🏷️ Basic Information Identification Make: Polaris Model: Sportsman 400 & Sportsman 500 Model Variant: ATV Model Years Covered: 2005, 2006 Codes Product Identifier: POL-SPORTSMAN-2005-2006-SRM-PDF 👋 Introduction Market Position Segment: Utility ATV Target Audience: Owners and technicians performing maintenance and repairs Competitive Analysis Competitors 2005 2006: Yamaha Grizzly, Honda Foreman, Suzuki King Quad, Can-Am Outlander Key Features Vehicle Power Delivery: Robust engine performance suitable for work and recreational riding Handling: Independent front suspension (IFS) for improved ride and handling Utility: Towing and hauling capabilities, durable chassis construction Manual Value Proposition Benefit To Owner: Empowers owners to perform routine maintenance and complex repairs, saving on labor costs and ensuring longevity 📋 Manual Details Coverage Areas Primary Coverage: Complete Workshop Service & Repair Secondary Coverage: Maintenance, Troubleshooting, Diagnostics, Overhaul Page Count Estimated Page Count: 500-700 (typical for comprehensive ATV service manuals) Manual Type Type: Workshop Service Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine: Engine teardown, assembly, timing, lubrication, cooling system, fuel system (carburetor/EFI), ignition system, starting system Transmission: Transmission disassembly, assembly, gear ratios, clutch operation, driveline components Drivetrain: CVT system, drive shafts, differentials, AWD system (if applicable), final drive Suspension: Front and rear suspension geometry, shock absorbers, control arms, bushings, spring rates Brakes: Hydraulic brake system, master cylinders, calipers, brake pads, rotors, brake lines, bleeding procedures Electrical: Wiring diagrams, charging system (stator, regulator/rectifier), battery, starter motor, lighting, ignition system components, sensors, control modules Fuel System: Fuel tank, fuel pump, fuel lines, carburetor tuning and rebuild (for applicable models), fuel injection system diagnosis Cooling System: Radiator, cooling fan, thermostat, coolant types, flushing procedures Frame And Body: Frame inspection, body panel removal and installation, seat, handlebars, racks Wheels And Tires: Tire pressure recommendations, wheel bearing maintenance, wheel installation Procedures Included Maintenance: Scheduled maintenance intervals, oil changes, filter replacements, spark plug replacement, lubrication points Troubleshooting: Diagnostic charts for common issues, symptom-based troubleshooting guides Repair: Step-by-step repair procedures for all major mechanical and electrical components Overhaul: Complete engine and transmission rebuild procedures Specifications: Torque specifications for all fasteners, clearances, and measurements Diagnostics: Identification of fault codes, diagnostic tool usage (if applicable) Technical Depth Depth: Comprehensive from basic maintenance to full engine and transmission rebuilds Diagnostic Level: Advanced diagnostics including electrical system troubleshooting and fuel system analysis Rebuild Scope: Detailed procedures for complete engine, transmission, and differential overhauls 📊 Manual Specifications File Format File Type: PDF Searchability: Searchable text content for efficient information retrieval Print Quality: High-resolution scans suitable for printing Print Quality Graphics Clarity: Clear, legible diagrams, illustrations, and photographs Binding Type Binding: N/A (Digital Download) Paper Type Paper: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine 400 Type: 4-stroke, SOHC, 2-valve Displacement Cc: 376 Bore X Stroke Mm: 80 x 74.4 Cooling System: Liquid-cooled Primary Engine 500 Type: 4-stroke, SOHC, 4-valve Displacement Cc: 499 Bore X Stroke Mm: 83 x 92 Cooling System: Liquid-cooled Performance Horsepower Approx 400: 26 hp @ 6500 rpm (estimated) Horsepower Approx 500: 30 hp @ 6000 rpm (estimated) Torque Approx 400: 26.5 lb-ft @ 5000 rpm (estimated) Torque Approx 500: 31.4 lb-ft @ 4500 rpm (estimated) Fuel System Carburetor 400: Mikuni BSR42 Carburetor 500: Mikuni BSR40 Fuel Type: Unleaded gasoline Fuel Tank Capacity Gallons: 3.2 🔧 Transmission Standard Type: Automatic (CVT) with Hi/Lo range and Reverse Optional Transmission Options: N/A (CVT is standard) Features Drive Engagement: On-demand AWD system with 2WD/4WD selector Engine Braking: Integral engine braking via CVT 📐 Dimensions Exterior Length In: 81.0 Width In: 46.0 Height In: 47.0 Wheelbase In: 50.1 Ground Clearance In: 11.0 Cargo Front Rack Capacity Lbs: 100 Rear Rack Capacity Lbs: 200 Weights Dry Weight Lbs 400: 643 Dry Weight Lbs 500: 660 Towing Capacity Lbs: 1500 Dimensions Tire Size Front: AT25x8-12 Tire Size Rear: AT25x10-12 Wheel Bolt Pattern: 4x110mm 🛡️ Safety Features Ratings Atv Safety Standards: Meets ANSI/SVIA 1-2003 standards Active Features Braking System: Hydraulic disc brakes, front and rear Parking Brake: Independent rear parking brake lever Passive Features Lighting: Dual 35W headlights, 25/50W taillight/brake light Operator Presence: Handlebar-mounted throttle and brake levers with self-retracting design 💡 Technology Features Infotainment Infotainment System: N/A (Basic utility vehicle, no integrated infotainment) Driver Assistance Driver Assistance Features: N/A (Basic utility vehicle) Connectivity Connectivity Options: N/A (Basic utility vehicle) Engine Management Ignition System: CDI (Capacitor Discharge Ignition) 🔧 Maintenance Service Intervals Oil Change Hours: Every 100 hours or annually Air Filter Cleaning Hours: Every 50 hours or more frequently in dusty conditions Spark Plug Replacement Miles: Every 1000 miles or annually Belt Inspection Hours: Every 200 hours Fluid Specifications Engine Oil Type: Polaris PS-4 5W-50 Synthetic or equivalent API SG rated Engine Oil Capacity Qts: 2.0 Transmission Oil Type: Polaris Angle Drive Fluid (ADF) for front and rear differentials, Polaris CVT Fluid for transmission Coolant Type: Ethylene glycol-based antifreeze (50/50 mix with distilled water) Known Issues Common Wear Items:...