2003 Polaris Sportsman 500 6x6 & Parts Workshop Service Repair & Owners Manual

2003 SPORTSMAN 6X6 SERVICE MANUAL PN 9918067 The Way Out.

2003 SPORTSMAN 6x6 SERVICE MANUAL Foreword This manual is designed primarily for use by certified Polaris Master Service Dealer technicians in a properly equipped shop and should be kept available for reference. All references to left and right side of the vehicle are from the operator’s perspective when seated in a normal riding position. Some procedures outlined in this manual require a sound knowledge of mechanical theory, tool use, and shop procedures in order to perform the work safely and correctly. Technicians 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. This manual includes procedures for maintenance operations, component identification and unit repair, along with service specifications for 2003 Polaris Sportsman 6x6 ATVs. Comments or suggestions about this manual may be directed to: Service Publications Dept. @ Polaris Sales Inc. 2100 Hwy 55 Medina Minnesota 55340. 2003 Sportsman 6x6 ATV Service Manual (PN 9918067) 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 improvements 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 omissions 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 1.2 ....................... Serial Number Location 1.2 ................... Machine Dimensions 1.3-1.4 ..................... Specifications - 2003 Sportsman 6x6 1.5-1.6 ....... Publication Numbers 1.7 ..................... Paint Codes 1.7 ............................. Replacement Keys 1.7 ....................... Standard Torque Specifications 1.8 ............ Decimal Equivalent Chart 1.9 ................. Unit of Measure Conversion Table 1.10 .......... Tap Drill Charts 1.11 .......................... Glossary of Terms 1.12 ........................

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 CL 50 AA Emissions & Model Option ENGINE DESIGNATION NUMBERS 50 EH50PLE10 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 L 5 0 A * Y 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 The transmission I.D. number is located on top of the transmission, right side of machine. A B Front

FRONT SIDE 41 in 104.1 cm 46 in 116.8 cm 29.25 in 74.3 cm 22 in 55.8 cm 35.5 in 90.2 cm 13.5 in 34.3 cm 11 in 27.9 cm 49 in 124.5 cm 27 in 68.6 cm 11.5 in 29.2 cm 43.5 in 110.5 cm 104.5 in 265.4 cm GENERAL INFORMATION 1.3 MACHINE DIMENSIONS

43.75 in 111.13 cm 32 in 81.3 cm 5.5 in 13.97 cm 34.875 in 88.5 cm 45.5 in 115.5 cm 40.5 in 102.9 cm 48 in 121.9 cm REAR GENERAL INFORMATION 1.4 MACHINE DIMENSIONS

GENERAL INFORMATION 1.5 2003 MODEL SPECIFICA TIONS MODEL: SPORTSMAN 6X6 .......... MODEL NUMBER: A03CL50AA . ENGINE MODEL: EH50PLE10 .. JETTING CHART AMBIENT TEMPERATURE Altitude Below 40F +40_to +80_F ltitude Below 40 F Below +5C +40 to +80 F +5_ to +26_C Meters 0-1800 147 5 142 5 Meters (Feet) 0-1800 (0-6000) 147.5 142.5 (Feet) Above 1800 140 135 Above 1800 Above (6000) 140 135 CLUTCH CHART Shift Drive Clutch Driven Clutch Driven Altitude Shift Weight Drive Clutch Spring Driven Clutch Spring Driven Helix Altitude Weight Spring Spring Helix Meters 0-1800 10MH Blue/Green Red 2 2 Meters (Feet) 0-1800 (0-6000) 10MH Blue/Green Red 2-2 (Feet) 1800-3700 10WH Blue/Green Red 2 2 1800-3700 (6000-12000) 10WH Blue/Green Red 2-2 ENGINE Type 4 Cycle, Single Cyl. ....................... Displacement 498 cc ............... Bore 3.625I (92mm) ....................... Stroke 2.955I (75mm) ..................... Valve Clearance In/Ex 0.006/0.006I ....... @TDC on compression Compression Ratio 10/2 Full Stroke .......... Cooling Liquid .................... Lubrication Type Dry Sump ............ Operating RPM200 6000 RPM ......... Idle RPM200 (lights off) 1200 RPM ..... Compression Pressure (Std) 15% ....... CARBURETION Type BST 34 Mikuni ................ Main Jet 142.5 ............ Pilot Jet 40 ............. Jet Needle 4HB41-3 ........... Needle Jet Q-4 (829) ........... Throttle Valve #100 ........ Pilot Screw 3 .......... Pilot Air Jet 160 .......... Valve Seat 1.5 ........... Float Height 14.7mm (.58I)  1 mm ......... Fuel Octane (R+M/2) 87 Non-Oxygenated or . 89 Oxygenated CLUTCH Type PVT .................... Belt 3211077 ..................... Belt Width (Projected) 1.188I (30.18 mm) ..... Side Angle (Overall) 26 ...... Outside Circumference 40.86 .12I .... Center Distance 10.12I (254.5 mm) .......... Clutch Offset 0.5I (12.7 mm) ............ Secondary Spring Red ........ Driven Helix Angle 40 ........ Spring Position (Helix) 2 .... Spring Position (Sheave) 2 ..

2003 Polaris Sportsman 500 6x6 & Parts Workshop Service Repair & Owners Manual

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