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Polaris Sportsman 400 HO 2010 Workshop Service Repair Manual

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The Polaris Sportsman 400 HO, produced in 2010, is a mid-size utility all-terrain vehicle renowned for its versatility and value within its segment. Engineered with a durable chassis and a...
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Art.-Nr: 98442
Polaris Sportsman 400 HO 2010 Workshop Service Repair Manual
The Polaris Sportsman 400 HO, produced in 2010, is a mid-size utility all-terrain vehicle renowned for its versatility and value within its segment. Engineered with a durable chassis and a capable suspension system, this model offers a comfortable and ergonomic design for rider comfort during various tasks and terrain. Key features include signature On-Demand All-Wheel Drive system for enhanced traction and an engine braking system that aids in control during descents, contributing to its reputation for reliability and off-road prowess. This model competes in a market with established brands, aiming to provide a balanced blend of performance and utility for demanding applications. This comprehensive workshop service repair manual, written in English, is designed to guide owners, technicians, and mechanics through the intricacies of the Polaris Sportsman 400 HO. It covers all models, engines, and trims, providing detailed information on maintenance procedures, troubleshooting, and repair. Within its hundreds of pages, users will find in-depth coverage of all major systems, including the engine, fuel, ignition, cooling, exhaust, transmission, drivetrain, suspension, steering, braking, and electrical systems. The manual also includes essential technical specifications, diagnostic flowcharts, and clear wiring diagrams, ensuring that all aspects of the vehicle's upkeep and repair can be addressed effectively.
🏷️ Basic Information
Identification
Make:
Polaris
Model:
Sportsman 400 HO
Year:
2010
Product Type:
Workshop Service Repair Manual
👋 Introduction
Market Position
Segment:
Mid-size utility ATV, known for versatility and value.
Competitive Analysis
Competitors:
Competes with models like Yamaha Grizzly 350/450, Honda Rancher 420, Can-Am Outlander 400.
Key Features
Features:
Durable chassis, capable suspension, Polaris's AWD system, ergonomic design for rider comfort.
📋 Manual Details
Coverage Areas
Coverage:
All Models/Engines/Trim
Page Count
Estimated Pages:
Hundreds (typical for comprehensive workshop manuals)
Manual Type
Type:
Workshop Service Repair Manual
Language
Language:
English
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Engine:
Complete engine overhaul, troubleshooting, diagnosis, specifications, torque values, disassembly, assembly.
Fuel System:
Fuel pump, carburetor (if applicable), fuel lines, fuel filter, fuel tank, pressure testing, cleaning, adjustment.
Ignition System:
Spark plugs, ignition coil, CDI unit, timing, troubleshooting.
Cooling System:
Radiator, hoses, thermostat, water pump, coolant specifications, bleeding procedures.
Exhaust System:
Muffler, pipes, gaskets, inspection, repair.
Transmission:
CVT system, belt inspection and replacement, clutch assembly, gears, lubrication, troubleshooting.
Drivetrain:
Front and rear driveshafts, differentials, axles, CV joints, boots, lubrication, maintenance.
Suspension:
Front and rear suspension components, shocks, springs, bushings, alignment specifications, troubleshooting.
Steering:
Handlebar, steering column, tie rods, ball joints, steering linkage, lubrication, adjustments, troubleshooting.
Braking System:
Front and rear brakes, calipers, master cylinder, brake lines, brake fluid specifications, bleeding, pad replacement, rotor inspection.
Electrical System:
Battery, charging system, starter, lighting, wiring diagrams, fuses, relays, troubleshooting electrical faults.
Body And Frame:
Frame inspection, body panels, plastics, seat, racks, fenders, removal, installation, troubleshooting.
Wheels And Tires:
Tire pressure, inspection, replacement, wheel torque specifications.
Lubrication And Filters:
Engine oil specifications, capacity, filter part numbers, chain lube, differential oil.
Procedures Included
Maintenance:
Scheduled maintenance, oil changes, filter replacements, lubrication, spark plug replacement, brake fluid changes, belt inspection/replacement.
Troubleshooting:
Step-by-step diagnostic procedures for common and uncommon issues across all systems.
Repair:
Detailed repair instructions for component removal, disassembly, inspection, repair, reassembly, and adjustment.
Overhaul:
Comprehensive instructions for complete engine and transmission overhauls.
Diagnosis:
Diagnostic flowcharts, symptom identification, and testing procedures.
Wiring Diagrams:
Detailed electrical schematics for easy fault tracing and repair.
Technical Depth
Depth:
Comprehensive, covering everything from basic maintenance to complete engine rebuilds and advanced electrical diagnostics.
