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2003 Polaris Sportsman 400 500 & Parts Workshop Service Repair Manual Download PDF

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$133.00
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$133.00
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This manual covers the Polaris Sportsman, a versatile all-terrain vehicle from the 3rd Generation series produced between 2000 and 2004. Engineered for reliability and performance, the Sportsman offers robust capabilities suitable for various off-road applications. Key features include a choice of 4-stroke single-cylinder engines, with displacements of 375 cc and 499 cc respectively, both liquid-cooled and equipped with Mikuni carburetors. The vehicle utilizes an Automatic PVT transmission with selectable 2WD/4WD modes and shaft drive, complemented by a MacPherson strut front suspension and Independent Rear Suspension for optimal handling and comfort across challenging terrain. This Workshop Service Repair Manual provides comprehensive guidance for the service, repair, and parts information for the Polaris Sportsman. Within its English-language pages, you will find detailed procedures for maintenance, including lubrication specifications and intervals for engine oil and transmission oil changes, as well as air filter cleaning and spark plug inspection. Technical specifications, troubleshooting tips, and essential safety guidelines are also included. This manual is an indispensable resource for owners, mechanics, and technicians seeking to maintain the performance and longevity of their 2003 Polaris Sportsman. 🏷️ Basic Information Identification Make: Polaris Model: Sportsman Year: 2003 Generation: 3rd Generation (2000-2004) 📋 Manual Details Publication Manual Type: Workshop Service Repair Manual Language: English Format: Download PDF Content Scope: Service, Repair, and Parts ⚙️ Engine Specifications Engine 400 Engine Type: 4-stroke Single-cylinder Displacement: 375 cc Bore X Stroke: 88 mm x 62 mm Cooling System: Liquid Cooled Engine 500 Engine Type: 4-stroke Single-cylinder Displacement: 499 cc Bore X Stroke: 92 mm x 76 mm Cooling System: Liquid Cooled Carburetion Carburetor 400: Mikuni BNS34 Carburetor 500: Mikuni BNS40 🔧 Transmission Drivetrain Type: Automatic PVT (Polaris Variable Transmission) Drive Modes: 2WD/4WD Final Drive: Shaft Drive 🔧 Maintenance Lubrication Engine Oil Type: SAE 10W-40 Synthetic Engine Oil Capacity: 2.1 L (2.2 US qt) Transmission Oil Type: SAE 80W-90 Gear Oil Transmission Oil Capacity: 0.24 L (0.25 US qt) Intervals Initial Engine Oil Change: 10 hours or 1 month Regular Engine Oil Change: 20 hours or 3 months Air Filter Cleaning: Every 20 hours Spark Plug Inspection: Every 40 hours 📄 Chassis And Suspension Suspension Front Suspension Type: MacPherson Strut Rear Suspension Type: Independent Rear Suspension (IRS) with Dual A-Arms Front Wheel Travel: 7 in (17.8 cm) Rear Wheel Travel: 9.5 in (24.1 cm) 📄 Brakes Braking System Front Brake Type: Hydraulic Disc Rear Brake Type: Sealed Hydraulic Disc 📄 Wheels And Tires Wheel Size Front Wheel Size: 12 in Rear Wheel Size: 12 in Tire Size Front Tire Size: AT25x8-12 Rear Tire Size: AT25x11-12
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Taper: Atv
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UGS: 44160
Collections: ALL ATV Powersports

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2003 Polaris Sportsman 400 500 & Parts Workshop Service Repair Manual Download PDF2003 Polaris Sportsman 400 500 & Parts Workshop Service Repair Manual Download PDF2003 Polaris Sportsman 400 500 & Parts Workshop Service Repair Manual Download PDF
This manual covers the Polaris Sportsman, a versatile all-terrain vehicle from the 3rd Generation series produced between 2000 and 2004. Engineered for reliability and performance, the Sportsman offers robust capabilities suitable for various off-road applications. Key features include a choice of 4-stroke single-cylinder engines, with displacements of 375 cc and 499 cc respectively, both liquid-cooled and equipped with Mikuni carburetors. The vehicle utilizes an Automatic PVT transmission with selectable 2WD/4WD modes and shaft drive, complemented by a MacPherson strut front suspension and Independent Rear Suspension for optimal handling and comfort across challenging terrain. This Workshop Service Repair Manual provides comprehensive guidance for the service, repair, and parts information for the Polaris Sportsman. Within its English-language pages, you will find detailed procedures for maintenance, including lubrication specifications and intervals for engine oil and transmission oil changes, as well as air filter cleaning and spark plug inspection. Technical specifications, troubleshooting tips, and essential safety guidelines are also included. This manual is an indispensable resource for owners, mechanics, and technicians seeking to maintain the performance and longevity of their 2003 Polaris Sportsman.
🏷️ Basic Information
Identification
Make:
Polaris
Model:
Sportsman
Year:
2003
Generation:
3rd Generation (2000-2004)
📋 Manual Details
Publication
Manual Type:
Workshop Service Repair Manual
Language:
English
Format:
Download PDF
Content
Scope:
Service, Repair, and Parts
⚙️ Engine Specifications
Engine 400
Engine Type:
4-stroke Single-cylinder
Displacement:
375 cc
Bore X Stroke:
88 mm x 62 mm
Cooling System:
Liquid Cooled
Engine 500
Engine Type:
4-stroke Single-cylinder
Displacement:
499 cc
Bore X Stroke:
92 mm x 76 mm
Cooling System:
Liquid Cooled
Carburetion
Carburetor 400:
Mikuni BNS34
Carburetor 500:
Mikuni BNS40
🔧 Transmission
Drivetrain
Type:
Automatic PVT (Polaris Variable Transmission)
Drive Modes:
2WD/4WD
Final Drive:
Shaft Drive
🔧 Maintenance
Lubrication
Engine Oil Type:
SAE 10W-40 Synthetic
Engine Oil Capacity:
2.1 L (2.2 US qt)
Transmission Oil Type:
SAE 80W-90 Gear Oil
Transmission Oil Capacity:
0.24 L (0.25 US qt)
Intervals
Initial Engine Oil Change:
10 hours or 1 month
Regular Engine Oil Change:
20 hours or 3 months
Air Filter Cleaning:
Every 20 hours
Spark Plug Inspection:
Every 40 hours
📄 Chassis And Suspension
Suspension
Front Suspension Type:
MacPherson Strut
Rear Suspension Type:
Independent Rear Suspension (IRS) with Dual A-Arms
Front Wheel Travel:
7 in (17.8 cm)
Rear Wheel Travel:
9.5 in (24.1 cm)
📄 Brakes
Braking System
Front Brake Type:
Hydraulic Disc
Rear Brake Type:
Sealed Hydraulic Disc
📄 Wheels And Tires
Wheel Size
Front Wheel Size:
12 in
Rear Wheel Size:
12 in
Tire Size
Front Tire Size:
AT25x8-12
Rear Tire Size:
AT25x11-12
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