This manual covers the 2004 Sportsman 400 and 500 All-Terrain Vehicles (ATVs). Known for their reliable 4-stroke engines, capable suspension, and user-friendly operation, these utility ATVs are designed for recreational riders, hunters, farmers, and general utility tasks. An established American powersports manufacturer, has a strong lineage in the ATV market, with the Sportsman line being a cornerstone of their offerings. The 2004 models, featuring an on-demand all-wheel-drive system and hydraulic disc brakes, provide a blend of performance and practicality for various terrains. This comprehensive workshop service repair manual, written in English, provides detailed guidance for the maintenance, repair, and troubleshooting of your 2004 Sportsman ATV. It covers all major systems, including the engine, drivetrain, chassis, and electrical components, with in-depth procedures for disassembly, assembly, diagnosis, and tuning. Key areas addressed include regular maintenance schedules, fluid specifications, and specific guidance on common wear items and potential issues. The manual's approximately 500+ pages offer extensive technical information, enabling owners and technicians to ensure optimal performance and longevity of the vehicle. 🏷️ Basic Information Identification Make: Polaris Model: Sportsman 400 / 500 Year: 2004 Vehicle Type: All-Terrain Vehicle (ATV) Codes Common Model Codes: May vary slightly by specific sub-model or region, but typically includes A04CH50/A04CH50FB/A04CH42/A04CH42FA 👋 Introduction Market Position Segment: Utility ATV Target Audience: Recreational riders, hunters, farmers, and general utility users. Competitive Analysis Key Competitors 2004: Honda FourTrax, Yamaha Grizzly, Kawasaki Prairie, Suzuki King Quad. Key Features Vehicle Strengths: Reliable engine, capable suspension, user-friendly operation, Polaris's established reputation in the ATV market. Manual Value Proposition Manual Benefit: Enables owners and technicians to perform comprehensive maintenance and repairs, extending vehicle life and ensuring optimal performance, saving on dealership service costs. 📋 Manual Details Coverage Areas Manual Coverage Scope: Comprehensive service, repair, maintenance, and troubleshooting for the 2004 Polaris Sportsman 400 and 500 ATVs. Page Count Estimated Page Count: Approximately 500+ pages (typical for a complete workshop manual of this era). Manual Type Manual Type: Workshop Service Repair Manual Language Language: English Format Format: Downloadable Digital Format (PDF) File Format: PDF (Portable Document Format) Searchability: Searchable text for quick access to specific information. Printability: Printable pages for in-shop use. 📖 Manual Coverage Systems Covered Engine Systems: Engine disassembly, assembly, diagnosis, tuning, cooling system, lubrication system, fuel system, ignition system, exhaust system. Drivetrain Systems: Transmission (PVT - Polaris Variable Transmission), drive belts, clutches (primary and secondary), final drive, drive shafts, differentials, AWD system (if equipped). Chassis Systems: Frame, suspension (front and rear), steering system, wheels, tires, brakes (hydraulic disc), bodywork, plastics, racks. Electrical Systems: Wiring diagrams, battery, charging system (stator, voltage regulator), starting system (starter motor, solenoid), lighting, ignition switch, sensors, electrical component testing. Procedures Included Maintenance Procedures: Regular scheduled maintenance, oil changes, filter replacements, spark plug replacement, battery maintenance, drive belt inspection and replacement, brake fluid flush, coolant checks and changes, lubrication points. Repair Procedures: Detailed step-by-step instructions for component removal, installation, and overhaul for all major systems. Troubleshooting Guides: Diagnostic procedures for common and uncommon faults, identifying symptoms, and recommending repair actions, including wiring diagrams for fault tracing. Technical Depth Diagnostic Capability: Advanced diagnostic procedures, including electrical testing with multimeters, component testing, and interpretation of symptoms. Rebuild Level: Complete engine and transmission rebuild procedures, including specifications for tolerances and wear limits. 📊 Manual Specifications File Format Digital Format Details: High-resolution PDF optimized for digital viewing and printing. Print Quality Image Resolution: Clear, legible diagrams, illustrations, and photographs. Binding Type Binding Type Digital: N/A (Digital file) Paper Type Paper Type Digital: N/A (Digital file) ⚙️ Engine Specifications Primary Engine Engine Type: 4-stroke, liquid-cooled, SOHC, 4-valve Sportsman 400 Engine Displacement: 375cc (approx.) Sportsman 500 Engine Displacement: 499cc (approx.) Bore X Stroke 500: 92.5 mm x 73.5 mm (approx.) Compression Ratio 500: 9.5:1 (approx.) Performance Horsepower 500: Approximately 26-30 hp (varies by specific model and tuning). Torque 500: Approximately 30-35 lb-ft (varies). Fuel System Fuel Delivery 500: Carbureted (Mikuni BSR42) Fuel Type: Unleaded gasoline, minimum 87 octane. Fuel Tank Capacity: 3.3 US gallons (12.5 liters) Lubrication System Oil Type Engine: SAE 10W-40, API SG or higher (Polaris Synthetic recommended) Oil Capacity Engine: 2.1 US quarts (2.0 liters) with filter change Cooling System Coolant Type: Ethylene glycol base antifreeze with corrosion inhibitors (Polaris recommends their brand) Ignition System Spark Plug Type 500: NGK CR7E or Champion RA8HC Spark Plug Gap 500: 0.028-0.032 inches (0.7-0.8 mm) 🔧 Transmission Standard Transmission Type: Polaris Variable Transmission (PVT) with Engine Braking (Automatic) Drive System: Shaft Drive Features Gear Selection: High, Low, Neutral, Reverse, Park All Wheel Drive: On-demand, automatic AWD system (ADC - Automatic Descent Control on some models) Fluid Specifications Transmission Oil Type: Polaris Synthetic Lubricant for PVT (or equivalent SAE 5W-50 Synthetic) Fluid Capacities Transmission Oil Capacity: 1.3 US quarts (1.2 liters) 📐 Dimensions Exterior Length: 81.5 inches (207 cm) Width: 46 inches (117 cm) Height: 45 inches (114...