Segment:
Mid-size utility ATV segment, known for its balance of power, maneuverability, and value.
Target Audience:
Outdoor enthusiasts, hunters, farmers, trail riders, and property owners requiring a reliable and capable off-road vehicle.
Competitors:
Competed with models such as Honda Foreman, Yamaha Kodiak, and Suzuki KingQuad in its class.
Versatility:
Designed for a wide range of tasks including trail riding, hauling, towing, and working on various terrains.
Durability:
Polaris's reputation for robust build quality and reliable components.
User Preference:
Caters to owners who prefer hands-on maintenance and repair for assurance of quality work.
General Coverage:
All service and repair procedures for Polaris Sportsman 400 HO models from 2008-2010.
Specific Coverage:
Engine, transmission, drivetrain, suspension, steering, brakes, electrical system, fuel system, cooling system, exhaust system, body panels, and maintenance.
Estimated Pages:
Approximately 500+ pages (typical for comprehensive service manuals of this era).
Type:
Factory Service Manual / Workshop Manual
Powertrain:
Engine overhaul, top-end and bottom-end repairs, cooling system maintenance, fuel system diagnostics and repair, exhaust system service, transmission removal and installation, clutch service, drive shaft inspection and repair, differential service.
Chassis And Suspension:
Front and rear suspension system repair, shock absorber and spring replacement, A-arm bushings and ball joint service, steering system diagnostics and repair (tie rods, steering rack), wheel bearing replacement, hub assembly service.
Brakes:
Brake caliper overhaul, brake pad replacement, brake line inspection and replacement, master cylinder service, bleeding procedures, parking brake adjustment.
Electrical System:
Wiring diagrams, starter motor testing and replacement, alternator (stator/generator) inspection, battery service and charging system diagnostics, ignition system troubleshooting, lighting system service, accessory wiring, fuse and relay identification and testing.
Body And Trim:
Body panel removal and installation, seat removal, fender and rack servicing, storage compartment maintenance.
Maintenance:
Scheduled maintenance tasks, fluid level checks and top-offs, filter replacements, lubrication points and intervals, spark plug replacement, air filter cleaning/replacement, battery maintenance.
Troubleshooting:
Systematic diagnostic procedures for common and uncommon problems, symptom-based troubleshooting charts, error code interpretation (if applicable).
Repair And Rebuild:
Step-by-step instructions for component disassembly, cleaning, inspection, repair, and reassembly, including torque specifications for all fasteners.
Special Tools:
Identification and usage of special tools required for specific repair procedures.
Depth:
Comprehensive, covering everything from routine maintenance and adjustments to complete engine and transmission overhauls, electrical system diagnostics, and chassis repairs. Suitable for both DIY enthusiasts and professional mechanics.
Compatibility:
Compatible with all devices capable of opening PDF files (computers, tablets, smartphones).
Searchability:
Fully searchable text for quick access to specific information and keywords.
Resolution:
High-resolution scans ensuring clear diagrams, illustrations, and text.
Printability:
Pages are printable, allowing users to create a physical copy for workshop use.
Format Note:
Digital download; binding type is not applicable.
Format Note:
Digital download; paper type is not applicable.
Engine Type:
4-stroke, SOHC, 4-valve
Engine Displacement:
375cc (actual displacement may vary slightly based on bore/stroke, typically around this figure for the 400 HO designation).
Engine Cooling:
Liquid-cooled
Bore X Stroke:
Refer to manual for exact specifications (typically around 85mm x 66mm).
Horsepower:
Approximately 24-27 HP (manufacturer data).
Torque:
Refer to manual for specific torque figures.
Fuel Delivery:
Carbureted (Mikuni BST40 or similar, specific model variation applies).
Fuel Type:
Unleaded gasoline, 87 octane or higher recommended.
Ignition System:
Electronic ignition with CDI module.
Recommended Oil Viscosity:
SAE 10W-40 or SAE 20W-50 (depending on ambient temperature range, refer to manual for specific recommendations).
