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Polaris Sportsman 400 2005 Online Service Repair Manual PDF Download
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Basic Information Identification Make: Polaris Model: Sportsman 400 Year: 2005 Vehicle Type: All-Terrain Vehicle (ATV) Introduction Market Position Positioning: The 2005 Polaris Sportsman 400 was positioned as a versatile and...
Tipo: Powersports
Fabricante:
Sku: 52622
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| Basic Information | |
| Identification | |
| Make: | Polaris |
| Model: | Sportsman 400 |
| Year: | 2005 |
| Vehicle Type: | All-Terrain Vehicle (ATV) |
| Introduction | |
| Market Position | |
| Positioning: | The 2005 Polaris Sportsman 400 was positioned as a versatile and capable mid-size utility ATV, balancing performance for recreational riding with the practicality needed for farm work or trail exploration. |
| Competitive Analysis | |
| Competitors: | Competed against models like the Honda Foreman 450, Yamaha Kodiak 400, and Kawasaki Prairie 360, offering a compelling blend of features and value. |
| Key Features | |
| Features: | Known for its robust build, reliable engine, independent rear suspension (IRS) on many models, and Polaris's signature comfort and handling. |
| Manual Details | |
| Coverage Areas | |
| Engine: | Yes |
| Transmission: | Yes |
| Drivetrain: | Yes |
| Suspension: | Yes |
| Brakes: | Yes |
| Electrical System: | Yes |
| Chassis And Body: | Yes |
| Cooling System: | Yes |
| Fuel System: | Yes |
| Exhaust System: | Yes |
| Steering: | Yes |
| Troubleshooting: | Yes |
| Maintenance Procedures: | Yes |
| Tune Up: | Yes |
| Wiring Diagrams: | Yes |
| Page Count | |
| Estimated Pages: | Detailed |
| Manual Type | |
| Type: | Service and Repair Manual |
| Language | |
| Language: | English |
| Format | |
| Format: | PDF Download |
| Manual Coverage | |
| Systems Covered | |
| Engine Internal Components: | Detailed coverage of piston, rings, cylinder, cylinder head, valves, camshaft, crankshaft, connecting rods, and lubrication system. |
| Carburetor: | Comprehensive overhaul and adjustment procedures for the carburetor. |
| Ignition System: | Diagnosis and repair of ignition coil, spark plug, CDI unit, and stator. |
| Cooling System: | Radiator, fan, thermostat, and coolant circulation system servicing. |
| Transmission And Clutch: | CVT system disassembly, inspection, belt replacement, and roller inspection. |
| Final Drive And Differentials: | Service and maintenance for rear drive unit and any applicable differential systems. |
| Suspension Geometry: | Front and rear suspension component inspection, adjustment, and replacement (shocks, control arms, bushings). |
| Braking System Components: | Hydraulic brake system, caliper service, pad replacement, fluid bleeding, and rotor inspection. |
| Electrical Diagnostics: | Battery, starter, charging system, lighting, and accessory circuits. |
| Frame And Body Panels: | Inspection and repair of frame integrity, plastic body panels, fenders, and racks. |
| Fuel Delivery: | Fuel tank, fuel pump (if applicable), fuel lines, and fuel filter service. |
| Exhaust Gas Recirculation: | Inspection and cleaning of EGR system components if equipped. |
| Procedures Included | |
| Routine Maintenance: | Detailed instructions for oil changes, filter replacements, air filter cleaning/replacement, spark plug service, and lubrication points. |
| Troubleshooting Guides: | Systematic diagnostic procedures for common and uncommon problems, including symptom-based troubleshooting. |
| Component Overhaul: | Step-by-step instructions for disassembling, inspecting, cleaning, and reassembling major components like the engine and transmission. |
| Rebuild Instructions: | Comprehensive guides for rebuilding engine, transmission, and other critical systems. |
| Adjustment Procedures: | Calibration of carburetor, throttle linkage, brake levers, and other adjustable components. |
| Safety Inspections: | Guidelines for pre-ride inspections and regular safety checks. |
| Electrical Troubleshooting: | Diagnosis using multimeter, checking for shorts, open circuits, and voltage drops. |
| Technical Depth | |
| Depth: | Comprehensive, covering everything from basic user maintenance to complete engine and transmission overhauls. |
| Manual Specifications | |
| File Format | |
| Format: | |
| Searchability: | Searchable text for quick information retrieval. |
| Print Quality | |
| Quality: | High-resolution, ensuring clarity of diagrams and text. |
| Binding Type | |
| Binding: | N/A (Digital Download) |
| Paper Type | |
| Paper: | N/A (Digital Download) |
| Engine Specifications | |
| Primary Engine | |
| Engine Type: | 4-Stroke, Liquid-Cooled, SOHC |
