Market Segment:
Mid-size utility ATV, known for its versatility in recreational and light work applications.
Competitors:
Competed against models like Yamaha Grizzly 400, Suzuki King Quad 400, and Can-Am Outlander 400 of the same era.
Powertrain:
Robust 400cc liquid-cooled engine, reliable AWD system.
Handling:
Independent front suspension, MacPherson strut front suspension, often praised for comfortable ride and capability.
Utility:
Front and rear racks for cargo carrying, towing capacity.
Engine:
Engine overhaul, cylinder head, piston, crankshaft, camshaft, valve timing, lubrication system, cooling system.
Fuel System:
Fuel injection system (EFI), fuel pump, injectors, throttle body, fuel lines, fuel tank.
Transmission Drivetrain:
CVT (Continuously Variable Transmission) system, drive clutch, driven clutch, belt replacement, gearcase, differential, driveshafts, AWD system operation and service.
Braking System:
Hydraulic brake system, brake calipers, brake pads, brake discs, master cylinder, brake lines, parking brake.
Electrical System:
Battery, charging system (stator, rectifier/regulator), starter motor, ignition system, lighting, wiring diagrams, fuse box, sensors (TPS, MAP, etc.), ECU.
Suspension Steering:
Front and rear suspension components, shock absorbers, A-arms, ball joints, tie rods, steering column, steering rack, wheel alignment.
Bodywork Chassis:
Frame, plastic body panels, racks, seat, fenders, handlebars, footrests.
Maintenance:
Scheduled maintenance, oil changes, filter replacements, spark plug service, lubrication points, fluid checks and changes.
Troubleshooting:
Diagnostic procedures for common and uncommon issues, symptom-based troubleshooting guides, error code interpretation.
Repair:
Step-by-step repair instructions for all major components and systems, including disassembly, inspection, repair, and reassembly.
Overhaul:
Complete engine and transmission overhaul procedures, including specifications and tolerances.
Diagnostics:
Diagnostic testing for electrical and mechanical systems, including specific testing procedures and expected results.
Depth:
Comprehensive, from basic maintenance tasks to complete engine and driveline rebuilds. Suitable for professional mechanics and experienced DIY enthusiasts.
File Format:
PDF (typically searchable, with high-resolution diagrams)
Print Quality:
High-resolution, clear diagrams and text (assuming a quality reproduction)
Binding Type:
If printed: Coil-bound or perfect-bound for lay-flat usability.
Paper Type:
If printed: Heavy-duty, coated paper to withstand shop conditions.
Engine Type:
4-stroke, SOHC, 4-valve, liquid-cooled
Displacement:
375cc to 400cc (Polaris often rounded up or used variations within this range for the '400 HO' designation).
Bore X Stroke:
Typical for this displacement range, likely around 90mm x 62mm.
Compression Ratio:
Likely around 10.0:1 to 11.0:1.
Power Output:
Estimated 28-32 HP (horsepower) at peak RPM.
Torque Output:
Estimated 25-28 lb-ft (foot-pounds) at peak RPM.
Top Speed:
Governed by CVT and gearing, typically around 45-55 mph.
Fuel Delivery:
Electronic Fuel Injection (EFI)
Fuel Type:
Unleaded gasoline, minimum 87 octane
Ignition Type:
Electronic ignition with CDI (Capacitor Discharge Ignition) or similar.
Cooling Method:
Liquid-cooled
Coolant Type:
Ethylene glycol-based antifreeze (e.g., Polaris P/N 2870553 or equivalent, typically a 50/50 mix with distilled water).
Oil Type:
Polaris PS-4 Full Synthetic 4-Stroke Engine Oil (e.g., SAE 5W-50, P/N 2877899) or equivalent API SG, SJ, SL rated oil.
Oil Capacity:
Approximately 2.2 quarts (2.1 liters) with filter change.
Transmission Type:
Automatic, Polaris Variable Transmission (PVT) with All-Wheel Drive (AWD) engagement.
Gear Selection:
High, Low, Neutral, Reverse, Park.
Clutch System:
CVT system with Primary (Drive) and Secondary (Driven) clutches.
AWD System:
On-demand AWD, automatically engages front wheels when rear wheels lose traction.
Gearcase Oil Type:
Polaris Synthetic Gearcase Lubricant (e.g., SAE 75W-90, P/N 2876145) or equivalent API GL-5 rated.
Gearcase Oil Capacity:
Approximately 0.5 quarts (0.47 liters) for rear differential/gearcase.
Length:
Approx. 83 inches (210.8 cm)
Width:
Approx. 46 inches (116.8 cm)
Height:
Approx. 48 inches (121.9 cm)
Wheelbase:
Approx. 50.5 inches (128.3 cm)
Ground Clearance:
Approx. 10.25 inches (26.0 cm)
Dry Weight:
Approx. 600 lbs (272 kg)
Towing Capacity:
1500 lbs (680.4 kg)
Rack Capacity Front:
75 lbs (34 kg)
Rack Capacity Rear:
150 lbs (68 kg)
Fuel Capacity:
3.2 gallons (12.1 liters)
Atv Safety Standards:
Meets ANSI standards for recreational ATVs.
Braking System Design:
Hydraulic disc brakes front and rear, often with sealed hydraulic rear brake system.
Rollover Protection:
None (standard for ATVs of this era; operator must use proper riding techniques).
Lighting:
Dual headlights, brake light.
Operator Training:
Manual likely emphasizes rider training and adherence to safety guidelines.
Instrument Cluster:
Digital instrument cluster displaying speed, RPM, fuel level, gear selection, AWD status, and basic indicators.
AWD System:
Polaris's Automatic All-Wheel Drive (AWD) system is a key technological feature for enhanced traction.
Diagnostic Ports:
Likely has a diagnostic port for connecting to a service computer for advanced diagnostics and tuning.
Engine Oil Change:
Every 100 hours or 6 months, whichever comes first (refer to manual for exact interval and conditions).
Air Filter Service:
Inspect every 25 hours, clean/replace as needed, especially in dusty conditions.
Spark Plug Service:
Replace every 100 hours or annually.
Cv Belt Inspection:
Inspect every 50 hours for wear and damage.
Gearcase Oil Change:
Every 100 hours or annually.
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid (refer to manual for specific recommendation).
Grease Type:
Lithium-based chassis grease for lubrication points.
Common Wear Items:
CVT belt, wheel bearings, ball joints, tie rod ends, brake pads.
Potential Electrical Issues:
Relay failures, stator issues, wiring harness wear (common in off-road environments).
Drive Train Maintenance:
Regular inspection and maintenance of the AWD system and gearcase are crucial for longevity.
Polarisfactory:
Polaris Industries Inc., a long-standing American manufacturer of powersports vehicles.
Sportsman Line:
The Sportsman line has been a cornerstone of Polaris's ATV offerings for decades, known for its utility and rider comfort.
400Ho Positioning:
The 400 HO model served as a popular mid-range option, balancing power, capability, and affordability within the Sportsman lineup.
Manufacturing Location:
Primarily manufactured in the USA by Polaris.
