Name: Polaris SPORTSMAN 400 2003 Service manual
Brand: Polaris
Rating: 5 (1 reviews)

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4. Table of Contents
7. GENERAL INFORMATION
8. General information
13. Publication Numbers
14. Standard Torque Specifications
15. Decimal equivalents
16. Conversion Table
17. Decimal Equivalent Chart
18. Glossary of Terms
21. Periodic Maintenance Chart
22. Pre-Ride Inspection
23. MAINTENANCE
25. Special Tools
28. Transmission Lubrication
29. TRANSMISSION
31. Idle speed adjustment
32. MAINTENANCE
33. Fuel filter
34. Compression Test
35. ELECTRICAL
36. Liquid cooling system overview
37. Coolant level inspection
38. Air Box Sediment Tube Service
39. Breather Filter
40. Oil Change/Filter
42. Valve Clearance
43. Exhaust valve clearance adjustment
44. Camber and caster
46. Exhaust pipe
47. Brake pad inspection
48. Controls
49. Wheel Removal/Installation
50. Tire Inspection
53. Torque Specifications
54. Engine service data
56. ENGINE FASTENER TORQUE PATTERNS
57. Cooling system
58. Cooling System Specifications
59. Engine Installation Notes
60. Honing to oversize
61. Oil pressure test
63. Eh50pl oil flow diagram
64. EH50PL Engine Exploded View
66. Cam chain tensioner inspection
69. Automatic compression release installati...
72. Cylinder head inspection
73. Valve inspection
74. Valve seat reconditioning
77. Cylinder head assembly
79. Piston removal
80. Cylinder inspection
81. Piston/rod inspection
82. Crankcase disassembly
84. Crankcase separation
85. Oil pump removal/inspection
86. Oil pump assembly
87. Crankshaft removal/inspection
88. Crankcase bearing inspection
89. Bearing installation
91. Oil pump shaft end play adjustment
92. Pump shaft oil seal installation
93. Water pump mechanical seal installation
94. One way valve installation
95. Piston ring installation
96. Cylinder installation
97. Cylinder head installation
100. Cam chain tensioner installation
101. Thermostat installation
102. Oil pipes
103. Recoil assembly
104. Spark Plug Fouling Checklist
109. Fuel Flow Diagram
110. Carburetor Jetting
111. CV Carburetor System Function (4 Cycle)
113. Float system
114. Carburetor cleaning
116. Float height adjustment
117. NEEDLE AND SEAT LEAKAGE TEST
118. Fuel pump disassembly
119. Troubleshooting
121. Cover/Panel Removal
122. Side Panel Removal
123. BODY ASSEMBLY EXPLODED VIEW
124. Headlight Pod Exploded View
125. Steering Assembly, Exploded View
126. A-Arm Replacement
127. Rear Suspension Assembly
128. Strut assembly
129. Front Strut Cartridge Replacement
130. Steering Post Assembly
132. PVT SYSTEM
133. Drive clutch operation
134. PVT Maintenance/Inspection
136. PVT Disassembly
137. PVT Assembly
138. PVT Sealing and Ducting Components
139. Drive clutch spring specifications
140. Shift Weights
141. Drive Clutch Inspection
142. Spider removal
143. DRIVE CLUTCH REASSEMBLY
144. Drive Belt Tension
145. Drive Belt Removal/Inspection
146. Drive Belt Installation
147. Clutch Alignment /Offset
148. Drive Clutch Bushing Service
150. Driven Clutch Disassembly/Inspection
152. Driven Clutch Assembly
156. Drive clutch inspection
157. EBS Driven Clutch Disassembly/Inspection
160. EBS Drive Clutch Bushing Service
161. EBS Driven Clutch Bushing Service
163. Troubleshooting
166. FINAL DRIVE
167. AWD Operation Overview
169. AWD Front Hub Bearing Adjustment
170. AWD Front Hub Exploded View
171. AWD Hub Seal Replacement
173. AWD Armature Plate Inspection
174. AWD Front Drive Axle Installation
177. AWD Front Drive Axle Exploded View
179. AWD Front Prop Shaft Removal
180. U-Joint Disassembly
181. AWD Front Housing Removal
182. AWD Front Housing Disassembly
184. AWD Front Housing Exploded View
185. Rear hub/bearing carrier removal
186. Rear Hub Installation
187. Rear Hub Disassembly/Assembly
188. Rear Drive Shaft Removal
189. Rear Driveshaft Installation
190. Rear Driveshaft Service
195. Torque Specifications
196. Gear Shift Selector Assembly
197. Gear Shift Selector Installation
198. Transmission Removal
199. TRANSMISSION INSTALLATION
201. Transmission Disassembly
210. Transmission Assembly
214. Troubleshooting
215. Transmission Exploded View
219. Brake system main components
221. Specifications
222. Brake System Service Notes
223. Hydraulic Caliper Bleeding
224. Brake Bleeding / Fluid Change
225. Master Cylinder Removal
226. Master Cylinder Installation
227. Front Pad Removal
228. Front Pad Assembly
229. Brake Burnishing
230. Front Caliper Removal
231. Front Caliper Inspection
232. Front Caliper Reassembly
233. Front Caliper Installation
234. Brake burnishing procedure
236. Rear Caliper Removal/Inspection
237. REAR CALIPER ASSEMBLY
238. Troubleshooting
240. ELECTRICAL
241. Special Tools/Service Notes
242. Gear position indicator
243. Instrument Cluster Troubleshooting
244. Diagnostic Mode
245. Speedometer Removal/Installation
246. Speedometer Troubleshooting
250. Fan motor current draw
251. Etc operation test
252. Ignition System Testing Flow Chart
253. Ignition System Troubleshooting
254. Alternator output test
255. CHARGING SYSTEM TESTING FLOW CHART
257. Battery installation
258. Load test
259. High beam headlight adjustment
260. Headlamp switch
261. Starter System Troubleshooting
263. Armature testing
264. Starter Drive
265. Starter System Testing Flow Chart

