Instruction/ maintenance manual of the product 400 H.O. Polaris
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1 WELCOME Thank you for purchasin g a Polaris vehicl e, an d welcome to our world- wide family of Polaris owners. W e proudly produce an excit ing line of utility and recreati onal products.
2 POLARIS and POLARIS TH E W A Y OUT are registered t rademarks of Polaris Indus - tries Inc. Copyright 2007 Polaris Sales Inc. All inform ation contained within this publication is based on the latest product information at th e time of publication.
3 T ABLE OF CONTENTS Know Y our V ehicle . . . . . . . . . . . . . . . . . . . . . . . 5 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 F eatures and Controls . . . . . . . . . . . . . . . . . . . 34 Operation . . . . . . .
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5 KNOW Y OUR VEHICLE As the operator of the vehicle, y o u are responsible for your persona l safety , the safety of others, and the protectio n of our enviro nment. Read and understand your owner's manu al, which includes valuable informa- tion about all aspe cts of your vehicle, incl uding safe operating pro ce- dures.
6 SAFETY Safety Decals and Locations W arning decals have been placed o n the A TV for yo ur protection. Read and follow the instructions of the de cals on the A TV carefully . If any of the decals depicted in this manual dif fer from the d ecals on your A TV , always read and follow the instruc tions of the decals on the A TV .
7 SAFETY Safety Decals and Locations Discretionary W arning WARNING • Never operate this A T V on HILLS steeper than 25 degrees 25 ° . T o 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.
8 SAFETY Safety Decals and Locations “No P assenger” W arning WARNING NEVER ride as a passenger . Pa ssengers can cause a loss of control, resulting in SEVERE INJURY or DEA TH. 7172566 Age 16 W arning WARNING Operating this A TV if you are und er th e age of 16 increa ses your chance of severe injury or death.
9 SAFETY Safety Decals and Locations Rack W arning, F ront and Rear WARNING • DO NOT TOW FROM RACK OR BUMPER. V ehicle da mage or tipover may result causing severe injury or deat h. T ow only from tow hooks or hitch. • Max Rack Loads: Front 70 lbs.
10 SAFETY Safe Riding Gear Always wear appropriate clothing when riding an A TV . W ear protective clothing for comfort and to redu ce the chance of in jury . Helmet W earing a helmet can prevent a sever e head injury . Whenever riding a Polaris vehicle, always wear a helmet that meets or exceeds established safety standards.
11 SAFETY Safe Riding Gear Eye Protection Do not depend on eyeglasses or sunglasses for eye protection. When- ever riding a Polaris vehicle, always wear shatterproof goggles o r use a shatterproof helmet face shield. Po laris recommends wearing approved Personal Prot ective Equi pment (PPE ) bearing markings such as VESC 8, V -8, Z87.
12 SAFETY Operator Safety Age Restrictions This vehicle is an ADUL T VEHIC LE ONL Y . Operation is prohibited for anyone under 16 years of age. WAR N I NG F ailure to follow the warnings contained in this manual can result in severe injury or death. A Polaris A TV is not a toy and can be haza rdous to operate.
13 SAFETY Operator Safety Safety T raining A TV safety t raining is a top priority for Polaris. Wh en you purchased your new A TV , your dealer instructed you on the autho rized A TV RiderCourse sm ava ilable to you and you r e ligible family members.
14 SAFETY Operator Safety The following signal words and symbol s appear throughout th is manual and on your vehicle. Y our safety is involved when these words and sym- bols are used. Become familiar with their meanings before reading the manual. The safe ty alert symbol , on your vehicle or in this manual, ale rts you to the potential for injury .
15 SAFETY Operator Safety • Read this manual and all labels careful ly , and follow the operating procedures described. • Never operate an A TV without prop er instruction. T ake a training course. Purchasers of a new Polari s A TV and their eligible family members are entitled to take the A TV Rider Course sm .
16 SAFETY Operator Safety • Always travel slowly and use extra caution when operating on unfa- miliar terrain. Be alert to changing terrain conditions. • Never operate on excessively ro ugh, slippery , or loose terrain. • Always follow proper turning proce dures as described in this manual .
