Polaris Sportsman 400 & Sportsman 500 ATV Complete Workshop Service Repair Manual 2005 2006

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Stichworte: 2005 2006 ATV Misc Polaris Powersports Sportsman 400 Sportsman 500

Produktvarianten

Beschreibung

This manual covers the 400 and 500 All-Terrain Vehicles (ATVs) from the 2005 and 2006 model years. These utility ATVs are engineered for robust performance, offering capable handling with independent front suspension and significant towing and hauling capacity, making them ideal for both work and recreational riding. A manufacturer with a strong heritage in off-road vehicles, developed the Sportsman line to be a dominant force in the utility ATV market, known for its balance of power, utility, and value. This comprehensive Workshop Service Repair Manual provides detailed guidance for maintenance, troubleshooting, diagnostics, and repair. It includes step-by-step procedures for engine and transmission overhauls, electrical system diagnostics, fuel system maintenance, and much more. The manual is designed to empower owners and technicians, offering the necessary information to keep these ATVs operating at peak performance and ensuring their longevity through proper care and timely repairs.

🏷️ Basic Information

Identification

Make:

Polaris

Model:

Sportsman 400 & Sportsman 500

Model Variant:

Model Years Covered:

2005, 2006

Codes

Product Identifier:

POL-SPORTSMAN-2005-2006-SRM-PDF

👋 Introduction

Market Position

Segment:

Utility ATV

Target Audience:

Owners and technicians performing maintenance and repairs

Competitive Analysis

Competitors 2005 2006:

Yamaha Grizzly, Honda Foreman, Suzuki King Quad, Can-Am Outlander

Key Features Vehicle

Power Delivery:

Robust engine performance suitable for work and recreational riding

Handling:

Independent front suspension (IFS) for improved ride and handling

Utility:

Towing and hauling capabilities, durable chassis construction

Manual Value Proposition

Benefit To Owner:

Empowers owners to perform routine maintenance and complex repairs, saving on labor costs and ensuring longevity

📋 Manual Details

Coverage Areas

Primary Coverage:

Complete Workshop Service & Repair

Secondary Coverage:

Maintenance, Troubleshooting, Diagnostics, Overhaul

Page Count

Estimated Page Count:

500-700 (typical for comprehensive ATV service manuals)

Manual Type

Type:

Workshop Service Repair Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine:

Engine teardown, assembly, timing, lubrication, cooling system, fuel system (carburetor/EFI), ignition system, starting system

Transmission:

Transmission disassembly, assembly, gear ratios, clutch operation, driveline components

Drivetrain:

CVT system, drive shafts, differentials, AWD system (if applicable), final drive

Suspension:

Front and rear suspension geometry, shock absorbers, control arms, bushings, spring rates

Brakes:

Hydraulic brake system, master cylinders, calipers, brake pads, rotors, brake lines, bleeding procedures

Electrical:

Wiring diagrams, charging system (stator, regulator/rectifier), battery, starter motor, lighting, ignition system components, sensors, control modules

Fuel System:

Fuel tank, fuel pump, fuel lines, carburetor tuning and rebuild (for applicable models), fuel injection system diagnosis

Cooling System:

Radiator, cooling fan, thermostat, coolant types, flushing procedures

Frame And Body:

Frame inspection, body panel removal and installation, seat, handlebars, racks

Wheels And Tires:

Tire pressure recommendations, wheel bearing maintenance, wheel installation

Procedures Included

Maintenance:

Scheduled maintenance intervals, oil changes, filter replacements, spark plug replacement, lubrication points

Troubleshooting:

Diagnostic charts for common issues, symptom-based troubleshooting guides

Repair:

Step-by-step repair procedures for all major mechanical and electrical components

Overhaul:

Complete engine and transmission rebuild procedures

Specifications:

Torque specifications for all fasteners, clearances, and measurements

Diagnostics:

Identification of fault codes, diagnostic tool usage (if applicable)

Technical Depth

Depth:

Comprehensive from basic maintenance to full engine and transmission rebuilds

Diagnostic Level:

Advanced diagnostics including electrical system troubleshooting and fuel system analysis

Rebuild Scope:

Detailed procedures for complete engine, transmission, and differential overhauls

📊 Manual Specifications

File Format

File Type:

Searchability:

Searchable text content for efficient information retrieval

Print Quality:

High-resolution scans suitable for printing

Print Quality

Graphics Clarity:

Clear, legible diagrams, illustrations, and photographs

Binding Type

Binding:

