Polaris SPORTSMAN 400 2003 User manual

PN 9918065
Printed in USA
2003 SPORTSMAN 400 / 500 SERVICE MANUAL PN 9918065
2003 SPORTSMAN 400 / 500
SERVICE MANUAL
PN 9918065
The Way Out.
218444_cover 6/27/02 7:12 AM Page 1

2003 SPORTSMAN 400/500
SERVICE MANUAL
Foreword
This manual is designed primarily for use by Polaris ATV service technicians in a properly equipped shop.
Persons using this manual should have a sound knowledge of mechanical theory, tool use, and shop proce-
dures in order to perform the work safely and correctly. The technician should read the text and be familiar
with service procedures before starting the work. Certain procedures require the use of special tools. Use
onlytheproper tools, as specified. Cleanlinessofpartsandtoolsaswellastheworkareaisofprimaryimpor-
tance.
All references to left and right side of the vehicle are from the operator’s perspective when seated in anormal
riding position.
This manualincludes proceduresformaintenanceoperations, componentidentificationandunitrepair,along
with service specifications for the 2003 Polaris Sportsman ATVs. A table of contents is placed at the
beginningof eachchapter,andanalphabetic index is providedat theendof themanualforlocationofspecific
page numbers and service information. Keep this manual available for reference in the shop area.
At the time of publication all information contained in this manual was technically correct. However, all
materials and specifications are subject to change without notice.
Comments or suggestions about this manual may be directed to: Polaris Sales Inc., Service Publications
Department, 2100 Hwy 55 Medina, Minnesota 55340.
2003 Sportsman 400/500 ATV Service Manual (PN 9918065)
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 improcvements 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 ommisions 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.
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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 tofollowDANGER instructionswillresult insevereinjuryordeathtotheoperator,bystanderorperson
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
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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
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