🏷️ Basic Information Identification Make: Polaris Model: Sportsman 500 Year: 2004 Codes Vin Code Prefix: 4X4 (Specific VIN decoding may vary; consult Polaris documentation for precise year/model identification) 👋 Introduction Market Position Market Position: A definitive resource for Polaris Sportsman 400 and 500 owners seeking to perform their own maintenance and repairs, offering factory-level information at a fraction of the cost of professional shop labor. Competitive Analysis Competitive Analysis: Positions itself as the most comprehensive and cost-effective solution compared to other aftermarket manuals or official Polaris service documentation, emphasizing completeness and usability. Key Features Key Features: 335 pages of factory-level data, step-by-step instructions, exploded views, detailed electrical/wiring section, PDF format for universal access. 📋 Manual Details Coverage Areas Models Covered: All 2004 Polaris Sportsman 400 ATV, All 2004 Polaris Sportsman 500 ATV Page Count Page Count: 335 Manual Type Manual Type: Factory Service Manual / Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Systems Covered: General Information, Maintenance, Engine, Fuel System/Carburetion, Body/Steering/Suspension, Clutching, Final Drive, Transmission, Brakes, Electrical (including wiring diagrams) Procedures Included Procedures Included: Step-by-step repair instructions, maintenance procedures, troubleshooting guides, component disassembly and assembly, electrical diagnostics, wiring diagram interpretation Technical Depth Technical Depth: Comprehensive: From basic maintenance and fluid changes to advanced engine rebuilds, transmission overhauls, and detailed electrical system troubleshooting. 📊 Manual Specifications File Format File Format: PDF Print Quality Print Quality: High-resolution, suitable for printing detailed diagrams and text. Binding Type Binding Type: Not applicable (digital download), printable for 3-ring binder assembly Paper Type Paper Type: Not applicable (digital download), recommended for printing on standard printer paper ⚙️ Engine Specifications Primary Engine Engine Type 400: 4-stroke, Single-cylinder, Liquid-cooled, SOHC (Note: Specific engine designation may vary, e.g., Fuji engine variant) Engine Displacement 400: Approximately 375cc to 400cc (Exact displacement confirmation required from specific model variations) Engine Type 500: 4-stroke, Single-cylinder, Liquid-cooled, SOHC (Note: Often referred to as the 'big bore' engine) Engine Displacement 500: Approximately 499cc to 500cc Performance Horsepower Estimate 400: Typically in the 20-25 HP range (exact figures vary by tuning and altitude) Horsepower Estimate 500: Typically in the 25-30 HP range (exact figures vary by tuning and altitude) Fuel System Fuel System Type: Carbureted (Specific carburetor model and jetting detailed in manual) Fuel Type: Unleaded Gasoline (Octane rating specified in manual, typically 87 AKI) Fuel Tank Capacity: Approximately 3.2 gallons (12.1 liters) - Check specific model for exact capacity 🔧 Transmission Standard Transmission Type: Automatic (PVT - Polaris Variable Transmission) Drive System: Shaft Drive, On-Demand All-Wheel Drive (AWD) Features Transmission Features: High/Low Range, Neutral, Reverse Fluid Specifications Transmission Fluid Type: Polaris AGL Premium Synthetic Gearcase Lubricant or equivalent API GL-4 rated 80W-90 hypoid gear oil (Consult manual for specific part numbers and viscosity) 📐 Dimensions Exterior Length Overall: Approximately 81-83 inches (2057-2108 mm) - Varies slightly by model Width Overall: Approximately 46 inches (1168 mm) Height Overall: Approximately 47 inches (1194 mm) Weights Dry Weight 400: Approximately 610 lbs (277 kg) Dry Weight 500: Approximately 620 lbs (281 kg) Gvw Gross Vehicle Weight: Not explicitly stated, but always consider payload capacity limits detailed in the manual. Towing Capacity: Typically rated at 1500 lbs (680 kg) - Always verify with manual for specific model limitations. Rack Capacity Front: 200 lbs (91 kg) Rack Capacity Rear: 400 lbs (181 kg) 🛡️ Safety Features Ratings Safety Ratings: ATVs are not subject to the same crash test ratings as passenger vehicles. Safety relies on proper operation and maintenance as outlined in the manual. Active Features Active Safety Features: On-Demand AWD system for improved traction, powerful braking system. Passive Features Passive Safety Features: Integrated lighting (headlights, taillights), durable chassis construction, handguards (often standard or optional). 💡 Technology Features Infotainment Infotainment Features: Basic: Analog speedometer, odometer, fuel gauge, indicator lights. No complex infotainment systems typical of modern vehicles. Driver Assistance Driver Assistance Features: On-Demand AWD system is the primary active assistance feature for traction management. Connectivity Connectivity Features: None. Primarily mechanical and electrical systems. 🔧 Maintenance Service Intervals Oil Change Interval: Every 100 hours or annually, whichever comes first (refer to manual for precise interval and operating conditions). Spark Plug Replacement Interval: Recommended at intervals specified in the manual, typically based on hours of operation or every 1-2 years for optimal performance. Air Filter Cleaning Interval: Regular inspection and cleaning/replacement based on operating conditions, especially in dusty environments. Consult manual for frequency. Gearcase Oil Change Interval: Every 100 hours or annually (for PVT system and final drive). Fluid Specifications Engine Oil Type: Polaris PS-4 4-stroke synthetic engine oil or equivalent SAE 10W-40 motorcycle/ATV oil meeting API SG or higher specifications (Check manual for exact Polaris part number and API rating). Coolant Type: Ethylene glycol-based antifreeze mixture with distilled water (50/50 ratio recommended). Consult manual for specific type and capacity. Brake Fluid Type: DOT 4...