🏷️ Basic Information Identification Make: Polaris Model: Sportsman 400 Year: 2005 Product Type: Parts Manual Download 👋 Introduction Market Position Target User: Owners, mechanics, and parts suppliers for the 2005 Polaris Sportsman 400. Competitive Analysis Value Proposition: Provides essential OEM part numbers and diagrams for efficient maintenance and repair, reducing downtime and incorrect part orders. Key Features Diagrams: High-quality, exploded-view diagrams illustrating all parts in their respective assemblies. Part Number Cross Reference: Includes official Polaris OEM part numbers for guaranteed fitment. 📋 Manual Details Coverage Areas Comprehensive Coverage: Yes Page Count Estimated Pages: 300+ Manual Type Type: Parts Manual / Catalog Language Language: English Format Format: PDF (Downloadable) 📖 Manual Coverage Systems Covered Engine Assembly: Complete component breakdown and part identification for the Polaris 400cc engine. Drivetrain: Detailed diagrams and part numbers for the transmission, driveshafts, and differential systems. Suspension And Steering: Component identification for front and rear suspension, A-arms, shocks, and steering linkage. Braking System: Parts breakdown for front and rear brake calipers, rotors, master cylinders, and brake lines. Electrical System: Component diagrams for ignition, lighting, charging system, starter, and wiring harness. Fuel System: Identification of fuel tank, carburetor/fuel injection components, fuel lines, and filters. Cooling System: Parts breakdown for radiator, hoses, fan, and thermostat. Exhaust System: Component identification for exhaust manifold, pipe, and muffler. Frame And Chassis: Diagrams for frame components, sub-frames, and mounting hardware. Bodywork And Plastics: Identification of fenders, racks, seat, and plastic body panels. Wheels And Tires: Part numbers for wheels and recommended tire specifications. Procedures Included Part Identification: Crucial for accurate ordering and replacement of all components. Assembly Disassembly Overview: Visual guidance through major assembly and disassembly sequences for parts reference. Component Replacement: Facilitates identification of parts needed for common replacement tasks. Technical Depth Level Of Detail: Highly detailed, with exploded views and OEM part numbers. Accuracy: Based on original manufacturer specifications for precision. 📊 Manual Specifications File Format Digital Format: PDF Print Quality Diagram Clarity: High quality, allowing for clear identification of components. Binding Type Binding: N/A (Digital Download) Paper Type Paper Quality: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: 4-stroke, SOHC, 2-valve Displacement: 375cc Bore X Stroke: 84 mm x 68 mm Cooling System: Liquid-cooled Performance Horsepower Est: 26-28 HP (estimated) Torque Est: N/A (specific torque figures often not provided in parts manuals) Fuel System Fuel Delivery: Carbureted (likely Mikuni) Fuel Type: Unleaded gasoline Fuel Capacity Tank: 3.2 gal (12.1 L) 🔧 Transmission Standard Type: Automatic (PVT - Polaris Variable Transmission) Drive: Shaft Drive Gear Selection: High, Low, Neutral, Reverse, Park Features On Demand AWD: Standard (All-Wheel Drive engages automatically when rear wheels lose traction). Engine Braking: Characteristic of PVT systems. 📐 Dimensions Exterior Length: 81 in (205.7 cm) Width: 46 in (116.8 cm) Height: 47 in (119.4 cm) Wheelbase: 50.25 in (127.6 cm) Weights Dry Weight: 613 lbs (278 kg) Ground Clearance: 10.5 in (26.7 cm) Cargo Front Rack Capacity: 100 lbs (45 kg) Rear Rack Capacity: 200 lbs (90 kg) Towing Towing Capacity: 1500 lbs (680.4 kg) Payload Capacity: N/A (typically not specified separately from rack capacity) 🛡️ Safety Features Ratings Atv Safety Standards: Complies with ANSI and other relevant ATV safety standards. Active Features Braking System: Hydraulic disc brakes, front and rear. Suspension: Independent front suspension (IFS) and independent rear suspension (IRS) contribute to stability. Passive Features Hand Grips And Levers: Ergonomic design for control and comfort. Lighting: Dual headlights and taillight/brake light. 💡 Technology Features Infotainment Features: Basic, focused on utility; typically no advanced infotainment systems on this model. Driver Assistance Features: On-Demand AWD system is the primary technological feature enhancing traction. Connectivity Features: None. 🔧 Maintenance Service Intervals Oil Change Interval: Refer to service manual for specific intervals (typically 100 hours or annually). Spark Plug Replacement: Refer to service manual for specific intervals (e.g., 250 hours). Air Filter Cleaning: Recommended to inspect and clean at frequent intervals, especially in dusty conditions. Fluid Specifications Engine Oil Type: Polaris Synthetic 2W-50 or equivalent SAE 5W-50 4-stroke engine oil meeting API Service Classification SG or higher. Engine Oil Capacity: Approx. 2.0 US quarts (1.9 L) with filter change. Transmission Fluid Type: Polaris AGL Synthetic Gearcase Lubricant or equivalent SAE 80W-90 API GL-4. Transmission Fluid Capacity: Refer to specific transmission housing fill plugs. Coolant Type: Ethylene Glycol-based antifreeze (e.g., Polaris Premium Antifreeze) with corrosion inhibitors. Known Issues Typical Wear Items: Brake pads, tires, drive belts (PVT), wheel bearings, ball joints, tie rod ends. Common Maintenance Points: Regular cleaning of air filter, proper tire inflation, PVT belt inspection. 📚 Vehicle History Brand Heritage Polarishistory: Polaris is a long-standing American manufacturer known for its off-road vehicles, including ATVs, snowmobiles, and UTVs. Model Evolution Sportsman Lineage: The Sportsman line is Polaris's flagship ATV series, known for its comfort, capability, and versatility. The 400 model typically represented a mid-range option. Production Model...