Polaris Sportsman 400 Ho 2008-2010 WSM Service Manual Repair
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This manual covers the All-Terrain Vehicle (ATV) for the model years 2008, 2009, and 2010. Known for its robust engineering and versatility, the 400 HO is equipped with a 375cc liquid-cooled, SOHC engine, Variable Transmission (PVT), and On-Demand All-Wheel Drive (AWD) capability. This ATV is designed to handle a wide range of terrains, offering reliable performance for both work and recreational activities. Its features include hydraulic disc brakes, a digital instrument cluster, and a substantial towing capacity, making it a capable and dependable choice for various outdoor pursuits. This comprehensive Workshop Service Manual (WSM) provides detailed information essential for the maintenance, troubleshooting, and repair of your 400 HO. It covers all major systems, including the 400cc HO engine, automatic PVT transmission, AWD drivetrain, chassis components, suspension, steering, brakes, and electrical systems. The manual offers step-by-step procedures for routine maintenance, component overhauls, diagnostics, and part replacement, along with critical technical specifications and torque values. This resource is designed to empower owners and professional technicians alike to effectively maintain the vehicle's performance, reliability, and longevity. 🏷️ Basic Information Identification Make: Polaris Model: Sportsman 400 HO Model Years: 2008, 2009, 2010 Vehicle Type: All-Terrain Vehicle (ATV) Codes Manual Product Name: Polaris Sportsman 400 Ho 2008-2010 WSM Service Manual Repair PDF Download 👋 Introduction Market Position Target User: Owners seeking to perform their own maintenance and repairs, independent repair shops Value Proposition: Significant cost savings on repairs and maintenance compared to dealership services Competitive Analysis Manual Advantage: Provides in-depth, professional-grade information often not readily available to the public, covering all aspects of service and repair. Key Features Digital Accessibility: Instant download in a portable PDF format, accessible on various devices. Problem Solving: Empowers users to diagnose and fix issues effectively, extending vehicle lifespan and performance. 📋 Manual Details Coverage Areas Engines Covered: 400cc HO (High Output) engine Transmission Covered: Automatic (PVT - Polaris Variable Transmission) Drivetrain Covered: On-Demand All-Wheel Drive (AWD) and 2WD Chassis Covered: SOHC chassis, suspension, steering, brakes, bodywork Electrical Covered: Ignition, lighting, charging system, starter, accessories Page Count Estimated Page Count: High volume, comprehensive detail (specific page count not provided but indicative of a full WSM) Manual Type Manual Type: Workshop Service Manual (WSM) / Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine Mechanical: Complete engine disassembly, inspection, repair, and reassembly of all internal components (cylinder, piston, rings, crankshaft, connecting rod, valves, camshaft, etc.) Fuel System: Carburetor (Mikuni BSR42) overhaul, cleaning, adjustment, fuel pump, fuel lines, fuel tank inspection and cleaning Cooling System: Radiator, fan, thermostat, water pump, coolant flush and replacement procedures Ignition System: CDI unit, ignition coil, spark plug specifications, timing checks Transmission And Drivetrain: PVT (CVT) belt inspection, replacement, roller maintenance, gearcase oil change, AWD system components and service Suspension And Steering: Front and rear suspension components (shocks, springs, control arms), steering system (tie rods, steering post, knuckle assembly) inspection and repair Brakes: Hydraulic brake system, caliper overhaul, master cylinder service, brake pad replacement, rotor inspection, bleeding procedures Electrical System: Wiring diagrams, battery maintenance, starter motor, charging system (stator, regulator/rectifier), lighting (headlights, taillight, brake light), switchgear, troubleshooting electrical faults Body And Frame: Fender removal, seat removal, rack installation/removal, frame inspection and repair guidelines Procedures Included Routine Maintenance: Oil changes, filter replacements, spark plug service, air filter cleaning/replacement, lubrication points Diagnostic Procedures: Troubleshooting guides for common problems, error code interpretation (if applicable), component testing procedures Repair Procedures: Step-by-step instructions for disassembly, repair, and reassembly of all major vehicle components Technical Specifications: Torque specifications for all fasteners, clearance measurements, alignment procedures, electrical resistance values Part Replacement: Detailed guidance on replacing wear items and faulty components Technical Depth Depth Of Coverage: Comprehensive (WSM level), suitable for professional mechanics and advanced DIYers Diagnostic Capability: Advanced diagnostics and troubleshooting for a wide range of issues Rebuild Instructions: Detailed instructions for complete engine and transmission rebuilds 📊 Manual Specifications File Format File Format: PDF Searchability: Likely text-searchable PDF for efficient information retrieval Print Quality Print Quality: Professional quality, optimized for clear viewing and printing Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: 4-Stroke, Liquid-Cooled, SOHC, 4-Valve Engine Displacement: 375cc (approx.) Bore X Stroke: Specifics available in manual, typically around 84mm x 68mm for this engine family. Horsepower: Approximately 28-30 HP (varies slightly by source and specific tune) Torque: Specifics available in manual, generally around 20-22 ft-lbs Performance Compression Ratio: Typically 10.0:1 or similar Fuel System Carburetor Model: Mikuni BSR42 Fuel Type: Unleaded Gasoline (87 Octane or higher recommended) Fuel Capacity: 4.1 gallons (15.5 liters) with 0.75 gallon reserve 🔧 Transmission Standard Transmission Type: Automatic (PVT - Polaris Variable Transmission) Gear Selection: High, Low, Neutral, Reverse, Park Features Drive Modes: 2WD / AWD (On-Demand) Final Drive: Shaft Drive Fluid Specifications Gearcase Oil Type: SAE 10W-40...
