SPORTSMAN
SPORTSMAN 400/500
400/500
6(59,&(0$18$/
6(59,&(0$18$/
319919425
3199194
319919425
3199194
, 2005 SPORTSMAN 400/500
SERVICE MANUAL
Foreword
This manual is designed primarily for use by Polaris ATV service technicians in a properly equipped shop.
Persons using this manual should have a sound knowledge of mechanical theory, tool use, and shop proce-
dures in order to perform the work safely and correctly. The technician should read the text and be familiar
with service procedures before starting the work. Certain procedures require the use of special tools. Use
only the proper tools, as specified. Cleanliness of parts and tools as well as the work area is of primary impor-
tance.
All references to left and right side of the vehicle are from the operator’s perspective when seated in a normal
riding position.
This manual includes procedures for maintenance operations, component identification and unit repair, along
with service specifications for the 2005 Polaris Sportsman ATVs. A table of contents is placed at the
beginning of each chapter, and an alphabetic index is provided at the end of the manual for location of specific
page numbers and service information. Keep this manual available for reference in the shop area.
At the time of publication all information contained in this manual was technically correct. However, all
materials and specifications are subject to change without notice.
Comments or suggestions about this manual may be directed to: Polaris Sales Inc., Service Publications
Department, 2100 Hwy 55 Medina, Minnesota 55340.
2005 Sportsman 400/500 ATV Service Manual (PN 9919425)
ECopyright 2004 Polaris Sales Inc. All information contained within this publication is based on the latest product information at the
time of publication. Due to constant improvements in the design and quality of production components, some minor discrepancies may
result between the actual vehicle and the information presented in this publication. Depictions and/or procedures in this publication are
intended for reference use only. No liability can be accepted for omissions or inaccuracies. Any reprinting or reuse of the depictions
and/or procedures contained within, whether whole or in part, is expressly prohibited. Printed in U.S.A.
,UNDERSTANDING SAFETY LABELS AND INSTRUCTIONS
Throughout these instructions, important information is brought to your attention by the following symbols:
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!
DANGER
Failure to follow DANGER instructions will result in severe injury or death to the operator, bystander or person
inspecting or servicing the ATV.
WARNING
Failure to follow WARNING instructions could result in severe injury or death to the operator, bystander or
person inspecting or servicing the ATV.
CAUTION:
A CAUTION indicates special precautions that must be taken to avoid personal injury, or ATV or property
damage.
NOTE:
A NOTE provides key information to clarify instructions.
Trademarks
Polaris acknowledges the following products mentioned in this manual:
FLEXLOC, Registered Trademark of SPS Technologies
Loctite, Registered Trademark of the Loctite Corporation
Nyogel, Trademark of Wm. F. Nye Co.
Fluke, Registered Trademark of John Fluke Mfg. Co.
Mity Vac, Registered Trademark of Neward Enterprises, Inc.
Torx, Registered Trademark of Textron
Hilliard, Trademark of the Hilliard Corporation
Warn, Trademark of the Warn Industries
Some Polaris factory publications can be downloaded from www.polarisindustries.com or purchased from
www.purepolaris.com or contact your nearest Polaris dealer.
, GENERAL
MAINTENANCE
ENGINE
CARBURETION
BODY AND STEERING
CLUTCHING
FINAL DRIVE
TRANSMISSION
BRAKES
ELECTRICAL
SPORTSMAN 400/500
400/500
6(59,&(0$18$/
6(59,&(0$18$/
319919425
3199194
319919425
3199194
, 2005 SPORTSMAN 400/500
SERVICE MANUAL
Foreword
This manual is designed primarily for use by Polaris ATV service technicians in a properly equipped shop.
Persons using this manual should have a sound knowledge of mechanical theory, tool use, and shop proce-
dures in order to perform the work safely and correctly. The technician should read the text and be familiar
with service procedures before starting the work. Certain procedures require the use of special tools. Use
only the proper tools, as specified. Cleanliness of parts and tools as well as the work area is of primary impor-
tance.
All references to left and right side of the vehicle are from the operator’s perspective when seated in a normal
riding position.
This manual includes procedures for maintenance operations, component identification and unit repair, along
with service specifications for the 2005 Polaris Sportsman ATVs. A table of contents is placed at the
beginning of each chapter, and an alphabetic index is provided at the end of the manual for location of specific
page numbers and service information. Keep this manual available for reference in the shop area.
At the time of publication all information contained in this manual was technically correct. However, all
materials and specifications are subject to change without notice.
Comments or suggestions about this manual may be directed to: Polaris Sales Inc., Service Publications
Department, 2100 Hwy 55 Medina, Minnesota 55340.
2005 Sportsman 400/500 ATV Service Manual (PN 9919425)
ECopyright 2004 Polaris Sales Inc. All information contained within this publication is based on the latest product information at the
time of publication. Due to constant improvements in the design and quality of production components, some minor discrepancies may
result between the actual vehicle and the information presented in this publication. Depictions and/or procedures in this publication are
intended for reference use only. No liability can be accepted for omissions or inaccuracies. Any reprinting or reuse of the depictions
and/or procedures contained within, whether whole or in part, is expressly prohibited. Printed in U.S.A.
,UNDERSTANDING SAFETY LABELS AND INSTRUCTIONS
Throughout these instructions, important information is brought to your attention by the following symbols:
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!
DANGER
Failure to follow DANGER instructions will result in severe injury or death to the operator, bystander or person
inspecting or servicing the ATV.
WARNING
Failure to follow WARNING instructions could result in severe injury or death to the operator, bystander or
person inspecting or servicing the ATV.
CAUTION:
A CAUTION indicates special precautions that must be taken to avoid personal injury, or ATV or property
damage.
NOTE:
A NOTE provides key information to clarify instructions.
Trademarks
Polaris acknowledges the following products mentioned in this manual:
FLEXLOC, Registered Trademark of SPS Technologies
Loctite, Registered Trademark of the Loctite Corporation
Nyogel, Trademark of Wm. F. Nye Co.
Fluke, Registered Trademark of John Fluke Mfg. Co.
Mity Vac, Registered Trademark of Neward Enterprises, Inc.
Torx, Registered Trademark of Textron
Hilliard, Trademark of the Hilliard Corporation
Warn, Trademark of the Warn Industries
Some Polaris factory publications can be downloaded from www.polarisindustries.com or purchased from
www.purepolaris.com or contact your nearest Polaris dealer.
, GENERAL
MAINTENANCE
ENGINE
CARBURETION
BODY AND STEERING
CLUTCHING
FINAL DRIVE
TRANSMISSION
BRAKES
ELECTRICAL
