🏷️ Basic Information Identification Make: Polaris Model: Sport 400 Model Years Covered: 1996, 1997, 1998 Product Type: Repair Service Manual Product Format: PDF Download Codes Atv Type: All-Terrain Vehicle (ATV) 👋 Introduction Market Position Atv Segment: Sport ATV, aimed at recreational riding and light trail use. Competitive Analysis Competitors Era: Competed with models from Yamaha (Warrior, Banshee), Suzuki (QuadSport), and Kawasaki (Bayou, Lakota) during its production run. Key Features Sport Focus: Designed for agile handling and sporty performance, distinguishing it from utility-focused ATVs. Engine Type: 2-stroke engine for a power-to-weight advantage characteristic of sport ATVs. 📋 Manual Details Coverage Areas Service Coverage: Comprehensive service, maintenance, and troubleshooting for all models within the specified years. Page Count Estimated Page Count: Likely 300-500 pages (typical for detailed workshop manuals of this era) Manual Type Manual Type: Workshop Repair Service Manual Language Language: English Format File Format: PDF (Portable Document Format) 📖 Manual Coverage Systems Covered Engine: Detailed breakdown of the 398cc liquid-cooled 2-stroke engine, including disassembly, assembly, timing, and adjustments. Fuel System: Carburetor (Mikuni VM34-3) inspection, cleaning, adjustment, jetting, and fuel pump operation. Ignition System: CDI ignition system, stator, coil, spark plug specifications, and troubleshooting. Cooling System: Radiator, fan, thermostat, water pump, hoses, and coolant specifications and maintenance. Transmission Drivetrain: CVT (Continuously Variable Transmission) system, drive belt inspection and replacement, clutch operation, and final drive components (chain/sprockets). Suspension: Front and rear suspension systems, shock absorber adjustments, bushings, and ball joint service. Brakes: Hydraulic disc brake system, caliper maintenance, pad replacement, fluid bleeding, master cylinder service, and brake line inspection. Electrical System: Wiring diagrams, lighting system, battery maintenance, starter motor, and charging system troubleshooting. Chassis Frame: Frame inspection, steering system service, and handlebar components. Bodywork Trim: Fender, seat, and panel removal and installation procedures. Procedures Included Routine Maintenance: Oil changes, filter replacements, chain lubrication, spark plug checks, and general inspection procedures. Troubleshooting Diagnostics: Step-by-step diagnostic flowcharts for common starting, running, and electrical issues. Engine Repair: Top-end rebuilds (piston, rings, cylinder), crankshaft seal replacement, and valve adjustments (if applicable, though likely none on this 2-stroke). Transmission Service: CVT clutch inspection, adjustment, and replacement procedures; drive clutch sheave service. Brake System Repair: Brake caliper overhaul, piston seal replacement, and hydraulic system bleeding. Electrical Diagnostics: Using a multimeter for testing ignition components, charging system, and lighting circuits. Suspension Component Replacement: Shock absorber and spring replacement procedures. Steering Component Service: Tie rod end replacement and steering stem bearing service. Technical Depth Depth Of Information: Detailed technical specifications, torque values, clearances, and diagnostic procedures for professional-level repairs and maintenance. Diagnostic Tools: Implied use of basic hand tools, torque wrenches, and a multimeter for troubleshooting. Component Rebuilds: Covers complete rebuilds of major components like the engine and carburetor. 📊 Manual Specifications File Format File Format Details: PDF format, likely allowing for text search and printing of individual pages. Print Quality Digital Quality: Assumed to be clear, legible scans or digitally created documents suitable for professional use. Binding Type Binding Type Digital: N/A (Digital PDF) Paper Type Paper Type Digital: N/A (Digital PDF) ⚙️ Engine Specifications Primary Engine Engine Type: 2-stroke, 1-cylinder, liquid-cooled Displacement: 398cc (24.3 cubic inches) Bore X Stroke: 80.0 mm x 79.0 mm Compression Ratio: 6.7:1 Carburetor: Mikuni VM34-3 Performance Horsepower: Approx. 30-35 HP (estimated for this class and era) Torque: Not explicitly stated in product info, but expected to be robust for its displacement. Fuel System Fuel Type: Unleaded gasoline (typically 87-91 octane recommended) Fuel Mixture: Automatic oil injection (pre-mix not required) Lubrication Oil Type: Polaris 2-stroke synthetic oil injection lubricant (refer to manual for specific part numbers/types) Cooling System Cooling Medium: Liquid Cooling Coolant Type: Ethylene Glycol based antifreeze with rust inhibitors (refer to manual for specific mix ratio) 🔧 Transmission Standard Transmission Type: Automatic Continuously Variable Transmission (CVT) with Forward, Neutral, Reverse. Optional Gear Reduction: Not applicable to CVT. Features Drive System: Shaft Drive to rear axle (likely). Clutch Type: Drive clutch and driven clutch (centrifugal type). Transmission Fluid: Refer to manual for specific CVT fluid type and capacity. Typically a specialized CVT fluid or ATF is used. 📐 Dimensions Exterior Length: Approx. 71.5 inches Width: Approx. 45 inches Height: Approx. 43 inches Weights Dry Weight: Approx. 450 lbs (204 kg) Ground Clearance: Approx. 5.5 inches Fuel Capacity: Approx. 3.2 gallons (12.1 liters) Towing Capacity: Not designed for towing. Rack Capacity: Not specified for this sport model, but typically minimal. 🛡️ Safety Features Ratings Safety Standards: Designed to meet industry safety standards for ATVs of its era. Active Features Braking System: Hydraulic disc brakes on all wheels for effective stopping power. Lighting: Headlights and taillight for visibility. Passive Features Operator Control: Handlebar steering with hand controls for throttle and brakes. Rollover Protection: N/A (standard for ATVs of this era). 💡 Technology Features Infotainment Infotainment Features: N/A (Basic recreational vehicle, no infotainment system). Driver Assistance...