🏷️ Basic Information Identification Make: Polaris Model: Sportsman 400 Year: 2004 Model Codes Covered: A04CH42AQ, A04CH42AT, A04CH42AV, A04CH42AR, A04CH42AS Product Type: Parts Manual Format: PDF Download 👋 Introduction Market Position Atv Segment: Mid-size utility ATV, known for its balance of capability and maneuverability. Competitive Analysis Key Competitors 2004: Honda FourTrax Foreman 400, Yamaha Kodiak 400, Suzuki Vinson 500 (indirectly due to displacement differences, but market segment overlap). Key Features Vehicle Design Philosophy: Reliable design, simple construction, and ease of repair for home mechanics. Key Features Manual Utility: Essential tool for DIY maintenance, repair, and parts sourcing. Benefit To Owner: Empowers owners to perform routine maintenance and repairs, saving costs and extending vehicle life. 📋 Manual Details Coverage Areas Primary Coverage: All components and assemblies for the 2004 Polaris Sportsman 400 ATV. Specific Assemblies Covered: Front cab, rear cab and seat, rear rack mounting, front rack and bumper mounting, engine mounting, cooling system, exhaust system, fuel tank, oil tank, air box, front drive, front tightener, front strut, CV joint – BTB, front wheel, front brake, controls (throttle, master cylinder, brake line), steering post, handlebar and headlight pod, A-arm/strut mounting, center tightener, swing arm/shock mounting, drive clutch, driven clutch, clutch cover, gearcase/brake and chain cover mounting, rear brake, rear wheel drive, electrical/taillight, gearcase, gear selector, piston and crankshaft, crankcase and cylinder, recoil starter, carburetor, oil pump, magneto, starting motor, tool kit. Page Count Total Pages: 59 Manual Type Type: Parts Manual with Exploded Diagrams and Part Number Lists Language Language: English Format Digital Format: PDF Printable Options: Allows printing of specific sections only. 📖 Manual Coverage Systems Covered Powertrain: Engine (piston, crankshaft, crankcase, cylinder, oil pump, magneto, recoil starter, carburetor), clutch system (drive clutch, driven clutch), gearcase, rear wheel drive. Chassis And Suspension: Front drive, front tightener, front strut, CV joints, front wheel, front brake, A-arm/strut mounting, center tightener, swing arm/shock mounting, rear brake, rear wheel drive. Body And Controls: Front cab, rear cab and seat, rear rack mounting, front rack and bumper mounting, engine mounting, cooling system, exhaust system, fuel tank, oil tank, air box, controls (throttle assembly, cables, master cylinder, brake lines), steering post, handlebar, headlight pod, clutch cover, gear selector. Electrical: Electrical system components including taillight and headlight pod. Procedures Included Part Identification: Detailed exploded diagrams for precise identification of all ATV components. Part Ordering: Comprehensive part number listings for all components, facilitating efficient ordering. Assembly Disassembly: Visual guidance through exploded views aids in understanding component relationships for assembly and disassembly. Technical Depth Depth: Comprehensive for parts identification and replacement, supporting DIY maintenance and repair. 📊 Manual Specifications File Format File Type: Portable Document Format (PDF) Searchability: Likely text-searchable within the PDF, enabling quick location of specific part numbers or descriptions. Print Quality Print Capability: High resolution, allowing for clear printing of diagrams and text. Binding Type Binding: N/A (Digital PDF Download) Paper Type Recommended Paper: Standard copier paper for printing specific pages. ⚙️ Engine Specifications Primary Engine Engine Type: Single-cylinder, 4-stroke Engine Displacement: Approximately 375cc - 400cc (exact displacement may vary slightly by specific sub-model, typical for this era's Polaris 400 class). Cooling System: Liquid-cooled Performance Horsepower Estimated: Around 24-28 HP (typical for this class of engine at the time). Torque Estimated: Around 25-28 lb-ft (estimated). Fuel System Fuel Delivery: Carburetor Fuel Type: Unleaded gasoline (typically 87 octane). Lubrication Oil Type Specification: API SG or higher, SAE 10W-40 motorcycle-specific or ATV oil recommended. Manual would list exact Polaris specification. Oil Capacity: Approx. 2.0-2.5 quarts (refer to manual for exact capacity). 🔧 Transmission Standard Transmission Type: Automatic (CVT - Continuously Variable Transmission) Drive System: On-Demand All-Wheel Drive (AWD) with 2WD/AWD selection. Features Gear Selection: Automatic with High/Low range and Reverse. Clutch Type: High-performance CVT drive and driven clutches. Fluid Specification Gearcase Oil Type: Polaris Demand Drive Fluid or equivalent SAE 80W-90 gear oil (refer to manual for specific Polaris part number or specification). 📐 Dimensions Exterior Length: Approx. 81 inches (refer to specific sub-model data). Width: Approx. 46 inches (refer to specific sub-model data). Height: Approx. 47 inches (refer to specific sub-model data). Weights Dry Weight: Approx. 630 lbs (refer to specific sub-model data). Towing Capacity: 650 lbs Rack Capacity Front: 100 lbs Rack Capacity Rear: 200 lbs 🛡️ Safety Features Ratings Atv Safety Standards: Complies with ANSI standards for All-Terrain Vehicles. Active Features Braking System: Hydraulic disc brakes on all four wheels, foot-operated rear brake, handlebar-operated front brakes. Throttle Control: Thumb-activated throttle lever. Passive Features Lighting: Dual headlights, taillight with brake light. Seatbelt Provision: N/A (ATVs typically do not have seatbelts; rider use of helmet and protective gear is paramount). 💡 Technology Features Infotainment Infotainment Features: N/A (Utility ATV focused on function, not typically equipped with infotainment systems). Driver Assistance Atv Assistance Features: On-Demand AWD system provides enhanced traction and stability. Connectivity Connectivity Features: N/A 🔧 Maintenance Service...