2003 Polaris Sportsman 400 / Sportsman 500 H.O. Service Manual
Complete 2003 Polaris Sportsman 400 & 500 H.O. ATV service and repair manual. Covers engine, fuel system, clutch, and more. Ref: A03CH42/A03CH50
Manual Preview
Sample pages from the 2003 Polaris Sportsman 400 / Sportsman 500 H.O. Service Manual manual
Purchase & Download
Models Covered & Key Technical Specifications
Polaris Sportsman 400 & Sportsman 500 H.O. (2003) (A03CH42/A03CH50) This comprehensive workshop manual provides essential service and repair data.
- Reference Power Framework: 200 Watts provides the maximum output capacity for the electrical system.
- Specific Operating Temps: For optimal performance, ambient temperatures between +40 and +80 F are recommended for the carburetor.
- Essential Cycle Rate: The engine operates at 6300 RPM for standard performance levels in the Sportsman 400 model.
- Baseline Package Size: Displacement measures 425 cc for the Sportsman 400 engine, contributing to its power output.
- Established Moment Values: The drive clutch retaining bolt requires 40 ft. lbs. to ensure proper torque.
- Integral General Specifications: The transmission mounting bolts require 25 ft. lbs. to secure the assembly effectively.
Professional Workshop Service Manual & Technical Specifications
In-Depth Workshop Safety Manual: Polaris Sportsman 400 & Sportsman 500 H.O. ATV Comprehensive Service & Repair Manual (2003) Logic-Archive
Product-Line: Complete Repair Procedures // Technical-Domain: ATV Mechanics / Drivetrain Logic // Diagnostic-Area: Component Level Troubleshooting.
| Integrated-Framework | Rating | Architecture |
|---|---|---|
| Electrical System | 200 Watts | Alternator Output |
| Engine Displacement | 425 cc | Sportsman 400 |
| Torque Specifications | 40 ft. lbs. | Drive Clutch Retaining Bolt |
| Transmission Mounting Bolts | 25 ft. lbs. | Secure Assembly |
| Drive Belt Width | 1.188 inches | Original Equipment Spec |
| Fuel Tank Capacity | 5.25 Gallons | Standard Volume |
Repair procedures are structured around the following chapters:
- Engine:
- Fuel System/Carburetion
- Clutch: PVT System
- Final Drive: AWD Operation
- Body/Steering/Suspension
- Transmission
This service manual details all systems and procedures necessary for the maintenance and repair of your Polaris Sportsman 400 and 500 H.O. ATV. Careful establishing of specifications ensures correct assembly and long-term operational integrity. Procedures cover engine, fuel, clutch, drive axle, and transmission systems.
FAQ
Customer Reviews
Read what our customers say about this Polaris ATV manual and share your own experience.
Add a Review
This policy contains information about your privacy. By posting, you are declaring that you understand this policy:
- Your name, rating, website address, town, country, state and comment will be publicly displayed if entered.
- Aside from the data entered into these form fields, other stored data about your comment will include:
- Your IP address (not displayed)
- The time/date of your submission (displayed)
- Your email address will not be shared. It is collected for only two reasons:
- Administrative purposes, should a need to contact you arise.
- To inform you of new comments, should you subscribe to receive notifications.
- A cookie may be set on your computer. This is used to remember your inputs. It will expire by itself.
This policy is subject to change at any time and without notice.
These terms and conditions contain rules about posting comments. By submitting a comment, you are declaring that you agree with these rules:
- Although the administrator will attempt to moderate comments, it is impossible for every comment to have been moderated at any given time.
- You acknowledge that all comments express the views and opinions of the original author and not those of the administrator.
- You agree not to post any material which is knowingly false, obscene, hateful, threatening, harassing or invasive of a person's privacy.
- The administrator has the right to edit, move or remove any comment for any reason and without notice.
Failure to comply with these rules may result in being banned from submitting further comments.
These terms and conditions are subject to change at any time and without notice.
Reviews (1)