🏷️ Basic Information Identification Make: Polaris Model: Sportsman 400 Model Year: 2005, 2006 Vehicle Type: All-Terrain Vehicle (ATV) Codes Vin Code Model Year 5Th Digit: 5 (2005), 6 (2006) 👋 Introduction Market Position Segment Positioning: The Polaris Sportsman 400 was positioned as a capable and versatile mid-size utility ATV, known for its comfort and all-wheel-drive capabilities, making it suitable for recreational trail riding, light farm work, and hunting. Competitive Analysis Competitors: Competed directly with models from Yamaha (Grizzly 350/400), Honda (FourTrax 400/420), Suzuki (KingQuad 400), and Can-Am (Outlander 400). Key Features Powertrain: Pro-Star 400 engine, Polaris Variable Transmission (PVT), On-Demand All-Wheel Drive (AWD). Suspension Type: Independent front and rear suspension for improved ride quality and ground clearance. Ergonomics: Known for its comfortable seating position and rider-friendly controls. 📋 Manual Details Coverage Areas Manual Coverage: Complete workshop service and repair manual covering all aspects of the Polaris Sportsman 400 for model years 2005 and 2006. Page Count Page Count: Estimated 300-400 pages (typical for a comprehensive workshop manual of this era). Manual Type Manual Type: Workshop Service Manual / Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine: Internal combustion engine, including disassembly, inspection, reassembly, tuning, and troubleshooting. Fuel System: Carburetor (Keihin), fuel pump, fuel lines, fuel tank, and related components. Ignition System: CDI ignition, spark plugs, ignition coil, timing specifications. Cooling System: Liquid cooling system, radiator, fan, water pump, coolant specifications. Transmission Drivetrain: Automatic transmission (PVT - Polaris Variable Transmission), drive clutch, driven clutch, belt inspection and replacement, gearbox, drive shafts, universal joints, differentials (front and rear). Suspension: Front and rear independent suspension, shocks, springs, bushings, alignment specifications. Steering: Handlebar steering, tie rods, steering column, ball joints, adjustment procedures. Braking System: Hydraulic disc brakes (front and rear), brake pads, rotors, calipers, brake lines, master cylinder, bleeding procedures. Electrical System: Starter motor, battery, charging system (stator, voltage regulator), lighting (headlights, taillight, brake light), wiring diagrams, fuses, relays. Chassis Frame: Frame inspection, welds, component mounting points. Bodywork Plastics: Fenders, body panels, racks, seat removal and installation. Procedures Included Maintenance: Routine maintenance checks, oil changes, filter replacements, lubrication points, spark plug replacement, air filter cleaning/replacement, coolant checks. Troubleshooting: Diagnostic procedures for common problems, symptom-based troubleshooting guides, error code interpretation. Repair: Detailed step-by-step instructions for component removal, disassembly, repair, reassembly, and installation. Disassembly Reassembly: Complete guide to taking apart and putting back together all major vehicle systems. Adjustments: Carburetor adjustments, idle speed settings, throttle cable adjustments, brake adjustments, clutch engagement adjustments. Torques Specifications: Torque values for critical fasteners, engine bolts, suspension components, etc. Technical Depth Depth Level: Comprehensive, suitable for professional technicians and advanced DIY mechanics. Diagnostics: In-depth diagnostic procedures, including electrical system testing and troubleshooting. Rebuilds: Detailed instructions for engine and transmission rebuilds. 📊 Manual Specifications File Format File Format: Portable Document Format (PDF) Searchable Text: Yes (typically, depending on the OCR quality of the source document) Print Quality Print Quality: Designed for digital viewing and printing. Clarity of diagrams and text is crucial. Binding Type Binding Type: N/A (Digital PDF download) Paper Type Paper Type: N/A (Digital PDF download) Completeness Completeness: Full workshop manual content, as opposed to owner's manual or condensed repair guides. ⚙️ Engine Specifications Primary Engine Engine Manufacturer: Polaris Engine Model Designation: Pro-Star 400 Engine Type: 4-stroke Displacement: 376.5 cc Bore X Stroke: 84.0 mm x 68.0 mm Cylinder Arrangement: Single Cylinder Valve Configuration: SOHC (Single Overhead Camshaft), 2-valve Performance Horsepower: Approx. 27 hp @ 6500 RPM (estimated, actual may vary slightly) Torque: Approx. 23 lb-ft @ 5000 RPM (estimated) Fuel System Fuel Delivery: Carburetor Carburetor Model: Keihin 36mm CV (Constant Velocity) Fuel Type: Unleaded Gasoline (87 Octane Minimum Recommended) Fuel Tank Capacity: 3.0 US gallons (11.4 L) Ignition System Ignition Type: Electronic CDI Spark Plug Type: NGK CR9EK (or equivalent) Cooling System Cooling Method: Liquid-Cooled Coolant Type: Ethylene Glycol Based Antifreeze (50/50 mix with distilled water recommended) 🔧 Transmission Standard Transmission Type: Polaris Automatic Variable Transmission (PVT) with Engine Braking Drive System: Shaft Drive Drive Modes: 2WD / 4WD with Active Descent Control (ADC) Features Gear Selection: High (H), Low (L), Neutral (N), Reverse (R), Park (P) Clutch Type: CVT (Continuously Variable Transmission) with Primary and Secondary Sheaves Transmission Fluid Type: Polaris PS-4 Full Synthetic 4-Stroke Engine Oil (or equivalent meeting API SG, JASO MA specifications) Transmission Fluid Capacity: Refer to manual for specific fill levels (typically ~1 quart/liter) 📐 Dimensions Exterior Length: Approx. 76 inches (193 cm) Width: Approx. 46 inches (117 cm) Height: Approx. 47 inches (119 cm) Wheelbase: Approx. 50.2 inches (127.5 cm) Ground Clearance: Approx. 10.5 inches (26.7 cm) Cargo Front Rack Capacity: Approx. 50 lbs (23 kg) Rear Rack Capacity: Approx. 100 lbs (45 kg) Weights Dry Weight: Approx. 562 lbs (255 kg) Curb Weight: Approx. 597 lbs (271 kg) Wheels Tires Front Tire Size: AT 25...