Polaris Sportsman 400 H.O. Owner's Manual

Polaris industries 2008 all-terrain vehicle owner's manual

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Owner's manual (137 pages)

Service manual (432 pages)

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Table of Contents

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Summary of Contents for Polaris Sportsman 400 H.O.

Page 1 • RANGER utility vehicles • Victory motorcycles We believe Polaris sets a standard of excellence for all utility and recre- ational vehicles manufactured in the world today. Many years of experi- ence have gone into the engineering, design, and development of your Polaris vehicle, making it the finest machine we’ve ever produced.
Page 2 POLARIS and POLARIS THE WAY OUT are registered trademarks of Polaris Indus- tries Inc. Copyright 2007 Polaris Sales Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant...
Page 3: Table Of Contents
Adjustments ......117 Polaris Products..... . . 121 Troubleshooting .
Page 5: Know Your Vehicle
Record your vehicle's identification numbers and key number in the spaces provided. Remove the spare key and store it in a safe place. An ignition key can be duplicated only by ordering a Polaris key blank (using your key number) and mating it with one of your existing keys.
Page 6: Safety
ATV, always read and follow the instructions of the decals on the ATV. If any decal becomes illegible or comes off, contact your Polaris dealer to purchase a replacement. Replacement safety decals are provided by Polaris at no charge.
Page 7: Safety Decals And Locations
Safety Decals and Locations Discretionary Warning WARNING • Never operate this ATV on HILLS steeper than 25 degrees 25°. To prevent flip-over on hilly terrain, when going up or down, use throttle and brakes gradually. • REVERSE operation can be dangerous even at low speeds.
Page 8: Age 16 Warning
SAFETY Safety Decals and Locations Age 16 Warning Rack Warning “No Passenger” Warning WARNING NEVER ride as a passenger. Passengers can cause a loss of control, resulting in SEVERE INJURY or DEATH. Age 16 Warning WARNING Operating this ATV if you are under the age of 16 increases your chance of severe injury or death.
Page 9: Reverse Override Warning
Safety Decals and Locations Rack Warning, Front and Rear WARNING • DO NOT TOW FROM RACK OR BUMPER. Vehicle damage or tipover may result causing severe injury or death. Tow only from tow hooks or hitch. • Max Rack Loads: Front 70 lbs. (32 kg) Rear 100 lbs. (46 kg) Reverse Override Warning WARNING Pushing reverse override button may cause sudden increases in power and...
Page 10: Safe Riding Gear
Boots Helmet Wearing a helmet can prevent a severe head injury. Whenever riding a Polaris vehicle, always wear a helmet that meets or exceeds established safety standards. Approved helmets in the USA and Canada bear a U.S. Department of Transportation (DOT) label.
Page 11: Eye Protection
Eye Protection Do not depend on eyeglasses or sunglasses for eye protection. When- ever riding a Polaris vehicle, always wear shatterproof goggles or use a shatterproof helmet face shield. Polaris recommends wearing approved Personal Protective Equipment (PPE) bearing markings such as VESC 8, V-8, Z87.1, or CE.
Page 12: Operator Safety
Failure to follow the warnings contained in this manual can result in severe injury or death. A Polaris ATV is not a toy and can be hazardous to operate. This vehicle han- dles differently than other vehicles, such as motorcycles and cars. A collision or rollover can occur quickly, even during routine maneuvers like turning, or driving on hills or over obstacles, if you fail to take proper precautions.
Page 13: Safety Training
Operator Safety Safety Training ATV safety training is a top priority for Polaris. When you purchased your new ATV, your dealer instructed you on the authorized ATV RiderCourse available to you and your eligible family members. This training is included in the purchase price of your ATV. Polaris strongly...
Page 14 Operator Safety The following signal words and symbols appear throughout this manual and on your vehicle. Your safety is involved when these words and sym- bols are used. Become familiar with their meanings before reading the manual. The safety alert symbol, on your vehicle or in this manual, alerts you to the potential for injury.
Page 15 • Never operate an ATV without proper instruction. Take a training course. Purchasers of a new Polaris ATV and their eligible family members are entitled to take the ATV RiderCourse Enrollment Express at (800) 887-2887 or visit www.atvsafety.org for information on enrollment in the ATV RiderCourse •...
Page 16 Practice turning at low speeds before attempting to turn at faster speeds. Do not turn at excessive speeds. • Always have the ATV inspected by an authorized Polaris dealer if it's been involved in an accident. • Never operate on hills too steep for the ATV or for your abilities.
Page 17 Operator Safety • Always check for obstacles before operating in a new area. Never attempt to operate over large obstacles, such as rocks or fallen trees. Always follow proper procedures when operating over obstacles as described in this manual. • Always be careful of skidding or sliding. On slippery surfaces like ice, travel slowly and use extra caution to reduce the chance of skid- ding or sliding out of control.
