Target User:
Designed for owners of the 2005 Polaris Sportsman 400 and 500 seeking to perform their own maintenance and repairs, saving on labor costs.
Value Proposition:
Offers comprehensive coverage and detailed instructions that are essential for maintaining the longevity and performance of these Polaris ATVs.
Diagrams:
Contains high-quality diagrams and illustrations essential for understanding complex assemblies and procedures.
Accessibility:
Instant download saves time and money on shipping, providing immediate access to critical repair information.
Engine:
Detailed repair, overhaul, and troubleshooting of the engine, including ignition, cooling, and lubrication systems.
Carburetion:
Comprehensive guide to carburetor removal, cleaning, adjustment, and troubleshooting for optimal performance.
Clutching:
In-depth coverage of primary and secondary clutch maintenance, repair, and adjustment, including belt inspection and replacement.
Final Drive:
Maintenance and repair procedures for the drive train, including differentials, axles, and drive shafts.
Body And Steering:
Procedures for body panel removal, installation, steering system diagnosis, and repair, including handlebar and tie-rod adjustments.
Transmission:
Coverage of transmission operation, maintenance, and repair, including gear shifting mechanisms and fluid servicing.
Brakes:
Detailed instructions for brake system maintenance, including hydraulic fluid replacement, pad inspection, caliper service, and bleeding procedures.
Electrical:
Extensive information on the electrical system, including wiring diagrams, component testing, battery maintenance, lighting, and ignition system diagnostics.
Maintenance:
Routine maintenance schedules, lubrication points, filter replacements, and fluid level checks.
Repair:
Step-by-step repair procedures for all major components and systems of the ATV.
Troubleshooting:
Diagnostic charts and troubleshooting guides for identifying and resolving common and complex mechanical and electrical issues.
Depth:
Comprehensive, covering from basic maintenance to complete engine and transmission overhauls, suitable for DIY enthusiasts and professional mechanics.
Engine Type 400:
4-stroke, Liquid-Cooled, SOHC, 4 Valve
Displacement 400:
375cc (Specific bore/stroke may be detailed in manual)
Engine Type 500:
4-stroke, Liquid-Cooled, SOHC, 4 Valve
Displacement 500:
499cc (Specific bore/stroke may be detailed in manual)
Horsepower 500:
Approximately 34 hp @ 6500 rpm (Manufacturer specification, manual will provide precise figures).
Carburetor Type:
Likely Mikuni BST (manual will specify exact model and tuning specs for both 400 and 500 variants).
Fuel Type:
Unleaded Gasoline (Manual will specify octane rating requirement).
Engine Oil Type:
SAE 20W-50 or 10W-40 (Manual will specify exact Polaris recommendation and capacity).
Coolant Type:
Ethylene glycol-based antifreeze/coolant (Manual will specify mix ratio and capacity).
Transmission Type:
Automatic (PVT - Polaris Variable Transmission) with Hi/Lo range and Reverse.
Optional Transmissions:
N/A for this model and year; PVT is standard.
Drive System:
Shaft Drive, AWD (All-Wheel Drive) engagement
Transmission Fluid Type:
Specific PVT Fluid or appropriate Synthetic Gear Lube (Manual will specify exact Polaris part number and type).
Length:
Approx. 81 inches (Manual will provide exact dimensions for both 400 and 500 if they differ).
Width:
Approx. 46 inches (Manual will provide exact dimensions for both 400 and 500 if they differ).
Height:
Approx. 47 inches (Manual will provide exact dimensions for both 400 and 500 if they differ).
Dry Weight 400:
Approx. 600 lbs (Manual will provide precise figure).
Dry Weight 500:
Approx. 605 lbs (Manual will provide precise figure).
Ground Clearance:
Approx. 10.5 inches (Manual will provide precise figure).
Rack Capacity Front:
200 lbs (Manual will confirm).
Rack Capacity Rear:
400 lbs (Manual will confirm).
Towing Capacity:
1500 lbs (Manual will confirm).
Safety Standards Compliance:
Meets ANSI standards for recreational ATVs (Manual will elaborate on specific safety guidelines).
Braking System:
Hydraulic Disc Brakes (Front and Rear), foot-actuated.
Parking Brake:
Hand-operated parking brake.
Lighting:
Dual Halogen Headlights, Tail Light, Brake Light.
Throttle Limiter:
Often present for safety, detailed in manual for adjustment/checking.
Instrument Panel:
Digital/Analog instrument cluster typically includes speedometer, odometer, trip meter, fuel gauge, and indicator lights. Manual explains readings and diagnostics.
AWD System:
Polaris's AWD system automatically engages front wheels when rear wheel slippage is detected. Manual details operation and maintenance.
Diagnostic Ports:
Access to diagnostic information may be available through specific connectors. Manual will illustrate locations and diagnostic procedures.
Oil Change Interval:
Typically every 100 hours or 6 months (Manual will provide precise schedule).
Air Filter Cleaning:
Check every 20 hours, clean/replace as needed (Manual will detail procedure).
Spark Plug Replacement:
Typically every 100 hours or 12 months (Manual will specify correct plug type and gap).
Brake Fluid Type:
DOT 4 Brake Fluid (Manual will confirm exact specification).
Gearcase Oil Type:
Specific Gear Lube or SAE 80W-90 (Manual will specify Polaris recommendation and capacity for front and rear differentials/gearcases).
Common Wear Items:
Drive belts, tie rod ends, wheel bearings, and brake components are common wear items on ATVs of this era. The manual will guide on their inspection and replacement.
Carburetor Tuning:
Carburetors can require adjustment due to altitude, fuel changes, or wear. The manual provides the correct procedures.
Manufacturer:
Polaris Industries is a long-standing manufacturer of powersports vehicles, known for its innovation and robust ATVs.
Sportsman Lineage:
The Sportsman line is Polaris's flagship utility ATV series, known for its comfort, handling, and capability. The 2005 models represent a refinement of earlier generations.
Manufacturing Location:
Polaris ATVs are primarily manufactured in the United States.
