2009 POLARIS SPORTSMAN 300 / SPORTSMAN 400 HO Service Repair Manual (Highly Detailed FSM PDF Preview) Download
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Basic Information Identification Make: Polaris Model: Sportsman 400 H.O. Year: 2009 Codes Chassis Code: Not specified in product information Engine Code: Not specified in product information Introduction Market Position Target Audience: Owners, DIY mechanics, service technicians Competitive Analysis Comparison: Equivalent to dealer-used service manuals Key Features Delivery: Instant download Value Proposition: Saves money on repairs and maintenance, provides comprehensive knowledge Manual Details Coverage Areas Covered Models: 2009 Polaris Sportsman 300, 2009 Polaris Sportsman 400 H.O. Page Count Total Pages: 292 Manual Type Type: Official Full Workshop Service and Repair Manual Language Language: English Format Format: PDF Manual Coverage Systems Covered Systems: General Information, Maintenance, Engine, Fuel System, Body, Steering, Suspension, CVT/Transmission, Final Drive, Brakes, Electrical, Wire Diagrams Procedures Included Procedures: Complete tear down and rebuild, maintenance, troubleshooting, repair, refurbishment, restoration, installation Technical Depth Depth: Highly detailed, workshop level Manual Specifications File Format File Type: PDF Print Quality Printability: All pages printable without restriction Binding Type Binding: Not applicable (Digital Download) Paper Type Paper Quality: Not applicable (Digital Download) Organization Features: Bookmarks, Searchable Text, Index Engine Specifications Primary Engine Engine Type: Not explicitly detailed in product information, but typical for the model year would be a single-cylinder, liquid-cooled engine. Displacement: Sportsman 300: Typically around 272cc. Sportsman 400 H.O.: Typically around 375cc (H.O. denotes High Output). Performance Horsepower Torque: Specific figures not provided, but the manual covers engine performance tuning and specifications. Fuel System Fuel Delivery: Likely carbureted for the Sportsman 300 and potentially Electronic Fuel Injection (EFI) for the Sportsman 400 H.O., with specific details covered in the manual. Components Cooling System: Liquid-cooled (as implied by radiator mention in tags) Ignition System: Covered in Electrical section, likely CDI or similar Transmission Standard Type: Automatic (CVT - Continuously Variable Transmission) Optional Optional Types: None typically for this model segment Features Features: High/Low range, Reverse. Manual covers CVT maintenance, clutch adjustment, belt replacement. Dimensions Exterior Length Width Height: Specific dimensions not provided, but manual covers bodywork, fenders, plastics. Weights Dry Weight: Not specified in product information, but relevant specifications are covered in the manual. Curb Weight: Not specified in product information, but relevant specifications are covered in the manual. Wheelbase Wheelbase: Not specified in product information, but relevant specifications are covered in the manual. Safety Features Ratings Safety Ratings: Not applicable for ATVs in the traditional automotive sense. Active Features Active Safety: Hydraulic brakes (covered), advanced suspension geometry (covered). Passive Features Passive Safety: Handlebar grips, rider positioning considerations for stability. Technology Features Infotainment Infotainment System: Basic instrumentation typical for ATVs of this era (speedometer, odometer, fuel gauge). No advanced infotainment. Driver Assistance Driver Assistance Features: None Connectivity Connectivity Options: None Electrical Lighting: Front and rear lighting systems covered, including troubleshooting for bulbs and wiring. Starting System: Electric starter and associated components covered. Charging System: Stator, rectifier/regulator, and battery charging system detailed. Wiring Diagrams: Comprehensive wiring diagrams are included for easy diagnosis and repair. Maintenance Service Intervals Scheduled Maintenance: The manual details comprehensive maintenance schedules for all systems, including oil changes, filter replacements, and inspections. Fluid Specifications Engine Oil: Specific viscosity and API rating for engine oil would be detailed in the manual. Likely SAE 5W-50 or similar for ATV applications. Coolant