The 2005 Sportsman 400 is a versatile All-Terrain Vehicle (ATV) designed for both recreational trail riding and utility tasks. Building on an established reputation for innovation and durability, this mid-size ATV offers a robust build, a reliable 375cc 4-stroke engine, and features like independent rear suspension (IRS) and on-demand 4WD. It was engineered to provide a comfortable and capable experience, competing effectively in its class by balancing performance with practical utility for various off-road environments. This comprehensive Service and Repair Manual provides detailed guidance for maintaining and repairing the 2005 Sportsman 400. It covers essential areas including engine overhaul, transmission and drivetrain service, suspension and brake systems, electrical diagnostics, and chassis and bodywork. Within its pages, you will find routine maintenance procedures, troubleshooting guides for common issues, component rebuild instructions, and adjustment procedures, all designed to assist owners and technicians in keeping the vehicle in optimal condition and ensuring its longevity and performance. 🏷️ Basic Information Identification Make: Polaris Model: Sportsman 400 Year: 2005 Vehicle Type: All-Terrain Vehicle (ATV) 👋 Introduction Market Position Positioning: The 2005 Polaris Sportsman 400 was positioned as a versatile and capable mid-size utility ATV, balancing performance for recreational riding with the practicality needed for farm work or trail exploration. Competitive Analysis Competitors: Competed against models like the Honda Foreman 450, Yamaha Kodiak 400, and Kawasaki Prairie 360, offering a compelling blend of features and value. Key Features Features: Known for its robust build, reliable engine, independent rear suspension (IRS) on many models, and Polaris's signature comfort and handling. 📋 Manual Details Coverage Areas Engine: Yes Transmission: Yes Drivetrain: Yes Suspension: Yes Brakes: Yes Electrical System: Yes Chassis And Body: Yes Cooling System: Yes Fuel System: Yes Exhaust System: Yes Steering: Yes Troubleshooting: Yes Maintenance Procedures: Yes Tune Up: Yes Wiring Diagrams: Yes Page Count Estimated Pages: Detailed Manual Type Type: Service and Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine Internal Components: Detailed coverage of piston, rings, cylinder, cylinder head, valves, camshaft, crankshaft, connecting rods, and lubrication system. Carburetor: Comprehensive overhaul and adjustment procedures for the carburetor. Ignition System: Diagnosis and repair of ignition coil, spark plug, CDI unit, and stator. Cooling System: Radiator, fan, thermostat, and coolant circulation system servicing. Transmission And Clutch: CVT system disassembly, inspection, belt replacement, and roller inspection. Final Drive And Differentials: Service and maintenance for rear drive unit and any applicable differential systems. Suspension Geometry: Front and rear suspension component inspection, adjustment, and replacement (shocks, control arms, bushings). Braking System Components: Hydraulic brake system, caliper service, pad replacement, fluid bleeding, and rotor inspection. Electrical Diagnostics: Battery, starter, charging system, lighting, and accessory circuits. Frame And Body Panels: Inspection and repair of frame integrity, plastic body panels, fenders, and racks. Fuel Delivery: Fuel tank, fuel pump (if applicable), fuel lines, and fuel filter service. Exhaust Gas Recirculation: Inspection and cleaning of EGR system components if equipped. Procedures Included Routine Maintenance: Detailed instructions for oil changes, filter replacements, air filter cleaning/replacement, spark plug service, and lubrication points. Troubleshooting Guides: Systematic diagnostic procedures for common and uncommon problems, including symptom-based troubleshooting. Component Overhaul: Step-by-step instructions for disassembling, inspecting, cleaning, and reassembling major components like the engine and transmission. Rebuild Instructions: Comprehensive guides for rebuilding engine, transmission, and other critical systems. Adjustment Procedures: Calibration of carburetor, throttle linkage, brake levers, and other adjustable components. Safety Inspections: Guidelines for pre-ride inspections and regular safety checks. Electrical Troubleshooting: Diagnosis using multimeter, checking for shorts, open circuits, and voltage drops. Technical Depth Depth: Comprehensive, covering everything from basic user maintenance to complete engine and transmission overhauls. 📊 Manual Specifications File Format Format: PDF Searchability: Searchable text for quick information retrieval. Print Quality Quality: High-resolution, ensuring clarity of diagrams and text. Binding Type Binding: N/A (Digital Download) Paper Type Paper: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: 4-Stroke, Liquid-Cooled, SOHC Displacement: 375cc Bore X Stroke: 83 mm x 69 mm Compression Ratio: 10.0:1 Fuel Delivery: Carburetor (likely Mikuni or Keihin) Performance Horsepower: Approximately 27 HP (estimated) Torque: Not officially published, but estimated to be around 23 lb-ft. Fuel System Fuel Type: Unleaded Gasoline (87 octane recommended) Fuel Tank Capacity: 4.25 US Gallons (16.1 Liters) 🔧 Transmission Standard Transmission Type: Automatic (PVT - Polaris Variable Transmission) Drive Modes: 2WD/4WD (On-Demand) Features Gear Selection: High, Low, Neutral, Reverse, Park Clutch Type: Centrifugal Clutch with CVT Drive Belt 📐 Dimensions Exterior Length: 81 inches (205.7 cm) Width: 46 inches (116.8 cm) Height: 47 inches (119.4 cm) Wheelbase: 50.5 inches (128.3 cm) Ground Clearance: 11 inches (27.9 cm) Weights Dry Weight: 562 lbs (255 kg) Gross Vehicle Weight Rating: 1050 lbs (476 kg) Cargo Front Rack Capacity: 25 lbs (11.3 kg) Rear Rack Capacity: 50 lbs (22.7 kg) 🛡️ Safety Features Ratings Safety Standards: Designed to meet ANSI standards for Class...