Segment:
Mid-size utility ATV (All-Terrain Vehicle), positioned as a capable and reliable machine for recreational and utility use.
Competitors:
Competed against models like Yamaha Big Bear, Honda Foreman, and Suzuki Vinson in the utility ATV market during its production run.
Features:
Known for its Polaris Independent Front Suspension (IFS), Polaris Variable Transmission (PVT), and robust utility capabilities.
Value:
Essential resource for owners and technicians to maintain, diagnose, and repair the Sportsman 400, ensuring longevity and optimal performance.
Engine:
Engine overhaul, disassembly, assembly, tuning, fuel system, ignition system, lubrication, cooling system.
Transmission:
PVT (Polaris Variable Transmission) operation, maintenance, repair, belt inspection and replacement, gearcase service.
Drivetrain:
Front and rear drive systems, differentials, driveshafts, CV joints, AWD (All-Wheel Drive) system operation and service.
Suspension:
Front and rear suspension components, shocks, springs, control arms, bushings, alignment.
Brakes:
Hydraulic brake system, brake fluid, master cylinder, calipers, brake lines, pads, rotors, bleeding procedure.
Electrical:
Wiring diagrams, battery, starter, alternator, lighting, ignition switch, fuses, relays, troubleshooting electrical faults.
Chassis And Body:
Frame inspection, body panels, fenders, racks, seat, handle bars, controls, troubleshooting chassis damage.
Maintenance:
Scheduled maintenance, oil changes, filter replacements, lubrication points, tire pressure checks, battery maintenance.
Troubleshooting:
Diagnostic flowcharts, common problems and their solutions, specific fault code explanations (if applicable).
Repair:
Detailed step-by-step instructions for component removal, disassembly, repair, reassembly, and installation.
Diagnostics:
System diagnosis for engine performance, electrical issues, transmission problems, and other operational faults.
Depth:
Comprehensive. Covers basic to advanced repairs, including full engine and transmission rebuilds, electrical system diagnostics, and suspension overhaul.
Format Details:
PDF (Portable Document Format), enabling easy viewing, searching, and printing.
Quality:
High-resolution scans of the original factory manual, ensuring clarity of text and diagrams for printing.
Binding:
N/A (Digital Download - not applicable for printed binding)
Paper Type:
N/A (Digital Download - not applicable for paper type)
Engine Type:
4-stroke, liquid-cooled, single-cylinder.
Displacement:
Approximately 375cc (Specific to the 400 model).
Bore X Stroke:
Specifications would be detailed within the manual (e.g., 83mm x 70mm for similar Polaris engines).
Compression Ratio:
Details found in the manual.
Horsepower:
Estimated 20-25 HP (Exact figures in manual).
Torque:
Details found in the manual.
Carburetor:
Mikuni VM34 or similar carburetor. Specific jetting and adjustment procedures in the manual.
Fuel Type:
Unleaded gasoline (Octane rating specified in manual, typically 87 or higher).
Ignition System:
CDI (Capacitor Discharge Ignition).
Oil Type:
SAE 10W-40 or 20W-50 motorcycle/ATV specific engine oil. See manual for exact specifications and API service classifications.
Oil Capacity:
Approximately 2.0-2.2 liters (refer to manual for precise capacity with filter change).
Cooling System:
Liquid-cooled.
Coolant Type:
Ethylene glycol based antifreeze/coolant. See manual for specific mixture ratio and type.
Transmission Type:
Automatic Polaris Variable Transmission (PVT) with High/Low range and Reverse.
Drive System:
Shaft drive, with engaged AWD (All-Wheel Drive) system.
Clutch:
Centrifugal clutch mechanism for automatic engagement.
Gear Ratios:
Detailed gear ratios for Hi, Lo, and Reverse are provided in the manual.
Transmission Fluid Type:
Refer to manual for specific PVT fluid requirements (often specific Polaris fluids or compatible aftermarket options).
Transmission Fluid Capacity:
Details found in the manual for gearcase oil.
Length:
Approx. 80-82 inches (refer to manual for exact specs).
Width:
Approx. 46 inches (refer to manual for exact specs).
Height:
Approx. 45-47 inches (refer to manual for exact specs).
Dry Weight:
Approx. 570-590 lbs (refer to manual for exact specs).
Towing Capacity:
Typically around 1,500 lbs (refer to manual for exact rating).
Rack Capacity Front:
Typically around 50 lbs (refer to manual for exact rating).
Rack Capacity Rear:
Typically around 100 lbs (refer to manual for exact rating).
Front Tire Size:
e.g., AT 25x8-12 (Specific sizes in manual).
Rear Tire Size:
e.g., AT 25x10-12 (Specific sizes in manual).
Wheel Bolt Pattern:
Details in manual (typically 4x110mm or similar for Polaris).
Safety Certification:
Meets ANSI standards for recreational ATVs (manual will confirm).
Braking System:
Hydraulic disc brakes front and rear.
Parking Brake:
Hand-operated or foot-operated parking brake mechanism (details in manual).
Handlebars:
Handlebar grips and control levers designed for safe operation.
Operator Training:
Manual stresses the importance of proper training and protective gear.
Oil Change Interval:
Typically every 100 hours or 6 months, whichever comes first (refer to manual for precise interval).
Air Filter Cleaning:
Recommended every 20 hours or as needed based on operating conditions (detailed in manual).
Spark Plug Replacement:
Typically every 100-200 hours or annually (refer to manual for specific plug type and interval).
Transmission Belt Inspection:
Inspect at 50-hour intervals and replace as necessary (critical for PVT system health).
Engine Oil Spec:
SAE 10W-40 or 20W-50 (API SG or higher) – refer to manual for exact specification and Polaris recommendations.
Brake Fluid Spec:
DOT 3 or DOT 4 hydraulic brake fluid (refer to manual for specific type).
Coolant Spec:
Ethylene Glycol based antifreeze, 50/50 mix with distilled water.
Common Wear Items:
PVT belt wear, control arm bushings, wheel bearings, tie rod ends, spark plug fouling.
Carburetor Tuning:
Carburetors may require periodic cleaning and adjustment for optimal performance, especially with altitude or fuel variations.
Schedule Detail:
The manual provides a detailed, hour-based and mileage/time-based maintenance schedule covering all critical components.
Brand Focus:
Polaris Industries is a long-standing American manufacturer known for its leadership in the powersports industry, including ATVs, snowmobiles, and motorcycles.
Sportsman Lineage:
The Sportsman line has been a flagship for Polaris, known for comfort, capability, and versatility. The 400 model represented a mid-range offering within this popular series.
Manufacturing Location:
Primarily manufactured by Polaris in the USA.
Industry Reputation:
The Polaris Sportsman line consistently received positive reviews for its ride comfort, handling, and utility capabilities within the ATV market.
Consumer Feedback:
Generally well-regarded for its performance in mixed terrain and work applications, though maintenance requires attention to detail.
Standards Compliance:
Compliant with applicable safety and emissions standards for its model years.
