Segment:
Mid-size utility ATV, popular for trail riding, light work, and recreational use
Competitors 2005:
Honda Rancher 400, Yamaha Kodiak 400, Suzuki King Quad 300/400, Arctic Cat 400 DVX
Features:
Independent Rear Suspension (IRS) on some models, reliable engine, capable 4x4 system, comfortable ergonomics for its class
Benefit To Owner:
Enables self-sufficiency in maintenance and repairs, reduces reliance on dealerships, extends vehicle lifespan, aids in identifying and resolving issues efficiently
Primary Coverage:
All mechanical and electrical systems, maintenance, troubleshooting, repair procedures
Secondary Coverage:
Component diagrams, torque specifications, electrical schematics
Estimated Pages:
Approximately 400-500 pages (typical for a comprehensive workshop manual of this era)
Type:
Official Polaris Workshop Manual / Service Manual
Engine:
Complete engine overhaul, internal components, cooling system, lubrication system, fuel system (carburetor), ignition system, exhaust system
Transmission Drivetrain:
PVT (Polaris Variable Transmission) system (drive clutch, driven clutch, belt), final drive, differentials (front and rear), drive shafts, CV joints
Electrical:
Starter system, charging system (stator, voltage regulator), battery, lighting system, ignition switch, control modules, wiring diagrams, diagnostic codes
Suspension Steering:
Front and rear suspension components (A-arms, shocks, springs), wheel bearings, steering system (tie rods, steering shaft, universal joints)
Brakes:
Hydraulic brake system, front and rear calipers, brake lines, master cylinder, brake fluid specifications, bleeding procedures
Frame Bodywork:
Chassis components, body panels, seat, racks, fenders, decals, plastics
Maintenance:
Oil changes, filter replacements, spark plug replacement, air filter cleaning/replacement, valve adjustments, coolant checks/flushes, greasing points
Troubleshooting:
Systematic diagnostic procedures for common and uncommon issues, symptom-based troubleshooting guides
Repair:
Detailed step-by-step repair instructions for all major components and systems, including engine rebuilds, transmission overhauls, suspension component replacement
Disassembly Assembly:
Complete breakdown and reassembly instructions for all serviceable parts
Depth:
Comprehensive, from basic routine maintenance to complete engine and transmission rebuilds, including detailed electrical schematics and diagnostic procedures
Searchable Text:
Yes (typically, depends on the PDF scan quality)
Print Readability:
High (designed for printing, clear diagrams and text)
Binding:
N/A (Digital PDF Download)
Paper Quality:
N/A (Digital PDF Download)
Engine Type:
4-stroke, Liquid-Cooled, SOHC, 4-valve
Engine Displacement:
376.5 cc
Bore X Stroke:
85 mm x 69 mm
Fuel Type:
Unleaded Gasoline
Horsepower Approx:
Approximately 27-30 HP (at the crankshaft, estimated)
Torque Approx:
Approximately 25-28 lb-ft (at the crankshaft, estimated)
Fuel Capacity:
3.3 US gallons (12.5 L)
Ignition Type:
Electronic Ignition
Cooling Method:
Liquid-Cooled
Oil Type:
SAE 10W-40 Motorcycle Oil (API SG or higher, JASO MA certified recommended)
Oil Capacity W Filter:
1.8 US quarts (1.7 L)
Transmission Type:
Automatic PVT (Polaris Variable Transmission) with Engine Braking
Gearing:
High (H), Low (L), Neutral (N), Reverse (R), Park (P)
Drive System:
Shaft Drive, On-Demand AWD (All-Wheel Drive) with 2WD/AWD selector
Clutch Type:
Primary Clutch (Drive Clutch), Secondary Clutch (Driven Clutch)
Atv Safety Standards:
ANSI/SVIA 1-2003 and BSR/SVIA 1-2007 (for general design and performance)
Braking System:
Hydraulic disc brakes front and rear, engine braking system
Drive Mode:
On-Demand AWD for enhanced traction
Handlebars Grip:
Comfortable, ergonomic handlebars with grip
Lighting:
Dual headlights, tail light, brake light
Footwells:
Full floorboards with heel guards for foot protection
Features:
Basic instrumentation: speedometer, odometer, trip meter, hour meter, fuel gauge. No advanced infotainment systems typical for modern vehicles.
Features:
On-Demand AWD system provides enhanced traction and stability. Engine braking aids in downhill control.
Features:
N/A (No electronic connectivity features)
Engine Oil Change:
Every 100 hours or 12 months, whichever comes first. Inspect more frequently in dusty conditions.
Air Filter Cleaning:
Every 25 hours. Clean more frequently in dusty/wet conditions. Replace if damaged.
Spark Plug Replacement:
Every 100 hours or 12 months.
Pvt Belt Inspection:
Inspect every 100 hours for wear and damage. Replace as needed. Belt life varies significantly with riding style.
Valve Lash Check:
First check at 200 hours, then every 400 hours.
Brake Fluid Type:
DOT 3 or DOT 4 Hydraulic Brake Fluid
Coolant Type:
Ethylene Glycol based antifreeze (50/50 mix with distilled water recommended)
Differential Fluid Type:
SAE 80W-90 Hypoid Gear Lubricant (for front and rear differentials)
Grease Type:
Lithium-based multi-purpose grease
Common Wear Items:
PVT belt wear, wheel bearings, tie rod ends, front shock bushings, starter solenoid
Carburetor Tuning:
Can be sensitive to altitude and temperature; requires proper jetting and adjustment for optimal performance.
Electrical Connector Corrosion:
Common in wet/muddy environments; regular inspection and dielectric grease application is beneficial.
Polar Heritage:
Polaris Industries is a long-standing American manufacturer known for its snowmobiles, ATVs, and UTVs, with a history of innovation in the powersports industry.
Sportsman Lineage:
The Sportsman line has been a cornerstone of Polaris' ATV offerings, evolving over the years to incorporate new technologies like IRS, fuel injection, and advanced AWD systems.
Model Era:
The 2005 Sportsman 400 represents a mid-2000s iteration of the popular model, built during a period of significant technological advancement for ATVs.
