The 2005 Sportsman 400 is a capable mid-size utility ATV designed for trail riding, light work, and recreational use. Known for its reliable engine and comfortable ergonomics, this model features a 4-stroke, liquid-cooled 376.5 cc engine paired with a Variable Transmission and an On-Demand All-Wheel Drive system for enhanced traction. Its robust engineering, including independent rear suspension on many variants, makes it a popular choice for various off-road applications, reflecting a long-standing heritage in powersports innovation. This comprehensive workshop manual provides essential information for maintaining and repairing the 2005 Sportsman 400. It covers all mechanical and electrical systems, offering detailed procedures for routine maintenance, troubleshooting common issues, and performing complete repairs, including engine and transmission overhauls. Included are component diagrams, torque specifications, and electrical schematics, ensuring that owners, mechanics, and technicians have the resources needed to keep this vehicle in optimal condition and extend its lifespan. 🏷️ Basic Information Identification Make: Polaris Model: Sportsman 400 Year: 2005 Product Type: Workshop Manual Codes Vin Code Prefix: 4X4Z 👋 Introduction Market Position Segment: Mid-size utility ATV, popular for trail riding, light work, and recreational use Competitive Analysis Competitors 2005: Honda Rancher 400, Yamaha Kodiak 400, Suzuki King Quad 300/400, Arctic Cat 400 DVX Key Features Features: Independent Rear Suspension (IRS) on some models, reliable engine, capable 4x4 system, comfortable ergonomics for its class Manual Value Benefit To Owner: Enables self-sufficiency in maintenance and repairs, reduces reliance on dealerships, extends vehicle lifespan, aids in identifying and resolving issues efficiently 📋 Manual Details Coverage Areas Primary Coverage: All mechanical and electrical systems, maintenance, troubleshooting, repair procedures Secondary Coverage: Component diagrams, torque specifications, electrical schematics Page Count Estimated Pages: Approximately 400-500 pages (typical for a comprehensive workshop manual of this era) Manual Type Type: Official Polaris Workshop Manual / Service Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine: Complete engine overhaul, internal components, cooling system, lubrication system, fuel system (carburetor), ignition system, exhaust system Transmission Drivetrain: PVT (Polaris Variable Transmission) system (drive clutch, driven clutch, belt), final drive, differentials (front and rear), drive shafts, CV joints Electrical: Starter system, charging system (stator, voltage regulator), battery, lighting system, ignition switch, control modules, wiring diagrams, diagnostic codes Suspension Steering: Front and rear suspension components (A-arms, shocks, springs), wheel bearings, steering system (tie rods, steering shaft, universal joints) Brakes: Hydraulic brake system, front and rear calipers, brake lines, master cylinder, brake fluid specifications, bleeding procedures Frame Bodywork: Chassis components, body panels, seat, racks, fenders, decals, plastics Procedures Included Maintenance: Oil changes, filter replacements, spark plug replacement, air filter cleaning/replacement, valve adjustments, coolant checks/flushes, greasing points Troubleshooting: Systematic diagnostic procedures for common and uncommon issues, symptom-based troubleshooting guides Repair: Detailed step-by-step repair instructions for all major components and systems, including engine rebuilds, transmission overhauls, suspension component replacement Disassembly Assembly: Complete breakdown and reassembly instructions for all serviceable parts Technical Depth Depth: Comprehensive, from basic routine maintenance to complete engine and transmission rebuilds, including detailed electrical schematics and diagnostic procedures 📊 Manual Specifications File Format Format: PDF Searchable Text: Yes (typically, depends on the PDF scan quality) Print Quality Print Readability: High (designed for printing, clear diagrams and text) Binding Type Binding: N/A (Digital PDF Download) Paper Type Paper Quality: N/A (Digital PDF Download) ⚙️ Engine Specifications Primary Engine Engine Type: 4-stroke, Liquid-Cooled, SOHC, 4-valve Engine Displacement: 376.5 cc Bore X Stroke: 85 mm x 69 mm Fuel Type: Unleaded Gasoline Performance Horsepower Approx: Approximately 27-30 HP (at the crankshaft, estimated) Torque Approx: Approximately 25-28 lb-ft (at the crankshaft, estimated) Fuel System Carburetor: Mikuni BSR34 Fuel Capacity: 3.3 US gallons (12.5 L) Ignition System Ignition Type: Electronic Ignition Cooling System Cooling Method: Liquid-Cooled Lubrication System Oil Type: SAE 10W-40 Motorcycle Oil (API SG or higher, JASO MA certified recommended) Oil Capacity W Filter: 1.8 US quarts (1.7 L) 🔧 Transmission Standard Transmission Type: Automatic PVT (Polaris Variable Transmission) with Engine Braking Optional Gearing: High (H), Low (L), Neutral (N), Reverse (R), Park (P) Features Drive System: Shaft Drive, On-Demand AWD (All-Wheel Drive) with 2WD/AWD selector Clutch Info Clutch Type: Primary Clutch (Drive Clutch), Secondary Clutch (Driven Clutch) 📐 Dimensions Exterior Length: 81.5 inches (207 cm) Width: 46 inches (116.8 cm) Height: 47 inches (119.4 cm) Wheelbase: 50.2 inches (127.5 cm) Ground Clearance: 11.5 inches (29.2 cm) Weights Dry Weight Approx: 614 lbs (278.5 kg) Towing Capacity: 1050 lbs (476 kg) Rack Capacity Front: 90 lbs (41 kg) Rack Capacity Rear: 180 lbs (82 kg) 🛡️ Safety Features Ratings Atv Safety Standards: ANSI/SVIA 1-2003 and BSR/SVIA 1-2007 (for general design and performance) Active Features Braking System: Hydraulic disc brakes front and rear, engine braking system Drive Mode: On-Demand AWD for enhanced traction Passive Features Handlebars Grip: Comfortable, ergonomic handlebars with grip Lighting: Dual headlights, tail light, brake light Footwells: Full floorboards with heel guards for...