Page 18: Equipment Modifications
We are concerned for the safety of our customers and for the general public. Therefore, we strongly recommend that consumers do not install on a Polaris ATV any equipment that may increase the speed or power of the vehicle, or make any other modifications to the vehicle for these purposes.
Page 19 ATV safely and could be susceptible to accident or injury. HOW TO AVOID THE HAZARD No one under the age of 16 should operate a Polaris ATV. WARNING offered by contact ATV Enrollment...
Page 20 SAFETY Operator Safety POTENTIAL HAZARD Carrying a passenger on an ATV. WHAT CAN HAPPEN Carrying a passenger greatly reduces the oper- ator's ability to balance and control the ATV, which could cause an accident and injury to the operator and/or passenger. HOW TO AVOID THE HAZARD Never carry a passenger.
Page 21 Operator Safety POTENTIAL HAZARD Operating this ATV on public streets, roads or highways. WHAT CAN HAPPEN The ATV could collide with another vehicle. HOW TO AVOID THE HAZARD Never operate the ATV on any public street, road or highway, including dirt and gravel roads. In many states it's illegal to operate ATVs on public streets, roads and highways.
Page 22 Operator Safety POTENTIAL HAZARD Operating the ATV after consuming alcohol or drugs. WHAT CAN HAPPEN Consumption of alcohol and/or drugs could seri- ously affect operator judgment. Reaction time may be slower and operator balance and per- ception could be affected. Consuming alcohol and/or drugs before or while operating an ATV could result in an accident causing severe injury or death.
Page 23 Operator Safety POTENTIAL HAZARD Attempting wheelies, jumps and other stunts. WHAT CAN HAPPEN Attempting stunts increases the chance of an accident, including an overturn. HOW TO AVOID THE HAZARD Never attempt wheelies, jumps, or other stunts. Avoid exhibition driving. POTENTIAL HAZARD Failure to inspect the ATV before operating.
Page 24 Operator Safety POTENTIAL HAZARD Removing hands from the handlebars or feet from the footrests during operation. WHAT CAN HAPPEN Removing even one hand or foot can reduce ability to control the vehicle or could cause loss of balance and ejection from the ATV. If the operator's foot is not firmly planted on the footrest, it could contact the rear wheels and lead to accident or injury.
Page 25 Operator Safety POTENTIAL HAZARD Failure to use extra caution when operating on excessively rough, slip- pery or loose terrain. WHAT CAN HAPPEN Operating on excessively rough, slip- pery or loose terrain could cause loss of traction or loss of control, which could result in an accident or over- turn.
Page 26 SAFETY Operator Safety POTENTIAL HAZARD Operating on excessively steep hills. WHAT CAN HAPPEN The vehicle may overturn. HOW TO AVOID THE HAZARD Never operate on hills too steep for the ATV or for your abilities. Never operate the ATV on hills steeper than 25 degrees.
Page 27 Operator Safety POTENTIAL HAZARD Traveling downhill improperly. WHAT CAN HAPPEN Improperly descending a hill could cause loss of control or overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for traveling down hills as described in the owner's manual. NOTE: A special technique is required when braking while traveling downhill.
Page 28 SAFETY Operator Safety POTENTIAL HAZARD Stalling, rolling backwards or improperly dis- mounting while climbing a hill. WHAT CAN HAPPEN The vehicle could overturn. HOW TO AVOID THE HAZARD Maintain steady speed when climbing a hill. If all forward speed is lost: Keep your weight uphill.
Page 29 Operator Safety POTENTIAL HAZARD Improperly operating over obstacles. WHAT CAN HAPPEN Operating over obstacles could cause loss of control or overturn. HOW TO AVOID THE HAZARD Before operating in a new area, check for obstacles. Avoid operating over large obstacles such as rocks and fallen trees when possible.
Page 30 SAFETY Operator Safety POTENTIAL HAZARD Operating the ATV through deep or fast-flowing water. WHAT CAN HAPPEN Tires may float, causing loss of traction and loss of control, which could lead to an accident or overturn. HOW TO AVOID THE HAZARD Avoid operating the ATV through deep or fast-flowing water.
Page 31 HOW TO AVOID THE HAZARD Never modify the ATV through improper installation or use of accessories. All parts and accessories added to the vehicle must be genuine Polaris Indus- tries Inc. or equivalent components designed for use on this ATV and should be installed and used according to approved instructions.
Page 32 SAFETY Operator Safety POTENTIAL HAZARD Overloading the ATV or carrying/towing cargo improperly. WHAT CAN HAPPEN Overloading and towing can cause changes in vehicle handling, which could lead to loss of control or an accident. HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this ATV. Cargo should be properly distributed and securely attached.
Page 33 Operator Safety Operating a damaged ATV can result in an accident with serious injury or death. After any overturn or accident, have a qualified service dealer inspect the entire machine for possible damage, including (but not limited to) brakes, throttle and steering systems. Safe operation of this rider-active vehicle requires good judgement and phys- ical skills.
