Basic Information Identification Make: Polaris Model: Sportsman 400 / 500 Year: 2005 Product Type: Service Repair Manual Introduction Market Position Vehicle Segment: All-Terrain Vehicle (ATV), Utility Quad Competitive Analysis Key Competitors 2005: Yamaha Grizzly, Honda Foreman, Can-Am Outlander, Arctic Cat 500 Key Features Vehicle Strengths: Proven Polaris AWD system, comfortable rider ergonomics, versatile for work and recreation Manual Purpose: To provide comprehensive diagnostic, repair, and maintenance information for the 2005 Sportsman 400 and 500 models. Manual Details Coverage Areas Manual Scope: Comprehensive workshop service and repair Page Count Estimated Page Count: Variable, typically 300-500+ pages for detailed service manuals Manual Type Type: Workshop Service Repair Manual Language Language: English Format Format: PDF Download Manual Coverage Systems Covered Engine: Engine overhaul, tuning, diagnostics, cooling system, lubrication system Fuel System: Carburetor service, fuel pump, fuel lines, fuel tank maintenance Electrical System: Ignition system, charging system (stator, regulator/rectifier), starting system (starter motor, solenoid), lighting, battery, wiring diagrams Drivetrain: All-Wheel Drive (AWD) system, drive shafts, differentials (front/rear), axle boots, CV joints Transmission: Automatic transmission (PVT - Polaris Variable Transmission), clutch service, belt replacement, gear case maintenance Suspension: Front and rear suspension systems, shock absorbers, control arms, bushings, wheel bearings Brakes: Hydraulic brake system, brake calipers, brake pads, brake lines, master cylinder, parking brake Steering: Steering column, tie rods, steering linkage, power steering system (if equipped) Cooling System: Radiator, fan, coolant, hoses, thermostat Exhaust System: Muffler, exhaust pipes, heat shields Body And Frame: Chassis, fenders, plastics, racks, seat, handlebars Procedures Included Routine Maintenance: Oil changes, filter replacements, lubrication, battery testing, tire pressure checks, air filter cleaning/replacement Troubleshooting: Diagnostic charts, common problem identification and resolution Repair Procedures: Step-by-step instructions for component disassembly, inspection, repair, and reassembly Overhaul: Engine rebuild, transmission overhaul, suspension component replacement Electrical Diagnostics: Using multimeters, interpreting wiring diagrams, testing electrical components Technical Depth Depth Level: In-depth for professional technicians, but accessible for experienced DIY users Manual Specifications File Format Digital Format Details: Searchable PDF, printable pages, high-resolution diagrams Print Quality Diagram Resolution: High-resolution, clear and detailed exploded views and schematics Binding Type Binding: N/A (Digital Download) Paper Type Paper Quality: N/A (Digital Download) Engine Specifications Primary Engine 400 Engine Type: 4-stroke, SOHC, 2-valve, Single Cylinder 400 Displacement: 375cc 500 Engine Type: 4-stroke, SOHC, 2-valve, Single Cylinder 500 Displacement: 499cc Performance Horsepower 500: Approx. 29-32 HP (engine dependent) Torque 500: Approx. 30-33 lb-ft (engine dependent) Fuel System Carburetor Type: Mikuni BSR42 (typical for 500), Keihin CVK32 (typical for 400) Fuel Type: Unleaded gasoline, 87 octane (minimum) Cooling System Cooling Method: Liquid-cooled Lubrication System Oil Type: Polaris Premium 2W-50 4-Stroke Synthetic (or equivalent API SG, JASO MA approved) Oil Capacity With Filter: Approx. 2.5 US quarts (2.4 liters) Transmission Standard Transmission Type: Polaris Variable Transmission (PVT) Automatic with Engine Braking Optional Optional Features: High/Low range gearbox Features Clutch System: Primary and Secondary clutch system, belt drive Fluid Specifications Transmission Oil Type: Polaris Demand Drive Fluid (Front Differential), Polaris Synthetic Gearcase Lube (Rear Gearcase) Dimensions Exterior Length: Approx. 81 inches (205.7 cm) Width: Approx. 46 inches (116.8 cm) Height: Approx. 48 inches (121.9 cm) Weights Dry Weight: Approx. 600-650 lbs (272-295 kg) Towing Capacity: 1500 lbs (680 kg) Cargo Capacity Rear Rack: 100 lbs (45 kg) Tires Front Tire Size: AT 25x8-12 Rear Tire Size: AT 25x11-12 Safety Features Ratings Crash Test Ratings: N/A (ATVs are not subject to the same crash testing as passenger vehicles) Active Features Braking System: Hydraulic disc brakes front and rear, sealed single-lever hydraulic disc front and rear Passive Features Ride Control: Engine braking from PVT system Technology Features Infotainment Display Features: Digital odometer, speedometer, fuel gauge, gear indicator (on some models) Driver Assistance Braking Assistance: Engine braking via PVT system Connectivity Accessory Power: Accessory power outlet/plug (optional, varies by trim) Maintenance Service Intervals Engine Oil Change: Every 100 hours or 6 months Air Filter Service: Every 50 hours or as needed based on conditions Spark Plug Replacement: Typically every 200 hours or 12 months Clutch Belt Inspection: Every 50 hours; replacement based on wear Fluid Specifications Coolant Type: Polaris Premium Antifreeze/Coolant (or ethylene glycol-based coolant with corrosion inhibitors, 50/50 mix with distilled water) Brake Fluid Type: DOT 3 or DOT 4 Known Issues Common Wear Items: Clutch drive belt, suspension bushings, tie rod ends, wheel bearings Potential Electrical Concerns: Stator failure, regulator/rectifier issues (early models); check wiring harness integrity Drive System Maintenance: Regular inspection of CV boots for tears, check differential fluids Vehicle History Brand Heritage Polarishistory: Polaris Industries is a US-based manufacturer founded in 1954, known for snowmobiles, ATVs, UTVs, and motorcycles. Model Evolution Sportsman Lineage: The Sportsman line has been a cornerstone of Polaris's ATV offerings, known for its blend of utility and comfort since its introduction. Production Manufacturing Location: Roseau, Minnesota, USA (and other Polaris facilities) Awards & Recognition Recognitions Atv Awards 2005: Polaris Sportsman line consistently...