Market Position:
The Polaris Sportsman 400, particularly in its generation represented by these codes, was positioned as a capable and versatile utility ATV, suitable for work and recreational trail riding. It offered a balance of power, comfort, and reliability for its class.
Competitive Analysis:
Competed with models from manufacturers like Yamaha (Grizzly), Honda (FourTrax/Rancher), and Can-Am (Outlander) in the mid-displacement utility ATV segment. Key selling points were often Polaris's independent rear suspension (IRS) and comfortable rider ergonomics.
Key Features:
Likely featured Polaris's proprietary Lock & Ride accessory system, automatic transmission (PVT - Polaris Variable Transmission), shaft drive, and a focus on rider comfort with features like comfortable seating and ergonomic controls.
Coverage Areas:
Complete parts identification and catalog for the Polaris Sportsman 400. Likely includes all major mechanical and electrical components, chassis parts, body panels, and accessories.
Page Count:
Not specified, but described as a 'complete guide'.
Manual Type:
Parts Manual / Catalog
Language:
English (Assumed, standard for North American market)
Format:
PDF Download (Instant download)
Systems Covered:
Engine, drivetrain, suspension, steering, braking, electrical system, fuel system, cooling system, chassis, frame, body panels, accessories, and potentially emissions components.
Cooling System Parts:
Radiator, hoses, water pump, thermostat, fan.
Braking System Parts:
Master cylinders, brake calipers, brake lines, brake pads, brake rotors, parking brake mechanism.
Steering System Parts:
Handlebars, steering shaft, tie rods, ball joints, steering knuckles.
Electrical System Parts:
Battery, starter, alternator/stator, ignition coil, wiring harness, lights, switches, CDI unit.
Chassis Frame Parts:
Frame, sub-frame, mounting brackets, hitch components.
Body Panels Accessories:
Fenders, racks, plastics, seat, footwells, bumpers, winch mounting points (if applicable).
Procedures Included:
Parts identification, assembly diagrams, part numbering, component lookup for ordering replacement parts. Does not typically include repair procedures, only part identification.
Part Number Lookup:
Primary function: Identify and locate specific part numbers for ordering. Includes detailed diagrams for visual confirmation.
Assembly Disassembly Diagrams:
Exploded views showing how components fit together, crucial for understanding part relationships.
Technical Depth:
Detailed breakdown of all replaceable parts with exploded views and corresponding part numbers. Essential for accurate part ordering and inventory management.
Compatibility Information:
Essential for ensuring that purchased parts are correct for the specific chassis codes (A04CH42AA, AE, AG) and potentially model years covered by the manual.
Engine Type:
Liquid-cooled, 4-stroke, SOHC, 4-valve, Single-cylinder
Displacement:
375 cc to 400 cc (Typical for this model designation, specific to the generation represented by A04CH codes)
Horsepower:
Estimated 20-25 HP (Approximate, actual may vary by year/tuning)
Torque:
Not specified, but designed for low-end torque for utility tasks.
Fuel System:
Carbureted (Likely Mikuni or Keihin, specific size not provided in product info)
Overall Length:
Approx. 81-83 inches (Varies by year)
Overall Width:
Approx. 46-48 inches (Varies by year)
Overall Height:
Approx. 48 inches (Varies by year)
Wheelbase:
Approx. 50.2 inches (Varies by year)
Dry Weight:
Approx. 560-580 lbs (Varies by year)
Rack Capacity Front:
90 lbs
Rack Capacity Rear:
180 lbs
Safety Ratings:
Not Applicable (ATVs are not typically rated by NCAP or similar automotive bodies; focus is on operational safety features.)
Active Features:
Engine braking in PVT, On-Demand AWD for improved traction, hydraulic disc brakes on all wheels.
Passive Features:
Full floorboards with heel guards, ergonomic handgrips, comfortable seating position. Designed with safety standards for ATVs in mind.
Oil Change Interval:
Typically every 50 hours or 6 months for engine oil and filter. (Consult specific manual for exact intervals).
Air Filter Cleaning:
Inspect every 25 hours, clean or replace as needed.
Spark Plug Replacement:
Recommended every 100 hours or annually.
Transmission Fluid Change:
Recommended every 100 hours or annually for PVT and final drive.
Engine Oil Type:
Polaris PS-4 5W-50 Synthetic (or equivalent API SG or higher rated oil)
Engine Oil Capacity:
Approx. 1.9 quarts (with filter)
Transmission Fluid Type:
Polaris Synthetic Gearcase Lube (or SAE 75W-90 GL-4)
Coolant Type:
Ethylene Glycol based antifreeze (50/50 mix with distilled water)
Known Issues:
Common issues across many ATVs of this era can include wear on suspension bushings, CV joint boots, brake component wear, and potential electrical connector corrosion if not maintained. Specific to Polaris, some PVT belt wear or clutch adjustments might be needed over time.
Common Part Replacements:
Drive belts, brake pads, suspension bushings, ball joints, tie rod ends, wheel bearings.
Brand Heritage:
Polaris Industries is a major American manufacturer of powersports vehicles, with a long history of innovation in ATVs, snowmobiles, and motorcycles. The Sportsman line is one of their most successful and enduring ATV families.
Model Evolution:
The Sportsman 400 has been produced in various iterations since its introduction. The 'A04CH' designation points to models from the mid-2000s, which typically featured updated styling, engine performance, and chassis improvements compared to earlier generations.
Production Period:
The Sportsman 400 was produced for many years, with models around the 2004-2005 timeframe corresponding to the A04CH codes.
Manufacturing Location:
Primarily manufactured in the United States by Polaris Industries.
