Polaris Sportsman 2003 Service
Polaris Sportsman · 2003 · service manual · 274 pages
Technical data
Numbers below were extracted automatically from the document. Verify them against the original manual before you order parts or apply torque.
Tightening torque
Values extracted from the document text. Check against the original before service work.
| Item | Value | Also | PDF page |
|---|---|---|---|
| Throttle lever operation | 4 N·m | 35 in·lb | p. 30 |
| Radiator hose clamp | 4.1 N·m | 36 in·lb | p. 36 |
| Front Wheel Nuts | 27.1 N·m | 27 N·m | p. 49 |
| Rear Wheel Nuts | 27.1 N·m | 27 N·m | p. 49 |
| Rear Hub Retaining Nut | 135.6 N·m | 136 N·m | p. 49 |
| Ring Profile | 8.1 N·m | 8 N·m | p. 95 |
| Bolts evenly | 27.1 N·m | 27 N·m | p. 102 |
| Vehicle Frame Bolt | 40.7 N·m | 30 ft·lb | p. 126 |
| Washer A-Arm Tube | 10.8 N·m | 8 ft·lb | p. 126 |
| Washer A-Arm Tube | 33.9 N·m | 25 ft·lb | p. 126 |
| Cotter Pin | 40.7 N·m | 41.4 N·m | p. 126 |
| Clamp | 24.4 N·m | 18 ft·lb | p. 128 |
| Clamp | 25 N·m | p. 128 | |
| Pinch bolts | 20.3 N·m | 21 N·m | p. 129 |
| Strut Rod Nut | 20.3 N·m | 21 N·m | p. 129 |
| Drive Clutch Retaining Bolt | 54.2 N·m | 54 N·m | p. 133 |
| Driven Clutch Retaining Bolt | 23 N·m | 23 N·m | p. 133 |
| PVT Inner Cover Bolts | 16.3 N·m | 16 N·m | p. 133 |
| Drive Clutch Spider EBS Clutch | 271.2 N·m | 200 ft·lb | p. 133 |
| Upward on drive clutch sheaves | 271 N·m | p. 133 | |
| Drive Clutch Spider Lock Nut | 20.3 N·m | 15 ft·lb | p. 133 |
| Drive Clutch Cover Plate | 10.2 N·m | 10 N·m | p. 133 |
| Rear Hub Retaining Nut | 108.5 N·m | 109 N·m | p. 167 |
| Retaining bolts | 24.4 N·m | 25 N·m | p. 169 |
| Spindle and axle assembly | 35 N·m | p. 178 | |
| Cover Bolts | 19 N·m | 19 N·m | p. 183 |
| O-ring and bolts | 19 N·m | 19 N·m | p. 183 |
| Pinion Shaft Lock Nut Fill Plug | 88.1 N·m | 89.7 N·m | p. 183 |
| Rear Wheel Nut | 27.1 N·m | 27 N·m | p. 186 |
| Cover screws | 16.3 N·m | 17 N·m | p. 197 |
| Rear Wheel Retaining Bolt | 27.1 N·m | 27 N·m | p. 200 |
| Anvil Bolts | 24.4 N·m | 18 ft·lb | p. 220 |
| Washers | 25 N·m | p. 220 | |
| Bleeder Screw | 3.4 N·m | p. 225 | |
| Sealing washers | 20.3 N·m | 15 ft·lb | p. 226 |
| Sealing washers | 21 N·m | p. 226 | |
| Mounting bolts | 2.8 N·m | 3 N·m | p. 226 |
| Bolt first | 2.8 N·m | 3 N·m | p. 226 |
| Front Caliper Mounting Bolts | 24.4 N·m | 25 N·m | p. 228 |
| Front Wheel Nut | 27.1 N·m | 27 N·m | p. 229 |
| Front Brake Disc Mounting Bolt | 24.4 N·m | 25 N·m | p. 230 |
| Front Caliper Mounting Bolt | 24.4 N·m | 25 N·m | p. 233 |
| Rear Brake Caliper | 24.4 N·m | 25 N·m | p. 235 |
| O-Rings | 25 N·m | p. 237 | |
| Brakes Squeal | 20.3 N·m | 21 N·m | p. 238 |
Spark plugs
Values extracted from the document text. Check against the original before service work.
| Item | Value | Also | PDF page |
|---|---|---|---|
| FF95 | — | p. 10 | |
| FF97 | — | p. 12 | |
| H50PL | — | p. 52 | |
| EH42PLE | — | p. 53 |
Service intervals
Values extracted from the document text. Check against the original before service work.
| Item | Value | Also | PDF page |
|---|---|---|---|
| Coolant change | 2 years | p. 21 |
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