Atv Segment:
Mid-size utility ATV, known for balance of performance and affordability.
Competitors:
Competed with models from Yamaha (Grizzly 400), Honda (FourTrax 400), and Kawasaki (Bayou 400).
Versatility:
Designed for recreational riding, light utility work, and trail riding.
Reliability:
Polaris is generally recognized for durable powertrain and chassis components.
Parts Availability:
This manual ensures owners and technicians can source the correct, genuine Polaris parts for maintenance and repair.
Primary Focus:
Parts identification and cataloging
Scope:
All components for specified models
Estimated Pages:
Varies (Typical parts manuals are 200-400+ pages, specific count not provided in product info)
Type:
Parts Manual / Parts Catalog
Engine Assembly:
Detailed breakdown of engine components, including cylinder head, piston, crankshaft, camshaft, valve train, lubrication system, and cooling system parts.
Drivetrain:
Exploded views and part numbers for the transmission, differential, drive shafts, axles, and CV joints.
Suspension And Steering:
Components for front and rear suspension (shocks, springs, control arms, bushings), steering linkage, tie rods, and steering column parts.
Brake Components:
Parts for front and rear brake assemblies, including calipers, rotors, brake pads, master cylinders, and brake lines.
Wiring And Components:
Diagrams and part numbers for starter, alternator, battery, ignition system components, lighting, switches, and wiring harnesses.
Fuel Delivery:
Parts for fuel tank, fuel pump, fuel filter, carburetor or fuel injection components.
Exhaust Components:
Exhaust manifold, pipes, muffler, and mounting hardware.
Frame And Panels:
Frame components, body panels (fenders, plastics), seats, handlebars, racks, and associated hardware.
Wheel Assembly:
Wheels, tires, lug nuts, and valve stems.
Part Identification:
Crucial for identifying correct replacement parts using diagrams and OEM part numbers.
Assembly Disassembly Order:
Implied through exploded views, guiding the sequence of part installation and removal.
Component Relationship:
Illustrates how different parts fit together within a system.
Level Of Detail:
High - Provides OEM part numbers, illustrations, and relationships between components, essential for accurate ordering and repair.
Utility:
Primarily for parts sourcing, inventory management, and visual reference during repair.
Type:
4-stroke, SOHC, Liquid-Cooled
Displacement:
375cc (approx.)
Bore X Stroke:
Specifics found within the manual's engine section.
Compression Ratio:
Specifics found within the manual's engine section.
Horsepower:
Estimated 25-30 HP (typical for this class and displacement).
Torque:
Specifics found within the manual's engine section.
Carburetion:
Typically a Mikuni carburetor (e.g., VM34) or a Keihin CVK. Specific model and jetting detailed in the manual.
Oil Type:
SAE 10W-40 motorcycle-specific synthetic or conventional oil is commonly recommended.
Oil Capacity:
Specific capacity detailed in the maintenance section of a comprehensive service manual; parts manual won't list this.
System:
Liquid-cooled with a radiator and fan.
Type:
Automatic Transmission (PVT - Polaris Variable Transmission)
Drive System:
Shaft Drive (2WD or AWD models available, likely 4WD for Sportsman)
Gearbox:
High/Low range with Reverse.
Clutch:
CVT belt drive system.
Transmission Fluid:
Specific Polaris AGL (Arctic Gear Lubricant) or equivalent is typically used in the transmission/gearcase. CVT cover gasket and belt are key parts identified.
Length:
Approx. 81 in. (205.7 cm)
Width:
Approx. 46 in. (116.8 cm)
Height:
Approx. 47 in. (119.4 cm)
Wheelbase:
Approx. 50.5 in. (128.3 cm)
Front Rack Capacity:
Approx. 100 lbs (45.4 kg)
Rear Rack Capacity:
Approx. 200 lbs (90.7 kg)
Dry Weight:
Approx. 620 lbs (281 kg)
Towing Capacity:
Up to 1,050 lbs (476 kg)
Front Tire Size:
25 x 8-12
Rear Tire Size:
25 x 10-12
Wheel Bolt Pattern:
Standard 4x110mm (confirm specific for model within manual if needed for aftermarket wheels).
Atv Safety Standards:
Designed to meet ANSI standards for recreational ATVs.
Braking System:
Hydraulic disc brakes front and rear.
Engine Braking:
Standard feature on PVT system for downhill control.
Lighting:
Headlights, taillight, and brake light for visibility.
Ergonomics:
Handlebar grips, throttle control, and braking levers designed for rider control.
Oil Change:
Typically every 20-50 operating hours or annually. Specific interval detailed in the service manual.
Air Filter:
Inspect and clean/replace every 20-40 operating hours. Manual will specify part number.
Spark Plug:
Inspect and gap every 50-100 operating hours. Manual will specify part number and gap.
Transmission Fluid:
Change annually or per operating hour recommendation (e.g., 100 hours). Specifics in service manual.
Engine Oil Spec:
SAE 10W-40 motorcycle-specific oil.
Coolant Type:
Ethylene glycol-based antifreeze (e.g., Polaris specific or equivalent universal type).
Brake Fluid Type:
DOT 3 or DOT 4 hydraulic brake fluid.
Cv Boots:
A common wear item on many ATVs; the manual will list replacement part numbers.
Belt Wear:
CVT belts can wear and stretch over time, affecting performance. The manual provides the correct belt part number.
Carburetor Cleaning:
Carburetors can become clogged with debris or fuel varnish, especially if the ATV sits for extended periods. Manual identifies jets and components.
Polaris Industries:
Polaris has a long history dating back to 1954, initially known for snowmobiles, expanding significantly into ATVs and powersports.
Sportsman Line:
The Sportsman line has been a cornerstone of Polaris's ATV offerings, evolving from its introduction to represent a versatile utility platform.
Manufacturing Location:
Polaris vehicles are primarily manufactured in the USA, including facilities in Minnesota and Iowa.
2003 Model Year:
The 2003 Sportsman 400 was a well-received model, offering a good blend of features and capability for its price point.
