Positioning:
Targeted at owners and independent repair shops seeking comprehensive DIY or professional repair guidance for the 2005 Polaris Sportsman 400/500 ATV.
Value Proposition:
Provides factory-level repair and maintenance information, mirroring what professional shops utilize, enabling cost-effective DIY repairs and accurate diagnostics.
Feature 1:
Authentic factory service manual content.
Feature 2:
Covers both 400 HO and 500 HO engine variants for the 2005 model year.
Feature 3:
Downloadable PDF format for immediate access and digital convenience.
Engine:
Complete engine overhaul, diagnostics, tuning, timing, lubrication, cooling system
Fuel System:
Carburetor (jetting, cleaning, rebuilding, synchronization), fuel pump, fuel lines, fuel tank
Transmission:
PVT (Polaris Variable Transmission) system, belt replacement, clutch maintenance, gearbox operation
Electrical System:
Ignition system, charging system (stator, rectifier/regulator), starter motor, battery, lighting, wiring diagrams, diagnostics
Brakes:
Hydraulic brake system maintenance, bleeding, pad replacement, caliper service, hydraulic lines
Suspension:
Front and rear suspension systems, shock absorbers, control arms, bushings, alignment
Steering:
Steering mechanism, tie rods, ball joints, wheel bearings, troubleshooting steering play
Chassis And Frame:
Frame inspection, component mounting, body panel removal and installation
Drivetrain:
Axles, CV joints, differential maintenance, driveshaft
Cooling System:
Radiator, fan, coolant, thermostat, hoses
Maintenance:
Routine inspections, lubrication points, filter changes, fluid level checks, valve adjustments
Troubleshooting:
Diagnostic flowcharts, symptom-based troubleshooting for common problems
Repair:
Step-by-step instructions for component removal, disassembly, inspection, repair, and reassembly
Diagnostics:
Methods for identifying and resolving mechanical and electrical issues
Technical Specifications:
Detailed torque specifications, clearances, measurements, and performance data
Depth:
Comprehensive, covering everything from basic maintenance to full engine and transmission rebuilds
400 Ho Engine:
Polaris 375cc liquid-cooled, SOHC, 4-valve, 4-stroke single-cylinder engine.
500 Ho Engine:
Polaris 499cc liquid-cooled, SOHC, 4-valve, 4-stroke single-cylinder engine.
Horsepower 400 Ho:
Approximately 26 HP (est.)
Horsepower 500 Ho:
Approximately 32 HP (est.)
Torque 400 Ho:
Approximately 25 ft-lbs (est.)
Torque 500 Ho:
Approximately 30 ft-lbs (est.)
Carburetor Type:
Keihin CV carburetor (specific model number varies by engine variant, likely 36mm for 400 HO and 38mm for 500 HO)
Fuel Type:
Unleaded gasoline, minimum 87 octane
Oil Type:
API SG, SH, SJ or higher, SAE 20W-50 4-stroke engine oil
Oil Capacity:
Approx. 2.25 quarts (2.1 liters) with filter change (refer to manual for precise spec)
Coolant Type:
Ethylene glycol based antifreeze/coolant, 50/50 mix with distilled water
Transmission Type:
Polaris Variable Transmission (PVT) automatic with engine braking
Gear Selection:
High, Low, Neutral, Reverse (with electronic actuator on some models)
Drive System:
Shaft drive, On-Demand AWD (All-Wheel Drive) with 2WD/4WD selector
Clutch System:
Primary and secondary clutch system for variable gear ratio
Length:
Approx. 81 inches (2057 mm)
Width:
Approx. 46 inches (1168 mm)
Height:
Approx. 48 inches (1219 mm)
Wheelbase:
Approx. 50.5 inches (1283 mm)
Dry Weight:
Approx. 620-630 lbs (281-286 kg)
Ground Clearance:
Approx. 11.5 inches (292 mm)
Front Rack Capacity:
200 lbs (90.7 kg)
Rear Rack Capacity:
400 lbs (181.4 kg)
Towing Capacity:
1500 lbs (680 kg)
Hitch Type:
2-inch receiver
Atv Safety Standards:
Complies with ANSI/SVIA standards for ATVs.
Braking System:
Hydraulic disc brakes, front and rear
Engine Braking:
Integrated into PVT system for controlled descents
Lighting:
Dual 25W headlights, 8W brake/taillight
Seat Belt Requirement:
N/A (ATVs are not designed for seat belts; operators should wear helmets and protective gear)
Oil Change Interval:
Every 100 hours or 12 months (refer to manual for exact, condition-dependent recommendations)
Air Filter Cleaning:
Inspect every 50 hours, clean as needed; replace if damaged.
Spark Plug Replacement:
Inspect every 100 hours, replace as needed (typical interval 300-500 hours).
Clutch Belt Inspection:
Inspect belt condition, tension, and wear at 50-hour intervals, replace as needed.
Valve Adjustment Interval:
Every 200 hours or 24 months.
Engine Oil Spec:
SAE 20W-50, API SG/SH/SJ or higher
Brake Fluid Spec:
DOT 3 or DOT 4 hydraulic brake fluid
Coolant Spec:
50/50 mix of ethylene glycol antifreeze and distilled water
Gearcase Oil Spec:
Polaris Synthetic Gearcase Lubricant or equivalent SAE 80W-90 GL-5 gear oil
Common Issue 1:
PVT belt wear and premature failure if subjected to excessive heat or abuse.
Common Issue 2:
Carburetor jetting can be sensitive to altitude and modifications, requiring careful tuning.
Common Issue 3:
Starter solenoid and battery issues are common on older ATVs due to usage and potential overcharging/undercharging if the charging system has faults.
Common Issue 4:
Water pump seal leaks or radiator hose issues can lead to cooling system problems.
Common Issue 5:
Wheel bearing and CV joint wear, especially in muddy or abrasive conditions.
Polarishistory:
Polaris Industries Inc. has a long-standing history in powersports, founded in 1954, and is a pioneer in the ATV market.
Sportsman Lineage:
The Sportsman line has been a cornerstone of Polaris' ATV offerings, known for its versatility, comfort, and capable 4x4 system. The 400 and 500 models represent mid-range displacement options within the lineup, evolving over several years.
Manufacturing Location:
Typically manufactured in Roseau, Minnesota, USA, or other Polaris manufacturing facilities.
Production Years For Gen:
The Sportsman 400 and 500 models were produced in various iterations from the late 1990s through the 2000s, with 2005 being a representative model year for this generation.
