The 2005 Sportsman 400 is a capable all-terrain vehicle (ATV) designed for both recreational pursuits and light utility tasks. As part of the popular Sportsman line, this mid-size ATV is recognized for its reliable engine, comfortable ride, and robust four-wheel-drive capability, often featuring technologies like On-Demand AWD. Engineered for versatility, it offers a towing capacity of 1500 lbs and rack capacities of 90 lbs in the front and 180 lbs in the rear, making it suitable for hauling gear or tackling various terrains. With a 4-stroke, liquid-cooled 400cc engine and an automatic CVT transmission, the Sportsman 400 provides a smooth and efficient power delivery for its intended applications. This comprehensive factory service repair manual provides detailed instructions and technical specifications for the 2005 Sportsman 400. It covers a wide array of systems, including engine overhaul and tuning, carburetion, clutch service, final drive, transmission, brakes, electrical systems, suspension, and bodywork. The manual includes diagnostic procedures, repair and rebuild instructions, maintenance schedules, and troubleshooting charts, offering in-depth information essential for maintaining and repairing the vehicle. It is designed to empower owners, mechanics, and technicians with the knowledge needed to ensure optimal performance and longevity of their Sportsman 400. 🏷️ Basic Information Identification Make: Polaris Model: Sportsman 400 Year: 2005 Vehicle Type: All-Terrain Vehicle (ATV) Platform: Sportsman Codes Vin Decoder Common Starting Digits: 4PF00000001 👋 Introduction Market Position Atv Segment: Mid-size utility ATV, popular for recreational and light work use Competitive Analysis Key Competitors 2005: Honda Foreman, Yamaha Kodiak, Suzuki King Quad, Arctic Cat 500 Key Features Atv Strengths 2005: Reliable engine, comfortable ride, Polaris's Active Descent Control (ADC) or similar features, four-wheel drive capability Manual Value Proposition Manual Benefit: Empowers owners to perform maintenance and repairs efficiently, saving time and money 📋 Manual Details Coverage Areas Manual Scope: Comprehensive Repair and Service Page Count Page Count: 312 Manual Type Manual Type: Factory Service Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine Coverage: Engine Overhaul, Diagnosis, Tuning, Cooling System, Lubrication System Carburetion Coverage: Carburetor Diagnosis, Cleaning, Adjustment, Rebuild Clutching Coverage: Drive Clutch, Driven Clutch Inspection, Service, Replacement, Belt Maintenance Final Drive Coverage: Gearcase, Drive Shaft, Axles, Bearings, Seals, Lubrication Body And Steering Coverage: Frame, Plastics, Handlebars, Steering Shaft, Tie Rods, Ball Joints, Wheel Bearings Transmission Coverage: Transmission Operation, Diagnosis, Internal Components, Shifting Mechanisms Brakes Coverage: Hydraulic System, Brake Pads, Rotors, Calipers, Master Cylinders, Bleeding Procedures Electrical Coverage: Wiring Diagrams, Lighting, Ignition System, Starting System, Charging System, Sensors, ECU Fuel System Coverage: Fuel Tank, Fuel Lines, Fuel Filter, Fuel Pump (if applicable) Suspension Coverage: Front and Rear Suspension Components, Shocks, Springs, Bushings Procedures Included Diagnostic Procedures: Fault Finding and Troubleshooting for all major systems Repair Procedures: Step-by-step instructions for component repair and replacement Rebuild Procedures: Detailed instructions for engine and transmission rebuilds Restoration Procedures: Guidance for bringing an older unit back to original specifications Maintenance Procedures: Regular servicing and preventative maintenance tasks Adjustment Procedures: Carburetor, clutch, and other component adjustments Troubleshooting Charts: Systematic guides for identifying and resolving common problems Technical Depth Depth Of Information: In-depth technical details suitable for professional technicians and experienced DIY mechanics 📊 Manual Specifications File Format Digital File Format: PDF Print Quality Printability: All pages printable without restriction Binding Type Binding Type: Digital Download (not physically bound) Paper Type Paper Type: Digital (for printing, high-quality paper recommended) Software Requirements PDF Reader Requirement: Adobe PDF Reader or compatible PDF reader recommended Archiving Software Requirement: WinRar or equivalent for extracted archives ⚙️ Engine Specifications Primary Engine Engine Type: 4-Stroke, Single-Cylinder Displacement: 400 cc (approximate) Cooling System: Liquid-Cooled Performance Horsepower Estimate: Estimated 20-25 HP (specific rating not provided in product info) Torque Estimate: Estimated 22-26 lb-ft (specific rating not provided in product info) Fuel System Fuel Delivery: Carburetor Carburetor Model Typical: Mikuni VM34SS or similar (specific model covered in manual) Ignition System Ignition Type: CDI (Capacitor Discharge Ignition) Lubrication System Oil Type Recommendation: API SG or higher, SAE 20W-50 motorcycle oil recommended (check manual for exact specification) Oil Capacity Engine Oil Capacity: Approximately 1.7 US quarts (1.6 Liters) with filter change (check manual for exact specification) 🔧 Transmission Standard Transmission Type: Automatic CVT (Continuously Variable Transmission) Features Gear Selection: High, Low, Neutral, Reverse Drive System: Shaft Drive with On-Demand AWD Clutch Type Primary Clutch: Centrifugal (Drive Clutch) Secondary Clutch: Roller/Spring Loaded (Driven Clutch) 📐 Dimensions Exterior Length: 81.5 inches (207 cm) (approximate) Width: 46 inches (117 cm) (approximate) Height: 47 inches (119 cm) (approximate) Weights Dry Weight: 580 lbs (263 kg) (approximate) Ground Clearance: 11.25 inches (28.6 cm) (approximate) Towing Capacity: 1500 lbs (680 kg) Rack Capacity Front: 90 lbs (41 kg) Rack Capacity Rear: 180 lbs (82 kg) 🛡️ Safety Features Ratings Safety Certification: Complies with ANSI B71.1-2003 and ASME B71.5-1987 standards Active Features Braking System: Hydraulic Disc Brakes Front and Rear 4Wd System:...