🏷️ Basic Information

Make:

Polaris

Model:

Sportsman

Variant:

300 / 400

Model Year:

2009

Engine Designation Es300Pfe:

Single, Air Cooled, SOHC 4 Stroke, Electric Start

Engine Designation Eh460Ple:

Single, Liquid Cooled, SOHC 4 Stroke, Electric Start

👋 Introduction

Vehicle Segment:

Mid-size All-Terrain Vehicle (ATV) / Utility Vehicle

Target Audience:

Recreational riders, hunters, trail enthusiasts, and utility users.

Competitors:

Yamaha Grizzly, Honda Foreman/Rancher, Can-Am Outlander, Suzuki KingQuad.

Atv Features:

Known for its robust chassis, comfortable rider ergonomics, and capable independent suspension. Offered in both 2WD and 4WD configurations, making it versatile for various terrains.

Value For Buyers:

Provides comprehensive, factory-accurate information crucial for maintaining and repairing the Polaris Sportsman 300/400, empowering owners to perform DIY maintenance, troubleshoot issues, and ensure longevity of their vehicle.

📋 Manual Details

Systems Covered:

Engine Mechanical, Fuel System, Ignition System, Cooling System (Liquid Cooled models), Electrical System, Transmission (CVT and AWD operation), Drivetrain (Axles, Drive Shafts, Differential), Braking System, Suspension System, Steering System, Chassis and Frame, Bodywork and Plastics, Maintenance Procedures, Troubleshooting and Diagnostics, Specifications, Torque Values, Wiring Diagrams, Component Removal and Installation.

Total Pages:

292

Type:

Official Factory Service / Repair / Workshop Manual

Language:

English

File Format:

PDF

Delivery Format:

Instant Download PDF

📖 Manual Coverage

Engine:

Comprehensive coverage including disassembly, inspection, repair, and reassembly of engine components (cylinder head, block, pistons, crankshaft, camshaft, valve train, oil pump, etc.). Includes detailed procedures for both ES300PFE (air-cooled) and EH460PLE (liquid-cooled) variants.

Fuel System:

Carburetor systems, fuel pump, fuel lines, fuel filter, and fuel tank maintenance and repair for applicable models.

Ignition System:

Ignition coil, spark plugs, CDI unit, wiring, and troubleshooting ignition issues.

Cooling System:

Specific to EH460PLE variant: radiator, fan, coolant hoses, water pump, thermostat, and coolant replacement procedures.

Drivetrain:

CVT (Continuously Variable Transmission) operation, belt inspection and replacement, clutch system, drive shafts, front and rear differential maintenance and repair, including AWD system operation.

Brakes:

Hydraulic brake system maintenance, including brake fluid replacement, caliper service, pad/shoe replacement, rotor inspection, and brake line bleeding.

Suspension Steering:

Front and rear suspension components (shocks, springs, bushings, ball joints), steering system (handlebar, tie rods, steering linkage), and alignment procedures.

Electrical:

Wiring diagrams, starter system, charging system (alternator), battery maintenance, lighting, switches, sensors, and electrical troubleshooting.

Chassis Body:

Frame inspection, body panel removal and installation, seat, fenders, racks, and trim components.

Routine Maintenance:

Oil changes, filter replacements, air filter cleaning/replacement, spark plug replacement, lubrication points, valve clearance checks, tire pressure checks, and general inspections.

Troubleshooting:

Detailed diagnostic procedures for common problems, including engine performance issues, electrical faults, starting problems, and drivetrain noises.

Repair Rebuild:

Step-by-step instructions for major component repairs and complete engine or transmission overhauls, including specific torque specifications and clearances.

Special Tools:

Identification and usage of specialized tools required for specific repair and maintenance procedures.

Depth:

Factory-level technical information, suitable for both professional technicians and experienced DIY mechanics. Covers everything from basic adjustments to complete engine rebuilds and electrical diagnostics.

📊 Manual Specifications

Compatibility:

PDF reader compatible with all modern operating systems (Windows, macOS, Linux) and mobile devices.

Printability:

Yes, pages are formatted for clear printing.

Zoom Functionality:

Yes, high-resolution PDF allows for easy zooming in on diagrams and text.

Binding:

N/A (Digital PDF Download)

Paper Type:

N/A (Digital PDF Download)

⚙️ Engine Specifications

Engine Type Es300Pfe:

Single-cylinder, SOHC, 4-stroke, air-cooled

Engine Type Eh460Ple:

Single-cylinder, SOHC, 4-stroke, liquid-cooled

Displacement Es300Pfe:

Approximately 299cc (specific bore/stroke not detailed in product info, but standard for this model range)

Displacement Eh460Ple:

Approximately 455cc (specific bore/stroke not detailed in product info, but standard for this model range)

Starter System:

Electric Start (standard)

Horsepower Estimate:

Varies by engine size (typically 15-25 HP for 300cc, 25-35 HP for 400cc class - exact figures not provided in product data).

