This manual covers the 2005 Sportsman 400, a versatile all-terrain vehicle renowned for its robust engineering and reliable performance. Designed for a wide range of utility and recreational applications, the Sportsman 400 features a capable 375cc liquid-cooled engine, an automatic Variable Transmission with On-Demand All-Wheel Drive, and independent front and rear suspension for enhanced stability and comfort. With a strong emphasis on durability and practical design, this model has established itself as a dependable choice for demanding tasks and adventurous outings. This comprehensive English-language Parts Manual/Catalog provides over 300 pages of detailed information crucial for the maintenance and repair of your 2005 Sportsman 400. It offers a complete breakdown of all major systems, including the engine, drivetrain, suspension, braking, electrical, and fuel systems, featuring high-quality exploded-view diagrams and official OEM part numbers. This resource is invaluable for owners, mechanics, and parts suppliers, ensuring accurate part identification, efficient component replacement, and streamlined ordering to minimize downtime and maintain optimal vehicle performance. 🏷️ 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...