Target Audience:
Polaris ATV Sport 400 owners and independent repair shops for model years 1996-1998.
Value Proposition:
Provides the same factory-level information as used by dealerships, offering a cost-effective solution for DIY repairs and maintenance.
Documentation Source:
Directly reflects the content used by authorized Polaris service centers.
Digital Benefits:
Instant download, no shipping costs or waiting, searchable and bookmarked for efficient use.
Covered Models:
Polaris ATV Sport 400 1996, Polaris ATV Sport 400 1997, Polaris ATV Sport 400 1998
Included Sections:
General Information, Maintenance, Engine, Fuel System/Carburetion, Body, Steering, Suspension, PVT System, Final Drive, Transmission, Brakes, Electrical
Estimated Page Count:
Estimated 300-500 pages (typical for factory service manuals of this era).
Manual Type:
Factory Service Repair Manual
Delivery Method:
Instant Download
Archive Format:
WinRAR (for download delivery)
Engine Systems:
Engine overhaul, component testing, cylinder head, piston, crankshaft, lubrication system, cooling system (if applicable), and more.
Fuel System:
Carburetor disassembly, adjustment, cleaning, fuel tank, fuel lines, fuel pump (if applicable).
Drivetrain Systems:
PVT (Polaris Variable Transmission) system operation, maintenance, belt inspection/replacement, primary and secondary clutch service, final drive unit, differential (if applicable), driveshafts.
Suspension Steering:
Front and rear suspension components, shock absorbers, springs, bushings, steering system overhaul, tie rods, ball joints, steering column.
Braking System:
Brake caliper service, master cylinder overhaul, brake fluid flushing and bleeding, brake pad replacement, brake line inspection.
Electrical System:
Wiring diagrams, ignition system, lighting, starting system, charging system (stator, regulator/rectifier), fuses, battery maintenance, troubleshooting electrical faults.
Bodywork Chassis:
Body panel removal and installation, seat, fenders, handlebars, frame inspection and repair (limited).
Maintenance Procedures:
Scheduled maintenance intervals, lubrication points, filter changes, spark plug replacement, fluid level checks.
Diagnostic Procedures:
Troubleshooting guides for common problems, symptom-based diagnostics, diagnostic charts.
Repair Procedures:
Step-by-step repair instructions for all major components and systems, including torque specifications and special tool requirements.
Disassembly Assembly:
Complete instructions for disassembling and reassembling engine, transmission, suspension, and other mechanical systems.
Depth Of Information:
Comprehensive factory-level service and repair information, suitable for professional mechanics and experienced DIY enthusiasts.
Diagnostic Tools References:
Likely references specialized tools required for certain procedures, but specific tool part numbers may not be listed extensively.
PDF Quality:
High quality, 'real files not scans', indicating clear text and legible diagrams.
Searchability:
Completely searchable text for quick information retrieval.
Bookmarking:
Completely bookmarked for easy navigation.
Printability:
All pages are printable, allowing users to print specific sections or the entire manual.
Binding Type:
Not applicable (digital download).
Paper Type:
Not applicable (digital download).
Operating Systems:
Win95/98/ME/XP/vista/7/Linux/MAC
Engine Type:
2-Stroke, Liquid-Cooled (typical for this model and era).
Displacement:
Likely around 375-400cc (specifics detailed in manual).
Bore X Stroke:
Detailed specifications available in the manual.
Compression Ratio:
Detailed specifications available in the manual.
Horsepower:
Estimated 25-35 HP (specifics detailed in manual).
Torque:
Detailed specifications available in the manual.
Carburetor Type:
Single Carburetor, likely Mikuni or similar, with detailed jetting and adjustment information.
Fuel Type:
Unleaded gasoline (specific octane rating detailed in manual).
Oil Type:
2-stroke oil (specific blend and ratio for premix or injection detailed in manual).
Cooling Method:
Liquid-cooled.
Coolant Type:
Ethylene glycol-based coolant (specific mixture ratio detailed in manual).
Transmission Type:
Polaris Variable Transmission (PVT) with automatic clutch and belt drive.
Gearbox Type:
Forward, Neutral, Reverse (often referred to as a gearbox or drive selector).
Clutch Type:
Centrifugal clutch (primary) and driver clutch (secondary).
Belt Drive Maintenance:
Detailed procedures for belt inspection, tension adjustment, and replacement.
Fluid Type:
Transmission/final drive fluid specifications (e.g., SAE 80W-90 gear oil, specific Polaris brand recommendations).
Overall Length:
Approx. 72-75 inches (typical for this class of ATV, specific figures in manual).
Overall Width:
Approx. 42-45 inches (typical, specific figures in manual).
Overall Height:
Approx. 40-43 inches (typical, specific figures in manual).
Dry Weight:
Approx. 450-500 lbs (specific figures in manual).
Payload Capacity:
Typically around 200-250 lbs for racks (specifics in manual).
Front Tire Size:
Typically 22x7-10 or similar (specifics in manual).
Rear Tire Size:
Typically 22x10-10 or similar (specifics in manual).
Wheel Bolt Pattern:
Typically 4/110 or 4/115 (specifics in manual).
Oil Change Interval:
Every 100 hours or annually (specifics in manual, depending on usage).
Air Filter Cleaning:
Regular inspection and cleaning, more frequently in dusty conditions (detailed schedule in manual).
Spark Plug Replacement:
As per manual recommendations, typically every 6-12 months or based on hours.
Engine Oil:
2-stroke oil for injection system or premix, specific type and ratio provided.
Transmission Fluid:
Refer to manual for specific SAE viscosity and type (e.g., SAE 80W-90 gear oil).
Brake Fluid:
DOT 3 or DOT 4 hydraulic brake fluid (specifics in manual).
Coolant Type:
Ethylene glycol-based, 50/50 mix with distilled water (specifics in manual).
Pvt Belt Wear:
Like all CVTs, belt wear is a normal maintenance item. The manual will detail inspection and replacement intervals.
Carburetor Fouling:
Can occur with poor fuel quality or extended storage. Manual provides cleaning and adjustment procedures.
Suspension Bushings:
Wear is possible over time; manual details inspection and replacement.