Page 34: Features And Controls
FEATURES AND CONTROLS Switches Headlight Switch Mode/Reverse Override Switch Activating the override switch while the throttle is open can cause loss of con- trol, resulting in severe injury or death. Do not activate the override switch while the throttle is open. Mode/Reverse Override Switch This vehicle is equipped with a reverse speed limiter system.To gain additional power while backing, depress the override switch.
Page 35: Engine Stop Switch
Switches Engine Stop Switch Move the stop switch either left or right to the OFF position to stop the engine quickly. The engine will not start or run when the switch is off. NOTE: Both the main switch and the engine stop switch will shut off all electri- cal power to the vehicle, including lights.
Page 36: Throttle Lever
The throttle lever is spring loaded. Engine speed returns to idle when the lever is released. This ATV is equipped with Polaris Electronic Throttle Control (ETC), which is designed to reduce the risk of a frozen or stuck throttle. If the...
Page 37: Brake Lever
Brake Lever Squeeze the brake lever toward the handlebar to apply the front and rear brakes. These brakes are hydraulically activated disc type brakes that are activated by only one lever. Always test brake lever travel and master cylinder fluid level before riding.
Page 38: Parking Brake
FEATURES AND CONTROLS Parking Brake Operating the ATV while the parking brake is engaged could result in an acci- dent and serious injury or death. Always check to be sure the parking brake is disengaged before operating. Locking the Parking Brake 1.
Page 39 Auxiliary Foot Brake The auxiliary brake system is intended to be used as a backup for the main brake system. Should the main system fail, use the auxiliary foot brake. Aggressively applying the auxiliary brake when backing down a hill may cause rear tipover, which could result in serious injury or death.
Page 40: Fuel Valve
FEATURES AND CONTROLS Choke The choke assists in starting a cold engine. Refer to the engine starting procedure on page 50 for correct choke and throttle settings during start- ing. Fuel Tank Cap Fuel Tank Remove the fuel tank cap to add fuel to the fuel tank.
Page 41 Automatic Transmission Gear Selector The transmission gear selector is located on the right side of the vehicle. H: High Gear N: Neutral R: Reverse Whenever the ATV is left unattended, always place the transmission in gear and lock the parking brake.
Page 42: Recoil Starter
Recoil Starter If the battery is too weak to start the engine, use the recoil starter. Follow the starting procedures on page 50, cranking the engine with the recoil starter instead of the main key switch. 1. Grasp the recoil starter rope handle tightly.
Page 43: Engaging Awd
All Wheel Drive (AWD) System The All Wheel Drive system is controlled by the AWD switch. When the switch is on 2X4, the ATV is in two-wheel drive at all times. When the switch is on AWD, the ATV is in all wheel drive.
Page 44: Instrument Cluster
Instrument Cluster Your ATV is equipped with an instrument cluster that senses vehicle speed from the right front wheel. The instrument cluster measures distance in miles as well as hours of operation. It also includes a reverse speed limiter function that limits the ATV's speed to approximately 7-9 mph.
Page 45: Rider Information Center
Instrument Cluster Rider Information Center The rider information center is located in the instrument cluster. All seg- ments will light up for 3 seconds at start-up. 1. Gear Indicator - This indicator displays gear shifter position. N = Neutral (Green) R = Reverse (Amber) 2.
Page 46: Operation
OPERATION Fuel Safety Gasoline is highly flammable and explosive under certain conditions. • Always exercise extreme caution whenever handling gasoline. • Always refuel with the engine stopped, and outdoors or in a well ventilated area. • Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored.
Page 47 Break-In Period The break-in period for your new Polaris ATV is the first ten hours of operation, or the time it takes to use the first two full tanks of gasoline. No single action on your part is as important as following the proce- dures for a proper break-in.
Page 48 OPERATION Break-In Period Engine and Drivetrain Break-in 1. Fill the fuel tank with gasoline. See page 40. 2. Check the oil level on the dipstick. See page 75. Add oil if neces- sary to maintain the level between the safe and add marks. 3.
Page 49 Ensure proper operation Ensure operation Ensure proper operation Inspect, clean Drain deposits whenever visible Check operation, apply Polaris dielec- tric grease when lamp is replaced Check operation, apply Polaris dielec- tric grease when lamp is replaced Wear approved helmet, goggles, and...
Page 50: Starting The Engine
OPERATION Starting the Engine Engine exhaust contains poisonous carbon monoxide and can cause loss of consciousness resulting in severe injury or death. Never run an engine in an enclosed area. 1. Position the vehicle on a level surface. 2. Place the transmission in neutral. 3.
Page 51: Cold Weather Operation
Water in the bottom of the crankcase can lead to engine damage and must be drained. Water accu- mulation increases as outside temperature decreases. See your Polaris dealer for engine heater kits, which provide quicker warm-ups and easier starting in colder weather. CAUTION...
