🏷️ Basic Information Identification Make: Polaris Model: Sportsman 400 / 500 Year: 2004 👋 Introduction Market Position Target Audience: Dealership mechanics, professional repair shops, and experienced ATV owners performing their own maintenance and repairs. Key Features Manual Value Proposition: Provides essential, factory-authorized information for efficient and accurate servicing, saving time and money. Technical Illustrations: Contains numerous clear pictures and detailed exploded-view illustrations for visual guidance. Organization: Organized in a convenient PDF format with advanced search and bookmarking features. 📋 Manual Details Coverage Areas Manual Type: Service and Repair Manual Language: English Format: PDF Delivery Method: Instant Download Page Count Estimated Page Count: Detailed and comprehensive, estimated to be several hundred pages covering all aspects. 📖 Manual Coverage Systems Covered Engine Mechanical: Complete engine teardown and rebuild procedures, including cylinder head, pistons, crankshaft, camshaft, valve train, lubrication system, and cooling system. Fuel System: Carburetor adjustment and overhaul, fuel pump operation, fuel lines, fuel filter replacement, and fuel tank service. Ignition System: Ignition timing, spark plugs, ignition coil testing, CDI unit diagnosis, and wiring schematics. Transmission Drivetrain: Clutch operation and adjustment, gearbox inspection and repair, drive shaft maintenance, CV joint service, and differential overhaul. Suspension Steering: Front and rear suspension component inspection, shock absorber replacement, steering linkage adjustments, wheel bearing service, and alignment procedures. Brakes: Brake caliper service, brake pad replacement, brake line inspection and replacement, master cylinder overhaul, and bleeding procedures. Electrical System: Battery testing and maintenance, starter motor operation, charging system (stator and regulator), lighting system, and comprehensive wiring diagrams. Bodywork Chassis: Frame inspection, body panel removal and installation, seat service, luggage rack mounting, and fender maintenance. Cooling System: Radiator inspection, coolant flush and refill, fan operation, thermostat testing, and hose replacement. Procedures Included Scheduled Maintenance: Detailed service intervals for oil changes, filter replacements, spark plug checks, valve adjustments, and lubrication points. Troubleshooting: Diagnostic charts and symptom-based troubleshooting guides for common performance issues, starting problems, and electrical faults. Repair Procedures: Step-by-step instructions for virtually all repair tasks, from minor adjustments to complete component overhauls. Disassembly Assembly: Exploded view illustrations clearly depicting the order of disassembly and reassembly for various components. Specifications Data: Torque specifications for all fasteners, clearances, fluid capacities, and performance data. Technical Depth Depth Of Coverage: Comprehensive, dealership-level technical information suitable for professional mechanics and experienced DIY enthusiasts. 📊 Manual Specifications File Format File Type: PDF Searchability: Fully keyword searchable Navigation: Completely bookmarked for easy navigation Compatibility: Compatible with Windows, MAC, and other PDF-enabled devices. Viewing Features: Allows zooming, printing, and easy viewing. Print Quality Quality Description: High-quality digital reprint, not a low-quality photocopy or scan. Clear text and sharp illustrations. Binding Type Binding: Not applicable (digital download) Paper Type Paper Quality: Not applicable (digital download) ⚙️ Engine Specifications Primary Engine Engine Type: 4-stroke Engine Configuration: Single-cylinder (commonly referred to as 400cc and 500cc variants, likely based on a common engine block with different bore/stroke or tuning). Displacement 400: Approximately 375cc (varies slightly by specific model variant within the 400 designation). Displacement 500: Approximately 499cc (varies slightly by specific model variant within the 500 designation). Performance Horsepower Approx 400: Typically in the range of 25-30 HP (exact figures depend on specific tuning and dynamometer testing). Horsepower Approx 500: Typically in the range of 30-35 HP (exact figures depend on specific tuning and dynamometer testing). Fuel System Carburetion: Mikuni or Keihin carburetor, specific model and size vary by engine displacement. Fuel Type: Unleaded gasoline (minimum octane rating specified in manual, typically 87 or 89). 🔧 Transmission Standard Transmission Type: Automatic (PVT - Polaris Variable Transmission) Drive System: Shaft drive with selectable 2WD/4WD and often locking front differential. Features Transmission Features: High/Low range gearing, Reverse, Park. Belt Drive Maintenance: Procedures for belt inspection, tension adjustment, and replacement of the CVT belt. 📐 Dimensions Exterior Length Approx: Approx. 81-83 inches (varies slightly by model variant). Width Approx: Approx. 46 inches (varies slightly by model variant). Height Approx: Approx. 45-48 inches (varies slightly by model variant). Weights Dry Weight Approx: Approx. 550-600 lbs (varies slightly by model variant). Ground Clearance Approx: Approx. 10-11 inches. Cargo Rack Capacity Front Approx: Approx. 50 lbs. Rack Capacity Rear Approx: Approx. 100 lbs. 🛡️ Safety Features Active Features Braking System Type: Hydraulic disc brakes, front and rear. Passive Features Lighting: Dual headlights, brake light, taillight. Ergonomics: Handlebar design, throttle and brake lever placement optimized for rider control. 💡 Technology Features Infotainment Infotainment Features: Basic instrumentation panel: speedometer, odometer, trip meter, fuel gauge, 4WD indicator, neutral indicator, oil pressure light, and engine temperature light. Driver Assistance Driver Assistance Features: Selectable 2WD/4WD system with potential for locking front differential provides enhanced traction control. 🔧 Maintenance Service Intervals Engine Oil Change: Recommended every 100 hours or 6 months, whichever comes first. Air Filter Cleaning: Inspect every 25 hours, clean or replace as needed depending on operating conditions. Replace annually....