Category:
All-Terrain Vehicle (ATV) Parts Manual
Value Proposition:
Provides essential part identification and reference for maintenance and repair of the 2005 Polaris Sportsman 400.
Utility:
Crucial for owners, technicians, and parts departments to correctly identify and order replacement components.
Segment:
Mid-size utility ATV segment, competing with models from Honda (e.g., FourTrax 350/400), Yamaha (e.g., Grizzly 350/400), and Kawasaki (e.g., Prairie 360).
Powertrain Components:
Engine (Crankcase, Crankshaft, Piston, Cylinder, Carburetor, Cooling System, Exhaust System, Fuel Pump, Fuel Tank, Oil Filter, Oil Pump, Oil Tank, Magneto, Recoil Starter, Starting Motor, Water Pump), Transmission (Gearcase, Gear Selector), Drive Train (Drive Clutch, Driven Clutch, Rear Wheel Drive, Prop Shaft, Drive Shaft Front, Drive Shaft Rear)
Chassis And Suspension:
A-Arm, Bumper Mounting, Front Cab, Rear Cab and Seat, Front Housing, Handlebar, Headlight Pod, Headlights, Rack Mounting Front, Rack Mounting Rear, Rear Suspension, Steering Post, Strut Mounting, Strut Front, Transmission Mounting
Controls And Electrical:
Brake Lines Front, Caliper Rear, Controls, Controls -- Throttle ASM./Cable, Foot Pedal, Master Cylinder Rear, Electrical/Taillight, Taillamps, Worklamps
Body And Accessories:
Air Box, Clutch Cover, Decals, Engine Mounting, Front Storage, Rear Storage Box
Lighting And Signals:
Headlights, Taillights, Worklamps, Electrical/Taillight components covered.
Fuel And Air Delivery:
Air box, carburetor components, fuel pump, and fuel tank are detailed.
Parts Identification:
Detailed diagrams and part numbers for all components listed in the Table of Contents.
Assembly Disassembly:
Implied by the nature of a parts manual; visual references for component relationships and assembly order.
Component Diagrams:
Exploded view diagrams for each section, showing part relationships and configurations.
Depth:
Component-level detail for parts identification, ordering, and visualization. Not a diagnostic or repair procedure manual.
Coverage Scope:
Exhaustive listing of all genuine Polaris parts with associated diagrams and part numbers for the specified models.
Part Number Accuracy:
Essential for ordering the correct, genuine Polaris replacement parts.
Control Systems:
Throttle assembly, cables, gear selector, handlebar controls are detailed.
Exterior Panels:
Bumper mounting, front housing, front/rear racks, storage boxes, decals are covered.
Engine Internals:
Detailed parts breakdown for crankshaft, piston, cylinder, and related components.
Drive System Components:
Drive clutches, driven clutches, drive shafts, and prop shafts are comprehensively listed.
Type:
Liquid-Cooled, 4-Stroke, SOHC, Single Cylinder (Inferred from typical Sportsman 400 engines of this era)
Displacement:
Likely around 375cc to 400cc (Specific displacement not provided, but consistent with '400' designation)
Carburetor:
Specified in Table of Contents, indicating a carbureted fuel system.
Oil System Components:
Oil Filter, Oil Pump, Oil Tank mentioned, indicating a dedicated oil system.
Oil Change:
Refer to vehicle owner's manual or full service manual for specific intervals and oil type (Parts manual does not detail service intervals).
Engine Oil:
Refer to vehicle owner's manual or full service manual for specific oil type and viscosity (Parts manual does not detail fluid specifications).
Coolant:
Refer to vehicle owner's manual or full service manual for specific coolant type and mixture (Parts manual does not detail fluid specifications).
Transmission Fluid:
Refer to vehicle owner's manual or full service manual for specific transmission fluid type (Parts manual does not detail fluid specifications).
Typical Atv Wear Items:
While this is a parts manual, common ATV wear items include drive belts, suspension bushings, ball joints, tie rod ends, and brake pads, all of which would have part numbers detailed within.
Engine Family:
Polaris ProStar (likely a variant)
Drive System:
2WD/4WD On-Demand
Frame Construction:
Steel (typical for Polaris ATVs)
Type:
MacPherson Strut (as indicated by 'STRUT, FRONT' and 'STRUT MOUNTING' in ToC)
Type:
Independent (as indicated by 'REAR SUSPENSION' in ToC, common for Sportsman models)
Type:
Hydraulic Disc (inferred from 'BRAKE LINES, FRONT' and presence of caliper/master cylinder)
Type:
Hydraulic Disc (inferred from 'CALIPER, REAR', 'MASTER CYLINDER, REAR')
Specification:
Refer to vehicle owner's manual or full service manual for exact tire sizes (Parts manual lists tire components, not specifications).
Specification:
Refer to vehicle owner's manual or full service manual for exact tire sizes (Parts manual lists tire components, not specifications).
Tank Volume:
Refer to vehicle owner's manual or full service manual for exact capacity (Parts manual lists fuel tank components).
System Components:
Radiator, hoses, fan (if applicable) are part of the cooling system components.
Components:
Muffler, head pipe, heat shields, and fasteners are listed.
Components:
Recoil starter and electric starting motor components are covered.
Lighting Coverage:
Front and rear lights, including headlight pods and taillight assemblies.
Storage Compartments:
Front and rear storage box components.
