🏷️ Basic Information Identification Make: Polaris Model: Sportsman 400 / 500 Year: 2004 Vehicle Type: All-Terrain Vehicle (ATV) Codes Vin Code Vehicle: Not Applicable for ATV VIN structure Manual Part Number: Likely specific to manual publisher, not factory P/N 👋 Introduction Market Position Segment: Mid-size utility ATV Target Audience: Recreational riders, utility users, farmers, hunters Competitive Analysis Key Competitors: Honda FourTrax, Yamaha Wolverine, Kawasaki Prairie, Suzuki King Quad Unique Selling Points: Polaris's rider-forward seating, powerful engine options, and capable suspension for its class. Key Features Engine Options: Available in 400cc and 500cc configurations Drivetrain: Often available in 2WD and 4WD configurations Suspension: Independent Front Suspension (IFS), Swingarm Rear Suspension Transmission: Polaris Variable Transmission (PVT) with engine braking 📋 Manual Details Coverage Areas Engine Overhaul: Complete Transmission Repair: Complete Electrical System: Complete (wiring diagrams, component testing) Suspension And Steering: Complete Braking System: Complete Fuel System: Complete Cooling System: Complete Exhaust System: Complete Body And Frame: Complete Maintenance And Troubleshooting: Comprehensive Page Count Estimated Pages: Likely 300-500 pages (typical for factory service manuals of this era) Manual Type Type: Factory Service Manual / Repair Manual Language Language: English Format Format: Downloadable PDF 📖 Manual Coverage Systems Covered Engine Mechanical: Engine assembly, disassembly, valve train, piston/cylinder, crankshaft, camshaft, lubrication system Engine Management: Ignition system, fuel injection system (EFI), sensors, ECU operation, troubleshooting Powertrain Components: Polaris Variable Transmission (PVT), final drive, differential, drive shafts, axles Cooling System: Radiator, fan, thermostat, coolant flow, pressure testing Electrical Components: Battery, starter, alternator, lighting system, ignition switch, CDI unit, fault diagnosis Braking System Details: Hydraulic brake system, brake calipers, master cylinders, brake fluid specifications, bleeding procedures, pad/shoe replacement Suspension And Steering Components: Front and rear suspension, shocks, springs, bushings, tie rods, steering column, universal joints Frame And Chassis: Frame inspection, welding points, chassis components, mounting hardware Procedures Included Routine Maintenance: Oil changes, filter replacements, spark plug checks, air filter cleaning/replacement, lubrication points Engine Rebuild: Detailed step-by-step instructions for complete engine overhaul Transmission Overhaul: PVT system clutch inspection, belt replacement, sheave maintenance, gearcase lubrication Electrical Diagnostics: Troubleshooting electrical faults using wiring diagrams, testing components with multimeters Suspension Adjustment: Preload adjustments, alignment procedures Brake System Service: Brake pad replacement, caliper service, master cylinder rebuild, brake fluid flush Fuel System Service: Fuel pump testing, injector cleaning, fuel filter replacement Cooling System Service: Coolant flush, thermostat replacement, fan motor testing Troubleshooting Guides: Systematic approach to diagnosing common and uncommon issues Component Replacement: Instructions for replacing virtually all serviceable parts Technical Depth Depth: Comprehensive factory-level repair and diagnostic information Diagnostics: Advanced diagnostic procedures, fault codes, and troubleshooting trees Rebuild Specifications: Detailed specifications for engine and transmission rebuilds (tolerances, clearances, torque values) Wiring Diagrams: High-quality, detailed electrical wiring diagrams for all circuits Special Tools: Identification of specialized tools required for specific procedures 📊 Manual Specifications File Format Format: PDF (Portable Document Format) Searchable: Likely searchable text, enabling quick information retrieval Print Quality Quality: High resolution for clarity of text and diagrams Printable: Printable pages for easy on-site reference Binding Type Binding: Not applicable (downloadable PDF) Paper Type Paper: Not applicable (downloadable PDF) ⚙️ Engine Specifications Primary Engine Engine Type 400: 4-stroke, SOHC, 2-valve, single cylinder Engine Type 500: 4-stroke, SOHC, 2-valve, single cylinder Displacement 400: 375cc (approximate) Displacement 500: 499cc (approximate) Bore X Stroke 400: Typical: 82mm x 71.2mm (verify with manual) Bore X Stroke 500: Typical: 94mm x 90mm (verify with manual) Cooling Method: Liquid-cooled Ignition System: Electronic CDI (Capacitor Discharge Ignition) Performance Horsepower 400: Approx. 25-30 HP (estimate) Horsepower 500: Approx. 30-35 HP (estimate) Torque: Torque figures vary by engine size, detailed in manual Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) or Carbureted (depending on specific sub-model) Fuel Type: Unleaded gasoline (87 octane or higher) Fuel Tank Capacity: Typically 3.4 gallons (12.9 L) 🔧 Transmission Standard Type: Polaris Variable Transmission (PVT) Drive System: Automatic CVT with engine braking Gear Selection: High, Low, Neutral, Reverse, Park Final Drive: Shaft drive with enclosed gearcase Optional Optional Drivetrain: 2WD or On-Demand AWD (All-Wheel Drive) Features Engine Braking: Standard feature for downhill control 📐 Dimensions Exterior Length: Approx. 81.5 inches (207 cm) Width: Approx. 46 inches (116.8 cm) Height: Approx. 48 inches (121.9 cm) Wheelbase: Approx. 50.5 inches (128.3 cm) Ground Clearance: Approx. 10.5 inches (26.7 cm) Cargo Front Rack Capacity: 200 lbs (90.7 kg) Rear Rack Capacity: 400 lbs (181.4 kg) Weights Dry Weight: Approx. 575-620 lbs (260.8-281.2 kg) depending on 2WD/4WD Towing Capacity: 1500 lbs (680.4 kg) Gcvw: Not specified, but typically Gross Combined Vehicle Weight includes vehicle and trailer. 🛡️ Safety Features Ratings Atv Safety Standards: Meets ANSI/SVIA 1-2001 and SAE J2570 standards Active Features Engine Braking: Provides control on descents On Demand AWD: Engages front wheels when rear wheels lose traction (on applicable models) Passive Features Handlebars: Ergonomically designed for rider control Footwells: Provide protection and grip Lighting: Dual headlights, brake...