Market Segment:
Utility All-Terrain Vehicle (ATV)
Target Audience:
Recreational riders, hunters, farmers, and utility users.
Competitors:
Competed with models from Honda (FourTrax), Yamaha (Grizzly), Kawasaki (Bayou/Brute Force), and Suzuki (KingQuad).
Powertrain Strength:
Known for robust engines and Polaris's proprietary Variable Transmission (PVT).
Suspension Design:
Typically featured independent front suspension and a swingarm or independent rear suspension (depending on specific model variant for that year), offering good ground clearance and ride quality.
Utility Focus:
Emphasis on towing capacity, cargo hauling, and off-road capability.
Primary Coverage:
Complete service and repair procedures for Polaris Sportsman 400 and Sportsman 500 models.
Secondary Coverage:
Maintenance, diagnostics, troubleshooting, specifications, diagrams, and exploded views.
Estimated Page Count:
Extensive; typically 500+ pages for a complete workshop manual of this era.
Manual Type:
Workshop Service Repair Manual
Engine System:
Engine overhaul, disassembly, assembly, lubrication, cooling, fuel, ignition, and exhaust systems.
Transmission Drivetrain:
Automatic transmission (PVT - Polaris Variable Transmission), drive clutch, driven clutch, belt, final drive, differentials, axles, and CV joints.
Braking System:
Hydraulic disc brakes (front and rear), brake calipers, master cylinders, brake lines, and bleeding procedures.
Electrical System:
Ignition system, charging system (stator, rectifier/regulator, battery), lighting, starter motor, wiring diagrams, fuses, relays, and control modules.
Suspension Steering:
Front and rear suspension (independent or dependent depending on specific 400/500 variant), shock absorbers, springs, control arms, wheel bearings, and steering components (tie rods, steering column).
Chassis Frame:
Frame inspection, repair, mounting points, and bodywork attachment.
Fuel System:
Fuel tank, fuel pump, fuel lines, carburetor/fuel injection system (depending on specific model variant), and emission controls.
Cooling System:
Radiator, fan, coolant hoses, thermostat, and coolant specifications.
Maintenance Procedures:
Oil changes, filter replacements, spark plug checks, air filter cleaning/replacement, coolant flushes, brake checks, tire pressure adjustments, and lubrication points.
Diagnostic Procedures:
Troubleshooting guides for common issues, symptom-based diagnostics, and testing electrical components.
Repair Procedures:
Complete step-by-step instructions for disassembling, repairing, and reassembling all major vehicle systems.
Technical Specifications:
Torque specifications for fasteners, clearances, fluid capacities, and electrical resistance values.
Schematics Diagrams:
Detailed electrical wiring diagrams, exploded view diagrams for component identification and assembly, and system schematics.
Depth Of Coverage:
Comprehensive, covering everything from routine maintenance to complete engine and transmission rebuilds.
Diagnostics Focus:
Detailed diagnostic procedures for pinpointing mechanical and electrical faults.
Special Tools:
Lists and descriptions of specialized tools required for specific procedures.
Sportsman 400 Engine:
Likely a 400cc class liquid-cooled, 4-stroke engine (e.g., 375cc or 399cc single-cylinder).
Sportsman 500 Engine:
Likely a 499cc liquid-cooled, 4-stroke, SOHC, 2-valve or 4-valve single-cylinder engine.
Engine Type:
Single-cylinder, 4-stroke, liquid-cooled.
Sportsman 400 Horsepower:
Estimated 20-30 HP (specific figures vary).
Sportsman 500 Horsepower:
Estimated 30-35 HP (specific figures vary).
Torque Delivery:
Designed for low-end torque for pulling and climbing.
Fuel Delivery:
Carbureted (likely Mikuni or Keihin) for most 2005 models. Some later variants or specific configurations might have had EFI.
Fuel Type:
Unleaded gasoline, 87 octane (87 AKI).
Transmission Type:
Polaris Variable Transmission (PVT) - Automatic Continuously Variable Transmission (CVT).
Gear Selection:
High (H), Low (L), Neutral (N), Reverse (R), Park (P).
Optional Gearboxes:
None standard, PVT is the primary transmission.
Drive System:
On-Demand All-Wheel Drive (AWD) with 2WD/AWD selector, or full-time AWD depending on model configuration.
Transmission Fluid:
Refer to manual for specific Polaris PVT fluid or equivalent; often a specialized synthetic blend.
Length:
Approx. 81-83 inches (Varies slightly between 400/500).
Width:
Approx. 46-48 inches (Varies slightly).
Height:
Approx. 48-50 inches (Varies slightly).
Wheelbase:
Approx. 50-52 inches (Varies).
Ground Clearance:
Approx. 8-11 inches (Varies).
Front Rack Capacity:
Typically 50 lbs (22.7 kg).
Rear Rack Capacity:
Typically 100 lbs (45.4 kg).
Dry Weight:
Approx. 580-630 lbs (Varies significantly between 400 and 500 models).
Towing Capacity:
Typically 1,500 lbs (680 kg).
Tongue Weight Capacity:
Typically 150 lbs (68 kg).
Atv Safety Standards:
Designed to meet ANSI standards for ATVs.
Braking System Type:
Hydraulic disc brakes on all wheels, often with parking brake mechanism.
Engine Braking:
PVT provides inherent engine braking in lower gears.
Rollover Protection:
None (standard ATV design - rider responsibility for safe operation).
Lighting:
Dual headlights, taillight, and brake light.
Engine Oil Change:
Typically every 100 hours or 12 months, whichever comes first (refer to manual for exact specification).
Air Filter Maintenance:
Inspect every 20 hours, clean or replace as needed. More frequent in dusty conditions.
Spark Plug Replacement:
Recommended every 100 hours or annually.
Belt Inspection:
Inspect drive belt for wear and damage at every oil change; replace as needed (typically based on mileage or hours).
Engine Oil Type:
Polaris Premium 4 Synthetic 0W-40 or equivalent SAE 0W-40 or 10W-40 motorcycle-specific oil meeting API SG or higher specifications.
Engine Oil Capacity:
Refer to manual, typically around 2.0 - 2.5 quarts (1.9 - 2.4 liters) with filter change.
Coolant Type:
Ethylene glycol-based antifreeze, mix with distilled water (50/50 ratio). Polaris brand or equivalent.
Brake Fluid Type:
DOT 3 or DOT 4 hydraulic brake fluid.
Common Wear Items:
Drive belts (PVT), wheel bearings, tie rod ends, and ball joints are common wear items on ATVs of this era.
Electrical Gremlins:
Older Polaris models can sometimes experience minor electrical issues, often related to connectors or grounds, which this manual would help diagnose.
Carburetor Cleaning:
Carburetors may require periodic cleaning and adjustment, especially if fuel is left standing for extended periods.
Polaris History:
Polaris Inc. is an American manufacturer known for powersports vehicles, including snowmobiles, ATVs, UTVs, and motorcycles. Founded in 1954.
Sportsman Line Introduction:
The Sportsman line has been a cornerstone of Polaris's ATV offerings, evolving significantly through various engine sizes and feature packages since its inception.
2005 Updates:
The 2005 models would have incorporated incremental improvements over previous years, focusing on reliability, performance enhancements, and potentially styling updates.
Manufacturing Location:
Primarily manufactured in the United States by Polaris Inc.