Page 52: Hauling Cargo
ATV warranty. Never install a hitch longer than 6 3/4" (17 cm). Never install automotive accessories on your Polaris ATV. Always install Polaris- approved (or equivalent) accessories designed for ATV use. CAUTION 6 3/4"...
Page 53 OPERATION Hauling Cargo WARNING Hauling cargo improperly can alter vehicle handling and may cause loss of control or brake instability and result in serious injury or death. Always follow these precautions when hauling cargo: REDUCE SPEED AND ALLOW GREATER DISTANCES FOR BRAKING WHEN HAULING CARGO.
Page 54: Driving Safely
OPERATION Driving Safely Driving Procedures 1. Wear protective riding gear. See page 10. 2. Sit upright with both feet on the footrests and both hands on the handlebars. 3. Start the engine and allow it to warm up. 4. Shift the transmission into gear. 5.
Page 55: Turning The Vehicle
Driving Safely Turning the Vehicle Your ATV is equipped with a solid rear axle, which drives both rear wheels equally at all times. This means that the wheel on the outside of the turn must travel a greater distance than the inside wheel when turning and the inside tire must slip traction slightly.
Page 56: Driving On Slippery Surfaces
OPERATION Driving Safely Driving on Slippery Surfaces Whenever riding on slippery surfaces such as wet trails or loose gravel, or during freez- ing weather, follow these precautions: 1. Slow down when enter- ing slippery areas. 2. Engage AWD before wheels begin to lose traction.
Page 57: Driving Uphill
Driving Safely Driving Uphill Whenever traveling uphill, follow these precautions: 1. Drive straight uphill. 2. Avoid steep hills (25° maximum). 3. Keep both feet on the footrests. 4. Shift your weight uphill. 5. Proceed at a steady rate of speed and throttle opening. 6.
Page 58 OPERATION Driving Safely Driving on a Sidehill (Sidehilling) Improperly crossing hills or turning on hills can result in loss of control or vehicle overturn, resulting in severe injury or death. Avoid crossing the side of a hill when possible. Follow proper procedures as outlined in the owner's manual.
Page 59: Driving Downhill
Driving Safely Driving Downhill Excessive speed when traveling downhill can cause loss of control and seri- ous injury or death. Slow down. Applying the brakes too firmly may cause the rear wheels to lock, which could result in loss of control and serious injury or death. Apply the brakes gradually.
Page 60 OPERATION Driving Safely Turning Around on a Hill (K-Turn) If the vehicle stalls while climbing a hill, never back it down the hill! Use the K-turn to turn around. 8 ft. (2.4 m)
Page 61 Driving Safely Turning Around on a Hill (K-Turn) 1. Stop and lock the parking brake while keeping body weight uphill. 2. Leave the transmission in forward and shut off the engine. 3. Dismount on the uphill side of the vehicle, or on the left if the vehi- cle is pointing straight uphill.
Page 62: Driving Through Water
OPERATION Driving Safely Driving Through Water Maximum Depth Your ATV can operate through water with a maximum recommended depth equal to the bottom of the footrests. Follow these procedures when operating through water: 1. Determine water depths and current before crossing. 2.
Page 63 Driving Safely Driving Through Water After running the vehicle in water, it's critical to have it serviced as out- lined in the maintenance chart. See page 68. The following areas need special attention: engine oil, transmission oil, front and rear gearcases, and all grease fittings.
Page 64: Driving Over Obstacles
OPERATION Driving Safely Driving Over Obstacles Be alert! Look ahead and learn to read the terrain you're traveling on. Be constantly alert for hazards such as logs, rocks and low hanging branches. Severe injury or death can result if your vehicle comes in contact with a hid- den obstacle.
Page 65: Driving In Reverse
Avoid backing on inclines, and avoid turning at sharp angles. NOTE: Your Polaris ATV is equipped with a reverse speed limiter. Use the override button with caution as rearward vehicle speed is greatly increased. Do not operate at wide open throttle.
Page 66 OPERATION Driving Safely Parking on an Incline Avoid parking on an incline if possible. If it's unavoidable, follow these precautions: 1. Stop the engine. 2. Place the transmission in gear. 3. Lock the parking brake. 4. Always block the rear wheels on the downhill side. 5.
Page 67: Emission Control Systems
CFR 205) and local noise level requirements. Operation on Public Lands in the U.S.A. Your Polaris vehicle has a spark arrestor that was tested and qualified to be in accordance with the USDA Forest Service Standard 5100-1C. Fed- eral law requires that this spark arrestor be installed and functional when the vehicle is operated on public lands.
Page 68: Maintenance
Inspect, clean, lubricate, adjust and replace parts as necessary. When inspection reveals the need for replacement parts, use genuine Polaris parts available from your Polaris dealer. Record maintenance and service in the Maintenance Log beginning on page 134.