📊 Manual Specifications
File Format
File Type:
PDF
Searchable Text:
Likely searchable, enhancing user experience.
Print Quality
Quality:
High resolution, ensuring clarity of diagrams and text.
Binding Type
Binding:
Not applicable for PDF download.
Paper Type
Paper:
Not applicable for PDF download.
⚙️ Engine Specifications
Primary Engine
Engine Type:
4-stroke, Single Cylinder, SOHC
Displacement:
398 cc
Bore X Stroke:
92 mm x 75 mm (typical for this engine)
Cooling System:
Liquid-cooled
Compression Ratio:
10.2:1 (typical)
Performance
Horsepower:
Approx. 29-30 HP @ 6500 RPM (estimated for 2010 model)
Torque:
Approx. 27 lb-ft @ 5000 RPM (estimated for 2010 model)
Fuel System
Fuel Delivery:
Carbureted (likely Mikuni BSR34 or similar)
Fuel Type:
Unleaded gasoline, 87 octane minimum.
Lubrication
Oil Type:
Polaris branded 2W-50 ATV 4-Stroke Synthetic (or equivalent SAE 5W-50)
Oil Capacity:
Approx. 2.0 US quarts (1.9 liters) with filter change.
🔧 Transmission
Standard
Type:
Automatic PVT (Polaris Variable Transmission) with Engine Braking
Gear Selection:
High, Low, Neutral, Reverse, Park
Features
Drive System:
On-Demand AWD/2WD
Final Drive:
Shaft Drive
Lubrication
Transmission Oil Type:
Polaris AGL Premium Synthetic Gearcase Lubricant (or equivalent SAE 75W-90)
Transmission Oil Capacity:
Approx. 0.5 US quarts (0.47 liters) for rear differential/gearcase.
📐 Dimensions
Exterior
Length:
Approx. 82 in (208.3 cm)
Width:
Approx. 46 in (116.8 cm)
Height:
Approx. 48 in (121.9 cm)
Weights
Dry Weight:
Approx. 600 lbs (272 kg)
Ground Clearance:
Approx. 11.25 in (28.6 cm)
Cargo
Front Rack Capacity:
100 lbs (45 kg)
Rear Rack Capacity:
200 lbs (90 kg)
Towing
Towing Capacity:
1500 lbs (680.4 kg)
Wheels And Tires
Front Tire Size:
25 x 8-12
Rear Tire Size:
25 x 10-12
Wheelbase:
50.5 in (128.3 cm)
🛡️ Safety Features
Ratings
Atv Safety Standards:
Meets ANSI B71.1-2003 standards.
Active Features
Engine Braking:
Standard, aids in deceleration and control on descents.
AWD System:
On-Demand All-Wheel Drive for enhanced traction.
Passive Features
Handlebars:
Ergonomically designed for control and comfort.
Footwells:
Wide floorboards with integrated heel guards.
💡 Technology Features
Infotainment
Infotainment System:
Not applicable for this utility ATV model. Focus is on functionality and ruggedness.
Driver Assistance
Driver Assistance:
Engine braking system, On-Demand AWD.
Connectivity
Connectivity:
Not applicable.
🔧 Maintenance
Service Intervals
Engine Oil Change:
Every 100 hours or 6 months, whichever comes first.
Air Filter Cleaning:
Every 25 hours or monthly. Replacement as needed.
Spark Plug Inspection:
Every 100 hours or annually.
Brake Fluid Flush:
Every 2 years or 200 hours.
Transmission Oil Change:
Every 200 hours or annually.
Cv Belt Inspection:
Every 50 hours or annually. Replacement based on condition.
Fluid Specifications
Coolant:
Polaris Premium All-Season Coolant or equivalent 50/50 mix of ethylene glycol antifreeze and distilled water.
Brake Fluid:
DOT 4 brake fluid.
Known Issues
Common Problems:
CV boot wear, occasional carburetor tuning issues, potential starter solenoid problems (common across many vehicles of this era).
📚 Vehicle History
Brand Heritage
Heritage:
Polaris Industries, founded in 1954, is a major manufacturer of powersports vehicles, known for innovation in ATVs and snowmobiles.
Model Evolution
Sportsman Line:
The Sportsman line is Polaris's flagship ATV series, continually evolving with new technologies and engine options since its introduction.
Production
Manufacturing Location:
Typically manufactured in the United States.
🏆 Awards & Recognition
Recognitions
Atv Awards:
While specific awards for the 2010 Sportsman 400 HO might not be widely publicized, the Sportsman line consistently receives positive reviews for its utility and off-road capability from ATV enthusiast publications.
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