Atv Segment:
Mid-size utility ATV, popular for recreational and light work use
Key Competitors 2005:
Honda Foreman, Yamaha Kodiak, Suzuki King Quad, Arctic Cat 500
Atv Strengths 2005:
Reliable engine, comfortable ride, Polaris's Active Descent Control (ADC) or similar features, four-wheel drive capability
Manual Benefit:
Empowers owners to perform maintenance and repairs efficiently, saving time and money
Engine Coverage:
Engine Overhaul, Diagnosis, Tuning, Cooling System, Lubrication System
Carburetion Coverage:
Carburetor Diagnosis, Cleaning, Adjustment, Rebuild
Clutching Coverage:
Drive Clutch, Driven Clutch Inspection, Service, Replacement, Belt Maintenance
Final Drive Coverage:
Gearcase, Drive Shaft, Axles, Bearings, Seals, Lubrication
Body And Steering Coverage:
Frame, Plastics, Handlebars, Steering Shaft, Tie Rods, Ball Joints, Wheel Bearings
Transmission Coverage:
Transmission Operation, Diagnosis, Internal Components, Shifting Mechanisms
Brakes Coverage:
Hydraulic System, Brake Pads, Rotors, Calipers, Master Cylinders, Bleeding Procedures
Electrical Coverage:
Wiring Diagrams, Lighting, Ignition System, Starting System, Charging System, Sensors, ECU
Fuel System Coverage:
Fuel Tank, Fuel Lines, Fuel Filter, Fuel Pump (if applicable)
Suspension Coverage:
Front and Rear Suspension Components, Shocks, Springs, Bushings
Diagnostic Procedures:
Fault Finding and Troubleshooting for all major systems
Repair Procedures:
Step-by-step instructions for component repair and replacement
Rebuild Procedures:
Detailed instructions for engine and transmission rebuilds
Restoration Procedures:
Guidance for bringing an older unit back to original specifications
Maintenance Procedures:
Regular servicing and preventative maintenance tasks
Adjustment Procedures:
Carburetor, clutch, and other component adjustments
Troubleshooting Charts:
Systematic guides for identifying and resolving common problems
Depth Of Information:
In-depth technical details suitable for professional technicians and experienced DIY mechanics
Printability:
All pages printable without restriction
Binding Type:
Digital Download (not physically bound)
Paper Type:
Digital (for printing, high-quality paper recommended)
PDF Reader Requirement:
Adobe PDF Reader or compatible PDF reader recommended
Archiving Software Requirement:
WinRar or equivalent for extracted archives
Engine Type:
4-Stroke, Single-Cylinder
Displacement:
400 cc (approximate)
Cooling System:
Liquid-Cooled
Horsepower Estimate:
Estimated 20-25 HP (specific rating not provided in product info)
Torque Estimate:
Estimated 22-26 lb-ft (specific rating not provided in product info)
Fuel Delivery:
Carburetor
Carburetor Model Typical:
Mikuni VM34SS or similar (specific model covered in manual)
Ignition Type:
CDI (Capacitor Discharge Ignition)
Oil Type Recommendation:
API SG or higher, SAE 20W-50 motorcycle oil recommended (check manual for exact specification)
Engine Oil Capacity:
Approximately 1.7 US quarts (1.6 Liters) with filter change (check manual for exact specification)
Transmission Type:
Automatic CVT (Continuously Variable Transmission)
Gear Selection:
High, Low, Neutral, Reverse
Drive System:
Shaft Drive with On-Demand AWD
Primary Clutch:
Centrifugal (Drive Clutch)
Secondary Clutch:
Roller/Spring Loaded (Driven Clutch)
Length:
81.5 inches (207 cm) (approximate)
Width:
46 inches (117 cm) (approximate)
Height:
47 inches (119 cm) (approximate)
Dry Weight:
580 lbs (263 kg) (approximate)
Ground Clearance:
11.25 inches (28.6 cm) (approximate)
Towing Capacity:
1500 lbs (680 kg)
Rack Capacity Front:
90 lbs (41 kg)
Rack Capacity Rear:
180 lbs (82 kg)
Safety Certification:
Complies with ANSI B71.1-2003 and ASME B71.5-1987 standards
Braking System:
Hydraulic Disc Brakes Front and Rear
4Wd System:
Polaris On-Demand All-Wheel Drive (AWD)
Throttle Limiter:
Adjustable throttle limiter for new riders
Parking Brake:
Hand-operated parking brake
Infotainment Features:
Basic instrumentation (speedometer, odometer, fuel gauge, indicator lights)
Driver Assistance Features:
On-Demand AWD, Engine Braking System (EBS) on some models (check specific VIN)
Connectivity Features:
N/A (This is an off-road vehicle of its era)
Initial Service Interval:
25-hour or 1-month service (refer to manual for exact details)
Engine Oil Change Interval:
Every 100 hours or 6 months (whichever comes first)
Air Filter Cleaning Interval:
Every 50 hours or as needed based on conditions
Spark Plug Replacement Interval:
Every 100 hours or annually
Brake Fluid Type:
DOT 3 or DOT 4 Hydraulic Brake Fluid (check manual for specific recommendation)
Coolant Type:
Ethylene glycol-based antifreeze (50/50 mix with distilled water) (check manual for specific recommendation)
Gearcase Oil Type:
Polaris HD Gearcase Lubricant or equivalent SAE 80W-90 GL-5 gear oil (check manual for exact specification)
Grease Type:
High-temperature, lithium-based grease (check manual for specific applications)
Common Wear Items:
Brake pads, wheel bearings, tie rod ends, drive belt, suspension bushings
Potential Engine Issues:
Carburetor gumming if not run regularly, valve adjustments needed, occasional starter issues
Potential Drive System Issues:
CV joint boot wear, AWD engagement issues if not maintained
Polaris History:
Polaris Inc. is an American manufacturer founded in 1954, known for snowmobiles, ATVs, and UTVs.
Sportsman Lineage:
The Sportsman line has been a cornerstone of Polaris's ATV offerings, known for its comfort, utility, and off-road capability. The 400 model represented a mid-range option.
Manufacturing Location Typical:
Roseau, Minnesota, USA
