Polaris Sportsman 400 2005 2006 Workshop Service Manual

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Stichworte: 2005 2006 ATV Misc Polaris Powersports Sportsman 400

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Beschreibung

The Polaris Sportsman 400, produced for the 2005 and 2006 model years, is a robust utility All-Terrain Vehicle (ATV) engineered for demanding tasks, hunting expeditions, and general trail riding. Known for its durability and practicality, this model features a 376 cc liquid-cooled, single-cylinder engine paired with a reliable Variable Transmission (PVT) and an on-demand All-Wheel Drive system, ensuring consistent performance in varied conditions. Its design prioritizes functionality, offering substantial cargo rack capacity and towing capabilities, making it a versatile companion for work and recreation. The Sportsman 400 is a testament to extensive experience in ATV manufacturing, building upon a legacy of dependable and user-friendly off-road vehicles. This comprehensive Workshop Service Manual provides detailed guidance for the repair and maintenance of your 2005-2006 Sportsman 400. Covering all essential systems, including the engine mechanicals, fuel system, electrical components, drivetrain, suspension, brakes, and cooling system, this manual is designed to empower owners and technicians. It includes step-by-step procedures for routine maintenance, component rebuilds, and troubleshooting common issues, along with information on special tool usage and technical specifications. With a total of 311 pages of clear, searchable, and printable English content, this resource ensures that you have the necessary information to keep your Sportsman 400 in optimal working condition.

🏷️ Basic Information

Identification

Make:

Polaris

Model:

Sportsman 400

Year:

2005, 2006

Codes

Vin Prefix General:

👋 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:

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 needed over time to ensure proper throttle response.

📚 Vehicle History

Brand Heritage

Manufacturer:

Polaris Industries, Inc.

Founding Year:

Model Evolution

Sportsman Lineage:

The Sportsman line is one of Polaris's longest-running and most successful ATV series, known for its comfort and utility.

400 Model Placement:

The 400 model typically served as a mid-range option, balancing power and affordability within the Sportsman lineup.

Production

Manufacturing Location:

United States (primarily Spirit Lake, Iowa, and Roseau, Minnesota)

🏆 Awards & Recognition

Recognitions

Atv Of The Year:

While the specific 400 model may not have individual awards, the Sportsman line has consistently received positive reviews and accolades for its utility and performance in its class.