17 SAFETY 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.
18 SAFETY Operator Safety FOR MORE INFORMA TION ABOU T A TV SAFETY , call the Con- sumer Product Safety Commission at 1- 800-638-2772, or visit www .cpsc.gov , visit www .atvsafety .org, or call Polaris at 1- 800-342- 3764. Equipment Modifications W e are concerned for the safety of our customers and for the general public.
19 SAFETY Operator Safety WAR N I NG POTENTIAL HAZARD Operating this A TV wi thout proper instruction. WHA T CAN HAPPEN The risk of an accident is greatly increased if th e operator does not know how to operate the A TV properly in different situ ations and on differ ent types of terrain.
20 SAFETY Operator Safety WAR N I NG POTENTIAL HAZARD Carrying a passe nger on an A TV . WHA T CAN HAPPEN Carrying a passenger greatly reduces the oper- ator's ability to balance and control the A TV , which could cause an accident and injury to the operator and/or passen ger .
21 SAFETY Operator Safety WAR N I NG POTENTIAL HAZARD Operating this A TV on publi c streets, roads or highways. WHA T CAN HAPPEN The A TV could collid e with another vehicle. HOW TO A VOID THE HAZARD Never operate the A TV on any public street, road or highway , incl uding dirt and gravel roads.
22 SAFETY Operator Safety WAR N I NG POTENTIAL HAZARD Operating the A TV after consuming alcoh ol or drugs. WHA T CAN HAPPEN Consumption of alcohol and/or drugs could seri- ously affect operator judgment. Reactio n time may be slower and operator balance and per- ception could be a ffected.
23 SAFETY Operator Safety WAR N I NG POTENTIAL HAZARD Attempting wheelies, jumps and other stunts. WHA T CAN HAPPEN Attempting stunts increa ses the chance of an accident, including an overturn. HOW TO A VOID THE HAZARD Never attempt wheelies, ju mps, or other stunts.
24 SAFETY Operator Safety WAR N I NG POTENTIAL HAZARD Removing hands from the handlebars or feet from the footrests during operation. WHA T CAN HAPPEN Removing even one hand or foot can reduce ability to control the vehicle or could cause loss of balance and ejection fro m the A TV .
25 SAFETY Operator Safety WAR N I NG POTENTIAL HAZARD F ailure to use extra caution when operating on excessive ly rough, slip- pery or loose terrain. WHA T CAN HAPPEN Operating on exce ssively rough, slip- pery or loose terrain could cause loss of traction or loss of co ntrol, which could result in an accident or over- turn.
26 SAFETY Operator Safety WAR N I NG POTENTIAL HAZARD Operating on exce ssively steep hills. WHA T CAN HAPPEN The vehicle may overturn. HOW TO A VOID THE HAZARD Never operate on hills too steep for the A TV or for your abilities. Never o perate the A TV on hills steeper than 25 degrees.
27 SAFETY Operator Safety WAR N I NG POTENTIAL HAZARD T raveling downhill imprope rly . WHA T CAN HAPPEN Improperly descending a hill could cause loss of control or overturn. HOW TO A VOID THE HAZARD Always follow proper procedures for traveling down hills as described in the owner's manual.
28 SAFETY Operator Safety WAR N I NG POTENTIAL HAZARD Stalling, rolling backwards or improperly dis- mounting while climbing a hill. WHA T CAN HAPPEN The vehicle could overturn. HOW TO A VOID THE HAZARD Maintain steady speed when climbing a hill. If all forward speed is lost: Keep your weight uphill.
29 SAFETY Operator Safety WAR N I NG POTENTIAL HAZARD Improperly operating over obstacles. WHA T CAN HAPPEN Operating o ver obstacles c ould cause loss of contro l or overturn. HOW TO A VOID THE HAZARD Before operating in a new area, check for obstacles.
30 SAFETY Operator Safety WAR N I NG POTENTIAL HAZARD Operating the A TV through dee p or fast-flowing water . WHA T CAN HAPPEN Tires may float, causing loss of traction and loss of control, which could lead to an accident or o verturn. HOW TO A VOID THE HAZARD Avoid operating the A TV through dee p or fast-flowing water .
