Basic Information Identification Make: Polaris Model: Sportsman 400 / 500 Year: 2003 Vehicle Type: All-Terrain Vehicle (ATV) Category: Utility ATV Introduction Market Position Market Segment: Mid-size utility ATVs, known for their versatility and Polaris's reputation in the off-road market. Competitive Analysis Competitors 2003: Honda Foreman/Rancher, Yamaha Kodiak/Grizzly, Kawasaki Prairie, Suzuki King Quad. Key Features Vehicle Strengths: Durable chassis, capable suspension, powerful engine options, Polaris Variable Transmission (PVT) for ease of use, on-demand AWD (likely on 500 model). Manual Value Proposition User Benefit: Empowers owners with the knowledge for preventive maintenance, troubleshooting, and repairs, saving time and money, and ensuring optimal vehicle performance. Manual Details Coverage Models Covered: 2003 Polaris Sportsman 400 ATV, 2003 Polaris Sportsman 500 ATV Page Count Total Pages: 274 Manual Type Type: Service Repair Manual Language Language: English Format File Format: PDF Manual Coverage Systems Systems Covered: General Information, Maintenance, Engine, Fuel System, Body/Suspension, PVT System (Polaris Variable Transmission), Final Drive, Transmission, Brakes, Electrical System, Wiring Diagrams Procedures Procedures Included: Routine maintenance, troubleshooting, repair procedures, component diagnostics, disassembly and reassembly, electrical system troubleshooting, wiring diagram interpretation, fluid checks and changes, brake system service, suspension adjustments, PVT system maintenance and repair, engine overhaul basics. Technical Depth Depth: Comprehensive; suitable for amateur owners to professional technicians, covering detailed procedures and diagnostics. Manual Specifications File Attributes Compatibility: All Versions of Windows & Mac Requirements: Adobe PDF Reader Print Quality Printability: Printable Searchability Text Search: Searchable text within PDF Engine Specifications Primary Engine 400 Engine Type: 4-stroke, Liquid-cooled, SOHC, Single Cylinder Displacement: 375cc Bore X Stroke: 90mm x 71.1mm Compression Ratio: 9.7:1 Primary Engine 500 Engine Type: 4-stroke, Liquid-cooled, SOHC, Single Cylinder Displacement: 499cc Bore X Stroke: 92mm x 75mm Compression Ratio: 9.0:1 Fuel System Carburetor 400: Mikuni BSR42 Carburetor 500: Mikuni BSR42 Ignition System: Electronic CDI Cooling System: Liquid Cooling with Fan Lubrication System: Wet Sump Fluid Specifications Engine Oil Type: SAE 10W-40, API SG or higher (Specific Polaris recommendation may vary, consult manual) Coolant Type: Ethylene Glycol based antifreeze (50/50 mix with distilled water) Transmission Primary Drive Type: Polaris Variable Transmission (PVT) - Automatic CVT Secondary Drive Type: Shaft Drive Gear Selection Modes: High, Low, Neutral, Reverse, Park Final Drive Gearing Differential: Limited Slip Front Differential (likely on 500), Sealed Rear Gearcase Fluid Specifications Transmission Fluid Type: Polaris AGL High Performance Synthetic Gearcase Lubricant (or equivalent SAE 80W-90 gear oil for rear gearcase, PVT may use specific belt lubricant/cleaner) Dimensions Exterior Length: Approx. 81 in (205.7 cm) Width: Approx. 48 in (121.9 cm) Height: Approx. 47 in (119.4 cm) Wheelbase Wheelbase: Approx. 50.5 in (128.3 cm) Ground Clearance Ground Clearance: Approx. 10.25 in (26.0 cm) Weights Dry Weight: Approx. 600-620 lbs (272-281 kg) depending on model Capacity Rack Capacity Front: 75 lbs (34 kg) Rack Capacity Rear: 150 lbs (68 kg) Towing Capacity: 1255 lbs (569 kg) Dimensions Fuel Capacity: 3.4 gal (12.9 L) with 0.7 gal (2.6 L) reserve Safety Features Active Features Braking System: Hydraulic disc brakes front and rear; Foot-activated hydraulic brake pedal, Left-hand handlebar brake lever (front). Passive Features Lighting: Dual Halogen 35W headlights, 8W taillight. Handlebars: High-rise handlebars with padding for control and comfort. Safety Warnings Manual Emphasis: Manual strongly emphasizes safe operating practices, wearing protective gear (helmet, eye protection, gloves, boots), and avoiding operation under the influence of alcohol or drugs. Technology Features Powertrain Technology Transmission Feature: Polaris Variable Transmission (PVT) with engine braking capabilities. Drive System: On-Demand All-Wheel Drive (AWD) system on 500 model, likely with ADC (Active Descent Control) on some variants; 2WD on 400 model. Instrumentation Dashboard Display: Digital odometer, trip meter, tachometer, gear indicator, fuel gauge, clock, and warning lights. Ignition System Starting Method: Electric Start with backup recoil starter. Lighting Technology Headlights: Dual Halogen headlights for excellent nighttime visibility. Wiring Diagram Importance: Manual includes detailed wiring diagrams essential for diagnosing electrical faults and understanding component functionality. Maintenance Service Intervals Oil Change Interval: Every 100 hours or 6 months (whichever comes first). Air Filter Cleaning: Every 25 hours or as needed based on conditions. Spark Plug Check: Every 50 hours. Valve Clearance Check: Every 100 hours. Brake Fluid Change: Every 12 months. Fluid Specifications Brake Fluid Type: DOT 4 Hydraulic Brake Fluid Fluid Capacities Engine Oil Capacity: Approx. 2.5 US quarts (2.4 L) with filter change. Cooling System Capacity: Approx. 1.8 US quarts (1.7 L) Known Issues Common Wear Items: PVT belt wear/replacement, suspension bushings and ball joints, starter solenoid, fuel pump, wheel bearings. Troubleshooting Focus Manual Utility: Manual provides detailed diagnostic flowcharts and procedures for common starting, running, and electrical issues. Vehicle History Brand Heritage Brand Focus: Polaris is a long-standing American manufacturer known for its pioneering work in snowmobiles and its expansion into ATVs, PWC, and other powersports vehicles. Model Evolution Sportsman Lineage: The Sportsman line, introduced in the early 1990s, is Polaris's flagship utility ATV series,...