The 2005 Sportsman 400 is a capable and versatile All-Terrain Vehicle (ATV) designed for a balance of performance and utility. Known for its reliable 400cc engine and signature True All-Wheel Drive (AWD) system, this ATV offers an enjoyable and dependable experience for recreational riding and various farm or ranch tasks. Its independent rear suspension contributes to a more comfortable ride, making it a well-rounded option within the competitive mid-size utility ATV market of its time. This factory service repair manual provides comprehensive coverage for the 2005 Sportsman 400, detailing essential maintenance, troubleshooting, and repair procedures. It covers all major systems, including the engine, transmission, drivetrain, suspension, brakes, and electrical system, offering step-by-step instructions for diagnostics, adjustments, and component overhauls. This manual is an indispensable resource for owners, mechanics, and technicians seeking to maintain the optimal performance and longevity of their vehicle. 🏷️ Basic Information Identification Make: Polaris Model: Sportsman 400 Year: 2005 Vehicle Type: All-Terrain Vehicle (ATV) 👋 Introduction Market Position Positioning: The Polaris Sportsman 400 (2005) was positioned as a capable and versatile mid-size utility ATV, offering a balance of performance and affordability for recreational riders and farm/ranch use. Competitive Analysis Competitors: Competed with models from Yamaha (Grizzly 350/400), Honda (FourTrax Foreman/Rancher), and Suzuki (KingQuad 300/400). Key Features Features: Known for its reliable 400cc engine, Polaris's True All-Wheel Drive (AWD) system, comfortable seating, and independent rear suspension (IRS) for improved ride quality. 📋 Manual Details Coverage Areas Coverage Scope: Comprehensive repair, maintenance, diagnostics, and specifications for the 2005 Polaris Sportsman 400 Page Count Estimated Pages: 300-400 Manual Type Type: Factory Service Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine: Detailed inspection, disassembly, assembly, and repair procedures for the 400cc engine. Includes carburetor, ignition, cooling, and exhaust systems. Transmission: Coverage of the automatic transmission (PVT - Polaris Variable Transmission), including belt inspection, adjustment, and replacement; clutch system; and gearcase. Drivetrain: Front and rear drive systems, including AWD engagement, driveshafts, universal joints, differentials, and axle components. Suspension: Front and rear suspension systems, including shock absorbers, springs, A-arms, bushings, and bearings. Adjustment and replacement procedures. Brakes: Hydraulic brake system components, including master cylinders, calipers, brake pads, rotors, brake lines, and bleeding procedures. Electrical System: Complete electrical diagnostics, including battery, charging system (stator, regulator/rectifier), starter motor, lighting, ignition switch, and accessory wiring. Fuel System: Fuel tank, fuel pump, fuel lines, and carburetor servicing and adjustments. Cooling System: Radiator, fan, hoses, thermostat, and coolant specifications and maintenance. Frame And Body: Frame inspection, body panel removal and installation, seat, rack, and fender components. Steering: Handlebar assembly, steering shaft, tie rods, and steering knuckle components. Alignment procedures. Wheels And Tires: Tire pressure specifications, wheel bearing maintenance, and lug nut torque. Procedures Included Maintenance: Regular scheduled maintenance, lubrication points, filter changes, and fluid checks. Troubleshooting: Systematic diagnostic charts and procedures for common performance issues, starting problems, and electrical faults. Repair: Step-by-step instructions for component removal, disassembly, repair, reassembly, and installation. Adjustments: Carburetor adjustments, chain tension (if applicable), brake lever free play, and throttle cable adjustments. Disassembly Assembly: Detailed guides for breaking down and rebuilding major components and sub-assemblies. Torque Specifications: All essential torque values for critical fasteners throughout the vehicle. Technical Depth Depth: Comprehensive coverage from basic owner maintenance to advanced engine and transmission rebuilds, including electrical schematics and diagnostic procedures. 📊 Manual Specifications File Format File Type: PDF Print Quality Quality: High-resolution scans of original factory documents, ensuring clear diagrams and text. Binding Type Binding: N/A (Digital PDF) Paper Type Paper: N/A (Digital PDF) ⚙️ Engine Specifications Primary Engine Engine Type: Four-stroke, liquid-cooled, SOHC, single-cylinder Displacement: 375 cc (approx.) Performance Horsepower: Approximately 25-28 HP (Estimate, exact figures often not published for ATVs of this era) Torque: Estimated torque figures would be in the range of 22-25 ft-lbs (Estimate) Fuel System Fuel Delivery: Carbureted (likely a Mikuni VM series carburetor) Ignition Ignition System: CDI (Capacitor Discharge Ignition) Cooling System Cooling Method: Liquid-cooled with fan 🔧 Transmission Standard Transmission Type: Automatic Polaris Variable Transmission (PVT) with High/Low range and Reverse Optional Optional Transmissions: N/A (Standard PVT for this model year) Features Clutch Type: Centrifugal clutch and drive/driven pulleys Drive System: Shaft drive to front and rear differentials Gearcase Fluid: Refer to manual for specific viscosity (likely SAE 75W-90 or similar) 📐 Dimensions Exterior Length: Approx. 81 inches (2057 mm) Width: Approx. 46 inches (1168 mm) Height: Approx. 48 inches (1219 mm) Wheelbase: Approx. 50.2 inches (1275 mm) Weights Dry Weight: Approx. 575 lbs (261 kg) Ground Clearance: Approx. 10.5 inches (267 mm) Cargo Front Rack Capacity: 50 lbs (22.7 kg) Rear Rack Capacity: 100 lbs (45.4 kg) Towing Capacity: 1050 lbs (476 kg) Fuel Capacity Fuel Tank Capacity: 3.0 US gallons (11.4 L) 🛡️ Safety Features Ratings Atv Safety Standards: Complies with ANSI standards for recreational off-highway vehicles. Active Features AWD...