Market Segment:
Mid-size utility ATV, targeted at recreational riders and light-duty farm/ranch work.
Competitors 2009:
Honda FourTrax 420, Yamaha Grizzly 450, Kawasaki Brute Force 400, Can-Am Outlander 400.
Engine Configuration:
Single-cylinder, liquid-cooled engine known for its reliable performance and good low-end torque.
Suspension Design:
Independent front and rear suspension for improved rider comfort and handling over varied terrain.
Drivetrain Capability:
Switchable 2WD/4WD with high and low range gearing for versatile traction control.
Braking System:
Hydraulic disc brakes on all four wheels for consistent stopping power.
Target Audience:
DIY mechanics, ATV enthusiasts, farm and ranch owners, and service technicians working on the 2009 Polaris Sportsman 400 H.O.
Primary Coverage:
Repair, Maintenance, Troubleshooting, Adjustments, Diagnostics
Specific Sections Covered:
Engine, Transmission, Drivetrain, Suspension, Steering, Brakes, Electrical System, Fuel System, Cooling System, Frame, Bodywork, Accessories, Troubleshooting Guides, Torque Specifications, Wiring Diagrams
Estimated Page Count:
300-500 (Typical for this model and scope)
Manual Type:
Factory Service Repair Manual
Powertrain:
Engine disassembly, assembly, inspection, troubleshooting, piston, rings, cylinder head, valves, camshaft, crankshaft, connecting rods, lubrication system, oil pump, oil filter, cooling system, radiator, water pump, thermostat, fuel system, carburetor/fuel injection (if applicable), fuel pump, fuel filter, exhaust system.
Drivetrain:
Clutch, transmission, gearbox, differential, drive shafts, CV joints, final drive, all-wheel drive (AWD) system operation and service.
Chassis And Suspension:
Front and rear suspension components, shock absorbers, springs, control arms, bushings, steering system, tie rods, steering column, wheel bearings, hub assemblies, tires, and wheels.
Brakes:
Hydraulic brake system, brake calipers, brake pads, brake rotors, brake lines, master cylinder, brake fluid specifications, bleeding procedures, parking brake system.
Electrical System:
Battery, starting system, charging system (alternator/stator), ignition system, lighting system, sensors, actuators, starter motor, wiring diagrams, fuse box, diagnostic connectors, ECU/ECM (if applicable).
Bodywork And Frame:
Frame inspection and repair, body panels, fenders, racks, seat removal and installation, handle bar removal and installation.
Maintenance Procedures:
Regular service checks, oil changes, filter replacements, lubrication points, spark plug replacement, air filter cleaning/replacement, coolant checks and changes, brake fluid flush, chain adjustment (if applicable).
Repair Procedures:
Step-by-step instructions for disassembly, inspection, repair, and reassembly of all major components and systems.
Troubleshooting Guides:
Diagnostic flowcharts and symptom-based troubleshooting for common and uncommon problems.
Installation Procedures:
Procedures for installing common accessories or replacement parts.
Adjustment Procedures:
Carburetor adjustments, clutch adjustments, brake lever adjustments, throttle cable adjustments.
Diagnostic Capabilities:
Detailed diagnostic information for electrical and mechanical systems, including sensor data interpretation (if applicable to the era).
Rebuild Scope:
Comprehensive coverage for complete engine and transmission rebuilds, including detailed part specifications and tolerances.
Wiring Diagrams:
Complete and detailed electrical wiring diagrams for all vehicle systems.
Torque Specifications:
Precise torque specifications for all critical fasteners and components.
Engine Type:
4-stroke, SOHC, 4-valve, Single-Cylinder
Bore X Stroke:
88 mm x 62 mm (Approximate)
Cooling System:
Liquid-cooled
Horsepower:
Approximately 26 hp (Manufacturer data varies slightly)
Torque:
Not Explicitly Stated in Product Info, but known for good low-end grunt.
Fuel Delivery:
Carburetor (Likely Mikuni BSR series)
Fuel Type:
Unleaded gasoline, minimum 87 octane
Ignition Type:
Electronic Ignition (CDI)
Exhaust Type:
Single muffler with catalytic converter (standard for emissions compliance)
Atv Safety Standards:
Designed to meet ANSI standards for ATVs.
Braking System:
Hydraulic disc brakes on all four wheels.
Engine Braking:
Standard feature of the PVT transmission for controlled descents.
Handlebars:
Ergonomic handlebars with handguards for improved grip and protection.
Lighting:
Dual 35W headlights, 40/60W brake light/taillight.
Protective Gear:
Always wear an approved helmet, eye protection, gloves, and protective clothing. Consult manual for specific recommendations.
Infotainment System:
Basic instrumentation cluster including speedometer, odometer, trip meter, fuel gauge, and indicator lights. No advanced infotainment features typical of modern vehicles.
Driver Assistance Features:
None specific beyond standard ATV safety features like engine braking and AWD.
Connectivity Features:
No on-board connectivity or Bluetooth features.
Diagnostic Port:
Likely equipped with a diagnostic connector for Polaris Digital Wrench or similar diagnostic tool, crucial for advanced troubleshooting detailed in the manual.
Oil Change Interval:
Every 100 hours or 6 months, whichever comes first (refer to manual for specific oil type and capacity).
Spark Plug Replacement:
Check every 100 hours, replace as needed. Specific plug type: NGK CR7HSA or equivalent.
Air Filter Maintenance:
Check/clean every 25 hours, replace as needed. Use genuine Polaris filter or equivalent.
Coolant Check Interval:
Check coolant level every 25 hours, flush and replace every 2 years or 100 hours.
Engine Oil Type:
Polaris Synthetic 2W-50 or equivalent API SG or higher (refer to manual for precise viscosity and specifications).
Engine Oil Capacity:
Approx. 2.5 US quarts (2.4 Liters) with filter change.
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid (refer to manual for exact specification).
Common Wear Items:
CV boots, tie rod ends, wheel bearings, brake pads, and PVT belt are common wear items requiring periodic inspection and replacement.
Pvt Belt Maintenance:
Regular inspection of the PVT belt for wear, cracks, and proper tension is crucial. Replacement interval varies based on usage, typically around 2-3 years or 200-300 hours.
Maintenance Recommendations
Post Ride Checks:
Recommended to inspect for loose fasteners, check tire pressure, and clean after each ride, especially in muddy or dusty conditions.