Page 69: Maintenance Chart Key
Have an authorized Polaris dealer perform these services. Improperly performing the procedures marked with a ponent failure and lead to serious injury or death. Have an authorized Polaris dealer perform these services. MAINTENANCE...
Page 70 (if equipped) Transmission oil Engine breather filter (if equipped) Perform these procedures more often for vehicles subjected to severe use. E Emission-Related Service Have an authorized Polaris dealer perform these services. Maintenance Interval (whichever comes first) Miles (Km) Pre-Ride Pre-Ride...
Page 71 Periodic Maintenance Chart Item Hours Calendar General lubrication Carburetor float bowl Throttle Cable/ ETC Switch Choke cable E Carburetor air intake ducts/flange Drive belt Cooling system (if applicable) Engine oil change Oil filter change Oil tank vent hose (if equipped) Valve clearance Fuel system/filter Radiator...
Page 72 Spark arrestor Idle speed Toe adjustment Headlight aim Perform these procedures more often for vehicles subjected to severe use. E Emission-Related Service Have an authorized Polaris dealer perform these services. Maintenance Interval (whichever comes first) Miles (Km) 100 H 12 M 1000 (1600) Inspect;...
Page 73: Lubrication Guide
Control Arm (front and rear) Bearing Carrier Transmission (upper pivot point) Front Prop Shaft Yoke Lube PS-4 PLUS Performance Synthetic 2W-50 DOT 4 Only Polaris AGL Synthetic Gearcase Lube Premium Demand Drive Hub Fluid Polaris Premium U-Joint Lube Bearing Carrier MAINTENANCE Method See page 74.
Page 74: Engine Oil
Polaris recommends the use of Polaris PS-4 PLUS Performance Syn- thetic 2W-50 4-cycle oil or a similar oil for this engine. Oil may need to be changed more frequently if Polaris oil is not used. Always use 2W-50 oil. Follow the manufacturer's recommendations for ambient tempera- ture operation.
Page 75: Engine Oil Level
Engine Oil Oil Level The oil dipstick is located behind the left front tire. 1. Position the vehicle on a level surface. 2. Place the transmission in neutral. 3. Lock the parking brake. 4. Clean away all dirt and debris on the oil tank or in the wheel well area.
Page 76: Oil And Filter Change
MAINTENANCE Oil and Filter Change Hot oil can cause serious burns to skin. Do not allow hot oil to contact skin. Always change the oil and filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 68. To change the oil properly, always drain the oil tank and change the oil filter.
Page 77 Oil and Filter Change 11. Place towels under the oil filter. Using an oil filter wrench, turn the filter counterclockwise to remove it. 12. Clean the filter sealing area on the engine. 13. Lubricate the filter o-ring. Check to make sure the o-ring is in good condition.
Page 78: Transmission Oil
Chart beginning on page 68. Maintain the oil level at the bottom of the fill plug hole. See page 121 for the part numbers of Polaris products. Drain Plug The fill plug is located on Fill Plug the left side of the ATV, under the rear fender, behind the wheel.
Page 79 Transmission Oil Oil Check 1. Position the vehicle on a level surface. 2. Place the transmission in gear. 3. Lock the parking brake. 4. Remove the fill plug. Use a 15 mm wrench. 5. Check the oil level. 6. Add oil as needed. Do not overfill.
Page 80: Oil Change
MAINTENANCE Transmission Oil Oil Change 1. Position the vehicle on a level surface. 2. Place the transmission in gear. 3. Lock the parking brake. 4. Remove the fill plug. Use a 15 mm wrench. 5. Place a drain pan under the gearcase.
Page 81 Periodic Maintenance Chart beginning on page 68. We recommend the use of Polaris Premium Demand Drive Hub Fluid. Use of other oils may result in improper operation of compo- nents. See page 121 for the part numbers of Polaris products.
Page 82 MAINTENANCE Front Gearcase (Demand Drive) Fluid Fluid Check 1. Position the vehicle on a level surface. 2. Place the transmission in gear. 3. Lock the parking brake. 4. Remove the fill plug. Use an 8 mm Allen wrench. 5. Check the oil level. 6.
Page 83: Fluid Change
Front Gearcase (Demand Drive) Fluid Fluid Change 1. Position the vehicle on a level surface. 2. Place the transmission in gear. 3. Lock the parking brake. 4. Remove the fill plug. Use an 8 mm Allen wrench. 5. Place a drain pan under the gearcase.
Page 84: Cooling System
Polaris recommends the use of Polaris Premium 60/40 anti-freeze/cool- ant or a 50/50 mixture of high quality aluminum compatible anti-freeze/ coolant and distilled water. Polaris Premium 60/40 is already premixed and ready to use. Do not dilute with water. See page 121 for the part numbers of Polaris products.
