Polaris Sportsman 400 2009 Service Repair Workshop Manual

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Tipo: Atv

Proveedor:

SKU: 89728

Etiquetas: 2009 ATV Misc Polaris Powersports Sportsman 400

Variantes de producto

Descripción

The 2009 Sportsman 400 is a versatile all-terrain vehicle (ATV) designed for utility and recreational purposes. Known for its robust performance and all-wheel-drive capability, this mid-size ATV offers a reliable 330cc liquid-cooled engine and an automatic PVT transmission with high/low range. Its engineering emphasizes durability and off-road prowess, making it a capable choice for various tasks and terrains, comparable to other leading ATVs of its era. The Sportsman line is a flagship series from a manufacturer with a long history in powersports. This comprehensive service manual provides detailed information for the maintenance, repair, and troubleshooting of the 2009 Sportsman 400. It covers all major systems, including the engine, fuel, cooling, drivetrain, suspension, steering, brakes, and electrical systems. The manual includes step-by-step repair instructions, routine maintenance schedules, diagnostic procedures, and detailed technical specifications, such as torque values and fluid capacities. This resource is designed to assist owners and technicians in keeping the ATV in optimal working condition.

🏷️ Basic Information

Identification

Make:

Polaris

Model:

Sportsman 400

Year:

Vehicle Type:

ATV (All-Terrain Vehicle)

👋 Introduction

Market Position

Segment:

Mid-size utility ATV segment, known for its versatility and robust performance

Competitive Analysis

Key Competitors 2009:

Honda Rancher, Yamaha Wolverine, Kawasaki Brute Force

Key Features

Powertrain Emphasis:

Focus on the reliable Polaris 330cc engine

Off Road Capability:

All-wheel drive (AWD) system, independent suspension

📋 Manual Details

Coverage Areas

Manual Scope:

Comprehensive service, repair, and troubleshooting

Page Count

Estimated Pages:

Manual Type

Type:

Service Manual / Workshop Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

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

Procedures Included

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

Technical Depth

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

📊 Manual Specifications

File Format

Format Details:

Searchable PDF for easy navigation and printing

Print Quality

Image Resolution:

High-resolution images and diagrams for clarity

Binding Type

Binding:

N/A (Digital PDF Download)

Paper Type

Paper Quality:

N/A (Digital PDF Download)

⚙️ Engine Specifications

Primary Engine

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

Performance

Horsepower:

Approximately 22-25 HP (estimated, actual figures vary)

Torque:

Approximately 20-22 lb-ft (estimated)

Fuel System

Carburetor Model:

Mikuni BNS34 or similar (specific model may vary, check manual)

Fuel Type:

Unleaded Gasoline (91 octane recommended)

Fluid Specifications

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

Standard

Transmission Type:

Automatic (PVT - Polaris Variable Transmission) with engine braking

Drive Modes:

2WD/4WD

Features

Gearbox Features:

High/Low range, Neutral, Reverse

Fluid Specifications

Transmission Fluid Type:

Polaris AGL Synthetic Gearcase Lubricant or equivalent

Transmission Fluid Capacity:

Refer to manual for specific gearbox fluid capacity

📐 Dimensions

Exterior

Length:

Approx. 82 inches (208 cm)

Width:

Approx. 46 inches (117 cm)

Height:

Approx. 47 inches (119 cm)

Weights

Dry Weight:

Approx. 630 lbs (286 kg)

Towing Capacity:

1500 lbs (680 kg)

Rack Capacity Front:

100 lbs (45 kg)

Rack Capacity Rear:

200 lbs (90 kg)

Wheels And Tires

Front Tire Size:

AT 25x8-12

Rear Tire Size:

AT 25x10-12

Wheelbase:

Approx. 50.5 inches (128 cm)

🛡️ Safety Features

Active Features

Braking System:

Hydraulic disc brakes front and rear

4Wd System:

On-Demand All-Wheel Drive

Passive Features

Throttle Safety:

Thumb throttle with safety mechanism

Parking Brake:

Handlebar mounted parking brake

💡 Technology Features

Infotainment

Display Panel:

Digital gauge cluster with speedometer, odometer, trip meter, fuel gauge, clock, gear indicator

Driver Assistance

Engine Braking:

Integrated into the PVT system for downhill control

Connectivity

Charging System:

12V DC outlet (if equipped) for charging accessories

🔧 Maintenance

Service Intervals

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

Fluid Specifications

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)

Known Issues

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

📚 Vehicle History

Brand Heritage

Manufacturer:

Polaris Industries Inc.

Founding:

Founded in 1954, a pioneer in snowmobiles and ATVs

Model Evolution

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.

Production

Manufacturing Location:

Primarily USA (Spirit Lake, Iowa)

🏆 Awards & Recognition

Recognitions

Polaris Reputation:

Polaris consistently recognized for innovation and durability in the ATV market.