Segment:
All-Terrain Vehicle (ATV)
Target Audience:
Recreational riders, hunters, utility users, farm operators
Key Competitors 2005:
Honda FourTrax, Yamaha Kodiak, Suzuki King Quad, Can-Am Outlander
Atv Features:
Independent Rear Suspension (IRS) on many 500 models, Electronic Fuel Injection (EFI) on some 500 variants, Shaft drive, On-demand AWD, Powerful engines for the class.
Manual Value Proposition:
Provides comprehensive guidance for maintaining and repairing the 2005 Polaris Sportsman 400 and 500, enabling owners to perform most service tasks themselves, saving time and money.
Market Coverage:
North America (Assumed based on product name)
Vehicle Variants Covered:
Polaris Sportsman 400, Polaris Sportsman 500
Estimated Page Count:
Comprehensive (Exact count not provided in product info, but implied to be extensive for 'complete workshop')
Type:
Workshop Service Repair Manual
Format:
Downloadable (Likely PDF)
Engine:
Complete Engine Overhaul, Tuning, Diagnostics, Components (e.g., piston, cylinder, valve train)
Fuel System:
Carburetor/Fuel Injection systems, fuel pump, fuel lines, filters, cleaning, adjustment
Ignition System:
Ignition coil, spark plugs, timing, CDI unit, diagnostics
Transmission Drivetrain:
PVT (Polaris Variable Transmission) operation, belt replacement, clutch servicing, drive shafts, differentials, AWD system
Brake System:
Hydraulic brake system, master cylinder, calipers, rotors, brake pads, bleeding procedures, parking brake
Suspension Steering:
Front and rear suspension components, shocks, A-arms, ball joints, tie rods, steering linkage, wheel alignment
Electrical System:
Wiring diagrams, battery, charging system (stator, regulator/rectifier), starter motor, lighting, switches, fuses, relays
Cooling System:
Radiator, fan, thermostat, water pump, coolant replacement, hoses
Exhaust System:
Muffler, exhaust pipes, heat shields, mounting hardware
Body Chassis:
Frame inspection, body panels, fenders, racks, seating, storage
Wheels Tires:
Tire specifications, pressure, wheel bolt torque, bearing maintenance
Maintenance:
Scheduled maintenance (oil changes, filter replacements, spark plugs, valve adjustments), lubrication points
Troubleshooting:
Diagnostic procedures for common and uncommon problems, symptom-based troubleshooting charts
Repair:
Step-by-step repair instructions for all covered systems, including component removal, installation, and adjustment
Overhaul:
Complete engine and transmission overhaul procedures
Diagnostics:
Fault code interpretation (if applicable), electrical system testing, mechanical component testing
Level Of Detail:
In-depth, suitable for professional technicians and experienced DIY mechanics
Diagnostic Capability:
Advanced diagnostic procedures and specifications
Rebuild Procedures:
Comprehensive rebuild instructions for major components
400 Engine Type:
4-stroke, SOHC, Single Cylinder (Liquid Cooled)
500 Engine Type:
4-stroke, SOHC, Single Cylinder (Liquid Cooled)
Bore Stroke:
Refer to Manual for Specifics (Varies by engine size)
Horsepower:
Varies by model and tuning. Typically 25-35 HP range for 400, 30-40 HP for 500 (Estimate based on typical outputs for these models).
Torque:
Refer to Manual for Specifics
Fuel Delivery 400:
Carburetor (Specific model varies, e.g., Mikuni BSR42)
Fuel Delivery 500:
Carburetor (e.g., Mikuni BSR42) or Electronic Fuel Injection (EFI) on select models
Fuel Type:
Unleaded gasoline, minimum 87 octane
Fuel Capacity:
Typically 3.35 gallons (12.7 L)
Oil Type:
SAE 10W-40, API SG or higher (Refer to Manual for Exact Specification)
Oil Capacity:
Approx. 1.9 US quarts (1.8 L) with filter change (Refer to Manual)
Spark Plug Type:
NGK CR7HSA (Typical, verify in manual)
Spark Plug Gap:
0.028-0.031 in (0.7-0.8 mm) (Typical, verify in manual)
Type:
Polaris Variable Transmission (PVT) Automatic
Drive System:
Shaft Drive, On-Demand All-Wheel Drive (AWD)
Gearing:
High, Low, Neutral, Reverse, Park
Clutch Type:
Dual centrifugal clutch system
Transmission Fluid Type:
Polaris Synthetic Gearcase Lubricant (or equivalent SAE 75W-90 synthetic gear oil)
Transmission Fluid Capacity:
Approx. 10.5 oz (0.31 L) (Verify in Manual)
Atv Safety Standards:
Meets ANSI standards for recreational Off-Highway Vehicles (OHV).
Braking System:
Hydraulic disc brakes front and rear, sealed automotive-style system.
AWD System:
On-demand AWD enhances traction and control.
Lighting:
Dual headlights, taillight, brake light.
Operator Controls:
Handlebar steering, thumb throttle, hand brake levers, foot brake pedal.
Roll Over Protection:
Not equipped with a roll cage; operator must use proper riding techniques and wear appropriate safety gear.
Initial Break In:
First 10 hours or 100 miles (Refer to Manual for detailed break-in procedure)
Engine Oil Change:
Every 100 hours or 6 months (whichever comes first)
Air Filter Cleaning Replacement:
Inspect every 20 hours or 1 month; clean/replace as needed
Spark Plug Replacement:
Every 12 months or 100 hours (whichever comes first)
Transmission Fluid Change:
Every 200 hours or 12 months (whichever comes first)
Brake Fluid Flush:
Every 24 months or as recommended by inspection
Valve Adjustment:
Every 100 hours or 12 months
Engine Oil:
SAE 10W-40, API SG or higher
Gearcase Lubricant:
Polaris Synthetic Gearcase Lubricant or SAE 75W-90 synthetic gear oil
Coolant:
Ethylene glycol-based antifreeze, 50/50 mix with distilled water (Specific Polaris recommendation available in manual)
Brake Fluid:
DOT 3 or DOT 4 Hydraulic Brake Fluid
Common Problems 2005 Sportsman:
PVT belt wear/failure, starter solenoid issues, some electrical connector corrosion, occasional fuel pump problems on EFI models, charging system component failures (stator/rectifier).
Preventative Measures:
Adherence to maintenance schedule, proper cleaning of air filter, checking electrical connections, ensuring proper battery voltage.
Polaris Atv History:
Polaris is a pioneer in the ATV market, introducing the first mass-produced ATV in 1985 (Polaris Trail Boss). The Sportsman line has been a cornerstone of their offerings for decades, known for its utility and recreational capabilities.
Sportsman Line Development:
The Sportsman line evolved from earlier utility-focused models to incorporate more comfort and performance features, including independent suspension and AWD, becoming a benchmark for the industry.
Manufacturing Location:
Primarily USA (Polaris facilities)
2005 Model Significance:
The 2005 models represent a mature iteration of the Sportsman platform, refining earlier designs and offering a strong balance of power, capability, and comfort for both work and play.
