Market Segment:
Sport ATV segment, designed for recreational off-road use, offering performance and handling.
Competitors:
Competed against other sport ATVs from manufacturers like Yamaha (Blaster, Warrior), Suzuki (LT series), and Kawasaki (Bayou, Mojave).
Key Features:
Liquid-cooled 2-stroke engine for potent power delivery, sporty handling characteristics, independent front suspension, and a focus on rider engagement.
Value:
A reliable and performant sport ATV for its era, offering a strong platform for trail riding and recreational use.
Systems Covered:
Engine, transmission, drivetrain, suspension, brakes, electrical system, fuel system, cooling system, chassis, bodywork, steering, maintenance, troubleshooting, diagnostics, specifications, adjustments, repairs.
Page Count:
Estimated 200-400 pages (typical for comprehensive service manuals of this era; exact count not provided in product description).
Manual Type:
Service Repair Manual
Engine:
Detailed coverage of the 398cc liquid-cooled 2-stroke engine, including disassembly, assembly, inspection, tuning, and component-specific repair procedures.
Transmission:
Comprehensive information on the automatic transmission, including clutch, gear selection, and drive belt maintenance and replacement.
Drivetrain:
Coverage of the shaft drive system, including universal joints, differential, and final drive maintenance and repair.
Suspension:
Front and rear suspension systems, including A-arms, shocks, springs, and pivot points; maintenance, adjustments, and replacement procedures.
Brakes:
Hydraulic disc brake systems (front and rear), including caliper overhaul, brake line replacement, fluid bleeding, and pad replacement.
Electrical System:
Detailed wiring diagrams, lighting system, ignition system (CDI), starting system (electric start), battery maintenance, and troubleshooting common electrical faults.
Fuel System:
Carburetor (likely Mikuni VM series) service, cleaning, adjustment, and jetting; fuel pump, fuel lines, and fuel tank maintenance.
Cooling System:
Radiator service, fan operation, coolant specifications, and leak detection for the liquid-cooled engine.
Chassis And Bodywork:
Frame inspection, plastics and body panel removal/installation, seat maintenance, and handlebar assembly.
Steering:
Steering mechanism, tie rods, ball joints, and wheel alignment procedures.
Maintenance:
Scheduled maintenance tasks, lubrication points, filter replacements (air, oil, fuel), spark plug service, and general upkeep.
Troubleshooting:
Systematic troubleshooting guides for common issues, with diagnostic charts and fault isolation techniques.
Repair:
Step-by-step repair instructions for all major components and systems, including detailed diagrams and torque specifications.
Disassembly And Assembly:
Complete instructions for disassembling and reassembling the engine, transmission, suspension, and other key assemblies.
Adjustments:
Procedures for adjusting carburetor settings, clutch engagement, brakes, and suspension preload.
Depth:
Comprehensive, covering everything from basic owner maintenance to complex engine rebuilds and electrical system diagnostics.
Diagnostic Capabilities:
Advanced diagnostic procedures, including testing ignition components, fuel system pressure, and electrical circuits.
Rebuild Information:
Detailed specifications and procedures for complete engine and transmission rebuilds, including wear limits and tolerances.
Engine Type:
2-stroke, liquid-cooled, reed valve induction
Displacement:
398 cc (approximate, exact specification to be confirmed in manual)
Bore X Stroke:
Specific dimensions will be detailed in the manual, crucial for rebuilds.
Horsepower:
Estimated 30-35 HP (typical for this class and engine size; exact figures in manual).
Torque:
Specific torque figures to be found in the manual.
Carburetor:
Single carburetor, likely a Mikuni VM series (e.g., VM34 or similar); precise model and jetting specifications in manual.
Fuel Type:
Unleaded gasoline, 87-octane or higher recommended (check manual for precise octane requirement).
Ignition System:
CDI (Capacitor Discharge Ignition) with electronic timing.
Cooling Method:
Liquid-cooled with fan assist.
