This workshop service manual covers the utility ATVs produced for the 2005 and 2006 model years. Known for their proven reliability, versatility for both work and recreation, and comfortable ride, these models are equipped with strong towing capacities and capable All-Wheel Drive systems. The line has a long-standing reputation for delivering robust performance, making it a respected choice in the utility ATV market. This comprehensive manual provides detailed information essential for the maintenance, repair, and troubleshooting of your vehicle. It covers all major systems, including the engine, transmission, drivetrain, chassis, and electrical components, along with specific procedures for routine maintenance, diagnostics, and component overhauls. With step-by-step instructions and technical specifications, this manual empowers owners and technicians to effectively maintain and repair their vehicles, ensuring optimal performance and longevity. 🏷️ Basic Information Identification Make: Polaris Model: Sportsman 400 / 500 Year: 2005, 2006 👋 Introduction Market Position Category: Utility ATV Target User: Owners, Technicians, Enthusiasts involved in repair and maintenance of Polaris Sportsman ATVs Competitive Analysis Competitors 2005 2006: Can-Am Outlander, Honda FourTrax/Rancher, Yamaha Grizzly, Kawasaki Prairie Key Features Vehicle Strengths: Proven reliability, Versatile for work and recreation, Comfortable ride, Strong towing capacity Manual Value Proposition: Empowers users with the knowledge to perform comprehensive maintenance and repairs, saving on labor costs and ensuring optimal vehicle performance. 📋 Manual Details Coverage Areas Covered Models: Polaris Sportsman 400 (2005-2006), Polaris Sportsman 500 (2005-2006) Page Count Total Pages: 311 Manual Type Type: Workshop Service Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Powertrain: Engine (400cc, 499cc), Transmission, Drivetrain (AWD/2WD systems) Chassis: Suspension (front and rear), Steering, Brakes (hydraulic disc), Frame Electrical: Ignition system, Lighting, Charging system (stator, regulator/rectifier), Battery, Starter motor, Wiring diagrams Fuel System: Carburetor (Mikuni BS34/BS36), Fuel pump, Fuel tank, Fuel lines Body And Trim: Body panels, Seat, Racks, Handlebars, Controls Procedures Included Maintenance: Routine inspections, Oil changes, Filter replacements, Spark plug servicing, Valve adjustments Diagnostics: Troubleshooting guides for common problems, Symptom-based diagnosis Repair: Engine overhaul, Transmission repair, Suspension component replacement, Brake system service, Electrical component repair Assembly Disassembly: Step-by-step instructions for dismantling and reassembling major components Technical Depth Depth: Comprehensive diagnostic procedures, detailed repair instructions, complete overhaul specifications 📊 Manual Specifications File Format Quality: High-resolution, searchable PDF for clear viewing and printing Printable: Yes, designed for printing specific sections or the entire manual Binding Type Binding: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine 400 Engine Type: 4-stroke, Single-cylinder, SOHC Displacement: 375cc (approximate) Primary Engine 500 Engine Type: 4-stroke, Single-cylinder, SOHC Displacement: 499cc Performance 500 Bore X Stroke: 92mm x 74mm Compression Ratio: 8.7:1 Horsepower Estimated: 30-35 HP (approximate, at crankshaft) Torque Estimated: 35-40 ft-lbs (approximate, at crankshaft) Fuel System Carburetor 400: Mikuni BS34 Carburetor 500: Mikuni BS36 Fuel Type: Unleaded gasoline (87 octane minimum) Lubrication Oil Type Engine: SAE 10W-40, API SG or higher Ignition Ignition System: CDI (Capacitor Discharge Ignition) Cooling Cooling System: Liquid-cooled 🔧 Transmission Standard Type: Automatic (PVT - Polaris Variable Transmission) Features Drive Modes: High, Low, Neutral, Reverse Drive System: Shaft Drive Selectable 4Wd: Yes (On Demand All-Wheel Drive) Fluid Specifications Transmission Fluid Type: Polaris AGL Premium Gearcase Lubricant or equivalent (e.g., SAE 80W-90 API GL-5) 📐 Dimensions Exterior Length: 81 inches (approximate) Width: 46 inches (approximate) Height: 47 inches (approximate) Wheelbase: 50.5 inches (approximate) Weights Dry Weight: 600-630 lbs (approximate, depending on model variant) Towing Capacity: 1500 lbs Rack Capacity Front: 100 lbs Rack Capacity Rear: 200 lbs 🛡️ Safety Features Ratings Atv Safety Standards: Compliance with ANSI B71.1-2003 standards for ATVs Active Features Braking System: Hydraulic disc brakes, front and rear Passive Features Lighting: Dual 35W headlights, 40W taillight/brakelight Handlebar Design: Ergonomic grips and controls for safe operation 💡 Technology Features Infotainment Infotainment System: N/A (Basic utility vehicle, no integrated infotainment) Driver Assistance Features: None Connectivity Features: None Other Features Lighting Technology: Halogen bulbs Instrumentation: Analog speedometer, odometer, trip meter, fuel gauge, tachometer, gear indicator, 4WD indicator 🔧 Maintenance Service Intervals Engine Oil Change: Every 100 hours or 12 months, whichever comes first Air Filter Inspection: Every 25 hours or 3 months Spark Plug Replacement: Every 100 hours or 12 months Valve Clearance Check: Every 100 hours or 12 months Fluid Specifications Engine Oil Capacity: Approx. 1.9 US quarts (1.8 Liters) with filter change Coolant Type: Ethylene glycol-based antifreeze/coolant, 50/50 mix with distilled water Known Issues Common Wear Items: Drive belts (PVT), wheel bearings, tie rod ends, brake pads Carburetor Tuning: Occasional need for carburetor cleaning and adjustment due to fuel quality and usage patterns Electrical Connections: Corrosion or looseness in electrical connectors, especially in wet environments 📚 Vehicle History Brand Heritage Manufacturer: Polaris Industries Inc., founded in 1954 Model Evolution Sportsman Lineage: The Sportsman line has been a cornerstone of Polaris' ATV offerings since its introduction, known for its comfort, capability,...