2003-2004 Polaris Sportsman 400 500 H.O. Service & Repair Manual

2003-04 SPORTSMAN 400 / 500 SERVICE MANUAL PN 9918065 The Way Out.

2003-04 SPORTSMAN 400/500 SERVICE MANUAL Foreword This manual is designed primarily for use by Polaris ATV service technicians in a properly equipped shop. Persons using this manual should have a sound knowledge of mechanical theory, tool use, and shop procedures in order to perform the work safely and correctly. The technician should read the text and be familiar with service procedures before starting the work. Certain procedures require the use of special tools. Use only the proper tools, as specified. Cleanliness of parts and tools as well as the work area is of primary impor- tance. All references to left and right side of the vehicle are from the operator’s perspective when seated in a normal riding position. This manual includes procedures for maintenance operations, component identification and unit repair, along with service specifications for the 2003 Polaris Sportsman ATVs. A table of contents is placed at the beginning of each chapter, and an alphabetic index is provided at the end of the manual for location of specific page numbers and service information. Keep this manual available for reference in the shop area. At the time of publication all information contained in this manual was technically correct. However, all materials and specifications are subject to change without notice. Comments or suggestions about this manual may be directed to: Polaris Sales Inc., Service Publications Department, 2100 Hwy 55 Medina, Minnesota 55340. 2003-04 Sportsman 400/500 ATV Service Manual (PN 9918065) ECopyright 2002 Polaris Sales Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant improcvements in the design and quality of production components, some minor descrepancies may result between the actual vehicle and the information presented in this publication. Depictions and/or procedures in this publication are intended for reference use only. No liability can be accepted for ommisions or inaccuracies. Any reprinting or reuse of the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited. Printed in U.S.A.

UNDERSTANDING SAFETY LABELS AND INSTRUCTIONS Throughout these instructions, important information is brought to your attention by the following symbols: The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! DANGER Failure to follow DANGER instructions will result in severe injury or death to the operator, bystander or person inspecting or servicing the ATV. WARNING Failure to follow WARNING instructions could result in severe injury or death to the operator, bystander or person inspecting or servicing the ATV. CAUTION: A CAUTION indicates special precautions that must be taken to avoid personal injury, or ATV or property damage. NOTE: A NOTE provides key information to clarify instructions. Trademarks Polaris acknowledges the following products mentioned in this manual: FLEXLOC, Registered Trademark of SPS Technologies Loctite, Registered Trademark of the Loctite Corporation STA-BIL, Registered Trademark of Gold Eagle FOX, Registered Trademark of Fox Shox Nyogel, Trademark of Wm. F. Nye Co. Fluke, Registered Trademark of John Fluke Mfg. Co. Mity Vac, Registered Trademark of Neward Enterprises, Inc. Ammco, Registered Trademark of Ammco Tools, Inc. Torx, Registered Trademark of Textron Hilliard, Trademark of the Hilliard Corporation

CHAPTER INDEX CHAPTER 1 GENERAL CHAPTER 2 MAINTENANCE CHAPTER 3 ENGINE CHAPTER 4 FUEL SYSTEM CHAPTER 5 BODY/SUSPENSION CHAPTER 6 PVT SYSTEM CHAPTER 7 FINAL DRIVE CHAPTER 8 TRANSMISSION CHAPTER 9 BRAKES CHAPTER 10 ELECTRICAL

1 GENERAL INFORMATION 1.1 CHAPTER 1 GENERAL INFORMA TION Model Identification 1.1 ....................... Serial Number Location 1.1 ................... Machine Dimensions 1.2--1.4 ..................... Specifications - Sportsman 400 1.5-1.6 ............ Specifications - Sportsman 500 H.O. 1.7-1.8 ........ Publication Numbers 1.9 ..................... Paint Codes 1.9 ............................. Replacement Keys 1.9 ....................... Standard Torque Specifications 1.10 ............ Torque Conversion Table 1.11-1.12 .................. Decimal Equivalent Chart 1.13 ................. Conversion Table 1.14 ........................ Tap Drill Charts 1.15 .......................... Glossary of Terms 1.16-1.17 ........................

