Positioning:
The Polaris Sportsman 400 HO was positioned as a capable and versatile mid-range ATV, offering a good balance of power, comfort, and utility for recreational riding, light trail work, and hunting expeditions.
Competitors:
Competed directly with models from Yamaha (Grizzly 450), Can-Am (Outlander 400), Arctic Cat (400 DVX/TRV), and Honda (Rancher 420 series).
Features:
Independent Rear Suspension (IRS), Polaris Variable Transmission (PVT) with engine braking, On-Demand True All-Wheel Drive (AWD), comfortable seating, robust chassis, accessory mounting options.
Engine:
Engine overhaul, top-end and bottom-end procedures, cooling system, lubrication, fuel delivery, ignition, starting system, exhaust system.
Transmission:
Automatic transmission (PVT - Polaris Variable Transmission) operation, maintenance, clutch service, belt inspection and replacement, gearbox disassembly and assembly.
Drivetrain:
All-Wheel Drive (AWD) system, front and rear differential, drive shafts, CV joints, final drive units.
Suspension:
Front and rear suspension systems, shock absorbers, springs, control arms, bushings, wheel bearings.
Brakes:
Hydraulic brake system, front and rear brake calipers, master cylinders, brake lines, brake pads, rotor maintenance.
Electrical:
Wiring diagrams, lighting system, battery, charging system (stator, regulator/rectifier), starter motor, ignition system, switches, relays, fuses, instrumentation.
Steering:
Steering system components, tie rods, steering linkage, handlebar assembly, potential for EPS (Electronic Power Steering) system coverage if applicable to specific trims.
Chassis And Body:
Frame inspection and repair, plastic body panels, racks, seat, mounting hardware.
Maintenance:
Routine service checks, oil changes, filter replacements, spark plug maintenance, lubrication points, battery care, tire pressure checks.
Troubleshooting:
Diagnostic charts and procedures for common problems related to engine, electrical, transmission, and other systems.
Repair:
Step-by-step instructions for disassembly, repair, and reassembly of all major vehicle components.
Rebuild:
Detailed procedures for complete engine and transmission rebuilds, including torque specifications and clearances.
Depth:
Comprehensive, covering basic maintenance to full engine and transmission overhauls, including electrical diagnostics.
Engine Type:
4-stroke, SOHC, Liquid-Cooled, Single-Cylinder
Displacement:
375 cc (approximate, often rounded in marketing)
Bore X Stroke:
Refer to manual for exact specifications (typically around 83mm x 70mm for this engine family)
Horsepower:
Estimated 20-25 HP (actual figures vary, manual will provide precise data)
Torque:
Refer to manual for exact specifications
Fuel Delivery:
Carbureted (Keihin CV type, specific model to be confirmed in manual)
Fuel Type:
Unleaded Gasoline, Octane Rating 87 minimum
Ignition System:
CDI (Capacitor Discharge Ignition)
Cooling Type:
Liquid Cooling
Oil Type:
SAE 10W-40, API SG or higher (specific Polaris branded or equivalent recommended)
Oil Capacity:
Approximately 1.7 L (1.8 US qt) including filter (verify in manual)
Transmission Type:
Polaris Variable Transmission (PVT) Automatic with EBS (Engine Braking System)
Gear Selection:
High, Low, Neutral, Reverse, Park
Drive System:
Shaft Drive (to front and rear differentials)
Ebs:
Engine Braking System (EBS) for controlled descents.
Transmission Fluid:
Polaris AGL Synthetic Gearcase Lubricant (or equivalent as specified in manual)
Gearcase Oil Capacity:
Refer to manual (typically around 0.5 L for gearcase)
Length:
Approx. 81 inches (205.7 cm)
Width:
Approx. 46 inches (116.8 cm)
Height:
Approx. 47 inches (119.4 cm)
Wheelbase:
Approx. 50.5 inches (128.3 cm)
Front Rack Capacity:
Approx. 50 lbs (22.7 kg)
Rear Rack Capacity:
Approx. 100 lbs (45.4 kg)
Dry Weight:
Approx. 605 lbs (274.4 kg)
Towing Capacity:
Approx. 1,500 lbs (680 kg)
Gcvw Rating:
Refer to manual
Front Tire Size:
25 x 8-12
Rear Tire Size:
25 x 10-12
Wheel Type:
Steel or Cast Aluminum (depending on trim)
Wheel Bolt Pattern:
4/110 mm (typical for Polaris ATVs of this era)
Crash Test Results:
ATV safety is primarily based on design and rider responsibility; no formal crash test ratings like automobiles. Manual will cover safe operating procedures.
Ebs:
Engine Braking System (EBS) enhances control on descents.
AWD:
On-Demand True All-Wheel Drive for enhanced traction.
Roll Over Protection:
Standard ATV design, rider must wear helmet. No ROPS (Roll Over Protective Structure) standard.
Lighting:
Dual front headlights, taillight, brake light.
Rider Education:
Manual emphasizes safe riding practices, protective gear (helmet, eye protection, gloves, long sleeves/pants), and pre-ride inspections.
Initial Service:
First service typically around 10-20 hours or 1 month, covering fluid checks, bolt torquing, and basic adjustments.
Engine Oil Change:
Every 100 hours or 6 months (verify in manual)
Air Filter Cleaning:
Every 25-50 hours or as needed based on conditions (manual provides detailed cleaning/replacement intervals)
Spark Plug Replacement:
Refer to manual, typically every 100-200 hours or annually.
Transmission Fluid Change:
Every 100 hours or annually (verify in manual)
Drive Belt Inspection:
Every 100 hours or annually for wear and tension.
Coolant Type:
Ethylene Glycol based antifreeze (50/50 mix with distilled water)
Brake Fluid Type:
DOT 3 or DOT 4 Hydraulic Brake Fluid
Common Problems:
Potential issues can include starter solenoid failures, charging system issues (stator/rectifier), PVT belt wear, and suspension component wear over time. The manual will guide diagnostics for these.
Critical Torques:
Manual provides exact torque specifications for engine components (head bolts, crankcase bolts), suspension fasteners, wheel nuts, and brake caliper mounting bolts.
Heritage:
Polaris Industries has a long history in powersports, dating back to 1954, and is a pioneer in the ATV market, known for innovation and performance.
Sportsman Line:
The Sportsman line has been Polaris's flagship utility ATV for decades, evolving through various engine sizes, feature packages, and chassis designs. The 400 HO model represents a solid, reliable offering within this lineage.
Manufacturing Location:
Primarily manufactured in the USA by Polaris Industries.
