POLARIS SPORT 400 EXPLORER 400 ATV Full Service & Repair Manual 1999

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The Polaris Sport 400 Explorer, manufactured in 1999, is a robust ATV designed for recreational and utility purposes. Building on Polaris's heritage as an industry pioneer, this model represents a...

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Taper: Atv

Distributeur:

UGS: 58305

Mots clés: 1999 ATV EXPLORER 400 Explorer Models Polaris Powersports SPORT 400

Variantes de produits

Description

The Polaris Sport 400 Explorer, manufactured in 1999, is a robust ATV designed for recreational and utility purposes. Building on Polaris's heritage as an industry pioneer, this model represents a significant period in ATV development, offering a blend of performance and reliability characteristic of its era. Engineered for diverse terrains, the Sport 400 Explorer is known for its capable handling and durable construction, making it a popular choice for riders seeking adventure and utility. This comprehensive factory service repair workshop manual provides in-depth coverage for the 1999 Polaris Sport 400 Explorer. It details essential maintenance procedures, troubleshooting guides, and technical specifications required for optimal performance and longevity. The manual covers all major systems, including the engine, transmission, fuel, cooling, electrical, suspension, braking, and steering systems, along with chassis and bodywork. It is an indispensable resource for owners, DIY enthusiasts, and professional mechanics to ensure proper upkeep and repair of the vehicle.

🏷️ Basic Information

Identification

Make:

Polaris

Model:

Sport 400 Explorer

Year:

Type:

👋 Introduction

Market Position

Target User:

Owners, DIY enthusiasts, professional mechanics

Competitive Analysis

Advantage:

Comprehensive factory-level detail, accessible digital format

Key Features

Content Richness:

Hundreds of pages with detailed photos and diagrams

Instructional Style:

Step-by-step instructions for clarity and accuracy

📋 Manual Details

Coverage Areas

Primary Coverage:

Full Service, Repair, and Workshop Procedures

Secondary Coverage:

Troubleshooting, Diagnostics, Maintenance

Page Count

Estimated Pages:

Hundreds (precise count not specified, but described as very detailed)

Manual Type

Type:

Factory Service Repair Workshop Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine:

Engine assembly, disassembly, diagnosis, tuning, performance adjustments

Transmission:

Gearbox overhaul, clutch service, drive system maintenance

Fuel System:

Carburetor service, fuel pump, fuel lines, fuel tank maintenance

Cooling System:

Radiator, fan, coolant circulation, thermostat service

Electrical System:

Ignition system, charging system, lighting, starter motor, battery service, wiring diagrams

Suspension System:

Front and rear suspension components, shock absorbers, bushings, alignment

Braking System:

Hydraulic brake system, calipers, master cylinder, brake pads, fluid service

Steering System:

Handlebars, steering column, tie rods, ball joints, steering linkage

Chassis And Frame:

Frame inspection, welds, component mounting, structural integrity

Bodywork And Plastics:

Fenders, plastics, seat, storage compartments, aesthetic components

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, lubrication, chain adjustment, spark plug service

Troubleshooting Guides:

Step-by-step diagnostics for common and complex issues

Rebuild Procedures:

Detailed instructions for engine, transmission, and component overhauls

Wiring Diagrams:

Comprehensive electrical schematics for all systems

Exploded Diagrams:

Highly detailed illustrations for part identification and assembly

Torque Specifications:

Precise torque values for all critical fasteners

Special Tools:

Identification of required special tools for specific procedures

Technical Depth

Depth:

Comprehensive, covering all aspects from basic maintenance to complete rebuilds

📊 Manual Specifications

File Format

File Type:

Searchability:

Likely text-searchable due to PDF format (though not explicitly stated)

Print Quality

Printable:

Yes, single pages or entire manual

Binding Type

Binding:

N/A (Digital Download)

Paper Type

Paper:

N/A (Digital Download)

Licensing

Usage Rights:

Unlimited use on multiple devices, lifetime access

Version Control

Updates:

No expiry, no renewal fees

⚙️ Engine Specifications

Primary Engine

Type:

2-stroke, liquid-cooled, single-cylinder (common for Polaris 400 series at this time)

Displacement:

Approx. 340-375cc (specific to the 400 model, exact value requires manual verification)

Performance

Horsepower:

Estimated 28-35 HP (typical for this engine size and era, requires manual verification)

Torque:

Estimated 25-30 lb-ft (typical for this engine size and era, requires manual verification)

Fuel System

Carburetion:

Single carburetor (likely Mikuni or Keihin, size dependent on specific model variant)

Lubrication

Oil System:

Pre-mix or oil injection system (common for 2-stroke ATVs)

🔧 Transmission

Standard

Type:

Automatic (CVT - Continuously Variable Transmission)

Features

Drive System:

Shaft drive to rear wheels, likely 2WD (2WD is typical for this model designation)

Gear Reduction:

Integrated into the CVT and rear differential

📐 Dimensions

Exterior

Length:

Approx. 74-78 inches (typical for 1999 Polaris 400 models)

Width:

Approx. 46-48 inches (typical for 1999 Polaris 400 models)

Height:

Approx. 44-46 inches (typical for 1999 Polaris 400 models)

Weights

Dry Weight:

Approx. 450-500 lbs (typical for 1999 Polaris 400 models)

Ground Clearance:

Approx. 7-10 inches (typical for 1999 Polaris 400 models)

🛡️ Safety Features

Ratings

Standards Compliance:

Meets ANSI standards for ATVs (standard for this era)

Active Features

Braking System:

Hydraulic disc brakes (front and rear, typically)

Passive Features

Handlebars:

Grip design for control, throttle control

Footwells:

Protective footrests with heel guards

💡 Technology Features

Infotainment

Features:

Basic instrumentation (speedometer, odometer, neutral indicator, oil light)

Driver Assistance

Features:

N/A (No advanced electronic driver assistance systems on this model)

🔧 Maintenance

Service Intervals

Engine Oil Change:

Typically every 30-50 hours of operation or annually (refer to manual for exact interval)

Air Filter Cleaning:

Check frequently, clean every 20-30 hours (refer to manual)

Spark Plug Replacement:

Typically every 100-200 hours (refer to manual)

Fluid Specifications

Engine Oil Type:

2-stroke oil pre-mix or injection oil (specific API rating and viscosity required, consult manual)

Transmission Fluid:

Specific gear oil or ATV transmission fluid (consult manual for exact type and viscosity)

Brake Fluid:

DOT 3 or DOT 4 hydraulic brake fluid (consult manual for specific type)

Known Issues

Carburetor Tuning:

Can be sensitive to altitude and temperature, requiring periodic adjustment

Clutch Belt Wear:

CVT belt requires periodic inspection for wear and proper tension

Cooling System Maintenance:

Regular flushing and coolant replacement to prevent overheating

📚 Vehicle History

Brand Heritage

Manufacturer:

Polaris Industries Inc.

Heritage:

Pioneer in the snowmobile and ATV industry

Model Evolution

Series Context:

Part of Polaris's popular 'Sport' and 'Explorer' line of utility/recreational ATVs

Production

Late 1990s, a significant period for ATV development and popularity

🏆 Awards & Recognition

Recognitions

Industry Standing:

Polaris ATVs of this era were generally well-regarded for performance and utility in their class.