Segment:
Entry-level to mid-range utility ATV segment
Target Audience:
Recreational riders, light utility users, DIY mechanics
Competitors:
Honda Foreman 400, Yamaha Kodiak 400, Suzuki King Quad 400
Vehicle Focus:
Reliability, maneuverability, value for money
Manual Value:
Empowers owners and technicians with factory-level repair knowledge
Engine:
Complete Engine Overhaul, Tuning, Repair
Drivetrain:
Transmission, Gearcase, Driveshafts, Differentials, AWD System
Fuel System:
Carburetor (if applicable), Fuel Pump, Lines, Tank, Fuel Injection (if equipped)
Cooling System:
Radiator, Fan, Thermostat, Hoses, Coolant Specifications
Electrical System:
Ignition, Charging System (Stator, Regulator/Rectifier), Starting System, Lighting, ECU Diagnostics, Wiring Diagrams
Brakes:
Hydraulic System, Calipers, Master Cylinder, Lines, Bleeding Procedures, Rotor Specifications
Suspension:
Front and Rear Suspension Components, Shock Absorbers, Bushings, Alignment
Steering:
Handlebars, Steering Column, Tie Rods, Steering Knuckles
Bodywork And Chassis:
Frame, Body Panels, Seat, Racks, Fender Maintenance
Routine Maintenance:
Oil Changes, Filter Replacements, Lubrication Points, Valve Adjustments
Troubleshooting:
Diagnostic Flowcharts, Symptom-Based Troubleshooting Guides
Rebuild Procedures:
Engine Rebuild, Transmission Rebuild, Suspension Component Replacement
Component Removal Installation:
Step-by-step instructions for removing and reinstalling all major components
Specifications:
Torque Specifications, Clearances, Measurements for all adjustable components
Depth:
Comprehensive from basic user maintenance to full mechanical overhauls
Diagnostic Capability:
Advanced diagnostics, including electrical troubleshooting and sensor testing
Detail Level:
Detailed diagrams, exploded views, and part identification
Searchability:
Likely text-searchable within the PDF, enabling quick navigation
Printability:
Designed for complete printing or selective page printing
Binding:
Not applicable (digital download)
Paper:
Not applicable (digital download)
Engine Type:
4-stroke, Single-Cylinder
Bore X Stroke:
83 mm x 70 mm
Cooling System:
Liquid-Cooled
Valve Train:
SOHC, 4 Valves
Horsepower:
Approximately 27-29 HP (estimated, specific factory data may vary)
Torque:
Approximately 24-26 lb-ft (estimated, specific factory data may vary)
Fuel Delivery:
Carbureted (Mikuni BSR34)
Fuel Type:
Unleaded Gasoline, 87 Octane Minimum
Ignition System:
Digital CDI
Oil Type:
Polaris Premium 4 Synthetic 0W-40 (or equivalent SAE 0W-40 API SG/SH/SJ)
Oil Capacity:
2.0 US qt (1.9 L) with filter change
Transmission Type:
Automatic (PVT - Polaris Variable Transmission)
Drive System:
Shaft Drive with On-Demand AWD (All-Wheel Drive)
Gear Selection:
High, Low, Neutral, Reverse, Park
Clutch Type:
Centrifugal Clutch and Drive/Driven Sheaves
Gearcase Oil Type:
SAE 80W-90 Hypoid Gear Lubricant
Gearcase Oil Capacity:
0.36 US qt (0.34 L)
Atv Safety Standards:
Compliant with ANSI/SVIA standards
Braking System:
Hydraulic Disc Brakes (Front and Rear)
Parking Brake:
Hand-operated caliper brake
Lighting:
Dual 35W Halogen Front Headlights, 35W Halogen Tail/Brake Light
Ergonomics:
Handlebar design for control and comfort, accessible controls
Engine Oil Change:
Every 50 operating hours or annually
Air Filter Cleaning:
Every 25 operating hours (more frequently in dusty conditions)
Spark Plug Inspection:
Every 100 operating hours
Valve Clearance Check:
Every 100 operating hours
Engine Oil:
SAE 0W-40 Synthetic, API SG/SH/SJ
Gearcase Oil:
SAE 80W-90 Hypoid Gear Lubricant
Coolant:
Ethylene Glycol based, 50/50 mix with distilled water (Polaris recommends specific coolant)
Common Wear Item:
Drive belts for the PVT system can wear over time and require replacement.
Electrical Component Consideration:
Regular inspection of electrical connections, especially for corrosion, is advised, particularly in wet environments.
Suspension Components:
Bushings and ball joints are subject to wear from off-road use and should be inspected regularly.
Manufacturer:
Polaris Industries, Inc.
Origin:
Founded in 1954, Minnesota, USA
Lineage:
The Sportsman line is one of Polaris's longest-running and most successful ATV series, known for its versatility and robust design.
Previous Generations:
Earlier Sportsman 400 models existed with different engine configurations and chassis designs.
Manufacturing Location:
Polaris facilities in the USA
Atv Awards:
Polaris Sportsman series generally well-regarded for performance and reliability in its class, though specific awards for the 2009 400 model are not readily cited.
Consumer Reviews:
Generally positive for its intended use, often praised for value and capability.
Manufacturing Standards:
Manufactured to Polaris's internal quality control and industry safety standards.