The 2009 Sportsman 400 is a versatile all-terrain vehicle (ATV) designed for utility and recreational purposes. Known for its robust performance and all-wheel-drive capability, this mid-size ATV offers a reliable 330cc liquid-cooled engine and an automatic PVT transmission with high/low range. Its engineering emphasizes durability and off-road prowess, making it a capable choice for various tasks and terrains, comparable to other leading ATVs of its era. The Sportsman line is a flagship series from a manufacturer with a long history in powersports. This comprehensive service manual provides detailed information for the maintenance, repair, and troubleshooting of the 2009 Sportsman 400. It covers all major systems, including the engine, fuel, cooling, drivetrain, suspension, steering, brakes, and electrical systems. The manual includes step-by-step repair instructions, routine maintenance schedules, diagnostic procedures, and detailed technical specifications, such as torque values and fluid capacities. This resource is designed to assist owners and technicians in keeping the ATV in optimal working condition. 🏷️ Basic Information Identification Make: Polaris Model: Sportsman 400 Year: 2009 Vehicle Type: ATV (All-Terrain Vehicle) 👋 Introduction Market Position Segment: Mid-size utility ATV segment, known for its versatility and robust performance Competitive Analysis Key Competitors 2009: Honda Rancher, Yamaha Wolverine, Kawasaki Brute Force Key Features Powertrain Emphasis: Focus on the reliable Polaris 330cc engine Off Road Capability: All-wheel drive (AWD) system, independent suspension 📋 Manual Details Coverage Areas Manual Scope: Comprehensive service, repair, and troubleshooting Page Count Estimated Pages: 300+ Manual Type Type: Service Manual / Workshop Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine Overhaul: Complete engine disassembly, inspection, repair, and reassembly Fuel System: Carburetor service, fuel pump, fuel lines, fuel filter replacement Cooling System: Radiator, fan, thermostat, coolant flush and replacement Exhaust System: Muffler, exhaust pipes, heat shields Transmission And Drivetrain: Gearbox, final drive, differential, drive shafts, CV joints Suspension: Front and rear suspension components, shocks, springs, bushings Steering: Handlebar, tie rods, steering column, steering rack Brakes: Hydraulic brake system, master cylinder, calipers, brake pads, fluid replacement Electrical System: Ignition system, starter motor, alternator, battery, lighting, wiring diagrams Frame And Bodywork: Chassis, body panels, plastics, seat, handlebars Wheels And Tires: Tire pressure, rotation, replacement Procedures Included Routine Maintenance: Oil changes, filter replacements, spark plug checks, lubrication Troubleshooting: Diagnostic flowcharts for common problems and their solutions Repair Instructions: Step-by-step guides for component removal, installation, and adjustment Rebuilds: Detailed instructions for major component rebuilds (e.g., engine, transmission) Adjustments: Carburetor adjustment, valve clearance, brake lever adjustments Wiring Diagrams: Complete electrical system schematics for accurate diagnosis and repair Technical Depth Diagnostic Capability: Advanced diagnostics with detailed symptom analysis and root cause identification Rebuild Depth: Full rebuild specifications including torque values, clearances, and component tolerances Service Level: Suitable for professional mechanics and advanced DIY enthusiasts 📊 Manual Specifications File Format Format Details: Searchable PDF for easy navigation and printing Print Quality Image Resolution: High-resolution images and diagrams for clarity Binding Type Binding: N/A (Digital PDF Download) Paper Type Paper Quality: N/A (Digital PDF Download) ⚙️ Engine Specifications Primary Engine Engine Type: 4-stroke, SOHC, 2-valve Engine Displacement: 330cc (Note: Model name '400' might refer to historical variants or a class designation, but the 2009 model typically features the 330cc engine) Bore X Stroke: Refer to specific manual for exact figures, typically around 78mm x 69mm Cooling Method: Liquid-cooled Performance Horsepower: Approximately 22-25 HP (estimated, actual figures vary) Torque: Approximately 20-22 lb-ft (estimated) Fuel System Carburetor Model: Mikuni BNS34 or similar (specific model may vary, check manual) Fuel Type: Unleaded Gasoline (91 octane recommended) Fluid Specifications Engine Oil Type: SAE 20W-50 or SAE 10W-40 (check manual for specific viscosity based on temperature) Engine Oil Capacity: Approximately 2.0 US quarts (1.9 L) with filter change (verify in manual) 🔧 Transmission Standard Transmission Type: Automatic (PVT - Polaris Variable Transmission) with engine braking Drive Modes: 2WD/4WD Features Gearbox Features: High/Low range, Neutral, Reverse Fluid Specifications Transmission Fluid Type: Polaris AGL Synthetic Gearcase Lubricant or equivalent Transmission Fluid Capacity: Refer to manual for specific gearbox fluid capacity 📐 Dimensions Exterior Length: Approx. 82 inches (208 cm) Width: Approx. 46 inches (117 cm) Height: Approx. 47 inches (119 cm) Weights Dry Weight: Approx. 630 lbs (286 kg) Towing Capacity: 1500 lbs (680 kg) Rack Capacity Front: 100 lbs (45 kg) Rack Capacity Rear: 200 lbs (90 kg) Wheels And Tires Front Tire Size: AT 25x8-12 Rear Tire Size: AT 25x10-12 Wheelbase: Approx. 50.5 inches (128 cm) 🛡️ Safety Features Active Features Braking System: Hydraulic disc brakes front and rear 4Wd System: On-Demand All-Wheel Drive Passive Features Throttle Safety: Thumb throttle with safety mechanism Parking Brake: Handlebar mounted parking brake 💡 Technology Features Infotainment Display Panel: Digital gauge cluster with speedometer, odometer, trip meter, fuel gauge, clock, gear indicator Driver Assistance Engine Braking: Integrated into the PVT system for downhill control Connectivity Charging System: 12V DC outlet...