🏷️ Basic Information Identification Make: Polaris Model: Sportsman 400 Year: 2005, 2006 Codes Vin Prefix General: 4XD 👋 Introduction Market Position Segment: Utility All-Terrain Vehicle (ATV) Competitive Analysis Competitors: Honda FourTrax, Yamaha Kodiak, Arctic Cat 400 Key Features Utility Focus: Designed for work, hunting, and general trail riding, emphasizing durability and practicality. Powertrain Reliability: Known for its robust engine and reliable automatic transmission for consistent performance. Manual Value Proposition Diy Capability: Empowers owners to perform extensive maintenance and repairs, reducing reliance on dealerships. 📋 Manual Details Coverage Areas Primary Coverage: Repair and Service for Polaris Sportsman 400 (2005-2006) Page Count Total Pages: 311 Manual Type Type: Workshop Service Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine Mechanical: Full engine disassembly, inspection, repair, and reassembly procedures. Fuel System: Carburetor tuning, fuel pump, fuel lines, and tank service. Electrical System: Wiring diagrams, component testing (ignition, lighting, charging system), battery service. Drivetrain: Transmission, drive shafts, differentials, CV joints, and clutch service. Suspension: Front and rear suspension geometry, shock absorber service, and linkage maintenance. Brakes: Hydraulic brake system service, caliper and rotor replacement, bleeding procedures. Cooling System: Radiator, fan, water pump, and coolant flush procedures. Bodywork Chassis: Frame inspection, body panel removal and installation, plastic component care. Procedures Included Routine Maintenance: Oil changes, filter replacements, lubrication, chain adjustment, and general inspection. Troubleshooting: Diagnostic charts for common performance issues and system failures. Component Rebuilds: Detailed instructions for overhauling engine components, transmission, and differentials. Special Tool Usage: Identification and usage of specialized tools required for specific repair tasks. Technical Depth Depth: Comprehensive repair and diagnostic information suitable for professional technicians and advanced DIY mechanics. 📊 Manual Specifications File Format PDF Quality: High-resolution, clear text and images for easy reading and printing. Searchable Text: Yes, the PDF is text-searchable for quick information retrieval. Print Quality Printable: Yes, designed for easy printing of individual pages or sections. Binding Type Binding: Not Applicable (Digital Download) Paper Type Paper Type: Not Applicable (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: 4-stroke, single-cylinder Displacement: 376 cc (23.0 cu. in.) Bore X Stroke: 92 mm x 71.2 mm (3.62 in. x 2.80 in.) Compression Ratio: 9.7:1 Cooling System: Liquid-cooled Valve Train: SOHC, 4 valves per cylinder Performance Horsepower Approximate: 20-25 HP (estimated, varies with tuning) Torque Approximate: 25-30 lb-ft (estimated) Fuel System Carburetor: Mikuni BSR42 Fuel Type: Unleaded gasoline, 87 octane minimum Fuel Tank Capacity: 3.2 US gallons (12.1 L) Ignition Ignition System: Electronic ignition, CDI Lubrication Oil Type Recommended: SAE 10W-40, API SG or higher (refer to manual for exact specification) Oil Capacity With Filter: 2.2 US quarts (2.1 L) 🔧 Transmission Standard Transmission Type: Automatic (PVT - Polaris Variable Transmission) Drive System: Shaft drive, On-Demand AWD (All-Wheel Drive) Features Gear Selection: High, Low, Neutral, Reverse Clutch System: Centrifugal clutch with engagement at low RPMs. Fluid Specifications Transmission Fluid Type: Polaris AGL Synthetic Gearcase Lubricant (refer to manual for exact specification) Transmission Fluid Capacity: 0.6 L (0.63 US qt) for transmission; 0.24 L (0.25 US qt) for front differential 📐 Dimensions Exterior Length: 206 cm (81 in.) Width: 117 cm (46 in.) Height: 114 cm (45 in.) Wheelbase: 127 cm (50 in.) Weights Dry Weight: 272 kg (600 lbs) Ground Clearance: 25.4 cm (10 in.) Cargo Front Rack Capacity: 45 kg (100 lbs) Rear Rack Capacity: 90 kg (200 lbs) Towing Towing Capacity: 567 kg (1250 lbs) Wheels Tires Front Tire Size: AT 25x8-12 Rear Tire Size: AT 25x10-12 Wheel Bolt Pattern: 4x110mm 🛡️ Safety Features Ratings Crash Test Ratings: Not applicable for ATVs in the same manner as passenger vehicles. Active Features Braking System: Hydraulic disc brakes front and rear. Engine Braking: Utilizes the engine and PVT system for downhill deceleration. Passive Features Hand Guard Protection: Standard handguards to protect riders' hands from trail debris. Roll Over Protection: None standard; proper riding techniques are essential. 💡 Technology Features Infotainment Display Features: Digital instrument cluster displaying speed, RPM, odometer, trip meter, fuel level, and gear indicator. Driver Assistance AWD Engagement: On-demand All-Wheel Drive system for enhanced traction when needed. Connectivity Charging System: 12V DC outlet for charging electronic devices (if equipped). 🔧 Maintenance Service Intervals Engine Oil Change: Every 100 hours or annually, whichever comes first. Air Filter Cleaning: Every 25 hours or as needed in dusty conditions. Spark Plug Replacement: Every 100 hours or annually. Transmission Fluid Change: Every 200 hours or annually. Fluid Specifications Brake Fluid Type: DOT 3 or DOT 4 (refer to manual for exact specification) Coolant Type: Ethylene glycol-based antifreeze, 50/50 mix with distilled water. Known Issues Pvt Belt Wear: Variable Transmission (PVT) belt wear can lead to slipping or reduced acceleration. Regular inspection and replacement are advised. Carburetor Tuning: Can sometimes require periodic adjustment due to altitude or fuel variations. Throttle Cable Tension: Throttle cable adjustment might be...