🏷️ Basic Information

Make:

Polaris

Model:

Sportsman 300 / Sportsman 400 HO

Model Year Range:

2009-2010

Product Type:

Service Repair Workshop Manual

Manual Identifier:

Likely includes specific Polaris OEM manual numbers, but not explicitly stated in product info.

👋 Introduction

Vehicle Segment:

Entry-to-mid level All-Terrain Vehicle (ATV)

Target Audience:

Recreational riders, utility users, and farm work.

Key Competitors:

Honda Rancher, Yamaha Grizzly 350, Suzuki King Quad 300, Can-Am Outlander 400.

Engine Variants:

Offers both 300cc and 400cc HO (High Output) engine options, providing a tiered performance choice.

Suspension Type:

Independent front and rear suspension for improved ride comfort and handling over varied terrain.

Drive System:

Available in 2WD and AWD (On-Demand All-Wheel Drive) configurations, enhancing traction.

Manual Value Proposition:

Provides factory-level repair information, enabling owners and independent shops to perform accurate and efficient maintenance and repairs.

📋 Manual Details

Coverage Scope:

All models and all repairs A-Z for 2009-2010 Sportsman 300 and Sportsman 400 HO.

Estimated Page Count:

Typically 300-600 pages for this type of comprehensive manual, but not explicitly stated.

Manual Classification:

Workshop Repair Manual

Language:

English

Delivery Format:

PDF Download

📖 Manual Coverage

Engine Mechanical:

Complete engine disassembly, inspection, repair, and reassembly procedures for all variants.

Fuel System:

Carburetor (if applicable) or EFI system diagnosis, repair, and adjustment; fuel pump, lines, and tank maintenance.

Ignition System:

Ignition timing, spark plugs, CDI unit, stator, and troubleshooting.

Cooling System:

Radiator, fan, coolant hoses, thermostat, and coolant specifications/replacement.

Exhaust System:

Muffler, head pipe, and catalytic converter (if equipped) inspection and replacement.

Transmission Drivetrain:

Automatic transmission (PVT - Polaris Variable Transmission) operation, maintenance, clutch adjustment, and belt replacement.

Drivetrain Components:

Axles, CV joints, drive shafts, differential inspection, and repair.

Suspension Steering:

Front and rear suspension geometry, shock absorbers, bushings, ball joints, tie rods, and steering linkage.

Braking System:

Hydraulic brake system diagnosis, caliper repair, brake line replacement, master cylinder service, and pad/shoe specifications.

Electrical System:

Wiring diagrams, battery maintenance, charging system (alternator/stator), lighting, starter motor, and accessory circuits.

Frame Chassis:

Frame inspection, straightening (if applicable), and body panel removal/installation.

Bodywork Plastics:

Fender, rack, and body panel removal, installation, and repair.

Maintenance Procedures:

Regular scheduled maintenance, lubrication points, and component replacement intervals.

Troubleshooting:

Diagnostic flowcharts and common issue identification for all major systems.

Engine Overhaul:

Detailed steps for complete engine rebuilds, including piston, ring, cylinder, valve train, and crankshaft service.

Transmission Rebuild:

Instructions for PVT system disassembly, clutch component servicing, and reassembly.

Suspension Alignment:

Wheel alignment procedures, camber, caster, and toe adjustments.

Electrical Diagnostics:

Using multimeters, wiring diagrams, and diagnostic tools to identify and resolve electrical faults.

Brake Bleeding:

Proper procedures for bleeding hydraulic brake systems.

Belt Replacement:

Step-by-step guide for replacing the drive belt on the PVT system.

Tire Wheel Service:

Tire mounting, balancing, and wheel installation.

Depth Of Information:

Comprehensive, covering basic maintenance to complex repairs and diagnostics, suitable for dealership technicians.

Diagnostic Capabilities:

Includes diagnostic trouble codes (DTCs) and troubleshooting flowcharts for EFI systems and other electronic components.

Torque Specifications:

Detailed torque values for all critical fasteners and components.

Special Tools:

Lists and descriptions of any specialized tools required for specific repair procedures.

📊 Manual Specifications

File Type:

PDF

Searchability:

Likely text-searchable PDF, allowing for quick keyword lookup.

Printability:

Designed to be printable for physical use in a workshop environment.

Binding Format:

N/A (Digital PDF download)

Paper Recommendation:

N/A (Digital PDF download) - Recommended for printing on durable paper for workshop use.

⚙️ Engine Specifications

Engine Type:

4-stroke, liquid-cooled, SOHC

Displacement 300:

Approximately 270-290cc (exact figure varies by specific sub-model, but generally around the 300cc class).

Displacement 400 Ho:

Approximately 375-400cc (exact figure varies by specific sub-model, but generally around the 400cc class).

