Target User:
Recreational riders, agricultural users, hunters, trail enthusiasts
Competitors:
Honda Foreman, Yamaha Kodiak, Kawasaki Prairie
Features:
4-stroke engine, shaft drive, independent front suspension, integrated storage
Years Covered:
1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003
Product Type:
ATV (All-Terrain Vehicle)
Engine Variants:
Covers the 376cc engine as equipped in the Sportsman 400 models within the specified years.
Estimated Page Count:
High (Typical comprehensive service manuals range from 300-600 pages)
Type:
Service Repair Manual
Engine:
Full engine overhaul, diagnostics, repair, component identification
Fuel System:
Carburetor service and tuning, fuel pump, fuel lines, fuel tank maintenance
Transmission Drivetrain:
Primary drive, secondary drive (CVT), gear cases, differentials, drive shafts, hubs
Suspension:
Front and rear suspension components, shock absorbers, A-arms, bushings, bearings
Brakes:
Hydraulic brake system, calipers, master cylinder, brake lines, brake pads, bleeding procedures
Electrical:
Ignition system, charging system (stator, regulator/rectifier), battery, lighting, starter motor, wiring diagrams
Steering:
Handlebar assembly, tie rods, steering knuckles, wheel alignment
Bodywork Chassis:
Frame inspection and repair, plastic body panels, racks, seating
Maintenance:
Scheduled maintenance, oil changes, filter replacements, lubrication points, valve adjustments
Troubleshooting:
Diagnostic charts for common problems, symptom-based troubleshooting
Repair:
Step-by-step repair procedures for all major components
Disassembly Reassembly:
Detailed instructions for component removal and installation
Wiring Diagrams:
Detailed electrical system wiring diagrams for accurate troubleshooting and repair.
Torque Specifications:
Precise torque values for critical fasteners throughout the vehicle.
Depth:
Comprehensive (from basic maintenance to complete engine and transmission rebuilds)
Special Tools:
Identification of and procedures for using any specialized tools required for specific repairs.
Quality:
High-resolution PDF, searchable text, clear diagrams and illustrations
Searchability:
Fully searchable PDF content for quick information retrieval.
Reproducibility:
Printable on demand, suitable for professional workshop use
Binding Format:
N/A (Digital Download)
Paper Quality:
N/A (Digital Download)
Engine Type:
4-stroke, SOHC, 2-valve
Displacement:
376 cc (approximate)
Bore X Stroke:
Specific dimensions would be detailed in the manual
Cooling System:
Liquid-cooled
Horsepower:
Estimated 24-28 HP (actual figures may vary by year/tune)
Torque:
Specific torque figures would be detailed in the manual
Carburetor Type:
Mikuni VM30 (typical for this era and displacement)
Fuel Type:
Unleaded gasoline
Fuel Tank Capacity:
3.3 US gal (12.5 L) (typical for this model)
Transmission Type:
Automatic (CVT - Continuously Variable Transmission)
Drive System:
Shaft Drive, Selectable 2WD/4WD
Gear Selection:
High, Low, Neutral, Reverse, Park
Clutch:
Automatic clutch engagement/disengagement
Final Drive:
Sealed driveshaft, bevel gear differential
Length:
80.5 in (204.5 cm) (approximate)
Width:
46 in (116.8 cm) (approximate)
Height:
47.5 in (120.7 cm) (approximate)
Wheelbase:
50.5 in (128.3 cm) (approximate)
Dry Weight:
572 lbs (259.5 kg) (approximate)
Ground Clearance:
9.5 in (24.1 cm) (approximate)
Front Rack Capacity:
100 lbs (45 kg) (typical)
Rear Rack Capacity:
200 lbs (90 kg) (typical)
Towing Capacity:
1050 lbs (476 kg) (typical)
Atv Safety Standards:
Compliance with ANSI/SVIA standards
Braking System:
Hydraulic disc brakes front and rear
Lighting:
Headlights, taillight, brake light
Tire Type:
ATV-specific off-road tires
Engine Oil Change:
Every 100 hours or 12 months (specifics in manual)
Air Filter Cleaning:
As needed, or every 25 hours (depending on conditions)
Spark Plug Replacement:
Every 100 hours or 12 months (typical)
Valve Adjustment:
Every 100 hours or 12 months (typical)
Engine Oil Type:
SAE 20W-50 (API SG or higher recommended, specific Polaris recommendations in manual)
Engine Oil Capacity:
Approx. 2.1 US qt (2.0 L) with filter change (verify in manual)
Gearcase Oil Type:
Polaris AGL Gearcase Lubricant or SAE 80W-90 GL-5 Hypoid Gear Oil
Coolant Type:
Ethylene glycol-based antifreeze (50/50 mix with distilled water)
Common Wear Items:
CVT belt wear, tie rod ends, wheel bearings, suspension bushings
Electrical Gremlins:
Wiring harness integrity, stator output, and regulator/rectifier functionality can be common checks for this era
Carburetor Tuning:
Carburetor jetting can require adjustment due to altitude or fuel variations
Brand Focus:
Polaris is a prominent American manufacturer of powersports vehicles, including ATVs, snowmobiles, and motorcycles.
Sportsman Lineage:
The Sportsman line has been a cornerstone of Polaris's ATV offerings, known for its comfort, utility, and capability. The 400 model was positioned as a mid-range utility/recreational option.
Production Period:
The Sportsman 400 was produced within the specified model years, with incremental updates across the generation.
