Segment:
Mid-size utility ATV segment, known for its versatility and robust performance
Key Competitors 2009:
Honda Rancher, Yamaha Wolverine, Kawasaki Brute Force
Powertrain Emphasis:
Focus on the reliable Polaris 330cc engine
Off Road Capability:
All-wheel drive (AWD) system, independent suspension
Engine Overhaul:
Complete engine disassembly, inspection, repair, and reassembly
Fuel System:
Carburetor service, fuel pump, fuel lines, fuel filter replacement
Cooling System:
Radiator, fan, thermostat, coolant flush and replacement
Exhaust System:
Muffler, exhaust pipes, heat shields
Transmission And Drivetrain:
Gearbox, final drive, differential, drive shafts, CV joints
Suspension:
Front and rear suspension components, shocks, springs, bushings
Steering:
Handlebar, tie rods, steering column, steering rack
Brakes:
Hydraulic brake system, master cylinder, calipers, brake pads, fluid replacement
Electrical System:
Ignition system, starter motor, alternator, battery, lighting, wiring diagrams
Frame And Bodywork:
Chassis, body panels, plastics, seat, handlebars
Wheels And Tires:
Tire pressure, rotation, replacement
Routine Maintenance:
Oil changes, filter replacements, spark plug checks, lubrication
Troubleshooting:
Diagnostic flowcharts for common problems and their solutions
Repair Instructions:
Step-by-step guides for component removal, installation, and adjustment
Rebuilds:
Detailed instructions for major component rebuilds (e.g., engine, transmission)
Adjustments:
Carburetor adjustment, valve clearance, brake lever adjustments
Wiring Diagrams:
Complete electrical system schematics for accurate diagnosis and repair
Diagnostic Capability:
Advanced diagnostics with detailed symptom analysis and root cause identification
Rebuild Depth:
Full rebuild specifications including torque values, clearances, and component tolerances
Service Level:
Suitable for professional mechanics and advanced DIY enthusiasts
Engine Type:
4-stroke, SOHC, 2-valve
Engine Displacement:
330cc (Note: Model name '400' might refer to historical variants or a class designation, but the 2009 model typically features the 330cc engine)
Bore X Stroke:
Refer to specific manual for exact figures, typically around 78mm x 69mm
Cooling Method:
Liquid-cooled
Horsepower:
Approximately 22-25 HP (estimated, actual figures vary)
Torque:
Approximately 20-22 lb-ft (estimated)
Carburetor Model:
Mikuni BNS34 or similar (specific model may vary, check manual)
Fuel Type:
Unleaded Gasoline (91 octane recommended)
Engine Oil Type:
SAE 20W-50 or SAE 10W-40 (check manual for specific viscosity based on temperature)
Engine Oil Capacity:
Approximately 2.0 US quarts (1.9 L) with filter change (verify in manual)
Transmission Type:
Automatic (PVT - Polaris Variable Transmission) with engine braking
Gearbox Features:
High/Low range, Neutral, Reverse
Transmission Fluid Type:
Polaris AGL Synthetic Gearcase Lubricant or equivalent
Transmission Fluid Capacity:
Refer to manual for specific gearbox fluid capacity
Display Panel:
Digital gauge cluster with speedometer, odometer, trip meter, fuel gauge, clock, gear indicator
Engine Braking:
Integrated into the PVT system for downhill control
Charging System:
12V DC outlet (if equipped) for charging accessories
Engine Oil Change:
Every 100 hours or 6 months (whichever comes first)
Air Filter Cleaning:
Inspect every 20 hours, clean/replace as needed
Spark Plug Check:
Every 100 hours or 12 months
Drive Belt Inspection:
Inspect every 50 hours for wear and tension
Brake Fluid Flush:
Every 2 years or as needed
Coolant Type:
Ethylene glycol-based antifreeze (e.g., Polaris recommended coolant or equivalent)
Coolant Capacity:
Approx. 1.5 US quarts (1.4 L) (verify in manual)
Common Wear Items:
Drive belt, tie rod ends, ball joints, suspension bushings
Potential Electrical:
Corrosion on connectors, battery terminal issues
Carburetor Issues:
Can become gummed up if fuel sits for extended periods
Manufacturer:
Polaris Industries Inc.
Founding:
Founded in 1954, a pioneer in snowmobiles and ATVs
Sportsman Lineage:
The Sportsman line is Polaris's flagship utility ATV series, known for comfort and capability.
400 Designation:
The '400' designation has been used on various Polaris models over the years, often signifying engine displacement class. For 2009, the primary engine is the 330cc, but manual coverage applies to the '400' model designation for that year.
Manufacturing Location:
Primarily USA (Spirit Lake, Iowa)