31 SAFETY Operator Safety WAR N I NG POTENTIAL HAZARD Operating this A T V with improper tires, or with improper or uneven tire pres- sure. WHA T CAN HAPPEN Use of improper tires, or operation of the A TV with improp er or uneven tire pressure, could cause loss of control or accident.
32 SAFETY Operator Safety WAR N I NG POTENTIAL HAZARD Overloading the A TV or carrying/towing cargo improperly . WHA T CAN HAPPEN Overloading and towing can cause change s i n vehicle handling, which coul d lead to loss of control or an accident. HOW TO A VOID THE HAZARD Never exceed the stated load capacity for this A TV .
33 SAFETY Operator Safety WAR N I NG Operating a dama ged A TV ca n result in an accident with seri ous injury or death. After any o verturn or accident , have a qualified se rvice dealer inspect the entire machine for possible damage, includin g (but not limited to) brakes, throttle and st eering systems.
34 FEA TURES AND CONTROLS Switches Mode/Reverse Override Switch This vehicle is equipped with a re verse speed limi ter sy s t em .T o gain additional power while backing, depress the override switch. NOTE: The override switch also allows activation of All Wheel Drive in reverse, if the AWD switch is on.
35 FEA TURES AND CONTROLS Switches Engine Stop Switch Move the stop switch either left or right to the OFF position to stop the engi ne quickly . The engine will no t start or run when the switch is of f. NOTE: Both the main sw itch and the engine stop switch will shut off all electri- cal power to the vehi cle, includi ng lights.
36 FEA TURES AND CONTROLS Throttle Lever Engine speed and vehicle move- ment are controlled by pressing the throttle lever . The throttle lever is spring loaded.
37 FEA TURES AND CONTROLS Brake Lever Squeeze the brake lever toward the handlebar to apply the fro nt an d rear brakes. These brakes are hydraulically activ ated disc type brakes tha t are activat ed by only one lever . Always test brake lever travel and master cylinder fluid level before riding.
38 FEA TURES AND CONTROLS Pa r k i n g B r a k e Locking the P arking Brake 1. Place the transmission in gear . 2. Squeeze and release the brake lever two or three times, then squeeze and hold. 3. Push the parking brake lock forward to engage the lock.
39 FEA TURES AND CONTROLS Auxiliary F oot Brake The auxili ary brake syst em is intend ed to be used as a backup for the main brake system. Should the main system fail, use the auxiliary foot brake. The auxili ary foot brake is located on the inside of the right footrest.
40 FEA TURES AND CONTROLS Choke The choke assists in s tarting a cold engine. Refer to the engine starting procedure on page 50 for correct ch oke and throttle settings during start- ing. Fu e l T a n k C a p Remove the fuel tank cap to add fuel to the fuel tank.
41 FEA TURES AND CONTROLS Automatic T ransmission Gear Selector The transmission gear selector is located on the right side of the vehicl e. H: High Gear N: Neutral R: Reverse Whenever the A TV is left unattended, always place the transmission in gear and lock the parking brake.
42 FEA TURES AND CONTROLS Recoil Starter If the battery is too weak to start the engine , use the recoi l starter . Follow the starting procedures on page 50, crank ing the engine with the recoil starter instead of the main key switch. 1. Grasp the recoil starter rope handle tightly .
43 FEA TURES AND CONTROLS All Wheel Drive (A WD) System The All Whee l Drive syst em is controlled by the A WD switch. When the switch is on 2X4, the A TV is in two-wheel drive at all times.
44 FEA TURES AND CONTROLS Instrument Cluster Y our A TV 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 A TV's speed to approximately 7-9 mph.
45 FEA TURES AND CONTROLS 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 st art-up. 1. Gear Indicator - This indicator displays gear shifter position.
46 OPERA TION F uel Safety WAR N I NG Gasoline is h ighly flammable and explosive under certain conditions. • Always exercise extreme caution w henever handling gasoline. • Always refuel with the engine stopped, and outdoors or in a well ventilated area.