Oil Capacity:
Approximately 2.5 quarts (2.4 liters) with filter change (refer to manual for exact capacity).
Transmission Type:
Automatic (CVT - Continuously Variable Transmission)
Drive System:
Shaft drive, selectable 2WD/4WD with front differential lock.
Gear Selection:
High, Low, Neutral, Reverse, Park.
Clutch Type:
Automatic centrifugal clutch and belt drive system.
Fluid Type:
Refer to manual for specific CVT fluid type; typically a specialized synthetic CVT fluid. Do NOT use standard automatic transmission fluid or motor oil.
Length:
Approx. 83 inches (210.8 cm).
Width:
Approx. 46 inches (116.8 cm).
Height:
Approx. 47 inches (119.4 cm).
Wheelbase:
Approx. 50.5 inches (128.3 cm).
Dry Weight:
Approx. 620 lbs (281 kg).
Ground Clearance:
Approx. 10.5 inches (26.7 cm).
Towing Capacity:
Refer to manual; typically rated for significant towing capacity, e.g., 1,000-1,500 lbs (454-680 kg).
Rack Capacity Front:
Approx. 50 lbs (22.7 kg).
Rack Capacity Rear:
Approx. 100 lbs (45.4 kg).
Front Tire Size:
25x8-12 (e.g., Carlisle AT489 or similar).
Rear Tire Size:
25x10-12 (e.g., Carlisle AT489 or similar).
Wheel Type:
Steel or Aluminum alloy, typically 12-inch diameter.
Atv Classification:
Utility ATV, designed for off-road use.
Braking System:
Hydraulic disc brakes on all wheels.
Parking Brake:
Handlebar-mounted parking brake lever, typically engages rear brake.
Operator Protection:
Handlebar with handguards, sturdy frame construction. Always recommended to wear appropriate PPE (helmet, gloves, boots, eye protection).
Features:
Basic instrumentation cluster including speedometer, odometer, trip meter, neutral/reverse indicators, and engine/charging system warning lights. No advanced infotainment features are present as this is a utility-focused ATV.
Features:
Selectable 2WD/4WD, engine braking from CVT.
Features:
No electronic connectivity features like Bluetooth or GPS.
Oil Change Interval:
Every 100 hours or 6 months, whichever comes first. (Refer to manual for precise interval).
Air Filter Cleaning:
Every 25 hours or as needed, depending on operating conditions. Replacement as required.
Spark Plug Replacement:
Refer to manual; typically every 100-200 hours or annually.
Valve Adjustment:
Refer to manual; typically every 500 hours or as needed based on performance.
Belt Inspection Cvt:
Inspect CVT belt at 50 hours, replace if worn or damaged, or as per manual recommendation (often around 100-200 hours).
Brake Fluid:
DOT 3 or DOT 4 hydraulic brake fluid (refer to manual for precise specification).
Coolant Type:
Ethylene glycol-based antifreeze mixture, typically 50/50 with distilled water. Refer to manual for specific Polaris recommendation or equivalent.
Cvt Belt Wear:
As with many ATVs, CVT belt wear can be accelerated by aggressive riding or improper maintenance. Early inspection and replacement are key.
Carburetor Adjustment:
Carburetors may require periodic cleaning and adjustment to maintain optimal performance, especially with variations in fuel quality or altitude.
Suspension Bushings:
Wear on A-arm and sway bar bushings can occur over time, leading to looseness and clunking noises. Manual provides replacement procedures.
Manufacturer Origin:
Polaris Industries Inc., founded in 1954, Roseau, Minnesota, USA. A long-standing leader in powersports vehicles.
Sportsman Lineage:
The Sportsman line is Polaris's flagship ATV series, known for its comfort, capability, and innovation since its introduction. The 400 HO represents a popular mid-range offering in this line, evolving from earlier 300/330cc models.
Manufacturing Location:
Primarily manufactured in Spirit Lake, Iowa, USA, and Roseau, Minnesota, USA.
Key Updates During Period:
Minor updates may have occurred between 2008-2010, such as color options or small component revisions. The core design remained consistent for this generation.