| Displacement: | 375cc |
| Bore X Stroke: | 83 mm x 69 mm |
| Compression Ratio: | 10.0:1 |
| Fuel Delivery: | Carburetor (likely Mikuni or Keihin) |
| Performance | |
| Horsepower: | Approximately 27 HP (estimated) |
| Torque: | Not officially published, but estimated to be around 23 lb-ft. |
| Fuel System | |
| Fuel Type: | Unleaded Gasoline (87 octane recommended) |
| Fuel Tank Capacity: | 4.25 US Gallons (16.1 Liters) |
| Transmission | |
| Standard | |
| Transmission Type: | Automatic (PVT - Polaris Variable Transmission) |
| Drive Modes: | 2WD/4WD (On-Demand) |
| Features | |
| Gear Selection: | High, Low, Neutral, Reverse, Park |
| Clutch Type: | Centrifugal Clutch with CVT Drive Belt |
| Dimensions | |
| Exterior | |
| Length: | 81 inches (205.7 cm) |
| Width: | 46 inches (116.8 cm) |
| Height: | 47 inches (119.4 cm) |
| Wheelbase: | 50.5 inches (128.3 cm) |
| Ground Clearance: | 11 inches (27.9 cm) |
| Weights | |
| Dry Weight: | 562 lbs (255 kg) |
| Gross Vehicle Weight Rating: | 1050 lbs (476 kg) |
| Cargo | |
| Front Rack Capacity: | 25 lbs (11.3 kg) |
| Rear Rack Capacity: | 50 lbs (22.7 kg) |
| Safety Features | |
| Ratings | |
| Safety Standards: | Designed to meet ANSI standards for Class 1 ATVs. |
| Active Features | |
| Braking System: | Hydraulic disc brakes front and rear, with parking brake. |
| Lighting: | Dual 35W headlights, 8W taillight/brakelight. |
| Passive Features | |
| Chassis Design: | Reinforced steel frame for durability and stability. |
| Operator Controls: | Ergonomically designed handlebars and controls for ease of use. |
| Technology Features | |
| Infotainment | |
| Instrument Cluster: | Digital instrument cluster typically includes speedometer, odometer, trip meter, fuel gauge, and indicator lights. |
| Driver Assistance | |
| 4Wd System: | Polaris's ADC (Active Descent Control) may be present on some models for controlled descents, though not standard on all 400s. On-demand 4WD activation is a key feature. |
| Connectivity | |
| Accessories: | Provisions for accessory lighting, winches, and storage solutions, often requiring basic electrical understanding covered in the manual. |
| Maintenance | |
| Service Intervals | |
| Oil Change Interval: | Every 100 hours or 6 months (whichever comes first). Check manual for specific conditions. |
| Air Filter Cleaning: | Clean every 25 hours or as needed in dusty conditions. Replace as necessary. |
| Spark Plug Replacement: | Inspect every 50 hours, replace as needed. Recommended replacement interval may vary. |
| Valve Adjustment: | Inspect and adjust every 100 hours or annually. Specific procedures in manual. |
| Transmission Belt Inspection: | Inspect drive belt for wear and damage every 50 hours. Replace if more than 3mm (1/8 inch) wear or damage is present. |
| Fluid Specifications | |
| Engine Oil Type: | Polaris PS-4 5W-50 Synthetic 4-Cycle Engine Oil or equivalent SAE 5W-50 API SG or higher, certified for 4-stroke engines. |
| Engine Oil Capacity: | 2.1 US quarts (2.0 liters) with filter change. |
| Transmission Fluid Type: | Polaris AGL Synthetic Gearcase Lubricant (for final drive/gearbox) and PVT system specific belt lubricant (if specified for CVT). |
| Brake Fluid Type: | DOT 3 or DOT 4 Hydraulic Brake Fluid. |
| Coolant Type: | Ethylene Glycol based antifreeze (50/50 mix with distilled water). |
| Known Issues | |
| Common Problems: | Potential issues include carburetor gumming if not run regularly, CVT belt wear, and occasional electrical connector corrosion. The manual addresses these and provides solutions. |
| Vehicle History | |
| Brand Heritage | |
| Polarís History: | Polaris Industries Inc. has a long history dating back to 1954, initially focused on snowmobiles and later expanding into ATVs, motorcycles, and powersports vehicles. They are known for innovation and a broad range of off-road vehicles. |
| Model Evolution | |
| Sportsman Lineage: | The Sportsman line has been a cornerstone of Polaris's ATV offerings for decades, evolving through various engine sizes and feature sets to meet diverse rider needs. The 400cc class represented a strong value proposition within the lineup. |
| Production | |
| Production Period: | The Sportsman 400 was a popular model produced for several years, with the 2005 model representing a refinement of earlier iterations. Production occurred at Polaris manufacturing facilities in the USA. |
| Awards & Recognition | |
| Recognitions | |
| Industry Acclaim: | While specific awards for the 2005 Sportsman 400 are not widely publicized, the Polaris Sportsman line consistently received praise for its utility, comfort, and off-road capability in consumer reviews and industry publications of the era. |