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Introduction
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Market Position
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Atv Segment:
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Mid-range utility ATV, positioned for recreational trail riding, light farm work, and general outdoor use.
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Competitive Analysis
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Competitors:
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Competed against models such as Honda FourTrax 350/400, Yamaha Wolverine/Grizzly 350/450, Kawasaki Prairie 360/400, and Suzuki King Quad 300/400.
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Key Features
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Polarissportsman Advantages:
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Known for its comfortable independent rear suspension (IRS) on many models, user-friendly AWD system, and robust build quality typical of Polaris products.
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Manual Value Proposition:
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This manual offers technicians and owners the critical technical data, step-by-step procedures, and diagnostic insights necessary to maintain and repair the 2005-2006 Polaris Sportsman 400 efficiently and effectively, ensuring optimal performance and longevity.
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Manual Coverage
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Systems Covered
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Engine:
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Complete engine assembly, disassembly, inspection, and repair procedures for the Polaris 400cc engine, including top-end, bottom-end, cooling system, and lubrication.
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Transmission Drivetrain:
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Detailed procedures for the Polaris PVT (Polaris Variable Transmission) automatic transmission, including belt inspection/replacement, clutch service, and final drive components (gears, shafts, seals).
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Fuel System:
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Carburetor (likely Mikuni BST40 or similar) overhaul, adjustment, and troubleshooting; fuel tank, fuel lines, and fuel pump (if applicable) inspection and replacement.
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Electrical System:
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Ignition system (CDI, coil, spark plug), charging system (stator, regulator/rectifier), starting system (starter motor, solenoid, battery), lighting, and wiring diagrams for all electrical components.
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Chassis Suspension Steering:
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Front and rear suspension (shocks, springs, control arms), steering system (handlebar, tie rods, steering column), wheel bearings, and chassis frame inspection and repair.
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Brakes:
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Hydraulic brake system, including front and rear calipers, brake lines, master cylinders, brake pads, and bleeding procedures. Parking brake mechanism.
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Bodywork Body Panels:
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Removal and installation of plastic body panels, fenders, racks, seats, and related trim components.
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Procedures Included
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Preventative Maintenance:
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Oil change intervals, filter replacement (oil, air), spark plug service, valve clearance checks, battery maintenance, chain adjustment (if applicable to specific 400 models), and lubrication points.
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Troubleshooting:
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Diagnostic procedures for common starting, running, electrical, and mechanical issues, often presented in a flowchart or symptom-based format.
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Repair Rebuild:
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Step-by-step instructions for disassembling, repairing, and reassembling major vehicle components and systems.
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Torque Specifications:
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Essential torque values for critical fasteners in engine, transmission, suspension, and brake systems.
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Wiring Diagrams:
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Detailed electrical schematics showing the layout and function of all wiring harnesses and components.
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Technical Depth
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Diagnostic Capabilities:
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Advanced diagnostic information, including how to interpret symptomology and perform tests for various systems, geared towards professional technicians.
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Component Rebuild:
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Comprehensive instructions for complete overhaul and rebuilding of complex components like the engine, transmission, and carburetors.
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Engine Specifications
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Primary Engine
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Engine Type:
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4-stroke, Single-cylinder, Liquid-cooled, SOHC (Single Overhead Cam)
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Displacement:
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400cc (actual displacement often around 375-376cc based on common Polaris engine architectures of the era)
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Bore X Stroke:
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Specifics usually found in manual, but typically in the range of 80mm x 75mm for similar displacements.
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Compression Ratio:
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Typically around 8.5:1 to 9.5:1 for this class of engine.
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Performance
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Horsepower:
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Estimated 20-25 HP (manufacturer specifications are often conservative or not widely published for ATVs).
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Torque:
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Estimated 20-25 lb-ft (approximate, dependent on exact RPM).
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Fuel System
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Fuel Delivery:
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Carburetor (e.g., Mikuni BST40 or similar size).
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Fuel Type:
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Unleaded gasoline, minimum 87 octane.
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Ignition
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Ignition System:
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CDI (Capacitor Discharge Ignition)
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Lubrication
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Oil Type:
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SAE 10W-40 motorcycle specific or ATV lubricant meeting API SG or higher and JASO MA specifications.
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Oil Capacity:
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Approximately 2.0-2.5 quarts (1.9-2.4 liters) with filter change. Exact specification in manual.
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Dimensions
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Exterior
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Length:
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Typically around 80-83 inches (203-211 cm) for this class of ATV.
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Width:
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Typically around 46-48 inches (117-122 cm).
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Height:
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Typically around 45-48 inches (114-122 cm) to handlebar.
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Wheelbase:
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Typically around 50-52 inches (127-132 cm).
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Weights
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Dry Weight:
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Around 600-650 lbs (272-295 kg).
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Gvw:
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Gross Vehicle Weight Rating (includes rider, accessories, and cargo) typically around 1000-1200 lbs.
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Cargo
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Front Rack Capacity:
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Typically rated for 50 lbs (22.7 kg).
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Rear Rack Capacity:
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Typically rated for 100 lbs (45.4 kg).
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Towing Capacity:
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Typically rated for 1500 lbs (680 kg) with appropriate hitch and ball.
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Tires Wheels
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Front Tire Size:
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Commonly 25x8-12 or 25x8.00-12.
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Rear Tire Size:
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Commonly 25x10-12 or 25x11.00-12.
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Wheel Bolt Pattern:
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Typically 4/110 or 4/115 mm (specific to Polaris hub design).
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Maintenance
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Service Intervals
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Engine Oil Change:
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Every 100 hours or 6 months, whichever comes first. More frequently under severe use.
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Air Filter Cleaning:
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Inspect every 25 hours, clean or replace as needed. Critical for engine longevity.
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Spark Plug Replacement:
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Typically every 100 hours or 1 year. Check gap and condition at each oil change.
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Cvtbelt Inspection:
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Inspect every 50 hours for wear, cracks, and delamination. Replace at first sign of damage.
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Fluid Specifications
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Transmission Fluid:
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The PVT system typically does not use a dedicated transmission fluid. Belt lubrication is critical. Some models may use a small amount of gear oil in the final drive/gearcase.
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Brake Fluid:
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DOT 3 or DOT 4 Hydraulic Brake Fluid.
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Coolant:
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Ethylene glycol based antifreeze/coolant. Typically a 50/50 mix with distilled water. Specific type in manual (e.g., green).
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Known Issues
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Cvt Belt Wear:
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CVT belts are a wear item and can fail prematurely if subjected to excessive heat, aggressive riding, or improper alignment. Regular inspection is key.
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Carburetor Issues:
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Carburetors can become clogged with debris or varnish if fuel sits for extended periods, leading to hard starting or poor running. Periodic cleaning and fresh fuel stabilization are recommended.
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Wheel Bearing Failure:
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Like many ATVs, wheel bearings can be susceptible to water and dirt ingress, leading to premature wear. Proper cleaning and greasing during maintenance can prolong life.
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Starter Solenoid Failure:
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The starter solenoid can sometimes fail, preventing the engine from cranking. This is a common component failure across many vehicle types.
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