This manual covers the ATVs manufactured between 2003 and 2004. These versatile machines are known for their comfort, utility, and reliable all-terrain performance, featuring independent rear suspension for a smoother ride. The line has a strong reputation for providing capable off-road experiences, making these models a popular choice for various recreational and utility purposes. With engine options including 400cc and 500cc variants, these ATVs are engineered for dependable operation in diverse conditions. This comprehensive service and repair workshop manual provides in-depth technical guidance for owners, DIY mechanics, and independent repair shops. It covers all essential aspects of vehicle maintenance and repair, including detailed step-by-step procedures for engine systems, drivetrain, chassis, braking, and electrical systems. You will find information on routine maintenance, component replacement, troubleshooting common issues, and detailed technical specifications and diagrams. This manual is designed to empower users to efficiently maintain and repair their ATVs, ensuring optimal performance and longevity. 🏷️ Basic Information Identification Make: Polaris Model: Sportsman 400 / Sportsman 500 Model Variant: ATV Year Range: 2003-2004 Engine Options: 400cc, 500cc 👋 Introduction Market Position Target Audience: Polaris Sportsman 400 and 500 owners, DIY mechanics, independent repair shops Competitive Analysis Value Proposition: Provides in-depth technical guidance, enabling owners to perform maintenance and repairs efficiently, saving on labor costs. Key Features Manual Features: Step-by-step repair procedures, detailed diagrams, troubleshooting guides, specifications, torque values. 📋 Manual Details Coverage Areas Coverage Type: Complete Service Repair Workshop Page Count Estimated Page Count: Extensive (typical workshop manual 500-1000+ pages, specific count not provided) Manual Type Manual Type: Service/Repair Manual Language Language: English Format Format: PDF Download File Format File Format: PDF Print Quality Print Quality: Professional quality, high resolution (typical for workshop manuals) Binding Type Binding Type: N/A (Downloadable PDF) Paper Type Paper Type: N/A (Downloadable PDF) 📖 Manual Coverage Systems Covered Engine Systems: Engine disassembly/assembly, tuning, lubrication, cooling, fuel delivery (carburetor/EFI), ignition, exhaust Drivetrain Systems: Transmission, final drive, driveshafts, CV joints, differentials (if applicable), clutch operation Chassis Systems: Frame, suspension (front and rear), steering, wheels, tires Braking Systems: Hydraulic brake system, calipers, master cylinders, brake lines, parking brake Electrical Systems: Starting system, charging system (stator, regulator/rectifier), battery, lighting, ignition system, wiring diagrams, sensors, ECUs Bodywork And Trim: Body panel removal/installation, seat, racks, fenders, handlebars Procedures Included Maintenance Procedures: Oil changes, filter replacements, spark plug checks, valve adjustments, lubrication points, chain adjustment (if applicable) Repair Procedures: Component replacement, seal and gasket replacement, bearing replacement, shock absorber service, brake pad replacement Troubleshooting: Diagnostic procedures, fault code interpretation (if applicable), common problem diagnosis Technical Depth Depth Of Information: Comprehensive (from basic maintenance to complete engine and transmission rebuilds) ⚙️ Engine Specifications Primary Engine 400 Engine Type 400: 4-stroke, SOHC, 2-valve, liquid-cooled, single-cylinder Displacement 400: 375cc (approx.) Primary Engine 500 Engine Type 500: 4-stroke, SOHC, 2-valve, liquid-cooled, single-cylinder Displacement 500: 499cc (approx.) Performance General Bore X Stroke Typical: Varies by model (e.g., 500 HO: 93.2mm x 72mm) Compression Ratio Typical: Varies by model (e.g., 8.4:1 to 10.25:1) Horsepower Typical: Approx. 28-30 HP for 400, 30-34 HP for 500 Torque Typical: Approx. 28-30 lb-ft for 400, 30-34 lb-ft for 500 Fuel System Fuel Delivery 400: Carburetor (e.g., Mikuni BSR42) Fuel Delivery 500: Carburetor (e.g., Mikuni BSR42) or Electronic Fuel Injection (EFI) on some HO models Fuel Type: Unleaded gasoline, minimum 87 octane Ignition System Ignition Type: CDI (Capacitor Discharge Ignition) with electronic timing advance Lubrication System Oil Type Recommendation: SAE 5W-30 or 10W-40, API SG or higher (refer to manual for exact specifications) Oil Capacity Typical: Approx. 2.2 - 2.5 quarts (2.1 - 2.4 liters) with filter change Cooling System Cooling Method: Liquid-cooled Coolant Type: Ethylene glycol-based antifreeze/coolant (50/50 mix with distilled water) 🔧 Transmission Primary Transmission Transmission Type: Automatic (PVT - Polaris Variable Transmission) Transmission Features: High and Low gear range, Neutral, Reverse Drive System Drive System: Shaft drive, On-Demand AWD (All-Wheel Drive) / 2WD Clutch System Clutch Type: Centrifugal clutch with drive and driven pulleys Fluid Type Transmission Fluid Type: Polaris ATV Synethetic Oil or equivalent, or specific PVT fluid (refer to manual) 📐 Dimensions Exterior Dimensions Length Typical: Approx. 81 inches (205.7 cm) Width Typical: Approx. 46 inches (116.8 cm) Height Typical: Approx. 45 inches (114.3 cm) Wheelbase Wheelbase Typical: Approx. 50.2 inches (127.5 cm) Ground Clearance Ground Clearance Typical: Approx. 10.5 inches (26.7 cm) Weights Dry Weight Typical: Approx. 618-640 lbs (280-290 kg) Towing Capacity Typical: 1500 lbs (680 kg) Rack Capacity Front: 100 lbs (45 kg) Rack Capacity Rear: 200 lbs (90 kg) Tires And Wheels Front Tire Size Typical: AT 25x8-12 Rear Tire Size Typical: AT 25x10-12 Wheel Bolt Pattern: 5x114.3mm (standard for many Polaris ATVs) 🛡️ Safety Features Ratings Atv Safety Standards: Complies with ANSI/SVIA standards (where applicable) Active Features Braking System: Hydraulic disc brakes front and rear Drive System Safety: On-Demand AWD system for enhanced traction Passive Features Operator...