POLARIS SPORT 400 EXPLORER 400 ATV Service Repair Manual 1999

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Tipo: Atv

Proveedor:

SKU: 144593

Etiquetas: 1999 ATV EXPLORER 400 Explorer Models Polaris Powersports SPORT 400

Variantes de producto

Descripción

Welcome to the comprehensive service and repair manual for the 1999 Sport 400 Explorer, a capable All-Terrain Vehicle (ATV) powered by a 2-stroke engine. Designed for recreational trail riding, this model offers a blend of performance and durability. Its engineering quality and reliability have made it a respected choice for those seeking adventure and utility in off-road environments. This manual provides complete A-Z service and repair information, covering all essential systems including the engine, drivetrain, chassis, and electrical components. You will find detailed step-by-step instructions, exploded diagrams, and troubleshooting guidance for maintenance, periodic checks, adjustments, and all repair procedures, from basic to complex. This resource is invaluable for ATV owners, DIY mechanics, and professional repair shops aiming to maintain, diagnose, and repair the Sport 400 Explorer effectively.

🏷️ Basic Information

Identification

Make:

Polaris

Model:

Sport 400 Explorer

Year:

Vehicle Type:

All-Terrain Vehicle (ATV)

Engine Type:

2-stroke

👋 Introduction

Market Position

Target Audience:

ATV Owners, DIY Mechanics, Professional Repair Shops

Competitive Analysis

Value Proposition:

High-quality, comprehensive manual that saves money on repairs and enhances vehicle care; superior to incomplete or cheaper versions.

Key Features

Manual Features:

Factory workshop manual equivalent, detailed diagrams, step-by-step instructions, A-Z coverage, instant download.

📋 Manual Details

Coverage Areas

Manual Coverage:

Complete A-Z Service and Repair

Page Count

Page Count:

Not specified, but described as 'COMPLETE' and 'highly detailed'

Manual Type

Manual Type:

Service Repair Workshop Manual

Language

Language:

English

Format

Format:

Accessibility

Delivery Method:

Instant Download

📖 Manual Coverage

Systems Covered

Engine Systems:

Engine Removal and Installation, Fuel System, Lubrication and Cooling, Combustion System, Lubrication System, Cylinder Head/Valves, Alternator/Starter Clutch, Crankcase/Piston/Cylinder, Crankshaft/Transmission/Balancer

Drivetrain Systems:

Gearbox & Clutch, Transmission System

Chassis Systems:

Front Wheel and Steering System, Rear Wheel System, Chassis, Frame/Body Panels/Exhaust System, Wheels/Tires/Brakes, Suspension

Electrical Systems:

Electrical System, Battery/Charging System, Ignition System, Electric Starter, Lights/Meters/Switches, Wiring Diagrams

Body Systems:

Body & Fixtures, Fenders and Exhaust Pipe

Procedures Included

Repair Procedures:

All repair procedures covered, from simple to complicated

Maintenance Procedures:

Maintenance, Periodic checks & Adjustments

Troubleshooting:

Troubleshooting

Technical Depth

Depth Of Information:

Professional Quality, Highly Detailed, Step-by-step instructions, Exploded pictures & diagrams

📊 Manual Specifications

File Format

Digital Format:

Compatibility

Operating Systems:

Win/MAC/Linux compatible

Print Quality

Printability:

Printable (entire manual or specific sections)

Binding Type

Binding:

N/A (Digital Download)

Paper Type

Paper Type:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Displacement:

398cc (approximate for 400cc class)

Engine Configuration:

Single-cylinder, 2-stroke

Performance

Horsepower:

Estimated 28-32 HP (typical for this class and era)

Torque:

Not specified, but typically in the 25-30 lb-ft range

Fuel System

Fuel Delivery:

Carbureted (likely a Mikuni VM series carburetor)

Fuel Type:

Unleaded gasoline (typically 87 octane or higher)

Cooling System

Cooling Method:

Liquid-cooled

Ignition System

Ignition Type:

CDI (Capacitor Discharge Ignition)

Lubrication System

Lubrication Method:

Oil Injection (Premix possibly also covered)

🔧 Transmission

Standard

Transmission Type:

Automatic (CVT - Continuously Variable Transmission)

Drive System:

2WD (Rear-wheel drive typical for Sport models, AWD not specified)

Features

Clutch Type:

Torque Converter (for CVT)

📐 Dimensions

Exterior

Length:

Approximately 72-74 inches

Width:

Approximately 45-48 inches

Height:

Approximately 43-45 inches

Weights

Dry Weight:

Approximately 450-500 lbs

Ground Clearance:

Approximately 8-10 inches

Towing Capacity:

Not typically specified for this sport model

🛡️ Safety Features

Ratings

Safety Standards:

ATV safety guidelines (ANSI/SVIA compliance expected)

Active Features

Braking System:

Hydraulic disc brakes (front and rear)

Lighting:

Headlights, taillight, brake light

Passive Features

Handlebars:

Grip handles with knuckle guards

Footwells:

Aggressive traction, protective guards

💡 Technology Features

Infotainment

Infotainment System:

N/A (Basic utility vehicle design)

Driver Assistance

Driver Assistance Features:

Connectivity

Connectivity Features:

Instrumentation

Gauge Cluster:

Speedometer, odometer, basic indicator lights (neutral, high beam, oil).

🔧 Maintenance

Service Intervals

Oil Change Interval:

Refer to manual for specific 2-stroke oil/fuel mix or injection system recommendations.

Spark Plug Replacement:

Typically every 100-200 hours or as needed based on condition.

Air Filter Cleaning:

Frequent cleaning recommended, especially in dusty conditions (e.g., every 10-20 hours).

Chain Lubrication:

Regular lubrication is critical for the drive chain (if applicable).

Fluid Specifications

Coolant Type:

Ethylene glycol-based antifreeze/coolant (e.g., SAE J1034)

Brake Fluid:

DOT 3 or DOT 4 hydraulic brake fluid

Transmission Fluid:

ATF (Automatic Transmission Fluid) for the CVT transmission, specific type to be confirmed in manual.

Known Issues

Common Wear Items:

Brake pads, tires, suspension bushings, drive belts (CVT), carburetor jets (clogging).

Engine Issues:

Overheating if cooling system is not maintained, carburetor tuning issues, potential wear on 2-stroke components with heavy use.

Electrical Issues:

Wiring harness chafing, stator/rectifier failures, battery health.

📚 Vehicle History

Brand Heritage

Manufacturer History:

Polaris Industries is a long-standing American manufacturer of powersports vehicles, founded in 1954, known for innovation in ATVs, snowmobiles, and motorcycles.

Model Evolution

Sport Lineup Evolution:

The Sport 400 was part of Polaris's line of sport-oriented ATVs, designed for recreational trail riding and performance, evolving from earlier models with improved suspension, engines, and features.

Production

Production Period:

1990s - early 2000s (1999 model falls within this era)

🏆 Awards & Recognition

Recognitions

Industry Awards:

Not specified for this particular model year.

Ratings

Consumer Ratings:

Varies by owner experience, but generally regarded as a capable trail ATV of its era.