47 OPERA TION Break-In P eriod The break-in period for yo ur new Polaris A TV is the first ten hours of operation, or the time it takes to use the first two full ta nks of gasoline. No single action on your part is as important as following the proce- dures for a proper break-in.
48 OPERA TION Break-In P eriod 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. Drive slowly at first.
49 OPERA TION Pre-Ride Checklist WAR N I NG If a proper inspection is not done befor e ea ch use, severe i njury or death could result. Always inspect the vehicl e before each use to ensure it's in proper operating condition.
50 OPERA TION Starting the Engine 1. Position the vehicle on a level surface. 2. Place the transmission in neutral. 3. Lock the parking brake. NOTE: The starter in terlock will prevent the engine from starting if the trans- mission is in gear and the brake is not enga ged.
51 OPERA TION Starting the Engine 8. T urn the ignition key past the ON position to engage the starter . Activate the starter for a maximum of five seconds, releasing the key when the engin e sta r ts . 9. If the engine does not start, return the key to the OFF position and wait five seconds before attemptin g to start again.
52 OPERA TION Hauling Cargo Y our A TV has been designed to carry or tow a certain amount of load. Always read and understand the load distribution warning labels on the vehicle, and never exceed the weight capacities out lined in the specifi- cations section of the owner's manual and on the safety decals.
53 OPERA TION Hauling Cargo WAR N I NG Hauling cargo imprope rly can alter vehicle handl ing and may cau se loss of control or brake instability and result in serious inju ry or death. Always follow these precautions when haul ing cargo: REDUCE SPEED AND ALL OW GREA TER DIST ANCES FOR BRAKING WHEN HAULING CARGO .
54 OPERA TION Driving Safely Driving Procedures 1. W ear protective ridin g gear . See page 10. 2. Sit upright with both feet on th e footrests and both hands on the handlebars. 3. Star t the engine and allow it to warm up. 4. Shift the transmission into gear .
55 OPERA TION Driving Safely T urning the V ehicle Y our A TV 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 .
56 OPERA TION 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 A WD before wheels begin to lose traction.
57 OPERA TION Driving Safely Driving Uphill Whenever traveling uphill, follow these precautions: 1. Drive straight uphill. 2. A void steep hills (25 ° maximum). 3. Keep both feet on the footrests. 4. Shift your weight uphill. 5. Proceed at a ste a dy rate of spee d an d throttle opening .
58 OPERA TION Driving Safely Driving on a Sidehi ll (Sidehilling) Sidehilling can be dangerou s and should be avoided if at all possible. If you encounter a situation where si dehilling is necessary , follow these precautions: 1. Slow down. 2. Shift your weight uphill.
59 OPERA TION Driving Safely Driving Downhill When driving downhill, follow these precautions: 1. Shift your weight uphill. 2. Drive straight downhill. 3. Slow down. 4. Squeeze the brake lever gradually . NOTE: Before operating yo ur A TV , learn ho w to use the auxiliary br ake for emergency situations (if singl e-lever brakes become inoperab le).
60 OPERA TION Driving Safely T urning Around on a Hill (K - T urn) If the vehicle stalls while climbing a hill, never back it down the hill! Use the K-turn to turn around.
61 OPERA TION Driving Safely T urning Around on a Hill (K - T urn) 1. S top and lock the parking brake wh ile keeping body weight uphill. 2. Leave the transmission in forward and shut off the engine. 3. Dismount on the uphill side of the ve hicle, or on the left if the vehi- cle is pointin g straight uphill.
62 OPERA TION Driving Safely Driving Through W ater Y our A TV can operate through wa ter with a maximum recommended depth equal to the bottom of the footrests. Follow these procedures when operating through wat er: 1. Determine water depths and current before crossing.
63 OPERA TION Driving Safely Driving Through W ater 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, transmi ssion oil, front and rear gearcases, and all grease fittings.
64 OPERA TION 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 lo w hanging branches. WAR N I NG Severe injury or death can result if your vehicle comes in contact with a hid- den obstacle.
