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SPORTSMAN 400 2003
Polaris SPORTSMAN 400 2003 User Manual
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PN 9918065
Printed in USA
2003 SPOR
TSMAN 400 / 500 SER
VICE MANU
AL
PN 9918065
2003 SPOR
TSMAN 400 / 500
SER
VICE MANU
AL
PN 9918065
The W
ay Out.
218444_cover 6/27/02 7:12 AM Page 1
2
Table of Contents
Chapter Index
4
Table of Contents
4
General Information
7
Model Identification
7
Serial Number Location
7
General Information
8
Machine Dimensions
8
Publication Numbers
13
Replacement Keys
13
Standard Torque Specifications
14
Decimal Equivalents
15
Conversion Table
16
Decimal Equivalent Chart
17
Glossary of Terms
18
Chapter 2 Maintenance
20
Periodic Maintenance Chart
21
General
22
Pre-Ride Inspection
22
Maintenance
23
Special Tools
25
Transmission Lubrication
28
Front Gearcase Lubrication
28
Transmission
29
Idle Speed Adjustment
31
Pilot Screw Adjustment
31
Engine
32
Fuel System
32
Fuel Filter
33
Compression Test
34
Battery Maintenance
34
Electrical
35
Liquid Cooling System Overview
36
Cooling System Hoses
36
Coolant Level Inspection
37
Cooling System Pressure Test
37
Radiator Coolant Level Inspection
37
Air Box Sediment Tube Service
38
Breather Filter
39
Recoil Housing
39
Oil Change/Filter
40
Engine Oil Level
40
Valve Clearance
42
Exhaust Valve Clearance Adjustment
43
Camber and Caster
44
Exhaust Pipe
46
Brake Pad Inspection
47
Controls
48
Front Suspension
48
Wheel Removal/Installation
49
Tire Inspection
50
Maintenance
32
Chapter 3 Engine
52
Special Tools
53
Engine Service Data
54
Torque Specifications
53
Engine Fastener Torque Patterns
56
Piston Identification
56
Cooling System
57
Cooling System Specifications
58
Engine Removal
58
Pvt System
58
Engine Installation Notes
59
Honing to Oversize
60
Cleaning the Cylinder after Honing
60
Crankshaft Straightening
60
Oil Pressure Test
61
Eh50Pl Oil Flow Diagram
63
EH50PL Engine Exploded View
64
Cam Chain Tensioner Inspection
66
Rocker Arm/Shaft Inspection
66
Automatic Compression Release Installation
69
Camshaft Inspection
69
Cylinder Head Inspection
72
Cylinder Head Disassembly
72
Cylinder Head Warpage
72
Valve Inspection
73
Valve Seat Reconditioning
74
Combustion Chamber
74
Cylinder Head Assembly
77
Valve Sealing Test
77
Piston Removal
79
Cylinder Inspection
80
Piston/Rod Inspection
81
Crankcase Disassembly
82
Piston Ring Installed Gap
82
Crankcase Separation
84
One Way Valve
84
Oil Pump Removal/Inspection
85
Oil Pump Assembly
86
Crankshaft Removal/Inspection
87
Crankcase Bearing Inspection
88
Crankcase Inspection
88
Bearing Installation
89
Crankshaft End Play Adjustment
89
Oil Pump Shaft End Play Adjustment
91
Pump Shaft Oil Seal Installation
92
Crankcase Assembly
92
Water Pump Mechanical Seal Installation
93
One Way Valve Installation
94
Piston Ring Installation
95
Piston Installation
95
Cylinder Installation
96
Cylinder Head Installation
97
Camshaft Timing
97
Cam Chain Tensioner Installation
100
Thermostat Installation
101
Oil Pipes
102
Recoil Disassembly/Inspection
102
Recoil Assembly
103
Spark Plug Fouling Checklist
104
Troubleshooting
104
Chapter 4 Fuel System/Carburetion
106
Fuel Flow Diagram
109
Carburetor Jetting
110
Mikuni Jet Part Numbers
110
Jetting Guidelines
110
Assembly, CV Carburetor
111
Mikuni CV Carb Operation
111
Float System
113
Main System
113
Carburetor Cleaning
114
Float Height Adjustment
116
CV Carburetor System Function (4 Cycle)
111
Fuel Level
117
Fuel Pump Service
117
Fuel Pump Disassembly
118
Needle and Seat Leakage Test
117
Troubleshooting
119
Chapter 5 Body and Steering
120
Cover/Panel Removal
121
Side Panel Removal
122
Body Assembly Exploded View
123
Headlight Pod Exploded View
124
Steering Assembly, Exploded View
125
A-Arm Replacement
126
Rear Suspension Assembly
127
Strut Assembly
128
Front Strut Cartridge Replacement
129
Decal Replacement