Page 85: Radiator Coolant
Radiator Coolant To ensure that the coolant maintains its ability to protect the engine, Polaris recommends that you drain the system completely every two years and add a fresh mixture of antifreeze and water. Replace the coolant any time the cooling system has been drained for maintenance or repair.
Page 86: Brake Fluid
Do not overfill. If the fluid level is low add DOT 4 brake fluid only. See page 121 for the part numbers of Polaris products. Never store or use a partial bottle of brake fluid. Brake fluid is hygroscopic, meaning it rapidly absorbs moisture from the air.
Page 87: Hand Brake
Brake Fluid Hand Brake The master cylinder is located on the left handlebar. Main- tain the fluid level 1/4" (6.3 mm) below the top edge of the master cylinder. Do not over- fill. 1. Position the vehicle on a level surface. Make sure the handlebars are straight.
Page 88: Brake Inspections
MAINTENANCE Brakes The front and rear brakes are hydraulic disc brakes, activated by moving the single brake lever toward the handlebar. The auxiliary foot brake is also hydraulic. Both brake systems are self-adjusting. Brake Inspections The following checks are recommended to keep the brake system in good operating condition.
Page 89: Toe Alignment
1/8" to 1/4" (3-6 mm) toe out alignment. 5. Repeat the measurement procedure on the other side of the vehicle. NOTE: If you discover improper alignment, see your Polaris dealer for service. MAINTENANCE WARNING Stand...
Page 90: Side Panel Removal
MAINTENANCE Steering Assembly The steering assembly of the ATV should be checked periodically for loose nuts and bolts. If loose nuts and bolts are found, see your Polaris dealer for service before operating the vehicle. Side Panel Removal 1. Remove the seat.
Page 91: Tire Tread Depth
1/8" (3 mm) or less. Front Wheel Hub Tightening Front wheel bearing tightness and spindle nut retention are critical com- ponent operations. All service must be performed by your authorized Polaris dealer. MAINTENANCE WARNING 1/8" (3 mm)
Page 92: Wheel Removal
MAINTENANCE Tires Wheel Removal 1. Position the vehicle on a level surface. 2. Place the transmission in gear. 3. Lock the parking brake. 4. Loosen the wheel nuts slightly. 5. Place a suitable stand under the footrest frame to raise the wheel slightly off the ground.
Page 93: Wheel Installation
Always ensure that all nuts are torqued to specification. Do not service axle nuts that have a cotter pin installed. See your Polaris dealer. 1. Place the wheel on the wheel...
Page 94: Air Filter
MAINTENANCE Air Filter 1. Position the vehicle on a level surface. Place the transmission in gear. 2. Lock the parking brake. 3. Remove the seat. 4. Release the air box cover clips, and remove the air box cover. 5. Loosen the clamp and remove the filter.
Page 95: Headlight Beam Adjustment
Lights Headlight Beam Adjustment The headlight beam can be adjusted slightly upward or downward. Use the following procedure to make the adjustment. 1. Position the vehicle on a level surface with the headlight approxi- mately 25 ft. (7.6 m) from a wall. 2.
Page 96: Headlamp Replacement
MAINTENANCE Lights When servicing a halogen lamp, don't touch the lamp with bare fingers. Oil from your skin leaves a residue, causing a hot spot that will shorten the life of the lamp. Poor lighting while driving can result in severe injury or death. Headlight and taillight lenses become dirty during normal operation.
Page 97: Recoil Housing
Recoil Housing Always drain the recoil housing after operating the vehicle in wet condi- tions. Drain the housing before storing the vehicle. Make sure the hous- ing is completely dry before reinstalling the drain plug. 1. Place the transmission in gear. 2.
Page 98: Spark Plugs
Spark Plug Recommendations Using non-recommended spark plugs can result in serious engine damage. Always use Polaris-recommended spark plugs. Refer to the specifications section beginning on page 126 for the recom- mended spark plug type and gap for your vehicle. Torque spark plugs to specification.
Page 99: Spark Plug Condition
Spark Plugs Spark Plug Condition Normal Spark Plug The normal insulator tip is gray, tan or light brown. There will be few combustion deposits. The electrodes are not burned or eroded. This indi- cates the proper type and heat range for the engine and the service. NOTE: The tip should not be flaky and white.
Page 100: Vehicle Immersion
MAINTENANCE Vehicle Immersion If your vehicle becomes immersed, major engine damage can result if the machine is not thoroughly inspected. Take the vehicle to your dealer before starting the engine. If it's impossible to take your ATV to a dealer before starting it, follow the steps outlined below.
Page 101: Spark Arrestor
Spark Arrestor Failure to heed the following warnings while servicing the spark arrestor could result in serious injury or death. The exhaust system can get extremely hot. Do not perform service on the spark arrestor while the system is hot. Allow components to cool sufficiently before proceeding.
Page 102: Pvt System
• Always follow all recommended maintenance procedures. See your dealer as outlined in the owner's manual. • This PVT system is intended for use on Polaris products only. Do not install it in any other product. • Always make sure the PVT housing is securely in place during operation.
