Polaris Sportsman 400 HO ATV 2008-2010 Service Repair Workshop Manual Pdf

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The Polaris Sportsman 400 HO, produced for the 2008, 2009, and 2010 model years, is a capable mid-size utility ATV designed for recreational riders and light farm or ranch work....

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Typ: Atv

Anbieter:

Art.-Nr: 96562

Stichworte: 2008 2009 2010 ATV Misc Polaris Powersports Sportsman 400 HO

Produktvarianten

Beschreibung

The Polaris Sportsman 400 HO, produced for the 2008, 2009, and 2010 model years, is a capable mid-size utility ATV designed for recreational riders and light farm or ranch work. This model is recognized for its balanced performance, featuring a 375cc liquid-cooled engine, Variable Transmission (PVT) with engine braking, and an On-Demand All-Wheel Drive (AWD) system with VersaTrac Turf Mode. Its engineering emphasizes a durable steel frame and an ergonomic rider position, making it suitable for trail riding and general utility tasks. The Sportsman line is known for its comfort and reliability, positioning the 400 HO as a strong contender in its segment against competitors like Yamaha, Suzuki, Honda, and Can-Am. This factory service repair workshop manual provides comprehensive guidance for the maintenance and repair of the Polaris Sportsman 400 HO. It covers all essential systems, including complete engine service, automatic transmission (PVT) repair, drivetrain components, suspension, steering, brakes, and electrical systems. The manual details routine and scheduled maintenance, diagnostic procedures for troubleshooting issues, and step-by-step repair and overhaul instructions for major components. Technical specifications, such as torque values, fluid capacities, and electrical data, are also included. This resource is intended for professional technicians, experienced DIY mechanics, and ATV enthusiasts seeking to maintain and repair their vehicles effectively.

🏷️ Basic Information

Identification

Make:

Polaris

Model:

Sportsman 400 HO

Model Variant:

HO (High Output)

Applicable Years:

2008, 2009, 2010

Codes

Manual Product Id:

N/A (Provided as a download PDF)

👋 Introduction

Market Position

Category:

Mid-size Utility ATV

Target User:

Recreational riders, light farm/ranch work, trail riding.

Competitive Analysis

Competitors:

Yamaha Grizzly 350/450, Suzuki KingQuad 400, Honda Rancher 400/420, Can-Am Outlander 400.

Key Features

Powertrain:

4-stroke, liquid-cooled engine, Polaris Variable Transmission (PVT) with engine braking.

Suspension Type:

Independent Front Suspension (IFS), MacPherson Strut Rear Suspension.

Drivetrain Features:

On-Demand All-Wheel Drive (AWD) with VersaTrac Turf Mode.

Chassis Design:

Durable steel frame, ergonomic rider position.

📋 Manual Details

Coverage Areas

Engine:

Complete Engine Service and Repair

Transmission:

Automatic Transmission (PVT) Service and Repair

Drivetrain:

AWD/2WD System, Final Drives, Driveshafts

Suspension:

Front and Rear Suspension, Shocks, Control Arms

Steering:

Steering System, Tie Rods, Handlebars

Brakes:

Hydraulic Brake System, Calipers, Lines, Master Cylinders

Electrical:

Wiring Diagrams, Charging System, Ignition, Lighting, Starters

Fuel System:

Fuel Delivery, Carburetor, Fuel Pump, Filters

Cooling System:

Radiator, Coolant, Water Pump

Exhaust System:

Muffler, Pipes, Heat Shields

Body And Frame:

Body Panels, Frame Inspection, Plastics

Troubleshooting:

Diagnostic Procedures and Fault Finding

Page Count

Estimated Pages:

Likely 300-600+ pages (typical for factory service manuals)

Manual Type

Type:

Factory Service Repair Workshop Manual

Language

Primary Language:

English

Format

File Format:

PDF (Downloadable)

📖 Manual Coverage

Systems Covered

Engine Systems:

Engine disassembly, assembly, valve adjustments, piston/cylinder inspection, lubrication system, timing, component specifications.

Transmission Systems:

PVT (Polaris Variable Transmission) operation, belt inspection/replacement, clutch service, gearbox lubrication and repair.

Drivetrain Systems:

Front and rear differential service, driveshaft maintenance, AWD engagement system troubleshooting, U-joint inspection.

Braking Systems:

Brake fluid specifications, bleeding procedures, caliper overhaul, rotor inspection, brake line routing.

Electrical Systems:

Detailed wiring diagrams, charging system testing (stator, regulator/rectifier), ignition coil and spark plug diagnosis, starter motor testing, lighting circuit troubleshooting.

Suspension Steering Systems:

Shock absorber adjustments and replacement, control arm bushing inspection, wheel bearing service, steering post and linkage maintenance.

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, spark plug checks, air filter cleaning/replacement, lubrication points, chain/belt tensioning.

Scheduled Maintenance:

Specific mile/hour-based service intervals for all major components.

Diagnostic Procedures:

Step-by-step troubleshooting guides for common and uncommon issues based on symptoms.

Repair Procedures:

Detailed instructions for component removal, overhaul, and reinstallation.