Carburetor:

Specific carburetor models would be detailed in the manual, likely Mikuni or Keihin.

Fuel Type:

Unleaded gasoline

Oil Type Recommendation:

Likely SAE 10W-40 or 20W-50 motorcycle or ATV specific oil. Manual will provide exact specifications and viscosity grades.

Oil Capacity:

Capacity varies by engine and oil filter. Manual will specify exact quantities.

🔧 Transmission

Transmission Type:

Automatic CVT (Continuously Variable Transmission) with High/Low range and Reverse.

Drive System:

Shaft drive, available in 2WD and On-Demand AWD (All-Wheel Drive).

Cvtsystem Operation:

The manual details the operation of the belt-driven CVT, including clutch engagement, variator function, and drive system engagement.

Transmission Fluid:

Manual will specify required transmission fluid type and capacity, often a dedicated ATV transmission fluid or specific gear oil.

📐 Dimensions

Overall Length:

Dimensions vary slightly between 300 and 400 models, but typically around 81-83 inches. Exact figures will be in the manual.

Overall Width:

Dimensions vary slightly, typically around 46-48 inches. Exact figures will be in the manual.

Overall Height:

Dimensions vary slightly, typically around 47-49 inches. Exact figures will be in the manual.

Dry Weight:

Varies by model and configuration, typically in the range of 570-630 lbs. Exact figures will be in the manual.

Ground Clearance:

Typically around 10-11 inches. Exact figures will be in the manual.

Towing Capacity:

Typically rated around 1500 lbs. Exact figures will be in the manual.

Rack Capacity Front:

Typically rated around 50 lbs. Exact figures will be in the manual.

Rack Capacity Rear:

Typically rated around 100 lbs. Exact figures will be in the manual.

🛡️ Safety Features

Atv Safety Standards:

Adherence to ANSI/SVIA 1-2001 and other relevant ATV safety standards. Manual will likely contain safety warnings and recommendations.

Braking System:

Hydraulic disc brakes on all wheels provide strong stopping power. Manual details proper maintenance and inspection.

AWD Engagement:

On-Demand All-Wheel Drive system provides enhanced traction when needed. Manual explains its operation and limitations.

Ergonomics:

Designed for comfortable rider positioning and control. Manual includes guidance on proper riding techniques and safety gear.

💡 Technology Features

Instrument Cluster:

Basic digital instrument cluster likely including speedometer, odometer, trip meter, fuel gauge, and indicator lights. Detailed operation will be in the manual.

Ignition System Features:

Electronic ignition system for reliable starting and combustion. Manual covers ignition system diagnostics.

Wiring Harness:

Detailed wiring diagrams are included in the manual, crucial for diagnosing electrical faults and understanding system connectivity.

🔧 Maintenance

Oil Change Interval:

Typically every 100 hours or annually, whichever comes first. Exact interval specified in the manual.

Cvtbelt Inspection:

Regular inspection recommended, typically every 300-500 hours or annually. Manual details inspection criteria and replacement guidelines.

Valve Adjustment Interval:

Typically recommended at first service (e.g., 20 hours) and then every 100-200 hours. Manual will provide precise intervals and procedures.

Spark Plug Replacement:

Recommended at intervals like 100-200 hours, or as needed based on inspection. Manual will list specific spark plug part numbers and gap settings.

Coolant Type Eh460Ple:

Likely a 50/50 mix of ethylene glycol-based antifreeze and distilled water. Manual will specify exact coolant type and capacity.

Brake Fluid Type:

DOT 3 or DOT 4 hydraulic brake fluid. Manual will specify the exact type and bleeding procedure.

Cvtcavitation Prevention:

Manual will likely contain information on proper CVT maintenance to prevent excessive wear and ensure optimal operation, including belt tension and alignment checks.

Air Filter Maintenance:

Importance of keeping the air filter clean for engine performance and longevity, especially in dusty conditions. Manual details cleaning/replacement procedures.

📚 Vehicle History

Polaris Heritage:

Polaris Industries Inc. has a long history in powersports, known for innovation in snowmobiles and ATVs since its founding in 1954.

Sportsman Lineage:

The Sportsman line has been a cornerstone of Polaris' ATV offerings for decades, evolving to incorporate advanced technology and rider comfort features. The 300 and 400 models represent mid-range utility and recreational options within this popular series.

Model Year Focus:

This manual specifically covers the 2009 model year, a period where Polaris was refining its engine technologies and chassis designs.

🏆 Awards & Recognition

Atv Segment Awards:

While specific awards for the 2009 Sportsman 300/400 are not detailed in the product information, Polaris ATVs consistently receive accolades for performance, reliability, and utility in industry reviews and consumer surveys.