Segment:
Mid-size utility ATV segment.
Target Audience:
Recreational riders, farmers, hunters, and light-duty trail use.
Competitors:
Yamaha Kodiak, Honda Rancher, Can-Am Outlander (lower displacement models).
Unique Selling Points:
Polaris's proprietary PVT automatic transmission, Electronic Fuel Injection (EFI) for consistent performance, and the robust Polaris On-Demand All-Wheel Drive system.
Manual Value Proposition:
This comprehensive service manual provides professional-level repair and maintenance information, empowering owners and technicians to maintain their ATVs to factory standards, reducing downtime and ensuring longevity.
Engine:
Detailed breakdown of engine components, troubleshooting, overhaul procedures, and specifications for both 300cc and 400cc HO engines.
Transmission:
Automatic transmission (PVT - Polaris Variable Transmission) service, belt inspection/replacement, roller/sheave maintenance, and troubleshooting.
Drivetrain:
Front and rear drive systems, including AWD (All-Wheel Drive) engagement, driveshafts, U-joints, differentials, and hubs.
Suspension:
Front and rear suspension components, including shocks, springs, control arms, bushings, and alignment procedures.
Brakes:
Hydraulic brake system, including caliper service, master cylinder overhaul, brake line maintenance, bleeding procedures, and rotor/pad replacement.
Electrical:
Full electrical system diagnosis, including ignition, lighting, charging system (stator, regulator/rectifier), battery, starter, and accessory wiring.
Fuel System:
Fuel delivery system, including fuel pump, fuel filter, fuel injection (EFI) system diagnostics, injector cleaning, and fuel tank service.
Cooling System:
Radiator, fan, thermostat, coolant flushing and refilling procedures, and troubleshooting overheating issues.
Exhaust System:
Muffler, head pipe, heat shields, and exhaust gasket replacement.
Steering:
Steering column, tie rods, ball joints, and wheel alignment procedures.
Bodywork And Frame:
Body panel removal/installation, frame inspection, and plastic component repair.
Maintenance:
Scheduled maintenance tasks, fluid checks and changes, filter replacements, spark plug service, and general inspection procedures.
Troubleshooting:
Systematic diagnostic flowcharts and troubleshooting guides for common and uncommon issues across all major vehicle systems.
Repair:
Step-by-step repair procedures for component removal, disassembly, assembly, and reinstallation.
Overhaul:
Complete engine and transmission overhaul procedures, including necessary specifications and torque values.
Diagnostics:
Diagnostic procedures for electrical and mechanical systems, including use of specialized tools and interpretation of symptoms.
Electrical Diagnostics:
Wiring diagrams, voltage drop testing, continuity checks, and component testing procedures.
Depth Level:
Comprehensive, covering everything from basic pre-ride checks to full engine rebuilds and complex electrical diagnostics.
Diagnostic Tools:
Information on necessary tools and equipment for effective diagnosis and repair, including specialized Polaris tools where applicable.
Specifications:
Detailed technical specifications, tolerances, clearances, torque values, and fluid capacities for all components.
Engine Type 300:
Liquid-cooled, 4-stroke, SOHC, single-cylinder
Engine Type 400Ho:
Liquid-cooled, 4-stroke, OHC, single-cylinder
Displacement 400Ho:
375cc
Bore X Stroke 300:
68.7mm x 74mm
Bore X Stroke 400Ho:
84mm x 68mm
Compression Ratio 300:
10.0:1
Compression Ratio 400Ho:
10.2:1
Horsepower 300:
Approximately 18 HP (estimated)
Horsepower 400Ho:
Approximately 26 HP (estimated)
Torque 300:
Not specified, but adequate for class
Torque 400Ho:
Not specified, but adequate for class
Induction:
Electronic Fuel Injection (EFI)
Fuel Type:
Unleaded gasoline, minimum 87 octane
Fuel Tank Capacity:
3.0 gallons (11.4 L)
Transmission Type:
Polaris Variable Transmission (PVT) - Automatic with Engine Braking
Drive Modes:
High, Low, Neutral, Reverse, Park
Optional Transmission:
N/A
Engine Braking:
Standard feature providing downhill control
Clutch Type:
Primary and secondary clutch system
Transmission Fluid Type:
Polaris Synthetic Gearcase Lubricant (or equivalent SAE 10W-40 API GL-4 transmission oil)
Transmission Fluid Capacity:
0.38 quarts (0.36 L)
Atv Safety Standards:
Complies with ANSI and ATV Safety Institute standards.
AWD System:
Polaris Automatic On-Demand All-Wheel Drive (AWD) for enhanced traction.
Engine Braking:
Provides engine braking on descents, aiding control.
Lighting:
Dual headlights, taillight, and brake light for visibility.
Hand Guards:
Standard for rider hand protection.
Handlebars:
Tapered handlebars for improved ergonomics and control.
Oil Change Interval:
Every 100 hours or 12 months, whichever comes first.
Air Filter Inspection:
Every 50 hours or monthly.
Spark Plug Replacement:
Every 100 hours or annually.
Transmission Fluid Change:
Every 100 hours or 12 months.
Brake Fluid Change:
Every 24 months or as needed.
Engine Oil Type:
Polaris 4-Stroke Synthetic 0W-40 (or API SG, SH, SJ rated SAE 0W-40 or 10W-40)
Engine Oil Capacity:
1.6 U.S. qt (1.5 L)
Coolant Type:
Ethylene Glycol based antifreeze (50/50 mix with distilled water)
Brake Fluid Type:
DOT 3 or DOT 4 Hydraulic Brake Fluid
Common Wear Items:
Drive belts, ball joints, tie rod ends, wheel bearings, and brake pads due to typical ATV usage.
Electrical Gremlins:
Corrosion in connectors, stator failure, or regulator/rectifier issues can occur with age and exposure to elements; the manual provides diagnostic steps.
Pvtlubrication:
Proper lubrication of the PVT clutch sheaves and rollers is crucial for smooth operation and longevity, as detailed in the manual.
Polaris History:
Polaris Industries Inc. has a long history dating back to 1954, known for its innovation in snowmobiles, ATVs, UTVs, and motorcycles. The Sportsman line has been a cornerstone of their ATV offerings, emphasizing utility and recreational capabilities.
Sportsman Line Evolution:
The Sportsman line has consistently evolved, introducing features like independent rear suspension (IRS), electronic fuel injection, and advanced AWD systems. The 2010 models represent a mature iteration of these technologies.
Manufacturing Location:
Primarily manufactured in the United States (e.g., Roseau, Minnesota).
