Polaris Sportsman 400 2009 Workshop Repair Service Manual

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Mots clés: 2009 ATV Misc Polaris Powersports Sportsman 400

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Description

This manual covers the 2009 Sportsman 400 All-Terrain Vehicle (ATV). The Sportsman 400 is recognized for its balanced performance, offering a blend of power and utility suitable for both recreational trail riding and demanding work tasks. Engineered with a reliable 4-stroke, SOHC, liquid-cooled engine, it delivers consistent performance across varied terrains. Key features include a comfortable rider position, robust chassis, selectable 2WD/4WD, and an automatic Variable Transmission (PVT) with Engine Braking System (EBS). Its design emphasizes durability and rider comfort, making it a capable and versatile machine in the mid-range ATV market. This comprehensive workshop repair service manual provides detailed information for all 2009 Sportsman 400 models, including all engines, trims, and transmissions. It covers essential areas such as engine and transmission systems, chassis components, electrical systems, fuel, cooling, and exhaust systems, as well as body and trim. The manual includes step-by-step procedures for scheduled maintenance, diagnostics, troubleshooting, and repairs, alongside critical technical specifications like torque values and fluid capacities. This resource is designed to assist owners, mechanics, and technicians in maintaining the optimal performance and longevity of their vehicle.

🏷️ Basic Information

Identification

Make:

Polaris

Model:

Sportsman 400

Year:

Vehicle Type:

All-Terrain Vehicle (ATV)

Codes

Model Code:

Refer to specific VIN or model designation for exact code

👋 Introduction

Market Position

Positioning:

The Polaris Sportsman 400 was a popular mid-range ATV, offering a balance of power, versatility, and value for recreational and utility use.

Competitive Analysis

Competitors:

Competed with models from brands like Yamaha (Grizzly 400), Arctic Cat (400 DVX), and Can-Am (Outlander 400).

Key Features

Features:

Known for its comfortable rider position, reliable engine, and robust chassis, making it suitable for various terrains.

📋 Manual Details

Coverage Areas

Covered Models:

All 2009 Polaris Sportsman 400 models, engines, trims, and transmissions

Page Count

Estimated Pages:

High (typically 400-600+ pages for comprehensive workshop manuals)

Manual Type

Type:

Workshop Repair Service Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Powertrain:

Engine, transmission, drive train, differential, PTO

Chassis:

Suspension, steering, brakes, frame, sub-frame, wheels, tires

Electrical:

Ignition system, charging system, starting system, lighting, instrumentation, wiring diagrams

Fuel System:

Fuel tank, fuel pump, fuel lines, carburetor/fuel injection (if applicable)

Cooling System:

Radiator, fan, coolant lines, thermostat

Exhaust System:

Muffler, exhaust pipe, catalytic converter (if applicable)

Body And Trim:

Body panels, fenders, racks, seating

Procedures Included

Maintenance:

Scheduled maintenance, oil changes, filter replacements, lubrication, tune-ups

Troubleshooting:

Diagnostic procedures, common fault identification, problem solving

Repair:

Component disassembly, reassembly, overhaul, replacement procedures

Diagnostics:

Engine diagnostics, electrical system testing, component failure analysis

Specifications:

Torque specifications, clearances, timing settings, fluid capacities

Technical Depth

Depth:

Comprehensive (covers everything from basic maintenance to full engine rebuilds and system diagnostics)

📊 Manual Specifications

File Format

File Type:

Searchability:

Likely text-searchable PDF for easy navigation

Printability:

Printable for physical reference

Print Quality

Quality:

High-resolution scans, clear diagrams and text

Binding Type

Binding:

N/A (Digital PDF)

Paper Type

Paper:

N/A (Digital PDF)

⚙️ Engine Specifications

Primary Engine

Engine Type:

4-stroke, SOHC, 2-valve, liquid-cooled, single-cylinder

Engine Displacement:

375cc to 400cc (exact displacement may vary slightly based on specific sub-model)

Bore X Stroke:

Refer to manual for precise dimensions (e.g., ~88mm x 64mm range)

Performance

Horsepower Estimate:

Approximately 25-30 HP (Horsepower), subject to exact configuration and condition

Torque Estimate:

Approximately 24-28 lb-ft (Foot-Pounds), subject to exact configuration and condition

Fuel System

Fuel Delivery:

Carburetor (likely Keihin CV type) or Electronic Fuel Injection (EFI) depending on specific variant

Fuel Type:

Unleaded Gasoline (Octane rating as specified in manual)

Ignition

Ignition System:

CDI (Capacitor Discharge Ignition)

Cooling System

Cooling Method:

Liquid-cooled

🔧 Transmission

Standard

Transmission Type:

Automatic, PVT (Polaris Variable Transmission) with engine braking

Optional

Optional Transmissions:

N/A for this model year (standard PVT)

Features

Drive Modes:

2WD/4WD selectable, Engine Braking System (EBS)

Gear Selection:

High, Low, Neutral, Reverse, Park

Fluid Type

Transmission Fluid:

Polaris AGL Synthetic Gearcase Lubricant or equivalent (refer to manual for specific part number and viscosity)

📐 Dimensions

Exterior

Length:

Approximately 83 in. (210.8 cm)

Width:

Approximately 46 in. (116.8 cm)

Height:

Approximately 47 in. (119.4 cm)

Wheelbase:

Approximately 50.5 in. (128.3 cm)

Cargo

Front Rack Capacity:

Typically 100 lbs (45 kg)

Rear Rack Capacity:

Typically 200 lbs (90 kg)

Weights

Dry Weight Estimate:

Approximately 590-610 lbs (268-277 kg)

Ground Clearance:

Approximately 10.5 in. (26.7 cm)

Towing

Towing Capacity:

Typically 1,100 lbs (499 kg)

Hitch Type:

Standard 2-inch receiver (check manual for specifics)

🛡️ Safety Features

Ratings

Safety Standards:

Compliant with ANSI B71.1 (may vary by region and specific features)

Active Features

Braking System:

Hydraulic disc brakes, front and rear

Parking Brake:

Parking brake integrated into transmission/shifter

Passive Features

Lighting:

Dual headlights, taillight/brake light

Ergonomics:

Handlebar design with thumb throttle for control

💡 Technology Features

Infotainment

Instrumentation:

Digital instrument cluster displaying speed, RPM, odometer, trip meter, 4WD indicator, fuel level, etc.

Driver Assistance

Engine Braking:

Standard Engine Braking System (EBS) on the PVT for controlled descents.

Connectivity

Connectivity Features:

N/A (Basic ATV functionality)

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 100 hours or 6 months (refer to manual for precise interval and specific oil type)

Air Filter Cleaning:

As needed, based on operating conditions; check every 25 hours.

Spark Plug Replacement:

Refer to manual; typically around 3,000-5,000 miles or as indicated by performance.

Fluid Specifications

Engine Oil Type:

Polaris PS-4 5W-50 Synthetic 4-Cycle Engine Oil or SAE 5W-50 API SG, JASO Approved

Engine Oil Capacity:

Refer to manual; typically around 2.0 quarts (1.9 liters) with filter change.

Coolant Type:

Polaris Premium All-Season Coolant (ethylene glycol-based) or equivalent 50/50 mix.

Brake Fluid Type:

DOT 3 or DOT 4 Brake Fluid

Known Issues

Common Wear Items:

Drive belts (PVT belt), wheel bearings, tie rod ends, ball joints.

Maintenance Tips:

Regular cleaning of the PVT system (clutch housing and primary/secondary clutches) is crucial for optimal performance and longevity.

Electrical Concerns:

Some models may experience issues with voltage regulators or battery charging systems if not properly maintained. Refer to manual for diagnostic procedures.

📚 Vehicle History

Brand Heritage

Brand Focus:

Polaris is a well-established manufacturer of powersports vehicles, known for innovation and performance in ATVs, UTVs, and snowmobiles.

Model Evolution

Sportsman Lineage:

The Sportsman line has a long history of providing versatile and reliable ATVs, with the 400 model representing a key offering in the mid-displacement segment.

Production

Manufacturing Location:

Primarily manufactured by Polaris Industries in the United States.

🏆 Awards & Recognition

Recognitions

Industry Awards:

Polaris Sportsman models have consistently received positive reviews and industry recognition for their utility, performance, and durability over the years.