This manual covers the All-Terrain Vehicle (ATV) for the model years 2008, 2009, and 2010. Known for its robust engineering and versatility, the 400 HO is equipped with a 375cc liquid-cooled, SOHC engine, Variable Transmission (PVT), and On-Demand All-Wheel Drive (AWD) capability. This ATV is designed to handle a wide range of terrains, offering reliable performance for both work and recreational activities. Its features include hydraulic disc brakes, a digital instrument cluster, and a substantial towing capacity, making it a capable and dependable choice for various outdoor pursuits.
This comprehensive Workshop Service Manual (WSM) provides detailed information essential for the maintenance, troubleshooting, and repair of your 400 HO. It covers all major systems, including the 400cc HO engine, automatic PVT transmission, AWD drivetrain, chassis components, suspension, steering, brakes, and electrical systems. The manual offers step-by-step procedures for routine maintenance, component overhauls, diagnostics, and part replacement, along with critical technical specifications and torque values. This resource is designed to empower owners and professional technicians alike to effectively maintain the vehicle's performance, reliability, and longevity.
🏷️ Basic Information
Identification
Make:
Polaris
Model:
Sportsman 400 HO
Model Years:
2008, 2009, 2010
Vehicle Type:
All-Terrain Vehicle (ATV)
Codes
Manual Product Name:
Polaris Sportsman 400 Ho 2008-2010 WSM Service Manual Repair PDF Download
👋 Introduction
Market Position
Target User:
Owners seeking to perform their own maintenance and repairs, independent repair shops
Value Proposition:
Significant cost savings on repairs and maintenance compared to dealership services
Competitive Analysis
Manual Advantage:
Provides in-depth, professional-grade information often not readily available to the public, covering all aspects of service and repair.
Key Features
Digital Accessibility:
Instant download in a portable PDF format, accessible on various devices.
Problem Solving:
Empowers users to diagnose and fix issues effectively, extending vehicle lifespan and performance.
High volume, comprehensive detail (specific page count not provided but indicative of a full WSM)
Manual Type
Manual Type:
Workshop Service Manual (WSM) / Repair Manual
Language
Language:
English
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Complete engine disassembly, inspection, repair, and reassembly of all internal components (cylinder, piston, rings, crankshaft, connecting rod, valves, camshaft, etc.)
Fuel System:
Carburetor (Mikuni BSR42) overhaul, cleaning, adjustment, fuel pump, fuel lines, fuel tank inspection and cleaning
Cooling System:
Radiator, fan, thermostat, water pump, coolant flush and replacement procedures
Ignition System:
CDI unit, ignition coil, spark plug specifications, timing checks
Transmission And Drivetrain:
PVT (CVT) belt inspection, replacement, roller maintenance, gearcase oil change, AWD system components and service
Suspension And Steering:
Front and rear suspension components (shocks, springs, control arms), steering system (tie rods, steering post, knuckle assembly) inspection and repair
Troubleshooting guides for common problems, error code interpretation (if applicable), component testing procedures
Repair Procedures:
Step-by-step instructions for disassembly, repair, and reassembly of all major vehicle components
Technical Specifications:
Torque specifications for all fasteners, clearance measurements, alignment procedures, electrical resistance values
Part Replacement:
Detailed guidance on replacing wear items and faulty components
Technical Depth
Depth Of Coverage:
Comprehensive (WSM level), suitable for professional mechanics and advanced DIYers
Diagnostic Capability:
Advanced diagnostics and troubleshooting for a wide range of issues
Rebuild Instructions:
Detailed instructions for complete engine and transmission rebuilds
📊 Manual Specifications
File Format
File Format:
PDF
Searchability:
Likely text-searchable PDF for efficient information retrieval
Print Quality
Print Quality:
Professional quality, optimized for clear viewing and printing
Binding Type
Binding Type:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Type:
4-Stroke, Liquid-Cooled, SOHC, 4-Valve
Engine Displacement:
375cc (approx.)
