🏷️ 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 Protection: Handlebar handguards, protective floorboards Lighting: Dual halogen headlights, brake light/taillight 💡 Technology Features Infotainment Infotainment Features: Basic digital display (odometer, trip meter, gear indicator, clock, fuel level) Driver Assistance Traction Control: On-Demand AWD system provides enhanced traction Connectivity Connectivity Features: N/A (No modern connectivity features expected for this era) 🔧 Maintenance Service Intervals Engine Oil Change Interval: Every 100 hours or 12 months (refer to manual for specific conditions) Air Filter Cleaning Interval: Check every 25 hours, clean/replace as needed Spark Plug Check Interval: Every 50 hours or annually Valve Clearance Check Interval: Every 100 hours or annually Transmission Fluid Change Interval: Every 100 hours or 12 months (verify with manual) Fluid Specifications Engine Oil Specification: SAE 5W-30 or 10W-40, API SG or higher (check specific model and climate recommendation in manual) Coolant Specification: Ethylene glycol-based antifreeze/coolant (50/50 mix with distilled water) Brake Fluid Specification: DOT 3 or DOT 4...