Sales Inc. 2100 Hwy 55 Medina Minnesota

55340.

2002 Sportsman 600/700 ATV Service Manual (PN 9918066)

ECopyright 2002 Polaris Sales Inc. All information contained within this publication is based on the latest product information at the
time of publication. Due to constant improvements in the design and quality of production components, some minor descrepancies
may result between the actual vehicle and the information presented in this publication. Depictions and/or procedures in this
publication are intended for reference use only. No liability can be accepted for omissions or inaccuracies. Any reprinting or reuse of
the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited. Printed in U.S.A.

CHAPTER INDEX

CHAPTER 1 GENERAL

CHAPTER 2 MAINTENANCE

CHAPTER 3 ENGINE

CHAPTER 4 FUEL SYSTEM

CHAPTER 5 BODY/SUSPENSION

CHAPTER 6 PVT SYSTEM

CHAPTER 7 FINAL DRIVE

CHAPTER 8 TRANSMISSION

CHAPTER 9 BRAKES

CHAPTER 10 ELECTRICAL

GENERAL INFORMATION

Model Identification 1.2.......................

Serial Number Location 1.2...................

2003 Sportsman Models 1.3..................

Machine Dimensions 1.4-1.5.....................

Specifications - 2002 Sportsman 700 1.6-1.7.......

Specifications - 2003 Sportsman 600 1.8-1.9.......

Specifications - 2003 Sportsman 700 1.10-1.11.......

Publication Numbers 1.12.....................

Paint Codes 1.12.............................

CHAPTER 1
GENERAL INFORMATION

1

Replacement Keys 1.12.......................

Standard Torque Specifications 1.13............

Decimal Equivalent Chart 1.14.................

Conversion Table 1.15........................

Tap Drill Charts 1.16..........................

Glossary of Terms 1.17-1.18........................

1.1

GENERAL INFORMATION

MODEL IDENTIFICA

The machine model number must be used with any correspondence regarding warranty or service.

TION

Machine Model Number Identification

A03CH68AA

Emissions &

Year Designation

ENGINE DESIGNATION

EH068OLE11 Twin cylinder, Liquid Cooled, 4 Stroke, Electric Start...............

EH059OLE11 Twin cylinder, Liquid Cooled, 4 Stroke, Electric Start...............

VIN IDENTIFICA

World Mfg. ID

1

2

4XA C H

Body Style

3

TION

Vehicle Description

5

4

Powertrain

6

68A* 2P0 00 0 00

Engine

Basic Chassis
Designation Engine Designation

NUMBERS

Vehicle Identifier

8

7

Emissions

9

Model
Year

Check Digit

10 1

Plant No.

13

12

1

Individual Serial No.

Model Option

14

15

16

17

* This could be either
a number or a letter

ENGINE SERIAL NUMBER LOCA

Whenever corresponding about an engine, be sure to refer to
the engine model number and serial number. This information
can be found on the sticker applied to the top side of the
crankcase (A). An additional number is stamped on the side of
the crankcase beneath the cylinder coolant elbow.

TION

MACHINE MODEL NUMBER AND

SERIAL NUMBER LOCATION

The machine model number and serial number are
important for vehicle identification. The machine serial
number is stamped on the lower left side of the frame
tube.(B)

TRANSMISSION I.D.

LOCA

TION

NUMBER

A

Front

B

The transmission I.D. number is located on
the right side of machine.

1.2

GENERAL INFORMATIONGENERAL INFORMATION

2003 SPRORTSMAN 600 & 700 MODELS

SPORTSMAN 600

SPORTSMAN 700

NOTE: MODELS WILL VARY IN COLOR.

1.3

MACHINE DIMENSIONS

GENERAL INFORMATION

FRONT

46 in

116.84 cm

85 in

215.90 cm

1.4

SIDE

50.75 in

128.90 cm

GENERAL INFORMATIONGENERAL INFORMATION

MACHINE DIMENSIONS

46 in

116.84 cm

47 in

119.38 cm

REAR

11 in

27.94 cm

46 in

116.84 cm

1.5

GENERAL INFORMATIONGENERAL INFORMATION

ltitude

Below40

F

+40

Fan

dabov

e

Meter

s

0-180

0

(Feet

)

Above1800

Altitud

e

ue/

Gre

e

Meter

s

0-180

0

Blue/Gree

n

(Feet

)

ue/

Gre

e

180

0-370

0

Blue/Gree

n

MODEL:

..........

