Category:
All-Terrain Vehicle (ATV)
Target User:
Recreational riders, utility users, DIY mechanics
Competitors:
Honda Foreman, Yamaha Big Bear, Suzuki King Quad, Arctic Cat 400
Vehicle Features:
400cc engine, shaft drive, independent rear suspension (IRS), selectable 2WD/4WD, rack capacity
Purpose:
Empower owners and technicians to perform accurate repairs and maintenance, reducing downtime and costs.
Primary Coverage:
All mechanical and electrical systems of the 2001 Polaris Sportsman 400
Secondary Coverage:
Diagnostic procedures, troubleshooting, specifications, routine maintenance
Estimated Pages:
Approximately 300-400 pages (typical for comprehensive factory manuals)
Type:
Factory Service Manual
Powertrain:
Engine, transmission, drivetrain (AWD system), drive shafts, differentials
Chassis And Suspension:
Frame, front and rear suspension, steering system, shocks, A-arms
Brakes:
Hydraulic brake system (front and rear), brake calipers, master cylinders, lines
Electrical System:
Battery, charging system (stator, regulator/rectifier), ignition system, lighting, starting system, sensors, ECU
Fuel And Exhaust:
Fuel tank, fuel pump, fuel lines, carburetor (likely Mikuni BSR42), exhaust system
Body And Trim:
Body panels, fenders, seat, racks, handle grips, controls
Maintenance:
Oil changes, filter replacements, spark plug checks, air filter cleaning, lubrication points, valve adjustments
Repair And Overhaul:
Engine disassembly and reassembly, transmission service, suspension component replacement, brake system bleeding and repair
Troubleshooting:
Diagnostic flowcharts, common problem identification, symptom-based troubleshooting
Installation And Removal:
Component removal and installation procedures for all major systems
Depth:
Comprehensive, covering routine maintenance, diagnostic procedures, and complete unit overhauls
Detail Level:
Step-by-step instructions, torque specifications, timing information, wiring diagrams, exploded views
Engine Type:
4-stroke, liquid-cooled, SOHC
Bore X Stroke:
83mm x 71.5mm
Horsepower:
Approximately 24 HP (estimated at peak)
Torque:
Approximately 23 lb-ft (estimated at peak)
Fuel Type:
Unleaded gasoline, 87 octane minimum
Oil Type Specification:
SAE 10W-40, API SG or higher (refer to manual for exact)
Ignition System:
Electronic Ignition (CDI)
Transmission Type:
Automatic (CVT - Continuously Variable Transmission)
Drive System:
Shaft drive, On-Demand All-Wheel Drive (AWD)
Gear Selection:
High, Low, Neutral, Reverse
Clutch Type:
Drive and driven clutches (CVT)
Cvt Fluid:
Polaris Variable Transmission Fluid (PVT) or equivalent (refer to manual for specific part number/type)
Atv Safety Standards:
Adheres to ANSI/SVIA standards
Braking System:
Hydraulic disc brakes (front and rear) with parking brake
Lighting:
Halogen headlights, taillight/brake light
Frame Construction:
Durable steel frame
Operator Safety:
Handlebar controls, footwells with heel guards, throttle limiter screw (factory adjustable)
Features:
Basic analog gauges (speedometer, odometer, fuel level, temperature), basic indicator lights
Features:
On-Demand AWD system provides enhanced traction
Features:
N/A (No advanced electronic connectivity features typical of modern ATVs)
Engine Oil Change:
Every 100 hours or 6 months, whichever comes first (refer to manual for exact)
Air Filter Cleaning:
Every 25 hours or as needed based on conditions (refer to manual)
Spark Plug Inspection:
Every 100 hours or annually
Cvtv Belt Inspection:
Every 100 hours or annually for wear and tension
Engine Oil Capacity:
Approximately 2.0 quarts (1.9 liters) with filter change
Coolant Type:
Ethylene glycol-based antifreeze/coolant (50/50 mix with distilled water)
Brake Fluid:
DOT 3 or DOT 4 hydraulic brake fluid
Common Wear Items:
CVT belt, wheel bearings, tie rod ends, brake pads
Potential Maintenance Concerns:
Proper CVT cooling and belt maintenance are crucial; timely lubrication of suspension and driveline components
Manufacturer:
Polaris Industries Inc.
Brand Focus:
Powersports vehicles, including ATVs, snowmobiles, and motorcycles
Sportsman Lineup:
The Sportsman line is Polaris's flagship ATV series, known for utility and comfort.
400 Cc Segment:
The 400cc class was a popular entry-level to mid-range offering, balancing power and maneuverability.
Manufacturing Location:
Primarily manufactured in the USA by Polaris
Brand Awards:
Polaris consistently receives recognition for its ATV innovation and market leadership.
Consumer Reviews:
Generally well-regarded for its utility, reliability, and capability for its class and time period.
Industry Certifications:
CE marking for European markets, EPA compliance for emissions.
