2003 Polaris Sportsman 400 500 ATV Service Repair Manual

Description

This Official 2003 Polaris Sportsman 400/500 Factory Service Repair Manual provides detailed service information, step-by-step repair instruction and maintenance specifications for 2003 Sportsman 400 and 500 ATVs.

Table of contents includes:

GENERAL INFORMATION – 2003 Model Identification, Serial Number Location, Replacement Keys, Machine Dimensions, Specifications, Publication Numbers, Paint Codes, Standard Torque Specifications, Tap Drill Charts, Decimal Equivalent Chart, Unit of Measure Conversion Table, Glossary of Terms

MAINTENANCE – Periodic Maintenance Chart, Pre-Ride Inspection, Lubricant and Maintenance Product Numbers, Special Tools, Lubrication Charts, Transmission Lubrication, Transmission Linkage Adjustment, Throttle / Carburetor Adjustments, Oil Pump Adjustment/Bleeding /Filter, Fuel System, Compression Test, Battery Maintenance, Electrical, Air Filter Service, Recoil Housing, Steering and Toe Alignment, Exhaust System Maintenance, Brake System Service, Drive Chain and Sprocket Service, Suspension Service, Wheel Removal/Installation, Tire Inspection

ENGINE – Special Tools, Torque Specifications, Torque Patterns, Piston Identification, Accessible Components, Engine Removal/Installation Notes, Engine Disassembly, Engine Inspection/crank endplay, Engine Assembly, Oil Pump End Play Adjustment, Oil Check Valve Testing, Recoil Disassembly/Assembly, Cooling System, Reed and Water pump Impeller, Crankcase seal orientation, Cylinder and Piston Inspection/Honing, Connecting Rod/Crankshaft Inspection, Spark Plug Fouling Checklist, Piston Damage Troubleshooting, Engine Troubleshooting

FUEL SYSTEM/CARBURETION – Fuel and Oil Tank Asm Exploded View, Carburetor Exploded View, Special Tools, Carburetor System Function, Carburetor Jetting / Guidelines, Air Screw Adjustment, Carburetor Circuit Operation, Carburetor Vent Systems, Float Height Adjustment, Needle and Seat Leakage Test, Main Jet / Pilot Jet Part Numbers, Fuel Flow Diagram, Troubleshooting

BODY AND STEERING – Body/Steering Assembly Exploded Views, Torque Specifications and Special Tools, Cover/Panel Removal, A-Arm Replacement, Concentric Swing Arm Removal, Concentric Swing Arm Assembly/Installation, Strut Assembly Exploded View, Front Strut/Ball Joint Replacement, Fox Shocks Service, Steering Post Assembly, Decal Replacement

PVT SYSTEM – Service Tools and Supplies, PVT System Torques, PVT System Operation Overview, PVT Maintenance/Inspection, PVT Drying, PVT Over heating, PVT Disassembly, PVT Assembly, PVT Sealing and Ducting Components, Drive Clutch Spring Specifications, Shift Weights, Drive Clutch Disassembly/Inspection, Drive Clutch Assembly, Drive Belt Tension, Drive Belt Removal/Inspection, Drive Belt Installation, Clutch Alignment /Offset, Drive Clutch Bushing Service, Driven Clutch Disassembly/Inspection, Driven Clutch Assembly, Driven Clutch Bushing Service, Drive/Driven Clutch Exploded View, Troubleshooting

FINAL DRIVE – Special Tools/ Torque Specifications Front Hub Disassembly/Inspection, Front Hub Assembly, Front Hub Installation, Front Hub Exploded View, Rear Axle Removal, Rear Axle Disassembly, Rear Axle Assembly, Rear Axle Installation, Rear Housing Removal, Rear Housing Disassembly, Rear Housing Installation, Rear Axle Exploded View

TRANSMISSION SERVICE – Special Tools, Torque Specifications, Transmission Remove/Install Transmission Disassembly, Transmission Assembly, Troubleshooting, Transmission Exploded View

BRAKES – Specifications/Torques, Special Tools, Brake System Service Notes, Brake Noise Troubleshooting, Hydraulic Brake System Operation, Brake System Main Components, Dual Hydraulic Caliper Bleeding, Fluid Replacement/Bleeding Procedure, Master Cylinder Disassembly, Master Cylinder Installation, Front Pad Removal, Front Pad Assembly, Front Disc Inspection, Front Disc Removal/Replacement, Front Caliper Removal, Front Caliper Disassembly, Front Caliper Inspection, Front Caliper Assembly, Front Caliper Installation, Front Caliper Exploded View, Rear Pad Removal, Rear Pad Installation, Rear Caliper Removal/Inspection, Rear Caliper Assembly, Rear Disc Inspection, Troubleshooting, Rear Caliper Exploded View

ELECTRICAL – Crankshaft Degree to Piston Position Conversion, Special Tools & Notes, Timing Check & Typical Timing Curve, Transmission Gear Position Switch Testing, Speed Limiter Specifications, Reverse Limit System Diagram, Reverse Limit Troubleshooting, Electronic Throttle Control System Operation, Flywheel Identification, Exploded View Ignition Components, Ignition Troubleshooting, CDI Output Test (peak reading meter), Charging System Testing, Break Even Test, Alternator Output Test, Battery Initial Service, Headlight/Headlamp Adjustment, Taillight/lndicator Lamp Replacement, Oil Level Sensor/Switch Testing, Brake Light/Headlamp Switch, Starter System Troubleshooting, Starter Motor Service, Starter Drive, Wiring Diagram