🏷️ 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 Standard Transmission Type: Automatic PVT (Polaris Variable Transmission) with Engine Braking Drive Modes: 2WD/4WD (On-Demand) Gear Selection: High, Low, Neutral, Reverse, Park Features Engine Braking: Standard feature providing downhill control. 📐 Dimensions Exterior Length: Approx. 81 inches (205.7 cm) Width: Approx. 46 inches (116.8 cm) Height: Approx. 45 inches (114.3 cm) Weights Dry Weight: Approx. 570 lbs (258.5 kg) Ground Clearance: Approx. 11.25 inches (28.6 cm) Cargo Rack Capacity Front: 50 lbs (22.7 kg) Rack Capacity Rear: 100 lbs (45.4 kg) Towing Towing Capacity: 1050 lbs (476 kg) Gcvwr: 1575 lbs (714 kg) 🛡️ Safety Features Ratings Atv Safety Standards: Compliant with ANSI/SVIA 1-2001 and 2005 standards. Active Features Braking System Type: Hydraulic Disc Brakes (Front and Rear) Parking Brake: Hand-operated lever engaging rear brake. Passive Features Lighting: Dual Halogen headlights, Taillight/Brake light. Warnings Operator Warnings: Manual would contain critical safety warnings regarding riding techniques, protective gear, and operational limits. 💡 Technology Features Infotainment Display Features: Basic LCD display typically showing odometer, trip meter, gear indicator, and 2WD/4WD mode. Driver Assistance Driver Assistance Systems: None (typical for...