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.