The Polaris Sportsman 400 / 500, manufactured in 2004, is a versatile All-Terrain Vehicle (ATV) designed for both recreational riding and demanding utility tasks. Known for its rider-forward seating position, robust engine options available in 400cc and 500cc configurations, and capable suspension featuring Independent Front Suspension (IFS) and a swingarm rear, the Sportsman excels in various terrains. Its Variable Transmission (PVT) with engine braking enhances control, while optional On-Demand All-Wheel Drive provides superior traction. The heritage in ATV innovation is evident in the Sportsman line, which has consistently been recognized for its durability and performance in its class, making it a popular choice for farmers, hunters, and recreational enthusiasts. This comprehensive manual serves as an essential guide for the maintenance and repair of your 2004 Polaris Sportsman 400 / 500 ATV. It covers all critical aspects of the vehicle, including complete engine overhaul, transmission repair, electrical system diagnostics with detailed wiring diagrams, suspension and steering system servicing, and brake system maintenance. The manual also provides in-depth information on fuel and cooling systems, body and frame, routine maintenance procedures, and troubleshooting guides for common and potential issues. With factory-level repair and diagnostic information, rebuild specifications, and instructions for component replacement, this resource empowers owners and technicians to effectively maintain and repair the ATV, ensuring its optimal performance and longevity. 🏷️ Basic Information Identification Make: Polaris Model: Sportsman 400 / 500 Year: 2004 Vehicle Type: All-Terrain Vehicle (ATV) Codes Vin Code Vehicle: Not Applicable for ATV VIN structure Manual Part Number: Likely specific to manual publisher, not factory P/N 👋 Introduction Market Position Segment: Mid-size utility ATV Target Audience: Recreational riders, utility users, farmers, hunters Competitive Analysis Key Competitors: Honda FourTrax, Yamaha Wolverine, Kawasaki Prairie, Suzuki King Quad Unique Selling Points: Polaris's rider-forward seating, powerful engine options, and capable suspension for its class. Key Features Engine Options: Available in 400cc and 500cc configurations Drivetrain: Often available in 2WD and 4WD configurations Suspension: Independent Front Suspension (IFS), Swingarm Rear Suspension Transmission: Polaris Variable Transmission (PVT) with engine braking 📋 Manual Details Coverage Areas Engine Overhaul: Complete Transmission Repair: Complete Electrical System: Complete (wiring diagrams, component testing) Suspension And Steering: Complete Braking System: Complete Fuel System: Complete Cooling System: Complete Exhaust System: Complete Body And Frame: Complete Maintenance And Troubleshooting: Comprehensive Page Count Estimated Pages: Likely 300-500 pages (typical for factory service manuals of this era) Manual Type Type: Factory Service Manual / Repair Manual Language Language: English Format Format: Downloadable PDF 📖 Manual Coverage Systems Covered Engine Mechanical: Engine assembly, disassembly, valve train, piston/cylinder, crankshaft, camshaft, lubrication system Engine Management: Ignition system, fuel injection system (EFI), sensors, ECU operation, troubleshooting Powertrain Components: Polaris Variable Transmission (PVT), final drive, differential, drive shafts, axles Cooling System: Radiator, fan, thermostat, coolant flow, pressure testing Electrical Components: Battery, starter, alternator, lighting system, ignition switch, CDI unit, fault diagnosis Braking System Details: Hydraulic brake system, brake calipers, master cylinders, brake fluid specifications, bleeding procedures, pad/shoe replacement Suspension And Steering Components: Front and rear suspension, shocks, springs, bushings, tie rods, steering column, universal joints Frame And Chassis: Frame inspection, welding points, chassis components, mounting hardware Procedures Included Routine Maintenance: Oil changes, filter replacements, spark plug checks, air filter cleaning/replacement, lubrication points Engine Rebuild: Detailed step-by-step instructions for complete engine overhaul Transmission Overhaul: PVT system clutch inspection, belt replacement, sheave maintenance, gearcase lubrication Electrical Diagnostics: Troubleshooting electrical faults using wiring diagrams, testing components with multimeters Suspension Adjustment: Preload adjustments, alignment procedures Brake System Service: Brake pad replacement, caliper service, master cylinder rebuild, brake fluid flush Fuel System Service: Fuel pump testing, injector cleaning, fuel filter replacement Cooling System Service: Coolant flush, thermostat replacement, fan motor testing Troubleshooting Guides: Systematic approach to diagnosing common and uncommon issues Component Replacement: Instructions for replacing virtually all serviceable parts Technical Depth Depth: Comprehensive factory-level repair and diagnostic information Diagnostics: Advanced diagnostic procedures, fault codes, and troubleshooting trees Rebuild Specifications: Detailed specifications for engine and transmission rebuilds (tolerances, clearances, torque values) Wiring Diagrams: High-quality, detailed electrical wiring diagrams for all circuits Special Tools: Identification of specialized tools required for specific procedures 📊 Manual Specifications File Format Format: PDF (Portable Document Format) Searchable: Likely searchable text, enabling quick information retrieval Print Quality Quality: High resolution for clarity of text and diagrams Printable: Printable pages for easy on-site reference Binding Type Binding: Not applicable (downloadable PDF) Paper Type Paper: Not applicable (downloadable PDF) ⚙️ Engine Specifications Primary Engine Engine Type 400: 4-stroke, SOHC, 2-valve, single cylinder Engine Type 500: 4-stroke, SOHC, 2-valve, single cylinder Displacement 400: 375cc (approximate) Displacement 500: 499cc (approximate) Bore X Stroke 400: Typical: 82mm x 71.2mm (verify with manual) Bore X Stroke 500: Typical: 94mm x 90mm (verify with manual) Cooling Method: Liquid-cooled Ignition System: Electronic CDI (Capacitor Discharge Ignition) Performance Horsepower 400: Approx. 25-30 HP (estimate) Horsepower 500: Approx. 30-35 HP (estimate)...