This comprehensive parts manual covers the 2004 Polaris Sportsman 500 ATV, specifically models A04CH50AA, A04CH50AC, A04CH50AE, and A04CH50AG. It provides detailed information and exploded diagrams for every component of your ATV, making it an invaluable resource for both routine maintenance and repairs.

The manual includes sections covering the following areas:

* **Specifications:** Essential details about your ATV's dimensions, weight, and other technical specifications.
* **Front Cab, Rear Cab, and Seat:** Detailed information on the ATV's cab components, including the seat, rear rack mounting, and decals.
* **Front Rack and Bumper Mounting:** Diagrams and part numbers for the front rack and bumper assembly.
* **Engine Mounting:** Detailed illustrations of the engine mounting system, aiding in engine removal and installation.
* **Cooling System:** Complete information on the ATV's cooling system components, including the radiator, hoses, and fan.
* **Exhaust System:** Exploded diagrams of the exhaust system components, including the muffler and exhaust pipe.
* **Fuel Tank and Oil Tank:** Detailed information on the fuel and oil tanks, including diagrams of the mounting and components.
* **Air Box:** Information on the air filter assembly and its components.
* **Front Drive, Front Tightener, and Front Strut:** Detailed information on the front drive system, including the axle, CV joints, and strut assembly.
* **Front Wheel and Front Brake:** Exploded diagrams and part numbers for the front wheel, brake caliper, and rotor.
* **Controls:** Information on the throttle assembly, master cylinder, and brake line.
* **Steering Post, Handlebar, and Headlight Pod:** Detailed diagrams of the steering components, including the handlebar, steering stem, and headlight assembly.
* **A-Arm/Strut Mounting:** Information on the A-arm and strut mounting system for the front suspension.
* **Center Tightener:** Detailed information on the center tightener assembly for the front suspension.
* **Swing Arm/Shock Mounting:** Detailed drawings of the rear swing arm and shock absorber assembly.
* **Drive Clutch and Driven Clutch:** Information on the drive and driven clutches, which are crucial for power transmission.
* **Clutch Cover:** Exploded diagrams of the clutch cover and its components.
* **Gearcase/Brake and Chain Cover Mounting:** Detailed illustrations of the gearcase, brake, and chain cover assembly.
* **Rear Brake and Rear Wheel Drive:** Information on the rear brake system and drive components, including the axle, CV joints, and wheel assembly.
* **Electrical/Taillight:** Detailed diagrams of the electrical system and taillight assembly.
* **Gearcase:** Complete information on the gearcase, including the internal components and mounting details.
* **Gear Selector:** Detailed explanation of the gear selector mechanism and its components.
* **Piston and Crankshaft:** Exploded diagrams of the piston and crankshaft assembly, essential for engine operation.
* **Crankcase and Cylinder:** Complete information on the crankcase and cylinder assembly, including the cylinder head and valve train.
* **Recoil Starter:** Details on the recoil starter system, used for starting the engine.
* **Carburetor:** Detailed information on the carburetor, responsible for fuel delivery and mixture.
* **Oil Pump:** Information on the oil pump, used for lubricating the engine.
* **Magneto:** Detailed drawings and information on the magneto, which generates electrical power for the ignition system.
* **Starting Motor:** Information on the starter motor, used to crank the engine for starting.
* **Tool Kit:** A list of tools included with the ATV.
* **Part Number Index:** A complete index of all parts included in the manual.

With this comprehensive parts manual, you'll be equipped to tackle any maintenance or repair task on your 2004 Polaris Sportsman 500 ATV with confidence.

The 2004 Polaris Sportsman 500 is a versatile and capable ATV designed for a wide range of recreational and utility applications. It boasts a powerful 499cc, liquid-cooled, single-cylinder engine that delivers ample power for tackling challenging terrain, pulling heavy loads, and enjoying spirited off-road adventures. This ATV features an advanced independent front and rear suspension system with a generous amount of travel, providing a smooth and comfortable ride even over rough surfaces. The Sportsman 500 also benefits from a robust frame and long travel suspension, ensuring durability and stability on demanding trails. With its all-wheel drive system and selectable 2WD/4WD capability, it offers excellent traction and control in various conditions. Its large cargo box and towing capacity make it ideal for hauling gear, supplies, or even small trailers.

The Sportsman 500 is known for its user-friendly design and intuitive controls. The ergonomically designed handlebars, comfortable seat, and easy-to-reach controls allow for a relaxed and enjoyable riding experience. This ATV is also equipped with features that enhance rider safety and convenience, including a standard handlebar-mounted headlight, a clear digital instrument cluster, and a robust disc brake system. The 2004 Polaris Sportsman 500 is a reliable and versatile ATV that can handle a wide range of tasks with ease. Its powerful engine, comfortable ride, and durable construction make it an excellent choice for both experienced riders and newcomers to the ATV world. Whether you're exploring the trails, hauling supplies, or simply enjoying a leisurely ride, the Sportsman 500 offers a satisfying and capable experience.