Atv Segment:
Mid-size utility ATV, designed for recreational trail riding, light work, and general outdoor use.
Competitors 2005:
Honda FourTrax 350/400, Yamaha Wolverine 350/450, Kawasaki Prairie 360/400, Suzuki Eiger 400.
Utility Focus:
Emphasis on reliable performance, comfortable ride, and practical features for recreational and light utility tasks.
Powertrain Description:
Known for its durable and user-friendly single-cylinder engine, coupled with a capable automatic transmission system.
Value For Owners:
Essential for identifying and sourcing the correct replacement parts, facilitating DIY maintenance and repairs, and maintaining the longevity of the vehicle.
Manual Title:
2005 Polaris Sportsman 400 Parts Manual PDF Download
Covered Models:
2005 Polaris Sportsman 400 (A05MH42AB, A05MH42AG, A05MH42AH)
Estimated Page Count:
Variable, typically 200-300 pages for a comprehensive parts manual of this era.
Manual Type:
Parts Manual / Parts Catalog
Engine Components:
Cylinder, piston, crankshaft, camshaft, valves, carburetor, ignition system, starter, exhaust system, cooling system (if applicable).
Drivetrain Components:
Transmission, drive shafts, CV joints, differential, final drive, clutch components, chain/belt drive (if applicable).
Suspension Components:
Front and rear shocks, A-arms, bushings, ball joints, tie rods, wheel hubs.
Brake Components:
Brake calipers, rotors, pads, master cylinder, brake lines, parking brake mechanism.
Electrical Components:
Wiring harness, battery, stator, rectifier/regulator, lights (headlight, taillight, brake light), switches, fuses.
Chassis And Body:
Frame components, body panels (fenders, plastics, racks), handlebars, seat, footpegs, steering system.
Wheels And Tires:
Wheels, tires, lug nuts, valve stems.
Parts Identification:
Exploded view diagrams with numbered parts, part numbers, and descriptions for each component.
Assembly Order:
Indication of correct assembly sequence for various components through diagram ordering.
Part Interchangeability:
May indicate commonality of parts across different assemblies or models (though typically focused on the specific model).
Technical Depth:
Comprehensive for parts identification, selection, and ordering. Does not typically include repair procedures, torque specifications, or diagnostic information, which are found in a service manual.
Engine Type:
4-stroke, Single-cylinder, SOHC
Displacement:
376 cc (23.0 cubic inches)
Bore X Stroke:
84.5 mm x 69 mm (approximate, based on similar Polaris engines of the era)
Cooling System:
Liquid-cooled
Horsepower:
Approx. 20-25 HP (estimated based on similar models)
Torque:
N/A (Torque figures not commonly published for ATVs of this class)
Fuel Delivery:
Carbureted (likely a Mikuni or Keihin CV-type carburetor)
Fuel Type:
Unleaded Gasoline (87 octane minimum recommended)
Ignition System:
CDI (Capacitor Discharge Ignition)
Oil Type:
SAE 20W-50 4-stroke ATV specific oil is commonly recommended by Polaris.
Oil Capacity:
Approx. 2.0-2.2 Liters (check manual for exact specification)
Transmission Type:
Automatic (PVT - Polaris Variable Transmission) with Hi/Lo range and Reverse
Drive System:
On-Demand AWD (All-Wheel Drive) or 2WD selectable
Clutch Type:
Centrifugal clutch with drive and driven clutches.
Gear Ratios:
Variable, specific ratios not typically detailed in parts manuals.
Transmission Fluid Type:
Polaris PVT Fluid (specific, not automotive ATF).
Length:
Approx. 81 inches (205.7 cm)
Width:
Approx. 46 inches (116.8 cm)
Height:
Approx. 47 inches (119.4 cm) to handlebars
Front Rack Capacity:
Approx. 90 lbs (41 kg)
Rear Rack Capacity:
Approx. 150 lbs (68 kg)
Dry Weight:
Approx. 573 lbs (260 kg)
Towing Capacity:
N/A (Polaris did not typically rate towing capacity for this model, but capable of light trailer hauling)
Front Tire Size:
25 x 8-12
Rear Tire Size:
25 x 10-12
Wheelbase:
Approx. 49 inches (124.5 cm)
Atv Safety Standards:
Complies with ANSI/SVIA standards where applicable for ATVs.
Braking System:
Hydraulic disc brakes front and rear.
Parking Brake:
Hand-operated lever engaging rear brake caliper.
Rollover Protection:
Standard ATV design offers no roll cage or seat belts; operator must wear helmet and appropriate protective gear.
Operator Training Recommendation:
Polaris strongly recommends reading the Owner's Manual and completing ATV rider training.
Infotainment Features:
Basic instrumentation: speedometer, odometer, fuel gauge, indicator lights. No advanced infotainment systems.
Driver Assistance Features:
None (traditional ATV design).
Connectivity Features:
None.
Lighting System:
Dual halogen headlights, taillight/brake light.
Oil Change Interval:
Every 100 hours or 6 months, whichever comes first. (Refer to Owner's Manual for specifics).
Spark Plug Replacement:
Recommended every 100-200 hours or annually.
Air Filter Cleaning Inspection:
Frequent inspection and cleaning, especially in dusty conditions (e.g., every 25-50 hours).
Transmission Belt Inspection:
Inspect drive belt for wear and damage every 100 hours. Replace as needed.
Coolant Type:
Polaris Premium Antifreeze/Coolant (or equivalent ethylene glycol-based antifreeze with corrosion inhibitors).
Brake Fluid Type:
DOT 3 or DOT 4 Hydraulic Brake Fluid.
Common Wear Items:
Tie rod ends, ball joints, bushings, drive belts, and wheel bearings are common wear items on ATVs of this age and usage.
Carburetor Tuning:
Carburetors can require periodic cleaning and tuning due to fuel deposits or wear.
AWD System Maintenance:
Proper maintenance of the AWD system, including fluid changes (if applicable to the specific differential), is crucial for longevity.
Polaris Atv Legacy:
Polaris is a pioneer in the ATV industry, having introduced one of the first mass-produced ATVs in the early 1980s. Known for innovation and rugged designs.
Sportsman Lineage:
The Sportsman line has been a cornerstone of Polaris' ATV offerings, evolving from early models to incorporate advancements in suspension, AWD, and ergonomics. The 400cc class represents a popular mid-range option.
Manufacturing Location:
Typically manufactured in Polaris' facilities in the United States.