65 OPERA TION Driving Safely Driving in Reverse Follow these precautions when operating in reverse: 1. Always check for obstacles or people behind the vehicle. 2. Always avoid backing downhill. 3. Back slowly . 4. Apply the bra kes lightly for stopping.
66 OPERA TION Driving Safely P arking on an Incline A void parking on an incline if possible. If it's unavoidable, follow these precautions: 1. S top the engine. 2. Place the transmission in gear . 3. Lock the parking brake. 4. Always block the rear wheels on the do wnhill side.
67 EMIS SION CONTROL SYSTEMS Noise Emission Control System Do not modify the engine, intake or exhaust components, as doing so may affect compliance with U.S.A. EP A noise control requirements (40 CFR 205) and local noise level requirements. Operation on Public Lands in the U.
68 MAINTENANCE P eriodic Maintenance Chart Careful periodic maintenance will help keep your vehicle in the safest, most reliable condition. Inspection, adjustment and lubrication of important components are explained in the periodic main ten a nc e ch art.
69 MAINTENANCE P eriodic Maintenance Chart Maintenance Chart K ey X Perform these operations more of ten for vehicles subjected to severe use. E Emission-related service (Failure to conduct this maintenance will not void the emissions warrant y but may affect emissions.
70 MAINTENANCE P eriodic Maintenance Chart Perform all services at whichever main tenance interval is reached first. X Perform these procedures more often fo r vehicles subjected to severe use. E Emission-Related Service Q Have an authorized Polaris dealer perform these services.
71 MAINTENANCE P eriodic Maintenance Chart Item Maintenance Interval (whichever comes first) Remarks Hours Calendar Miles (Km) X General lubrication 50 H 3 M 500 (800) Lubricate all fittings, pivots, cables, etc.
72 MAINTENANCE P eriodic Maintenance Chart X Perform these procedures more often fo r vehicles subjected to severe use. E Emission-Related Service Q Have an authorized Polaris dealer perform these services.
73 MAINTENANCE Lubrication Guide Check and lubricate all components at the intervals outlined in the Peri- odic Maintenance Ch art beginning on page 68. Items not listed in the chart should be lubricated at the General Lubrication interval. Item Lube Method Engine Oil PS-4 PLUS P erformance Synthetic 2W-50 See page 74.
74 MAINTENANCE Engine Oil Oil Recommendations 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 Polari s oil is not used. Always use 2W -50 oil.
75 MAINTENANCE 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.
76 MAINTENANCE Oil and Filter Change Always change the oil and filter at th e intervals outlined in the Periodic Maintenance Chart beginn ing on page 68.
77 MAINTENANCE Oil and Filter Change 1 1. 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 filte r o-ring. Check to make sure the o-ring is in good condition.
78 MAINTENANCE T ransmission Oil Always check and change the transmission oil at the intervals outlined in the Periodic Maintenance Chart beginning on pa ge 68. Maintain the oil level at the bottom of the fill plug hole. See page 121 for the part numbers of Polaris products.
79 MAINTENANCE T ransmission 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.
80 MAINTENANCE T ransmission 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. 6. Remove the drain plug.
81 MAINTENANCE F ront Gearcase (Demand Drive) Fluid Always check and change the demand drive fluid at the inter- vals outlined in the Periodic Maintenance Chart beginni ng on page 68. W e recommend the use of Polaris Premium Demand Drive Hub Fluid. Use of other oils may result in improper operation of compo- nents.
82 MAINTENANCE F ront 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. Add the recommend ed oil as needed to bring the level to the bottom of the fill hole threads.
83 MAINTENANCE F ront 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.
84 MAINTENANCE Cooling System The engine coolant level is controll ed, or maintained, by the recovery system. The recovery system compon ents are the reco very bottle, the radiator filler neck, the radiator pressure cap and the connecting hose.
85 MAINTENANCE Cooling System Radiator Coolant T o ensure that the coolant maintain s 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 coo ling system has been drained for maintenance or repair .
86 MAINTENANCE Brake Fluid Check brake fluid levels for both brake systems before each ride. Always maintain brake fluid at the recommended level. Do not overfill. If the fluid leve l is low add DOT 4 bra ke fluid only . See page 121 for the part numbers of Po laris products.
