Welcome to the comprehensive guide for your 2004 All-Terrain Vehicle. The series is renowned for its blend of utility and recreational capability, offering robust performance across diverse terrains. These 2004 models are characterized by their durable engineering, reliable 4-stroke engines, and advanced features like independent rear suspension and on-demand all-wheel drive, making them a trusted choice for both work and adventure. This Factory Service & Repair Manual provides detailed instructions and technical information essential for maintaining and repairing your ATV. It covers a wide range of topics, including complete engine tear-down and rebuild, maintenance schedules, troubleshooting common issues, and in-depth procedures for the electrical system, drivetrain, chassis, brakes, and fuel system. With 335 pages of expert guidance, this manual is an indispensable resource for owners and technicians seeking to ensure the optimal performance and longevity of their ATV. 🏷️ Basic Information Identification Make: Polaris Model: Sportsman 400 / 500 Year: 2004 Vehicle Type: ATV (All-Terrain Vehicle) 👋 Introduction Market Position Market Position: The Polaris Sportsman series is a highly regarded line of ATVs known for their versatility, utility, and robust performance in various terrains. The 2004 models represent a key generation for these machines, popular among recreational riders, hunters, and utility users. Competitive Analysis Competitive Analysis: Competed directly with models from brands like Arctic Cat, Yamaha, Can-Am, and Suzuki in the utility and recreational ATV segments. The Sportsman line often stood out for its comfortable ride, independent rear suspension, and range of engine options. Key Features Key Features: The 2004 Sportsman 400 and 500 models typically featured powerful 4-stroke engines, shaft drive, independent rear suspension (IRS) for a smoother ride, and often Polaris's on-demand All-Wheel Drive (AWD) system. They were designed for durability and capability in off-road conditions. 📋 Manual Details Coverage Coverage Areas: Complete tear down and rebuild, maintenance, troubleshooting, electrical system, engine, drivetrain, chassis, suspension, brakes, bodywork, fuel system, exhaust system, cooling system, steering, starting system, charging system, lighting, accessories. Page Count Page Count: 335 Manual Type Manual Type: Factory Service & Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine Systems: Engine overhaul, cylinder head, piston, connecting rods, crankshaft, camshafts, valve clearance adjustment, timing, lubrication system, cooling system, ignition system, starting system, charging system, fuel system (carburetor/EFI), air intake, exhaust. Drivetrain Systems: Transmission, primary reduction gear, clutch, drive shafts, axles, differential (if applicable), reverse gear, chain drive maintenance (if applicable), U-joints. Chassis And Suspension: Frame inspection and repair, front suspension (forks, struts, steering linkage, A-arms), rear suspension (swingarm, shocks, linkages), wheel bearings, tires, wheels, brakes (hydraulic lines, calipers, master cylinders, pads, rotors), steering system (handlebar, steering stem). Electrical Systems Electrical Systems: Wiring diagrams, battery, charging system (stator, rectifier/regulator), ignition system (CDI, coil, spark plug), lighting (headlights, taillights, auxiliary), switches, sensors, ECU (if applicable), starter motor, fuse box. Procedures Included Maintenance Procedures: Oil change schedule and specifications, filter replacement, spark plug checks and replacement, air filter cleaning/replacement, coolant flush and refill, brake fluid flush and bleed, lubrication points, tire pressure checks, battery maintenance, drive belt inspection/replacement. Repair Procedures: Complete engine rebuild (bore, piston, rings, bearings), carburetor cleaning and adjustment, fuel injection system troubleshooting, transmission overhaul, clutch service, suspension component replacement, brake caliper rebuilding, steering linkage repair, electrical component diagnosis and replacement. Troubleshooting Guidance: Diagnosing common problems such as no-start conditions, poor performance, unusual noises, electrical faults, braking issues, suspension problems. Includes error code interpretation (if applicable). Technical Depth Technical Depth: Comprehensive, covering basic user maintenance to advanced engine and transmission rebuilds. Includes detailed torque specifications, measurement tolerances, and diagnostic procedures. 📊 Manual Specifications File Attributes File Format: PDF Searchable Text: Yes Printable: Yes Save Restrictions: No restrictions on saving/burning to disc Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) Print Quality Print Quality: High-resolution, suitable for professional printing ⚙️ Engine Specifications Primary Engine 400 Engine Type 400: 4-Stroke, Single-Cylinder, SOHC (likely Liquid-Cooled) Displacement 400: Approximately 375-400cc (specifics vary by sub-model/generation, often a 375cc variant) Bore X Stroke 400: Refer to manual for exact specifications Fuel System 400: Carbureted (likely Keihin or similar, with pilot jet, main jet, mixture screw adjustments covered) Horsepower 400: Estimated 25-30 HP (refer to manual for exact figures) Torque 400: Refer to manual for specifications Primary Engine 500 Engine Type 500: 4-Stroke, Single-Cylinder, SOHC (likely Liquid-Cooled) Displacement 500: Approximately 499cc Bore X Stroke 500: Refer to manual for exact specifications Fuel System 500: Carbureted (likely dual-carburetor setup or single large bore, with pilot jet, main jet, mixture screw adjustments covered) Horsepower 500: Estimated 30-35 HP (refer to manual for exact figures) Torque 500: Refer to manual for specifications Performance Compression Ratio: Refer to manual for specifications Fuel System Fuel Type: Unleaded gasoline (Octane rating as specified in manual) Fuel Pump: Electric fuel pump (if EFI variant exists, otherwise mechanical for carbureted) Lubrication...