🏷️ Basic Information Identification Make: Polaris Model: Sportsman 400/500 Year: 2004 Vehicle Type: All-Terrain Vehicle (ATV) 👋 Introduction Market Position Target Audience: Owners and technicians performing maintenance, repair, and troubleshooting on 2004 Polaris Sportsman 400 and 500 ATVs. Competitive Advantage Of Manual: Comprehensive coverage of two popular models and engine variants, offering detailed technical information essential for proper upkeep and repair. Product Value Proposition: Empowers users with the knowledge to maintain their ATVs effectively, diagnose issues, and perform repairs, saving time and money. Key Features Ease Of Use: PDF format allows for easy navigation, searching, and printing of specific sections. Completeness: Aims to provide complete documentation for all repair and maintenance aspects of the covered models. Authoritative Information: Based on factory service manual standards, providing accurate and reliable technical data. 📋 Manual Details Coverage Areas Manual Type: Repair Manual Language: English Format: PDF Download Coverage Scope: All versions of 2004 Polaris Sportsman 400 and 2004 Polaris Sportsman 500 ATVs 📖 Manual Coverage Systems Covered Engine Systems: Engine overhaul, top-end and bottom-end components, cooling system, lubrication system, fuel system, ignition system, starting system, exhaust system. Drivetrain Systems: Transmission (PVT - Polaris Variable Transmission), drive shafts, differential, final drive, clutch system (drive and driven clutches). Chassis Suspension Steering: Frame, front and rear suspension (including shocks, control arms, bushings), steering system (handlebars, tie rods, steering post, rack and pinion assembly), wheels, tires. Braking Systems: Front and rear hydraulic disc brakes, brake calipers, master cylinders, brake lines, brake pads, parking brake mechanism. Electrical Systems: Battery, charging system (stator, voltage regulator), lighting system (headlights, taillights, brake lights), ignition switch, starter motor, wiring harnesses, fuses, relays, DC accessory outlet. Fuel And Emission Controls: Carburetor (Mikuni BSR42 for 500, specific carb for 400), fuel pump, fuel lines, fuel filter, emissions control components (if applicable). Body And Trim: Body panels, racks (front and rear), fenders, seat, storage compartments. Procedures Included Routine Maintenance: Oil changes, filter replacements (oil, air), spark plug checks and replacement, drive belt inspection and replacement, chain adjustment and lubrication (if applicable), lubrication points, coolant checks and changes. Troubleshooting: Diagnostic charts for common problems (e.g., starting issues, poor performance, braking problems, electrical faults), symptom-based troubleshooting guides. Component Disassembly Reassembly: Detailed step-by-step instructions for removing, inspecting, servicing, and reinstalling all major and minor components across all systems. Torque Specifications: Precise torque values for all critical fasteners, bolts, and nuts to ensure proper assembly and prevent damage. Special Tool Requirements: Identification of specialized tools required for specific maintenance or repair procedures, with potential references to Polaris part numbers for these tools. Technical Depth Diagnostic Procedures: In-depth diagnostic procedures for electrical systems, fuel delivery, and engine performance, including identification of common failure points and testing methods. Engine Rebuild: Comprehensive guides for engine teardown, inspection of internal components (pistons, rings, cylinders, crankshaft, valves), reassembly, and break-in procedures. Transmission Overhaul: Detailed instructions for servicing the Polaris Variable Transmission (PVT), including clutch inspection, belt replacement, sheave maintenance, and gearcase service. Wiring Diagrams: Complete and detailed electrical wiring diagrams for all model variations, illustrating component connections, wire colors, and fuse locations. Specifications And Tolerances: Extensive listing of all essential technical specifications, including engine clearances, bearing tolerances, fluid capacities, and electrical system parameters. 📊 Manual Specifications File Format File Type: PDF Searchability: Likely contains searchable text for quick information retrieval. Printability: Designed to be printable for users who prefer hard copies. Resolution Quality: High-resolution images and diagrams for clarity. Binding Type Binding Method: N/A (Digital Download) Paper Type Paper Quality: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Sportsman 400 Engine Type: Single-cylinder, 4-stroke, liquid-cooled, SOHC Sportsman 400 Engine Displacement: Approximately 375cc (specific displacement may vary slightly by sub-model or internal Polaris designation) Sportsman 500 Engine Type: Single-cylinder, 4-stroke, liquid-cooled, SOHC Sportsman 500 Engine Displacement: 499cc Performance Sportsman 400 Horsepower: Estimated 28-30 HP (varies by specific model and tuning) Sportsman 500 Horsepower: Estimated 32-34 HP (varies by specific model and tuning) Fuel System Sportsman 400 Fuel Delivery: Carbureted (e.g., Mikuni BSR40 or similar, specific model dependent) Sportsman 500 Fuel Delivery: Carbureted (typically Mikuni BSR42) Fuel Type: Unleaded gasoline, 87 octane minimum. 🔧 Transmission Standard Transmission Type: Polaris Variable Transmission (PVT) with Engine Braking Gear Selection: Automatic (High, Low, Neutral, Reverse, Park) Features Drive System: Shaft Drive (typically with On-Demand AWD and 2WD options) Transmission Fluid Type: Polaris AGL Premium Synthetic Gearcase Lubricant (or equivalent) Drive Belt Part Number Example: Common belts include 3211077 or similar, exact number varies by specific model and usage. 📐 Dimensions Exterior Wheelbase: Approx. 50.5 inches (128.3 cm) Ground Clearance: Approx. 9.5 inches (24.1 cm) Weights Dry Weight: Approx. 580-630 lbs (263-286 kg) depending on model configuration. Towing Capacity: Typically 1500 lbs (680 kg) Rack Capacity Front: Approx. 100 lbs (45 kg) Rack Capacity Rear: Approx. 200 lbs (90 kg) 🛡️ Safety Features Ratings Safety Certification: Meets ANSI standards for...