This manual covers the Polaris Sportsman 400 4x4, a mid-size utility all-terrain vehicle produced for the 1994 and 1995 model years. Known for its capable four-wheel-drive system and robust performance, the Sportsman 400 was a significant model in Polaris's expanding ATV lineup. It offered a blend of utility and durability, competing effectively in its segment. The vehicle is powered by a liquid-cooled, 2-stroke engine, featuring a Variable Transmission with high/low range and reverse, and a shaft-driven 4x4 system. This comprehensive service repair workshop manual provides essential technical information for owners and technicians. It details maintenance procedures, troubleshooting guides, technical specifications, and safety guidelines necessary for the upkeep and repair of the Polaris Sportsman 400 4x4. Coverage includes engine overhaul, fuel and cooling systems, transmission and drivetrain, suspension, brakes, electrical systems, and chassis components. By following the step-by-step instructions and torque specifications within this manual, users can ensure the longevity and optimal performance of their vehicle. 🏷️ Basic Information Identification Make: Polaris Model: Sportsman 400 Model Variant: 4x4 Generation Generation Code: This generation covers the 1994-1995 model years. 👋 Introduction Market Position Segment: Mid-size utility ATV, known for its capable 4x4 system. Competitive Analysis Competitors: Competed with other utility ATVs from brands like Yamaha (Grizzly), Honda (FourTrax), and Suzuki (King Quad) in its era. Key Features Features Highlight: Polaris's 400 4x4 was a significant player in the burgeoning ATV market, offering a reliable 4-wheel drive system and robust performance for its class. Manual Value Proposition: Provides essential technical information for owners and technicians to maintain and repair the Polaris 400 4x4, ensuring longevity and optimal performance. 📋 Manual Details Coverage Areas Model Years Covered: 1994, 1995 Geographical Coverage: North America (assumed, typical for Polaris ATVs of this era) Page Count Estimated Page Count: Approximately 300-500 pages (typical for a comprehensive service manual) Manual Type Type: Service Repair Workshop Manual Language Language: English Format Format: Downloadable PDF 📖 Manual Coverage Systems Covered Engine Overhaul: Complete engine disassembly, inspection, repair, and reassembly procedures for the 2-stroke engine. Fuel System: Carburetor tuning, cleaning, and rebuilding; fuel pump and lines inspection and replacement. Cooling System: Radiator, fan, hoses, and thermostat inspection and replacement. Transmission And Drivetrain: Detailed procedures for the Polaris Variable Transmission (PVT), gearcases, drive shafts, and final drive components. Suspension: Front and rear suspension component inspection, adjustment, and replacement (shocks, A-arms, bushings). Brakes: Hydraulic brake system service, including master cylinders, calipers, brake pads, rotors, and fluid bleeding. Electrical System: Wiring diagrams, component testing (starter, alternator/stator, ignition, lighting), battery maintenance, and troubleshooting. Steering: Steering column, tie rods, and linkage inspection and replacement. Bodywork And Chassis: Frame inspection, plastic body panel removal and installation, seat, and rack components. Procedures Included Preventative Maintenance: Recommended service intervals for fluid changes, filter replacements, lubrication, and general inspections. Troubleshooting Guides: Systematic diagnostic charts and common problem identification for various issues. Component Replacement: Step-by-step instructions for replacing major and minor components. Adjustments: Carburetor idle speed, throttle cable, brake cables, and clutch adjustments. Torque Specifications: Crucial torque values for engine, drivetrain, suspension, and chassis fasteners. Technical Depth Depth Of Coverage: Comprehensive, covering routine maintenance to complete engine and transmission rebuilds. Diagnostic Capabilities: Advanced diagnostic procedures and troubleshooting for electrical and mechanical systems. 📊 Manual Specifications File Format File Type: PDF Searchability: Likely text-searchable for efficient information retrieval. Print Quality Print Readability: Designed for clarity, suitable for printing on standard printers. Binding Type Binding: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: 2-stroke, single-cylinder Displacement: 375 cc (approximate, specific model variant might have slight variations) Bore X Stroke: Technical specification will be detailed in the manual. Cooling System: Liquid-cooled Ignition System: CDI (Capacitor Discharge Ignition) Performance Horsepower: Approximately 26-30 hp (specific figure dependent on exact tuning and model year). Torque: Technical specification will be detailed in the manual. Fuel System Carburetor Type: Mikuni VM34 or similar (specific model dependent, detailed in manual). Fuel Type: Unleaded gasoline Oil System Oil Type: 2-stroke oil injection (likely, or pre-mix, manual will specify) Maintenance Spark Plug Type: NGK BR9ES or equivalent (to be confirmed in manual). Valve Clearance: N/A (2-stroke engine) 🔧 Transmission Standard Transmission Type: Automatic, Polaris Variable Transmission (PVT) with High/Low range and Reverse. Drive System: Shaft drive, 4-wheel drive (selectable or full-time 4x4). Optional Optional Transmission: N/A for this model and year. Features Clutch Type: Centrifugal clutch (part of PVT system). Fluid Specifications Transmission Fluid Type: Specific ATV/UTV transmission fluid (e.g., Polaris brand or equivalent, manual will specify exact type and viscosity). Maintenance Fluid Capacity Transmission: Capacity will be detailed in the manual. 📐 Dimensions Exterior Length: Approx. 80-82 inches (specific to model, detailed in manual). Width: Approx. 42-44 inches (specific to model, detailed in manual). Height: Approx. 46-48 inches (specific to model, detailed in manual). Wheelbase: Approx. 50-52 inches (specific to model, detailed...