Vehicle Segment:
All-Terrain Vehicle (ATV), utility and recreational focus.
Target Audience:
Off-road enthusiasts, farmers, hunters, and recreational riders seeking a robust and capable ATV.
Key Competitors:
Honda FourTrax, Yamaha Wolverine, Kawasaki Bayou, Suzuki QuadRunner.
Engine Type:
Liquid-cooled, 4-stroke, single-cylinder engine, known for reliable power delivery.
Transmission Type:
Polaris Variable Transmission (PVT) with automatic clutch, providing seamless gear changes.
Drivetrain:
Selectable 2WD/4WD system offering enhanced traction in challenging terrain.
Suspension:
Independent front suspension and a single shock rear suspension setup for improved ride comfort and handling.
Engine Overhaul:
Complete disassembly, inspection, repair, and reassembly procedures for the 400cc engine.
Fuel System:
Carburetor tuning, cleaning, and rebuilding; fuel pump operation and testing.
Ignition System:
Ignition coil testing, spark plug specifications, CDI unit diagnostics.
Cooling System:
Radiator, fan, thermostat, and coolant hose inspection and replacement.
Drivetrain:
Primary drive clutch, secondary clutch (driven clutch), belt inspection and replacement.
Transmission Drive:
PVT (Polaris Variable Transmission) system service, belt tension, roller and sheave maintenance.
Drive Shafts And Axles:
CV joint inspection, boot replacement, driveshaft alignment.
Suspension Front:
A-arm bushings, ball joint inspection and replacement, shock absorber service, steering components.
Suspension Rear:
Swing arm bushings, shock absorber service, linkage inspection.
Braking System Front:
Brake caliper overhaul, brake pad replacement, rotor inspection, brake line bleeding.
Braking System Rear:
Brake caliper overhaul, brake pad replacement, rotor inspection, brake line bleeding.
Wheels And Tires:
Tire pressure specifications, wheel bearing service, hub maintenance.
Electrical System:
Wiring diagrams, battery testing and charging, lighting system troubleshooting, starter and charging system diagnostics.
Frame And Body:
Frame inspection for damage, plastic panel removal and installation, seat repair.
Preventive Maintenance:
Detailed schedules for oil changes, filter replacements, lubrication points, and periodic inspections.
Troubleshooting Guides:
Systematic diagnostic procedures for common and uncommon problems with step-by-step solutions.
Engine Repair:
Piston and cylinder replacement, valve adjustment, gasket replacement, crankshaft and connecting rod checks.
Transmission Repair:
PVT clutch component replacement, roller service, spring replacement, drive belt adjustment.
Brake System Service:
Brake caliper rebuilding, master cylinder service, brake pad and rotor replacement, bleeding procedures.
Electrical Diagnostics:
Using a multimeter for component testing, tracing electrical faults, starter motor and charging system testing.
Suspension Component Replacement:
Ball joint, tie rod end, bushing, and shock absorber replacement.
Carburetor Adjustment:
Idle speed settings, mixture adjustments, jetting recommendations.
Special Tool Identification:
Lists and descriptions of specialized tools required for specific repair procedures.
Repair Scope:
Comprehensive coverage from basic maintenance to complete engine and transmission rebuilds.
Diagnostic Capability:
Advanced diagnostic information for electrical and mechanical systems, including troubleshooting flowcharts.
Specifications Detail:
Detailed torque specifications, clearances, fluid capacities, and electrical resistance values.
Engine Type:
4-stroke, liquid-cooled, single-cylinder
Displacement:
378cc (approximate, specific variants may vary slightly)
Bore X Stroke:
Refer to specific year sections in manual for exact dimensions
Compression Ratio:
Refer to specific year sections in manual for exact ratios
Horsepower:
Estimated 20-25 HP (varies by year and specific tuning)
Torque:
Refer to specific year sections in manual for torque figures
Fuel Delivery:
Carburetor (specific model varies by year, e.g., Mikuni BSR32)
Fuel Type:
Unleaded gasoline, 87 octane minimum
Fuel Tank Capacity:
Approximately 3.7 gallons (14.0 liters)
Engine Oil Change:
Every 50 hours or annually, whichever comes first (refer to manual for precise intervals).
Air Filter Cleaning Replacement:
Inspect every 25 hours, clean or replace as needed. More frequently in dusty conditions.
Spark Plug Replacement:
Refer to manual for specific interval, typically annually or every 100 hours.
Drive Belt Inspection:
Inspect at every 25 hours of operation, replace as needed based on wear and damage.
Brake Fluid Flush:
Recommended every 2 years or as per manual for optimal braking performance.
Engine Oil Type:
SAE 20W-50 API SG or higher (Polaris recommends specific formulations, consult manual).
Engine Oil Capacity:
Approximately 1.9 US quarts (1.8 liters) 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.
Pv T Belt Wear:
Drive belts can wear prematurely if subjected to excessive heat, improper alignment, or abuse. Regular inspection is crucial.
Carburetor Fouling:
Fuel sitting in the carburetor can lead to varnish and fouling, especially after storage. Periodic cleaning and proper storage procedures are recommended.
Cv Joint Boots:
CV joint boots can degrade over time, leading to grease loss and contamination, which can damage the joints. Inspection and replacement are important for longevity.
Electrical Connector Corrosion:
Exposure to elements can lead to corrosion in electrical connectors, causing intermittent faults. Cleaning and dielectric grease application can mitigate this.
Manufacturer Origin:
Polaris Industries, Inc. is an American manufacturer founded in 1954, known for its powersports vehicles.
Sportsman Lineage:
The Sportsman line, introduced in the early 1990s, became a cornerstone for Polaris, emphasizing comfort, durability, and utility.
Sportsman 400 Positioning:
The Sportsman 400 represented an entry-level to mid-range option within the Sportsman lineup, offering a balance of performance and value.
Production Period:
The 1996-2003 models represent a specific generation of the Sportsman 400, undergoing evolutionary updates during this period.
Manufacturing Location:
Primarily manufactured in the United States by Polaris Industries.
