This comprehensive factory service and repair manual for the 2005 Polaris Sportsman 500 and 400 ATVs provides detailed instructions and diagrams for every aspect of maintenance and repair. The manual covers a wide range of topics, including engine overhaul, transmission repair, electrical system troubleshooting, suspension and steering adjustments, brake system maintenance, and much more. Whether you are a professional mechanic or a DIY enthusiast, this manual is an invaluable resource for anyone looking to perform repairs or maintenance on their Polaris Sportsman 500 or 400. With its clear and concise language, detailed illustrations, and step-by-step instructions, this manual will guide you through every repair process with ease. The manual encompasses a wide range of components and systems including the engine, transmission, electrical system, suspension, steering, brakes, cooling system, fuel system, and more. It includes detailed information on: * **Engine:** Disassembly, reassembly, and repair of engine components including cylinder head, pistons, crankshaft, connecting rods, camshaft, valves, and oil pump. * **Transmission:** Disassembly, reassembly, and repair of transmission components including gears, shafts, clutches, and bearings. * **Electrical System:** Troubleshooting and repair of electrical components including wiring harnesses, sensors, and control modules. * **Suspension & Steering:** Adjustment and repair of suspension and steering components including shocks, struts, tie rods, and steering knuckles. * **Brakes:** Maintenance and repair of brake components including calipers, rotors, pads, and hydraulic lines. * **Cooling System:** Maintenance and repair of cooling system components including radiator, hoses, thermostat, and water pump. * **Fuel System:** Maintenance and repair of fuel system components including carburetor, fuel pump, fuel lines, and fuel filter. * **And much more...** This manual includes comprehensive wiring diagrams, torque specifications, and troubleshooting guides to help you diagnose and resolve any issues you may encounter. With this manual in hand, you will have all the information and guidance you need to keep your Polaris Sportsman 500 or 400 running smoothly.

The Polaris Sportsman 500 and 400 are popular and reliable all-terrain vehicles (ATVs) known for their versatility and performance. Both models are powered by fuel-injected, liquid-cooled, single-cylinder engines, renowned for their smooth power delivery and durability. The Sportsman 500 packs a 499cc engine, while the 400 model features a 397cc unit, both delivering ample torque for tackling diverse terrains. These ATVs come equipped with automatic transmissions, providing seamless gear changes and ease of operation. The Sportsman 500 and 400 are built with a rugged steel frame, offering strength and stability. They boast independent front and rear suspension systems with adjustable preload settings, guaranteeing a comfortable ride and excellent handling. The Polaris Sportsman 500 and 400 are designed for both recreational and utility purposes, catering to a wide variety of riders. Their versatility shines through with features like a large cargo box capacity, a front rack, and optional accessories like a winch, plow, and more. These ATVs are ideal for hunting, fishing, trail riding, and hauling cargo. Whether you are tackling rugged trails or navigating farm work, the Sportsman 500 and 400 provide the power, performance, and functionality needed. Their compact size and maneuverability make them adept at navigating tight spaces, while their robust construction ensures durability even in challenging conditions. With their reliable engines, comfortable ride, and versatile capabilities, the Polaris Sportsman 500 and 400 remain popular choices among ATV enthusiasts seeking a blend of performance and practicality.