Overhaul Procedures:

Complete rebuild instructions for engine, transmission, and differentials.

Technical Specifications:

Torque values, clearances, fluid capacities, electrical specifications, diagnostic trouble codes (DTCs).

Technical Depth

Depth:

Comprehensive; covers everything from basic rider maintenance to full engine and transmission rebuilds.

Target Audience:

Professional technicians, experienced DIY mechanics, and serious ATV enthusiasts.

📊 Manual Specifications

File Format

Searchability:

Likely text-searchable PDF for efficient information retrieval.

Print Quality

Image Resolution:

High-resolution images and diagrams suitable for printing.

Binding Type

Binding:

N/A (Digital Download)

Paper Type

Paper Type:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Type:

4-stroke, SOHC, 2-valve, Single Cylinder

Displacement:

375cc

Bore X Stroke:

84.0 mm x 68.0 mm

Cooling System:

Liquid-Cooled

Fuel Delivery:

Carburetor (Mikuni VM34SS typically)

Ignition System:

Electronic Ignition

Exhaust System:

Single muffler with catalytic converter (check emissions standards for specific years).

Performance

Horsepower:

Approx. 24 HP @ 6500 RPM (Subject to variation by year/tuning)

Torque:

Approx. 23 lb-ft @ 4500 RPM (Subject to variation)

Fuel System

Fuel Type:

Unleaded Gasoline (87 Octane Minimum)

Fuel Tank Capacity:

3.0 gal (11.4 L)

🔧 Transmission

Standard

Type:

Polaris Variable Transmission (PVT) Automatic with Engine Braking

Gear Selection:

High, Low, Neutral, Reverse, Park

Features

Drive Modes:

2WD / AWD (On-Demand)

Fluid Specifications

Transmission Fluid Type:

Polaris AGL Premium Gearcase Lubricant or equivalent (e.g., SAE 80W-90 Hypoid Gear Oil)

📐 Dimensions

Exterior

Length:

81 in (205.7 cm)

Width:

46 in (116.8 cm)

Height:

47 in (119.4 cm)

Wheelbase:

50.5 in (128.3 cm)

Ground Clearance:

11.25 in (28.6 cm)

Cargo

Front Rack Capacity:

100 lbs (45 kg)

Rear Rack Capacity:

200 lbs (90 kg)

Weights

Dry Weight:

608 lbs (275.8 kg)

Towing Capacity:

1,500 lbs (680.4 kg)

Gcvwr:

2,100 lbs (952.6 kg)

🛡️ Safety Features

Ratings

Safety Standards:

Meets ANSI standards for recreational ATVs.

Active Features

Braking System:

Hydraulic front disc brakes, hydraulic rear disc brake (often with left-hand lever operating front and rear, foot brake for rear).

Engine Braking:

PVT provides effective engine braking on descents.

Passive Features

Handlebars:

Comfort-grip handlebars with integrated throttle and brake levers.

Lighting:

Dual handlebar-mounted headlights, single brakelight/taillight.

💡 Technology Features

Infotainment

Display:

Basic LCD display providing speed, RPM, odometer, trip meter, gear indicator, AWD status, and basic warning lights.

Driver Assistance

Traction Control:

N/A (Traction is managed by the AWD system).

Connectivity

Charging Port:

Accessory power port (cigarette lighter style) for charging devices.

🔧 Maintenance

Service Intervals

Engine Oil Change:

Every 100 hours or 6 months (refer to manual for exact interval).

Air Filter Service:

Clean every 25 hours, replace as needed or annually.

Spark Plug Inspection:

Inspect every 50 hours or annually.

Transmission Oil Change:

Every 100 hours or annually.

Fluid Specifications

Engine Oil Type:

Polaris PS-4 5W-50 Synthetic (or equivalent API SG or higher specification oil).

Engine Oil Capacity:

Approx. 1.7 US qt (1.6 L) with filter change.

Coolant Type:

Ethylene Glycol based antifreeze (50/50 mix with distilled water).

Brake Fluid Type:

DOT 3 or DOT 4 Hydraulic Brake Fluid.

Known Issues

Common Wear Items:

PVT belt wear, wheel bearings, tie rod ends, brake pads.

Potential Electrical Issues:

Stator or regulator/rectifier failure (requires testing).

Cooling System Maintenance:

Regular flushing and checking of coolant levels is crucial for preventing overheating.

📚 Vehicle History

Brand Heritage

Manufacturer:

Polaris Industries Inc.

Brand Focus:

Known for innovation in ATVs, snowmobiles, and powersports vehicles.

Model Evolution

Sportsman Lineage:

The Sportsman line is Polaris's flagship utility ATV series, known for its comfortable ride and capable performance.

400 Ho Positioning:

The 400 HO model provided a balance of performance and value within the Sportsman lineup, often featuring a Polaris-designed engine.

Production

Manufacturing Origin:

Primarily manufactured in the USA by Polaris Industries.

🏆 Awards & Recognition

Recognitions

Industry Awards:

Polaris Sportsman line consistently receives positive reviews for its comfort, utility, and all-around performance in its class.

Ratings

User Reviews:

Generally positive for durability and capability, with specific model year feedback often available online.