Model Years Covered:
1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003
Product Name:
Polaris Sportsman 400 1996-2003 Repair Service Manual PDF Download
Category:
All-Terrain Vehicle (ATV)
Target Audience:
Owners, technicians, and DIY enthusiasts for the Polaris Sportsman 400.
Competitors:
This manual covers a specific model, but the Sportsman 400 competed with other utility ATVs from brands like Honda (FourTrax), Yamaha (Grizzly), and Kawasaki (Bayou/Prairie) during its production run.
Product Value:
Essential resource for maintaining peak performance, diagnosing issues, and performing repairs, extending the life and usability of the ATV.
General Coverage:
Comprehensive service, maintenance, and troubleshooting for Polaris Sportsman 400 ATVs.
Engine Coverage:
Engine repair, overhaul, diagnosis, performance tuning.
Drivetrain Coverage:
Transmission, gearbox, differential, driveshafts, AWD system maintenance and repair.
Chassis Coverage:
Frame, suspension (front and rear), steering, wheels, tires.
Electrical Coverage:
Ignition system, starting system, charging system, lighting, instruments, wiring diagrams.
Braking Coverage:
Hydraulic brake system maintenance, caliper repair, bleeding procedures.
Body Coverage:
Body panels, plastics, seats, racks, winch mounting (if applicable).
Troubleshooting Coverage:
Diagnostic procedures for common and uncommon issues, fault finding.
Estimated Pages:
Likely 300-600 pages (typical for comprehensive workshop manuals of this era).
Type:
Workshop Repair Service Manual
Engine Systems:
Lubrication, cooling, fuel delivery, ignition, starting, emissions (where applicable).
Drivetrain Systems:
PVT (Polaris Variable Transmission) belt service, clutch adjustment, gearcase oil change, driveshaft lubrication.
Suspension Steering:
Front and rear shock absorber specifications, steering linkage adjustment, wheel alignment.
Electrical Systems:
Starter motor testing, stator output checks, battery maintenance, lighting circuit diagnosis.
Braking Systems:
Brake pad replacement, disc rotor inspection, master cylinder and caliper servicing.
Routine Maintenance:
Oil changes, filter replacements, spark plug checks, air filter cleaning/replacement, lubrication points.
Engine Repair:
Top-end rebuild (cylinder, piston, rings), valve adjustment, carburetor tuning/rebuild.
Transmission Service:
PVT system inspection and replacement, gearcase overhaul, torque converter service.
Suspension Overhaul:
Shock absorber replacement, A-arm bushing inspection, steering component replacement.
Electrical Diagnostics:
Troubleshooting starting and charging issues, wiring harness repair, component testing.
Brake Service:
Brake fluid flush and replacement, pad and caliper service, bleeding procedures.
Troubleshooting Guides:
Step-by-step diagnostic flowcharts for common operational issues.
Depth:
Comprehensive, from basic owner maintenance to full engine and transmission rebuilds.
Detail Level:
Detailed step-by-step instructions with clear diagrams and torque specifications.
Diagnostic Capabilities:
Advanced troubleshooting for electrical, fuel, and mechanical systems.
Searchability:
Likely text-searchable if OCR'd properly, facilitating quick information retrieval.
Resolution:
Typically high-resolution for clear image reproduction of diagrams and illustrations.
Diagrams:
Includes detailed exploded views, schematics, and repair diagrams.
Binding:
N/A (Digital PDF download)
Paper:
N/A (Digital PDF download)
Type:
4-stroke, liquid-cooled, SOHC, single-cylinder (likely based on Polaris engine architecture of the era).
Displacement:
Approximately 375-400cc (exact specification varies by specific sub-model or year within the range).
Bore X Stroke:
Specific dimensions would be detailed in the manual; typically around 80-85mm bore.
Horsepower:
Estimated 20-25 HP (typical for this class of ATV).
Torque:
Specifications would be provided in the manual.
Carburetor:
Likely a Mikuni or Keihin carburetor (specific model TBD in manual).
Fuel Type:
Unleaded gasoline (87 octane or higher recommended).
Oil Type:
SAE 10W-40 or 20W-50 motorcycle-specific or ATV oil (check manual for exact OEM specification).
Type:
Automatic Polaris Variable Transmission (PVT) with high/low range and reverse.
Drive System:
Shaft drive, with AWD engagement (typically on-demand).
Transmission Options:
N/A for this model, PVT was standard.
Clutch Type:
Centrifugal clutch and drive/driven clutches for PVT.
Gear Reduction:
High and low range gears for varying terrain and towing needs.
Gearcase Oil Type:
SAE 80W-90 hypoid gear oil (check manual for exact OEM specification and capacity).
Length:
Approx. 80-83 inches (203-211 cm).
Width:
Approx. 45-46 inches (114-117 cm).
Height:
Approx. 46-48 inches (117-122 cm).
Dry Weight:
Approx. 550-570 lbs (250-259 kg).
Ground Clearance:
Approx. 7-10 inches (18-25 cm).
Front Rack Capacity:
Approx. 25-50 lbs (11-23 kg).
Rear Rack Capacity:
Approx. 50-100 lbs (23-45 kg).
Towing Capacity:
Typically around 660 lbs (300 kg).
Atv Safety Standards:
Subject to ATV safety recommendations and guidelines of the era; not typically crash-tested like automobiles.
Braking System:
Hydraulic disc brakes front and rear.
Throttle Governor:
Some models may have adjustable throttle limiters for novice riders.
Lighting:
Headlights, taillight, and brake light for visibility.
Handguards:
Standard on many models for protection from brush and debris.
Infotainment Features:
Basic; typically includes odometer, trip meter, hour meter, fuel gauge, and indicator lights.
Assistance Features:
Limited; focus on mechanical and drivetrain components. No electronic driver aids common in modern vehicles.
Connectivity Features:
N/A
Engine Oil Change:
Typically every 30-60 operating hours or annually, whichever comes first (refer to manual for precise intervals).
Air Filter Service:
Check and clean every 20-30 operating hours, replace as needed.
Spark Plug Inspection:
Inspect and gap every 60 operating hours, replace as needed.
Pvt Belt Inspection:
Inspect for wear and damage every 50-100 operating hours, replace as needed.
Engine Oil Capacity:
Approximately 1.7-2.0 quarts (1.6-1.9 liters) (specific capacity in manual).
Gearcase Oil Capacity:
Approximately 0.3-0.5 quarts (0.3-0.5 liters) (specific capacity in manual).
Coolant Type:
Ethylene glycol based antifreeze mixture (50/50 ratio recommended) for liquid-cooled engines.
Common Wear Items:
PVT belt wear, suspension bushings, tie rod ends, carburetor performance degradation due to age/gumming.
Electrical Component Longevity:
Early models might have issues with CDI boxes or charging systems, though improvements were made over the years.
Carburetor Issues:
Clogging from fuel varnish, float level adjustment issues.
Polarish History:
Polaris is a long-standing American manufacturer known for snowmobiles, ATVs, and powersports vehicles, founded in 1954.
Sportsman Lineage:
The Sportsman line is Polaris's flagship utility ATV series, renowned for its comfort, independent rear suspension, and AWD capabilities. The 400 model was a popular mid-range offering.
Manufacturing Location:
Primarily manufactured in the United States by Polaris.
