This manual covers the 2003 all-terrain vehicles. The series is a cornerstone of the ATV lineup, recognized for its ruggedness and utility, offering robust off-road capability and comfort. These models feature a 4-stroke, SOHC, liquid-cooled, single-cylinder engine, with displacements of approximately 375cc for the 400 and 499cc for the 500 HO, paired with an Automatic PVT transmission. Known for their reliability and engineering quality, these ATVs are designed for a variety of demanding tasks and recreational use. This comprehensive Factory Service Repair Manual, provided in English, offers detailed guidance for owners, DIY mechanics, and professional technicians. It covers all essential aspects of vehicle care, including scheduled maintenance, routine checks, and in-depth repair procedures for every major system. Key areas include engine, fuel system, PVT system, transmission, final drive, brakes, electrical systems, and body/suspension. The manual also provides crucial troubleshooting guides, technical specifications, safety precautions, and information on common wear items, empowering users to maintain and repair their ATVs effectively. 🏷️ Basic Information Identification Make: Polaris Model: Sportsman 400 / 500 HO Year: 2003 👋 Introduction Market Position Target Audience: Owners of 2003 Polaris Sportsman 400 and 500 HO ATVs, DIY mechanics, and professional service technicians. Key Features Benefit: Enables users to perform all necessary repairs and maintenance, reducing reliance on external service providers. 📋 Manual Details Coverage Areas Primary Coverage: Repair and maintenance for 2003 Polaris Sportsman 400 and 500 HO models. Manual Type Type: Factory Service Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine: Detailed coverage of engine disassembly, inspection, repair, and reassembly, including top-end, bottom-end, cooling system, and lubrication. Fuel System: Carburetor adjustment, cleaning, and rebuilding; fuel pump testing; fuel tank and line maintenance. Pvt System: Primary and secondary clutch service, belt inspection and replacement, variable transmission system diagnostics. Transmission: Gearbox inspection, repair, and maintenance; driveshaft and U-joint service. Final Drive: Hub and wheel assembly, axle maintenance, differential inspection and service. Brakes: Brake caliper service, pad replacement, fluid bleeding, master cylinder inspection, rotor and drum servicing. Electrical: Ignition system diagnostics, starter motor and charging system testing, lighting and accessory circuits, wiring diagrams. Body Suspension: Front and rear suspension component inspection, replacement, and adjustment; steering system maintenance; body panel removal and installation. General: General information, safety precautions, torque specifications, special tools, troubleshooting guides. Procedures Included Maintenance: Scheduled maintenance tasks, fluid level checks, filter replacements, lubrication points, tire pressure recommendations. Repair: Comprehensive step-by-step repair instructions for all major systems, including engine rebuilds and driveline overhauls. Troubleshooting: Diagnostic charts and procedures to identify and resolve common and uncommon issues. Technical Depth Depth: Comprehensive, covering from basic routine maintenance to advanced engine and transmission rebuilding. 📊 Manual Specifications File Format Compatibility: Requires any standard PDF reader (e.g., Adobe Acrobat Reader). Print Quality Quality: Digital PDF, allowing for clear viewing and printing of pages. ⚙️ Engine Specifications Primary Engine Engine Type 400: 4-stroke, SOHC, 2-valve, single-cylinder, liquid-cooled Engine Type 500: 4-stroke, SOHC, 2-valve, single-cylinder, liquid-cooled Engine Displacement Displacement 400: Approx. 375cc (specifics detailed in manual) Displacement 500: Approx. 499cc (specifics detailed in manual) Performance Horsepower Torque: Specific horsepower and torque figures for each model variant are detailed within the manual. Fuel System Carburetor Type: Mikuni BSR carburetor (specific models and tuning details provided). 🔧 Transmission Standard Transmission Type: Automatic PVT (Polaris Variable Transmission) with Engine Braking. Features Gear Selection: High, Low, Neutral, Reverse (and Park as applicable for the transmission system). 📐 Dimensions Weights Dry Weight: Approx. 590-600 lbs (varies slightly between 400 and 500 HO models; exact figures in manual). Towing Capacity: 1500 lbs (680 kg) (standard for most models of this era). Ground Clearance: Approx. 11.5 inches (29.2 cm) (standard for both models). 🛡️ Safety Features Ratings Atv Safety: General ATV safety guidelines, operation best practices, and risk mitigation are typically covered in service manuals. 💡 Technology Features Infotainment Features: Basic functionality focused on essential controls; no infotainment or advanced electronic features typical of modern vehicles. 🔧 Maintenance Service Intervals Oil Change: Recommended every 100 hours or annually, whichever comes first (specific fluid type and capacity detailed in manual). Spark Plug: Inspection/replacement intervals are provided, typically every 100-200 hours of operation. Air Filter: Service intervals based on operating conditions (frequent cleaning/replacement recommended for dusty environments). Fluid Specifications Engine Oil Type: SAE 5W-50 Synthetic or Polaris Synthetic 2W-50 (specific API service classification will be noted in manual). Coolant Type: Ethylene Glycol based antifreeze/coolant, pre-mixed 50/50 with distilled water. Brake Fluid: DOT 3 or DOT 4 brake fluid (refer to manual for precise specification). Known Issues Common Wear Items: PVT belt wear, starter solenoid issues, and occasional carburetor jetting sensitivity are common wear items for this era. Cooling System: Regular inspection of hoses, radiator, and coolant level is crucial to prevent overheating. 📚 Vehicle History Model Evolution Series Context: The Sportsman series is a cornerstone of...