Bore X Stroke:
Specifics available in manual, typically around 84mm x 68mm for this engine family.
Horsepower:
Approximately 28-30 HP (varies slightly by source and specific tune)
Torque:
Specifics available in manual, generally around 20-22 ft-lbs
Performance
Compression Ratio:
Typically 10.0:1 or similar
Fuel System
Carburetor Model:
Mikuni BSR42
Fuel Type:
Unleaded Gasoline (87 Octane or higher recommended)
Fuel Capacity:
4.1 gallons (15.5 liters) with 0.75 gallon reserve
🔧 Transmission
Standard
Transmission Type:
Automatic (PVT - Polaris Variable Transmission)
Gear Selection:
High, Low, Neutral, Reverse, Park
Features
Drive Modes:
2WD / AWD (On-Demand)
Final Drive:
Shaft Drive
Fluid Specifications
Gearcase Oil Type:
SAE 10W-40 Polaris Synthetic Gearcase Oil or equivalent
📐 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)
Weights
Dry Weight:
Approx. 595 lbs (270 kg)
Towing Capacity:
1500 lbs (680 kg)
Rack Capacity Front:
100 lbs (45 kg)
Rack Capacity Rear:
200 lbs (90 kg)
Suspension Travel
Front Suspension Travel:
8.2 inches (20.8 cm)
Rear Suspension Travel:
9.5 inches (24.1 cm)
🛡️ Safety Features
Ratings
Atv Safety Considerations:
ATV safety is paramount; proper training, protective gear (helmet, goggles, gloves, boots, long sleeves/pants) are essential. The manual covers safe operating procedures.
Active Features
Braking System:
Hydraulic disc brakes (front and rear), front and rear brake lever operation
Passive Features
Lighting:
Dual 35W headlights, 8W taillight/brake light
Roll Over Protection:
Not equipped with a roll cage; operation requires careful handling and awareness of terrain.
💡 Technology Features
Infotainment
Instrumentation:
Digital instrument cluster with speedometer, odometer, trip meter, tachometer, high beam, neutral, reverse, AWD indicators.
Driver Assistance
Engine Management:
CDI ignition system for precise spark timing.
Connectivity
Charging System:
12V DC charging system with stator and regulator/rectifier for battery charging and powering accessories.
🔧 Maintenance
Service Intervals
Engine Oil Change:
Every 100 hours or 12 months, whichever comes first (refer to manual for specifics)
Air Filter Service:
Inspect every 25 hours, clean/replace as needed (more frequently in dusty conditions)
Spark Plug Service:
Inspect and gap every 100 hours or 12 months
Transmission Oil Change:
Every 200 hours or 24 months
Fluid Specifications
Engine Oil Type:
Polaris Synthetic 0W-40 or 10W-40 (refer to manual for precise recommendation)
Engine Oil Capacity:
Approx. 2.0 quarts (1.9 liters) with filter change
Coolant Type:
Ethylene glycol-based antifreeze with corrosion inhibitors (e.g., Polaris Premium Antifreeze)
Brake Fluid Type:
DOT 3 or DOT 4 Hydraulic Brake Fluid
Known Issues
Common Wear Items:
CVT belt wear, suspension bushings, tie rod ends, wheel bearings.
Carburetor Tuning:
Carburetor can require periodic adjustment for optimal performance and to prevent lean conditions, especially with altitude or aftermarket modifications.
A-Arm Bushings:
Early models could experience wear in the A-arm bushings, leading to play in the suspension. The manual will detail inspection and replacement.
📚 Vehicle History
Brand Heritage
Polaris Legacy:
Polaris Industries has a long history in powersports, known for innovation in snowmobiles and ATVs.
Model Evolution
Sportsman Lineage:
The Sportsman line is Polaris's flagship ATV series, renowned for comfort, capability, and versatility for work and recreation. The 400 HO model represents a balance of performance and value in this line.
Production
Manufacturing Location:
Polaris vehicles are primarily manufactured in the USA (e.g., Minnesota, Iowa, South Dakota, Wyoming).
🏆 Awards & Recognition
Recognitions
Industry Standing:
Polaris Sportsman models are consistently recognized for their utility, comfort, and off-road capability, making them popular among riders for various purposes.
Ratings
Owner Satisfaction:
Generally high owner satisfaction for the Sportsman line due to its robust build and capability.