The Polaris Sport 400, including the 400L variant, represents a significant offering from a manufacturer with a rich history in powersports. Produced for the 1996 and 1997 model years, this ATV was designed with a focus on agility and performance, catering to recreational riders and enthusiasts. Its engineering quality is evident in its robust steel frame and a 375cc liquid-cooled, 2-stroke engine, delivering approximately 28-32 horsepower through an Automatic Variable Transmission. Key features include hydraulic disc brakes for reliable stopping power and a suspension system designed for off-road capability. This comprehensive factory service repair workshop manual provides in-depth guidance for the maintenance, troubleshooting, and repair of your Polaris Sport 400. It covers all major systems, including detailed procedures for engine overhaul, transmission servicing, drivetrain components, suspension, brakes, and the electrical system. The manual is designed to assist owners, independent repair shops, and technicians in performing everything from routine oil changes and filter replacements to complete engine and transmission rebuilds. With its extensive coverage and step-by-step instructions, this manual is an essential resource for ensuring the longevity and optimal performance of your vehicle. 🏷️ Basic Information Identification Make: Polaris Model: Sport 400 Model Variant: 400L Years Covered: 1996, 1997 👋 Introduction Market Position Target Audience: Polaris Sport 400/400L owners, independent repair shops, DIY enthusiasts. Competitive Analysis Value Proposition: Provides professional-grade repair and maintenance information at a fraction of dealer costs, enabling owners to perform their own servicing and repairs. Key Features Content Quality: Highly detailed, step-by-step instructions with detailed photos and diagrams, identical to what professional mechanics use. Accessibility: Instant download, compatible with all Windows and Mac computers, tablets, and smartphones. 📋 Manual Details Coverage Areas Primary Coverage: Service, Repair, Workshop Page Count Estimated Pages: Hundreds (specific number not provided, but described as extensive) Manual Type Type: Factory Service Repair Workshop Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine: Complete overhaul, diagnostics, tuning, lubrication, cooling system, fuel system (carburetor, fuel pump), exhaust system. Transmission: Removal, installation, inspection, adjustment, lubrication, drive clutch, driven clutch, belt service, gearbox. Drivetrain: Drive shafts, U-joints, differential (if applicable), rear axle, chain drive (if applicable). Suspension: Front and rear suspension components, shock absorbers, springs, bushings, control arms, steering linkage, wheel bearings. Brakes: Hydraulic system, brake calipers, brake pads, brake discs, master cylinder, brake lines, bleeding procedures, parking brake. Electrical System: Battery, charging system (stator, regulator/rectifier), ignition system (CDI, coil, spark plug), lighting, starting system (starter motor, solenoid), wiring diagrams, component testing. Chassis And Frame: Frame inspection, welds, component mounting, seat assembly, handlebars, footpegs. Bodywork And Trim: Fenders, plastic body panels, decals, seat cover, storage compartments. Procedures Included Maintenance: Oil changes, filter replacements, spark plug service, air filter cleaning/replacement, chain lubrication/adjustment, clutch adjustment, general inspection. Troubleshooting: Systematic diagnostic guides for common and uncommon problems, error code interpretation (if applicable), electrical system fault finding. Repair: Step-by-step instructions for component removal, disassembly, inspection, repair, reassembly, and installation for all major systems. Rebuilds: Detailed instructions for complete engine and transmission rebuilds. Technical Depth Depth: Comprehensive, from basic maintenance to complete engine and transmission overhauls, including in-depth electrical diagnostics. 📊 Manual Specifications File Format Format: PDF Searchable Text: Likely searchable (standard for modern PDFs, though not explicitly stated) Print Quality Print Capability: Printable (single pages or entire manual) Binding Type Binding: Digital (downloadable, no physical binding) Paper Type Paper: Not Applicable (Digital Format) Licensing Usage Rights: Unlimited use on multiple devices, lifetime access, no expiry ⚙️ Engine Specifications Primary Engine Type: 2-stroke, liquid-cooled, reed-valve inducted Displacement: 375cc (approximately, based on common knowledge of the 400cc class at the time) Bore X Stroke: Specific dimensions would be detailed in the manual, typical for this class ~64mm x 60mm. Performance Horsepower Estimate: Approximately 28-32 HP (typical for this engine class) Torque Estimate: Specific figures not readily available without the manual, but sufficient for ATV use. Fuel System Carburetion: Mikuni VM34 or similar (typical for this model) Fuel Type: Unleaded gasoline Lubrication Oil Type: 2-stroke engine oil, premix or oil injection system (manual will specify exact type and ratio). Cooling System Type: Liquid-cooled Coolant Type: Ethylene glycol-based antifreeze/coolant (manual will specify OAT or HOAT and concentration). 🔧 Transmission Standard Type: Automatic Variable Transmission (AVT) with Polaris Variable Induction (PVI) clutch system. Optional Options: N/A (standard for this model) Features Drive System: Shaft drive to rear wheels. Gear Reduction: Integrated into the transmission/drivetrain assembly. Fluid Specifications Clutch Fluid: Specific fluid type and capacity for the PVT system will be detailed in the manual. 📐 Dimensions Exterior Length: Specific dimensions would be detailed in the manual, typically around 70-75 inches. Width: Specific dimensions would be detailed in the manual, typically around 44-46 inches. Height: Specific dimensions would be detailed in the manual, typically around 40-42 inches. Weights Dry Weight: Approximately 450-470 lbs. Ground Clearance: Approximately 8-10 inches. Towing Capacity: Not typically...