Polaris Sportsman 400 & Sportsman 500 H.O. ATV Comprehensive Service & Repair Manual (2003)
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Sample pages from the Polaris Sportsman 400 & Sportsman 500 H.O. ATV Comprehensive Service & Repair Manual (2003) manual
Purchase Information
Technical Specifications
- Document Number / Seller:
- 31999 / Jennifer Mason
- File Size:
- 7.51 MB
- File Type:
- Language:
- English
- Pages:
- 269
- Printable:
- Yes
- Estimated Download Time:
- 0.15 Minutes
- Delivery Format:
- Digital (PDF) - Instant Access
- Category:
- ATV
- Brand:
- Polaris
- Reviewed and Approved:
- Dec 29, 2025
Polaris Models and Parts Covered in this ATV Manual
- Polaris Sportsman 400 (2003)
- Polaris Sportsman 500 H.O. (2003)
- Polaris Sportsman 400 A03CH42 (2003)
- Polaris Sportsman 500 A03CH50 (2003)
- Polaris Sportsman 400 Early Build (2003)
Complete Manual Information
Polaris Sportsman 400 & 500 H.O. ATV Service Manual (2003)
Upgrade your garage with the definitive professional-grade service manual for the 2003 Polaris Sportsman series. This comprehensive guide is specifically designed for the Sportsman 400 and the high-output Sportsman 500 H.O. models. Whether you are performing a simple oil change or a complete engine rebuild, this manual provides the exact factory specifications and step-by-step procedures required to keep your ATV trail-ready.
This manual is an essential resource for owners of the following 2003 models:
- Polaris Sportsman 400 A03CH42 (2003)
- Polaris Sportsman 500 H.O. A03CH50 (2003)
- Polaris Sportsman 400 Early Build (2003)
- Polaris Sportsman 400 Late Build (2003)
Complete Technical Mastery
Don't guess when it comes to your engine's health. This manual includes deep-dive technical data for both the EH42PLE05 (400cc) and EH50PLE13 (500cc) engines.
- Precise Engine Specs: Coverage includes everything from the 9.2:1 compression ratio of the 400 to the 10.2:1 full-stroke ratio of the 500 H.O.
- Carburetor Calibration: Specific jetting charts for the Mikuni BST 34 and BST 40 carburetors, ensuring your Sportsman runs perfectly at any altitude or temperature.
- PVT System: Detailed maintenance for the Polaris Variable Transmission, including belt replacement (Part No. 3211069) and clutch offset adjustments.
Advanced Maintenance & Troubleshooting
Go beyond the basics with specialized chapters that cover the entire vehicle architecture:
- Electrical Systems: Full wiring diagrams for both Early and Late Build 400 models, plus stator tests and ignition timing specs (30 degrees BTDC at 5000 RPM).
- Final Drive & AWD: Maintenance procedures for the Demand Drive hubs and front gearcase, including the exact fluid capacities (2.5 oz for hubs).
- Suspension & Chassis: Complete torque patterns for the Gen IV body style and MacPherson Strut front suspension.
Identification & Serial Numbers
Keep your records accurate. This manual provides clear instructions on locating every critical number on your machine:
- Machine Serial Number: Stamped on the lower left side of the frame tube.
- Engine Serial Number: Located on the sticker on the recoil housing (right side) and stamped on the center top of the crankcase.
- Transmission I.D.: Found on top of the transmission snorkel, right side.
Detailed Chapter Breakdown
- Chapter 1: General Information - VIN identification, paint codes, and standard torque specs.
- Chapter 2: Maintenance - Periodic maintenance charts and pre-ride inspection checklists.
- Chapter 3: Engine - Comprehensive top and bottom end disassembly for EH42 and EH50 engines.
- Chapter 4: Fuel System - Carburetor cleaning, fuel pump testing, and tank venting.
- Chapter 5: Body/Suspension - Strut assembly and independent rear suspension service.
- Chapter 6: PVT System - Drive and driven clutch operation and troubleshooting.
- Chapter 7: Final Drive - AWD magnetic coil service and U-joint assembly.
- Chapter 8: Transmission - Gear shift selector box repair and snorkel assembly.
- Chapter 9: Brakes - Hydraulic caliper bleeding and pad wear limits (3/64" minimum).
- Chapter 10: Electrical - Speedometer troubleshooting and battery activation.
This manual is optimized for quick reference and professional accuracy, ensuring that every repair on your 2003 Sportsman is done right the first time.
Download Instructions for Polaris ATV Manual
Frequently Asked Questions - Polaris ATV Manual
Is this manual suitable for beginners?
Yes, this Polaris manual is designed for both professional technicians and DIY enthusiasts. It includes step-by-step procedures with clear illustrations and safety guidelines for ATV maintenance and repair.
What file format will I receive?
You will receive this manual as a PDF file (7.51 MB), which is compatible with all devices. The manual is fully searchable and printable for your convenience.
How quickly can I access the manual after purchase?
You'll receive instant access to your Polaris ATV manual immediately after payment completion. The download link is valid for 3 days, with lifetime re-download guarantee.
Can I print specific sections of the manual?
Absolutely! This digital manual allows you to print any section you need, from individual pages to complete chapters, making it perfect for workshop use.
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