Polaris Sportsman 300 & 400 HO Service & Repair Manual 2009 (P/N 9921818)

This Polaris service and repair manual (P/N 9921820) covers the 2009 Sportsman 300 and 400 H.O. ATVs, including models A09LH27AX, A09LH27AZ, A09LH46AQ, A09LH46AX, and A09LH46AZ.

Provided as one 292-page PDF in English.

• Engine repair: Top-end overhaul, valve clearance adjustment, valve seat cutting, camshaft timing, crankshaft inspection, starting clutch service, and model-specific oil pump procedures.

• Fuel system: Mikuni BST 34mm carburetor service, float-height adjustment, needle-and-seat testing, fuel pump service, and altitude/temperature jetting charts.

• CVT and transmission: Drive and driven clutch service, belt drying and wear checks, shift weight charts, and transmission disassembly, inspection, and reassembly.

• AWD and final drive: Centralized Hilliard clutch diagnosis, armature plate and roller inspection, front gearcase repair, and front and rear CV joint boot replacement.

• Steering and suspension: MacPherson strut maintenance, A-arm and ball joint service, steering alignment, IRS component removal and installation, and suspension preload adjustment.

• Brake repair: Front and rear caliper rebuilding, hydraulic bleeding, brake pad and disc inspection, and hand and foot master cylinder service.

• Electrical diagnosis: DC/CDI ignition tests, charging system troubleshooting, starter motor repair, AWD and interlock circuits, and model-specific wiring diagrams.

Suited to technicians experienced in ATV diagnosis and engine rebuilding. The CVT section specifies a trained, certified Polaris Master Service Dealer technician for CVT maintenance and repair.

Engine Service and Component Documentation

The engine chapters distinguish the 299 cc air/oil-cooled ES300PFE012 and 455 cc liquid-cooled EH460PLE020 Fuji engines. Exploded views, oil flow diagrams, and camshaft timing illustrations support tear-down and assembly work, including cylinder head reconditioning and automatic decompressor inspection.

The 300’s starting clutch procedure requires engine and transmission removal; the 400 H.O. starting clutch can be serviced in-frame. The 300 crankshaft is treated as a replacement assembly, with inspection rather than component rebuilding.

Lubrication and cooling: The dry-sump 400 H.O. section includes oil pump priming after oil-line disconnection, cooling-system pressure tests, and mechanical water pump seal replacement with the engine installed.

Seal removal uses puller P/N 2872105. The procedure explains how side-loading the puller can bend the shaft, making engine removal and crankcase separation necessary.

Fuel System and CVT Service

Carburetor coverage includes diaphragm and jet needle inspection, float-height adjustment, needle-and-seat testing, and fuel pump service. Altitude/temperature jetting charts and clutch shift weight charts help identify the specified setup for the operating conditions.

Transmission exploded views accompany reverse chain, shift fork, gear, and shift drum inspection. The manual also documents CVT overheating diagnosis and clutch wear limits.

AWD and Chassis Maintenance

For AWD faults, electrical coil and supply-voltage tests sit alongside armature plate pole-gap, roller, and wear checks. That combination helps distinguish an electrical engagement fault from a mechanical front gearcase problem before selecting repair parts.

CV joint scope: Front and rear boot replacement procedures include inspection and clamping details. Complete CV joint disassembly is discouraged because mixing precision-fit internal components can cause binding or premature failure.

Chassis coverage includes body-panel removal, steering geometry, struts, rear suspension, and hydraulic brake service. Ensure the ATV is securely supported on suitable stands during drivetrain service.

Electrical System Diagnostics

The electrical chapter includes model-specific ignition tests, peak-voltage checks, starter voltage-drop testing, and a charging system troubleshooting flow chart. Wiring diagrams cover starting interlocks, AWD, reverse-speed limiting, ETC, and the 400 H.O. cooling circuit.

Specification Highlights and Technical Reference

Specification tables provide SAE and metric tightening torques, engine assembly torque sequences, bore and stroke, compression ratios, compression-test ranges, and idle settings.

Further references include valve clearances, AGL transmission-fluid capacity, alternator output, spark plug gaps, electrical resistance values, and service wear limits.

PDF Search, Bookmarks and Diagram Readability

Embedded bookmarks cover the service chapters and both model-specific wiring sections; chapter text is searchable, but wiring-diagram labels are not. Small schematic labels require zooming for comfortable reading. The file includes 282 chapter pages and 10 wiring-section pages, with five notes pages and two blank pages already included in those totals.