The Polaris Sportsman 400, produced from 1996 to 2003, is a capable All-Terrain Vehicle designed for a variety of uses, from demanding utility tasks to recreational trail riding. This ATV is powered by a reliable liquid-cooled, 4-stroke, single-cylinder engine, offering dependable performance. Its engineering emphasizes durability and user-friendliness, featuring a Variable Transmission with automatic clutch for seamless operation and a selectable 2WD/4WD system to conquer challenging terrain. With independent front suspension and a robust chassis, the Sportsman 400 provides a stable and comfortable ride, making it a versatile choice for off-road enthusiasts, farmers, and hunters. This comprehensive Factory Service Repair Manual provides detailed guidance for the maintenance, repair, and troubleshooting of your Polaris Sportsman 400. It covers essential systems including the engine overhaul, fuel system, ignition, cooling, drivetrain, and braking systems. You will find step-by-step procedures for preventive maintenance, detailed troubleshooting guides, engine and transmission repair instructions, electrical diagnostics, and suspension component replacement. The manual also includes critical technical specifications, torque values, fluid capacities, and wiring diagrams, ensuring that owners and technicians have the necessary information to keep the vehicle in optimal condition. 🏷️ Basic Information Identification Make: Polaris Model: Sportsman 400 Model Years Covered: 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003 👋 Introduction Market Position Vehicle Segment: All-Terrain Vehicle (ATV), utility and recreational focus. Target Audience: Off-road enthusiasts, farmers, hunters, and recreational riders seeking a robust and capable ATV. Competitive Analysis Key Competitors: Honda FourTrax, Yamaha Wolverine, Kawasaki Bayou, Suzuki QuadRunner. Key Features Engine Type: Liquid-cooled, 4-stroke, single-cylinder engine, known for reliable power delivery. Transmission Type: Polaris Variable Transmission (PVT) with automatic clutch, providing seamless gear changes. Drivetrain: Selectable 2WD/4WD system offering enhanced traction in challenging terrain. Suspension: Independent front suspension and a single shock rear suspension setup for improved ride comfort and handling. 📋 Manual Details Coverage Areas Manual Type: Factory Service Repair Manual Language: English Format: PDF Download 📖 Manual Coverage Systems Covered Engine Overhaul: Complete disassembly, inspection, repair, and reassembly procedures for the 400cc engine. Fuel System: Carburetor tuning, cleaning, and rebuilding; fuel pump operation and testing. Ignition System: Ignition coil testing, spark plug specifications, CDI unit diagnostics. Cooling System: Radiator, fan, thermostat, and coolant hose inspection and replacement. Drivetrain: Primary drive clutch, secondary clutch (driven clutch), belt inspection and replacement. Transmission Drive: PVT (Polaris Variable Transmission) system service, belt tension, roller and sheave maintenance. Drive Shafts And Axles: CV joint inspection, boot replacement, driveshaft alignment. Suspension Front: A-arm bushings, ball joint inspection and replacement, shock absorber service, steering components. Suspension Rear: Swing arm bushings, shock absorber service, linkage inspection. Braking System Front: Brake caliper overhaul, brake pad replacement, rotor inspection, brake line bleeding. Braking System Rear: Brake caliper overhaul, brake pad replacement, rotor inspection, brake line bleeding. Wheels And Tires: Tire pressure specifications, wheel bearing service, hub maintenance. Electrical System: Wiring diagrams, battery testing and charging, lighting system troubleshooting, starter and charging system diagnostics. Frame And Body: Frame inspection for damage, plastic panel removal and installation, seat repair. Procedures Included Preventive Maintenance: Detailed schedules for oil changes, filter replacements, lubrication points, and periodic inspections. Troubleshooting Guides: Systematic diagnostic procedures for common and uncommon problems with step-by-step solutions. Engine Repair: Piston and cylinder replacement, valve adjustment, gasket replacement, crankshaft and connecting rod checks. Transmission Repair: PVT clutch component replacement, roller service, spring replacement, drive belt adjustment. Brake System Service: Brake caliper rebuilding, master cylinder service, brake pad and rotor replacement, bleeding procedures. Electrical Diagnostics: Using a multimeter for component testing, tracing electrical faults, starter motor and charging system testing. Suspension Component Replacement: Ball joint, tie rod end, bushing, and shock absorber replacement. Carburetor Adjustment: Idle speed settings, mixture adjustments, jetting recommendations. Special Tool Identification: Lists and descriptions of specialized tools required for specific repair procedures. Technical Depth Repair Scope: Comprehensive coverage from basic maintenance to complete engine and transmission rebuilds. Diagnostic Capability: Advanced diagnostic information for electrical and mechanical systems, including troubleshooting flowcharts. Specifications Detail: Detailed torque specifications, clearances, fluid capacities, and electrical resistance values. 📊 Manual Specifications File Format File Type: PDF (Portable Document Format) Searchability: Searchable text content allowing for quick lookup of specific terms and components. Printability: Printable pages, suitable for use in a workshop environment. Resolution: High-resolution for clear display of diagrams, illustrations, and text. Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: 4-stroke, liquid-cooled, single-cylinder Displacement: 378cc (approximate, specific variants may vary slightly) Bore X Stroke: Refer to specific year sections in manual for exact dimensions Compression Ratio: Refer to specific year sections in manual for exact ratios Performance Horsepower: Estimated 20-25 HP (varies by year and specific tuning) Torque: Refer to specific year sections in manual for torque figures Fuel System Fuel Delivery: Carburetor (specific model varies by year, e.g., Mikuni BSR32) Fuel Type: Unleaded gasoline,...