Polaris 2003 ATV Sportsman 500 H.O. - Manual

1
Owner’s Manual Supplement
PN 9917540
2003 Sportsman 500 HO A03CH50AA/AB/AE/AF/AG/AH
IMPORTANT: This is a supplement to your owner’s manual. This information should remain with your owner’s manual at all times.
Capacities
Body Style Gen IV
Gross Vehicle Weight 1200 Lbs.
Fuel Capacity 4.75 U.S. Gallons
Gearcase Oil 32 Ounces
Engine Oil Capacity 2 Quarts
Front Rack (Maximum Capacity) 90 Lbs.
Rear Rack 180 Lbs.
Tongue Weight 120 Lbs.
Tow Hitch Standard
Hitch Towing Rating 1225 Lbs. .
Unbraked Trailer Towing Capacity* 1786 Lbs./810 kg
Turn Radius
65″
Ground Clearance 11″
Height 47″
Length 81″
Seat Height 34″
Dry Weight 697
Wheel Base 50.50 ″
Width 46″
Suspension and Brakes
Front Susp. - Mac Strut 6.7″
Rear Susp. - Progressive rate, fully
independent with anti-roll-bar
9.5″
Shock Adjustment CAM
Front Brake Hydraulic Disc
Rear Brake Hydraulic, opposed piston caliper,
fixed disc
Auxiliary Brake Hydraulic, opposed piston caliper,
fixed disc
Park Brake Hydraulic lock, all wheel
Drive System
Drive System Type EBS
Shift Type Side Lever (Hi/Lo-R-N)
Gear Reduction - Low 8.27/1
Gear Reduction - Reverse 5.17/1
Gear Reduction - Foward 3.34/1
Front Drive (ratio) 2:1
Final Drive (ratio) 3.16:1
Front Tire (psi) 25 x 8-12 (5 psi)
Rear Tire (psi) 25 x 11-12 (5 psi)
Engine & Cooling
Engine Model Number EH50PLE-13
Engine Type 4 Cycle, Single Cylinder
Lubrication Dry Sump
Bore x Stroke 92 x 75
Displacement 498
Compression Ratio 10:2 Full Stroke
Engine Cooling Liquid
Alternator Output (watts) 250
Carburetion 1/BST40
Main Jet 152.5
Pilot Jet 40
Needle Jet X-6
Pilot Screw 2 Turn
Jet Needle 6MEH1--94--3
Ignition CDI
Timing 30 @ 5000
Spark Plug Gap .9 mm/.036 in.
Spark Plug Type NGK BKR6E
Exhaust USFS Approved
Features
Headlight (watts) On Handlebar - 1 single beam, 50
/
on Grill - 2 single beam, 27
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
* Based on EU Directive 76/432/EC
Carburetor Jetting Clutching Chart
Alti-
tude
AMBIENT
TEMPERA-
TURE
Below 40° F
Below 5° C
+40°Fand above
+5°C to and above
Altitude Shift
Weight
Drive
Clutch
Spring
Driven
Clutch
Spring
Helix*
Me-
ters
(Feet)
0-1800
(0-6000)
157.5 152.5 Meters
(Feet)
0-1800
(0-6000)
10WH
(5630710)
Blue/
Green
(7041157)
White/
Yellow
(7041635)
EBS
5131674
Me-
ters
(Feet)
1800-3700
(6000-12000)
150 145 Meters
(Feet)
1800-3700
(6000-12000)
10RH
(5630709)
Blue/
Green
(7041157)
White/
Yellow
(7041635)
EBS
5131674
EBS models require no helix / spring adjustment
PN 9917540 Rev 03 6/09
E
2002 Polaris Sales Inc. Printed in U.S.A.