Type: Manual will specify the correct type of antifreeze/coolant for the liquid-cooled engine. Brake Fluid: Manual will specify the DOT rating for brake fluid. Gear Oil: Manual will specify the correct type and viscosity for final drive and transmission lubrication. Known Issues Common Problems: While not explicitly stated as 'known issues', the manual's troubleshooting sections address common problems such as starting issues, drive belt wear, suspension noise, and electrical gremlins. Torque Specs Torque Values: Extensive torque specifications for all fasteners and critical components are provided. Filter Part Numbers Filters: While specific part numbers aren't listed in the product description, the manual will identify the correct oil filters, air filters, and fuel filters. Vehicle History Brand Heritage Brand Focus: Polaris is a well-established manufacturer of powersports vehicles, including ATVs. Model Evolution Series History: The Sportsman line is a popular and long-standing series of ATVs known for their utility and trail riding capabilities. The 300 and 400 H.O. are mid-size offerings within this lineup. Production Manufacturing Location: Not specified in product information, but Polaris primarily manufactures in the USA. Awards & Recognition Recognitions Industry Recognition: Polaris Sportsman line generally receives positive reviews for utility and off-road capability, though specific awards for the 2009 models are not detailed here. Ratings Consumer Ratings: The manual's existence and comprehensiveness reflect a commitment to product support and customer satisfaction, which indirectly contributes to positive ownership experiences. Certifications Manufacturing Certifications: Not specified in product information. Vehicle Specifications Engine Engine Description: Single-cylinder, four-stroke, liquid-cooled engine with overhead valve (OHV) or single overhead cam (SOHC) configuration. Specifics vary between 300 and 400 H.O. Suspension Front Suspension: MacPherson strut or independent double...
General Information, Maintenance, Engine, Fuel System, Body, Steering, Suspension, CVT/Transmission, Final Drive, Brakes, Electrical, Wire Diagrams
Procedures Included
Procedures:
Complete tear down and rebuild, maintenance, troubleshooting, repair, refurbishment, restoration, installation
Technical Depth
Depth:
Highly detailed, workshop level
Manual Specifications
File Format
File Type:
PDF
Print Quality
Printability:
All pages printable without restriction
Binding Type
Binding:
Not applicable (Digital Download)
Paper Type
Paper Quality:
Not applicable (Digital Download)
Organization
Features:
Bookmarks, Searchable Text, Index
Engine Specifications
Primary Engine
Engine Type:
Not explicitly detailed in product information, but typical for the model year would be a single-cylinder, liquid-cooled engine.
Displacement:
Sportsman 300: Typically around 272cc. Sportsman 400 H.O.: Typically around 375cc (H.O. denotes High Output).
Performance
Horsepower Torque:
Specific figures not provided, but the manual covers engine performance tuning and specifications.
Fuel System
Fuel Delivery:
Likely carbureted for the Sportsman 300 and potentially Electronic Fuel Injection (EFI) for the Sportsman 400 H.O., with specific details covered in the manual.
Components
Cooling System:
Liquid-cooled (as implied by radiator mention in tags)
Ignition System:
Covered in Electrical section, likely CDI or similar
Handlebar grips, rider positioning considerations for stability.
Technology Features
Infotainment
Infotainment System:
Basic instrumentation typical for ATVs of this era (speedometer, odometer, fuel gauge). No advanced infotainment.
Driver Assistance
Driver Assistance Features:
None
Connectivity
Connectivity Options:
None
Electrical
Lighting:
Front and rear lighting systems covered, including troubleshooting for bulbs and wiring.
Starting System:
Electric starter and associated components covered.
Charging System:
Stator, rectifier/regulator, and battery charging system detailed.
Wiring Diagrams:
Comprehensive wiring diagrams are included for easy diagnosis and repair.
Maintenance
Service Intervals
Scheduled Maintenance:
The manual details comprehensive maintenance schedules for all systems, including oil changes, filter replacements, and inspections.