Horsepower 300:

Estimated 17-20 HP (figure not explicitly stated in product info, typical for class).

Horsepower 400 Ho:

Estimated 25-28 HP (figure not explicitly stated in product info, typical for class).

Torque 400 Ho:

Estimated 28-30 lb-ft (figure not explicitly stated in product info, typical for class).

Fuel Delivery 300:

Likely carburetor (e.g., Mikuni BS32).

Fuel Delivery 400 Ho:

Likely Electronic Fuel Injection (EFI).

Fuel Type:

Unleaded gasoline, 87 octane minimum.

Cooling Method:

Liquid-cooled

🔧 Transmission

Transmission Type:

Polaris Variable Transmission (PVT) - Automatic

Gear Selection:

High (H), Low (L), Neutral (N), Reverse (R), Park (P).

Drive Modes:

2WD/AWD selector (On-Demand All-Wheel Drive).

Engine Braking:

Integrated engine braking via PVT system for downhill control.

Transmission Fluid Type:

Polaris Synthetic 2-Cycle Oil (for clutch, not engine) or specified PVT fluid. Manual will detail exact specifications.

📐 Dimensions

Length Approx:

81-83 inches (varies slightly by model year/trim)

Width Approx:

46-48 inches (varies slightly by model year/trim)

Height Approx:

47-49 inches (varies slightly by model year/trim)

Dry Weight Approx 300:

550-580 lbs

Dry Weight Approx 400 Ho:

580-610 lbs

Towing Capacity:

1500 lbs (check specific model for confirmation)

Rack Capacity Front:

75 lbs

Rack Capacity Rear:

150 lbs

Front Tire Size:

25x8-12 (common size)

Rear Tire Size:

25x10-12 (common size)

Wheel Bolt Pattern:

4/110

🛡️ Safety Features

Atv Safety Classification:

Classified as an All-Terrain Vehicle (ATV). Follow manufacturer safety guidelines and wear appropriate protective gear.

Braking System:

Hydraulic disc brakes front and rear.

Lighting:

Dual headlights, taillight, and brake light.

Rollover Protection:

ATVs do not typically have integrated ROPS. Riders must exercise caution.

Manual Emphasis:

Manual will contain critical safety warnings, operating procedures, and maintenance requirements.

💡 Technology Features

Infotainment System:

Basic ATV instrumentation: speedometer, odometer, trip meter, high beam indicator, neutral indicator, AWD indicator.

AWD System:

On-Demand All-Wheel Drive (AWD) automatically engages front wheels when rear wheels lose traction.

Charging System:

12V DC electrical system with battery charging via stator.

Lighting System:

Dual headlights and a single rear brake/taillight.

🔧 Maintenance

Oil Change Interval Engine:

Typically every 100 hours or annually, whichever comes first. Manual will provide exact interval.

Air Filter Inspection:

Inspect every 25 hours, clean/replace as needed. More frequent in dusty conditions.

Spark Plug Replacement:

Refer to manual for recommended interval, typically based on hours or mileage.

Pvt Belt Inspection:

Inspect at 50 hours, replace based on wear. Crucial for performance and preventing damage.

Lubrication:

Regular greasing of suspension, steering components, and linkage points as per the manual's schedule.

Engine Oil Type:

Polaris PS-4 Full Synthetic 5W-50 (or equivalent as specified in manual).

Engine Oil Capacity:

Approximately 1.5 - 2.0 quarts (refer to manual for exact capacity).

Coolant Type:

Ethylene glycol-based antifreeze, 50/50 mix with distilled water.

Brake Fluid Type:

DOT 3 or DOT 4 hydraulic brake fluid.

Common Wear Items:

PVT belt wear, suspension bushings, ball joints, and tie rod ends are common wear items requiring periodic inspection and replacement.

Efi Issues:

Potential for clogged fuel injectors or sensor issues on EFI models if fuel quality is poor or maintenance is neglected.

Cooling System Performance:

Overheating can occur with low coolant levels or a malfunctioning fan/radiator.

📚 Vehicle History

Polaris Atv History:

Polaris has a long-standing reputation for producing ATVs, with the Sportsman line being a cornerstone of their off-road vehicle offerings since the early 1990s.

Sportsman Line:

The Sportsman line has evolved significantly, offering various engine sizes and features. The 300 and 400 HO models represent a segment focused on a balance of capability and accessibility.

Manufacturing Location:

Polaris vehicles are primarily manufactured in the United States.

🏆 Awards & Recognition

Model Specific Awards:

Specific awards for the 2009-2010 Sportsman 300/400 HO are not widely documented as distinct accolades, but the Sportsman line itself has consistently received positive reviews for its utility and recreational capabilities.

Industry Perception:

Polaris Sportsman models are generally regarded as reliable and capable ATVs for their class.