Polaris 2003 ATV Sportsman 400 - Manual

1
OWNER’S MANUAL SUPPLEMENT
2003 SPORTSMAN 400
IMPORTANT: Keep this supplement with your owner’s manual at all times.
Capacities
Body Style Gen IV
Gross Vehicle Weight 1200 lbs.
Fuel Capacity 5.25 U.S. Gallons
Oil Capacity 2 Quarts
Front Rack (Maximum -
Capacity)
90 Lbs.
Rear Rack 180 Lbs.
Tongue Weight 120 Lbs.
Tow Hitch Standard
Tow Capacity 1225 Lbs.
Turn Radius 65²
Ground Clearance 11²
Height 47²
Length 81²
Seat Height 34²
Dry Weight 697
Wheel Base 50.50 ²
Width 46²
Drive System
Drive System Type Dual sensing,
Automatic PVT (Polaris Vari-
able Transmission)
Shift Type Side Lever (Hi/Lo-R-N)
Gear Reduction - Low 8.27 / 1
Gear Reduction - Reverse 5.17 / 1
Gear Reduction - Forward 3.34 / 1
Front Drive (ratio) 2:1
Final Drive (ratio) 3.16:1
Front Tire (PSI) 25 x 8-12 (5)
Rear Tire (PSI) 25 x 11-12 (5)
Suspension and Brakes
Front Susp. - Mac Strut 6.7²
Rear Susp., fully independent with
anti-roll bar
9.5²
Shock Adjustment CAM
Front Brake Hydraulic Disc
Rear Brake Hydraulic, opposed piston
caliper, fixed disc
Auxiliary Brake Hydraulic, opposed piston cali-
per, fixed disc
Park Brake Hydraulic lock, all wheel
Engine & Cooling
Engine Model Number EH42PLE-05
Engine Type 4 Cycle, Single Cylinder
Lubrication Dry Sump
Bore x Stroke 87.9 x 70
Displacement 425
Compression Ratio 9:2 Full Stroke
Engine Cooling Liquid
Alternator Output (watts) 250
Carburetion 1/BST34
Main Jet 167.5
Pilot Jet 40
Needle Jet Q-0 (829)
Pilot Screw 2 3/4 Turn (taper 12.5_)
Jet Needle 4GAC33-3
Ignition Digital CDI
Timing 30_ ± 2° @ 5000
Spark Plug Gap .9 mm/.036 in.
Spark Plug Type NGK BKR5E
Exhaust USFS Approved
Features
Headlight (on grill) (watts) 2 single beam, 27
Headlight (on handlebar) (watts) 1 single beam, 60
Taillight (watts) 8.26
Brake Light (watts) 26.9
3-Point Hitch Accessory
Battery 12V 14AH
DC Plug In - Rear Accessory
DC Socket - Forward Standard
Electric Start Standard
High Beam Indicator Standard
High Temp Indicator Standard
Windshield Accessory
Neutral Indicator Standard
Reverse Indicator Standard
Speedometer Standard
Tool Kit Standard
Carburetor Jetting Clutching Chart
Altitude AMBIENT
TEMPERATURE
Below +40° F
Below +5° C
+40° F & Above
+5° C & Above
Altitude Shift
Weight
Drive
Clutch
Spring
Driven
clutch
Spring
Helix and
Spring
Setting
Meters
(Feet)
0-1800
(0-6000)
175 167.5 Meters
(Feet)
0-1800
(0-6000)
10BH
5630711
Blue/
Green
7041157
Black
7041782
41-37°
5132344
2+2
1800 & above
(6000 & above)
165 160 1800 & above
(6000 &
above)
10WH
5630710
Blue/
Green
7041157
Black
7041782
41-37°
5132344
2+2
PN 9917536 Rev 01 4/02
E
2002 Polaris Sales Inc.
Printed in U.S.A.