Fluid Specifications
Engine Oil:
Specific viscosity and API rating for engine oil would be detailed in the manual. Likely SAE 5W-50 or similar for ATV applications.
Coolant Type:
Manual will specify the correct type of antifreeze/coolant for the liquid-cooled engine.
Brake Fluid:
Manual will specify the DOT rating for brake fluid.
Gear Oil:
Manual will specify the correct type and viscosity for final drive and transmission lubrication.
Known Issues
Common Problems:
While not explicitly stated as 'known issues', the manual's troubleshooting sections address common problems such as starting issues, drive belt wear, suspension noise, and electrical gremlins.
Torque Specs
Torque Values:
Extensive torque specifications for all fasteners and critical components are provided.
Filter Part Numbers
Filters:
While specific part numbers aren't listed in the product description, the manual will identify the correct oil filters, air filters, and fuel filters.
Vehicle History
Brand Heritage
Brand Focus:
Polaris is a well-established manufacturer of powersports vehicles, including ATVs.
Model Evolution
Series History:
The Sportsman line is a popular and long-standing series of ATVs known for their utility and trail riding capabilities. The 300 and 400 H.O. are mid-size offerings within this lineup.
Production
Manufacturing Location:
Not specified in product information, but Polaris primarily manufactures in the USA.
Awards & Recognition
Recognitions
Industry Recognition:
Polaris Sportsman line generally receives positive reviews for utility and off-road capability, though specific awards for the 2009 models are not detailed here.
Ratings
Consumer Ratings:
The manual's existence and comprehensiveness reflect a commitment to product support and customer satisfaction, which indirectly contributes to positive ownership experiences.
Certifications
Manufacturing Certifications:
Not specified in product information.
Vehicle Specifications
Engine
Engine Description:
Single-cylinder, four-stroke, liquid-cooled engine with overhead valve (OHV) or single overhead cam (SOHC) configuration. Specifics vary between 300 and 400 H.O.
Suspension
Front Suspension:
MacPherson strut or independent double A-arm front suspension, covered in detail. Likely features adjustable spring preload.
Rear Suspension:
Independent Rear Suspension (IRS) with dual A-arms and shock absorbers, covered in detail. Likely features adjustable spring preload.
Brakes
Front Brakes:
Hydraulic disc brakes, typically dual discs.
Rear Brakes:
Hydraulic disc brake, typically single disc.
Wheels Tires
Wheels:
Steel wheels, typically 12-inch diameter. Bolt pattern not specified but covered in manual.
Tires:
All-terrain tires. Tire pressures and recommended sizes are covered.
Steering
Steering System:
Rack and pinion steering. Manual covers steering linkage, tie rods, and potential for electronic power steering (EPS) on some variants, though likely not standard on these models.
Body
Body Construction:
Steel frame with plastic body panels (fenders, plastics, side covers). Manual covers bodywork repair and component removal/installation.
Frame
Frame Type:
Steel frame
Lighting
Headlights:
Dual headlights, likely 35W/35W or similar halogen bulbs. Rear taillight/brakelight.
Fuel
Fuel Tank Capacity:
Typically around 3.2 gallons (12.1 liters). Manual covers fuel system components and maintenance.
Drive Train
Drive System:
Selectable 2WD/AWD. Manual covers front and rear driveshafts, differentials, and hub components.
Controls
Throttle Control:
Thumb throttle. Manual covers throttle cable adjustment and operation.
Brake Controls:
Left handlebar lever for front brakes, right handlebar lever for rear brakes.
Towing Capacity
Towing Capacity:
Typically rated for around 750-1000 lbs (340-454 kg) for towing. Manual may cover hitch installation and trailer wiring.
Rack Capacity
Front Rear Rack Capacity:
Typically rated for around 50 lbs (23 kg) on the front rack and 100 lbs (45 kg) on the rear rack. Manual covers rack mounting and specifications.