Vehicle Segment:
Sport/Performance ATV
Target Audience:
Recreational riders seeking a capable and agile ATV for trail riding and sport.
Key Competitors:
Yamaha Warrior, Suzuki QuadSport, Honda Sportrax (specific models within the same era).
Performance Focus:
Known for its powerful 2-stroke engine and agile handling, making it a fun and capable machine on varied terrain.
Manual Utility:
Provides in-depth technical knowledge crucial for maintaining and repairing this performance-oriented ATV.
Engine Details:
2-stroke engine overhaul, top-end rebuild, carburetor tuning, cooling system, exhaust system.
Drivetrain Details:
CVT (Continuously Variable Transmission) service, belt inspection/replacement, clutch operation, gear case lubrication.
Suspension Steering Details:
Front and rear suspension component inspection, shock absorber service, steering linkage adjustment, wheel bearing service.
Braking System Details:
Hydraulic brake system diagnosis, pad replacement, caliper service, fluid flush and bleed procedures, parking brake adjustment.
Electrical Ignition Details:
Wiring diagrams, lighting system, battery maintenance, starter system, ignition system troubleshooting, CDI unit.
Fuel System Details:
Fuel tank service, fuel lines, fuel filter replacement, carburetor assembly and disassembly.
Frame Body Details:
Frame inspection for damage, body panel removal and installation, seat service, handlebar replacement.
Scheduled Maintenance:
Oil changes (gearcase), spark plug replacement, air filter cleaning/replacement, drive belt inspection, brake system checks.
Diagnostic Procedures:
Step-by-step troubleshooting guides for common performance issues, starting problems, and system failures.
Repair Overhaul:
Complete engine rebuild procedures, carburetor overhaul, CVT clutch servicing, suspension component replacement.
Adjustment Calibration:
Carburetor jetting and idle speed adjustments, throttle cable adjustment, brake lever free play adjustment.
Wiring Diagrams:
Detailed electrical schematics for all vehicle systems.
Depth:
Comprehensive, suitable for professional technicians and advanced DIY mechanics. Covers routine maintenance to complete engine and transmission overhauls.
Searchability:
Likely text-searchable PDF, allowing for quick keyword lookups.
Resolution Quality:
Variable depending on the original source, but typically sufficient for clear viewing of diagrams and text.
Printability:
Designed to be printable, allowing users to create physical copies of specific sections or the entire manual.
Binding:
N/A (Digital PDF Download)
Paper Type:
N/A (Digital PDF Download)
Engine Type:
2-stroke, liquid-cooled
Bore X Stroke:
80 mm x 75 mm
Carburetion:
Mikuni VM34SS (typically)
Ignition System:
CDI (Capacitor Discharge Ignition)
Horsepower Estimate:
~25-30 HP (at peak, approximate)
Torque Estimate:
Not officially published, but provides strong low-end and mid-range pull.
Fuel Type:
Unleaded gasoline (91 octane or higher recommended)
Fuel Oil Mix Ratio:
50:1 (for oil injection system)
Fuel Tank Capacity:
3.2 US gallons (approx. 12.1 liters)
Transmission Type:
CVT (Continuously Variable Transmission) with Polaris Variable Transmission (PVT) system
Drive System:
Shaft drive to rear axle
Optional Drive:
N/A (Typically rear-wheel drive only for this model)
Clutch Type:
Automatic centrifugal clutch system
Gear Reduction:
Integrated gear reduction within the drivetrain
Transmission Fluid Type:
Polaris AGL Fluid or equivalent (refer to manual for exact specification)
Length:
73.5 inches (approx. 186.7 cm)
Width:
42.5 inches (approx. 108 cm)
Height:
42.0 inches (approx. 106.7 cm)
Wheelbase:
49.5 inches (approx. 125.7 cm)
Ground Clearance:
4.5 inches (approx. 11.4 cm)
Dry Weight:
418 lbs (approx. 189.6 kg)
Curb Weight:
Not specified, but will be higher than dry weight due to fluids.
Front Tire Size:
AT 22 x 7-10
Rear Tire Size:
AT 22 x 10-9
Bolt Pattern:
Typically 4/110 for front and rear
Safety Certification:
As with most ATVs of this era, certified for off-road use only. No government crash test ratings apply.
Braking System:
Hydraulic disc brakes front and rear.
Throttle Limiter:
Thumb throttle with safety mechanism.
Lighting:
Headlights and taillight for visibility.
Operator Controls:
Handlebar controls for throttle, brakes, and ignition.
Operator Training Recommendation:
Emphasis on wearing protective gear (helmet, goggles, gloves, boots) and following manufacturer safety guidelines.
Infotainment System:
N/A (Minimalist design focused on performance, no infotainment system.
Driver Assistance Features:
N/A (No electronic driver assistance features)
Connectivity Options:
N/A (No connectivity features)
Oil Change Gearcase:
Every 100 hours or annually (refer to manual for exact hours/intervals).
Spark Plug Check Replace:
Inspect every 20-30 hours, replace as needed. Specific plug: NGK BPR7ES or equivalent.
Air Filter Cleaning:
Clean every 20-30 hours, replace as needed. Use UNI filter oil or similar.
Drive Belt Inspection:
Inspect every 50 hours for wear, cracking, or glazing. Replace if any signs of damage are present.
Brake System Check:
Inspect at every major service interval, check fluid levels and pad wear.
Engine Oil Mix:
2-stroke oil suitable for powersports, mixed at 50:1 ratio with unleaded gasoline.
Gearcase Oil Type:
Polaris AGL (Advanced Gear Lube) or SAE 80W-90 hypoid gear oil meeting API GL-4 or GL-5 specification.
Brake Fluid Type:
DOT 3 or DOT 4 hydraulic brake fluid.
Coolant Type:
Ethylene glycol-based antifreeze/coolant, 50/50 mix with distilled water.
Common Wear Items:
Drive belts, spark plugs, carburetor jets, suspension bushings, wheel bearings.
Potential Problems:
Overheating due to improper coolant levels or radiator blockages, CVT belt slippage, carburetor performance issues due to age/varnish.
Polariss Heritage:
Polaris has a long history in powersports, beginning with snowmobiles and expanding into ATVs and motorcycles. Known for innovation and performance.
400 Sport Lineage:
Part of Polaris's successful line of 2-stroke sport ATVs, evolving from earlier models like the Trail Boss and Sport.
Manufacturing Location:
Typically manufactured in the USA by Polaris Industries.
