Polaris ATV Sport 400 User Manual

OWNER’S MANUAL SUPPLEMENT

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1999 SPORT 400
PN 9914952

IMPORTANT: This is a supplement to your owner’s manual. This information should remain with your owner’s

manual at all times.

Specifications

SPORT 400

Body Style Gen III

Gross Vehicle Weight 790 lbs.

Fuel Capacity (4 U.S. Gallons) 4

Gearcase Oil (ounces) 11

Injector Oil Capacity (Quarts) 2

Front Rack
(Maximum - Capacity)

C

Rear Rack

A

(Maximum Capacity)

Tongue Weight 20 lbs

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C

Tow H it c h Accessory

Tow Capacity 850 lbs

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Turn Radius 60²

Ground Clearance 6²

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Height 47²

Length 74.5²

Seat Height 33²

Weight 475 lbs.

Wheel Base 49.75 ²

Width 46.5²

Drive System Type PVT

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Shift Type Side Lever (Forward/Neutral/Reverse)

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Gear Reduction - Low Not Applicable

Gear Reduction - Reverse 3.05/1

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Gear Reduction - Foward 2.68/1

Front Drive (ratio) Not Appicable

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Final Drive (ratio) 13/36 78P

Center Drive (ratio) Not Applicable

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Drive Chain 520 O-Ring

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Front Tire 23 x 7 - 10

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Rear Tire 22 x 11 - 10

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Tire Pressure (front) 4

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Tire Pressure (rear) 3

Accessory (30 lbs)

Accessory (60 lbs)

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SPORT 400

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Front Susp. - Mac Strut 8.2²

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Rear Susp. - Progressive Rate

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Swing Arm

S
P

Shock Adjustment Theaded Adjust

Front Brake Single lever, hydraulic disc, hydraulic foot

B
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Rear Brake Hydraulic opposing piston caliper, rear

A

ESAuxiliary Brake Hydraulic opposing piston caliper, rear

Park Brake Hydraulic lock - all wheel

Engine Model Number EC38PLE-09

Engine Type 2 Cycle, Single Cylinder

Lubrication Oil Injection

Bore x Stroke 83.0 x 70

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Displacement 378

Compression Ratio 6.9/1 Effective

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Engine Cooling Liquid

Alternator Output (watts) 150

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Carburetion 1 VM34SS

Main Jet 230

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Pilot Jet 35

Needle Jet 0-6 (480)

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Pilot Screw 1.5 Turn

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Jet Needle 6CEY6-3

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G

Ignition CDI

Timing 23.5 @ 3000

Spark Plug Gap .028

Spark Plug Type NGK BR8ES

Exhaust USFS Approved

LIHeadlight (watts) Not Applicable

8.5²

brake

axle fixed disc

axle fixed disc

G

Taillight (watts) 8.26

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Brake Light (watts) 26.9

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SPORT 400

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Battery 12V 14AH

DC Plug In - Rear Accessory

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DC Socket - Forward Accessory

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Electric Start Standard

High Beam Indicator Not Applicable

E

High Temp Indicator Standard

Windshield Accessory

F

Low Oil Light Standard

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Neutral Indicator Standard

Reverse Indicator Standard

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Speedometer Accessory

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Tool Kit Standard

SPORT 400
(Engine - EC38PLE-09)
Carburetor Jetting

Altitude Ambient

Meters

(Feet)

Temperature

0-900

(0-3000)

900-1800

(3000-6000)

1800-2700

(6000-9000)

2700-3700

(9000-12000)

Below 0°F

(Below --18°C)

270 MJ

0.5 AS

250 MJ

0.5 AS

220 MJ

1.5 AS

200 MJ

1.5 AS

Clutching

Altitude Shift

Meters

(Feet)

0-900

(0-3000)

900-1800

(3000-6000)

1800-2700

(6000-9000)

2700-3700

(9000-12000)

0° to 40°F

(--18°Cto

+5°C)

250 MJ

1.0 AS

230 MJ

1.0 AS

210 MJ

1.5 AS

190 MJ

1.75 AS

Weight

S-55 White 2/2

S-55 White 2/2 or 2/1

S White 2/1

S or 10MH White 2/1

+40° to +80°F

(+5°Cto

+26°C)

230 MJ

1.5 AS

210 MJ

1.5 AS

195 MJ

1.75 AS

175 MJ

1.75 AS

Clutch
Spring

+80°F&Above

210 MJ

1.5 AS

195 MJ

1.75 AS

175 MJ

1.75 AS

160 MJ

1.75 AS

Driven *

Helix

(+26°C&

Above)

3

The following information (page 35) of your ATV Owner’s Manual, has been revised.

