🏷️ Basic Information Identification Make: Polaris Model: Sportsman 400 / 500 Model Variant: ATV Applicable Years: 2003, 2004 Codes Platform Code: Not specified in product info 👋 Introduction Market Position Target Audience: Owners of 2003-2004 Polaris Sportsman 400 and 500 ATVs, mechanics, and repair shops specializing in powersports vehicles. Competitive Analysis Value Proposition: Provides essential, detailed information for maintaining and repairing these specific Polaris models, enabling cost savings and extending vehicle lifespan. Key Features Document Type: Official or factory-level service manual, providing the most accurate repair data. Format Benefit: Digital PDF format offers portability, searchability, and easy access across multiple devices. 📋 Manual Details Coverage Areas Primary Coverage: Maintenance and Repair Procedures Secondary Coverage: Troubleshooting, Diagnostics, Technical Specifications Page Count Estimated Page Count: Detailed, likely several hundred pages (typical for comprehensive service manuals) Manual Type Type: Service Repair Manual Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Engine: Complete engine assembly, disassembly, tuning, lubrication, cooling system, fuel system, exhaust system, ignition system, starting system, charging system. Transmission: Gearbox operation, maintenance, and repair; drive clutch, driven clutch, belt inspection and replacement. Drivetrain: Shaft drive systems, differentials, axle maintenance, CV joint service, wheel hub assembly. Suspension: Front and rear suspension component inspection and replacement, shock absorber service, A-arm bushings, ball joint service. Brakes: Hydraulic brake system diagnostics, caliper service, master cylinder overhaul, brake pad replacement, rotor inspection, bleeding procedures. Electrical System: Wiring diagrams, battery service, charging system troubleshooting (stator, regulator/rectifier), lighting system, ignition system components, starter motor, electrical component testing. Steering: Steering column, tie rod ends, steering linkage maintenance and adjustment. Bodywork And Chassis: Frame inspection, body panel removal and installation, seat service, fender and rack maintenance. Fuel System: Carburetor (or EFI) overhaul, fuel pump, fuel lines, fuel tank inspection and cleaning. Cooling System: Radiator, fan, thermostat, coolant type, fluid capacity, flushing procedures (if applicable). Procedures Included Preventative Maintenance: Scheduled maintenance checks, lubrication points, filter replacement intervals, fluid level checks, pre-ride inspections. Routine Repairs: Common repair tasks such as tire changes, brake pad replacement, belt replacement, spark plug service. Engine Rebuild: Complete engine disassembly, inspection, measurement of critical components (bore, stroke, piston ring gap), piston and cylinder replacement, valve adjustments, gasket replacement. Transmission Overhaul: Gearbox disassembly, inspection of gears and bearings, clutch assembly service, rebuild procedures. Electrical Diagnostics: Troubleshooting electrical faults, testing voltage and resistance, wiring harness repair, component testing. Troubleshooting Guides: Systematic diagnostic charts and procedures for identifying and resolving common problems. Technical Depth Depth: Comprehensive, covering everything from basic maintenance to complete engine and transmission overhauls. Suitable for professional technicians and experienced DIY mechanics. Detail Level: Includes step-by-step instructions, exploded views, diagrams, and torque specifications for all procedures. 📊 Manual Specifications File Format File Type: PDF Searchability: Likely text-searchable for quick information retrieval. Print Quality Image Quality: Recommended to use Adobe PDF Reader for optimal display of images/graphics. Indicates high-resolution images and diagrams. Binding Type Binding: N/A (digital PDF format) Paper Type Paper Type: N/A (digital PDF format) ⚙️ Engine Specifications Primary Engine Engine Type 400: 4-stroke, single-cylinder, liquid-cooled (typically SOHC or OHV depending on specific sub-model/year variant). Engine Type 500: 4-stroke, single-cylinder, liquid-cooled, SOHC (or similar OHV configuration). Bore Stroke 400: Specific figures to be found within the manual, but typically around 88mm x 64.2mm for a ~375cc class engine. Bore Stroke 500: Specific figures to be found within the manual, but typically around 92.5mm x 73.6mm for a ~499cc class engine. Performance Horsepower 400: Estimated 25-30 HP (actual figures vary by specific tuning and model year, to be confirmed in manual). Horsepower 500: Estimated 30-35 HP (actual figures vary by specific tuning and model year, to be confirmed in manual). Torque: Refer to manual for specific torque figures, generally optimized for low-end grunt and trail performance. Fuel System Fuel Delivery: Carbureted (likely Mikuni or Keihin) or possibly early Electronic Fuel Injection (EFI) depending on specific trim/package, detailed in manual. Fuel Type: Unleaded Gasoline Fuel Capacity: Refer to manual, typically around 3.5 - 4.0 gallons (13.2 - 15.1 liters). 🔧 Transmission Standard Type: Automatic CVT (Continuously Variable Transmission) with Hi/Lo range and Reverse. Optional Optional Transmissions: None typically offered for these models; CVT was standard. Features Clutch System: Polaris P-85/P-90 primary and PVT secondary clutches, belt-driven. Drive System: Shaft drive, often with Polaris's on-demand AWD system (Active Descent Control). 📐 Dimensions Exterior Wheelbase: Refer to manual for exact specifications, typically around 50.5 inches (1283 mm). Ground Clearance: Refer to manual for exact specifications, often in the range of 10-11 inches (254-279 mm). Weights Dry Weight: Refer to manual for exact specifications, typically in the range of 570-620 lbs (258-281 kg). Towing Capacity: Refer to manual for exact specifications, generally limited but suitable for light loads. 🛡️ Safety Features Ratings Atv Safety Standards: Adheres to ANSI/SVIA standards for ATVs. Active Features Braking System: Hydraulic disc brakes front...