Segment:
Mid-size utility ATV for recreational and light-duty work applications.
Target Audience:
Outdoor enthusiasts, farmers, ranchers, and individuals seeking a reliable and versatile off-road vehicle.
Competitors 2005:
Honda FourTrax, Yamaha Kodiak, Suzuki Eiger, Arctic Cat 400.
Standard Features 2005 Sportsman 400:
On-Demand All-Wheel Drive, independent rear suspension, 4-stroke engine, powerful braking system, comfortable seating.
Manual Value:
Provides the essential OEM part numbers and visual references required for accurate maintenance, repair, and part sourcing, saving time and preventing costly errors.
Primary Coverage:
All components and assemblies of the 2005 Polaris Sportsman 400 ATV.
Secondary Coverage:
Genuine Polaris OEM part numbers, exploded diagrams for visual identification and assembly order.
Estimated Page Count:
Varies by specific sub-assembly, but comprehensive, typically 200-400+ pages for a full parts catalog.
Manual Type:
Parts Manual / Parts Catalog
Format:
PDF (Downloadable)
Engine:
Complete breakdown of engine components, including cylinder, piston, crankshaft, camshaft, valve train, cooling system, lubrication system, and ignition system parts.
Drivetrain:
All parts related to the transmission, driveshafts, differentials, axles, and final drive mechanisms.
Suspension:
Front and rear suspension components, including A-arms, shocks, springs, bushings, ball joints, and tie rods.
Brakes:
Brake system components for both front and rear, including calipers, rotors, brake lines, master cylinders, and brake pads.
Electrical:
Wiring harnesses, battery, starter, alternator, lighting components, ignition switch, and control modules.
Bodywork And Chassis:
Frame components, body panels, fenders, racks, seats, handlebars, and associated hardware.
Fuel System:
Fuel tank, fuel lines, carburetor/fuel injection components, fuel pump, and filters.
Cooling System:
Radiator, fan, hoses, thermostat, and coolant reservoir.
Part Identification:
Clear identification of every individual part with its corresponding Polaris OEM part number.
Assembly Disassembly Guidance:
Exploded diagrams provide visual sequencing for assembly and disassembly, aiding in part replacement and reassembly.
Component Location:
Diagrams illustrate the precise location of each part within its respective assembly.
Depth:
High. Provides OEM part numbers, quantities per assembly, and detailed visual breakdowns of all systems and components.
Utility:
Essential for accurate parts ordering, replacement, and understanding of the ATV's construction.
Searchability:
Typically searchable text within the PDF, allowing for quick part number or keyword lookups.
Image Resolution:
Professional quality, allowing for enlargement to view even the smallest parts clearly.
Scalability:
High, designed for clear viewing on digital devices and potential printing.
Binding:
N/A (Digital Download - PDF)
Paper Type:
N/A (Digital Download - PDF)
Engine Type:
4-Stroke, Liquid-Cooled, SOHC
Displacement:
376cc (approx.)
Bore X Stroke:
Specific bore and stroke figures would be detailed within the manual's engine section, but typically around 83mm x 71.4mm.
Horsepower:
Estimated 20-25 HP (specific figures often not publicly stated for ATVs of this era, but performance characteristics are implied).
Torque:
Torque figures would be detailed in a service manual, not typically a parts catalog, but indicative of strong low-end power for towing and climbing.
Fuel Delivery:
Carburetor (likely Mikuni or Keihin, specific model detailed in manual).
Fuel Type:
Unleaded gasoline
Ignition System:
Electronic Ignition (CDI)
Starter System:
Electric Start
Transmission Type:
Automatic (CVT - Continuously Variable Transmission)
Drive System:
Shaft Drive, On-Demand AWD
Gear Selection:
High, Low, Neutral, Reverse
Cv Belt Part Numbers:
The manual would list the specific Polaris OEM part number for the CVT drive belt and driven clutch components.
Length:
Approx. 81 inches (205.7 cm)
Width:
Approx. 46 inches (116.8 cm)
Height:
Approx. 48 inches (121.9 cm)
Wheelbase:
Approx. 50 inches (127 cm)
Dry Weight:
Approx. 570 lbs (258.5 kg)
Towing Capacity:
650 lbs (295 kg)
Rack Capacity Front:
90 lbs (41 kg)
Rack Capacity Rear:
180 lbs (82 kg)
Atv Safety Standards:
Designed to meet ANSI standards for ATVs.
Braking System:
Hydraulic disc brakes front and rear.
Drivetrain Safety:
On-Demand AWD system provides enhanced traction and stability.
Lighting:
Dual Halogen headlights, brake light/taillight.
Ergonomics:
Handlebar design and controls positioned for rider comfort and control.
Instrumentation:
Digital/analog instrument cluster displaying speed, RPM, odometer, trip meter, fuel level, and gear selection indicator.
AWD System:
Polaris's On-Demand All-Wheel Drive system automatically engages the front wheels when traction is lost, providing superior off-road capability.
Accessories Integration:
Provisions for mounting accessories like winches, lights, and storage boxes, supported by available part numbers in the catalog.
Oil Change Interval:
Typically every 100 hours or 6 months (refer to service manual for exact intervals and specifications).
Cv Belt Inspection:
Regular inspection recommended, replacement based on wear and condition.
Spark Plug Replacement:
Typically every 1-2 years or as needed based on performance (specific plug type and gap in manual).
Engine Oil Type:
Polaris PS-4 5W-50 or equivalent API SG/SH/SJ/SL rated oil (specific viscosity and API rating detailed in the manual).
Engine Oil Capacity:
Approx. 2.1 US quarts (2.0 Liters) with filter change (confirm with manual).
Gearcase Oil Type:
Polaris Demand Drive Fluid or equivalent SAE 80W-90 GL-5 hypoid gear lubricant (specific type and capacity in manual).
Coolant Type:
Antifreeze/coolant mixture (e.g., 50/50 ethylene glycol) suitable for powersports applications.
Common Wear Items:
CV joint boots, tie rod ends, wheel bearings, brake pads, and the CVT belt are common wear items on ATVs of this era.
Electrical Connections:
Corrosion on electrical connectors can sometimes lead to intermittent issues, requiring inspection and cleaning.
Polaris Atv History:
Polaris is a long-standing manufacturer of ATVs, known for innovation and durability in the powersports industry.
Sportsman Lineage:
The Sportsman line is Polaris's flagship utility ATV range, continuously updated with new technologies and features since its inception.
Manufacturing Location:
Primarily manufactured in the United States by Polaris Inc.
