Atv Segment:
Mid-range utility ATV, positioned for recreational trail riding, light farm work, and general outdoor use.
Competitors:
Competed against models such as Honda FourTrax 350/400, Yamaha Wolverine/Grizzly 350/450, Kawasaki Prairie 360/400, and Suzuki King Quad 300/400.
Polarissportsman Advantages:
Known for its comfortable independent rear suspension (IRS) on many models, user-friendly AWD system, and robust build quality typical of Polaris products.
Manual Value Proposition:
This manual offers technicians and owners the critical technical data, step-by-step procedures, and diagnostic insights necessary to maintain and repair the 2005-2006 Polaris Sportsman 400 efficiently and effectively, ensuring optimal performance and longevity.
Engine:
Complete engine assembly, disassembly, inspection, and repair procedures for the Polaris 400cc engine, including top-end, bottom-end, cooling system, and lubrication.
Transmission Drivetrain:
Detailed procedures for the Polaris PVT (Polaris Variable Transmission) automatic transmission, including belt inspection/replacement, clutch service, and final drive components (gears, shafts, seals).
Fuel System:
Carburetor (likely Mikuni BST40 or similar) overhaul, adjustment, and troubleshooting; fuel tank, fuel lines, and fuel pump (if applicable) inspection and replacement.
Electrical System:
Ignition system (CDI, coil, spark plug), charging system (stator, regulator/rectifier), starting system (starter motor, solenoid, battery), lighting, and wiring diagrams for all electrical components.
Chassis Suspension Steering:
Front and rear suspension (shocks, springs, control arms), steering system (handlebar, tie rods, steering column), wheel bearings, and chassis frame inspection and repair.
Brakes:
Hydraulic brake system, including front and rear calipers, brake lines, master cylinders, brake pads, and bleeding procedures. Parking brake mechanism.
Bodywork Body Panels:
Removal and installation of plastic body panels, fenders, racks, seats, and related trim components.
Preventative Maintenance:
Oil change intervals, filter replacement (oil, air), spark plug service, valve clearance checks, battery maintenance, chain adjustment (if applicable to specific 400 models), and lubrication points.
Troubleshooting:
Diagnostic procedures for common starting, running, electrical, and mechanical issues, often presented in a flowchart or symptom-based format.
Repair Rebuild:
Step-by-step instructions for disassembling, repairing, and reassembling major vehicle components and systems.
Torque Specifications:
Essential torque values for critical fasteners in engine, transmission, suspension, and brake systems.
Wiring Diagrams:
Detailed electrical schematics showing the layout and function of all wiring harnesses and components.
Diagnostic Capabilities:
Advanced diagnostic information, including how to interpret symptomology and perform tests for various systems, geared towards professional technicians.
Component Rebuild:
Comprehensive instructions for complete overhaul and rebuilding of complex components like the engine, transmission, and carburetors.
File Type:
PDF (Portable Document Format)
Searchable:
Likely text-searchable, allowing for quick navigation to specific topics.
Printable:
Designed to be printable, allowing users to create physical copies for workshop use.
Image Resolution:
High-resolution images and diagrams for clarity in repair procedures.
Physical Binding:
N/A (Digital PDF Download)
Physical Paper:
N/A (Digital PDF Download)
Engine Type:
4-stroke, Single-cylinder, Liquid-cooled, SOHC (Single Overhead Cam)
Displacement:
400cc (actual displacement often around 375-376cc based on common Polaris engine architectures of the era)
Bore X Stroke:
Specifics usually found in manual, but typically in the range of 80mm x 75mm for similar displacements.
Compression Ratio:
Typically around 8.5:1 to 9.5:1 for this class of engine.
Horsepower:
Estimated 20-25 HP (manufacturer specifications are often conservative or not widely published for ATVs).
Torque:
Estimated 20-25 lb-ft (approximate, dependent on exact RPM).
Fuel Delivery:
Carburetor (e.g., Mikuni BST40 or similar size).
Fuel Type:
Unleaded gasoline, minimum 87 octane.
Ignition System:
CDI (Capacitor Discharge Ignition)
Oil Type:
SAE 10W-40 motorcycle specific or ATV lubricant meeting API SG or higher and JASO MA specifications.
