🏷️ Basic Information Identification Make: Polaris Model: Sportsman 400 Product Name: Polaris Sportsman 400 Parts Manual PDF Download Codes Chassis Code: A04CH42AA, AE, AG 👋 Introduction Market Position Market Position: The Polaris Sportsman 400, particularly in its generation represented by these codes, was positioned as a capable and versatile utility ATV, suitable for work and recreational trail riding. It offered a balance of power, comfort, and reliability for its class. Competitive Analysis Competitive Analysis: Competed with models from manufacturers like Yamaha (Grizzly), Honda (FourTrax/Rancher), and Can-Am (Outlander) in the mid-displacement utility ATV segment. Key selling points were often Polaris's independent rear suspension (IRS) and comfortable rider ergonomics. Key Features Key Features: Likely featured Polaris's proprietary Lock & Ride accessory system, automatic transmission (PVT - Polaris Variable Transmission), shaft drive, and a focus on rider comfort with features like comfortable seating and ergonomic controls. 📋 Manual Details Coverage Areas Coverage Areas: Complete parts identification and catalog for the Polaris Sportsman 400. Likely includes all major mechanical and electrical components, chassis parts, body panels, and accessories. Page Count Page Count: Not specified, but described as a 'complete guide'. Manual Type Manual Type: Parts Manual / Catalog Language Language: English (Assumed, standard for North American market) Format Format: PDF Download (Instant download) 📖 Manual Coverage Systems Covered Systems Covered: Engine, drivetrain, suspension, steering, braking, electrical system, fuel system, cooling system, chassis, frame, body panels, accessories, and potentially emissions components. Cooling System Parts: Radiator, hoses, water pump, thermostat, fan. Braking System Parts: Master cylinders, brake calipers, brake lines, brake pads, brake rotors, parking brake mechanism. Steering System Parts: Handlebars, steering shaft, tie rods, ball joints, steering knuckles. Electrical System Parts: Battery, starter, alternator/stator, ignition coil, wiring harness, lights, switches, CDI unit. Chassis Frame Parts: Frame, sub-frame, mounting brackets, hitch components. Body Panels Accessories: Fenders, racks, plastics, seat, footwells, bumpers, winch mounting points (if applicable). Procedures Included Procedures Included: Parts identification, assembly diagrams, part numbering, component lookup for ordering replacement parts. Does not typically include repair procedures, only part identification. Part Number Lookup: Primary function: Identify and locate specific part numbers for ordering. Includes detailed diagrams for visual confirmation. Assembly Disassembly Diagrams: Exploded views showing how components fit together, crucial for understanding part relationships. Technical Depth Technical Depth: Detailed breakdown of all replaceable parts with exploded views and corresponding part numbers. Essential for accurate part ordering and inventory management. Compatibility Information: Essential for ensuring that purchased parts are correct for the specific chassis codes (A04CH42AA, AE, AG) and potentially model years covered by the manual. 📊 Manual Specifications File Format File Format: PDF Print Quality Print Quality: Digital, quality depends on source document; expected to be clear for diagrams and text. Binding Type Binding Type: N/A (Digital) Paper Type Paper Type: N/A (Digital) ⚙️ Engine Specifications Primary Engine Engine Type: Liquid-cooled, 4-stroke, SOHC, 4-valve, Single-cylinder Displacement: 375 cc to 400 cc (Typical for this model designation, specific to the generation represented by A04CH codes) Performance Horsepower: Estimated 20-25 HP (Approximate, actual may vary by year/tuning) Torque: Not specified, but designed for low-end torque for utility tasks. Fuel System Fuel System: Carbureted (Likely Mikuni or Keihin, specific size not provided in product info) Ignition Ignition System: CDI 🔧 Transmission Standard Transmission Type: Automatic (Polaris Variable Transmission - PVT) with high/low range and reverse Optional Optional Transmission: N/A (Automatic PVT was standard on most Sportsman 400 models) Features Drive System: Shaft Drive, On-Demand All-Wheel Drive (AWD) / 2WD selectable 📐 Dimensions Exterior Overall Length: Approx. 81-83 inches (Varies by year) Overall Width: Approx. 46-48 inches (Varies by year) Overall Height: Approx. 48 inches (Varies by year) Wheelbase: Approx. 50.2 inches (Varies by year) Weights Dry Weight: Approx. 560-580 lbs (Varies by year) Towing Capacity: 660 lbs Rack Capacity Front: 90 lbs Rack Capacity Rear: 180 lbs 🛡️ Safety Features Ratings Safety Ratings: Not Applicable (ATVs are not typically rated by NCAP or similar automotive bodies; focus is on operational safety features.) Active Features Active Features: Engine braking in PVT, On-Demand AWD for improved traction, hydraulic disc brakes on all wheels. Passive Features Passive Features: Full floorboards with heel guards, ergonomic handgrips, comfortable seating position. Designed with safety standards for ATVs in mind. 💡 Technology Features Infotainment Infotainment Features: N/A (Utility ATV - no traditional infotainment systems). Driver Assistance Driver Assistance Features: N/A (Focus is on mechanical operation, not electronic driver aids). Connectivity Connectivity Features: N/A 🔧 Maintenance Service Intervals Oil Change Interval: Typically every 50 hours or 6 months for engine oil and filter. (Consult specific manual for exact intervals). Air Filter Cleaning: Inspect every 25 hours, clean or replace as needed. Spark Plug Replacement: Recommended every 100 hours or annually. Transmission Fluid Change: Recommended every 100 hours or annually for PVT and final drive. Fluid Specifications Engine Oil Type: Polaris PS-4 5W-50 Synthetic (or equivalent API...