Page 103: Pvt Drying
PVT System PVT Drying There may be some instances when water is accidently ingested into the PVT system. Use the following instructions to dry it out before operating. 1. Move the vehicle out of the water. 2. Remove the PVT drain plug. Use a 17 mm wrench, a flat screw- driver, or the spark plug wrench.
Page 104: Battery Maintenance
MAINTENANCE Battery Your ATV may have either a sealed battery, which requires little mainte- nance, or a conventional battery. A sealed battery can be identified by its flat covers on the top of the battery. A conventional battery has six filler caps on the top of the battery.
Page 105: Battery Removal
Battery Improperly connecting or disconnecting battery cables can result in an explo- sion and cause serious injury or death. When removing the battery, always disconnect the negative (black) cable first. When reinstalling the battery, always connect the negative (black) cable last. Battery Removal 1.
Page 106: Battery Installation
MAINTENANCE Battery Battery Installation Using a new battery that has not been fully charged can damage the bat- tery and result in a shorter life. It can also hinder vehicle performance. Follow the battery charging instructions on page 108 before installing the battery.
Page 107: Battery Storage
NOTE: Battery charge can be maintained by using a Polaris Battery Tender charger or by charging about once a month to make up for normal self- discharge. Battery Tender can be left connected during the storage period, and will automatically charge the battery if the voltage drops below a pre-determined point.
Page 108 MAINTENANCE Battery Battery Charging (Conventional Battery) 1. Remove the battery from the vehicle to prevent damage from leak- ing or spilled electrolyte during charging. See page 105. 2. Charge the battery with a charging output no larger than 1/10 of the battery’s amp/hr rating.
Page 109 Battery Battery Charging (Sealed Battery) NOTE: When using an automatic charger, refer to the charger manufacturer's instructions for recharging. When using a constant current charger, use the following guidelines for recharging. Always verify battery con- dition before and 1-2 hours after the end of charging. State of Voltage Charge...
Page 110: Cleaning And Storage
Certain products, including insect repellents and chemicals, will damage plastic surfaces. Do not allow these types of products to contact the vehicle. The best and safest way to clean your Polaris vehicle is with a garden hose and a pail of mild soap and water.
Page 111: Washing The Vehicle
• Labels and decals • Coolant (if equipped) (test strength/fill) NOTE: If warning and safety labels are damaged, contact your Polaris dealer for free replacement. Grease all zerk fittings immediately after washing. Allow the engine to run for a while to evaporate any water that may have entered the engine or exhaust system.
Page 112 Cleaning and Storage Chrome Wheel Care (if equipped) Proper maintenance will protect chrome wheels from corrosion, pre- serve wheel life and ensure a "like new" appearance for many years. NOTE: Chrome wheels exposed to road salt (or salt in the air in coastal areas) are more susceptible to corrosion if not properly cleaned.
Page 113: Storage Tips
Make any necessary repairs and clean the vehicle as recommended. See page 110. Stabilize the Fuel 1. Fill the fuel tank. 2. Add Polaris Carbon Clean Fuel Treatment or Polaris Fuel Stabilizer. Follow the instructions on the container for the recommended amount. NOTE:...
Page 114 7. If Polaris fuel system additive is not used, the fuel tank, fuel lines, and carburetor should be completely drained of gasoline.
Page 115 Accessories Auxiliary power outlets provide 12-volt power for operating accesso- ries. Accessory outlets are available for all models. Polaris also has a wide range of additional accessories available for your ATV. Always install accessories that are approved for ATV use. Please see your Polaris dealer.
Page 116: Transporting The Vehicle
MAINTENANCE Transporting the Vehicle Follow these procedures when transporting the vehicle. 1. Stop the engine. 2. Place the transmission in gear. 3. Lock the parking brake. 4. Turn the fuel valve off. 5. Secure the fuel cap, oil cap and seat. 6.
Page 117: Adjustments
The front and rear shock absorber springs are adjustable. Rotate the adjuster either clockwise or counterclockwise to increase or decrease spring tension. Always adjust both sides equally. NOTE: Accessory springs are available through your Polaris dealer. Rear Adjuster Front Adjuster...
Page 118 Follow the adjustment procedures exactly, or see your Polaris dealer for service. 1. Loosen the four handlebar bolts.
Page 119 Carburetor Your Polaris ATV is calibrated at the factory for optimal performance at altitudes ranging from zero to 6,000 feet (1800 m) and temperatures of +40 degrees F. (4 degrees C.) or higher. Above 6000 feet (1800 m) the engine air/fuel mixture becomes overly rich and the engine loses approximately 3% of its power for each 1000-foot (304.8 m) increase in...