Oil Capacity:
Approximately 2.0-2.5 quarts (1.9-2.4 liters) with filter change. Exact specification in manual.
Transmission Type:
Automatic Continuously Variable Transmission (CVT) - Polaris PVT
Gear Selection:
High (H), Low (L), Neutral (N), Reverse (R), Park (P)
Drive System:
Shaft Drive (typically to rear differential); Chain drive to front differential for AWD models (if applicable to specific 400 configuration).
Cvtfail Safe Mode:
Many Polaris PVTs feature a self-preservation mode if belt slippage is detected.
Length:
Typically around 80-83 inches (203-211 cm) for this class of ATV.
Width:
Typically around 46-48 inches (117-122 cm).
Height:
Typically around 45-48 inches (114-122 cm) to handlebar.
Wheelbase:
Typically around 50-52 inches (127-132 cm).
Dry Weight:
Around 600-650 lbs (272-295 kg).
Gvw:
Gross Vehicle Weight Rating (includes rider, accessories, and cargo) typically around 1000-1200 lbs.
Front Rack Capacity:
Typically rated for 50 lbs (22.7 kg).
Rear Rack Capacity:
Typically rated for 100 lbs (45.4 kg).
Towing Capacity:
Typically rated for 1500 lbs (680 kg) with appropriate hitch and ball.
Front Tire Size:
Commonly 25x8-12 or 25x8.00-12.
Rear Tire Size:
Commonly 25x10-12 or 25x11.00-12.
Wheel Bolt Pattern:
Typically 4/110 or 4/115 mm (specific to Polaris hub design).
Instrument Cluster:
Basic digital/analog cluster usually includes speedometer, odometer, trip meter, fuel gauge (if equipped), and indicator lights for AWD, neutral, oil pressure, etc.
Awt System:
The Automatic All-Wheel Drive system is a significant technological feature, enhancing traction and control in varied terrain.
Engine Oil Change:
Every 100 hours or 6 months, whichever comes first. More frequently under severe use.
Air Filter Cleaning:
Inspect every 25 hours, clean or replace as needed. Critical for engine longevity.
Spark Plug Replacement:
Typically every 100 hours or 1 year. Check gap and condition at each oil change.
Cvtbelt Inspection:
Inspect every 50 hours for wear, cracks, and delamination. Replace at first sign of damage.
Transmission Fluid:
The PVT system typically does not use a dedicated transmission fluid. Belt lubrication is critical. Some models may use a small amount of gear oil in the final drive/gearcase.
Brake Fluid:
DOT 3 or DOT 4 Hydraulic Brake Fluid.
Coolant:
Ethylene glycol based antifreeze/coolant. Typically a 50/50 mix with distilled water. Specific type in manual (e.g., green).
Cvt Belt Wear:
CVT belts are a wear item and can fail prematurely if subjected to excessive heat, aggressive riding, or improper alignment. Regular inspection is key.
Carburetor Issues:
Carburetors can become clogged with debris or varnish if fuel sits for extended periods, leading to hard starting or poor running. Periodic cleaning and fresh fuel stabilization are recommended.
Wheel Bearing Failure:
Like many ATVs, wheel bearings can be susceptible to water and dirt ingress, leading to premature wear. Proper cleaning and greasing during maintenance can prolong life.
Starter Solenoid Failure:
The starter solenoid can sometimes fail, preventing the engine from cranking. This is a common component failure across many vehicle types.
Polarishistorical Context:
Polaris Industries is a long-standing American manufacturer known for its pioneering work in snowmobiles and later expanding into ATVs and UTVs. The Sportsman line has been a cornerstone of their ATV offerings for decades, emphasizing comfort, capability, and utility.
Sportsman 400 Lineage:
The Sportsman 400 model, while perhaps not as prominent as the larger displacement models, represented Polaris's commitment to providing a mid-range utility ATV with a balance of power and affordability. It typically featured a more compact engine than the 500 or 700cc models but retained the core Sportsman chassis and features.
Manufacturing Location:
Polaris ATVs are primarily manufactured in the United States, with key facilities in Minnesota and Iowa.