GENERAL INFORMATION 1.2 MODEL IDENTIFICA TION The machine model number must be used with any correspondence regarding warranty or service. Machine Model Number Identification Year Designation Basic Chassis Designation Engine Designation A 03 CH 50 AA Emissions & Model Option ENGINE DESIGNATION NUMBERS 42 EH42PLE05 Single, L/C, SOHC 4 Stroke, Electric Start ............ 50 EH50PLE13 Single, L/C, SOHC 4 Stroke, Electric Start ............ VIN IDENTIFICA TION 1 2 3 4 5 6 7 8 9 10 1 1 12 13 14 15 16 17 4 X A C H 5 0 A * 2 P 0 0 0 0 0 0 Vehicle Descriptor Vehicle Identifier Powertrain Engine Emissions Model Year Plant No. Individual Serial No. Body Style Check Digit World Mfg. ID * This could be either a number or a letter ENGINE SERIAL NUMBER LOCA TION Whenever corresponding about an engine, be sure to refer to the engine model number and serial number. This information can be found on the sticker applied to the recoil housing on the right side of engine.(A) An additional number is stamped on the center top of crankcase beneath the cylinder coolant elbow. MACHINE MODEL NUMBER AND SERIAL NUMBER LOCA TION The machine model number and serial number are important for vehicle identification. The machine serial number is stamped on the lower left side of the frame tube.(B) TRANSMISSION I.D. NUMBER LOCA TION A B Front The transmission I.D. number is located on top of the transmission snorkel, right side of machine.

SPORTSMAN 400/500 47 in 114 cm 11 in 28 cm 46 in 117 cm 46 in 117 cm 51 in 129.5 cm 81 in 205.7 cm 51 in 128 cm 400 -- 500 -- 85 in 216 cm GENERAL INFORMATION 1.3 MACHINE DIMENSIONS

GENERAL INFORMATION 1.4 MODEL: SPORTSMAN 400 .......... MODEL NUMBER: A03CH42 . ENGINE MODEL: EH42PLE05 .. JETTING CHART AMBIENT TEMPERATURE Altitude Below 40F +40_F and above ltitude Below 40 F Below +5C +40 F and above +5_C and above Meters 0-1800 175 167 5 Meters (Feet) 0-1800 (0-6000) 175 167.5 (Feet) Above 1800 Above 1800 Above (6000) 165 160 CLUTCH CHART Shift Clutch Driven Cluthc Driven Altitude Shift Weight Clutch Spri g Driven Cluthc Spri g Driven Helix Altitude Weight Spring Spring Helix Meters 0-1800 10BH Blue/ ree Bl ck 2+2 Meters (Feet) 0-1800 (0-6000) 10BH Blue/Green Black 2+2 (Feet) 1800-3700 16 Blue/ ree Bl ck 2+2 1800-3700 (6000-12000) 16 Blue/Green Black 2+2 ENGINE Type 4 Cycle, Single Cyl. ....................... Displacement 425 cc ............... Bore 3.461I (87.9mm) ....................... Stroke 2.756I (70mm) ..................... Valve Clearance In/Ex 0.006/0.006I@ TDC on compression ....... Compression Ratio 9.2/1 Full Stroke .......... Cooling Liquid .................... Lubrication Type Dry Sump ............ Operating RPM200 6300 RPM ......... Idle RPM200 (lights off) 1200 RPM ..... Compression Pressure (Std) 15% ....... CARBURETION Type BST 34 Mikuni ................ Main Jet 167.5 ............ Pilot Jet 40 ............. Jet Needle 4GAC33--3 ........... Needle Jet Q-0 (829) ........... Throttle Valve #100 ........ Pilot Screw 2 3/4 Turns Out .......... Pilot Air Jet 160 .......... Valve Seat 1.5 ........... Float Height 13.0mm (.51I)1mm ......... Fuel Octane (R+M/2) 87 Non-Oxygenated or . 89 Oxygenated CLUTCH Type PVT .................... Belt 3211069 ..................... Belt Width (Projected) 1.188I (30.18mm) ..... Side Angle (Overall) 26 ...... Outside Circumference 40.86 .12I .... Center Distance 10.12I (254.5mm) .......... Clutch Offset 0.5I (12.7mm) ............ Secondary Spring Black ........ Driven Helix 44-36 ............. Spring Position (Helix) 2 .... Spring Position (Sheave) 2 ..