Engine Electrical Switches

1. Override Switch (Reverse Speed
Limiter) - This vehicle is equipped with

a reverse speed limiter system. To ob­tain additional power while backing up,
depress the override button. WARN-
ING: Never activate the override button
while throttle is open as loss of control
may result, causing severe personal in­jury or death.

2. Main Switch - This switch must be
turned clockwise to the “on” position to
start the engine.

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WARNING

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3. Emergency Engine Stop Switch ­The engine will not start or run when the
switch is in its “off” position. Its purpose
is to provide the operator with a quick
means of engine shutdown in case of
stuck throttle or other emergency.

NOTE: Both the main switch and the emer­gency engine stop switch shut off all electri­cal power to the entire vehicle including
lights.

4. Engine Start Button - Slide the stop switch to the center “run” position and push up to start.

4

Backing your ATV can be dangerous!

You could hit an obstacle or person behind you; or the vehicle could tip
over rearward on a steep incline causing severe injury or death.

Always back slowly avoidingexcessive speed and do notuse the reverse
speed override switch system unless additional power is required for ve­hicle movement.

Avoid backing on steep inclines.

Avoid turning at sharp angles in reverse.

4

The following Throttle Lever information, taken from page 38 of your ATV Owner’s Manual, has been revised.

CONTROL AND PARTS FUNCTIONS

Engine Throttle and Choke

Throttle Lever

Engine speed and vehicle movement are controlled by pressing the throttle le­ver. The throttle system is spring loaded and engine speed returns to idle when
the lever is released. This vehicle is equipped with a Polaris Electronic Throttle
Control (ETC) which is designed to reduce the risk of a frozen or stuck throttle.
In the event the throttle cable should stick in an open position, the engine will stop
and power to the rear wheels will cease when the operator releases the throttle
lever.

Choke Lever

Refer to the engine starting procedure on page 56 for correct choke and throttle
settings during starting.

Choke

Throttle

WARNING

The Electronic Throttle Control (ETC) stops the engine in the event of a throttle system malfunction and is
provided for your safety. Do not attempt t o modify the ETC system or replace it with any after market throttle
mechanisms.

WARNING

Do not start or operate an ATV with sticking or improperly operating throttle controls. A stuck or improperly
operating throttle could cause an accident resulting in severe injury or death.

Always contact your dealer for service repairs whenever throttle problems arise.
Failure to check or maintain proper operation of the throttle system can result in the throttle lever sticking

during riding and cause an accident.
Always check the lever for free movement and return before starting the engine and occasionally during rid-

ing.

Throttle Cable Free Play Adjustment

Throttle cable free play is adjusted at the
handlebar.

1. Slide the boots off inline cable adjuster
sleeve. Loosen adjuster locknut.

2. Turn adjuster sleeve until 1/16² to 1/8²
freeplay is achieved at thumb lever.

3. Tighten locknut and slide boots over
cable adjuster until they touch at the
middle point of adjuster.

Boot

Adjuster
Sleeve

Locknut

Boot

5

The following Oil Pump Adjustment Procedure, taken from page 106 of your ATV Owner’s Manual, has been revised.

MAINTENANCE

Oil Pump Adjustment Procedure
400 Engines

1. Before adjusting the oil pump, check engine idle RPM and carburetor adjust­ments which are found in the owner’s manual supplement.

2. Loosen throttle cable jam nut and turn adjuster in or out until there is 1/16²

-1/8² (.16 - .32 cm) of throttle lever travel before throttle slide starts to open.
See Owner’s Manual Supplement.

3. Place very slight pressure on the throttle lever until all freeplay is removed
from throttle cable (to the point where the carb slide is just starting to rise).

4. Lift boot up off adjuster sleeve. Remove the oil pump cover. Loosen the cable
adjuster locknut. Adjust oil pump cable until marks align (D) when the throttle

Oil Pump Adjustment 400

slide just begins to raise.

5. Tighten the locknut.

6. Recheck adjustment. If correct, slide boot all the way down over the upper portion of the bottom nut to ensure
good sealing against water entry. Reinstall oil pump cover and gasket.

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PN 9914952 Rev 02 1/99

Printed in U.S.A.

Boot

Adjuster
Sleeve

Upper Portion
of Bottom Nut

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