Bombardier Service Manual: Outlander 400 & 400 XT ATV, PDF (2003)
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Sample pages from the Bombardier Service Manual: Outlander 400 & 400 XT ATV, PDF (2003) manual
Purchase Information
2003 Bombardier Outlander 400 & 400 XT ATV Shop Manual - PDF - Technical Specifications
- Document Number / Seller:
- 24593 / Michael Hicks
- File Size:
- 20.05 MB
- File Type:
- ZIP
- Language:
- English
- Pages:
- 358
- Printable:
- Yes
- Estimated Download Time:
- 0.41 Minutes
- Delivery Format:
- Digital (PDF) - Instant Access
- Category:
- ATV
- Brand:
- Bombardier
- Reviewed and Approved:
- Dec 24, 2025
Bombardier Models and Parts Covered in this ATV Manual
Outlander 400 / Bombardier Recreational Products Inc
- Outlander 400 (2003)
- Outlander 400 XT (2003)
Complete Manual Information
2003 Bombardier Outlander 400 & 400 XT ATV Service Manual - Digital PDF
Master Your Maintenance with the Professional-Grade 2003 Outlander Series Shop Manual
Maintain, diagnose, and repair your vehicle with absolute confidence using the original factory service manual for the 2003 Bombardier Outlander 400 series. This is not a generic aftermarket guide; it is the comprehensive, 358-page technical resource used by authorized dealership technicians. Designed for both the dedicated DIY enthusiast and professional mechanics, this manual provides clear, step-by-step instructions paired with high-resolution diagrams to ensure your 4x4 performs at its peak.
Detailed Model Coverage
This manual is specifically engineered for the 2003 model year and covers the following 400cc 4-TEC models:
- Outlander 400 (Standard): The foundation of the series, featuring the innovative Rotax 4-TEC engine and SST frame.
- Outlander 400 XT: The premium equipment package including factory-installed winch, heavy-duty bumpers, and specialized tires.
Identification and Serial Numbers: To ensure you are using the correct technical data for your specific unit, this manual identifies crucial serial number locations:
- Vehicle Identification Number (VIN): Located on the frame under the seat or on the front cross member.
- Engine Identification Number (EIN): Stamped directly on the engine crankcase for precise engine part matching.
- Model Designations: Specifically covers 2003 series models 7535, 7734, 7716, and 7735.
Engineered for Excellence
The 2003 Outlander 400 was a pioneer in the ATV industry, introducing the revolutionary Surround Spar Technology (SST) frame and the Trailing Torsional Independent (TTI) rear suspension. This manual provides the specialized knowledge required to service these unique systems, including:
- Expert Troubleshooting: Factory-standard flowcharts to isolate engine, electrical, and drive system issues quickly.
- Rotax 400 4-TEC Engine: Full teardown and assembly instructions, including critical valve clearance specs (Exhaust: 0.10–0.18 mm; Intake: 0.05–0.13 mm).
- Drivetrain Precision: Detailed procedures for the CVT transmission, including belt replacement, pulley alignment, and maintenance.
Comprehensive Table of Contents
- 01 Service Tools & Products: Essential equipment and specialized lubricants.
- 02 Maintenance: Official service schedules and preseason preparation guides.
- 03 Engine: Comprehensive mechanical data for the 400cc liquid-cooled engine.
- 04 Fuel System: Carburetor adjustments, fuel pump testing, and tank removal.
- 05 Electrical System: Battery, charging system, and ignition coil diagnostic tests.
- 06 Drive System: Service for front/rear differentials and the constant variable transmission.
- 07 Steering System: Steering column service and toe-out alignment specs (0 mm +/- 2 mm).
- 08 Suspension: Detailed guides for MacPherson front struts and TTI rear suspension.
- 09 Brakes: Hydraulic system bleeding and master cylinder rebuild instructions.
- 10 Body & Frame: Plastic component removal and SST frame inspection points.
- 11 Technical Data: Full torque specification charts and fluid capacities.
- 12 Wiring Diagrams: High-resolution, color-coded schematics for the entire vehicle.
Product Specifications
- Format: High-Quality Digital PDF (Fully Searchable & Printable)
- Mobile Optimized: Perfect for use on smartphones, tablets, and laptops in the garage.
- Page Count: 358 Technical Pages.
- Language: US English.
Ensure your 2003 Outlander 400 continues to deliver the power and reliability it was built for. Download the factory-spec service manual today and get the job done right the first time.
Download Instructions for Bombardier ATV Manual
Frequently Asked Questions - Bombardier ATV Manual
What does this Bombardier manual cover?
This comprehensive service manual covers detailed repair procedures, maintenance schedules, troubleshooting guides, and technical specifications for Bombardier Service Manual: Outlander 400 & 400 XT ATV, PDF (2003). It includes information for the following models: **Outlander 400 / Bombardier Recreational Products Inc** - Outlander 400 (2003) - Outlander 400 XT (2003).
Is this manual suitable for beginners?
Yes, this Bombardier 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 ZIP file (20.05 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 Bombardier 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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