Segment:
Mid-size utility ATV.
Target Audience:
Recreational riders, hunters, farmers, and those needing a capable off-road utility vehicle.
Competitors:
Honda Foreman, Yamaha Kodiak, Kawasaki Prairie.
Utility Focus:
Designed for work and recreational trail riding, offering a balance of power and maneuverability.
4X4 Capability:
Features Polaris's Automatic 4x4 system for enhanced traction.
Diy Support:
Enables owners to perform a wide range of maintenance and repairs, saving on labor costs.
Diagnostic Aid:
Provides essential diagnostic flowcharts and troubleshooting steps.
Engine System:
Engine diagnosis, disassembly, inspection, repair, and reassembly.
Fuel System:
Carburetor service, fuel pump, fuel lines, fuel tank.
Ignition System:
Ignition coil, CDI unit, spark plug, timing.
Cooling System:
Radiator, fan, coolant, thermostat.
Exhaust System:
Muffler, exhaust pipe, heat shields.
Transmission System:
PVT (Polaris Variable Transmission) operation, belt inspection/replacement, clutch service.
Drivetrain System:
Front and rear drive shafts, differentials, CV joints, U-joints.
Suspension System:
Front and rear shock absorbers, control arms, bushings, ball joints.
Braking System:
Hydraulic brake system, master cylinders, calipers, brake pads, brake lines, parking brake.
Electrical System:
Wiring diagrams, battery, starter, alternator, lighting, switches, fuses.
Steering System:
Handlebar assembly, steering shaft, tie rods, steering components.
Frame And Bodywork:
Frame inspection, body panel removal/installation, fenders, racks.
Routine Maintenance:
Oil changes, filter replacements, spark plug service, chain adjustment (if applicable), lubrication.
Troubleshooting:
Diagnosing common performance issues, starting problems, electrical faults.
Component Repair:
Detailed steps for repairing or replacing major components.
Rebuild Procedures:
Engine and transmission rebuild procedures.
Electrical Diagnostics:
Using multimeters and troubleshooting flowcharts.
Torque Specifications:
Crucial torque values for fasteners across all systems.
Special Tools:
Identification of required special tools for specific procedures.
Depth Of Information:
Detailed diagnostic procedures, component testing, specifications, and step-by-step repair instructions suitable for DIY mechanics and professional technicians.
File Type:
PDF (Portable Document Format)
Resolution:
High-resolution, suitable for digital viewing and printing.
Binding:
N/A (Digital PDF download)
Paper Type:
N/A (Digital PDF download)
Searchable Text:
Typically included, allowing users to quickly find specific information.
Printable:
Yes, pages can be printed for convenient on-site use.
Engine Type:
4-stroke, liquid-cooled, SOHC, 1-cylinder
Displacement:
Approximately 375cc (specific variations may exist)
Bore X Stroke:
Typically around 84.5 mm x 68 mm (verify specific model year within range)
Horsepower Estimate:
Estimated 24-28 HP (varies by year and tuning)
Torque Estimate:
Estimated 23-26 lb-ft (varies by year)
Fuel Delivery:
Carburetor (e.g., Mikuni BST34 or similar, specific model varies)
Fuel Type:
Unleaded gasoline
Oil Type:
SAE 10W-40, API SG or higher (verify with manual specific to model year)
Coolant Type:
Ethylene glycol-based antifreeze (e.g., Polaris Premium All-Season Coolant or equivalent)
Transmission Type:
Polaris Variable Transmission (PVT) automatic with engine braking
Gear Selection:
High, Low, Neutral, Reverse, Park
Belt Drive:
CVT belt drive system
Final Drive:
Shaft drive with 4WD and engine braking
Transmission Fluid Type:
ATF (Automatic Transmission Fluid) or specialized PVT fluid (verify specific manual requirement for clutch system)
Length:
Approx. 82 inches (208.3 cm) (varies slightly by year)
Width:
Approx. 46 inches (116.8 cm) (varies slightly by year)
Height:
Approx. 47 inches (119.4 cm) (varies slightly by year)
Dry Weight:
Approx. 580-600 lbs (263-272 kg) (varies by year and features)
Ground Clearance:
Approx. 10.5 inches (26.7 cm)
Towing Capacity:
Typically 1,500 lbs (680 kg)
Rack Capacity Front:
Approx. 90 lbs (41 kg)
Rack Capacity Rear:
Approx. 180 lbs (82 kg)
Wheelbase:
Approx. 50.5 inches (128.3 cm)
Front Tire Size:
25x8-12 (typical)
Rear Tire Size:
25x10-12 (typical)
Wheel Bolt Pattern:
4x110 mm
Atv Safety Standards:
Complies with ANSI standards for ATVs.
Automatic 4X4:
Engages front drive wheels automatically when rear wheels lose traction.
Engine Braking:
Provides downhill braking assist.
Handlebars With Padding:
For improved grip and comfort.
Full Floorboards With Raised Toe And Heel Guards:
For foot protection.
Protective Gear:
Always wear a helmet, eye protection, gloves, and protective clothing.
Instrument Cluster:
Basic LCD display with speedometer, odometer, trip meter, fuel gauge, 4WD indicator, and neutral/reverse indicators.
Automatic 4X4:
The primary technological feature for enhanced traction.
No Electronic Connectivity:
These ATVs predated modern electronic connectivity features.
Initial Break In Service:
Typically at 10-20 hours or 100 miles (check manual for specific recommendation).
Engine Oil Change:
Every 100 hours or annually, whichever comes first.
Air Filter Cleaning Inspection:
Every 50 hours or more frequently in dusty conditions.
Spark Plug Check Gap:
Every 100 hours.
Transmission Belt Inspection:
Every 100 hours or annually.
Engine Oil Capacity:
Approx. 2.0 quarts (1.9 liters) with filter change (verify specific model)
Coolant Capacity:
Approx. 4.0 quarts (3.8 liters) (verify specific model)
Pvta Belt Wear:
CVT belt wear is a common maintenance item; proper tension and condition are crucial for performance.
Carburetor Cleaning:
Carburetors can become gummed up if the ATV sits for extended periods without fuel stabilizer.
Electrical Connections:
Corrosion or loose connections can cause intermittent electrical issues.
Suspension Bushings:
Wear on control arm bushings can lead to steering looseness and poor handling.
Manufacturer:
Polaris Inc., founded in 1954, a prominent American manufacturer of recreational vehicles.
Sportsman Line:
The Sportsman line has been a cornerstone of Polaris's ATV offerings, known for its robust utility and 4x4 capabilities.
Sportsman 400 Positioning:
The 400 model provided a more affordable entry into the Sportsman lineup, balancing capability with value.
Production Period:
1996-2003 (as covered by this manual). Subsequent models continued the Sportsman 400 lineage with updates.
