The 2004 Sportsman 400 is a capable utility ATV designed for recreational riding and light work tasks. Known for its reliable, torquey single-cylinder engine, this model features signature automatic PVT (Polaris Variable Transmission) with engine braking, providing smooth power delivery and control. Its Independent Front Suspension (IFS) and solid rear axle offer a balance of comfort and durability, making it a practical choice for various terrains. The brand has a strong heritage in the ATV market, and the Sportsman line has consistently been recognized for its comfort, utility, and value. This comprehensive parts manual serves as an essential resource for owners and technicians maintaining the 2004 Sportsman 400. It provides detailed exploded views and part numbers for all major systems, including the engine, drivetrain, suspension, steering, braking, electrical system, chassis, and bodywork. While it focuses on parts identification and component layout rather than step-by-step repair procedures, the clear diagrams and extensive part listings are invaluable for accurate part ordering, assembly understanding, and general maintenance. The manual is presented in English and is available in a digital format. 🏷️ Basic Information Identification Make: Polaris Model: Sportsman 400 Year: 2004 Product Type: Parts Manual Product Format: Downloadable PDF 👋 Introduction Market Position Atv Segment: Utility ATV, positioned for recreational riding and light work tasks. Competitive Analysis Competitors 2004: Honda FourTrax, Yamaha Kodiak, Suzuki Eiger, Can-Am Outlander (base models). Key Features Powertrain: Polaris's signature automatic PVT (Polaris Variable Transmission) with engine braking. Engine Type: Known for reliable, torquey single-cylinder engines optimized for utility. Suspension Type: Independent Front Suspension (IFS) and solid rear axle (typical for this model year) for a balance of comfort and durability. Manual Value Proposition Practicality: Extremely practical for owners needing to identify and order replacement parts, perform maintenance, or understand the ATV's construction. 📋 Manual Details Coverage Areas Systems Covered: Engine, Drivetrain, Suspension, Steering, Braking, Electrical System, Chassis, Bodywork, Fuel System, Cooling System, Exhaust System, Accessories Page Count Estimated Page Count: 200-300 pages (estimated based on typical ATV parts manuals of this era) Manual Type Manual Type: Parts Catalog / Parts Manual Language Language: English Format File Format: PDF 📖 Manual Coverage Systems Covered Engine Assembly: Detailed breakdown of engine components including cylinder, piston, crankshaft, camshaft, valve train, timing components, and gaskets. Drivetrain Components: Exploded views and part numbers for transmission, differential (if applicable), drive shafts, CV joints, axles, and final drive components. Suspension And Steering: Comprehensive listing of parts for front and rear suspension (A-arms, shocks, bushings, ball joints), steering column, tie rods, and steering rack. Braking System: Detailed diagrams and part numbers for brake calipers, rotors, pads, master cylinders, brake lines, and levers/pedals. Electrical System: Coverage of starter motor, alternator/stator, battery, wiring harnesses, lights (headlights, taillights, brake lights), ignition system components, and switches. Fuel System: Parts for carburetor (or fuel injection system if applicable), fuel tank, fuel pump, fuel lines, and filters. Cooling System: Components for radiator, cooling fan, hoses, thermostat, and coolant reservoir. Exhaust System: Part numbers for exhaust pipe, muffler, heat shields, and mounting hardware. Chassis And Frame: Breakdown of frame components, subframes, and mounting brackets. Bodywork And Plastics: Diagrams and part numbers for fenders, racks, seat, handlebars, and various plastic body panels. Procedures Included Part Identification: Provides detailed exploded views with associated part numbers for every component of the ATV. Assembly Disassembly Guidance: Illustrative diagrams implicitly guide the order of assembly and disassembly for efficient part replacement. Component Interchangeability: While primarily a parts manual, diagrams can sometimes highlight similarities or differences between components used in different configurations. Technical Depth Depth Of Coverage: Highly detailed for parts identification and replacement. Focuses on the 'what' and 'where' of parts, not the 'how-to' of repair procedures, which would be found in a service manual. Diagnostic Support: Limited to identifying faulty components based on visual wear or damage inferred from exploded diagrams. Replacement Procedures: Does not provide step-by-step repair instructions but shows the order and location of parts for replacement. 📊 Manual Specifications File Format Digital Format: PDF (Portable Document Format) Print Quality Graphic Quality: High-quality diagrams and illustrations ensuring clarity for part identification. Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) Searchability Text Searchability: Typically PDF format allows for text search of part numbers and descriptions if the OCR layer is present and accurate. ⚙️ Engine Specifications Primary Engine Engine Type: 4-Stroke, Liquid-Cooled, SOHC Displacement: 375cc - 400cc (approximate, specific variant may vary) Bore X Stroke: Typically around 83mm x 71.5mm (exact may vary by specific engine code) Performance Horsepower: Approx. 20-25 HP (estimated for a 400cc class utility ATV) Torque: Sufficient low-end torque for trail riding and utility tasks. Fuel System Carburetor Type: Mikuni BS36 (common for this model) or similar 36mm carburetor. Fuel Type: Unleaded Gasoline Ignition Ignition System: CDI (Capacitor Discharge Ignition) Cooling Cooling Method: Liquid-Cooled 🔧 Transmission...