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Polaris Sportsman 300 400 H.O 2009 Workshop Service Repair Manual Pdf Download

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Basic Information Identification Make: Polaris Model: Sportsman Year: 2009 Sub Model: 300 / 400 H.O. Type: ATV (All-Terrain Vehicle) Codes Chassis Codes: Not specified, typically VIN breakdown for specific model variants. Engine Codes: Not specified, but likely refers to specific engine designations for the 300 and 400 H.O. models. Generation Generation: Third Generation Sportsman (2005-2009) Introduction Market Position Market Segment: Entry-level to mid-range utility ATV segment, offering a balance of performance and value. Competitive Analysis Competitors: Competed with models from Honda (e.g., Rancher), Yamaha (e.g., Kodiak), Kawasaki (e.g., Brute Force), Can-Am (e.g., Outlander 400). Key Features Powertrain: Single-cylinder, liquid-cooled engines with Polaris's H.O. (High Output) designation for improved performance. Drivetrain: Available in 2x4 and 4x4 configurations, featuring automatic PVT (Polaris Variable Transmission) with engine braking. Suspension: Independent Front Suspension (IFS) for improved ride comfort and handling, and a robust rear suspension system. Manual Details Coverage Areas Models Covered: 2009 Polaris Sportsman 300 / 400 2x4 H.O., 2009 Polaris Sportsman 300 4x4, 2009 Polaris Sportsman 400 4x4 H.O. Geographic Coverage: Assumed North American market based on product description, but general technical information is likely universal. Page Count Page Count: Not specified. Service manuals of this nature are typically comprehensive, often exceeding 500 pages. Manual Type Manual Type: Workshop Service Repair Manual Language Language: English Format File Format: PDF Compatibility: Windows / macOS Required Software: Adobe PDF Reader Print Quality Printability: Yes Manual Coverage Systems Covered Engine: Complete engine disassembly, assembly, inspection, and repair. Includes cylinder head, piston, crankshaft, connecting rods, valve train, timing. Fuel System: Carburetor (likely Mikuni for these models) service, adjustments, fuel pump, fuel tank, lines, and filter. EFI details if applicable to specific sub-models (though 300/400 typically carbureted). Body Steering Suspension: Body panel removal/installation, steering column, tie rods, ball joints, A-arms, bushings, shock absorbers, wheel bearings, spindle assembly. Cvt Transmission: Continuously Variable Transmission (CVT) disassembly, inspection, belt replacement, drive clutch, driven clutch service, gearbox lubrication. Final Drive: Front and rear differential service, axle shafts, U-joints, seal replacement, lubrication. Brakes: Hydraulic brake system, master cylinder, brake calipers, brake pads, brake discs, bleeding procedure, parking brake mechanism. Electrical: Battery, charging system (stator, regulator/rectifier), starter motor, ignition system, lighting, switches, sensors, instrumentation, fuses, relays. Wire Diagram: Detailed electrical wiring schematics for all systems, aiding in troubleshooting and component identification. Procedures Included Maintenance: Routine maintenance tasks, fluid changes, filter replacements, lubrication points, bolt torque specifications. Diagnostics: Troubleshooting guides, symptom-based diagnostics, diagnostic trouble codes (if applicable), testing procedures for electrical components. Repair: Step-by-step instructions for component repair, replacement, and adjustment across all covered systems. Rebuild: Comprehensive procedures for major component overhauls, such as engine and transmission rebuilds. Technical Depth Depth: Comprehensive. Covers everything from basic fluid checks and adjustments to full engine and transmission overhauls, including detailed electrical diagnostics. Target Audience: Professional dealership technicians and experienced DIY mechanics. Manual Specifications File Format File Format: PDF Searchability: Typically PDF manuals are searchable by keywords. Print Quality Print Quality: Printable, allowing users to create hard copies for workshop use. Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) Engine Specifications Primary Engine Engine Type 300: Single-cylinder, liquid-cooled, SOHC (Single Overhead Cam), 4-stroke. Engine Displacement 300: Approximately 270cc (specific bore/stroke data not provided). Engine Type 400 Ho: Single-cylinder, liquid-cooled, SOHC (Single Overhead Cam), 4-stroke. Engine Displacement 400 Ho: Approximately 375cc (specific bore/stroke data not provided). Performance Horsepower 300: Estimated 18-20 HP (at crankshaft, not specified). Horsepower 400 Ho: Estimated 26-28 HP (at crankshaft, not specified). Torque 400 Ho: Estimated 24-26 lb-ft (at crankshaft, not specified). Fuel System Fuel Delivery: Carbureted (likely Mikuni BSR series for both models). Fuel Type: Unleaded gasoline, 87 octane minimum recommended. Fuel Capacity: Typically around 3.2 gallons (12.1 liters) for this generation Sportsman. Transmission Standard Transmission Type: Polaris Variable Transmission (PVT) automatic with High, Low, Neutral, Reverse, and Park. Drive System: Shaft drive, with on-demand AWD (All-Wheel Drive) for 4x4 models, and 2WD for 2x4 models. Optional Optional Transmission: N/A (PVT is standard for this model) Features Engine Braking: Standard on PVT for downhill control. Cvt Fluid Type: Polaris AGL Synthetic Gearcase Lubricant or equivalent. Dimensions Exterior Length: Approximately 81 inches (205.7 cm) for 400 H.O., slightly less for 300. Width: Approximately 46 inches (116.8 cm). Height: Approximately 48 inches (121.9 cm). Weights Dry Weight 400 Ho: Approximately 600 lbs (272 kg). Dry Weight 300: Approximately 550 lbs (250 kg). Ground Clearance: Typically around 10.5 inches (26.7 cm). Cargo Front Rack Capacity: Typically 50 lbs (22.7 kg). Rear Rack Capacity: Typically 100 lbs (45.4 kg). Towing Towing Capacity: Typically 1,050 lbs (476 kg). Hitch Receiver: Standard 1.25 inch receiver (often requires an adapter for standard ball hitches). Safety Features Ratings Safety Ratings: ATVs are not typically rated by organizations like NHTSA. Safety relies on operator training and adherence to manufacturer guidelines. Active Features Active Safety: On-demand AWD...
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Polaris Sportsman 300 400 H.O 2009 Workshop Service Repair Manual Pdf Download
Basic Information
Identification
Make: Polaris
Model: Sportsman
Year: 2009
Sub Model: 300 / 400 H.O.
Type: ATV (All-Terrain Vehicle)
Codes
Chassis Codes: Not specified, typically VIN breakdown for specific model variants.
Engine Codes: Not specified, but likely refers to specific engine designations for the 300 and 400 H.O. models.
Generation
Generation: Third Generation Sportsman (2005-2009)
Introduction
Market Position
Market Segment: Entry-level to mid-range utility ATV segment, offering a balance of performance and value.
Competitive Analysis
Competitors: Competed with models from Honda (e.g., Rancher), Yamaha (e.g., Kodiak), Kawasaki (e.g., Brute Force), Can-Am (e.g., Outlander 400).
Key Features
Powertrain: Single-cylinder, liquid-cooled engines with Polaris's H.O. (High Output) designation for improved performance.
Drivetrain: Available in 2x4 and 4x4 configurations, featuring automatic PVT (Polaris Variable Transmission) with engine braking.
Suspension: Independent Front Suspension (IFS) for improved ride comfort and handling, and a robust rear suspension system.
Manual Details
Coverage Areas
Models Covered: 2009 Polaris Sportsman 300 / 400 2x4 H.O., 2009 Polaris Sportsman 300 4x4, 2009 Polaris Sportsman 400 4x4 H.O.
Geographic Coverage: Assumed North American market based on product description, but general technical information is likely universal.
Page Count
Page Count: Not specified. Service manuals of this nature are typically comprehensive, often exceeding 500 pages.
