🏷️ Basic Information Identification Make: Polaris Model: Sportsman 400 / Sportsman 500 Year: 2005 Vehicle Type: All-Terrain Vehicle (ATV) Codes Product Identifier: 2005 Polaris Sportsman 400 500 Service Repair Manual Download PDF 👋 Introduction Market Position Target User: Designed for owners of the 2005 Polaris Sportsman 400 and 500 seeking to perform their own maintenance and repairs, saving on labor costs. Competitive Analysis Value Proposition: Offers comprehensive coverage and detailed instructions that are essential for maintaining the longevity and performance of these Polaris ATVs. Key Features Diagrams: Contains high-quality diagrams and illustrations essential for understanding complex assemblies and procedures. Accessibility: Instant download saves time and money on shipping, providing immediate access to critical repair information. 📋 Manual Details Coverage Areas Primary Coverage: Complete service and repair of 2005 Polaris Sportsman 400 and 500 ATVs Page Count Estimated Page Count: Extensive (specific number not provided, but described as 'most complete ever compiled') Manual Type Type: Service Repair Manual Language Language: English Format File Format: PDF 📖 Manual Coverage Systems Covered Engine: Detailed repair, overhaul, and troubleshooting of the engine, including ignition, cooling, and lubrication systems. Carburetion: Comprehensive guide to carburetor removal, cleaning, adjustment, and troubleshooting for optimal performance. Clutching: In-depth coverage of primary and secondary clutch maintenance, repair, and adjustment, including belt inspection and replacement. Final Drive: Maintenance and repair procedures for the drive train, including differentials, axles, and drive shafts. Body And Steering: Procedures for body panel removal, installation, steering system diagnosis, and repair, including handlebar and tie-rod adjustments. Transmission: Coverage of transmission operation, maintenance, and repair, including gear shifting mechanisms and fluid servicing. Brakes: Detailed instructions for brake system maintenance, including hydraulic fluid replacement, pad inspection, caliper service, and bleeding procedures. Electrical: Extensive information on the electrical system, including wiring diagrams, component testing, battery maintenance, lighting, and ignition system diagnostics. Procedures Included Maintenance: Routine maintenance schedules, lubrication points, filter replacements, and fluid level checks. Repair: Step-by-step repair procedures for all major components and systems of the ATV. Troubleshooting: Diagnostic charts and troubleshooting guides for identifying and resolving common and complex mechanical and electrical issues. Technical Depth Depth: Comprehensive, covering from basic maintenance to complete engine and transmission overhauls, suitable for DIY enthusiasts and professional mechanics. 📊 Manual Specifications File Format Compatibility: Compatible with all versions of Windows and Mac operating systems. Print Quality Printability: All pages are printable for hard copy reference. Binding Type Binding: Digital Download (PDF) Paper Type Paper Type Equivalent: High-quality digital document suitable for on-screen viewing or printing on standard paper. ⚙️ Engine Specifications Primary Engine Engine Type 400: 4-stroke, Liquid-Cooled, SOHC, 4 Valve Displacement 400: 375cc (Specific bore/stroke may be detailed in manual) Engine Type 500: 4-stroke, Liquid-Cooled, SOHC, 4 Valve Displacement 500: 499cc (Specific bore/stroke may be detailed in manual) Performance Horsepower 500: Approximately 34 hp @ 6500 rpm (Manufacturer specification, manual will provide precise figures). Fuel System Carburetor Type: Likely Mikuni BST (manual will specify exact model and tuning specs for both 400 and 500 variants). Fuel Type: Unleaded Gasoline (Manual will specify octane rating requirement). Fluid Specifications Engine Oil Type: SAE 20W-50 or 10W-40 (Manual will specify exact Polaris recommendation and capacity). Coolant Type: Ethylene glycol-based antifreeze/coolant (Manual will specify mix ratio and capacity). 🔧 Transmission Standard Transmission Type: Automatic (PVT - Polaris Variable Transmission) with Hi/Lo range and Reverse. Optional Optional Transmissions: N/A for this model and year; PVT is standard. Features Drive System: Shaft Drive, AWD (All-Wheel Drive) engagement Fluid Requirements Transmission Fluid Type: Specific PVT Fluid or appropriate Synthetic Gear Lube (Manual will specify exact Polaris part number and type). 📐 Dimensions Exterior Length: Approx. 81 inches (Manual will provide exact dimensions for both 400 and 500 if they differ). Width: Approx. 46 inches (Manual will provide exact dimensions for both 400 and 500 if they differ). Height: Approx. 47 inches (Manual will provide exact dimensions for both 400 and 500 if they differ). Weights Dry Weight 400: Approx. 600 lbs (Manual will provide precise figure). Dry Weight 500: Approx. 605 lbs (Manual will provide precise figure). Ground Clearance: Approx. 10.5 inches (Manual will provide precise figure). Cargo Rack Capacity Front: 200 lbs (Manual will confirm). Rack Capacity Rear: 400 lbs (Manual will confirm). Towing Capacity: 1500 lbs (Manual will confirm). 🛡️ Safety Features Ratings Safety Standards Compliance: Meets ANSI standards for recreational ATVs (Manual will elaborate on specific safety guidelines). Active Features Braking System: Hydraulic Disc Brakes (Front and Rear), foot-actuated. Parking Brake: Hand-operated parking brake. Passive Features Lighting: Dual Halogen Headlights, Tail Light, Brake Light. Throttle Limiter: Often present for safety, detailed in manual for adjustment/checking. 💡 Technology Features Infotainment Instrument Panel: Digital/Analog instrument cluster typically includes speedometer, odometer, trip meter, fuel gauge, and indicator lights. Manual explains readings and diagnostics. Driver Assistance AWD System: Polaris's AWD system automatically engages front wheels when rear wheel slippage...