87 MAINTENANCE 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.
88 MAINTENANCE Brakes The front and rear brakes are hydraulic disc brakes, activated by moving the single brake lever toward the hand lebar . The auxiliary foot brake is also hydraulic. Both brake systems are self-adjusting. Brake Inspections The following checks are recommende d to keep the brake system in good operating condition.
89 MAINTENANCE T oe Alignment Use the following procedure to check the toe alignment of the vehicle. The recommended toe alig nment is 1/8" to 1/4" (3-6 mm) toe out. 1. Position the vehicle on a level surface. 2. Place the handlebars in a straight-ahead position.
90 MAINTENANCE Steering Assembly The steering assembly o f the A TV should be check ed p eriodically for loose nuts and bolts. If loose nu ts and bolts are found, see your Polaris dealer for service before operati ng the vehicl e. Side P anel Removal 1.
91 MAINTENANCE Tires Refer to the specifications section begin ning on page 126 for recom- mended tire type, size and pressure. Tire T read Depth Always replace tires when tread depth is worn to 1/8" (3 mm) or less. F ront Wheel Hub Tightening Front wheel bearing tightness and spin dle nut retention are critical com- ponent operations.
92 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 whee l slightly off the ground.
93 MAINTENANCE Tires Wheel Installation 1. Place the wheel on the wheel hub with the valve stem toward the outside and the rotation arrows on the tire pointing toward forward rotation. 2. Install the wheel nuts finger tight. 3. Lower the vehicle to th e ground.
94 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 .
95 MAINTENANCE 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 su rface with the headlight approxi- mately 25 ft. (7.
96 MAINTENANCE Lights When servicing a halog en 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. Headlamp Replacement 1. T urn the back of the headlight harness counterclockwise and pull the harness assembly away from the headlight assembly .
97 MAINTENANCE 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 .
98 MAINTENANCE Spark Plugs Spark Plug Recommendations Refer to the specifications sect ion beg inn ing on pa ge 1 26 for the recom- mended spark plug t ype and gap for yo ur vehicle. T orque spark plugs to specification. Spark Plug Inspection Spark plug condition is i ndicative of engine operation.
99 MAINTENANCE Spark Plugs Spark Plug Condition Normal Spark Pl ug The normal insulator tip is gray , ta n 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.
100 MAINTENANCE V ehicle Immersion If it's impossible to take your A TV to a dealer before starting it, follow the steps outlined below . 1. Move the vehicle out o f the water . 2. T urn the fuel valve off. 3. Check the air box. If water is present, dry the air box and replace the filter with a new filter .
101 MAINTENANCE Spark Arrestor Use the following procedure to peri odically pur ge accumulated carbon from the exhaus t pipe/muffler . 1. Position the vehicle on a level surface. 2. Place the transmission in neutral. 3. Lock the parking brake. 4. Remove the arrestor clean-out plu g from the bottom of the muffl er .
102 MAINTENANCE PVT System WAR N I NG F ailure to comply with the instructions in this warning can result in severe injury or death. Do not modify any component of the PVT system. Doing so may reduce its strength so that a failu re may occur at a high speed.
103 MAINTENANCE PVT System PVT Drying There ma y be some ins tances when water is accidently ingested into the PVT system. Use the following instructions to dry it out before operating. 1. Move the vehicle out o f the water . 2. Remove the PVT drain p lug.
104 MAINTENANCE Battery Y our A TV 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 .
105 MAINTENANCE Battery Battery Removal 1. Place the transmission in gear . 2. Lock the parking brake. 3. Remove the sp lash shield behind the right front tire. 4. Remove the left side panel to access the battery hold- down bracket. Remove the screw at the bottom rear of the bracket and move the bracket aside.
106 MAINTENANCE Battery Battery Installation Using a new battery that has not been fully char ged can damage the bat- tery and result in a shorter life. It can also hinder vehicle performance. Follow the battery charging instructio ns on page 108 before installing the battery .
