2003 Polaris Sportsman 400 500 & Parts Workshop Service Repair Manual Download PDF

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🏷️ Basic Information Identification Make: Polaris Model: Sportsman Year: 2003 Generation: 3rd Generation (2000-2004) 📋 Manual Details Publication Manual Type: Workshop Service Repair Manual Language: English Format: Download PDF Content...

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Sku: 44160

Tags: 2003 ATV Misc Polaris Powersports Sportsman 400 Sportsman 500

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Description

🏷️ Basic Information

Identification

Make:

Polaris

Model:

Sportsman

Year:

Generation:

3rd Generation (2000-2004)

📋 Manual Details

Publication

Manual Type:

Workshop Service Repair Manual

Language:

English

Format:

Download PDF

Content

Scope:

Service, Repair, and Parts

⚙️ Engine Specifications

Engine 400

Engine Type:

4-stroke Single-cylinder

Displacement:

375 cc

Bore X Stroke:

88 mm x 62 mm

Cooling System:

Liquid Cooled

Engine 500

Engine Type:

4-stroke Single-cylinder

Displacement:

499 cc

Bore X Stroke:

92 mm x 76 mm

Cooling System:

Liquid Cooled

Carburetion

Carburetor 400:

Mikuni BNS34

Carburetor 500:

Mikuni BNS40

🔧 Transmission

Drivetrain

Type:

Automatic PVT (Polaris Variable Transmission)

Drive Modes:

2WD/4WD

Final Drive:

Shaft Drive

🔧 Maintenance

Lubrication

Engine Oil Type:

SAE 10W-40 Synthetic

Engine Oil Capacity:

2.1 L (2.2 US qt)

Transmission Oil Type:

SAE 80W-90 Gear Oil

Transmission Oil Capacity:

0.24 L (0.25 US qt)

Intervals

Initial Engine Oil Change:

10 hours or 1 month

Regular Engine Oil Change:

20 hours or 3 months

Air Filter Cleaning:

Every 20 hours

Spark Plug Inspection:

Every 40 hours

📄 Chassis And Suspension

Suspension

Front Suspension Type:

MacPherson Strut

Rear Suspension Type:

Independent Rear Suspension (IRS) with Dual A-Arms

Front Wheel Travel:

7 in (17.8 cm)

Rear Wheel Travel:

9.5 in (24.1 cm)

📄 Brakes

Braking System

Front Brake Type:

Hydraulic Disc

Rear Brake Type:

Sealed Hydraulic Disc

📄 Wheels And Tires

Wheel Size

Front Wheel Size:

12 in

Rear Wheel Size:

12 in

Tire Size

Front Tire Size:

AT25x8-12

Rear Tire Size:

AT25x11-12