2002 SPORTSMAN 700

MODEL NUMBER: A02CH68AA/CA.
ENGINE MODEL: EH68ALOE1..

CARBURETION

Type BST 34 Mikuni................

Main Jet 162.5............

Pilot Jet 45.............

Jet Needle 4BH41--4...........

Needle Jet P-6...........

Throttle Valve #100........

Pilot Screw 1.5 Turns Out..........

Pilot Air Jet 160..........

Valve Seat 1.5...........

Float Height 14.7mm (.58I)±1mm.........

Fuel Octane (R+M/2) 87 Non-Oxygenated or.

89 Oxygenated

CLUTCH

Type PVT....................

Belt 3211091.....................

Belt Width (Projected) 1.188I (30.18mm).....

Side Angle (Overall) 28°±2°......

Outside Circumference 40.875 ±.188I....

Center Distance 10±.12I (254.5mm)..........

Clutch Offset 0.5I (12.7mm)............

Secondary Spring White/Yellow........

Driven Helix Compound (EBS).............

Spring Position (Helix) N/A....

Spring Position (Sheave) N/A..

JETTING CHART

Altitude

Meters

(Feet)

0-1800

(0-6000)

Above 1800

Above (6000)

AMBIENT TEMPERATURE

Below 40 °F
Below +5°C

167.5 162.5

160 155

CLUTCH CHART

*EBS require no helix/spring adjustment

SAShift

Weight Spring Spring Helix

Meters

(Feet)

0-1800

(0-6000)

1800-3700

(6000-12000)

20--56

20--54

Drive Clutch

Bl

(5631215)

Bl

(5631214)

+40_F and above

+5_C and above

Driven Clutch

n

White/Yellow EBS

n

White/Yellow EBS

Driven

ENGINE

Type 4 Cycle, Twin Cyl........................

Displacement 683 cc...............

Bore 3.149I (80 mm).......................

Stroke 2.677I (68 mm).....................

Valve Clearance In/Ex 0.006/0.006I@ TDC on compression.......

Compression Ratio 9.78/1 Full Stroke..........

Cooling Liquid....................

Lubrication Type Pressurized Wet Sump............

Operating RPM±200 6000 RPM.........

Idle RPM±200 (lights off) 1100 RPM.....

Compression Pressure (Std) ±15%.......

1.6

GENERAL INFORMATIONGENERAL INFORMATION

MODEL:
MODEL NUMBER: A02CH68AA/CA...

ENGINE MODEL: EH68ALOE1....

............

2002 SPORTSMAN 700

ELECTRICAL FLUID Capacity Type

Flywheel I.D. 4060152 Fuel Tank 4.75 gals. (17.9 L)...... ..........

CDI Marking 4010364 Coolant 3.2 qts. (3 L) *PP6....... ............ .

Alternator Output 300 Watts Transmission 13.50 oz. *PPS... ....... ....

Ignition Timing 25° BTDC@3000±500RPM Gearcase Oil (Front).. 5 oz. (150 ml)...*PDD.....

Spark Plug / Gap RC7YC -- 0.036I (0.9mm) Gearcase Oil (Rear) 5oz. (150 ml) 80--90 GL5... . .

Lights: Head 50 Watt Quartz Engine Oil 2 qts. (1.9L) *PP4...... .......... ..

Grill (2) 27 Watts Quartz Brake (Hand) Dot 3.... .......

Tail 8.26 watts Brake (Foot) Dot 3........ ........

Brake 26.9 watts......

Voltage Regulator LR39 *PP6 Polaris Premium 60/40 Antifreeze/Coolant..

Electric Start Standard *PPS Polaris Premium Synthetic Gear Case Oi.......

Instrument Cluster LCD *PP4 Polaris 0W--40 Synthetic Engine Lubricant..

Lubricant Key

*PDD Premium Demand Drive Hub Fluid

SUSPENSION / CHASSIS DRIVE TRAIN

Body Style Gen IV 4 Wheel Independent Shaft Drive........

Front Suspension MacPherson Strut Gear Reduction-Low 7.5/1.. .

Tow Capacity 1225 lbs. (555.6 kg) Gear Reduction-Rev 5.11/1...... .

Turning Radius 76I (181.61 cm) Gear Reduction-High 3.09/1.....

Toe Out 1/8I-1/4I (3-6.35 mm) Front Drive Ratio 3.82/1........... ....

