Positioning:
The Polaris Sportsman 400 HO 2009 is positioned as a capable and versatile mid-size ATV, suitable for recreational riding, utility tasks, and light trail work. It aims to offer a balance of power, comfort, and value within the Polaris lineup.
Competitors:
Competes with similar offerings from brands like Can-Am (Outlander 400), Honda (FourTrax 400 AT), Yamaha (Grizzly 400), and Suzuki (KingQuad 400).
Features:
On-Demand All-Wheel Drive (AWD), independent rear suspension (IRS), electric power steering (optional on some trims), engine braking, Polaris PVT (Polaris Variable Transmission) with engine braking.
Value Proposition:
This manual is essential for owners and technicians looking to maintain, diagnose, and repair the 2009 Polaris Sportsman 400 HO, providing dealership-level technical information to ensure longevity and optimal performance.
Engine Mechanical:
Engine disassembly, assembly, overhaul, valve adjustment, piston/cylinder inspection, crankshaft and connecting rod service.
Engine Fuel System:
Carburetor overhaul and adjustment, fuel pump, fuel filter, fuel lines.
Engine Ignition System:
Ignition timing, spark plug specifications, ignition coil testing.
Engine Cooling System:
Radiator, fan, coolant flushing and replacement, thermostat.
Transmission Drivetrain:
CVT system (Primary and Secondary Clutch service, belt inspection/replacement), Gearcase disassembly and assembly, driveshaft, differential service.
Brakes:
Brake pad replacement, caliper service, brake fluid flush and bleeding, master cylinder service.
Suspension:
Front and rear shock absorber service, A-arm bushings, steering linkage components.
Steering:
Steering column, tie rod ends, steering rack inspection and adjustment.
Electrical System:
Wiring diagrams, battery maintenance, charging system (stator, regulator/rectifier), starter motor, lighting, instrumentation.
Frame Chassis:
Frame inspection, body panel removal and installation, seat assembly.
Wheels Tires:
Tire pressure recommendations, wheel bearing inspection and replacement, lug nut torque specifications.
Scheduled Maintenance:
Oil change intervals, filter replacement, valve clearance checks, lubrication points, drive belt inspection.
Troubleshooting:
Diagnostic flowcharts for common starting, running, and electrical issues.
Repair Procedures:
Step-by-step instructions for component replacement and overhaul.
Diagnostic Tests:
Specific tests for ignition, charging, fuel system components.
Torque Specifications:
Precise torque values for all critical fasteners.
Depth:
Comprehensive, covering everything from basic maintenance to complete engine and transmission rebuilds.
Detail Level:
Detailed illustrations, diagrams, and exploded views.
Engine Type:
4-Stroke Single Cylinder
Engine Displacement:
375cc (approximate, often rounded up or specified by internal designation)
Bore X Stroke:
Not explicitly stated, but typical for its class.
Cooling System:
Liquid-Cooled
Valvetrain:
SOHC (Single Overhead Camshaft), 2 Valves per cylinder
Horsepower:
Approx. 28-30 HP (exact figures vary slightly by source)
Torque:
Not explicitly stated, but robust low-end torque for utility.
Fuel Delivery:
Carburetor (Mikuni BSR33).
Fuel Type:
Unleaded Gasoline (91 octane recommended)
Fuel Tank Capacity:
3.3 gallons (12.5 Liters)
Type:
Polaris Variable Transmission (PVT) Automatic with Engine Braking
Drive Modes:
2WD/AWD On-Demand
Gear Selection:
High, Low, Neutral, Reverse, Park
Engine Braking:
Integrated engine braking for controlled descents.
Cvtoverdrive Gear:
N/A (CVT provides continuously variable ratios).
Gearcase Oil:
Polaris Premium Synthetic Gearcase Lubricant or equivalent SAE 75W-90 (API GL-4 or GL-5).
Crash Test Ratings:
N/A (ATVs are not typically rated by government agencies like NHTSA for crash safety in the same way as passenger vehicles).
Braking System:
Hydraulic disc brakes front and rear.
Drive Control:
On-Demand AWD system for enhanced traction.
Handlebars:
Ergonomically designed handlebars with throttle and control levers.
Lighting:
Dual 25W headlights, 8W brake light.
Operator Training:
Always wear a helmet, eye protection, and appropriate protective clothing. Read the owner's manual before operation.
Display Instrumentation:
Digital odometer, speedometer, tachometer, trip meter, fuel gauge, clock, AWD indicator, reverse indicator, engine hour meter.
Eps Availability:
Electronic Power Steering (EPS) was an option on some trims or available as an accessory, enhancing steering effort at low speeds and reducing kickback.
Charging System:
12V DC electrical system with charging via stator and regulator/rectifier.
Engine Oil Change:
Every 100 hours or 12 months, whichever comes first.
Air Filter Cleaning:
Every 25 hours or 6 months (more often in dusty conditions).
Spark Plug Inspection:
Every 100 hours or 12 months.
Cv Belt Inspection:
Every 100 hours or 12 months.
Brake Fluid Flush:
Every 24 months.
Engine Oil:
Polaris PS-4 5W-50 Synthetic 4-Stroke Engine Oil or equivalent SAE 5W-50 (API SG, SH, SJ, SL) with JASO Certified.
Coolant:
Ethylene Glycol-based antifreeze with corrosion inhibitors (e.g., Polaris Premium 2-Stroke Oil/Antifreeze or a 50/50 mix of distilled water and automotive antifreeze).
Brake Fluid:
DOT 3 or DOT 4 brake fluid.
Common Problems:
CV belt wear (especially under heavy load), starter solenoid issues, occasional carburetor tuning needs, rear differential bearing wear (in some extreme use cases).
Air Filter Oem:
2540086 (Illustrative, confirm with manual)
Oil Filter Oem:
2414909 (Illustrative, confirm with manual)
Cv Belt Oem:
3211075 (Illustrative, confirm with manual)
Heritage:
Polaris Industries, founded in 1954, has a long history of manufacturing off-road vehicles, including snowmobiles and ATVs. The Sportsman line, introduced in 1993, is one of their most successful and enduring ATV families.
Evolution Points:
The Sportsman 400 HO is part of a generation of Polaris ATVs that refined engine performance, introduced advanced suspension systems (like IRS), and improved ergonomics. The 'HO' designation typically signifies 'High Output' for increased engine performance compared to earlier or base models.
Manufacturing Location:
Polaris vehicles are primarily manufactured in the United States.
