🏷️ Basic Information Identification Make: Polaris Model: Sportsman 400 / 500 Year: 2005, 2006 👋 Introduction Market Position Category: Utility ATV Target User: Owners, Technicians, Enthusiasts involved in repair and maintenance of Polaris Sportsman ATVs Competitive Analysis Competitors 2005 2006: Can-Am Outlander, Honda FourTrax/Rancher, Yamaha Grizzly, Kawasaki Prairie Key Features Vehicle Strengths: Proven reliability, Versatile for work and recreation, Comfortable ride, Strong towing capacity Manual Value Proposition: Empowers users with the knowledge to perform comprehensive maintenance and repairs, saving on labor costs and ensuring optimal vehicle performance. 📋 Manual Details Coverage Areas Covered Models: Polaris Sportsman 400 (2005-2006), Polaris Sportsman 500 (2005-2006) Page Count Total Pages: 311 Manual Type Type: Workshop Service Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Powertrain: Engine (400cc, 499cc), Transmission, Drivetrain (AWD/2WD systems) Chassis: Suspension (front and rear), Steering, Brakes (hydraulic disc), Frame Electrical: Ignition system, Lighting, Charging system (stator, regulator/rectifier), Battery, Starter motor, Wiring diagrams Fuel System: Carburetor (Mikuni BS34/BS36), Fuel pump, Fuel tank, Fuel lines Body And Trim: Body panels, Seat, Racks, Handlebars, Controls Procedures Included Maintenance: Routine inspections, Oil changes, Filter replacements, Spark plug servicing, Valve adjustments Diagnostics: Troubleshooting guides for common problems, Symptom-based diagnosis Repair: Engine overhaul, Transmission repair, Suspension component replacement, Brake system service, Electrical component repair Assembly Disassembly: Step-by-step instructions for dismantling and reassembling major components Technical Depth Depth: Comprehensive diagnostic procedures, detailed repair instructions, complete overhaul specifications 📊 Manual Specifications File Format Quality: High-resolution, searchable PDF for clear viewing and printing Printable: Yes, designed for printing specific sections or the entire manual Binding Type Binding: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine 400 Engine Type: 4-stroke, Single-cylinder, SOHC Displacement: 375cc (approximate) Primary Engine 500 Engine Type: 4-stroke, Single-cylinder, SOHC Displacement: 499cc Performance 500 Bore X Stroke: 92mm x 74mm Compression Ratio: 8.7:1 Horsepower Estimated: 30-35 HP (approximate, at crankshaft) Torque Estimated: 35-40 ft-lbs (approximate, at crankshaft) Fuel System Carburetor 400: Mikuni BS34 Carburetor 500: Mikuni BS36 Fuel Type: Unleaded gasoline (87 octane minimum) Lubrication Oil Type Engine: SAE 10W-40, API SG or higher Ignition Ignition System: CDI (Capacitor Discharge Ignition) Cooling Cooling System: Liquid-cooled 🔧 Transmission Standard Type: Automatic (PVT - Polaris Variable Transmission) Features Drive Modes: High, Low, Neutral, Reverse Drive System: Shaft Drive Selectable 4Wd: Yes (On Demand All-Wheel Drive) Fluid Specifications Transmission Fluid Type: Polaris AGL Premium Gearcase Lubricant or equivalent (e.g., SAE 80W-90 API GL-5) 📐 Dimensions Exterior Length: 81 inches (approximate) Width: 46 inches (approximate) Height: 47 inches (approximate) Wheelbase: 50.5 inches (approximate) Weights Dry Weight: 600-630 lbs (approximate, depending on model variant) Towing Capacity: 1500 lbs Rack Capacity Front: 100 lbs Rack Capacity Rear: 200 lbs 🛡️ Safety Features Ratings Atv Safety Standards: Compliance with ANSI B71.1-2003 standards for ATVs Active Features Braking System: Hydraulic disc brakes, front and rear Passive Features Lighting: Dual 35W headlights, 40W taillight/brakelight Handlebar Design: Ergonomic grips and controls for safe operation 💡 Technology Features Infotainment Infotainment System: N/A (Basic utility vehicle, no integrated infotainment) Driver Assistance Features: None Connectivity Features: None Other Features Lighting Technology: Halogen bulbs Instrumentation: Analog speedometer, odometer, trip meter, fuel gauge, tachometer, gear indicator, 4WD indicator 🔧 Maintenance Service Intervals Engine Oil Change: Every 100 hours or 12 months, whichever comes first Air Filter Inspection: Every 25 hours or 3 months Spark Plug Replacement: Every 100 hours or 12 months Valve Clearance Check: Every 100 hours or 12 months Fluid Specifications Engine Oil Capacity: Approx. 1.9 US quarts (1.8 Liters) with filter change Coolant Type: Ethylene glycol-based antifreeze/coolant, 50/50 mix with distilled water Known Issues Common Wear Items: Drive belts (PVT), wheel bearings, tie rod ends, brake pads Carburetor Tuning: Occasional need for carburetor cleaning and adjustment due to fuel quality and usage patterns Electrical Connections: Corrosion or looseness in electrical connectors, especially in wet environments 📚 Vehicle History Brand Heritage Manufacturer: Polaris Industries Inc., founded in 1954 Model Evolution Sportsman Lineage: The Sportsman line has been a cornerstone of Polaris' ATV offerings since its introduction, known for its comfort, capability, and utility. Production Manufacturing Location: Polaris manufacturing facilities in the USA 🏆 Awards & Recognition Recognitions Atv Awards: Polaris Sportsman series consistently recognized for utility and all-around performance in industry reviews and publications during its era.