Ground Clearance 11I (27.94 cm) Final Drive Ratio 3.10/1.. ....

Front Vertical Travel 6.7I (17.02 cm) Brake (Hand) Single Lever, Hyd. Disc.......

Rear Suspension Progressive Rate Independent Brake (Auxiliary Foot) Hydraulic...

Rear Travel 9.5I (24.13 cm) Transmission Park Lock........

Rear Shock 2I Twin Tube........

Shock Adjustment Cam..

TIRES

TireSize-Front 25x8-12....

Tire Size - Rear 25 x 11 - 12....

Tire Pressure - F/R 5/5 lbs.

Total Width 46I (116.84 cm)........

Total Length 85I (215.90 cm).......

Total Height 47I (119.38 cm)........

Wheel Base 50.75I (128.90 cm).......

Weight - Dry 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.

1.7

GENERAL INFORMATION

Altitud

e

Below40

F

+40Fandabov

e

Meter

s

0-180

0

(Feet

)

Above1800

Altitud

e

ue/

Gre

e

Meter

s

0-180

0

Blue/Gree

n

(Feet

)

ue/

Gre

e

180

0-370

0

Blue/Gree

n

MODEL:

..........

2003 SPORTSMAN 600

MODEL NUMBER: A03CH59.
ENGINE MODEL: EH059OLE..

CARBURETION

Type BST 34 Mikuni................

Main Jet 155............

Pilot Jet 45.............

Jet Needle J8--4FA01--3...........

Needle Jet P-4...........

Throttle Valve #100........

Pilot Screw 1.5 Turns Out..........

Pilot Air Jet 160..........

Valve Seat 1.5...........

Float Height 14.7mm (.58I)r1mm.........

Fuel Octane (R+M/2) 87 Non-Oxygenated or.

89 Oxygenated

CLUTCH

Type PVT....................

Belt 321 1091.....................

Belt Width (Projected) 1.188I (30.18mm).....

Side Angle (Overall) 28qr2q......

Outside Circumference 40.875 r.188I....

Center Distance 10r.12I (254.5mm)..........

Clutch Offset 0.5I (12.7mm)............

Secondary Spring White/Y ellow........

Driven Helix Compound (EBS).............

Spring Position (Helix) N/A....

Spring Position (Sheave) N/A..

JETTING CHART

Altitude

Meters

(Feet)

0-1800

(0-6000)

Above 1800

Above (6000)

AMBIENT TEMPERATURE

Below 40 qF
Below +5qC

162.5 155

150 145

CLUTCH CHART

*EBS require no helix/spring adjustment

Shift

Weight Spring Spring Helix

Meters

(Feet)

0-1800

(0-6000)

1800-3700

(6000-12000)

10 MH

10 WH

Drive Clutc h

Bl

(5631215)

Bl

(5631214)

+40_F and above

+5_C and above

Driven Clutch

n

White/Yellow EBS

n

White/Yellow EBS

Driven

ENGINE

Type 4 Cycle, Twin Cyl........................

Displacement 597 cc...............

Bore 3.012I (76.5 mm).......................

Stroke 2.559I (65 mm).....................

Compression Ratio 9.35/1 Full Stroke..........

Cooling Liquid....................

Lubrication Type Pressurized Wet Sump............

Operating RPMr200 6000 RPM.........

Idle RPM r 100 (lights off) 1 100 RPM....

Compression Pressure 150--170psi r15%.......

1.8

GENERAL INFORMATION

MODEL:
MODEL NUMBER: A03CH59...

ENGINE MODEL: EH059OLE....

............

2003 SPORTSMAN 600

ELECTRICAL FLUID Capacity Type

Flywheel I.D. 4060152 Fuel Tank 4.75 gals. (17.9 L)...... ..........

CDI Marking 4010785 Coolant 3.2 qts. (3 L) *PP6....... ............ .

Alternator Output 300Watts Transmission 13.50 oz. *PPS... ....... ....

Ignition Timing 25q BTDC@3000RPMr500 Gearcase Oil (Front).. 5 oz. (150 ml)...*PDD.....

Spark Plug / Gap RC7YC -- 0.035I (0.9mm) Gearcase Oil (Rear) 5oz. (150 ml) 80--90 GL5... . .

Lights: Head 50 Watt Quartz Engine Oil 2 qts. (1.9L) *PP4...... .......... ..

Grill (2) 27 Watts Quartz Brake (Hand) Dot 3.... .......

