Positioning:
The 2005 Polaris Sportsman 400 was positioned as a versatile and capable mid-size utility ATV, balancing performance for recreational riding with the practicality needed for farm work or trail exploration.
Competitors:
Competed against models like the Honda Foreman 450, Yamaha Kodiak 400, and Kawasaki Prairie 360, offering a compelling blend of features and value.
Features:
Known for its robust build, reliable engine, independent rear suspension (IRS) on many models, and Polaris's signature comfort and handling.
Engine Internal Components:
Detailed coverage of piston, rings, cylinder, cylinder head, valves, camshaft, crankshaft, connecting rods, and lubrication system.
Carburetor:
Comprehensive overhaul and adjustment procedures for the carburetor.
Ignition System:
Diagnosis and repair of ignition coil, spark plug, CDI unit, and stator.
Cooling System:
Radiator, fan, thermostat, and coolant circulation system servicing.
Transmission And Clutch:
CVT system disassembly, inspection, belt replacement, and roller inspection.
Final Drive And Differentials:
Service and maintenance for rear drive unit and any applicable differential systems.
Suspension Geometry:
Front and rear suspension component inspection, adjustment, and replacement (shocks, control arms, bushings).
Braking System Components:
Hydraulic brake system, caliper service, pad replacement, fluid bleeding, and rotor inspection.
Electrical Diagnostics:
Battery, starter, charging system, lighting, and accessory circuits.
Frame And Body Panels:
Inspection and repair of frame integrity, plastic body panels, fenders, and racks.
Fuel Delivery:
Fuel tank, fuel pump (if applicable), fuel lines, and fuel filter service.
Exhaust Gas Recirculation:
Inspection and cleaning of EGR system components if equipped.
Routine Maintenance:
Detailed instructions for oil changes, filter replacements, air filter cleaning/replacement, spark plug service, and lubrication points.
Troubleshooting Guides:
Systematic diagnostic procedures for common and uncommon problems, including symptom-based troubleshooting.
Component Overhaul:
Step-by-step instructions for disassembling, inspecting, cleaning, and reassembling major components like the engine and transmission.
Rebuild Instructions:
Comprehensive guides for rebuilding engine, transmission, and other critical systems.
Adjustment Procedures:
Calibration of carburetor, throttle linkage, brake levers, and other adjustable components.
Safety Inspections:
Guidelines for pre-ride inspections and regular safety checks.
Electrical Troubleshooting:
Diagnosis using multimeter, checking for shorts, open circuits, and voltage drops.
Depth:
Comprehensive, covering everything from basic user maintenance to complete engine and transmission overhauls.
Engine Type:
4-Stroke, Liquid-Cooled, SOHC
Bore X Stroke:
83 mm x 69 mm
Compression Ratio:
10.0:1
Fuel Delivery:
Carburetor (likely Mikuni or Keihin)
Horsepower:
Approximately 27 HP (estimated)
Torque:
Not officially published, but estimated to be around 23 lb-ft.
Fuel Type:
Unleaded Gasoline (87 octane recommended)
Fuel Tank Capacity:
4.25 US Gallons (16.1 Liters)
Instrument Cluster:
Digital instrument cluster typically includes speedometer, odometer, trip meter, fuel gauge, and indicator lights.
4Wd System:
Polaris's ADC (Active Descent Control) may be present on some models for controlled descents, though not standard on all 400s. On-demand 4WD activation is a key feature.
Accessories:
Provisions for accessory lighting, winches, and storage solutions, often requiring basic electrical understanding covered in the manual.
Oil Change Interval:
Every 100 hours or 6 months (whichever comes first). Check manual for specific conditions.
Air Filter Cleaning:
Clean every 25 hours or as needed in dusty conditions. Replace as necessary.
Spark Plug Replacement:
Inspect every 50 hours, replace as needed. Recommended replacement interval may vary.
Valve Adjustment:
Inspect and adjust every 100 hours or annually. Specific procedures in manual.
Transmission Belt Inspection:
Inspect drive belt for wear and damage every 50 hours. Replace if more than 3mm (1/8 inch) wear or damage is present.
Engine Oil Type:
Polaris PS-4 5W-50 Synthetic 4-Cycle Engine Oil or equivalent SAE 5W-50 API SG or higher, certified for 4-stroke engines.
Engine Oil Capacity:
2.1 US quarts (2.0 liters) with filter change.
Transmission Fluid Type:
Polaris AGL Synthetic Gearcase Lubricant (for final drive/gearbox) and PVT system specific belt lubricant (if specified for CVT).
Brake Fluid Type:
DOT 3 or DOT 4 Hydraulic Brake Fluid.
Coolant Type:
Ethylene Glycol based antifreeze (50/50 mix with distilled water).
Common Problems:
Potential issues include carburetor gumming if not run regularly, CVT belt wear, and occasional electrical connector corrosion. The manual addresses these and provides solutions.
Polarís History:
Polaris Industries Inc. has a long history dating back to 1954, initially focused on snowmobiles and later expanding into ATVs, motorcycles, and powersports vehicles. They are known for innovation and a broad range of off-road vehicles.
Sportsman Lineage:
The Sportsman line has been a cornerstone of Polaris's ATV offerings for decades, evolving through various engine sizes and feature sets to meet diverse rider needs. The 400cc class represented a strong value proposition within the lineup.
Production Period:
The Sportsman 400 was a popular model produced for several years, with the 2005 model representing a refinement of earlier iterations. Production occurred at Polaris manufacturing facilities in the USA.
