This manual covers the Polaris Sportsman 400, a versatile recreational All-Terrain Vehicle (ATV) manufactured between 1996 and 2003. Known for its capable off-road performance, the Sportsman 400 was designed for trail riding and utility tasks, featuring its characteristic Variable Transmission (PVT). It competed with other major ATV manufacturers, offering a blend of comfort and rider-friendly features that established the Sportsman line as a significant player in the powersports market. This comprehensive Factory Service Repair Manual in English provides detailed information for the maintenance, repair, and restoration of your Polaris Sportsman 400 ATV. It covers essential systems including the engine, fuel system, body, suspension, clutch, transmission, final drive, brakes, and electrical components. With 504 pages of content, this manual offers step-by-step instructions, diagnostic procedures, and technical specifications to assist owners and technicians in keeping the vehicle in optimal condition. 🏷️ Basic Information Identification Make: Polaris Model: Sportsman 400 Applicable Years: 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003 👋 Introduction Market Position Segment: Recreational All-Terrain Vehicle (ATV). Competitive Analysis Competitors: Competed against models from Honda (FourTrax), Yamaha (Grizzly), Suzuki (KingQuad), and Kawasaki (Bayou) during its production run. Key Features Atv Focus: Known for its capable off-road performance, versatility for trail riding and utility tasks, and Polaris's characteristic Polaris Variable Transmission (PVT). Manual Value Target User: ATV owners and mechanics seeking to perform repairs, maintenance, and restoration on the Polaris Sportsman 400. 📋 Manual Details Coverage Areas Primary Coverage: Comprehensive service, repair, and maintenance for the Polaris Sportsman 400 ATV. Specific Systems: Engine, Fuel System, Body, Suspension, Clutch, Transmission, Final Drive, Brakes, Electrical, International components. Page Count Total Pages: 504 Manual Type Type: Factory Service Repair Manual Language Primary Language: English Format Digital Format: PDF Download 📖 Manual Coverage Systems Covered Engine Systems: Engine overhaul, cylinder head, piston, crankshaft, connecting rod, timing, lubrication system, cooling system (if applicable to specific models within the range), starting system. Fuel System: Carburetor adjustment and overhaul, fuel pump, fuel lines, fuel tank maintenance, air filter service. Drivetrain: Clutch operation and service (drive clutch, driven clutch), CVT (Continuously Variable Transmission) maintenance and repair, gearbox overhaul, final drive unit inspection and repair, driveshafts, U-joints. Suspension Steering: Front and rear suspension components, shock absorbers, control arms, bushings, steering system, tie rods, wheel alignment. Braking System: Hydraulic brake system, brake calipers, master cylinder, brake lines, brake pads, brake discs, parking brake system. Electrical System: Ignition system, battery maintenance, charging system (stator, voltage regulator), starter motor, lighting system, wiring diagrams, diagnostic procedures for electrical faults. Body Chassis: Body panel removal and installation, seat service, fender maintenance, frame inspection, plastics repair. Procedures Included Maintenance Procedures: Scheduled maintenance, lubrication points, fluid changes, filter replacement, spark plug service, valve clearance adjustment, battery care. Diagnostic Procedures: Troubleshooting guides for common problems, diagnostic flowcharts, symptom-based repair guidance. Repair Procedures: Step-by-step instructions for component disassembly, inspection, repair, and reassembly. Rebuild Refurbish: Detailed instructions for engine rebuilds, transmission overhauls, and component refurbishment. Technical Depth Depth: Comprehensive from basic maintenance to advanced engine and transmission rebuilds. Includes detailed illustrations and diagnostic information. 📊 Manual Specifications File Format Digital Requirements: Adobe PDF Reader or compatible PDF viewer. WinRar recommended for archived files. Print Quality Printability: All pages are printable with no restriction. Binding Type Binding: N/A (Digital Download) Paper Type Paper Quality Digital: High quality digital pages. ⚙️ Engine Specifications Primary Engine Engine Type: Likely a 2-stroke engine for earlier models, potentially transitioning to 4-stroke variants within this range, though the '400' designation often implies a displacement around 400cc. Displacement: Approximately 375cc to 400cc (specific displacement may vary slightly by year and specific model variant within the Sportsman 400 line). Performance Horsepower Estimated: Estimated 25-35 HP (typical for this class and era of 400cc ATVs, exact figures vary). Torque Estimated: Estimated 20-28 lb-ft (typical for this class and era). Fuel System Carburetion: Likely a Mikuni carburetor (e.g., VM34 or similar) for fuel delivery. Fuel Type: Unleaded gasoline. Cooling Cooling Method: Liquid-cooled (common for this engine size and performance focus). 🔧 Transmission Standard Transmission Type: Polaris Variable Transmission (PVT) automatic with High/Low range and Reverse. Optional Gearbox Options: N/A (PVT is the standard and sole transmission type for this model). Features Clutch System: Automatic belt-driven CVT with centrifugal drive clutch and spring-loaded driven clutch. Final Drive: Shaft drive to rear axle and front axle (for 4x4 models). Likely enclosed, oil-lubricated driveshafts. 📐 Dimensions Exterior Length: Approx. 80-84 inches (varies slightly by year). Width: Approx. 46-48 inches (varies slightly by year). Height: Approx. 47-50 inches (varies slightly by year). Weights Dry Weight: Approx. 550-600 lbs (varies by 2WD/4WD configuration and specific year). Towing Capacity: Typically around 1500 lbs. Rack Capacity Front: Approx. 50 lbs. Rack Capacity Rear: Approx. 100 lbs. 🛡️ Safety Features Ratings Atv Safety Standards: Designed to meet ANSI standards for ATVs at the time of manufacture. Safety warnings regarding...