Polaris Sportsman Magnum 330 330HDS 500HDS Service Repair Manual 2003

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Loaded with Hi Resolution illustrations, instructions, photos, and diagrams, complete to service and repair your snowmobile. Read and print pages directly from the CD.


Models Covered :

Polaris Sportsman Magnum 330
Polaris Sportsman Magnum 330HDS
Polaris Sportsman Magnum 500HDS



Manual Covers :


General :

Model Identification

Serial Number Location

Machine Dimensions

Specifications 2003 Sportsman 6x6

Publication Numbers

Paints Codes

Replacement Keys

Standard Torque Specifications

Decimal Equivalent Chart

Unit of Measure Conversion Table

Tap Drill Charts

Glossary of Terms



Maintenance :

Periodic Maintenance Chart

Pre-Ride Inspection

Recommended Lubricants and Capacities

Special Tools

Lubrication Charts

Transmission Lubrication

Front Gearcase Lubrication

Transmission Linkage Adjustment

Carburetor Adjustments

Fuel System

Compression Test

Battery Maintenance

Electrical

Coolant System Maintenance

Air Filter Service

Air Box Sediment Tube Service

Breather Filter

Recoil Housing

Engine Oil Service

Valve Clearance

Steering

Front Hub Maintenance

Exhaust System Maintenance

Brake System Inspection

Drive Chain Service

Suspension Service

Wheel Removal/Installation

Tire Inspection



Engine :

Torque Specifications

Special Tools

EH50PL Service Data

Torque Patterns

Piston Identification

Cooling System Pressure Test

Cooling System Routing/Specifications

Engine Removal

Engine Installation Notes

Cylinder Honing

Crankshaft Runout Inspection/Straightening

EH50PL Engine Lubrication

EH50PL Oil Pump Priming Procedure

EH50PL Lubrication/Oil Flow

EH50PL Engine Oil Flow Charts

EH50PL Engine Exploded Views

EH50PL Engine Top End Disassembly

EH50PL Valve Seat Service

EH50PL Cylinder Head Assembly

EH50PL Cylinder Service

EH50PL Engine Bottom End Disassembly

EH50PL Crankcase And Bearing Assembly

EH50PL Crankshaft End Play Inspection

EH50PL Counter Balancer End Play Inspection

EH50PL Oil Pump Shaft End Play Inspection

EH50PL Engine Assembly/Inspection

Sealed Recoil Disassembly/Inspection

Sealed Recoil Assembly

Spark Plug Fouling Checklist

Troubleshooting



Fuel System / Carburation :

Exploded View, Mikuni BST 34 Carburetor

Fuel Tank Asm. Exploded View

Fuel Flow Diagram

Special Tool and Jetting Guidelines

Carburetor Jetting

Main Jet/ Pilot Jet Part Numbers

CV Carburetor System Function (4 Cycle)

CV Carburetor Vent System (4 Cycle)

CV Carburetor Operation

Disassembly Notes, CV Carburetor

Cleaning, CV Carburetor

Inspection, CV Carburetor

Assembly, CV Carburetor

Float Adjustment, CV Carburetor

Needle and Seat Leakage Test

Fuel Level

Fuel Pump Service

Fuel Pump Exploded View

Troubleshooting



Body and Steering :

Torque Specifications and Special Tools

Cover/Panel Removal

Dump Box, Exploded View

Body Assembly, Exploded View

Headlight Pod, Exploded View

Side Panel Removal

Steering Assembly, Exploded View

A-Arm Replacement

Concentric Swing Arm Removal

Concentric Swing Arm Assembly/Installation

Rear Strut Stabilizer, Exploded View

Rear Swing Arm Weldment

Strut Assembly Exploded View

Front Strut Cartridge Replacement

Front Strut Ball Joint Replacement

Steering Post Assembly

Decal Replacement



PVT System :

Service Tools and Supplies

PVT System Torques

PVT System Operation Overview

PVT Maintenance/Inspection

PVT Disassembly

PVT Assembly

PVT Sealing and Ducting Components

Drive Clutch Exploded View

Drive Clutch Spring Specifications

Shift Weights

Drive Clutch Inspection

Drive Clutch Disassembly/Inspection

Drive Clutch Assembly

Drive Belt Tension

Drive Belt Removal/Inspection

Drive Belt Installation

Clutch Alignment/Offset

Drive Clutch Bushing Service

Driven Clutch Disassembly/Inspection

Driven Clutch Assembly

Driven Clutch Bushing Service

Troubleshooting



Final Drive :

Final Drive Torque Specifications

AWD Operation Overview

AWD Front Hub Removal

AWD Hub/Bearing Installation

AWD Front Hub Bearing Adjustment

AWD Front Hub Exploded

AWD Hub Seal Replacement

AWD Magnetic Coil Service

AWD Hilliard Clutch Disassembly/Inspection

AWD Armature Plate Inspection

AWD Front Drive Axle Removal

AWD Front Drive Axle Installation

AWD Front CV Joint Boot Replace

AWD Front Drive Axle Exploded View

AWD Strut Casting Seal Replacement

AWD Strut Seal Sleeve Replacement

AWD Front Prop Shaft Removal

U-Joint Disassembly

U-Joint Assembly

AWD Front Housing Removal

AWD Front Housing Disassembly

AWD Front Housing Assembly

AWD Front Housing Installation

AWD Front Housing Exploded View

Middle Axle Removal

Middle Axle Disassembly

Middle Axle Assembly

Middle Axle Installation

Middle Axle Exploded View

Middle Housing Removal

Middle Housing Service

Rear Axle Removal

Rear Axle Installation

Rear Axle Service



Transmission Service :

Special Tools and Torque Specifications

Gear Shift Selector Removal

Gear Shift Selector Disassembly

Gear Shift Selector Assembly

Gear Shift Selector Installation

Boot Replacement

Transmission Removal/Installation

Transmission Disassembly

Transmission Assembly

Transmission Exploded View

Troubleshooting



Brakes :

Specifications/Torques

Special Tools

Brake System Service Notes

Brake Noise Troubleshooting

Hydraulic Brake System Operation

Dual Hydraulic Caliper Bleeding

Brake System Main Components

Front Caliper Exploded View

Fluid Replacement/ Bleeding Procedure

Master Cylinder Disassembly

Master Cylinder Installation

Front Pad Removal

Front Pad Assembly/Adjust

Front Disc Inspection

Front Disc Removal/Replacement

Front Caliper Removal

Front Caliper Disassembly

Front Caliper Inspection

Front Caliper Assembly

Front Caliper Installation

Rear Pad Removal

Rear Pad Installation

Rear Caliper Removal/Inspection

Rear Caliper Assembly

Rear Disc Inspection

Troubleshooting



Electrical :

Special Tools and Electrical Notes

Timing Check Procedure

Transmission Gear Position Switch Test

Instrument Cluster Troubleshooting

Coolant Sensor Tests

Fan Control Circuit Operation

Fan Motor Current Draw Test

ETC System Operation

Flywheel Identification

250 Watt Alternator, Exploded View

Ignition System Testing

Ignition System Troubleshooting

Cranking Output Test

Charging System Testing

Battery Service

Head Light/ Brake Light Lamp Servicew

Starter System Testing

Starter Motor Service

Starter Drive

Starter System Troubleshooting

Wiring Diagram



This manual is the same as the manual used by workshops. Service Manual contains detailed instructions and step by step diagrams for all workshop procedures.

COMPATIBLE WITH ALL WINDOWS
WINDOWS 7, VISTA 32 and 64, XP, ME, 98, NT, 2000 ETC.