The 2004 Sportsman 400 and 500 represent robust All-Terrain Vehicles (ATVs) designed for utility and recreational off-road use. These models are powered by liquid-cooled, single-cylinder engines, available in approximately 400cc and 500cc displacements, paired with an Automatic On-Demand 4WD system and a PVT automatic transmission. Key features include independent front and rear suspension for enhanced comfort and capability, substantial rack capacity for hauling, and a towing capacity of up to 1,225 lbs, making them versatile workhorses. A well-established manufacturer in the powersports industry, engineered the Sportsman line for reliability and performance in demanding conditions. This comprehensive Factory Service Repair Workshop Manual provides essential information for maintaining and repairing the 2004 Sportsman 400 and 500 ATVs. It covers a wide range of systems, including detailed procedures for engine and powertrain, chassis and suspension, brakes, and the electrical system. The manual outlines routine maintenance tasks, troubleshooting guides for common issues, and instructions for major repairs. It also specifies required special tools and includes technical specifications, torque values, and diagnostic flowcharts, making it an indispensable resource for owners, mechanics, and technicians seeking to ensure the optimal performance and longevity of their vehicles. 🏷️ Basic Information Identification Make: Polaris Model: Sportsman 400 / 500 Year: 2004 👋 Introduction Market Position Category: All-Terrain Vehicle (ATV) / Utility Quad Target Audience: Owners, mechanics, and service departments for Polaris Sportsman 400 and 500 ATVs. Competitive Analysis Competitors 2004: Honda FourTrax, Yamaha Kodiak, Suzuki King Quad, Arctic Cat 400/500. Key Features Vehicle Powertrain Options: Available in 400cc and 500cc engine configurations, typically single-cylinder, liquid-cooled. Drivetrain: Selectable 2WD/4WD, often with Polaris's Automatic On-Demand 4WD system. Suspension: Independent front and rear suspension for comfortable and capable off-road riding. Key Features Manual Value Proposition: Provides complete factory-level repair and maintenance procedures, essential for preserving vehicle longevity and performance. 📋 Manual Details Coverage Areas Primary Coverage: 2004 Polaris Sportsman 400 and 500 ATV Models Page Count Estimated Page Count: Approximately 350-450 pages (typical for this era of detailed factory manuals) Manual Type Type: Factory Service Repair Workshop Manual Language Language: English Format Format: PDF (Downloadable) 📖 Manual Coverage Systems Covered Engine And Powertrain: Engine disassembly/assembly, fuel system, cooling system, ignition system, exhaust system, transmission, drive shafts, differentials, clutch systems. Chassis And Suspension: Frame, front suspension (A-arms, shocks, ball joints), rear suspension (swingarm, shocks, linkage), steering system, wheel bearings. Brakes: Hydraulic brake system, front and rear calipers, brake lines, master cylinders, brake pads, rotors, bleeding procedures. Electrical System: Wiring diagrams, battery, starter, alternator, lighting, ignition switch, fuses, relays, electronic control units (ECUs), diagnostic connectors. Body And Trim: Body panels, fenders, seat, handlebars, footrests, storage compartments, decals. Procedures Included Routine Maintenance: Oil changes, filter replacements, spark plug inspection/replacement, air filter cleaning/replacement, chain adjustment (if applicable), greasing points. Troubleshooting: Diagnostic procedures for common problems, symptom-based troubleshooting charts, electrical diagnostics. Major Repairs: Engine rebuilds, transmission overhauls, suspension component replacement, brake system repairs, electrical component replacement. Special Tools: Identification and usage of specialized tools required for specific procedures. Technical Depth Depth: Comprehensive factory-level repair information, suitable for professional technicians and experienced DIY mechanics. Includes detailed exploded views, torque specifications, and diagnostic flowcharts. 📊 Manual Specifications File Format File Type: PDF Searchability: Likely text-searchable (if originally digitized from a source document with OCR). Print Quality Quality: High-resolution scans, optimized for clear viewing and printing of diagrams and text. Binding Type Binding: N/A (Digital PDF download) Paper Type Paper: N/A (Digital PDF download) ⚙️ Engine Specifications Primary Engine Engine Type 400: 4-stroke, SOHC, Single Cylinder (approx. 375cc - 400cc) Engine Type 500: 4-stroke, SOHC, Single Cylinder (approx. 499cc - 500cc) Cooling System: Liquid-Cooled Performance Horsepower 400: Estimated 22-28 HP (varies slightly by sub-model/tuning) Horsepower 500: Estimated 28-34 HP (varies slightly by sub-model/tuning) Fuel System Carburetor Type 400: Mikuni BS34 or similar (typical) Carburetor Type 500: Mikuni BSR42 or similar (typical) Fuel Type: Unleaded Gasoline Ignition System Ignition Type: CDI (Capacitor Discharge Ignition) Engine Oil Oil Specification: SAE 5W-50 API SG or higher (check manual for exact specification, often a motorcycle specific oil) Oil Capacity: Approx. 2.0-2.5 Liters (check manual for exact capacity with filter change) 🔧 Transmission Standard Transmission Type: Automatic PVT (Polaris Variable Transmission) with engine braking Gear Selection: High, Low, Neutral, Reverse Features Drive System: Shaft Drive (2WD/4WD) Final Drive: Gear reduction (front and rear) Fluid Specification Transmission Fluid: Polaris Variable Transmission Fluid (PVT Fluid) or equivalent SAE 5W-50 synthetic (check manual for precise specification and alternatives) 📐 Dimensions Exterior Length: Approx. 83 inches (210.8 cm) Width: Approx. 46 inches (116.8 cm) Height: Approx. 47 inches (119.4 cm) to handlebars Weights Dry Weight: Approx. 575 lbs (261 kg) to 600 lbs (272 kg) depending on exact model Ground Clearance: Approx. 10.5 inches (26.7 cm) Cargo Front Rack Capacity: Approx. 90 lbs (41 kg) Rear Rack Capacity: Approx. 170 lbs (77 kg) Towing Towing Capacity: Approx. 1,225 lbs...