The 2004 Sportsman 400 and 500 Hunter Edition All-Terrain Vehicles (ATVs) represent a significant offering in the utility ATV market. Known for their ruggedness and versatility, these models were designed to excel in demanding conditions, particularly for hunting and general outdoor use. Key features include Independent Rear Suspension (IRS) for superior ride comfort, the Variable Transmission (PVT) with engine braking for controlled descents, and robust engine options available in 400cc and 500cc displacements. These ATVs were engineered to provide reliable performance and durability, making them a popular choice for those requiring a capable and dependable machine for work or recreation. This comprehensive workshop service repair manual provides detailed guidance for the maintenance and repair of your 2004 Sportsman 400 and 500 Hunter ATVs. It covers all essential systems, including the engine, drivetrain, transmission, suspension, steering, brakes, and electrical systems. Within its pages, you will find step-by-step procedures for routine maintenance, troubleshooting common issues, detailed technical specifications, and diagnostic information. This manual is an indispensable resource for owners, mechanics, and technicians seeking to ensure the optimal performance, longevity, and safe operation of their Sportsman ATV. 🏷️ Basic Information Identification Make: Polaris Model: Sportsman 400 / 500 Hunter Year: 2004 Vehicle Type: All-Terrain Vehicle (ATV) Body Style: Hunter Edition 👋 Introduction Market Position Market Position: The Polaris Sportsman series has historically been a dominant force in the ATV market, known for its versatility, ruggedness, and rider comfort, particularly appealing to hunters and utility users. Competitive Analysis Competitive Analysis: Competed against other major utility ATV manufacturers such as Can-Am (Outlander), Yamaha (Grizzly), and Honda (Rancher/Foreman) in the mid-size to large displacement utility segment. Key Features Key Features: Independent Rear Suspension (IRS) for improved ride quality, Polaris Variable Transmission (PVT) with engine braking, powerful engine options (400cc and 500cc), and the 'Hunter Edition' typically includes features like enhanced tires, racks, and possibly a winch or gun scabbard. 📋 Manual Details Coverage Areas Coverage Areas: Comprehensive service and repair for 2004 Polaris Sportsman 400 and 500 Hunter ATVs Page Count Page Count: Not specified in product information, but implies extensive coverage typical of a complete workshop manual. Manual Type Manual Type: Complete Workshop Service Repair Manual Language Language: English Format Format: Downloadable (PDF) 📖 Manual Coverage Systems Covered Systems Covered: Engine, drivetrain, transmission, suspension, steering, brakes, electrical system, fuel system, cooling system, exhaust system, chassis, bodywork, maintenance procedures, troubleshooting, diagnostic procedures. Procedures Included Procedures Included: Routine maintenance, scheduled servicing, disassembly, assembly, inspection, adjustment, repair, troubleshooting, component replacement, wiring diagrams, torque specifications, diagnostic flowcharts. Technical Depth Technical Depth: In-depth, covering from basic adjustments and fluid changes to complete engine and transmission overhauls, electrical system diagnostics, and major component repairs. Suitable for professional technicians and advanced DIY enthusiasts. 📊 Manual Specifications File Format File Format: Digital (PDF) Print Quality Print Quality: Optimized for digital viewing and printing, featuring clear text, diagrams, and illustrations. Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Primary Engine: Polaris 4-stroke, liquid-cooled, SOHC engine Engine Displacement Engine Displacement: 400cc (approx. 375cc actual) and 500cc (approx. 499cc actual) variants Bore X Stroke 400 Bore X Stroke 400: 68.5mm x 64.4mm (typical for this era) Bore X Stroke 500 Bore X Stroke 500: 94mm x 71mm (typical for this era) Compression Ratio 400 Compression Ratio 400: 10.0:1 (approx.) Compression Ratio 500 Compression Ratio 500: 9.0:1 (approx.) Horsepower 400 Horsepower 400: Estimated 25-30 HP Horsepower 500 Horsepower 500: Estimated 35-40 HP Torque 400 Torque 400: Estimated 25-30 lb-ft Torque 500 Torque 500: Estimated 35-40 lb-ft Fuel System Fuel System: Carbureted (likely Mikuni BSR series) Carburetor Size 400 Carburetor Size 400: 30mm (typical) Carburetor Size 500 Carburetor Size 500: 34mm (typical) Ignition System Ignition System: CDI (Capacitor Discharge Ignition) Cooling System Cooling System: Liquid-cooled with fan Spark Plug Type Spark Plug Type: NGK CR9EB (typical, verify with manual) 🔧 Transmission Standard Standard: Polaris Variable Transmission (PVT) with Engine Braking Optional Optional: N/A for this model year and trim Drive System Drive System: Shaft drive, AWD (All-Wheel Drive) with automatic engagement Gear Selection Gear Selection: High, Low, Neutral, Reverse, Park Clutch Type Clutch Type: Centrifugal automatic clutch with drive and driven pulleys Transmission Fluid Type Transmission Fluid Type: Polaris Synthetic 2-Cycle Oil or equivalent SAE 10W-30 API SG, JASO MA (verify with manual) 📐 Dimensions Exterior Length Exterior Length: 81.1 inches (2060 mm) Exterior Width Exterior Width: 46 inches (1168 mm) Exterior Height Exterior Height: 47.1 inches (1196 mm) Wheelbase Wheelbase: 50.5 inches (1283 mm) Ground Clearance Ground Clearance: 11.25 inches (286 mm) Cargo Rack Capacity Front Cargo Rack Capacity Front: 100 lbs (45 kg) Cargo Rack Capacity Rear Cargo Rack Capacity Rear: 200 lbs (90 kg) Towing Capacity Towing Capacity: 1500 lbs (680 kg) Dry Weight Dry Weight: Approx. 600 lbs (272 kg) (varies slightly by...