Target Audience:
Recreational riders, hunters, farmers, and general utility users.
Key Competitors 2004:
Honda FourTrax, Yamaha Grizzly, Kawasaki Prairie, Suzuki King Quad.
Vehicle Strengths:
Reliable engine, capable suspension, user-friendly operation, Polaris's established reputation in the ATV market.
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 Coverage Scope:
Comprehensive service, repair, maintenance, and troubleshooting for the 2004 Polaris Sportsman 400 and 500 ATVs.
Estimated Page Count:
Approximately 500+ pages (typical for a complete workshop manual of this era).
Manual Type:
Workshop Service Repair Manual
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.
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.
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.
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.
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.)
Horsepower 500:
Approximately 26-30 hp (varies by specific model and tuning).
Torque 500:
Approximately 30-35 lb-ft (varies).
Fuel Delivery 500:
Carbureted (Mikuni BSR42)
Fuel Type:
Unleaded gasoline, minimum 87 octane.
Fuel Tank Capacity:
3.3 US gallons (12.5 liters)
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
Coolant Type:
Ethylene glycol base antifreeze with corrosion inhibitors (Polaris recommends their brand)
Spark Plug Type 500:
NGK CR7E or Champion RA8HC
Spark Plug Gap 500:
0.028-0.032 inches (0.7-0.8 mm)
Transmission Type:
Polaris Variable Transmission (PVT) with Engine Braking (Automatic)
Drive System:
Shaft Drive
Gear Selection:
High, Low, Neutral, Reverse, Park
All Wheel Drive:
On-demand, automatic AWD system (ADC - Automatic Descent Control on some models)
Transmission Oil Type:
Polaris Synthetic Lubricant for PVT (or equivalent SAE 5W-50 Synthetic)
Transmission Oil Capacity:
1.3 US quarts (1.2 liters)
Atv Safety Standards:
Meets ANSI standards for Class ATVs (recreational use).
Braking System:
Hydraulic disc brakes on all four wheels, with parking brake.
Engine Braking:
Integral to the PVT system for downhill control.
Handlebars:
Ergonomically designed handlebars with comfortable grips.
Footwells:
Wide, serrated footwells with heel guards for secure footing.
Lighting:
Dual headlights, taillight/brake light.
Infotainment Features:
Basic instrumentation (speedometer, odometer, fuel gauge, indicator lights). No advanced infotainment systems.
Driver Assistance Systems:
On-Demand All-Wheel Drive, Automatic Descent Control (on some models).
Connectivity Features:
N/A (No modern connectivity features like Bluetooth or smartphone integration).
First Service:
20 hours or 100 miles (160 km)
Regular Oil Change:
Every 100 hours or 1000 miles (1600 km), or annually.
Air Filter Cleaning:
Every 50 hours, or more frequently in dusty conditions.
Spark Plug Replacement:
Every 100 hours or annually.
Brake Fluid Type:
DOT 3 or DOT 4 hydraulic brake fluid.
Coolant Capacity:
1.9 US quarts (1.8 liters)
Common Wear Items:
Drive belts (PVT belt), suspension bushings, ball joints, tie rod ends, wheel bearings, brake pads.
Potential Electrical Issues:
Intermittent electrical connections, stator failures, voltage regulator issues (check wiring and connections).
Pvt Belt Maintenance:
Regular inspection for wear, cracks, or fraying is critical for proper operation and to prevent catastrophic failure.
Polaris Atv History:
Polaris is a long-standing American manufacturer with a rich history in powersports, particularly known for its pioneering role in the ATV market since the 1980s.
Sportsman Lineage:
The Sportsman line has been a cornerstone of Polaris's ATV offerings, consistently updated with new features and technologies. The 400 and 500 models represent popular mid-range utility ATVs.
Manufacturing Origin:
Primarily manufactured in the United States by Polaris Inc.