Manual Type
Manual Type: Workshop Service Repair Manual
Language
Language: English
Format
File Format: PDF
Compatibility: Windows / macOS
Required Software: Adobe PDF Reader
Print Quality
Printability: Yes
Manual Coverage
Systems Covered
Engine: Complete engine disassembly, assembly, inspection, and repair. Includes cylinder head, piston, crankshaft, connecting rods, valve train, timing.
Fuel System: Carburetor (likely Mikuni for these models) service, adjustments, fuel pump, fuel tank, lines, and filter. EFI details if applicable to specific sub-models (though 300/400 typically carbureted).
Body Steering Suspension: Body panel removal/installation, steering column, tie rods, ball joints, A-arms, bushings, shock absorbers, wheel bearings, spindle assembly.
Cvt Transmission: Continuously Variable Transmission (CVT) disassembly, inspection, belt replacement, drive clutch, driven clutch service, gearbox lubrication.
Final Drive: Front and rear differential service, axle shafts, U-joints, seal replacement, lubrication.
Brakes: Hydraulic brake system, master cylinder, brake calipers, brake pads, brake discs, bleeding procedure, parking brake mechanism.
Electrical: Battery, charging system (stator, regulator/rectifier), starter motor, ignition system, lighting, switches, sensors, instrumentation, fuses, relays.
Wire Diagram: Detailed electrical wiring schematics for all systems, aiding in troubleshooting and component identification.
Procedures Included
Maintenance: Routine maintenance tasks, fluid changes, filter replacements, lubrication points, bolt torque specifications.
Diagnostics: Troubleshooting guides, symptom-based diagnostics, diagnostic trouble codes (if applicable), testing procedures for electrical components.
Repair: Step-by-step instructions for component repair, replacement, and adjustment across all covered systems.
Rebuild: Comprehensive procedures for major component overhauls, such as engine and transmission rebuilds.
Technical Depth
Depth: Comprehensive. Covers everything from basic fluid checks and adjustments to full engine and transmission overhauls, including detailed electrical diagnostics.
Target Audience: Professional dealership technicians and experienced DIY mechanics.
Manual Specifications
File Format
File Format: PDF
Searchability: Typically PDF manuals are searchable by keywords.
Print Quality
Print Quality: Printable, allowing users to create hard copies for workshop use.
Binding Type
Binding Type: N/A (Digital Download)
Paper Type
Paper Type: N/A (Digital Download)
Engine Specifications
Primary Engine
Engine Type 300: Single-cylinder, liquid-cooled, SOHC (Single Overhead Cam), 4-stroke.
Engine Displacement 300: Approximately 270cc (specific bore/stroke data not provided).
Engine Type 400 Ho: Single-cylinder, liquid-cooled, SOHC (Single Overhead Cam), 4-stroke.
Engine Displacement 400 Ho: Approximately 375cc (specific bore/stroke data not provided).
Performance
Horsepower 300: Estimated 18-20 HP (at crankshaft, not specified).
Horsepower 400 Ho: Estimated 26-28 HP (at crankshaft, not specified).
Torque 400 Ho: Estimated 24-26 lb-ft (at crankshaft, not specified).
Fuel System
Fuel Delivery: Carbureted (likely Mikuni BSR series for both models).
Fuel Type: Unleaded gasoline, 87 octane minimum recommended.
Fuel Capacity: Typically around 3.2 gallons (12.1 liters) for this generation Sportsman.
Transmission
Standard
Transmission Type: Polaris Variable Transmission (PVT) automatic with High, Low, Neutral, Reverse, and Park.
Drive System: Shaft drive, with on-demand AWD (All-Wheel Drive) for 4x4 models, and 2WD for 2x4 models.
Optional
Optional Transmission: N/A (PVT is standard for this model)
Features
Engine Braking: Standard on PVT for downhill control.
Cvt Fluid Type: Polaris AGL Synthetic Gearcase Lubricant or equivalent.