Page 1 of 274

Polaris SPORTSMAN 400 2003 Service manual

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4. Table of Contents
7. GENERAL INFORMATION
8. General information
13. Publication Numbers
14. Standard Torque Specifications
15. Decimal equivalents
16. Conversion Table
17. Decimal Equivalent Chart
18. Glossary of Terms
21. Periodic Maintenance Chart
22. Pre-Ride Inspection
23. MAINTENANCE
25. Special Tools
28. Transmission Lubrication
29. TRANSMISSION
31. Idle speed adjustment
32. MAINTENANCE
33. Fuel filter
34. Compression Test
35. ELECTRICAL
36. Liquid cooling system overview
37. Coolant level inspection
38. Air Box Sediment Tube Service
39. Breather Filter
40. Oil Change/Filter
42. Valve Clearance
43. Exhaust valve clearance adjustment
44. Camber and caster
46. Exhaust pipe
47. Brake pad inspection
48. Controls
49. Wheel Removal/Installation
50. Tire Inspection
53. Torque Specifications
54. Engine service data
56. ENGINE FASTENER TORQUE PATTERNS
57. Cooling system
58. Cooling System Specifications
59. Engine Installation Notes
60. Honing to oversize
61. Oil pressure test
63. Eh50pl oil flow diagram
64. EH50PL Engine Exploded View
66. Cam chain tensioner inspection
69. Automatic compression release installati...
72. Cylinder head inspection
73. Valve inspection
74. Valve seat reconditioning
77. Cylinder head assembly
79. Piston removal
80. Cylinder inspection
81. Piston/rod inspection
82. Crankcase disassembly
84. Crankcase separation
85. Oil pump removal/inspection
86. Oil pump assembly
87. Crankshaft removal/inspection
88. Crankcase bearing inspection
89. Bearing installation
91. Oil pump shaft end play adjustment
92. Pump shaft oil seal installation
93. Water pump mechanical seal installation
94. One way valve installation
95. Piston ring installation
96. Cylinder installation
97. Cylinder head installation
100. Cam chain tensioner installation
101. Thermostat installation
102. Oil pipes
103. Recoil assembly
104. Spark Plug Fouling Checklist
109. Fuel Flow Diagram
110. Carburetor Jetting
111. CV Carburetor System Function (4 Cycle)
113. Float system
114. Carburetor cleaning
116. Float height adjustment
117. NEEDLE AND SEAT LEAKAGE TEST
118. Fuel pump disassembly
119. Troubleshooting
121. Cover/Panel Removal
122. Side Panel Removal
123. BODY ASSEMBLY EXPLODED VIEW
124. Headlight Pod Exploded View
125. Steering Assembly, Exploded View
126. A-Arm Replacement
127. Rear Suspension Assembly
128. Strut assembly
129. Front Strut Cartridge Replacement
130. Steering Post Assembly
132. PVT SYSTEM
133. Drive clutch operation
134. PVT Maintenance/Inspection
136. PVT Disassembly
137. PVT Assembly
138. PVT Sealing and Ducting Components
139. Drive clutch spring specifications
140. Shift Weights
141. Drive Clutch Inspection
142. Spider removal
143. DRIVE CLUTCH REASSEMBLY
144. Drive Belt Tension
145. Drive Belt Removal/Inspection
146. Drive Belt Installation
147. Clutch Alignment /Offset
148. Drive Clutch Bushing Service
150. Driven Clutch Disassembly/Inspection
152. Driven Clutch Assembly
156. Drive clutch inspection
