Polaris Sportsman 300 400 2009 Repair Service Manual

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Tipo: Atv

Proveedor:

SKU: 85333

Etiquetas: 2009 ATV Misc Polaris Powersports Sportsman 300 Sportsman 400

Variantes de producto

Descripción

The 2009 Sportsman 300 and 400 are versatile all-terrain vehicles designed for recreational riders and light utility tasks. Building on a reputation for performance and durability, these models offer user-friendly operation and a capable On-Demand All-Wheel Drive system for enhanced traction. With comfortable ergonomics and a robust chassis, the Sportsman 300 and 400 are well-suited for various terrains, making them a reliable choice for farm use or trail riding. Their engineering emphasizes a balance of power, handling, and practicality within their class. This comprehensive 291-page English-language repair service manual provides detailed information for the maintenance, troubleshooting, and repair of the 2009 Sportsman 300/400. It covers all major systems, including complete engine and transmission overhaul procedures, drivetrain, suspension, brakes, and electrical systems. The manual includes scheduled maintenance guidelines, diagnostic flowcharts for common issues, and critical torque specifications. Its depth is suitable for professional technicians and experienced enthusiasts seeking to maintain or repair their vehicle effectively and safely.

🏷️ Basic Information

Identification

Make:

Polaris

Model:

Sportsman 300 / 400

Year:

Generation

Generation Code:

Codes

Vin Prefix:

👋 Introduction

Market Position

Segment:

Entry-level to mid-range All-Terrain Vehicle (ATV) / Utility Vehicle.

Target Audience:

Recreational riders, light utility work, farm use.

Competitive Analysis

Competitors:

Honda Foreman, Yamaha Grizzly, Can-Am Outlander (lower displacement models).

Key Features

Features:

Polaris's reputation for performance and durability, user-friendly operation, capable AWD system, comfortable ergonomics for its class.

📋 Manual Details

Coverage Areas

Comprehensive Coverage:

Complete teardown and rebuild procedures, maintenance, troubleshooting, diagnostics, electrical systems, engine, transmission, chassis, bodywork.

Page Count

Number Of Pages:

Manual Type

Type:

Repair Service Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine:

Complete engine overhaul, top-end rebuild, bottom-end rebuild, cooling system, lubrication system, fuel delivery system, ignition system, exhaust system.

Transmission:

Automatic transmission (PVT - Polaris Variable Transmission) operation, maintenance, service, and common issues.

Drivetrain:

All-Wheel Drive (AWD) system, front and rear differentials, driveshafts, CV joints, clutch system.

Suspension And Steering:

Front and rear suspension components (shocks, springs, control arms), steering linkage, wheel bearings, universal joints.

Brakes:

Hydraulic brake system, brake fluid specifications, caliper service, brake pad replacement, bleeding procedures.

Electrical System:

Wiring diagrams, battery, starter, charging system, lighting, ignition switch, ECU (Engine Control Unit) basics, accessory circuits.

Body And Frame:

Fenders, body panels, seat, handlebars, racks, chassis components, fastener torque specifications.

Procedures Included

Maintenance:

Scheduled maintenance intervals, oil changes, filter replacements, spark plug service, lubrication points, battery maintenance.

Troubleshooting:

Diagnostic flowcharts for common starting, running, and operational issues. Symptom-based troubleshooting guides.

Repair:

Detailed step-by-step repair procedures for all major mechanical and electrical components, including complete engine and transmission rebuilds.

Diagnostics:

Information on diagnosing electrical faults, engine performance problems, and drivetrain issues.

Technical Depth

Depth:

Comprehensive, suitable for professional technicians and experienced DIY enthusiasts. Covers complete disassembly and reassembly.

📊 Manual Specifications

File Format

File Type:

Searchable:

Print Quality

Quality:

High-resolution, clear images and diagrams.

Binding Type

Binding:

N/A (Digital PDF)

Paper Type

Paper Type:

N/A (Digital PDF)

⚙️ Engine Specifications

Primary Engine

Type:

4-stroke, liquid-cooled, SOHC

Displacement 300:

271cc

Displacement 400:

375cc

Bore X Stroke 300:

71.5 mm x 68.6 mm

Bore X Stroke 400:

83 mm x 69.5 mm

Compression Ratio 300:

10.2:1

Compression Ratio 400:

9.7:1

Performance

Horsepower 300:

Approx. 21 HP

Horsepower 400:

Approx. 28 HP

Torque 300:

N/A (manual will specify)

Torque 400:

N/A (manual will specify)

Fuel System

Fuel Delivery:

Carbureted (Keihin CVK)

Carburetor Size 300:

Carburetor Size 400:

Fuel Type:

Unleaded gasoline, 87 octane (minimum)

Ignition

Ignition Type:

Electronic Ignition

Cooling System

Cooling Method:

Liquid-cooled

Oil And Lubrication

Engine Oil Type:

SAE 20W-50 Polaris 4-Stroke ATV Oil (or equivalent JASO MA certified)

Engine Oil Capacity W Filter:

1.8 L (1.9 US qt)

Final Drive Oil Type:

Polaris HP Synthetic Gearcase Lube

Final Drive Oil Capacity:

0.24 L (0.25 US qt)

🔧 Transmission

Standard

Type:

Polaris Variable Transmission (PVT) Automatic

Drive System:

Shaft Drive, On-Demand All-Wheel Drive (AWD)

Gear Selection:

Park, Reverse, Neutral, Low, High

Features

Engine Braking:

Integrated engine braking through PVT system

Maintenance

Pvt Belt Inspection Interval:

Every 100 hours or annually

Pvt Belt Replacement Criteria:

Inspect for wear, cracking, fraying, or damage. Replace if width is reduced by 3mm or more.

📐 Dimensions

Exterior

Length:

81 inches (205.7 cm)

Width:

46 inches (116.8 cm)

Height:

45.5 inches (115.6 cm)

Wheelbase:

50.5 inches (128.3 cm)

Ground Clearance:

11.5 inches (29.2 cm)

Cargo

Front Rack Capacity:

25 lbs (11.3 kg)

Rear Rack Capacity:

50 lbs (22.7 kg)

Weights

Dry Weight 300:

600 lbs (272 kg)

Dry Weight 400:

605 lbs (274.4 kg)

Towing Capacity:

1500 lbs (680 kg)

N/A (Manual will specify)

Wheels And Tires

Front Tire Size:

25 x 8-12

Rear Tire Size:

25 x 11-12

Wheel Type:

Steel or Aluminum alloy

Bolt Pattern:

4x110mm

🛡️ Safety Features

Ratings

Atv Safety Standards:

Meets ANSI standards for recreational ATVs.

Active Features

AWD System:

On-Demand All-Wheel Drive for enhanced traction.

Braking System:

Hydraulic disc brakes front and rear for reliable stopping power.

Passive Features

Lighting:

Dual 35W headlights, 8.2W brake/taillight.

Hand Guards:

Standard on some models for hand protection.

User Warnings

Operation Safety:

Manual provides critical safety warnings, recommended riding gear, and operation guidelines.

💡 Technology Features

Infotainment

Features:

Basic instrumentation cluster (speedometer, odometer, fuel gauge, indicator lights). No advanced infotainment systems typical of automotive applications.

Driver Assistance

Features:

Not applicable in the traditional automotive sense. The AWD system provides traction assistance.

Connectivity

Features:

Not applicable.

🔧 Maintenance

Service Intervals

Initial Service:

First service typically at 20 hours or 1 month (refer to manual for exact specifics).

Engine Oil Change:

Every 100 hours or 6 months

Air Filter Cleaning:

Every 25 hours or 3 months (more frequently in dusty conditions)

Spark Plug Replacement:

Every 100 hours or 12 months

Transmission Oil Change:

Every 100 hours or 12 months

Fluid Specifications

Coolant Type:

Polaris Premium Antifreeze/Coolant (ethylene glycol based, 50/50 mix with distilled water)

Brake Fluid Type:

DOT 4 Hydraulic Brake Fluid

Known Issues

Common Problems:

PVT belt wear, potential carburetor adjustments, occasional electrical connector issues, suspension wear over time.

Preventative Maintenance:

Adherence to the manual's service schedule is crucial for longevity and preventing common issues.

Torque Specs

Importance:

Manual provides critical torque specifications for engine, drivetrain, suspension, and body fasteners for correct assembly and safety.

📚 Vehicle History

Brand Heritage

Polarise History:

Polaris Industries Inc. is a prominent American manufacturer of powersports vehicles, known for innovation and off-road capability.

Model Evolution

Sportsman Lineage:

The Sportsman line has been a cornerstone of Polaris's ATV offerings for decades, emphasizing comfort, utility, and versatility. The 300/400 models represent a more accessible entry point into the Sportsman family.

Production

Manufacturing Location:

Typically manufactured in USA or Mexico facilities by Polaris.

Sales Performance:

Sportsman models are consistently strong sellers, reflecting their broad appeal and reputation.

🏆 Awards & Recognition

Recognitions

Brand Awards:

Polaris consistently receives high marks in industry reviews for its ATV performance, reliability, and innovation. Specific awards for the 2009 Sportsman 300/400 may not be individually documented but the model line is well-regarded.