Polaris Sportsman 400 500 2005 2006 Workshop Service Manual

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This workshop service manual covers the utility ATVs produced for the 2005 and 2006 model years. Known for their proven reliability, versatility for both work and recreation, and comfortable ride,...

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Typ: Atv

Anbieter:

Art.-Nr: 67176

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

Produktvarianten

Beschreibung

This workshop service manual covers the utility ATVs produced for the 2005 and 2006 model years. Known for their proven reliability, versatility for both work and recreation, and comfortable ride, these models are equipped with strong towing capacities and capable All-Wheel Drive systems. The line has a long-standing reputation for delivering robust performance, making it a respected choice in the utility ATV market. This comprehensive manual provides detailed information essential for the maintenance, repair, and troubleshooting of your vehicle. It covers all major systems, including the engine, transmission, drivetrain, chassis, and electrical components, along with specific procedures for routine maintenance, diagnostics, and component overhauls. With step-by-step instructions and technical specifications, this manual empowers owners and technicians to effectively maintain and repair their vehicles, ensuring optimal performance and longevity.

🏷️ Basic Information

Identification

Make:

Polaris

Model:

Sportsman 400 / 500

Year:

2005, 2006

👋 Introduction

Market Position

Category:

Utility ATV

Target User:

Owners, Technicians, Enthusiasts involved in repair and maintenance of Polaris Sportsman ATVs

Competitive Analysis

Competitors 2005 2006:

Can-Am Outlander, Honda FourTrax/Rancher, Yamaha Grizzly, Kawasaki Prairie

Key Features

Vehicle Strengths:

Proven reliability, Versatile for work and recreation, Comfortable ride, Strong towing capacity

Manual Value Proposition:

Empowers users with the knowledge to perform comprehensive maintenance and repairs, saving on labor costs and ensuring optimal vehicle performance.

📋 Manual Details

Coverage Areas

Covered Models:

Polaris Sportsman 400 (2005-2006), Polaris Sportsman 500 (2005-2006)

Page Count

Total Pages:

Manual Type

Type:

Workshop Service Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Powertrain:

Engine (400cc, 499cc), Transmission, Drivetrain (AWD/2WD systems)

Chassis:

Suspension (front and rear), Steering, Brakes (hydraulic disc), Frame

Electrical:

Ignition system, Lighting, Charging system (stator, regulator/rectifier), Battery, Starter motor, Wiring diagrams

Fuel System:

Carburetor (Mikuni BS34/BS36), Fuel pump, Fuel tank, Fuel lines

Body And Trim:

Body panels, Seat, Racks, Handlebars, Controls

Procedures Included

Maintenance:

Routine inspections, Oil changes, Filter replacements, Spark plug servicing, Valve adjustments

Diagnostics:

Troubleshooting guides for common problems, Symptom-based diagnosis

Repair:

Engine overhaul, Transmission repair, Suspension component replacement, Brake system service, Electrical component repair

Assembly Disassembly:

Step-by-step instructions for dismantling and reassembling major components

Technical Depth

Depth:

Comprehensive diagnostic procedures, detailed repair instructions, complete overhaul specifications

📊 Manual Specifications

File Format

Quality:

High-resolution, searchable PDF for clear viewing and printing

Printable:

Yes, designed for printing specific sections or the entire manual

Binding Type

Binding:

N/A (Digital Download)

Paper Type

Paper Type:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine 400

Engine Type:

4-stroke, Single-cylinder, SOHC

Displacement:

375cc (approximate)

Primary Engine 500

Engine Type:

4-stroke, Single-cylinder, SOHC

Displacement:

499cc

Performance 500

Bore X Stroke:

92mm x 74mm

Compression Ratio:

8.7:1

Horsepower Estimated:

30-35 HP (approximate, at crankshaft)

Torque Estimated:

35-40 ft-lbs (approximate, at crankshaft)

Fuel System

Carburetor 400:

Mikuni BS34

Carburetor 500:

Mikuni BS36

Fuel Type:

Unleaded gasoline (87 octane minimum)

Lubrication

Oil Type Engine:

SAE 10W-40, API SG or higher

Ignition

Ignition System:

CDI (Capacitor Discharge Ignition)

Cooling

Cooling System:

Liquid-cooled

🔧 Transmission

Standard

Type:

Automatic (PVT - Polaris Variable Transmission)

Features

Drive Modes:

High, Low, Neutral, Reverse

Drive System:

Shaft Drive

Selectable 4Wd:

Yes (On Demand All-Wheel Drive)

Fluid Specifications

Transmission Fluid Type:

Polaris AGL Premium Gearcase Lubricant or equivalent (e.g., SAE 80W-90 API GL-5)

📐 Dimensions

Exterior

Length:

81 inches (approximate)

Width:

46 inches (approximate)

Height:

47 inches (approximate)

Wheelbase:

50.5 inches (approximate)

Weights

Dry Weight:

600-630 lbs (approximate, depending on model variant)

Towing Capacity:

1500 lbs

Rack Capacity Front:

100 lbs

Rack Capacity Rear:

200 lbs

🛡️ Safety Features

Ratings

Atv Safety Standards:

Compliance with ANSI B71.1-2003 standards for ATVs

Active Features

Braking System:

Hydraulic disc brakes, front and rear

Passive Features

Lighting:

Dual 35W headlights, 40W taillight/brakelight

Handlebar Design:

Ergonomic grips and controls for safe operation

💡 Technology Features

Infotainment

Infotainment System:

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

Driver Assistance

Features:

Connectivity

Features:

Other Features

Lighting Technology:

Halogen bulbs

Instrumentation:

Analog speedometer, odometer, trip meter, fuel gauge, tachometer, gear indicator, 4WD indicator

🔧 Maintenance

Service Intervals

Engine Oil Change:

Every 100 hours or 12 months, whichever comes first

Air Filter Inspection:

Every 25 hours or 3 months

Spark Plug Replacement:

Every 100 hours or 12 months

Valve Clearance Check:

Every 100 hours or 12 months

Fluid Specifications

Engine Oil Capacity:

Approx. 1.9 US quarts (1.8 Liters) with filter change

Coolant Type:

Ethylene glycol-based antifreeze/coolant, 50/50 mix with distilled water

Known Issues

Common Wear Items:

Drive belts (PVT), wheel bearings, tie rod ends, brake pads

Carburetor Tuning:

Occasional need for carburetor cleaning and adjustment due to fuel quality and usage patterns

Electrical Connections:

Corrosion or looseness in electrical connectors, especially in wet environments

📚 Vehicle History

Brand Heritage

Manufacturer:

Polaris Industries Inc., founded in 1954

Model Evolution

Sportsman Lineage:

The Sportsman line has been a cornerstone of Polaris' ATV offerings since its introduction, known for its comfort, capability, and utility.

Production

Manufacturing Location:

Polaris manufacturing facilities in the USA

🏆 Awards & Recognition

Recognitions

Atv Awards:

Polaris Sportsman series consistently recognized for utility and all-around performance in industry reviews and publications during its era.