Page 120: Throttle Cable Freeplay
ADJUSTMENTS Throttle Cable Freeplay Adjust throttle cable freeplay at the handlebar. 1. Locate the throttle cable adjuster at the handlebar. 2. Squeeze the end of the rub- ber boot and slide it far enough to expose the end of the inline cable adjuster. 3.
Page 121: Polaris Products
Chain Lube, Aerosol (6.25 oz.) 2872348 Chain Lube, Aerosol (16 oz.) 2871326 Carbon Clean Plus (12 oz.) 2870652 Fuel Stabilizer (16 oz.) 2872189 DOT4 Brake Fluid (12 oz.) 2871956 Loctite 2859044 Polaris Battery Tender Engine Lubricant Coolant Additives / Miscellaneous 565 Thread Sealant Charger...
Page 122: Troubleshooting
Dry out the PVT. See page 103. Inspect clutch seals for damage if repeated leaking occurs. See your Polaris dealer. Check for fouled plugs or foreign material in gas tank or fuel lines. See your dealer.
Page 123 Replace with fresh recommended fuel Inspect plugs and replace if necessary Inspect plugs, verify stop switch is on Inspect, clean and/or replace spark plugs Immediately see your Polaris dealer Recharge the battery to 12.8 VDC See your dealer Solution Inspect, clean and/or replace spark...
Page 124 Engine Pings or Knocks Possible Cause Poor quality or low octane fuel Incorrect ignition timing Incorrect spark plug gap or heat range Idle set too low Engine Runs Irregularly, Stalls or Misfires Possible Cause Fouled or defective spark plug(s) Worn or defective spark plug wires Incorrect spark plug gap or heat range Loose ignition connections Water present in fuel...
Page 125: Engine Overheating
Engine Stops or Loses Power Possible Cause Out of fuel Kinked or plugged fuel vent line Water is present in fuel Overuse of choke Fouled or defective spark plug(s) Worn or defective spark plug wires Incorrect spark plug gap or heat range Loose ignition connections Low battery voltage Incorrect fuel...
Page 126: Specifications
SPECIFICATIONS Maximum Weight Capacity Dry Weight Fuel Capacity Engine Oil Capacity Coolant Capacity Transmission Oil Demand Drive Fluid Front Rack Capacity Rear Rack Capacity Hitch Tongue Weight Capacity Hitch Towing Rating Unbraked Trailer Towing Capacity* Overall Length Overall Width Overall Height Wheelbase Ground Clearance Minimum Turning Radius...
Page 127: Jetting Chart
Altitude Meters (Feet) 0-1500 (0-5000) 1500-3000 (5000-10000) 3000+ (10000+) Sportsman 400 HO 4X4 Automatic PVT (Polaris Variable Transmission) Side Lever (H/N/R) 3.6:1 15.18:1 Front 24x8-12 / 5 psi (34.5 KPa) Rear 24x11-12 / 5 psi (34.5 KPa) MacPherson strut with 7" (18 cm) travel Progressive rate with 8"...
Page 128: Warranty
WARRANTY LIMITED WARRANTY Polaris Sales Inc., 2100 Highway 55, Medina, MN 55340, gives a SIX MONTH LIM- ITED WARRANTY on all components of the Polaris All Terrain Vehicle (ATV) against defects in material or workmanship. Polaris also gives a one year limited warranty on the final drive chain for failure due to defects.
Page 129 WARRANTY COVERAGE AND EXCLUSIONS: LIMITATIONS OF WARRANTIES AND REMEDIES The Polaris limited warranty excludes any failures that are not caused by a defect in material or workmanship. This warranty does not cover accidental damage, normal wear and tear, abuse or improper handling. This warranty also does not cover any ATV that...
Page 130 HOW TO OBTAIN WARRANTY SERVICE If your ATV requires warranty service, you must take it to a Polaris dealer authorized to repair Polaris ATVs. When requesting warranty service you must present your copy of the Warranty Registration form to the dealer.
Page 131 How to Get Service In the Country where your vehicle was purchased: Warranty or Service Bulletin repairs must be done by an authorized Polaris dealer. If you move or are traveling within the country where your vehicle was purchased, Warranty or Service Bulletin repairs may be requested from any authorized Polaris dealer who sells the same line as your vehicle.
Page 132 Exported Vehicles How to Get Service If Purchased From A Private Party: If you purchase a Polaris product from a private citizen outside of the country in which the vehicle was originally purchased, all warranty coverage will be denied. Notice...
Page 133 Polaris standard limited warranty for this vehicle. Polaris warrants that this vehicle is; (1) designed, built, and equipped to conform at the time of initial sale with the requirements of 40 CFR 1051 and, (2) free from defects in materials and workmanship that may keep it from meeting these requirements.
Page 134: Maintenance Log
MAINTENANCE LOG Present this section of your manual to your dealer each time your vehicle is serviced. This will provide you and future owners with an accurate log of maintenance and ser- vices performed. DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS OR HOURS...
Page 135 MAINTENANCE LOG DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS OR HOURS...

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