Vehicle Segment:
Entry-level to mid-range All-Terrain Vehicle (ATV).
Target Audience:
Recreational riders, utility users, DIY enthusiasts seeking comprehensive repair information.
Key Competitors:
Honda FourTrax, Yamaha Kodiak, Suzuki KingQuad, Can-Am Outlander (in comparable engine displacements).
Manual Utility:
Enables owners and mechanics to maintain, diagnose, and repair their Sportsman 400 with factory-correct procedures.
Vehicle Value Proposition:
Offers robust performance and versatility for trail riding and light utility tasks at an accessible price point.
Engine Systems:
Engine assembly/disassembly, lubrication, cooling, fuel delivery, ignition, exhaust, starting, charging.
Drivetrain Systems:
Transmission (PVT - Polaris Variable Transmission), drive clutch, driven clutch, belt replacement, chain drive, differential, axles, CV joints.
Chassis Systems:
Frame, suspension (front and rear), steering system, wheel alignment, hubs, bearings.
Braking Systems:
Brake caliper overhaul, hydraulic lines, master cylinder, brake fluid specifications, bleeding procedures.
Electrical Systems:
Wiring diagrams, battery, lighting, starter motor, charging system (alternator/stator), ignition system components, troubleshooting electrical faults.
Body And Trim:
Body panel removal/installation, fenders, racks, seat, storage compartments.
Maintenance Procedures:
Oil changes, filter replacements, spark plug inspection/replacement, air filter cleaning/replacement, chain adjustment, lubrication points.
Diagnostic Procedures:
Troubleshooting guides for common performance issues, starting problems, and system malfunctions.
Repair Procedures:
Detailed step-by-step instructions for disassembly, inspection, repair, and reassembly of all major vehicle components.
Installation Procedures:
Guidance for installing new parts or rebuilding existing ones.
Depth Of Coverage:
Comprehensive, covering everything from basic maintenance to complete engine rebuilds and advanced diagnostics.
Engine Type:
4-Stroke, Liquid-Cooled, SOHC
Bore X Stroke:
80mm x 74mm
Compression Ratio:
10.0:1 (Typical for this era/engine type)
Horsepower Estimate:
Approximately 25-28 HP (Actual dyno figures may vary).
Torque Estimate:
Approximately 20-22 lb-ft (Actual dyno figures may vary).
Fuel Delivery:
Carbureted (Likely Mikuni BSR42 or similar).
Fuel Type:
Unleaded Gasoline, 87 Octane minimum.
Ignition System:
Electronic Ignition (CDI).
Cooling Method:
Liquid-Cooled.
Engine Oil Type:
SAE 10W-40, API SG or higher (Consult manual for exact specifications).
Engine Oil Capacity:
Approx. 2.1 quarts (2.0 Liters) with filter change (Consult manual for exact capacity).
Transmission Type:
Polaris Variable Transmission (PVT) with Engine Braking
Drive System:
Shaft Drive, On-Demand All-Wheel Drive (AWD).
Gear Selection:
High, Low, Neutral, Reverse, Park.
Clutch System:
Primary and Secondary CVT clutches with belt drive.
Transmission Fluid Type:
Polaris AGL Synthetic Gearcase Lubricant (or equivalent).
Gearcase Fluid Capacity:
Approx. 0.47 quarts (0.44 Liters) (Consult manual for exact capacity).
Length:
Approx. 81.2 inches (2063 mm).
Width:
Approx. 46 inches (1168 mm).
Height:
Approx. 47 inches (1194 mm).
Wheelbase:
Approx. 50.5 inches (1283 mm).
Dry Weight:
Approx. 575 lbs (261 kg).
Ground Clearance:
Approx. 10.25 inches (260 mm).
Front Rack Capacity:
75 lbs (34 kg).
Rear Rack Capacity:
150 lbs (68 kg).
Towing Capacity:
1225 lbs (556 kg).
Atv Safety Standards:
Compliant with ANSI standards for ATVs.
Braking System:
Hydraulic Disc Brakes (Front and Rear).
Lighting:
Dual Halogen Headlights, Tail Light, Brake Light.
Ergonomics:
Comfortable seating, intuitive controls, handguards (typical).
Oil Change Interval:
Typically every 3 months or 1,500 miles (or 50 hours of operation) – refer to manual for specifics.
Air Filter Cleaning:
Inspect frequently, clean or replace as needed based on operating conditions (e.g., dusty environments).
Spark Plug Check:
Inspect and gap at first 3 months/500 miles, then every 6 months/1,000 miles (or 100 hours).
Transmission Fluid Change:
Typically every 12 months or 3,000 miles (or 200 hours) – refer to manual for specifics.
Drive Belt Inspection:
Inspect regularly for wear and damage, replace as per manual recommendations (e.g., at 24 months or 1200 miles).
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:
Drive belts, ball joints, tie rod ends, wheel bearings, brake pads, and suspension bushings are common wear items on ATVs of this vintage.
Typical Maintenance Focus:
Proper drive belt maintenance and CVT cooling are crucial for longevity. Keeping the air intake and exhaust clean is also important.
Manufacturer Origin:
Polaris Industries, founded in 1954, is a leading American manufacturer of powersports vehicles.
Sportsman Lineage:
The Sportsman line has been a cornerstone of Polaris' ATV offerings, known for comfort, utility, and off-road capability. The 400 model often represented a balance of power and affordability.
Production Era:
The Sportsman 400 model was produced for several years, with the 2003 model representing a specific iteration within the broader Sportsman family.
