Polaris Sportsman 400 Ho 2008-2010 Workshop Service Repair Manual

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The Polaris Sportsman 400 HO is an All-Terrain Vehicle (ATV) produced for the model years 2008 through 2010. Known for its versatility and capability, this ATV is designed for a...

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Tipo: Atv

Proveedor:

SKU: 89335

Etiquetas: 2008 2009 2010 ATV Misc Polaris Powersports Sportsman 400 Ho

Variantes de producto

Descripción

The Polaris Sportsman 400 HO is an All-Terrain Vehicle (ATV) produced for the model years 2008 through 2010. Known for its versatility and capability, this ATV is designed for a wide range of uses, from recreational trail riding to utility work. The Sportsman line is a popular offering from a manufacturer with a long heritage in powersports. The 'HO' designation typically signifies a 'High Output' engine, indicating enhanced performance. This particular model features a 375cc, single-cylinder, 4-stroke engine with SOHC and four valves, paired with a Variable Transmission (PVT) system offering High, Low, Neutral, Reverse, and Park gears, along with On-Demand AWD. Its robust design includes a liquid-cooled engine, hydraulic disc brakes, and ample cargo capacity, making it a reliable choice for various terrains and tasks. This comprehensive Service Repair Manual for the Polaris Sportsman 400 HO (2008-2010) provides detailed information essential for maintenance, repair, and troubleshooting. Covering over 300 pages, the manual delves into all major systems, including engine mechanicals, fuel and ignition systems, cooling, exhaust, drivetrain, suspension, steering, braking, and electrical systems. It offers step-by-step instructions for disassembly and assembly, preventive maintenance schedules, diagnostic procedures, and specific adjustments. Furthermore, it includes crucial technical specifications, torque values, lubrication requirements, and detailed wiring diagrams. This resource is invaluable for ATV owners, mechanics, and technicians seeking to maintain the performance, reliability, and longevity of their Sportsman 400 HO.

🏷️ Basic Information

Identification

Make:

Polaris

Model:

Sportsman 400 HO

Year:

2008-2010

Product Type:

Workshop Service Repair Manual

👋 Introduction

Market Position

Target Audience:

ATV owners, mechanics, maintenance technicians.

Value Proposition:

Cost-effective solution for maintaining and repairing the Polaris Sportsman 400 HO.

Competitive Analysis

Competitor Alternatives:

Official Polaris service manuals (often more expensive), generic ATV repair guides (less specific).

Key Features

Comprehensiveness:

Covers all aspects of maintenance, repair, and troubleshooting.

Clarity:

Detailed step-by-step instructions and clear diagrams.

Accessibility:

Digital format allows for easy searching and access on various devices.

📋 Manual Details

Coverage Areas

Model Years Covered:

2008, 2009, 2010

Vehicle Type:

All-Terrain Vehicle (ATV)

Page Count

Estimated Page Count:

Manual Type

Manual Type:

Service Repair Manual

Language

Language:

English

Format

Format:

Digital (PDF)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Complete engine overhaul, cylinder head, piston, crankshaft, connecting rods, valve train, timing.

Fuel System:

Carburetor (carburetor troubleshooting, cleaning, adjustment, jetting), fuel pump, fuel tank, fuel lines.

Ignition System:

CDI unit, spark plugs, ignition coil, stator, wiring diagrams.

Cooling System:

Radiator, fan, thermostat, coolant, hoses, water pump.

Exhaust System:

Muffler, exhaust pipe, heat shields.

Drivetrain:

Transmission (gearbox disassembly, assembly, maintenance), final drive, differential.

Drive System:

Polaris Variable Transmission (PVT) clutch service (primary and secondary clutch maintenance, belt replacement, alignment), drive shafts, U-joints.

Suspension:

Front and rear suspension components, shocks, control arms, bushings, bearings.

Steering System:

Handlebars, steering shaft, tie rods, steering rack, universal joints.

Braking System:

Hydraulic brake system, brake calipers, master cylinders, brake lines, brake pads, rotors, bleeding procedures.

Electrical System:

Battery, charging system (alternator/stator), starter motor, lighting (headlights, taillights, brake lights), horn, switches, wiring diagrams.

Chassis And Frame:

Frame inspection, welds, component mounting.

Bodywork And Trim:

Fenders, plastics, seats, racks, decals.

Special Tools:

Required special tools for specific repairs and adjustments.

Procedures Included

Preventive Maintenance:

Scheduled maintenance checks, lubrication points, filter replacements.

Troubleshooting:

Diagnostic procedures for common problems, symptom-based troubleshooting charts.

Disassembly And Assembly:

Step-by-step instructions for removing and reinstalling all major components.

Torque Specifications:

Detailed torque values for all critical fasteners.

Adjustments:

Carburetor adjustments, clutch adjustments, valve adjustments (if applicable).

Lubrication:

Specific lubricant types and intervals for all moving parts.

Wiring Diagrams:

Comprehensive electrical system wiring diagrams for easy fault finding.

Technical Depth

Depth Level:

Comprehensive, from basic maintenance to complete engine and transmission rebuilds.

Diagnostic Capabilities:

Detailed diagnostic information for identifying and resolving issues.

📊 Manual Specifications

File Format

File Format:

Searchable Text:

Print Quality

Print Quality:

High-resolution, clear diagrams and text.

