The Polaris Sportsman 400, produced between 1996 and 2003, is a capable and reliable all-terrain vehicle renowned for its robust chassis and versatile performance. Designed for both trail riding and light utility work, this model offers a dependable platform that has made it a popular choice for outdoor enthusiasts. Its engineering emphasizes durability and straightforward operation, making it a practical option for various recreational and practical applications. This comprehensive Service and Repair Manual provides detailed guidance for maintaining and repairing your Polaris Sportsman 400. It covers a wide array of systems, including engine, transmission, drivetrain, suspension, brakes, electrical, fuel, cooling, body, chassis, and steering. Within its pages, you will find step-by-step repair procedures, diagnostic charts for troubleshooting, preventative maintenance schedules, and essential technical specifications, including torque values and wiring diagrams, ensuring you can keep your ATV in optimal working condition. 🏷️ Basic Information Identification Make: Polaris Model: Sportsman 400 Product Type: Service Repair Manual Codes Covered Years: 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003 👋 Introduction Market Position Vehicle Segment: Entry-level to mid-range utility ATV. Competitive Analysis Competitors: Honda FourTrax 300/350, Yamaha Timberwolf 350, Kawasaki Bayou 300. Key Features Vehicle Highlights: Reliable, capable utility quad known for its robust chassis and versatile performance for trail riding and light work. Manual Value Proposition Benefit To Owner: Empowers owners to perform routine maintenance, diagnose issues, and conduct repairs confidently, saving time and money. 📋 Manual Details Coverage Areas General Coverage: Comprehensive repair, maintenance, and troubleshooting for the Polaris Sportsman 400 ATV. Page Count Estimated Page Count: 300+ Manual Type Type: Service and Repair Manual Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Engine: Detailed breakdown, diagnostics, rebuild procedures, timing, cooling system. Transmission: PVT (Polaris Variable Transmission) clutch service, belt replacement, gearbox maintenance. Drive Train: AWD system, differentials, driveshafts, U-joints, final drive. Suspension: Front and rear suspension components, shocks, A-arms, bearings, bushings. Brakes: Hydraulic brake system, calipers, master cylinders, brake lines, bleeding procedures. Electrical: Ignition system, charging system (stator, regulator/rectifier), battery, starter, lighting, wiring diagrams. Fuel System: Carburetor service and tuning, fuel pump, fuel lines, fuel tank. Cooling System: Radiator, fan, coolant, thermostat, hoses. Body Chassis: Frame inspection, body panels, fenders, racks, seat. Steering: Handlebars, steering shaft, tie rods, steering components. Exhaust System: Muffler, exhaust pipe, heat shields. Procedures Included Preventative Maintenance: Regular service checks, lubrication points, filter changes, fluid checks. Troubleshooting: Diagnostic charts for common problems, symptom analysis, potential causes. Repair Procedures: Step-by-step instructions for component removal, installation, and adjustment. Rebuild Instructions: Complete engine and transmission rebuild procedures. Special Tool Usage: Identification and use of specialized tools required for specific repairs. Torque Specifications: Crucial torque values for critical fasteners throughout the vehicle. Technical Depth Diagnostic Capabilities: Detailed diagnostic procedures for identifying and resolving mechanical and electrical issues. Rebuild Level: Comprehensive enough for a complete engine and transmission overhaul. Electrical Diagrams: Includes detailed, easy-to-read wiring diagrams for all electrical systems. 📊 Manual Specifications File Format File Type: PDF (Portable Document Format) Searchability: Fully searchable text for quick information retrieval. Printability: Printable pages for field use. Print Quality Image Clarity: High-resolution images and diagrams. Binding Type Binding: N/A (Digital PDF) Paper Type Paper Type: N/A (Digital PDF) ⚙️ Engine Specifications Primary Engine Engine Type: 4-stroke, 4-valve, SOHC Displacement: 376cc Bore X Stroke: 80 mm x 75 mm (approximate, verify with manual) Cooling System: Liquid-cooled Performance Horsepower: Approximately 20-22 HP (varies by year and tuning) Torque: Approximate peak torque 20-22 ft-lbs (varies by year and tuning) Fuel System Carburetor: Mikuni BSR32 (typically, check manual for exact spec) Fuel Type: Unleaded gasoline Fuel Capacity: 3.0 gallons (11.4 L) 🔧 Transmission Standard Transmission Type: Automatic (Polaris Variable Transmission - PVT) Drive Modes: 2WD/AWD selectable Gear Selection: High, Low, Neutral, Reverse Features Clutch Type: Sheave-type centrifugal clutch Transmission Fluid: Polaris AGL Synthetic Gearcase Lubricant or equivalent (verify with manual) Final Drive Fluid: Polaris Demand Drive Fluid (front diff) or AGL (rear diff/gearcase) (verify with manual) 📐 Dimensions Exterior Length: Approx. 76 inches (193 cm) Width: Approx. 44 inches (111.8 cm) Height: Approx. 47 inches (119.4 cm) Weights Dry Weight: Approx. 550 lbs (249 kg) Ground Clearance: Approx. 8-10 inches (20.3-25.4 cm) Cargo Front Rack Capacity: Approx. 100 lbs (45 kg) Rear Rack Capacity: Approx. 200 lbs (90 kg) Towing Capacity: Approx. 1500 lbs (680 kg) Wheels Tires Front Tire Size: 25x8-12 (typical, verify with manual) Rear Tire Size: 25x10-12 (typical, verify with manual) Wheel Bolt Pattern: 4/110 mm (typical, verify with manual) 🛡️ Safety Features Ratings Atv Safety Standards: Complies with ANSI standards. Active Features Braking System: Hydraulic disc brakes front and rear. Passive Features Lighting: Dual front headlights, taillight/brake light. Throttle Limiter: Thumb throttle with safety governor (typically user-adjustable). 💡 Technology Features Infotainment Infotainment System: N/A (No integrated infotainment system, focus is on utility and performance). Driver Assistance Electronic Aids: None typically found...