Lubricant Key GENERAL INFORMATION 1.5 MODEL: SPORTSMAN 400 ............ MODEL NUMBER: A03CH42 ... ENGINE MODEL: EH42PLE05 .... ELECTRICAL FLUID Capacity Type Flywheel I.D. FF95 Fuel Tank 5.25 gals. (19.9L) ...... .......... CDI Marking CU2557 Injector Oil N/A ....... .......... ......... **Alternator Output 200 Watts / 250 Watts Coolant 2.25 qts. (2.1L) PP6* . ............ Ignition Timing 30 BTDC@5000RPM2 Transmission 32 oz. PPS* ..... ....... ....... Spark Plug / Gap NGK BKR5E / 0.036I (0.9mm) Gearcase Oil (Front) 4 oz. (120ml) 80-90 GL5 ... . . Lights: Head Halogen Gearcase Oil (Center) N / A ...... High Beam 50watts Gearcase Oil (Rear) N/A . . Low Beam 27 watts Engine Counter Bal. N/A . . ......... Tail 8.26 watts Engine Oil 2 qts. (1.9L) PP4* ........ .......... .. Brake 26.9 watts Brake (Hand) Dot 3 ...... ....... Voltage Regulator LR39 Brake (Foot) Dot 3 .. ........ Electric Start Standard Front Hubs (AWD) 2.5 oz. (75ml) PDD* ....... ... **Early Build Units Have 200 Watt Altnerantor Shift Selector Box 1 oz. (30ml) PP4* ... .. *PP6 Polaris Premium 60/40 Antifreeze/Coolant *PPS Polaris Premium Synthetic Gear Case Oil *PP4 Polaris 0W/40 Synthetic Engine Lubricant *PDD Premium Demand Drive Hub Fluid SUSPENSION / CHASSIS DRIVE TRAIN Body Style Gen IV Chain Type Shaft Drive ........ ......... Front Suspension MacPherson Strut Gear Reduction-Low 6.69/1 .. . Tow Capacity 1225 lbs. (555.6 kg) Gear Reduction-Rev 5.17/1 ...... .. Turning Radius 65I (165.1 cm) Gear Reduction-High 3.34/1 ..... Toe Out 1/8I-1/4I (3-6.35 mm) Front Drive Ratio 2/1 ........... .... Ground Clearance 11I (27.94 cm) Center Drive Ratio N/A .. ... Front Vertical Travel 6.7I (17.02 cm) Final Drive Ratio 3.16/1 .... Rear Suspension Progressive Rate Independent Brake (Hand) Single Lever, Hyd. Disc ... ....... Rear Travel 9.5I (24.13cm) Brake (Auxiliary Foot) Hydraulic ........ Rear Shock 2I Twin Tube ........ Shock Adjustment Cam .. TIRES Tire Size - Front 25 x 8 - 12 .... Tire Size - Rear 25 x 11 - 12 .... Tire Size - Center N/A .. Tire Pressure - F/R 5/5 lbs . Total Width 46I (116.84 cm) ........ Total Length 81I (205.74 cm) ....... Total Height 47I (119.38 cm) ........ Wheel Base 50.50I (128.27 cm) ....... Weight - Dry 697 lbs. (316.4 kg) ....... OPTIONAL SUSPENSION SPRINGS SPRING TYPE SOFT STANDARD FIRM Rear Compression Spring N/A 7041453-067 Standard 100 lb/in. 7041519-067 Option 140 lb/in. Front Strut Spring 7041238-067 Option 61 lb/in. 7041375-067 Standard 64/113 lb/in. 7041450-067 Option 101 lb/in. LOAD CAPACITY Front Rack (Std) 90 lbs. ..... Rear Rack (Std) 180 lbs. ...... Tongue Weight 120 lbs. .... Tow Hitch Std ...........

2003-2004 Polaris Sportsman 400 500 H.O. Service & Repair Manual

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