Polaris Sportsman 400 1997 Factory Service Repair Manual

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类型: Atv

斯库: 54144

标签: 1997 Atv Indy Models Polaris Powersports Snowmobiles Sportsman 400

产品多属性

Description

The 1997 Sportsman 400 is a capable all-terrain vehicle renowned for its reliability and robust all-wheel-drive system. Designed for both recreational riders and utility users, this model offers a comfortable ride and solid performance for its era, distinguishing itself through independent rear suspension and dependable operation. With a 376cc liquid-cooled engine and a versatile Automatic Variable Transmission, the Sportsman 400 was engineered to handle a variety of terrains and tasks. This factory service repair manual provides comprehensive guidance for the complete service, repair, and maintenance of the 1997 Sportsman 400. It covers all major systems, including detailed procedures for engine, transmission, drivetrain, suspension, brakes, steering, and electrical systems. The manual also includes essential information on scheduled maintenance, troubleshooting common issues, diagnostic charts, and technical specifications, serving as an indispensable resource for owners and technicians seeking to ensure optimal performance and longevity of their vehicle.

🏷️ Basic Information

Identification

Make:

Polaris

Model:

Sportsman 400

Year:

Codes

Chassis Code:

👋 Introduction

Market Position

Category:

All-Terrain Vehicle (ATV)

Target Audience:

Recreational riders, utility users, mechanics

Competitive Analysis

Competitors 1997:

Honda FourTrax, Yamaha Kodiak, Kawasaki Bayou

Key Features

Vehicle Strengths:

Reliability, capable AWD system, comfortable ride for its era

Manual Value Proposition:

Essential resource for maintaining and repairing the 1997 Sportsman 400, saving time and money on repairs.

📋 Manual Details

Coverage Areas

Primary Coverage:

Complete service, repair, and maintenance

Secondary Coverage:

Troubleshooting, diagnostics, adjustments, overhauls

Page Count

Estimated Pages:

Manual Type

Type:

Factory Service Repair Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine:

Complete engine disassembly, assembly, and overhaul (carburetor, ignition, cooling, lubrication)

Transmission:

Automatic transmission (PVT - Polaris Variable Transmission) service, clutch inspection, belt replacement

Drivetrain:

All-wheel drive (AWD) system, front and rear differential service, driveshaft maintenance

Suspension:

Front and rear suspension system, shock absorber service, control arm and bushing replacement

Brakes:

Hydraulic brake system, caliper service, brake pad replacement, bleeding procedures

Steering:

Steering column, tie rod ends, steering mechanism inspection and repair

Electrical:

Wiring diagrams, battery maintenance, charging system (stator, regulator/rectifier), lighting, starter system, ignition system diagnostics

Fuel System:

Fuel tank, fuel lines, fuel pump, carburetor service and adjustment

Cooling System:

Radiator service, coolant replacement, fan operation

Bodywork:

Body panel removal and installation, fender and rack components

Procedures Included

Maintenance:

Scheduled maintenance, oil changes, filter replacements, lubrication points

Troubleshooting:

Diagnostic charts for common problems, symptom-based troubleshooting guides

Repair:

Detailed step-by-step repair instructions for all major components

Disassembly Assembly:

Comprehensive instructions for complete teardown and reassembly of vehicle systems

Adjustments:

Carburetor adjustments, valve clearance adjustments (if applicable), brake adjustments

Technical Depth

Depth:

Full mechanical and electrical system coverage, suitable for professional mechanics and advanced DIYers

📊 Manual Specifications

File Format

File Type:

Searchability:

Searchable text content for quick information retrieval

Print Quality

Quality:

High-resolution scans of original factory documentation

Binding Type

Binding:

N/A (Digital Download)

Paper Type

Paper:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Type:

4-stroke, single-cylinder

Displacement:

376cc (23.0 cu. in.)

Bore X Stroke:

80 mm x 74 mm (3.15 in x 2.91 in)

Cooling System:

Liquid-cooled

Ignition System:

CDI (Capacitor Discharge Ignition)

Starting System:

Electric start with manual recoil backup

Performance

Horsepower:

Approx. 25-30 HP (estimated, actual varies)

Torque:

N/A (specific figures not readily available for this model year)

Fuel System

Carburetor:

Mikuni VM34SS (or similar) single barrel carburetor

Fuel Type:

Unleaded gasoline, 87 octane minimum

Fuel Capacity:

3.2 US gallons (12.1 L)

🔧 Transmission

Standard

Type:

Polaris Automatic Variable Transmission (PVT) with automatic engine braking

Drive Modes:

2WD / 4WD selectable

Features

Clutch Type:

CVT (Continuously Variable Transmission) with belt drive

Transmission Fluid Spec:

Polaris LUBRICANT, Transmission - 2870444 (or equivalent API GL-4, SAE 75W-90 gear oil)

📐 Dimensions

Exterior

Length:

81 inches (2057 mm)

Width:

45 inches (1143 mm)

Height:

47 inches (1194 mm)

Wheelbase:

50 inches (1270 mm)

Ground Clearance:

10.5 inches (267 mm)

Weights

Dry Weight:

538 lbs (244 kg)

Towing Capacity:

1500 lbs (680 kg)

Rack Capacity Front:

100 lbs (45 kg)

Rack Capacity Rear:

200 lbs (90 kg)

🛡️ Safety Features

Ratings

Rollover Protection:

N/A (ATV, requires rider awareness)

Active Features

Braking System:

Hydraulic disc brakes front and rear

Passive Features

Lighting:

Dual headlights, taillight/brake light

💡 Technology Features

Infotainment

Features:

N/A (Basic utility ATV, no infotainment system)

Driver Assistance

Features:

N/A (Basic utility ATV, no electronic driver aids)

Connectivity

Features:

🔧 Maintenance

Service Intervals

Engine Oil Change:

Every 100 hours or annually (whichever comes first)

Air Filter Cleaning Or Replacement:

Every 50 hours or as needed based on conditions

Spark Plug Check And Gap:

Every 100 hours

Transmission Fluid Change:

Every 200 hours or annually

Belt Inspection:

Every 100 hours or annually

Fluid Specifications

Engine Oil Type:

Polaris Premium 4 Synthetic 0W-40 (or equivalent JASO MA approved 4-stroke motorcycle oil)

Engine Oil Capacity:

2.1 US quarts (2.0 L) with filter change

Coolant Type:

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

Brake Fluid Type:

DOT 3 or DOT 4 hydraulic brake fluid

Known Issues

Common Wear Items:

CVT belt wear, wheel bearing longevity, carburetor jetting sensitivity to altitude/fuel quality.

Electrical Gremlins:

Fraying wiring harnesses in high-flex areas, occasional issues with rectifier/stator.

📚 Vehicle History

Brand Heritage

Company Origin:

Polaris Industries Inc. founded in 1954, Roseau, Minnesota.

Model Evolution

Sportsman Line Introduction:

The Sportsman line was introduced in 1993, becoming a cornerstone of Polaris' ATV offerings.

1997 Model Year Significance:

The 1997 Sportsman 400 was a popular mid-size utility ATV, known for its independent rear suspension and AWD capabilities.

Production

Manufacturing Location:

Primarily USA

🏆 Awards & Recognition

Recognitions

Atv Of The Year:

N/A specific awards for the '97 400, but Polaris Sportsman line consistently received praise for innovation and utility.

Ratings

Consumer Reviews:

Generally positive for its utility and performance for the price point at the time of release.