Tail 8.26 watts Brake (Foot) Dot 3........ ........

Brake 26.9 watts......

Voltage Regulator LR39 *PP6 Polaris Premium 60/40 Antifreeze/Coolant..

Electric Start Standard *PPS Polaris Premium Synthetic Gear Case Lube.......

Instrument Cluster LCD *PP4 Polaris 0W--40 Synthetic Engine Lubricant..

Lubricant Key

*PDD Premium Demand Drive Hub Fluid

SUSPENSION / CHASSIS DRIVE TRAIN

Body Style Gen IV 4 Wheel Independent Shaft Drive........

Front Suspension MacPherson Strut Gear Reduction-Low 7.49:1.. .

Tow Capacity 1225 lbs. (555.6 kg) Gear Reduction-Rev 5.11:1...... .

Turning Radius 76I (181.61 cm) Gear Reduction-High 2.89:1.....

Toe O u t 1/ 8 I-1/4I (3-6.35 mm) Front Drive Ratio 3.82:1........... ....

Ground Clearance 11I (27.94 cm) Final Drive Ratio 3.10:1.. ....

Front Vertical Travel 6.7I (17.02 cm) Brake (Hand) Single Lever, Hyd. Disc.......

Rear Suspension Progressive Rate Independent Brake (Auxiliary Foot) Hydraulic...

Rear Travel 9.5I (24.13 cm) Transmission Park Lock........

Rear Shock 2I Twin Tube........

Shock Adjustment Cam..

TIRES

TireSize-Front 25x8-12....

Tire Size - Rear 25 x 11 - 12....

Tire Pressure - F /R 5/5 lbs.

Total Width 46I (116.84 cm)........

Total Length 85I (215.90 cm).......

Total Height 47I (119.38 cm)........

Wheel Base 50.75I (128.90 cm).......

Weight - Dry 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

Altitud

e

Below40

F

+40Fandabov

e

Meter

s

0-180

0

(Feet

)

Above1800

Altitud

e

ue/

Gre

e

Meter

s

0-180

0

Blue/Gree

n

(Feet

)

ue/

Gre

e

180

0-370

0

Blue/Gree

n

MODEL:

..........

2003 SPORTSMAN 700

MODEL NUMBER: A03CH68.
ENGINE MODEL: EH068OLE..

CARBURETION

Type BST 34 Mikuni................

Main Jet 155............

Pilot Jet 47.5.............

Jet Needle J8--4FA01--3...........

Needle Jet P-6M (829)...........

Throttle Valve #100........

Pilot Screw 1.5 Turns Out..........

Pilot Air Jet 160..........

Valve Seat 1.5...........

Float Height 14.7mm (.58I)r1mm.........

Fuel Octane (R+M/2) 87 Non-Oxygenated or.

89 Oxygenated

CLUTCH

Type PVT....................

Belt 321 1091.....................

Belt Width (Projected) 1.188I (30.18mm).....

Side Angle (Overall) 28qr2q......

Outside Circumference 40.875 r.188I....

Center Distance 10r.12I (254.5mm)..........

Clutch Offset 0.5I (12.7mm)............

Secondary Spring White/Y ellow........

Driven Helix Compound (EBS).............

Spring Position (Helix) N/A....

Spring Position (Sheave) N/A..

JETTING CHART

Altitude

Meters

(Feet)

0-1800

(0-6000)

Above 1800

Above (6000)

AMBIENT TEMPERATURE

Below 40 qF
Below +5qC

160 155

147.5 142.5

CLUTCH CHART

*EBS require no helix/spring adjustment

Shift

Weight Spring Spring Helix

Meters

(Feet)

0-1800

(0-6000)

1800-3700

(6000-12000)

20--56

20--54

Drive Clutc h

Bl

(5631215)

Bl

(5631214)

+40_F and above

+5_C and above

Driven Clutch

n

White/Yellow EBS

n

White/Yellow EBS

Driven

ENGINE

Type 4 Cycle, Twin Cyl........................

Displacement 683 cc...............

Bore 3.149I (80 mm).......................

Stroke 2.677I (68 mm).....................

Compression Ratio 9.78/1 Full Stroke..........

Cooling Liquid....................

Lubrication Type Pressurized Wet Sump............

Operating RPMr200 6000 RPM.........

Idle RPMr100 (lights off) 1100 RPM.....

Compression Pressure 150--170psi r15%.......

