Target Audience:
Owners of 2009 Polaris Sportsman 300 and 400 HO ATVs, DIY mechanics, and professional repair shops.
Value Proposition:
Provides factory-level diagnostic and repair information at a fraction of the cost of dealership services, empowering users to perform maintenance and repairs efficiently.
Accessibility:
Instant download allows immediate access to critical repair information, saving time and reducing downtime.
Clarity Of Instructions:
Features easy-to-read text with high-quality diagrams and step-by-step instructions, simplifying complex repair tasks.
Countries Of Sale:
Global (assumed based on typical manual distribution)
Manual Formats Covered:
PDF Download
Estimated Page Count:
Not explicitly stated, but factory service manuals for this era are typically extensive (e.g., 300-600+ pages depending on scope).
Manual Type:
Factory Service Repair Workshop Manual
Compatibility:
All Versions of Windows & Mac
Requirements:
Adobe PDF Reader & WinZip
Printability:
All pages are printable
Delivery Method:
Instant Download
Engine:
Complete engine overhaul, including disassembly, assembly, inspection, and repair of all internal components (pistons, rings, valves, camshaft, crankshaft, etc.). Includes ignition system and related components.
Fuel System:
Carburetor tuning, cleaning, and rebuilding; fuel pump operation and testing; fuel tank and lines maintenance.
Transmission:
Continuously Variable Transmission (CVT) service, including belt inspection and replacement, clutch assembly maintenance, and gearcase lubrication.
Drivetrain:
Final drive assembly (differential, axles, driveshafts), gearcase lubrication, seals, bearings, and U-joints. Includes 2WD and 4X4 system components.
Brakes:
Hydraulic brake system diagnosis, repair, and bleeding. Includes caliper, master cylinder, brake lines, and brake pad replacement.
Electrical:
Wiring diagrams, battery maintenance, starter system, charging system (stator, rectifier/regulator), lighting, ignition switch, and accessory wiring.
Body Steering Suspension:
Front and rear suspension components (shocks, A-arms, bushings), steering system (handlebar, tie rods, steering shaft), chassis maintenance, and body panels.
Maintenance Procedures:
Regular scheduled maintenance, fluid changes (oil, coolant, brake fluid, gear lube), filter replacement, spark plug service, and lubrication points.
Troubleshooting:
Diagnostic charts and procedures for common and uncommon problems related to engine, electrical, fuel, and drivetrain systems.
Repair Procedures:
Step-by-step instructions for component disassembly, repair, reassembly, and adjustment of all major systems.
Technical Specifications:
Torque specifications, clearances, timing, fluid capacities, and other critical data for accurate repair.
Wiring Diagrams:
Detailed electrical system schematics with component identification.
Depth Of Coverage:
Comprehensive, covering everything from basic fluid changes to complete engine and transmission rebuilds. Suitable for DIY enthusiasts and professional mechanics.
Detail Level:
Highly detailed, with exploded views, diagrams, and step-by-step instructions for each procedure.
Engine Type 300:
Liquid-cooled, 4-stroke, SOHC, 2-valve
Engine Displacement 300:
271cc (approx.)
Engine Type 400 Ho:
Liquid-cooled, 4-stroke, SOHC, 2-valve
Engine Displacement 400 Ho:
375cc (approx.)
Horsepower Estimate:
Typically in the range of 20-30 HP, depending on specific model and tuning.
Fuel Delivery 300:
Carburetor (likely Mikuni B24)
Fuel Delivery 400 Ho:
Carburetor (likely Mikuni B28)
Fuel Type:
Unleaded gasoline
Wheelbase:
Approximately 49.5 inches (125.7 cm)
Dry Weight Approx 300:
Approximately 640 lbs (290 kg)
Dry Weight Approx 400 Ho:
Approximately 670 lbs (304 kg)
Towing Capacity:
Typically 1,500 lbs (680 kg)
Rack Capacity Front:
Typically 100 lbs (45 kg)
Rack Capacity Rear:
Typically 200 lbs (90 kg)
Safety Standards:
Adheres to industry safety standards for ATVs. Specific crash ratings not typically issued for ATVs.
Braking System:
Hydraulic disc brakes front and rear.
Engine Braking:
Integrated into the PVT system for downhill control.
Lighting:
Dual headlights, tail light, and brake light.
Operator Safety:
Handlebar grips, footwells with heel guards, and throttle limiter adjustment.
Oil Change Interval:
Recommended every 100 hours or 6 months, whichever comes first (refer to manual for specific oil type).
Air Filter Cleaning:
Inspect every 20-40 hours, clean or replace as needed based on operating conditions.
Cv Belt Inspection:
Inspect at 100 hours for wear and damage, replace as needed.
Spark Plug Replacement:
Typically at 100-200 hours or annually.
Engine Oil Type:
Polaris synthetic 0W-40 PS-4 or equivalent SAE 0W-40 API CI-4, ACEA B3-98 rated.
Engine Oil Capacity:
Approximately 2.0 U.S. quarts (1.9 L) with filter change.
Transmission Gearcase Lube:
Polaris AGL Synthetic Gearcase Lubricant or equivalent SAE 75W-90 API GL-5.
Transmission Gearcase Capacity:
Approximately 10 oz (0.3 L).
Brake Fluid:
DOT 3 or DOT 4 hydraulic brake fluid.
Common Wear Items:
CVT belt wear, suspension bushings, tie rod ends, and wheel bearings are common wear items subject to maintenance and eventual replacement.
Cooling System:
Regular coolant checks and flushes are important to prevent overheating, especially in heavy-duty use.
Polaris History:
Polaris Industries is a long-standing American manufacturer known for its innovation in powersports vehicles, including snowmobiles, ATVs, and UTVs, dating back to the 1950s.
Sportsman Lineage:
The Sportsman line is Polaris's flagship ATV series, recognized for its comfort, capability, and versatility, with continuous development since its introduction.
Production Region:
Typically manufactured in the United States.
