This manual covers the 400 and 500 All-Terrain Vehicles (ATVs) from the 2005 and 2006 model years. These utility ATVs are engineered for robust performance, offering capable handling with independent front suspension and significant towing and hauling capacity, making them ideal for both work and recreational riding. A manufacturer with a strong heritage in off-road vehicles, developed the Sportsman line to be a dominant force in the utility ATV market, known for its balance of power, utility, and value. This comprehensive Workshop Service Repair Manual provides detailed guidance for maintenance, troubleshooting, diagnostics, and repair. It includes step-by-step procedures for engine and transmission overhauls, electrical system diagnostics, fuel system maintenance, and much more. The manual is designed to empower owners and technicians, offering the necessary information to keep these ATVs operating at peak performance and ensuring their longevity through proper care and timely repairs. 🏷️ 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...