1.10

GENERAL INFORMATION

MODEL:
MODEL NUMBER: A03CH68...

ENGINE MODEL: EH068OLE....

............

2003 SPORTSMAN 700

ELECTRICAL FLUID Capacity Type

Flywheel I.D. 4060152 Fuel Tank 4.75 gals. (17.9 L)...... ..........

CDI Marking 4010364 Coolant 3.2 qts. (3 L) *PP6....... ............ .

Alternator Output 300 Watts Transmission 13.50 oz. *PPS... ....... ....

Ignition Timing 32q BTDC@5760RPMr200 Gearcase Oil (Front).. 5 oz. (150 ml)...*PDD.....

Spark Plug / Gap RC7YC -- 0.036I (0.9mm) Gearcase Oil (Rear) 5oz. (150 ml) 80--90 GL5... . .

Lights: Head 50 Watt Quartz Engine Oil 2 qts. (1.9L) *PP4...... .......... ..

Grill (2) 27 Watts Quartz Brake (Hand) Dot 3.... .......

Tail 8.26 watts Brake (Foot) Dot 3........ ........

Brake 26.9 watts......

Voltage Regulator LR39 *PP6 Polaris Premium 60/40 Antifreeze/Coolant..

Electric Start Standard *PPS Polaris Premium Synthetic Gear Case Lube.......

Instrument Cluster LCD *PP4 Polaris 0W--40 Synthetic Engine Lubricant..

Lubricant Key

*PDD Premium Demand Drive Hub Fluid

SUSPENSION / CHASSIS DRIVE TRAIN

Body Style Gen IV 4 Wheel Independent Shaft Drive........

Front Suspension MacPherson Strut Gear Reduction-Low 7.49:1.. .

Tow Capacity 1225 lbs. (555.6 kg) Gear Reduction-Rev 5.1:1...... .

Turning Radius 76I (181.61 cm) Gear Reduction-High 2.89:1.....

Toe O u t 1/ 8 I-1/4I (3-6.35 mm) Front Drive Ratio 3.82:1........... ....

Ground Clearance 11I (27.94 cm) Final Drive Ratio 3.10:1.. ....

Front Vertical Travel 6.7I (17.02 cm) Brake (Hand) Single Lever, Hyd. Disc.......

Rear Suspension Progressive Rate Independent Brake (Auxiliary Foot) Hydraulic...

Rear Travel 9.5I (24.13 cm) Transmission Park Lock........

Rear Shock 2I Twin Tube........

Shock Adjustment Cam..

TIRES

TireSize-Front 25x8-12....

Tire Size - Rear 25 x 11 - 12....

Tire Pressure - F /R 5/5 lbs.

Total Width 46I (116.84 cm)........

Total Length 85I (215.9 cm).......

Total Height 47I (119.38 cm)........

Wheel Base 50.75I (128.90 cm).......

Weight - Dry 740 lbs. (335.60 kg).......

LOAD CAPACITY

Front Rack (Std) 90 lbs......

Rear Rack (Std) 180 lbs.......

Tongue Weight 150 lbs.....

Hitch T owing Capacity...1500 lbs.

1.11

PUBLICATION NUMBERS

GENERAL INFORMATIONGENERAL INFORMATION

Year Model Model No. Owner’s

Manual

Parts

Manual PN

PN

2003 Sportsman 600/700 A03CH59 / A03CH68 9918213 9917718 9917719

When ordering service parts be sure to use the correct parts manual.

Parts

Micro Fiche

PN

PAINT CODES

PAINTED PART COLOR

DESCRIPTION

Springs Black 9440 P-067

FRAME COLOR - (All) P067 Medium Gloss Black 9440 / 8520147.
Order direct from Midwest Industrial Coatings (952-942-1840). Mix as directed.

DITZLER

NUMBER

POLARIS

NUMBER

REPLACEMENT KEYS

Replacement keys can be made from the original
key. To identify which series the key is, take the
first two digits on the original key and refer to the
chart to the right for the proper part number.
Should both keys become lost, ignition switch
replacement is required.

31XX

Key Series
Number

Series # Part Number

20 4010278

21 4010278

22 4010321

23 4010321

27 4010321

28 4010321

31 4110141

32 4110148

67 4010278

68 4010278

1.12

GENERAL INFORMATIONGENERAL INFORMATION

STANDARD TORQUE SPECIFICATIONS

The following torque specifications are to be used as a general guideline. There are exceptions in the steering,
suspension, and engine areas. Always consult the exploded views in each manual section for torque values of
fasteners before using standard torque.

