Segment:
All-terrain vehicle (ATV), utility and recreational
Target Audience:
ATV owners, service technicians, repair shops
Competitors:
Honda Foreman, Yamaha Kodiak, Kawasaki Prairie, Suzuki King Quad
Atv Platform:
Robust chassis, reliable engine, versatile for work and play
Engine Service:
Complete Engine Overhaul and Repair
Transmission Service:
Drive System and Transmission Repair
Chassis And Suspension:
Suspension, Steering, and Chassis Components
Electrical System:
Wiring Diagrams, Ignition, Charging, and Accessories
Bodywork And Plastics:
Body Panel Removal, Installation, and Repair
Maintenance:
Routine Maintenance Schedules and Procedures
Troubleshooting:
Diagnostic Procedures for Common Issues
Estimated Pages:
Comprehensive (Exact count not specified, but described as complete)
Type:
Factory Service Repair Manual
Engine Mechanical:
Top-end (cylinder head, valves), bottom-end (crankshaft, connecting rods), piston, rings, timing components
Fuel System:
Carburetor (or EFI if applicable), fuel pump, fuel filter, fuel lines, tank inspection
Cooling System:
Radiator, hoses, thermostat, water pump, coolant specifications
Ignition System:
Spark plugs, ignition coils, stator, CDI unit, timing adjustments
Lubrication System:
Oil pump, oil filter, oil specifications, oil passages
Drive System:
CVT (Continuously Variable Transmission), primary and secondary clutches, belt inspection and replacement, gearcase, final drive
Suspension System:
Front and rear suspension components, shocks, springs, bushings, calibration
Steering System:
Handlebars, steering column, tie rods, steering linkage, wheel alignment
Braking System:
Hydraulic brake system, master cylinders, calipers, brake pads, brake lines, bleeding procedures
Electrical Components:
Battery, starter motor, alternator/stator, lighting (headlights, taillights, brake lights), instrumentation, wiring harnesses
Frame And Body:
Frame integrity, plastic body panels, fenders, racks, seat assembly
Engine Rebuild:
Full engine disassembly, inspection, measurement, and reassembly
Clutch Service:
CVT clutch inspection, service, and replacement
Suspension Adjustment:
Shock preload and damping adjustments
Brake Bleeding:
Step-by-step guide for bleeding hydraulic brake systems
Electrical Diagnostics:
Troubleshooting electrical faults using wiring diagrams and test procedures
Carburetor Tuning:
Carburetor adjustment and cleaning procedures
Wheel Alignment:
Checking and adjusting wheel alignment
Troubleshooting Charts:
Symptom-based diagnostic flowcharts
Depth:
Comprehensive, suitable for both DIY mechanics and professional repair shops
Detail Level:
Includes torque specifications, clearances, tolerances, and diagnostic parameters
Engine Type 400:
400cc, 4-stroke, SOHC, liquid-cooled, single-cylinder
Engine Type 500:
500cc, 4-stroke, SOHC, liquid-cooled, single-cylinder
Bore Stroke 400:
Details found within the manual
Bore Stroke 500:
Details found within the manual
Horsepower Estimated:
Approx. 26-30 HP for 400, 34-38 HP for 500 (specific figures in manual)
Torque Estimated:
Details found within the manual
Fuel Delivery:
Carburetor (likely Mikuni BSR series, specific model in manual)
Fuel Type:
Unleaded gasoline
Fuel Tank Capacity:
Approximately 3.3 US gallons (12.5 L) - check manual for exact spec
Transmission Type:
Automatic (CVT - Continuously Variable Transmission)
Gear Selection:
High, Low, Neutral, Reverse, Park
Drive System:
On-demand AWD (All-Wheel Drive) with 2WD/AWD selector
Gear Ratios:
Specific ratios for Hi/Lo ranges detailed in the manual
Fluid Type:
CVT Fluid / Polaris Synthetic Gearcase Lube (specific P/N and viscosity in manual)
Length:
Approx. 81 in. (205.7 cm) - check manual for exact spec
Width:
Approx. 46 in. (116.8 cm) - check manual for exact spec
Height:
Approx. 47 in. (119.4 cm) - check manual for exact spec
Front Rack Capacity:
Approx. 90 lbs (41 kg) - check manual for exact spec
Rear Rack Capacity:
Approx. 175 lbs (79 kg) - check manual for exact spec
Dry Weight 400:
Approx. 570 lbs (259 kg) - check manual for exact spec
Dry Weight 500:
Approx. 595 lbs (270 kg) - check manual for exact spec
Towing Capacity:
1500 lbs (680 kg) - check manual for exact spec
Gvw:
Gross Vehicle Weight - check manual for exact spec
Oil Change Interval:
Every 100 hours or annually (refer to manual for precise interval and conditions)
Air Filter Cleaning:
Inspect every 25 hours, clean as needed (more frequently in dusty conditions)
Spark Plug Replacement:
Check gap and condition every 100 hours, replace as needed
Brake Fluid Flush:
Recommended every 2 years or as per manual instructions
Engine Oil:
SAE 0W-40 Synthetic (Polaris Premium 4-Stroke Synthetic or equivalent - check manual for exact spec and API rating)
Coolant:
Ethylene glycol-based antifreeze coolant (50/50 mix with distilled water) - verify specific type in manual
Gearcase Oil:
Polaris Synthetic Gearcase Lube (specific P/N and viscosity, often 75W-90, in manual)
Cvt Belt Wear:
Common for all CVTs; proper maintenance and avoiding excessive load prolongs belt life. Manual details inspection.
Suspension Bushings:
Wear and tear on suspension bushings is common with use; manual provides replacement procedures.
Electrical Connections:
Corrosion or loose connections can cause electrical gremlins; manual provides wiring diagrams for diagnostics.
Manufacturer:
Polaris Industries Inc., a long-standing leader in powersports
Sportsman Line:
The Sportsman line is Polaris's flagship ATV, known for its utility and comfort. Evolved from earlier models with continuous improvements in engine, suspension, and features.
Production Years:
The Sportsman 400 and 500 have been in continuous production with various updates across many model years, including 2005.
Manufacturing Location:
Typically manufactured in the USA (Roseau, Minnesota and other Polaris facilities)
