The Polaris 400 Sport is an All-Terrain Vehicle (ATV) produced between 1996 and 1998, designed as a sport/performance model for recreational riders seeking an agile and capable machine for trail riding. Known for its potent 2-stroke engine and responsive handling, this ATV offers an engaging experience on varied terrain. Its engineering emphasizes performance and maneuverability, making it a competitive option within its segment, often compared to similar models from other major manufacturers of the era. This workshop service manual provides comprehensive guidance for the maintenance and repair of the Polaris 400 Sport. It covers all essential systems, including the engine, transmission, suspension, brakes, and electrical components. Within its pages, you will find detailed procedures for routine maintenance, troubleshooting common issues, component overhauls, and technical specifications. This manual is an indispensable resource for owners and technicians aiming to ensure the optimal performance and longevity of their vehicle. 🏷️ Basic Information Identification Make: Polaris Model: 400 Sport Generation Production Years: 1996-1998 Codes Vehicle Type: All-Terrain Vehicle (ATV) 👋 Introduction Market Position Vehicle Segment: Sport/Performance ATV Target Audience: Recreational riders seeking a capable and agile ATV for trail riding and sport. Competitive Analysis Key Competitors: Yamaha Warrior, Suzuki QuadSport, Honda Sportrax (specific models within the same era). Key Features Performance Focus: Known for its powerful 2-stroke engine and agile handling, making it a fun and capable machine on varied terrain. Manual Utility: Provides in-depth technical knowledge crucial for maintaining and repairing this performance-oriented ATV. 📋 Manual Details Coverage Areas Engine: Yes Transmission: Yes Suspension: Yes Brakes: Yes Electrical System: Yes Frame Chassis: Yes Bodywork Bodypanels: Yes Troubleshooting: Yes Maintenance Schedules: Yes Page Count Estimated Pages: Varies (typically 300-500 pages for comprehensive workshop manuals) Manual Type Type: Workshop Service Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine Details: 2-stroke engine overhaul, top-end rebuild, carburetor tuning, cooling system, exhaust system. Drivetrain Details: CVT (Continuously Variable Transmission) service, belt inspection/replacement, clutch operation, gear case lubrication. Suspension Steering Details: Front and rear suspension component inspection, shock absorber service, steering linkage adjustment, wheel bearing service. Braking System Details: Hydraulic brake system diagnosis, pad replacement, caliper service, fluid flush and bleed procedures, parking brake adjustment. Electrical Ignition Details: Wiring diagrams, lighting system, battery maintenance, starter system, ignition system troubleshooting, CDI unit. Fuel System Details: Fuel tank service, fuel lines, fuel filter replacement, carburetor assembly and disassembly. Frame Body Details: Frame inspection for damage, body panel removal and installation, seat service, handlebar replacement. Procedures Included Scheduled Maintenance: Oil changes (gearcase), spark plug replacement, air filter cleaning/replacement, drive belt inspection, brake system checks. Diagnostic Procedures: Step-by-step troubleshooting guides for common performance issues, starting problems, and system failures. Repair Overhaul: Complete engine rebuild procedures, carburetor overhaul, CVT clutch servicing, suspension component replacement. Adjustment Calibration: Carburetor jetting and idle speed adjustments, throttle cable adjustment, brake lever free play adjustment. Wiring Diagrams: Detailed electrical schematics for all vehicle systems. Technical Depth Depth: Comprehensive, suitable for professional technicians and advanced DIY mechanics. Covers routine maintenance to complete engine and transmission overhauls. 📊 Manual Specifications File Format Searchability: Likely text-searchable PDF, allowing for quick keyword lookups. Resolution Quality: Variable depending on the original source, but typically sufficient for clear viewing of diagrams and text. Print Quality Printability: Designed to be printable, allowing users to create physical copies of specific sections or the entire manual. Binding Type Binding: N/A (Digital PDF Download) Paper Type Paper Type: N/A (Digital PDF Download) ⚙️ Engine Specifications Primary Engine Engine Type: 2-stroke, liquid-cooled Displacement: 378cc Bore X Stroke: 80 mm x 75 mm Carburetion: Mikuni VM34SS (typically) Ignition System: CDI (Capacitor Discharge Ignition) Compression Ratio: 6.7:1 Performance Horsepower Estimate: ~25-30 HP (at peak, approximate) Torque Estimate: Not officially published, but provides strong low-end and mid-range pull. Fuel System Fuel Type: Unleaded gasoline (91 octane or higher recommended) Fuel Oil Mix Ratio: 50:1 (for oil injection system) Fuel Tank Capacity: 3.2 US gallons (approx. 12.1 liters) 🔧 Transmission Standard Transmission Type: CVT (Continuously Variable Transmission) with Polaris Variable Transmission (PVT) system Drive System: Shaft drive to rear axle Optional Optional Drive: N/A (Typically rear-wheel drive only for this model) Features Clutch Type: Automatic centrifugal clutch system Gear Reduction: Integrated gear reduction within the drivetrain Transmission Fluid Type: Polaris AGL Fluid or equivalent (refer to manual for exact specification) 📐 Dimensions Exterior Length: 73.5 inches (approx. 186.7 cm) Width: 42.5 inches (approx. 108 cm) Height: 42.0 inches (approx. 106.7 cm) Wheelbase: 49.5 inches (approx. 125.7 cm) Ground Clearance: 4.5 inches (approx. 11.4 cm) Weights Dry Weight: 418 lbs (approx. 189.6 kg) Curb Weight: Not specified, but will be higher than dry weight due to fluids. Tires Wheels Front Tire Size: AT 22 x 7-10 Rear Tire Size: AT 22 x 10-9 Bolt Pattern: Typically 4/110 for front and rear 🛡️ Safety Features Ratings Safety Certification: As with...