Bolt Size Threads/In Grade 2 Grade 5 Grade 8

Torque in. lbs. (Nm)

#10 - 24 27 (3.1) 43 (5.0) 60 (6.9).............. ................ ..............

#10 - 32 31 (3.6) 49 (5.6) 68 (7.8).............. ................ ..............

Torque ft. lbs. (Nm)

1/4 - 20 5 (7) 8 (11) 12 (16).............. .................. ................

1/4 - 28 6 (8) 10 (14) 14 (19).............. .................. ..............

5/16 - 18 11 (15) 17 (23) 25 (35).............. ................ ..............

5/16 - 24 12 (16) 19 (26) 29 (40).............. ................ ..............

3/8 - 16 20 (27) 30 (40) 45 (62).............. ................ ..............

3/8 - 24 23 (32) 35 (48) 50 (69).............. ................ ..............

7/16 - 14 30 (40) 50 (69) 70 (97).............. ................ ..............

7/16 - 20 35 (48) 55 (76) 80 (110).............. ................ ..............

1/2 - 13 50 (69) 75 (104) 110 (152).............. ................ .............

1/2 - 20 55 (76) 90 (124) 120 (166).............. ................ .............

*

Metric

6 x 1.0 72-78 In. lbs.
8 x 1.25 14-18 ft. lbs.
10 x 1.25 26-30 ft. lbs.

*To convert ft. lbs. to Nm multiply foot pounds by .1.382
*To convert Nm to ft. lbs. multiply Nm by .7376.

SPECIFIC TORQUE VALUES OF FASTENERS

Refer to exploded views in the appropriate section.

1.13

DECIMAL EQUIVALENTS

1/64 .0156.........................

1/32 .0312 1 mm = .0394²................... ................

3/64 .0469.........................

1/16 .0625..............

5/64 .0781 2 mm = .0787²......................... ................

3/32 .0938...................

7/64 .1094 3 mm = .1181²....................... ................

1/8 . 1250. .......

9/64 .1406.........................

5/32 .1563 4 mm = .1575²................... ................

11/64 .1719........................

3/16 .1875 5 mm = .1969².............. ................

13/64 .2031........................

7/32 .2188...................

15/64 .2344 6 mm = .2362²........................ ................

1/4 .25..........

17/64 .2656 7 mm = .2756²........................ ................

9/32 .2813...................

19/64 .2969........................

5/16 .3125 8 mm = .3150².............. ................

21/64 .3281........................

11/32 .3438 9 mm = .3543².................. ................

23/64 .3594........................

3/8 .375..........

25/64 .3906 10 mm = .3937²........................ ................

13/32 .4063..................

27/64 .4219 11 mm = .4331²........................ ................

7/16 .4375..............

29/64 .4531........................

15/32 .4688 12 mm = .4724².................. ................

31/64 .4844........................

1/2 .5 13 mm = .5118.......... ...................

33/64 .5156........................

17/32 .5313..................

35/64 .5469 14 mm = .5512²........................ ................

9/16 .5625..............

37/64 .5781 15 mm = .5906²........................ ................

19/32 .5938..................

39/64 .6094........................

5/8 .625 16 mm = .6299².......... .................

41/64 .6406........................

21/32 .6563 17 mm = .6693².................. ................

43/64 .6719.......................

11/16 .6875.............

45/64 .7031 18 mm = .7087²........................ ................

23/32 .7188..................

47/64 .7344 19 mm = .7480²........................ ................

3/4 .75..........

49/64 .7656........................

25/32 .7813 20 mm = .7874².................. ................

51/64 .7969........................

13/16 .8125 21 mm = .8268²............. ................

53/64 .8281........................

27/32 .8438..................

55/64 .8594 22 mm = .8661²........................ ................

7/8 .875..........

57/64 .8906 23 mm = .9055²........................ ................

29/32 .9063..................

59/64 .9219.......................

15/16 .9375 24 mm = .9449²............. ................

61/64 .9531........................

31/32 .9688 25 mm = .9843.................. ................

63/64 .9844........................

11.0............