Dimensions
Exterior
Length: Approximately 81 inches (205.7 cm) for 400 H.O., slightly less for 300.
Width: Approximately 46 inches (116.8 cm).
Height: Approximately 48 inches (121.9 cm).
Weights
Dry Weight 400 Ho: Approximately 600 lbs (272 kg).
Dry Weight 300: Approximately 550 lbs (250 kg).
Ground Clearance: Typically around 10.5 inches (26.7 cm).
Cargo
Front Rack Capacity: Typically 50 lbs (22.7 kg).
Rear Rack Capacity: Typically 100 lbs (45.4 kg).
Towing
Towing Capacity: Typically 1,050 lbs (476 kg).
Hitch Receiver: Standard 1.25 inch receiver (often requires an adapter for standard ball hitches).
Safety Features
Ratings
Safety Ratings: ATVs are not typically rated by organizations like NHTSA. Safety relies on operator training and adherence to manufacturer guidelines.
Active Features
Active Safety: On-demand AWD (for 4x4 models), engine braking, hydraulic disc brakes.
Passive Features
Passive Safety: Handlebar guards, comfortable seating position, integrated lighting.
Technology Features
Infotainment
Infotainment Features: Basic instrumentation cluster (speedometer, odometer, trip meter, fuel gauge, indicator lights). No complex infotainment systems.
Driver Assistance
Driver Assistance Features: On-demand AWD (for 4x4 models) is the primary advanced drivetrain technology. No electronic stability control or similar advanced driver-assistance systems.
Connectivity
Connectivity Features: N/A - designed for off-road use with no integrated connectivity features.
Maintenance
Service Intervals
Oil Change Interval: Every 100 hours or 6 months. Use Polaris PS-4 Full Synthetic 5W-50 engine oil.
Air Filter Cleaning: Inspect every 25 hours, clean/replace as needed. Replace every 100 hours.
Spark Plug Replacement: Replace every 100 hours or annually.
Cv Belt Inspection: Inspect every 50 hours for wear and damage. Replace as needed.
Fluid Specifications
Engine Oil Type: Polaris PS-4 Full Synthetic 5W-50 (API SG, SH, SJ, SL rated).
Engine Oil Capacity: Approximately 2.1 US quarts (2.0 liters) with filter change.
Coolant Type: Polaris Premium 2-Stroke Synthetic Oil is NOT the coolant. Use a 50/50 mix of ethylene glycol antifreeze and distilled water (meeting ASTM D3306).
Gearcase Lubricant: Polaris AGL Synthetic Gearcase Lubricant or SAE 75W-90 synthetic gear oil meeting API GL-4 specification.
Known Issues
Known Issues Cv Belt: CVT belt wear and slippage, especially under heavy load or with aggressive riding. Regular inspection and timely replacement are crucial.
Known Issues Electrical: While not as common as on earlier models, potential issues with stator or voltage regulator/rectifier can occur, impacting charging system performance.
Known Issues Suspension: Worn bushings or ball joints can lead to steering play or clunks, especially with high mileage or off-road use.
Vehicle History
Brand Heritage
Brand Origin: Polaris Industries, founded in 1954, is an American manufacturer known for powersports vehicles including ATVs, snowmobiles, and motorcycles.
Model Evolution
Sportsman Lineage: The Sportsman line is Polaris's flagship ATV series, evolving significantly since its introduction. The 2009 models represent a mature iteration of the third generation, building upon previous designs with engine and suspension refinements.
Production
Production Years Model: The Sportsman 300 and 400 models were produced for several years within this generation, with significant updates in 2005 and minor refinements thereafter.
Manufacturing Location: Primarily manufactured in the United States by Polaris Industries.
Awards & Recognition
Recognitions
Industry Awards: The Polaris Sportsman line has historically received positive reviews and awards for its comfort, handling, and utility. Specific awards for the 2009 300/400 H.O. models are not readily available but it was a strong performer in its class.
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