The Polaris Sportsman 400, identified by chassis codes A04CH42AA, AE, and AG, represents a capable and versatile utility all-terrain vehicle. Engineered for both demanding work and recreational trail riding, it offers a robust blend of power, comfort, and reliability characteristic of its esteemed ATV line. Key features often include independent rear suspension for enhanced ride quality, an automatic Variable Transmission (PVT) with selectable All-Wheel Drive, and a focus on ergonomic design for rider comfort during extended use. This model competed effectively in the mid-displacement utility ATV segment, known for its balance and practical application. This manual serves as a comprehensive parts catalog for the Polaris Sportsman 400, specifically detailing components for the chassis codes mentioned. Its primary purpose is to provide clear and accurate identification of all replaceable parts across various systems, including the engine, drivetrain, suspension, steering, braking, and electrical systems. Through detailed exploded views and associated part numbers, this guide is an indispensable resource for owners, technicians, and mechanics. It facilitates the precise ordering of replacement parts, ensuring the correct components are sourced for maintenance and repair, thereby supporting the longevity and optimal performance of the vehicle. 🏷️ 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...