GENERAL INFORMATIONGENERAL INFORMATION

1.14

GENERAL INFORMATIONGENERAL INFORMATION

CONVERSION TABLE

Unit of Measure Multiplied by Converts to

ft. lbs. x12 =in.lbs.

in. lbs. x .0833 = ft. lbs.

ft. lbs. x 1.356 =Nm

in. lbs. x .0115 =kg-m

Nm x .7376 = ft.lbs.

kg-m x 7.233 = ft. lbs.

kg-m x 86.796 =in.lbs.

kg-m x10 =Nm

in. x 25.4 =mm

mm x .03937 =in.

in. x2.54 =cm

mile (mi.) x1.6 =km

km x .6214 = mile (mi.)

Ounces (oz) x 28.35 = Grams (g)

Fluid Ounces (fl. oz.) x 29.57 = Cubic Centimeters (cc)

Cubic Centimeters (cc) x .03381 = Fluid Ounces (fl. oz.)

Grams (g) x 0.035 = Ounces (oz)

lb. x .454 =kg

kg x 2.2046 =lb.

Cubic inches (cu in) x 16.387 = Cubic centimeters (cc)

Cubic centimeters (cc) x 0.061 = Cubic inches (cu in)

Imperial pints (Imp pt) x 0.568 = Liters (l)

Liters (l) x1.76 = Imperial pints (Imp pt)

Imperial quarts (Imp qt) x 1.137 = Liters (l)

Liters (l) x0.88 = Imperial quarts (Imp qt)

Imperial quarts (Imp qt) x 1.201 = US quarts (US qt)

US quarts (US qt) x 0.833 = Imperial quarts (Imp qt)

US quarts (US qt) x 0.946 = Liters (l)

Liters (l) x 1.057 = US quarts (US qt)

US gallons (US gal) x 3.785 =Liters (l)

Liters (l) x 0.264 = US gallons (US gal)

Pounds - force per square inch (psi) x 6.895 = Kilopascals (kPa)

Kilopascals (kPa) x 0.145

Kilopascals (kPa) x0.01 = Kilograms - force per square cm

Kilograms - force per square cm x 98.1 = Kilopascals (kPa)

p (3.14) xR2x H (height) = Cylinder Volume

= Pounds - force per square inch (psi)

°Cto°F: 9 (°C + 40) ¸ 5-40=°F
°Fto°C: 5 (°F + 40) ¸ 9-40=°C

1.15

GENERAL INFORMATIONGENERAL INFORMATION

SAE TAP DRILL SIZES

Thread Size Drill Size Thread Size Drill Size

#0-80 3/64
#1-64 53
#1-72 53
#2-56 51
#2-64 50
#3-48 5/64
#3-56 45
#4-40 43
#4-48 42
#5-40 38
#5-44 37
#6-32 36
#6-40 33
#8-32 29
#8-36 29
#10-24 24
#10-32 21
#12-24 17
#12-28 4.6mm
1/4-20 7
1/4-28 3
5/16-18 F
5/16-24 I
3/8-16 O
3/8-24 Q
7/16-14 U
7/16-20 25/64

1/2-13 27/64
1/2-20 29/64
9/16-12 31/64
9/16-18 33/64
5/8-11 17/32
5/8-18 37/64
3/4-10 21/32
3/4-16 11/16
7/8-9 49/64
7/8-14 13/16
1-8 7/8
1-12 59/64
1 1/8-7 63/64
1 1/8-12 1 3/64
11/4-7 17/64
1 1/4-12 1 11/64
11/2-6 111/32
1 1/2-12 1 27/64
13/4-5 19/16
1 3/4-12 1 43/64
2-4 1/2 1 25/32
2-12 1 59/64
2 1/4-4 1/2 2 1/32
21/2-4 21/4
23/4-4 21/2
3-4 2 3/4

METRIC TAP DRILL SIZES

Tap Size Drill Size Decimal Equivalent Nearest Fraction

3x.50
3x.60
4x.70
4x.75
5x.80
5x.90
6 x 1.00
7 x 1.00
8 x 1.00
8 x 1.25
9 x 1.00
9 x 1.25
10 x 1.25
10 x 1.50
11 x 1.50
12 x 1.50
12 x 1.75

#39
3/32
#30
1/8
#19
#20
#9
16/64
J
17/64
5/16
5/16
11/32
R
3/8
13/32
13/32

1.16

0.0995

0.0937

0.1285

0.125

0.166

0.161

0.196

0.234

0.277

0.265

0.3125

0.3125

0.3437

0.339

0.375

0.406

0.406

3/32
3/32
1/8
1/8
11/64
5/32
13/64
15/64
9/32
17/64
5/16
5/16
11/32
11/32
3/8
13/32
13/32

GENERAL INFORMATIONGENERAL INFORMATION

GLOSSARY OF TERMS

ABDC: After bottom dead center.
ACV: Alternating current voltage.
Alternator: Electrical generator producing alternating current voltage.
ATDC: After top dead center.
BBDC: Before bottom dead center.
BDC: Bottom dead center.
BTDC: Before top dead center.
CC: Cubic centimeters.
Center Distance: Distance between center of crankshaft and center of driven clutch shaft.
Chain Pitch: Distance between chain link pins (No. 35 = 3/8² or 1 cm). Polaris measures chain length in number of

pitches.

