This manual covers the 2005 Sportsman 400 and 500 All-Terrain Vehicles (ATVs). The Sportsman line is renowned for its robust engineering, reliability, and versatility, serving a wide range of users from recreational riders and hunters to utility and farm operators. Key features of these models include independent rear suspension on many 500 variants, on-demand all-wheel drive for superior traction, and powerful engines designed for demanding off-road conditions. The brand has a long history as a pioneer in the ATV market, with the Sportsman series representing a mature and refined platform that balances performance, comfort, and capability. This comprehensive workshop service repair manual in English provides in-depth guidance for maintaining and repairing the 2005 Sportsman 400 and 500 models. It covers all essential systems, including engine overhaul, fuel and ignition systems, transmission and drivetrain, brakes, suspension, steering, and electrical systems. The manual details scheduled maintenance, troubleshooting procedures for common issues, step-by-step repair instructions, and complete overhaul procedures for major components. Its detailed technical information and diagnostic capabilities are suitable for professional technicians and experienced DIY mechanics, empowering users to keep their vehicles in optimal condition. 🏷️ Basic Information Identification Make: Polaris Model: Sportsman Year: 2005 Model Variant: 400 & 500 Codes Chassis Code: Not Specified in Product Info Engine Code: Not Specified in Product Info (Covers multiple variants) 👋 Introduction Market Position Segment: All-Terrain Vehicle (ATV) Target Audience: Recreational riders, hunters, utility users, farm operators Competitive Analysis Key Competitors 2005: Honda FourTrax, Yamaha Kodiak, Suzuki King Quad, Can-Am Outlander Key Features Atv Features: Independent Rear Suspension (IRS) on many 500 models, Electronic Fuel Injection (EFI) on some 500 variants, Shaft drive, On-demand AWD, Powerful engines for the class. Manual Value Proposition: Provides comprehensive guidance for maintaining and repairing the 2005 Polaris Sportsman 400 and 500, enabling owners to perform most service tasks themselves, saving time and money. 📋 Manual Details Coverage Areas Market Coverage: North America (Assumed based on product name) Vehicle Variants Covered: Polaris Sportsman 400, Polaris Sportsman 500 Page Count Estimated Page Count: Comprehensive (Exact count not provided in product info, but implied to be extensive for 'complete workshop') Manual Type Type: Workshop Service Repair Manual Language Language: English Format Format: Downloadable (Likely PDF) 📖 Manual Coverage Systems Covered Engine: Complete Engine Overhaul, Tuning, Diagnostics, Components (e.g., piston, cylinder, valve train) Fuel System: Carburetor/Fuel Injection systems, fuel pump, fuel lines, filters, cleaning, adjustment Ignition System: Ignition coil, spark plugs, timing, CDI unit, diagnostics Transmission Drivetrain: PVT (Polaris Variable Transmission) operation, belt replacement, clutch servicing, drive shafts, differentials, AWD system Brake System: Hydraulic brake system, master cylinder, calipers, rotors, brake pads, bleeding procedures, parking brake Suspension Steering: Front and rear suspension components, shocks, A-arms, ball joints, tie rods, steering linkage, wheel alignment Electrical System: Wiring diagrams, battery, charging system (stator, regulator/rectifier), starter motor, lighting, switches, fuses, relays Cooling System: Radiator, fan, thermostat, water pump, coolant replacement, hoses Exhaust System: Muffler, exhaust pipes, heat shields, mounting hardware Body Chassis: Frame inspection, body panels, fenders, racks, seating, storage Wheels Tires: Tire specifications, pressure, wheel bolt torque, bearing maintenance Procedures Included Maintenance: Scheduled maintenance (oil changes, filter replacements, spark plugs, valve adjustments), lubrication points Troubleshooting: Diagnostic procedures for common and uncommon problems, symptom-based troubleshooting charts Repair: Step-by-step repair instructions for all covered systems, including component removal, installation, and adjustment Overhaul: Complete engine and transmission overhaul procedures Diagnostics: Fault code interpretation (if applicable), electrical system testing, mechanical component testing Technical Depth Level Of Detail: In-depth, suitable for professional technicians and experienced DIY mechanics Diagnostic Capability: Advanced diagnostic procedures and specifications Rebuild Procedures: Comprehensive rebuild instructions for major components 📊 Manual Specifications File Format File Type: Digital Download (PDF) Searchability: Text-searchable (Assumed for quality PDF manuals) Printability: Printable (Assumed for workshop use) Print Quality Image Resolution: High-resolution (Assumed for technical diagrams and photos) Binding Type Type: N/A (Digital Download) Paper Type Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine 400 Engine Type: 4-stroke, SOHC, Single Cylinder (Liquid Cooled) 400 Displacement: 375cc 500 Engine Type: 4-stroke, SOHC, Single Cylinder (Liquid Cooled) 500 Displacement: 499cc Bore Stroke: Refer to Manual for Specifics (Varies by engine size) Performance Horsepower: Varies by model and tuning. Typically 25-35 HP range for 400, 30-40 HP for 500 (Estimate based on typical outputs for these models). Torque: Refer to Manual for Specifics Fuel System Fuel Delivery 400: Carburetor (Specific model varies, e.g., Mikuni BSR42) Fuel Delivery 500: Carburetor (e.g., Mikuni BSR42) or Electronic Fuel Injection (EFI) on select models Fuel Type: Unleaded gasoline, minimum 87 octane Fuel Capacity: Typically 3.35 gallons (12.7 L) Lubrication Oil Type: SAE 10W-40, API SG or higher (Refer to Manual for Exact Specification) Oil Capacity: Approx. 1.9 US quarts (1.8 L) with filter change (Refer to Manual) Ignition Spark Plug Type: NGK CR7HSA (Typical, verify in manual) Spark Plug Gap: 0.028-0.031 in (0.7-0.8 mm) (Typical, verify...