This manual covers the ATV Sport 400, manufactured for the model years 1996, 1997, and 1998. Designed as a performance-oriented sport ATV, the Sport 400 emphasizes agility, speed, and maneuverability, making it suitable for recreational riders, trail enthusiasts, and sporting competitors. Engineered with a two-stroke, liquid-cooled 377cc engine, it offers a robust power output for its class, complemented by a 5-speed manual transmission with an automatic clutch and a 2WD drive system. The vehicle's construction, originating from USA facilities, reflects a commitment to off-road capability and dynamic riding experiences. This comprehensive factory service repair manual provides in-depth technical guidance for maintaining and repairing the ATV Sport 400. It covers all essential systems, including detailed procedures for engine overhaul, transmission service, chassis, suspension, steering, braking, electrical, and fuel systems. Owners and technicians will find step-by-step instructions for maintenance tasks, component disassembly and reassembly, troubleshooting guides, and critical technical specifications such as torque values and fluid requirements. The manual's scope ensures that users can effectively diagnose issues, perform routine maintenance, and execute complex repairs, ensuring the optimal performance and longevity of the vehicle. 🏷️ Basic Information Identification Make: Polaris Model: ATV Sport 400 Model Years: 1996, 1997, 1998 Product Type: Workshop Service Repair Manual 👋 Introduction Market Position Vehicle Segment: Sport ATV Target Audience: Recreational riders, trail enthusiasts, sporting competitors Competitive Analysis Key Competitors: Yamaha Warrior, Suzuki Quadsport, Kawasaki Mojave (during the period) Key Features Performance Orientation: Designed for agility, speed, and maneuverability on varied terrain Manual Value Proposition: Provides in-depth technical guidance for owners and mechanics to maintain and repair the Sport 400 efficiently and effectively. 📋 Manual Details Coverage Areas Manual Coverage Scope: Complete official full factory service repair manual Page Count Estimated Page Count: Hundreds of pages Manual Type Manual Classification: Service Manual Language Manual Language: English Format Delivery Format: PDF Download 📖 Manual Coverage Systems Covered Engine Service: Engine overhaul, cylinder head, piston, crankshaft, connecting rods, lubrication system, cooling system, intake and exhaust systems Transmission Service: Gearbox, clutch, drive shafts, differential, lubrication Chassis Suspension Steering: Front and rear suspension, shock absorbers, steering linkage, steering column, hub carriers Braking System: Hydraulic system, brake calipers, brake discs, brake pads, master cylinder, bleeding procedures Electrical System: Ignition system, charging system, starting system, lighting, wiring diagrams, fuses, relays, battery Fuel System: Carburetor service and adjustment, fuel pump, fuel lines, fuel tank Body Frame Bodywork: Frame inspection and repair, body panels, fenders, seat, handlebars, controls Procedures Included Maintenance Procedures: Oil changes, filter replacements, spark plug service, chain adjustment, brake adjustments, lubrication points Troubleshooting Guide: Diagnostic charts, symptom-based troubleshooting for engine, electrical, and mechanical issues Repair Procedures: Step-by-step instructions for component removal, disassembly, repair, and reassembly Component Disassembly Reassembly: Detailed guides for all major components Torque Specifications: Essential torque values for critical fasteners across all systems Technical Depth Diagnostic Capabilities: Comprehensive diagnostics for engine performance, electrical faults, and mechanical binding Rebuild Procedures: Full engine and transmission rebuild instructions Adjustment Procedures: Carburetor tuning, ignition timing, brake adjustments, suspension setup 📊 Manual Specifications File Format File Type: PDF Print Quality Printability: Printable pages Binding Type Binding Style If Printed: Not applicable (digital download) Paper Type Paper Quality If Printed: Not applicable (digital download) ⚙️ Engine Specifications Primary Engine Engine Type: Two-stroke, liquid-cooled Engine Displacement: 377cc Bore X Stroke: 64.0 mm x 58.0 mm Compression Ratio: 6.5:1 Carburetion: Mikuni VM34SS Ignition System: CDI (Capacitor Discharge Ignition) Performance Horsepower Approximate: Approximately 33-35 HP (Estimate based on similar engines of the era) Torque Approximate: Not explicitly stated, but sufficient for its class. Fuel System Fuel Type: Unleaded gasoline (typically 87 octane) Fuel Mixture: Pre-mix or Oil Injection System (check manual for specifics) Fuel Tank Capacity: 4.5 US gallons (approximate) 🔧 Transmission Standard Transmission Type: 5-speed manual with automatic clutch Drive System: 2WD (Rear Wheel Drive) Final Drive: O-ring sealed chain Features Clutch Type: Automatic centrifugal clutch Gear Ratios: Specific gear ratios detailed within the manual. 📐 Dimensions Exterior Length: Approximately 71.5 inches (1816 mm) Width: Approximately 46.0 inches (1168 mm) Height: Approximately 44.5 inches (1130 mm) Weights Dry Weight: Approximately 400 lbs (181 kg) Ground Clearance: Approximately 5.0 inches (127 mm) Wheelbase Wheelbase: Approximately 48.7 inches (1237 mm) 🛡️ Safety Features Ratings Atv Safety Standards: Complies with ANSI standards for recreational ATVs. Active Features Braking System Type: Hydraulic disc brakes, front and rear Passive Features Lighting System: Headlights, taillight, brake light Handlebar Design: Ergonomic handlebar with integrated controls for safety and ease of operation. 💡 Technology Features Infotainment Infotainment Features: Not applicable for this model; focus is on core off-road functionality. Driver Assistance Assistance Systems: Not applicable for this model; design prioritizes mechanical engagement. Connectivity Connectivity Features: Not applicable for this model. 🔧 Maintenance Service Intervals Engine Oil Change Interval: Recommended every 20-30 hours of operation or annually (refer to manual for exact specification). Air Filter Cleaning Interval: Recommended...