This manual covers the 2001 Sportsman 400, an all-terrain vehicle renowned for its utility and capability. Built by a leader in powersports, this model is recognized for its robust 400cc engine, shaft drive, and independent rear suspension, offering a blend of power and maneuverability suitable for both recreational riding and demanding utility tasks. Its design emphasizes reliability and ease of use, making it a popular choice in its segment, competing with other major manufacturers. The Sportsman 400 is engineered with a durable steel frame and features like selectable 2WD/4WD and substantial rack capacity, underscoring its practical application in various environments. This comprehensive factory service repair manual provides detailed guidance for all mechanical and electrical systems of the 2001 Sportsman 400. It is an essential resource for performing accurate maintenance, diagnostics, and repairs, ensuring the longevity and optimal performance of your vehicle. The manual includes step-by-step instructions, torque specifications, wiring diagrams, and exploded views for engine, transmission, chassis, brakes, and electrical components. Furthermore, it covers routine maintenance schedules, troubleshooting common issues, and component removal and installation procedures, empowering owners and technicians to effectively service and maintain this all-terrain vehicle. 🏷️ Basic Information Identification Make: Polaris Model: Sportsman 400 Year: 2001 Product Type: Factory Service Repair Manual Codes Vehicle Platform Code: A01AA42AA 👋 Introduction Market Position Category: All-Terrain Vehicle (ATV) Target User: Recreational riders, utility users, DIY mechanics Competitive Analysis Competitors: Honda Foreman, Yamaha Big Bear, Suzuki King Quad, Arctic Cat 400 Key Features Vehicle Features: 400cc engine, shaft drive, independent rear suspension (IRS), selectable 2WD/4WD, rack capacity Manual Value Purpose: Empower owners and technicians to perform accurate repairs and maintenance, reducing downtime and costs. 📋 Manual Details Coverage Areas Primary Coverage: All mechanical and electrical systems of the 2001 Polaris Sportsman 400 Secondary Coverage: Diagnostic procedures, troubleshooting, specifications, routine maintenance Page Count Estimated Pages: Approximately 300-400 pages (typical for comprehensive factory manuals) Manual Type Type: Factory Service Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered 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 Procedures Included 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 Technical Depth 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 📊 Manual Specifications File Format Type: PDF (Portable Document Format) Searchability: Likely text-searchable for quick information retrieval Print Quality Quality: High-resolution scans ensuring clarity of diagrams and text Binding Type Binding: N/A (Digital PDF) Paper Type Paper Type: N/A (Digital PDF) ⚙️ Engine Specifications Primary Engine Engine Type: 4-stroke, liquid-cooled, SOHC Displacement: 376cc Bore X Stroke: 83mm x 71.5mm Compression Ratio: 8.3:1 Performance Horsepower: Approximately 24 HP (estimated at peak) Torque: Approximately 23 lb-ft (estimated at peak) Fuel System Carburetor: Mikuni BSR42 Fuel Type: Unleaded gasoline, 87 octane minimum Lubrication Oil Type Specification: SAE 10W-40, API SG or higher (refer to manual for exact) Ignition Ignition System: Electronic Ignition (CDI) 🔧 Transmission Standard Transmission Type: Automatic (CVT - Continuously Variable Transmission) Drive System: Shaft drive, On-Demand All-Wheel Drive (AWD) Features Gear Selection: High, Low, Neutral, Reverse Clutch Type: Drive and driven clutches (CVT) Fluid Specification Cvt Fluid: Polaris Variable Transmission Fluid (PVT) or equivalent (refer to manual for specific part number/type) 📐 Dimensions Exterior Length: 81 inches (205.7 cm) Width: 46 inches (116.8 cm) Height: 47 inches (119.4 cm) Wheelbase: 50.5 inches (128.3 cm) Ground Clearance: 11 inches (27.9 cm) Weights Dry Weight: Approximately 565 lbs (256 kg) Payload Capacity: 200 lbs (91 kg) on rear rack Towing Capacity: 1500 lbs (680 kg) Cargo Front Rack Capacity: 100 lbs (45 kg) Rear Rack Capacity: 200 lbs (91 kg) 🛡️ Safety Features Ratings Atv Safety Standards: Adheres to ANSI/SVIA standards Active Features Braking System: Hydraulic disc brakes (front and rear) with parking brake Lighting: Halogen headlights, taillight/brake light Passive Features Frame Construction: Durable steel frame Operator Safety: Handlebar controls, footwells with heel guards, throttle limiter screw (factory adjustable) 💡 Technology Features Infotainment Features: Basic analog gauges (speedometer, odometer, fuel level, temperature), basic indicator lights Driver Assistance Features: On-Demand AWD system provides enhanced traction Connectivity Features: N/A (No advanced electronic connectivity features typical of modern ATVs) 🔧 Maintenance Service Intervals Engine...