The Polaris Sport 400 Explorer, manufactured in 1999, is a robust ATV designed for recreational and utility purposes. Building on Polaris's heritage as an industry pioneer, this model represents a significant period in ATV development, offering a blend of performance and reliability characteristic of its era. Engineered for diverse terrains, the Sport 400 Explorer is known for its capable handling and durable construction, making it a popular choice for riders seeking adventure and utility. This comprehensive factory service repair workshop manual provides in-depth coverage for the 1999 Polaris Sport 400 Explorer. It details essential maintenance procedures, troubleshooting guides, and technical specifications required for optimal performance and longevity. The manual covers all major systems, including the engine, transmission, fuel, cooling, electrical, suspension, braking, and steering systems, along with chassis and bodywork. It is an indispensable resource for owners, DIY enthusiasts, and professional mechanics to ensure proper upkeep and repair of the vehicle. 🏷️ Basic Information Identification Make: Polaris Model: Sport 400 Explorer Year: 1999 Type: ATV 👋 Introduction Market Position Target User: Owners, DIY enthusiasts, professional mechanics Competitive Analysis Advantage: Comprehensive factory-level detail, accessible digital format Key Features Content Richness: Hundreds of pages with detailed photos and diagrams Instructional Style: Step-by-step instructions for clarity and accuracy 📋 Manual Details Coverage Areas Primary Coverage: Full Service, Repair, and Workshop Procedures Secondary Coverage: Troubleshooting, Diagnostics, Maintenance Page Count Estimated Pages: Hundreds (precise count not specified, but described as very detailed) Manual Type Type: Factory Service Repair Workshop Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine: Engine assembly, disassembly, diagnosis, tuning, performance adjustments Transmission: Gearbox overhaul, clutch service, drive system maintenance Fuel System: Carburetor service, fuel pump, fuel lines, fuel tank maintenance Cooling System: Radiator, fan, coolant circulation, thermostat service Electrical System: Ignition system, charging system, lighting, starter motor, battery service, wiring diagrams Suspension System: Front and rear suspension components, shock absorbers, bushings, alignment Braking System: Hydraulic brake system, calipers, master cylinder, brake pads, fluid service Steering System: Handlebars, steering column, tie rods, ball joints, steering linkage Chassis And Frame: Frame inspection, welds, component mounting, structural integrity Bodywork And Plastics: Fenders, plastics, seat, storage compartments, aesthetic components Procedures Included Routine Maintenance: Oil changes, filter replacements, lubrication, chain adjustment, spark plug service Troubleshooting Guides: Step-by-step diagnostics for common and complex issues Rebuild Procedures: Detailed instructions for engine, transmission, and component overhauls Wiring Diagrams: Comprehensive electrical schematics for all systems Exploded Diagrams: Highly detailed illustrations for part identification and assembly Torque Specifications: Precise torque values for all critical fasteners Special Tools: Identification of required special tools for specific procedures Technical Depth Depth: Comprehensive, covering all aspects from basic maintenance to complete rebuilds 📊 Manual Specifications File Format File Type: PDF Searchability: Likely text-searchable due to PDF format (though not explicitly stated) Print Quality Printable: Yes, single pages or entire manual Binding Type Binding: N/A (Digital Download) Paper Type Paper: N/A (Digital Download) Licensing Usage Rights: Unlimited use on multiple devices, lifetime access Version Control Updates: No expiry, no renewal fees ⚙️ Engine Specifications Primary Engine Type: 2-stroke, liquid-cooled, single-cylinder (common for Polaris 400 series at this time) Displacement: Approx. 340-375cc (specific to the 400 model, exact value requires manual verification) Performance Horsepower: Estimated 28-35 HP (typical for this engine size and era, requires manual verification) Torque: Estimated 25-30 lb-ft (typical for this engine size and era, requires manual verification) Fuel System Carburetion: Single carburetor (likely Mikuni or Keihin, size dependent on specific model variant) Lubrication Oil System: Pre-mix or oil injection system (common for 2-stroke ATVs) 🔧 Transmission Standard Type: Automatic (CVT - Continuously Variable Transmission) Features Drive System: Shaft drive to rear wheels, likely 2WD (2WD is typical for this model designation) Gear Reduction: Integrated into the CVT and rear differential 📐 Dimensions Exterior Length: Approx. 74-78 inches (typical for 1999 Polaris 400 models) Width: Approx. 46-48 inches (typical for 1999 Polaris 400 models) Height: Approx. 44-46 inches (typical for 1999 Polaris 400 models) Weights Dry Weight: Approx. 450-500 lbs (typical for 1999 Polaris 400 models) Ground Clearance: Approx. 7-10 inches (typical for 1999 Polaris 400 models) 🛡️ Safety Features Ratings Standards Compliance: Meets ANSI standards for ATVs (standard for this era) Active Features Braking System: Hydraulic disc brakes (front and rear, typically) Passive Features Handlebars: Grip design for control, throttle control Footwells: Protective footrests with heel guards 💡 Technology Features Infotainment Features: Basic instrumentation (speedometer, odometer, neutral indicator, oil light) Driver Assistance Features: N/A (No advanced electronic driver assistance systems on this model) 🔧 Maintenance Service Intervals Engine Oil Change: Typically every 30-50 hours of operation or annually (refer to manual for exact interval) Air Filter Cleaning: Check frequently, clean every 20-30 hours (refer to manual) Spark Plug Replacement: Typically every 100-200 hours (refer to manual) Fluid Specifications Engine Oil Type: 2-stroke oil pre-mix or injection oil (specific...