157. EBS Driven Clutch Disassembly/Inspection
160. EBS Drive Clutch Bushing Service
161. EBS Driven Clutch Bushing Service
163. Troubleshooting
166. FINAL DRIVE
167. AWD Operation Overview
169. AWD Front Hub Bearing Adjustment
170. AWD Front Hub Exploded View
171. AWD Hub Seal Replacement
173. AWD Armature Plate Inspection
174. AWD Front Drive Axle Installation
177. AWD Front Drive Axle Exploded View
179. AWD Front Prop Shaft Removal
180. U-Joint Disassembly
181. AWD Front Housing Removal
182. AWD Front Housing Disassembly
184. AWD Front Housing Exploded View
185. Rear hub/bearing carrier removal
186. Rear Hub Installation
187. Rear Hub Disassembly/Assembly
188. Rear Drive Shaft Removal
189. Rear Driveshaft Installation
190. Rear Driveshaft Service
195. Torque Specifications
196. Gear Shift Selector Assembly
197. Gear Shift Selector Installation
198. Transmission Removal
199. TRANSMISSION INSTALLATION
201. Transmission Disassembly
210. Transmission Assembly
214. Troubleshooting
215. Transmission Exploded View
219. Brake system main components
221. Specifications
222. Brake System Service Notes
223. Hydraulic Caliper Bleeding
224. Brake Bleeding / Fluid Change
225. Master Cylinder Removal
226. Master Cylinder Installation
227. Front Pad Removal
228. Front Pad Assembly
229. Brake Burnishing
230. Front Caliper Removal
231. Front Caliper Inspection
232. Front Caliper Reassembly
233. Front Caliper Installation
234. Brake burnishing procedure
236. Rear Caliper Removal/Inspection
237. REAR CALIPER ASSEMBLY
238. Troubleshooting
240. ELECTRICAL
241. Special Tools/Service Notes
242. Gear position indicator
243. Instrument Cluster Troubleshooting
244. Diagnostic Mode
245. Speedometer Removal/Installation
246. Speedometer Troubleshooting
250. Fan motor current draw
251. Etc operation test
252. Ignition System Testing Flow Chart
253. Ignition System Troubleshooting
254. Alternator output test
255. CHARGING SYSTEM TESTING FLOW CHART
257. Battery installation
258. Load test
259. High beam headlight adjustment
260. Headlamp switch
261. Starter System Troubleshooting
263. Armature testing
264. Starter Drive
265. Starter System Testing Flow Chart

Description

The Service Manual of the Polaris SPORTSMAN 400 and 500 2003 Offroad Vehicle is essential for any off-road enthusiast. It covers all aspects of the vehicle, from general information and assembly to troubleshooting and maintenance. The manual is easy to read and packed with information on safety and operation. It also includes torque specifications, engine oil capacities, and other important details. The manual also offers detailed diagrams and schematics to help you understand the correct way to assemble and maintain the vehicle. The diagrams are especially helpful in identifying parts and components. The Service Manual of the Polaris SPORTSMAN 400 and 500 2003 Offroad Vehicle provides the information and resources needed to get the most out of your off-road vehicle.

Also for: SPORTSMAN 500 2003

File size: 9.40 MB

Created: January 31, 2023

Last updated: March 23, 2023