Target Audience:
Polaris Sportsman 400 2000 owners, DIY enthusiasts, independent repair shops
Value Proposition:
Provides essential information for maintaining, troubleshooting, and repairing the 2000 Polaris Sportsman 400, saving time and money on repairs.
Manual Advantage:
As a factory-certified manual, it offers the most accurate and complete information directly from the manufacturer, superior to generic aftermarket guides.
Content Highlight:
Comprehensive coverage of all mechanical and electrical systems, detailed exploded views, troubleshooting charts, and factory specifications.
Engine:
Complete overhaul, diagnostics, timing, lubrication, cooling, fuel, exhaust
Transmission:
PVT (Polaris Variable Transmission) clutch service, drive belt inspection, gearbox maintenance
Drivetrain:
Front and rear drive shafts, differentials, universal joints, wheel hubs
Suspension:
Front and rear shock absorbers, A-arms, bushings, ball joints
Brakes:
Hydraulic brake system, master cylinders, calipers, brake pads, brake lines, parking brake
Steering:
Handlebar assembly, tie rods, steering shafts, steering column
Electrical:
Ignition system, starter, charging system (stator, regulator/rectifier), battery, lighting, wiring diagrams, accessory circuits
Fuel System:
Carburetor (Mikuni VM32), fuel pump, fuel lines, fuel tank
Cooling System:
Radiator, fan, coolant, hoses, thermostat
Exhaust System:
Muffler, exhaust pipe, heat shields
Bodywork:
Fenders, racks, body panels, seat removal
Maintenance:
Oil changes, filter replacements, spark plug service, lubrication points, air filter cleaning/replacement, valve adjustments
Troubleshooting:
Diagnostic flowcharts, symptom-based troubleshooting for common issues
Repair:
Component removal, disassembly, assembly, and reinstallation procedures for all major systems
Installation:
Guidance on installing genuine Polaris accessories or replacement parts
Diagnostics:
Detailed diagnostic procedures for electrical and mechanical systems, including component testing
Rebuilds:
Instructions for complete engine and transmission rebuilds
Depth:
Comprehensive, from basic scheduled maintenance to complete overhaul and advanced diagnostics
Detail Level:
Step-by-step instructions with detailed diagrams and torque specifications
Engine Type:
4-stroke, Liquid-cooled, Single-cylinder, SOHC
Displacement:
375cc (23.0 cu. in.)
Bore X Stroke:
83 mm x 70 mm (3.27 in. x 2.76 in.)
Horsepower:
Approximately 25 HP (at 6500 RPM)
Torque:
Approximately 22 ft-lbs (at 4500 RPM)
Carburetor Model:
Mikuni VM32
Fuel Type:
Unleaded gasoline, 87 octane minimum
Fuel Capacity:
3.0 gal (11.4 L) with 0.8 gal (3.0 L) reserve
Oil Type:
SAE 20W-50 API SG or higher (Polaris recommended)
Oil Capacity:
1.7 US qt (1.6 L)
Ignition System:
CDI (Capacitor Discharge Ignition)
Spark Plug Type:
NGK CR6E or Champion RA8HC
Spark Plug Gap:
0.024-0.028 in. (0.6-0.7 mm)
Coolant Type:
Ethylene glycol-based antifreeze (50/50 mix with distilled water)
Coolant Capacity:
Approximately 1.3 US qt (1.2 L)
Type:
Polaris Variable Transmission (PVT) with engine braking
Drive System:
Shaft Drive, AWD (All-Wheel Drive) on demand
Clutch Engagement:
Approximately 1800 RPM
Transmission Fluid:
SAE 20W-40 Synthetic (Polaris recommended for PVT)
Transmission Fluid Capacity:
N/A (Sealed unit; clutch system specific)
Atv Safety Standards:
Compliant with ANSI/SVIA 1-2001 and other applicable standards for ATVs
Braking System:
Hydraulic disc brakes front and rear with hand-lever actuation for front, foot-lever for rear.
Parking Brake:
Mechanical disc brake caliper lock
Lighting:
Dual 30W halogen headlights, 8W taillight/brakelight
Ergonomics:
Handlebar design for control, thumb throttle, comfortable seating position
Instrument Cluster:
Analog speedometer, tachometer (on some models), fuel gauge, odometer, trip meter, indicator lights (oil, battery, neutral, AWD).
AWD System:
On-Demand All-Wheel Drive (AWD) system automatically engages front drive when rear wheels lose traction.
Accessory Charging:
Provision for accessory power outlet (cigarette lighter style) for charging devices.
Initial Service:
20-hour break-in service (oil change, filter check, clutch adjustment)
Regular Oil Change:
Every 100 hours or annually
Air Filter Cleaning:
Every 50 hours or as needed based on conditions
Spark Plug Replacement:
Every 100 hours or annually
Valve Adjustment:
Every 200 hours or biennially
Drive Belt Inspection:
Every 100 hours or annually (check for cracks, wear, and proper tension)
Engine Oil:
SAE 20W-50 API SG or higher (Polaris Premium 2W-50)
Brake Fluid:
DOT 3 or DOT 4 hydraulic brake fluid
Coolant:
50/50 mix of ethylene glycol and distilled water
Grease Points:
Polaris All-Season Grease or equivalent lithium-based grease
Common Wear Items:
Drive belts, wheel bearings, tie rod ends, bushings, suspension components.
Carburetor Maintenance:
Carburetor cleaning and adjustment due to potential for gumming if fuel is left standing.
Electrical Connections:
Occasional issues with corrosion on electrical connectors if exposed to moisture.
Manufacturer:
Polaris Industries Inc.
Brand Focus:
Polaris is a long-standing American manufacturer known for powersports vehicles including ATVs, snowmobiles, and motorcycles.
Sportsman Lineage:
The Sportsman line has been a cornerstone of Polaris's ATV offerings, emphasizing comfort, utility, and rider-friendly features since its inception.
2000 Model Significance:
The 2000 Sportsman 400 represented a refinement of Polaris's popular mid-size utility ATV platform, incorporating features that enhanced its performance and usability for trail riding and light work.
Manufacturing Location:
Medina, Minnesota, USA and other Polaris manufacturing facilities
Production Period:
The Sportsman 400 model, in various engine displacements, was produced for many years, with the 400cc variant being popular in the late 1990s and early 2000s.