Segment:
Recreational All-Terrain Vehicle (ATV).
Competitors:
Competed against models from Honda (FourTrax), Yamaha (Grizzly), Suzuki (KingQuad), and Kawasaki (Bayou) during its production run.
Atv Focus:
Known for its capable off-road performance, versatility for trail riding and utility tasks, and Polaris's characteristic Polaris Variable Transmission (PVT).
Target User:
ATV owners and mechanics seeking to perform repairs, maintenance, and restoration on the Polaris Sportsman 400.
Primary Coverage:
Comprehensive service, repair, and maintenance for the Polaris Sportsman 400 ATV.
Specific Systems:
Engine, Fuel System, Body, Suspension, Clutch, Transmission, Final Drive, Brakes, Electrical, International components.
Type:
Factory Service Repair Manual
Primary Language:
English
Digital Format:
PDF Download
Engine Systems:
Engine overhaul, cylinder head, piston, crankshaft, connecting rod, timing, lubrication system, cooling system (if applicable to specific models within the range), starting system.
Fuel System:
Carburetor adjustment and overhaul, fuel pump, fuel lines, fuel tank maintenance, air filter service.
Drivetrain:
Clutch operation and service (drive clutch, driven clutch), CVT (Continuously Variable Transmission) maintenance and repair, gearbox overhaul, final drive unit inspection and repair, driveshafts, U-joints.
Suspension Steering:
Front and rear suspension components, shock absorbers, control arms, bushings, steering system, tie rods, wheel alignment.
Braking System:
Hydraulic brake system, brake calipers, master cylinder, brake lines, brake pads, brake discs, parking brake system.
Electrical System:
Ignition system, battery maintenance, charging system (stator, voltage regulator), starter motor, lighting system, wiring diagrams, diagnostic procedures for electrical faults.
Body Chassis:
Body panel removal and installation, seat service, fender maintenance, frame inspection, plastics repair.
Maintenance Procedures:
Scheduled maintenance, lubrication points, fluid changes, filter replacement, spark plug service, valve clearance adjustment, battery care.
Diagnostic Procedures:
Troubleshooting guides for common problems, diagnostic flowcharts, symptom-based repair guidance.
Repair Procedures:
Step-by-step instructions for component disassembly, inspection, repair, and reassembly.
Rebuild Refurbish:
Detailed instructions for engine rebuilds, transmission overhauls, and component refurbishment.
Depth:
Comprehensive from basic maintenance to advanced engine and transmission rebuilds. Includes detailed illustrations and diagnostic information.
Engine Type:
Likely a 2-stroke engine for earlier models, potentially transitioning to 4-stroke variants within this range, though the '400' designation often implies a displacement around 400cc.
Displacement:
Approximately 375cc to 400cc (specific displacement may vary slightly by year and specific model variant within the Sportsman 400 line).
Horsepower Estimated:
Estimated 25-35 HP (typical for this class and era of 400cc ATVs, exact figures vary).
Torque Estimated:
Estimated 20-28 lb-ft (typical for this class and era).
Carburetion:
Likely a Mikuni carburetor (e.g., VM34 or similar) for fuel delivery.
Fuel Type:
Unleaded gasoline.
Cooling Method:
Liquid-cooled (common for this engine size and performance focus).
Transmission Type:
Polaris Variable Transmission (PVT) automatic with High/Low range and Reverse.
Gearbox Options:
N/A (PVT is the standard and sole transmission type for this model).
Clutch System:
Automatic belt-driven CVT with centrifugal drive clutch and spring-loaded driven clutch.
Final Drive:
Shaft drive to rear axle and front axle (for 4x4 models). Likely enclosed, oil-lubricated driveshafts.
Length:
Approx. 80-84 inches (varies slightly by year).
Width:
Approx. 46-48 inches (varies slightly by year).
Height:
Approx. 47-50 inches (varies slightly by year).
Dry Weight:
Approx. 550-600 lbs (varies by 2WD/4WD configuration and specific year).
Towing Capacity:
Typically around 1500 lbs.
Rack Capacity Front:
Approx. 50 lbs.
Rack Capacity Rear:
Approx. 100 lbs.
Oil Change Engine:
Typically every 100 hours or annually. Specific interval may vary; consult manual for precise details.
Gearbox Oil Change:
Typically every 200 hours or annually. Consult manual for precise details.
Air Filter Cleaning:
Regular inspection, cleaning frequency dependent on operating conditions (e.g., dusty environments require more frequent cleaning).
Engine Oil Type:
SAE 10W-40 or 20W-50 motorcycle or ATV specific oil, API SG or higher. Consult manual for exact viscosity and API rating.
Gearbox Oil Type:
API GL-4 or GL-5 gear oil, SAE 80W-90. Consult manual for exact specifications.
Coolant Type:
Ethylene glycol-based antifreeze, 50/50 mixture with distilled water. Consult manual for specific type.
Brake Fluid Type:
DOT 3 or DOT 4 hydraulic brake fluid. Consult manual for exact specification.
Common Wear Items:
Drive belt wear on the CVT, suspension bushings, wheel bearings, and starter solenoid can be common wear items.
Carburetor Tuning:
Carburetor may require periodic cleaning and adjustment, especially if the ATV has been stored for extended periods or used with stale fuel.
Cooling System Maintenance:
Regular checks of coolant level and condition, radiator and hoses for leaks or blockages are important for preventing overheating.
Polaris Heritage:
Polaris Industries is a long-standing American manufacturer of powersports vehicles, known for its innovation in snowmobiles and ATVs.
Sportsman Lineage:
The Sportsman line is Polaris's flagship ATV series, emphasizing comfort, independent suspension, and rider-friendly features. The 400 model served as a popular mid-size offering.
Manufacturing Location:
Primarily manufactured in the USA by Polaris Industries.
