Model Years Covered:
1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003
Vin Code:
Not specified in product data, but typically includes engine type and model year indicators.
Target Audience:
DIY enthusiasts, independent repair shops, Polaris service technicians, and owners seeking to perform their own maintenance and repairs.
Manual Value:
Provides comprehensive, factory-level repair information, significantly reducing reliance on expensive dealership service.
Navigability:
Hyperlinked table of contents and index for efficient navigation within the PDF.
Mechanical Systems:
Engine, Fuel System, Ignition System, Cooling System, Exhaust System, Drivetrain (Transmission, Driveshafts, Differentials), Suspension, Steering, Brakes, Wheels & Tires, Chassis.
Electrical Systems:
Charging System, Starting System, Lighting System, Ignition System (Component Level), Sensors, ECU, Wiring Diagrams, Accessories.
Maintenance:
Scheduled maintenance, oil changes, filter replacements, fluid checks and changes, lubrication, pre-ride inspections.
Repair:
Engine overhaul, carburetor tuning/rebuilding, transmission repair, brake system service, suspension component replacement, steering linkage repair, electrical diagnostics and repair.
Troubleshooting:
Diagnostic flowcharts, common problems and solutions, electrical troubleshooting guides, symptom-based troubleshooting.
Diagnostic Capabilities:
Advanced diagnostics, including component testing, wiring continuity checks, sensor data interpretation (where applicable via diagnostic tools or procedures).
Rebuild Procedures:
Complete engine and transmission disassembly, inspection, overhaul, and reassembly procedures with detailed specifications.
Engine Type:
4-Stroke, Liquid-Cooled, Single-Cylinder (Likely derived from Polaris's ATV engine technology of the era).
Displacement:
Approximately 375-400cc (Specific model year variations may exist).
Bore X Stroke:
Typical range for this displacement would be around 85mm x 70mm, but precise figures are in the manual.
Compression Ratio:
Likely around 9.0:1 to 10.0:1, specific to the model variant.
Power Output:
Estimated 25-30 HP (Horsepower). Exact figures are detailed in the manual.
Torque Output:
Estimated 25-30 lb-ft (Pound-feet). Exact figures are detailed in the manual.
Top Speed:
Approximate 50-55 mph (depending on terrain, rider weight, and configuration).
Carburetion:
Likely a single Mikuni or Keihin carburetor (e.g., VM34 or similar), with specific jetting and adjustment procedures detailed.
Fuel Type:
Unleaded gasoline, 87 octane or higher recommended.
Fuel Tank Capacity:
Typically around 3.2 - 3.5 gallons, including reserve. Exact capacity is in the manual.
Type:
Automatic (CVT - Continuously Variable Transmission) with Polaris Variable Transmission (PVT) system.
Drive System:
Shaft Drive, AWD (All-Wheel Drive) with automatic engagement, often featuring electronic descent control (ADC) on some models.
Gear Selection:
Forward (Hi/Low Range), Neutral, Reverse.
Optional Drivetrains:
Not applicable for this model; shaft drive AWD was standard.
Clutch Type:
Primary and Secondary Clutch System (CVT components).
Gear Reduction:
High and Low range gear reduction ratios are specified for performance optimization.
Transmission Fluid:
Specific Polaris PVT fluid or equivalent is required. Manual will specify exact type and capacity.
Length:
Approximately 81-83 inches (206-211 cm). Precise dimensions provided in manual.
Width:
Approximately 46 inches (117 cm). Precise dimensions provided in manual.
Height:
Approximately 48 inches (122 cm) to the handlebars. Precise dimensions provided in manual.
Front Rack Capacity:
Typically 50 lbs (22.7 kg).
Rear Rack Capacity:
Typically 100 lbs (45.4 kg).
Dry Weight:
Around 550-580 lbs (250-263 kg). Exact weight varies by configuration.
Ground Clearance:
Approximately 10-11 inches (25-28 cm). Exact clearance specified in manual.
Towing Capacity:
Typically rated for 1,225 lbs (553 kg) if equipped with a hitch receiver.
Payload Capacity:
Usually around 200-250 lbs (90-113 kg).
Atv Safety Standards:
Compliant with ANSI/SVIA standards for ATVs.
Braking System:
Hydraulic disc brakes front and rear. Specific brake pad types and rotor specifications are in the manual.
Parking Brake:
Mechanical parking brake mechanism, typically engaged via lever or shifter.
All Wheel Drive:
Automatic All-Wheel Drive (AWD) system enhances traction and stability.
Lighting:
Dual front headlights, brake light, and taillight. Bulb types and wattages specified.
Handlebars:
Ergonomically designed handlebars with integrated controls for safety and ease of use.
Display Panel:
Basic LCD display for odometer, trip meter, gear indicator, and warning lights (e.g., AWD indicator, oil pressure). Specific features vary by trim.
Automatic AWD:
Polaris's automatic all-wheel drive system provides enhanced traction and stability without rider input.
Descent Control:
Some models may feature Automatic Descent Control (ADC) for controlled downhill braking.
Charging Port:
Likely a 12V accessory outlet for charging devices, but not advanced connectivity features.
Oil Change Interval:
Typically every 100 hours or 6 months. Refer to manual for exact intervals based on usage.
Air Filter Cleaning:
Check every 20 hours, clean/replace as needed. More frequent cleaning in dusty conditions.
Spark Plug Replacement:
Typically every 100 hours or annually. Manual will specify plug type and gap.
Transmission Fluid Change:
As per manual recommendations, often tied to engine hours or specific usage patterns.
Engine Oil:
Polaris recommended synthetic 0W-40 or 5W-50 engine oil. Manual specifies exact viscosity and API rating.
Engine Oil Capacity:
Approximately 2.5 quarts (2.4 liters) with filter change. Exact capacity in manual.
Coolant:
Ethylene glycol based coolant, 50/50 mix with distilled water. Manual specifies type and capacity.
Brake Fluid:
DOT 3 or DOT 4 hydraulic brake fluid. Manual specifies correct type.
Common Wear Items:
CVT belt wear, carburetor jetting issues, suspension bushings, starter solenoid failures, fuel pump issues (on EFI models if applicable, though 400 is likely carb'd).
Preventative Maintenance Tips:
Regular cleaning of air filter, proper clutch maintenance, checking for loose electrical connections, fluid level checks.
Polar Atv History:
Polaris pioneered many features in the ATV industry, including shaft drive and independent rear suspension (IRS) on some models.
Sportsman Lineage:
The Sportsman line has consistently been Polaris's flagship utility ATV, known for its comfort, power, and versatility. The 400 model served as a mid-range option in this popular series.
Manufacturing Location:
Primarily manufactured in the United States by Polaris Industries.
Polar Atv Reputation:
Polaris Sportsman models generally receive positive reviews for their comfort, utility, and off-road capability, often lauded for their robust suspension and drivetrain.
Consumer Satisfaction:
Historically, the Sportsman line has maintained high consumer satisfaction for durability and performance in its class.
Regulatory Compliance:
Manufactured to meet relevant safety and environmental regulations for ATVs in North America.