Binding Type

Binding Type:

N/A (Digital)

Paper Type

Paper Type:

N/A (Digital)

⚙️ Engine Specifications

Primary Engine

Engine Type:

4-stroke, SOHC, Liquid-Cooled, 4-Valve

Engine Displacement:

375cc (approximate, 'HO' often denotes specific tuning)

Bore X Stroke:

Not explicitly stated in product info, requires manual lookup.

Compression Ratio:

Not explicitly stated in product info, requires manual lookup.

Cylinder Arrangement:

Single Cylinder

Performance

Horsepower:

Varies by year and specific tuning, estimated 25-30 HP. Manual provides specifics.

Torque:

Varies by year. Manual provides specifics.

Fuel System

Fuel Delivery:

Carburetor (specific model like Mikuni BSR36 or similar)

Fuel Type:

Unleaded gasoline

Fuel Tank Capacity:

Approximately 3.25 US gallons (12.3 liters). Manual confirms.

🔧 Transmission

Standard

Transmission Type:

Automatic, Polaris Variable Transmission (PVT) with Engine Braking

Optional

Optional Transmission:

Features

Gear Selection:

High, Low, Neutral, Reverse, Park.

Drive Modes:

2WD/4WD (On-Demand, AWD)

Clutch System:

Dual Clutch (Primary and Secondary)

Transmission Fluid Type:

Polaris Premium AGL Synthetic Gearcase Lubricant or equivalent. Manual specifies exact type and viscosity.

📐 Dimensions

Exterior

Length:

Approximately 81 inches (205.7 cm). Manual confirms specific model year dimensions.

Width:

Approximately 46 inches (116.8 cm). Manual confirms specific model year dimensions.

Height:

Approximately 47 inches (119.4 cm). Manual confirms specific model year dimensions.

Wheelbase:

Approximately 50.2 inches (127.5 cm). Manual confirms specific model year dimensions.

Weights

Dry Weight:

Approximately 610 lbs (277 kg). Manual confirms specific model year weights.

Ground Clearance:

Approximately 10.5 inches (26.7 cm). Manual confirms specific model year clearance.

Cargo

Front Rack Capacity:

100 lbs (45 kg)

Rear Rack Capacity:

200 lbs (90 kg)

Towing Capacity:

1500 lbs (680 kg)

Dimensions

Tire Size Front:

25 x 8-12

Tire Size Rear:

25 x 10-12

Wheel Bolt Pattern:

4x110mm (typical for this era Polaris)

🛡️ Safety Features

Ratings

Atv Safety Standards:

Compliant with ANSI standards for Class I ATVs. Manual details specific safety warnings.

Active Features

Braking System Type:

Hydraulic Disc Brakes (Front and Rear)

Engine Braking:

Standard feature of the PVT transmission for controlled descents.

Passive Features

Lighting Package:

Dual Halogen Headlights, Taillight/Brake Light.

Seat Belt Provision:

N/A (ATVs typically do not use seat belts)

Rollover Protection:

N/A (Standard ATV design)

💡 Technology Features

Infotainment

Infotainment System:

N/A (Basic ATV instrumentation: speedometer, odometer, trip meter, hour meter, neutral/reverse indicator).

Driver Assistance

Driver Assistance Features:

Connectivity

Connectivity Features:

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 100 hours or 6 months. Manual provides precise OEM schedule.

Air Filter Cleaning:

Every 25 hours or as needed based on riding conditions. Manual specifies inspection and cleaning procedure.

Spark Plug Replacement:

Typically every 1000 hours or 12 months, or per manual recommendation. Manual specifies gap and type.

Clutch Belt Inspection:

Every 50 hours or annually. Manual details inspection for wear and proper tension.

Valve Clearance Check:

Typically at 1000 or 2000 hour intervals, or if engine performance degrades. Manual provides specification and adjustment procedure.

Fluid Specifications

Engine Oil Type:

Polaris Synthetic 0W-40 or SAE 10W-40. Manual specifies exact API classification and viscosity.

Engine Oil Capacity:

Approximately 2.1 US quarts (2.0 liters) with filter change. Manual confirms exact capacity.

Coolant Type:

Ethylene glycol-based antifreeze. Manual specifies mix ratio and type.

Brake Fluid Type:

DOT 3 or DOT 4 hydraulic brake fluid. Manual specifies exact type.

Known Issues

Common Wear Items:

PVT belt wear, suspension bushings, tie rod ends, water pump seal.

Electrical Connectors:

Potential for corrosion or loose connections in humid or dirty environments. Manual guides inspection.

Carburetor Tuning:

May require periodic cleaning and adjustment due to fuel quality or debris. Manual provides detailed procedures.

📚 Vehicle History

Brand Heritage

Brand Establishment:

Polaris Industries Inc. is a long-standing American manufacturer of powersports vehicles, founded in 1954.

Model Evolution

Sportsman Lineage:

The Sportsman line is one of Polaris's most popular ATV series, known for its versatility and capability, with the 400 HO being a mid-range offering.

Engine Development:

The 'HO' designation often indicates a 'High Output' version of the engine, suggesting tuning or component upgrades over base models of similar displacement.

Production

Production Period:

Model years 2008, 2009, 2010.

Manufacturing Location:

Primarily manufactured in the USA by Polaris Industries.

🏆 Awards & Recognition

Recognitions

Atv Industry Awards:

The Polaris Sportsman line consistently receives positive reviews and awards for its performance and utility, though specific awards for the 400 HO model from 2008-2010 may vary. The manual itself is a tool, not an award recipient.