Lubrication System:
Premix oil/fuel or oil injection system (specifics to be confirmed in manual). If premix, ratio will be specified.
Transmission Type:
Automatic with variable ratio (CVT - Continuously Variable Transmission) or a torque converter automatic with centrifugal clutch, likely a belt-driven system.
Optional Transmissions:
Not applicable for this model year and type; typically a single automatic transmission offering.
Drive System:
Shaft drive to rear wheels.
Gear Selection:
Forward, Neutral, Reverse (F-N-R) likely operated by a lever.
Transmission Fluid:
Specific fluid type and capacity will be detailed in the manual; likely a specialized ATV transmission fluid or gear oil.
Length:
Specific dimensions available in manual (typical for sport ATVs of the era: ~70-75 inches).
Width:
Specific dimensions available in manual (typical: ~45-48 inches).
Height:
Specific dimensions available in manual (typical: ~44-47 inches).
Dry Weight:
Estimated 450-500 lbs (specific figure in manual).
Ground Clearance:
Specific ground clearance figures available in manual (typically 7-10 inches).
Front Tire Size:
Commonly 22x7-10 or 23x7-10; exact specification in manual.
Rear Tire Size:
Commonly 22x10-10 or 23x11-10; exact specification in manual.
Wheel Bolt Pattern:
Specific pattern to be found in the manual.
Safety Certifications:
ATVs of this era generally met US EPA emissions standards and ANSI safety standards for off-highway vehicles. Specific certifications to be found in manual or on vehicle plates.
Braking System:
Front and rear hydraulic disc brakes for effective stopping power.
Throttle Limiter:
Some models may have had adjustable throttle limiters for new riders; check manual for existence and adjustment.
Handguards:
Standard handguards to protect hands from debris and weather.
Seatbelt:
N/A - ATVs are operated without seatbelts, requiring rider balance and control.
Initial Service:
First service typically around 10-20 hours or one month; detailed in manual.
Routine Maintenance:
Regular checks of tire pressure, fluid levels, chain/belt tension, and lubrication every few rides. More comprehensive service every 50-100 hours. Specific intervals in manual.
Engine Oil Change:
Intervals for engine oil (if applicable, e.g., transmission oil) and gear oil changes will be specified in the manual, likely every 50-100 hours or annually.
Engine Oil:
Specific viscosity grade (e.g., SAE 10W-40 or 20W-50) and API service classification for the 2-stroke engine oil (if separate oil tank) or pre-mix ratio and oil type will be detailed in the manual.
Transmission Fluid:
Specific ATV transmission fluid or gear oil type and capacity for the final drive and transmission will be listed in the manual.
Coolant:
Type of antifreeze/coolant (e.g., ethylene glycol-based) and mixture ratio (typically 50/50 with distilled water) specified in manual.
Brake Fluid:
DOT 3 or DOT 4 hydraulic brake fluid; specific type and replacement interval in manual.
Common Problems:
Potential issues for 2-stroke ATVs of this era can include carburetor gumming, drive belt wear (if CVT), worn suspension bushings, and electrical connection corrosion. Manual provides troubleshooting for these.
2 Stroke Carb Issues:
Carburetors can be sensitive to fuel quality and storage; manual details cleaning and jetting procedures.
Drive Belt Maintenance:
Regular inspection and replacement of the drive belt (if applicable) are critical for transmission longevity; covered in manual.
Brand History:
Polaris Industries is a well-established American manufacturer of powersports vehicles, known for innovation and a strong presence in the ATV market since the early 1980s.
Sport Series Evolution:
The Sport 400 was part of Polaris's lineup of sport-oriented ATVs, evolving from earlier models with a focus on performance and handling for trail riding and recreational use.
Production Years:
The Polaris Sport 400 model was produced in the late 1990s. The 1999 model year represents a specific iteration within its production run. Specific start/end years for the 'Sport 400' nameplate will be detailed in the manual's history section if available.
Manufacturing Location:
Polaris vehicles are primarily manufactured in the United States.
