2003 Polaris Sportsman 400 500 ATV Service Repair Manual Instant Download PDF
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🏷️ Basic Information
Identification
Make:
Polaris
Model:
Sportsman 400/500
Year:
2003
Generation:
2nd Generation Sportsman (1996-2005)
📋 Manual Details
Publication
Manual Type:
Service and Repair Manual
Format:
PDF
Delivery Method:
Instant Download
Language:
English
⚙️ Engine Specifications
Engine 400
Engine Type:
4-stroke, 2-cylinder, liquid-cooled, SOHC
Displacement:
499 cc
Bore X Stroke:
77.0 mm x 61.5 mm
Compression Ratio:
9.0:1
Engine 500
Engine Type:
4-stroke, single-cylinder, liquid-cooled, SOHC
Displacement:
499 cc
Bore X Stroke:
92.0 mm x 75.0 mm
Compression Ratio:
8.4:1
Common
Fuel System:
Carburetor (Mikuni BSR42)
Ignition System:
CDI
🔧 Transmission
Drivetrain
Type:
Automatic PVT (Polaris Variable Transmission)
Drive System:
Shaft Drive, On-Demand AWD
Gear Selection:
High, Low, Neutral, Reverse
📐 Dimensions
Physical
Length:
83 inches (approx.)
Width:
46 inches (approx.)
Height:
47 inches (approx.)
Wheelbase:
50 inches (approx.)
Ground Clearance:
11.25 inches (approx.)
🔧 Maintenance
Lubrication 400
Oil Capacity:
2.1 quarts (2.0 L) with filter change
Lubrication 500
Oil Capacity:
2.1 quarts (2.0 L) with filter change
Service Schedule
Oil Change Interval:
Refer to manual for specific intervals (e.g., every 100 hours or annually)
Filter Change Interval:
Refer to manual for specific intervals (e.g., every 100 hours or annually)
📄 Chassis And Suspension
Front Suspension
Type:
MacPherson Strut
Rear Suspension
Type:
Independent
Brakes
Front Brake Type:
Dual Hydraulic Disc
Rear Brake Type:
Single Hydraulic Disc
Wheels And Tires
Front Tire Size:
AT 25x8-12 (typical)
Rear Tire Size:
AT 25x10-12 (typical)
📄 Capacities
Fuel
Fuel Tank Capacity:
3.25 gallons (12.3 L)
Towing
Towing Capacity:
1500 lbs (680 kg)
Rack Capacity
Front Rack Capacity:
100 lbs (45 kg)
Rear Rack Capacity:
200 lbs (90 kg)
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Sku: 50415
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