N/A (Digital Download)

Paper Type

Paper:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine 400

Type:

4-stroke, SOHC, 2-valve

Displacement Cc:

Bore X Stroke Mm:

80 x 74.4

Cooling System:

Liquid-cooled

Primary Engine 500

Type:

4-stroke, SOHC, 4-valve

Displacement Cc:

Bore X Stroke Mm:

83 x 92

Cooling System:

Liquid-cooled

Performance

Horsepower Approx 400:

26 hp @ 6500 rpm (estimated)

Horsepower Approx 500:

30 hp @ 6000 rpm (estimated)

Torque Approx 400:

26.5 lb-ft @ 5000 rpm (estimated)

Torque Approx 500:

31.4 lb-ft @ 4500 rpm (estimated)

Fuel System

Carburetor 400:

Mikuni BSR42

Carburetor 500:

Mikuni BSR40

Fuel Type:

Unleaded gasoline

Fuel Tank Capacity Gallons:

🔧 Transmission

Standard

Type:

Automatic (CVT) with Hi/Lo range and Reverse

Optional

Transmission Options:

N/A (CVT is standard)

Features

Drive Engagement:

On-demand AWD system with 2WD/4WD selector

Engine Braking:

Integral engine braking via CVT

📐 Dimensions

Exterior

Length In:

Width In:

Height In:

Wheelbase In:

Ground Clearance In:

Cargo

Front Rack Capacity Lbs:

Rear Rack Capacity Lbs:

Weights

Dry Weight Lbs 400:

Dry Weight Lbs 500:

Towing Capacity Lbs:

Dimensions

Tire Size Front:

AT25x8-12

Tire Size Rear:

AT25x10-12

Wheel Bolt Pattern:

4x110mm

🛡️ Safety Features

Ratings

Atv Safety Standards:

Meets ANSI/SVIA 1-2003 standards

Active Features

Braking System:

Hydraulic disc brakes, front and rear

Parking Brake:

Independent rear parking brake lever

Passive Features

Lighting:

Dual 35W headlights, 25/50W taillight/brake light

Operator Presence:

Handlebar-mounted throttle and brake levers with self-retracting design

💡 Technology Features

Infotainment

Infotainment System:

N/A (Basic utility vehicle, no integrated infotainment)

Driver Assistance

Driver Assistance Features:

N/A (Basic utility vehicle)

Connectivity

Connectivity Options:

N/A (Basic utility vehicle)

Engine Management

Ignition System:

CDI (Capacitor Discharge Ignition)

🔧 Maintenance

Service Intervals

Oil Change Hours:

Every 100 hours or annually

Air Filter Cleaning Hours:

Every 50 hours or more frequently in dusty conditions

Spark Plug Replacement Miles:

Every 1000 miles or annually

Belt Inspection Hours:

Every 200 hours

Fluid Specifications

Engine Oil Type:

Polaris PS-4 5W-50 Synthetic or equivalent API SG rated

Engine Oil Capacity Qts:

Transmission Oil Type:

Polaris Angle Drive Fluid (ADF) for front and rear differentials, Polaris CVT Fluid for transmission

Coolant Type:

Ethylene glycol-based antifreeze (50/50 mix with distilled water)

Known Issues

Common Wear Items:

CV joint boots, tie rod ends, wheel bearings, brake pads

Cv Belt Durability:

While generally robust, excessive abuse or improper belt maintenance can lead to premature wear.

Charging System Reliability:

Occasionally, stator or regulator/rectifier failures can occur, impacting battery charging.

📚 Vehicle History

Brand Heritage

Brand Focus:

Polaris is a long-standing manufacturer of off-road vehicles, known for innovation in ATVs and Snowmobiles.

Model Evolution

Sportsman Lineage:

The Sportsman line is Polaris's flagship utility ATV, evolving significantly since its introduction. The 400 and 500 models represent mid-range offerings for their respective years, emphasizing a balance of power, utility, and value.

Production

Manufacturing Location:

USA (Roseau, Minnesota, and other Polaris facilities)

Market Introduction Sportsman:

The Sportsman line was introduced in 1993, quickly becoming a dominant force in the utility ATV market.

🏆 Awards & Recognition

Recognitions

Atv Industry Awards:

The Polaris Sportsman line has historically received numerous awards for performance, innovation, and utility from various ATV publications and organizations.

Ratings

Consumer Ratings General:

Generally well-regarded for its capability and durability in utility applications.