CI: Cubic inches.
Clutch Buttons: Plastic bushings which transmit rotation of the clutch to the movable sheave in the drive and driven

clutch.
Clutch Offset: Drive and driven clutches are offset so that drive belt willstay nearly straight as it movesalong theclutch

faces.
Clutch Weights: Three levers in the drive clutch which relative to their weight, profile and engine RPM cause the drive

clutch to close.

Condenser/Capacitor: A storage reservoir for DC voltage.
Crankshaft Run-Out: Run-out or “bend” of crankshaft measured with a dial indicator while crankshaft is supported

between centers on V blocks or resting in crankcase. Measure at various points especially at PTO end.

DCV: Direct current voltage.
Dial Bore Gauge: A cylinder measuring instrument which uses a dial indicator. Good for showing taper and

out-of-round in the cylinder bore.

Electrical Open: Open circuit. An electrical circuit which isn’t complete.
Electrical Short: Short circuit. An electrical circuit which is completed before the current reaches the intended load.

(i.e. a bare wire touching the chassis).

End Seals: Rubber seals at each end of the crankshaft.
Engagement RPM: Engine RPM at which the drive clutch engages to make contact with the drive belt.
ft.: Foot/feet.
Foot Pound: Ft. lb. A force of one pound at the end of a lever one foot in length, applied in a rotational direction.
g: Gram. Unit of weight in the metric system.
gal.: Gallon.
HP: Horsepower.
ID: Inside diameter.
in.: Inch/inches.
Inch Pound: In. lb. 12 in. lbs. = 1 ft. lb.

2

kg/cm
kg-m: Kilogram meters.
Kilogram/meter: A force of one kilogram at the end of a lever one meter in length, applied in a rotational direction.
lorltr: Liter.

lbs/in
Left Side: Always referred to based on normal operating position of the driver.

: Kilograms per square centimeter.

2

: Pounds per square inch.

1.17

GENERAL INFORMATIONGENERAL INFORMATION

GLOSSARY OF TERMS

m: Meter/meters.
Mag: Magneto.
Magnetic Induction: As a conductor (coil) is moved through a magnetic field, a voltage will be generated in the

windings. Mechanical energy is converted to electrical energy in the stator.

mi.: Mile/miles.
mm: Millimeter. Unit of length in the metric system. 1mm = approximately .040².
Nm: Newton meters.
OD: Outside diameter.
Ohm: The unit of electrical resistance opposing current flow.
oz.: Ounce/ounces.
Piston Clearance: Total distance between piston and cylinder wall.
psi.: Pounds per square inch.
PTO: Power take off.
PVT: Polaris Variable Transmission (Drive Clutch System)
qt.: Quart/quarts.
Regulator: Voltage regulator. Regulates battery charging system output at approx. 14.5 DCV as engine RPM

increases.

Reservoir Tank: The fill tank in the liquid cooling system.
Resistance: In the mechanical sense,friction orload. In the electrical sense, ohms. Both result in energy conversion to

heat.

Right Side: Always referred to based on normal operating position of the driver.
RPM: Revolutions per minute.
Secondary Clutch: Driven clutch on chaincase or jackshaft.
SeizedPiston: Galling of the sides of apiston. Usually there is a transfer ofaluminum from the piston onto thecylinder

wall. Possible causes: 1) improper lubrication; 2) excessive temperatures; 3) insufficient piston clearance; 4) stuck
piston rings.

Stator Plate: The plate mounted under the flywheel supporting the battery and ignition charging coils.
TDC: Top dead center. Piston’s most outward travel from crankshaft.
Vol t: The unit of measure for electrical pressure of electromotive force. Measured by a voltmeter in parallel with the

circuit.

Watt: Unit of electrical power. Watts = amperes x volts.
WOT: Wide open throttle.

1.18