2003 Polaris Sportsman 400 Owners Manual - Page 1

OWNER'S MANUAL SUPPLEMENT 2003 SPORTSMAN 400 IMPORTANT: Keep this supplement with your owner's manual at all times. Body Style Gross Vehicle Weight Fuel Capacity Oil Capacity Front Rack (Maximum Capacity) Rear Rack Tongue Weight Tow Hitch Tow Capacity Turn Radius Ground Clearance Height Length Seat Height Dry Weight Wheel Base Width Capacities Gen IV 1200 lbs. 5.25 U.S. Gallons 2 Quarts 90 Lbs. 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 180 Lbs. 120 Lbs. Standard 1225 Lbs. 65² 11² 47² 81² 34² 697 50.50 ² 46² Drive System Drive System Type Dual sensing, Automatic PVT (Polaris Variable 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 9.5² anti-roll bar Shock Adjustment Front Brake Rear Brake Auxiliary Brake CAM Hydraulic Disc Hydraulic, opposed piston caliper, fixed disc Hydraulic, opposed piston caliper, fixed disc Carburetor Jetting Altitude AMBIENT TEMPERATURE 0-1800 (0-6000) 1800 & above (6000 & above) Below +40° F Below +5° C 175 +40° F & Above +5° C & Above 167.5 Clutching Chart Altitude Shift Weight 10BH 5630711 10WH 5630710 Drive Clutch Spring Blue/ Green 7041157 Blue/ Green 7041157 Driven clutch Spring Black 7041782 Black 7041782 Helix and Spring Setting 41-37° 5132344 2+2 41-37° 5132344 2+2 Meters (Feet) Meters (Feet) 0-1800 (0-6000) 1800 & above (6000 & above) 165 160 PN 9917536 Rev 01 4/02 E 2002 Polaris Sales Inc. Printed in U.S.A. 1