107 MAINTENANCE Battery Battery Storage Whenever the vehicle is not used for a period of three month s or more, remove the battery from the vehicle, ensure that it's fully char ged, and store it out of the sun in a cool, dry place. Check battery voltage each month during storag e an d recharge as needed to maintain a full char ge.
108 MAINTENANCE Battery Battery Charging (Conventional Battery) 1. Remove the battery from the vehi cle to prevent damage from leak- ing or spilled electrolyt e du ring charging. See page 105. 2. Charge the battery with a char ging output no larger than 1/10 of the battery’ s amp/hr rating.
109 MAINTENANCE Battery Battery Charging (Sealed Battery) NOTE: When using an a utomatic charger , re fe r to the charger manufacturer' s instructions for recharging . When using a constant current charger , use the following guideli nes for recharging.
110 MAINTENANCE Cleaning and Storage W ashing the V ehicle Keeping your Polaris vehicle clean will not only improve its appearance but it can also extend the life of various comp onents. The best and safest way to clean your Polaris vehicle is with a garden hose and a pail of mild soap and water .
111 MAINTENANCE Cleaning and Storage W ashing the V ehicle If a high pressure water system is u sed for cleaning (n ot recommended), exercise extreme caution.
112 MAINTENANCE 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.
113 MAINTENANCE Cleaning and Storage Storage Tips Clean the Exterior Make any necessary repairs and clean the vehicle as recommended. See page 1 10. Stabilize the F uel 1. Fill the fuel tank. 2. Add Polaris Carbon Clean Fuel T reatment or Polaris Fuel S tabilizer .
114 MAINTENANCE Cleaning and Storage Storage Tips Fluid Levels Inspect the fluid levels. Change flu ids as recommended in th e Pe riodic Maintenance Chart beginn ing on page 68. • Demand drive unit (front gearcase) • T ransmission • Brake fluid (change every two years and any time the fluid loo ks dark or contaminated) Fog the Engine 1.
115 MAINTENANCE Cleaning and Storage Storage Tips Inspect and Lubricate Inspect all cables and lubricate al l a reas of the vehicle as recommended in the Periodic Maintenance Chart beginning on page 68. Battery Storage See pages 107-108 for storage and charging procedures.
116 MAINTENANCE T ransporting the V ehicle Follow these procedures when transporting the vehicle. 1. S top the engine. 2. Place the transmission in gear . 3. Lock the parking brake. 4. T urn the fuel valve off. 5. Secure the fuel cap, oil cap and seat.
117 ADJUSTMENTS Camber and Caster The camber and caster are non-adjustable. Spring Adjustments The front and rear shock absorber springs are adjustable. Rotate the adjuster either clockwise or counterclockwise to increase or decrease spring tension. Always ad just both sides equally .
118 ADJUSTMENTS Handlebars The handlebars can be adjusted for rider preference. 1. Loosen the four h andlebar bolts. 2. Adjust the handlebar to the desired height . NOTE: Be sure the handleb ars do not contact the gas tank or any other part of the m achine when turned fully to the left or right.
119 ADJUSTMENTS Carburetor Y our Polaris A TV is calibrated at the fa ctory for optimal performance at altitudes ranging from zero to 6,000 feet (1800 m) and temperatures of +40 degrees F .
120 ADJUSTMENTS Throttle Cable F reeplay 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 sli de it far enough to ex pose the end of the inline cable adjuster .
121 POL A RIS PRODUCTS Pa rt Number Description Engine Lubr icant 2870791 F ogging Oil (12 oz. Aerosol) 2876244 PS-4 PL US Performance Synthetic 2W -50 4-Cycle Oil (qt.) 2876245 PS-4 PL US Performance Synthetic 2W -50 4-Cycle Oil (gal.) Gearcase / T ransmission L ubricants 2873602 Premium AGL Synthetic Gearcase Lubricant (qt.
122 TROUBLESHOOTING Drive Belt Wear/Burn Possible Cause Solution Driving onto a pickup or tall trailer in high range Use low range (if equipped). Starting out going up a steep incl ine Use low range (if equipped) or turn around using the K- turn (see page 60).
