Target Audience:
Polaris Sport 400 ATV owners, DIY mechanics, and service technicians.
Value Proposition:
Provides essential part identification for maintaining and repairing a 1999 Polaris Sport 400, promoting cost savings and vehicle longevity.
Manual Type Advantage:
A dedicated parts manual offers superior detail for parts sourcing compared to general service or owner's manuals.
Exploded Diagrams:
Crucial for visual understanding of component relationships and locations.
Part Number Index:
Essential for ordering correct OEM or aftermarket replacement parts.
Comprehensive Coverage:
Covers nearly all major systems and components of the ATV.
Primary Coverage:
Parts identification and listing for the 1999 Polaris Sport 400 ATV.
Secondary Coverage:
Components related to maintenance, repair, and assembly.
Type:
Parts Manual / Catalog
Format:
PDF (Portable Document Format)
Printability:
Selectable pages for printing
Chassis And Body:
Front Cab, Rear Cab and Seat, Rear Rack Mounting, Front Rack and Bumper Mounting, Decals
Engine And Cooling:
Engine Mounting, Cooling System, Exhaust System, Fuel Tank, Oil Tank, Air Box
Drivetrain And Suspension:
Front Drive, Front Tightener, Front Strut, CV Joint – BTB, Front Wheel, Rear Wheel Drive, Swing Arm/Shock Mounting, Gearcase/Brake and Chain Cover Mounting
Brakes And Controls:
Front Brake, Controls -- Throttle ASM./Cable, Controls - Master Cylinder/Brake Line, Steering Post, Handlebar and Headlight Pod, Rear Brake, Gear Selector
Powertrain Components:
Drive Clutch, Driven Clutch, Clutch Cover, Gearcase, Piston and Crankshaft, Crankcase and Cylinder, Oil Pump, Magneto, Starting Motor
Electrical:
Electrical/Taillight
Miscellaneous:
Recoil Starter, Carburetor, Tool Kit
Identification Of Parts:
Detailed exploded diagrams and comprehensive part number lists for accurate part identification.
Assembly Disassembly Guidance:
Implied through the provision of exploded diagrams for major assemblies, aiding in disassembly and reassembly reference.
Maintenance Support:
Facilitates routine maintenance by identifying required replacement parts (e.g., filters, spark plugs, belts).
Repair Planning:
Enables mechanics to source correct replacement parts for planned repairs.
Detail Level:
High; specifically designed for parts identification with OEM part numbers.
Diagnostic Capability:
Indirect; aids diagnostics by confirming the correct part is installed or identifying missing components.
Rebuild Scope:
Supports component-level rebuilds by providing part breakdowns for major assemblies like the engine and gearcase.
Features:
Searchable text, bookmark navigation (typical for professionally created PDFs).
Resolution:
High, suitable for clear reproduction of diagrams and text.
Print Options:
Selective page printing allows users to print only necessary sections, saving ink and paper.
Digital:
N/A (Digital Download)
Digital:
N/A (Digital Download)
Engine Type:
Likely a 2-stroke, liquid-cooled, single-cylinder engine based on typical Polaris Sport 400 configurations.
Displacement:
Approximately 378cc (specific details would be in a service manual, but parts manual implies engine components are covered).
Cooling System:
Liquid-cooled (indicated by 'COOLING SYSTEM' section).
Fuel Delivery:
Carburetor (indicated by 'CARBURETOR' section).
Fuel Type:
Unleaded gasoline (standard for this era of ATV).
Oil System:
Oil Tank with likely oil injection system (indicated by 'OIL TANK' section and common for 2-stroke ATVs of this era).
Type:
Automatic (CVT - Continuously Variable Transmission) is standard for this model series.
Drive System:
Likely 2WD or 4WD selectable, with front and rear drive components listed.
Components:
Drive Clutch and Driven Clutch are explicitly listed, indicating a CVT system.
Components:
Gearcase, Gear Selector, and Brake/Chain Cover are detailed, suggesting internal gear reduction and drive chain/sprocket components.
Chassis Layout:
Standard ATV layout with front and rear racks, handlebars, and seating.
Estimated Dry Weight:
Typically in the range of 450-500 lbs for this class of ATV (precise weight not in parts manual, but component weight can be inferred).
Front Tire Size:
Commonly 22x7-10 or similar (parts manual would list specific wheel and tire parts).
Rear Tire Size:
Commonly 22x10-10 or similar (parts manual would list specific wheel and tire parts).
Bolt Pattern:
Likely 4/110 or 4/115 for front and rear wheels (specific part numbers for wheels would confirm).
Frame Construction:
Steel frame (implied by 'ENGINE MOUNTING' and chassis components).
Lighting:
Headlight and Taillight components listed, indicating standard lighting for trail use and basic visibility.
Braking System:
Front and Rear Brakes (hydraulic disc brakes are typical for this model) are detailed, ensuring stopping power.
Steering System:
Steering Post and Handlebar assembly are detailed for control and maneuverability.
General Recommendation:
Frequent, regular intervals for maintenance as per the product description. Specific intervals (e.g., oil change every 100 hours, spark plug every 1000 miles) would be in a service manual but parts are identifiable here.
Engine Oil:
Likely a 2-stroke specific oil for the injection system and a suitable gear oil for the transmission/gearcase. Specific grades would be in a service manual. Part numbers for oil filters (if applicable) would be in this manual.
Coolant:
Ethylene glycol-based antifreeze (for liquid-cooled engines). Specific type and capacity would be in a service manual. Radiator cap and hose part numbers would be here.
Common Wear Items:
Drive belts, CV joint boots, wheel bearings, brake pads, and suspension components are typical wear items for ATVs of this age and usage, all of which are covered by parts listings.
Air Filter:
Air Box components and likely a specific air filter part number are covered.
Fuel Filter:
Fuel Tank and related fuel line components, including potential inline fuel filter parts, would be listed.
Spark Plug:
Magneto and Starting Motor sections imply the presence of a spark plug, with its part number likely available through related engine component listings.
Polaris Atv Legacy:
Polaris has been a major player in the ATV market since the late 1980s, known for its innovation and range of utility and sport ATVs.
Sport Series Positioning:
The Sport 400 was part of Polaris's line of more performance-oriented ATVs, offering a balance of power and handling for trail riding.
Production Era:
Late 1990s, specifically 1999 for this manual.