130
Steering Post Assembly
130
Chapter 6 Pvt System
132
Chapter 1 Chapter 5
132
Pvt System
132
Drive Clutch Operation
133
Pvt System Fastener Torques
133
Driven Clutch Operation
133
PVT Maintenance/Inspection
134
Pvt Drying
134
PVT Disassembly
136
PVT Assembly
137
PVT Sealing and Ducting Components
138
Drive Clutch Exploded View
138
Drive Clutch Spring Specifications
139
Shift Weights
140
Drive Clutch Inspection
141
Drive Clutch Disassembly
141
Spider Removal
142
Drive Clutch Reassembly
143
Drive Belt Tension
144
Drive Belt Removal/Inspection
145
Drive Belt Installation
146
Clutch Alignment /Offset
147
Clutch Offset
147
Drive Clutch Bushing Service
148
Driven Clutch Disassembly/Inspection
150
Driven Clutch Assembly
152
Driven Clutch Bushing Service
152
Drive Clutch Inspection
156
EBS Driven Clutch Disassembly/Inspection
157
EBS Drive Clutch Bushing Service
160
EBS Driven Clutch Bushing Service
161
Troubleshooting
163
Chapter 7 Final Drive 7
166
Final Drive
166
AWD Operation Overview
167
AWD Front Hub Bearing Adjustment
169
AWD Front Hub Exploded View
170
AWD Hub Seal Replacement
171
AWD Armature Plate Inspection
173
AWD Front Drive Axle Removal
173
AWD Front Drive Axle Installation
174
AWD Front Drive Axle Exploded View
177
AWD Front Prop Shaft Removal
179
U-Joint Disassembly
180
U-Joint Assembly
180
AWD Front Housing Removal
181
AWD Front Housing Disassembly
182
AWD Front Housing Assembly
182
AWD Front Housing Installation
182
AWD Front Housing Exploded View
184
Rear Hub/Bearing Carrier Removal
185
Rear Hub Installation
186
Rear Hub Disassembly/Assembly
187
Rear Hub Assembly
187
Rear Drive Shaft Removal
188
Rear Driveshaft Installation
189
Rear Driveshaft Service
190
Chapter 8 Transmission Service
194
Gear Shift Selector Disassembly
195
Gear Shift Selector Removal
195
Special Tools
195
Torque Specifications
195
Gear Shift Selector Assembly
196
Boot Replacement
197
Gear Shift Selector Installation
197
Transmission Removal
198
Transmission Installation
199
Transmission Disassembly
201
Transmission Assembly
210
Troubleshooting
214
Troubleshooting Checklist
214
Transmission Exploded View
215
Chapter 9 Brakes
218
Brake System Main Components
219
Specifications
221
Brake Noise Troubleshooting
222
Brake System Service Notes
222
Hydraulic Caliper Bleeding
223
Brake Bleeding / Fluid Change
224
Master Cylinder Removal
225
Master Cylinder Installation
226
Front Pad Removal
227
Front Pad Assembly
228
Brake Burnishing
229
Front Disc Inspection
229
Front Caliper Disassembly
230
Front Caliper Removal
230
Front Caliper Inspection
231
Front Caliper Reassembly
232
Front Caliper Installation
233
Brake Burnishing Procedure
234
Rear Caliper Removal/Inspection
236
Rear Caliper Assembly
237
Troubleshooting
238
Chapter 10 Electrical
240
Chapter 9
240
Electrical
240
Special Tools/Service Notes
241
Timing Check Procedure
241
Electrical Service Notes
241
Gear Position Indicator
242
Instrument Cluster Troubleshooting
243
Diagnostic Mode
244
Speedometer Removal/Installation
245
Speedometer Troubleshooting
246
Fan Motor Current Draw
250
Etc Operation Test
251
Ignition System Testing Flow Chart
252
Ignition System Troubleshooting
253
Alternator Output Test
254
Charging System Testing Flow Chart
255
Battery Installation
257
Load Test
258
Charging Procedure
258
Off Season Storage
258
High Beam Headlight Adjustment
259
Headlight Housing Replacement
259
Headlamp Switch
260
Brake Light Switch
260
Starter System Troubleshooting
261
Voltage Drop Test
261
Starter Motor Disassembly
261
Armature Testing
263
Starter Drive
264
Starter Assembly
264
Starter System Testing Flow Chart
265
4
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Polaris SPORTSMAN 400 2003 Specifications
General
Brand
Polaris
Model
SPORTSMAN 400 2003
Category
Offroad Vehicle
Language
English
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