123 TROUBLESHOOTING Engine Doesn't T urn Over Engine T urns Over , F ails to Start Engine Backfires Possible Cause Solution Blown fuse Replace fuse Low battery voltage Recharge th e battery to 12.
124 TROUBLESHOOTING Engine Pings or Knocks Engine Runs Irregularl y , Stalls or Misfires Possible Cause Solution Poor quality or low octane fu el Replace with recommended fuel Incorrect ignition timin.
125 TROUBLESHOOTING Engine Stops or Loses Power Engine Overheating Possible Cause Solution Out of fuel Refuel, cycle key to ON position three times for 5 seconds each, then start Kinked or plugged fue.
126 SPECIFICA TIONS * Based on EU Directive 76/432/EC Sportsman 400 HO 4X4 Maximum W eight Capacity 365 lbs. (166 kg) (includes weight of opera- tor , cargo and accessor ies) Dry W eight 5 98 lbs. (271 kg) Fuel Capacity 4.5 gal. (17 l) Engine Oil Capacity 2 qts.
127 SPECIFICA TIONS Jetting Chart Clutching Chart Sportsman 400 HO 4X4 Driving System T ype Automa tic PVT (Polaris V ariable T ransmission) Shift T ype Side Lever (H/N/R) Drive Ratio, Front 3.6:1 Drive Ratio, Final 15.18:1 T i res/Pressure Front 24x8-12 / 5 psi (34.
128 W ARRANTY LIMITED WARRANTY Polaris Sales Inc., 2100 Highway 55, Medina, MN 55340, gives a SIX MONTH LIM- ITED W ARRANTY on all components of the Po laris All T errain V ehicle (A TV) against defects in material or work manship. Polaris also gives a one year limited warranty on the final drive chain for failure due to defect s.
129 WA RRANTY WARRANTY COVERAGE AND EX CLUSIONS: LIMIT A TIONS OF WARR ANTIES AND REMEDIES The Polaris limi ted warranty excludes any failu res that are not caused by a defect in material or workmanship. Th is warranty does not cover acci dental damage, normal wear and tear , abuse or improper handling.
130 W ARRANTY ALL IMPLIED W ARRANTIES (INCLUDING BUT NOT LIMITED TO THE IMPLIED W ARRANTIES OF MERCHANT ABILITY AN D FITNESS FOR A P AR- TICULAR PURPOSE) ARE LIMITED IN DURA TION TO THE ABOVE SIX MONTH W ARRANTY PERIOD. POLARIS FUR THER DISCLAIMS ALL EXPRESS W ARRANTIES NOT ST A TED IN THIS W A RR ANTY .
131 WA RRANTY Exported V ehicles EXCEP T WHERE SPECIFICALL Y REQUIRED BY LA W , THERE IS NO W AR- RANTY OR SER VICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD OUTSIDE THE COUNTR Y OF THE SELLING DEALER'S AUTHORIZED LOCA- TION. This policy does not apply to vehicles that have received authorization for expo rt from Polaris Industries.
132 W ARRANTY Exported V ehicles 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, a ll warranty coverage will be denied.
133 WA RRANTY U.S.A. EP A Emissions Limited Warranty This All T errain V ehicle (A TV) or Off Road Utility V ehicle (ORUV) emissions limited warranty is in addition to the Polaris st andard limited warrant y for this vehicle.
134 MAINTENANCE L OG Present this section of your manual to your dealer each ti me your vehicle is serviced. This will provide you and future owners with an accurate log of maintenance and ser- vices performed.
135 MAINTENANCE L OG DA TE MILES (KM) OR HOURS TECHNICIAN SERVICE PERFORMED / COM MENTS.
An important point after buying a device Polaris 400 H.O. (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Polaris 400 H.O. yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Polaris 400 H.O. - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Polaris 400 H.O. you will learn all the available features of the product, as well as information on its operation. The information that you get Polaris 400 H.O. will certainly help you make a decision on the purchase.
If you already are a holder of Polaris 400 H.O., but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Polaris 400 H.O..
However, one of the most important roles played by the user manual is to help in solving problems with Polaris 400 H.O.. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Polaris 400 H.O. along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
