Target User:
Owners, mechanics, and parts suppliers for the 2005 Polaris Sportsman 400.
Value Proposition:
Provides essential OEM part numbers and diagrams for efficient maintenance and repair, reducing downtime and incorrect part orders.
Diagrams:
High-quality, exploded-view diagrams illustrating all parts in their respective assemblies.
Part Number Cross Reference:
Includes official Polaris OEM part numbers for guaranteed fitment.
Engine Assembly:
Complete component breakdown and part identification for the Polaris 400cc engine.
Drivetrain:
Detailed diagrams and part numbers for the transmission, driveshafts, and differential systems.
Suspension And Steering:
Component identification for front and rear suspension, A-arms, shocks, and steering linkage.
Braking System:
Parts breakdown for front and rear brake calipers, rotors, master cylinders, and brake lines.
Electrical System:
Component diagrams for ignition, lighting, charging system, starter, and wiring harness.
Fuel System:
Identification of fuel tank, carburetor/fuel injection components, fuel lines, and filters.
Cooling System:
Parts breakdown for radiator, hoses, fan, and thermostat.
Exhaust System:
Component identification for exhaust manifold, pipe, and muffler.
Frame And Chassis:
Diagrams for frame components, sub-frames, and mounting hardware.
Bodywork And Plastics:
Identification of fenders, racks, seat, and plastic body panels.
Wheels And Tires:
Part numbers for wheels and recommended tire specifications.
Part Identification:
Crucial for accurate ordering and replacement of all components.
Assembly Disassembly Overview:
Visual guidance through major assembly and disassembly sequences for parts reference.
Component Replacement:
Facilitates identification of parts needed for common replacement tasks.
Level Of Detail:
Highly detailed, with exploded views and OEM part numbers.
Accuracy:
Based on original manufacturer specifications for precision.
Type:
Automatic (PVT - Polaris Variable Transmission)
Gear Selection:
High, Low, Neutral, Reverse, Park
On Demand AWD:
Standard (All-Wheel Drive engages automatically when rear wheels lose traction).
Engine Braking:
Characteristic of PVT systems.
Atv Safety Standards:
Complies with ANSI and other relevant ATV safety standards.
Braking System:
Hydraulic disc brakes, front and rear.
Suspension:
Independent front suspension (IFS) and independent rear suspension (IRS) contribute to stability.
Hand Grips And Levers:
Ergonomic design for control and comfort.
Lighting:
Dual headlights and taillight/brake light.
Oil Change Interval:
Refer to service manual for specific intervals (typically 100 hours or annually).
Spark Plug Replacement:
Refer to service manual for specific intervals (e.g., 250 hours).
Air Filter Cleaning:
Recommended to inspect and clean at frequent intervals, especially in dusty conditions.
Engine Oil Type:
Polaris Synthetic 2W-50 or equivalent SAE 5W-50 4-stroke engine oil meeting API Service Classification SG or higher.
Engine Oil Capacity:
Approx. 2.0 US quarts (1.9 L) with filter change.
Transmission Fluid Type:
Polaris AGL Synthetic Gearcase Lubricant or equivalent SAE 80W-90 API GL-4.
Transmission Fluid Capacity:
Refer to specific transmission housing fill plugs.
Coolant Type:
Ethylene Glycol-based antifreeze (e.g., Polaris Premium Antifreeze) with corrosion inhibitors.
Typical Wear Items:
Brake pads, tires, drive belts (PVT), wheel bearings, ball joints, tie rod ends.
Common Maintenance Points:
Regular cleaning of air filter, proper tire inflation, PVT belt inspection.
Polarishistory:
Polaris is a long-standing American manufacturer known for its off-road vehicles, including ATVs, snowmobiles, and UTVs.
Sportsman Lineage:
The Sportsman line is Polaris's flagship ATV series, known for its comfort, capability, and versatility. The 400 model typically represented a mid-range option.
Model Years Covered:
Specifically for the 2005 model year, with potential applicability to closely related years within the generation.
