Atv Segment:
Utility ATV, positioned for recreational riding and light work tasks.
Competitors 2004:
Honda FourTrax, Yamaha Kodiak, Suzuki Eiger, Can-Am Outlander (base models).
Powertrain:
Polaris's signature automatic PVT (Polaris Variable Transmission) with engine braking.
Engine Type:
Known for reliable, torquey single-cylinder engines optimized for utility.
Suspension Type:
Independent Front Suspension (IFS) and solid rear axle (typical for this model year) for a balance of comfort and durability.
Practicality:
Extremely practical for owners needing to identify and order replacement parts, perform maintenance, or understand the ATV's construction.
Systems Covered:
Engine, Drivetrain, Suspension, Steering, Braking, Electrical System, Chassis, Bodywork, Fuel System, Cooling System, Exhaust System, Accessories
Estimated Page Count:
200-300 pages (estimated based on typical ATV parts manuals of this era)
Manual Type:
Parts Catalog / Parts Manual
Engine Assembly:
Detailed breakdown of engine components including cylinder, piston, crankshaft, camshaft, valve train, timing components, and gaskets.
Drivetrain Components:
Exploded views and part numbers for transmission, differential (if applicable), drive shafts, CV joints, axles, and final drive components.
Suspension And Steering:
Comprehensive listing of parts for front and rear suspension (A-arms, shocks, bushings, ball joints), steering column, tie rods, and steering rack.
Braking System:
Detailed diagrams and part numbers for brake calipers, rotors, pads, master cylinders, brake lines, and levers/pedals.
Electrical System:
Coverage of starter motor, alternator/stator, battery, wiring harnesses, lights (headlights, taillights, brake lights), ignition system components, and switches.
Fuel System:
Parts for carburetor (or fuel injection system if applicable), fuel tank, fuel pump, fuel lines, and filters.
Cooling System:
Components for radiator, cooling fan, hoses, thermostat, and coolant reservoir.
Exhaust System:
Part numbers for exhaust pipe, muffler, heat shields, and mounting hardware.
Chassis And Frame:
Breakdown of frame components, subframes, and mounting brackets.
Bodywork And Plastics:
Diagrams and part numbers for fenders, racks, seat, handlebars, and various plastic body panels.
Part Identification:
Provides detailed exploded views with associated part numbers for every component of the ATV.
Assembly Disassembly Guidance:
Illustrative diagrams implicitly guide the order of assembly and disassembly for efficient part replacement.
Component Interchangeability:
While primarily a parts manual, diagrams can sometimes highlight similarities or differences between components used in different configurations.
Depth Of Coverage:
Highly detailed for parts identification and replacement. Focuses on the 'what' and 'where' of parts, not the 'how-to' of repair procedures, which would be found in a service manual.
Diagnostic Support:
Limited to identifying faulty components based on visual wear or damage inferred from exploded diagrams.
Replacement Procedures:
Does not provide step-by-step repair instructions but shows the order and location of parts for replacement.
Engine Type:
4-Stroke, Liquid-Cooled, SOHC
Displacement:
375cc - 400cc (approximate, specific variant may vary)
Bore X Stroke:
Typically around 83mm x 71.5mm (exact may vary by specific engine code)
Horsepower:
Approx. 20-25 HP (estimated for a 400cc class utility ATV)
Torque:
Sufficient low-end torque for trail riding and utility tasks.
Carburetor Type:
Mikuni BS36 (common for this model) or similar 36mm carburetor.
Fuel Type:
Unleaded Gasoline
Ignition System:
CDI (Capacitor Discharge Ignition)
Cooling Method:
Liquid-Cooled
Atv Safety Standards:
Compliant with ANSI/SVIA 1-2001 and 2005 standards.
Braking System Type:
Hydraulic Disc Brakes (Front and Rear)
Parking Brake:
Hand-operated lever engaging rear brake.
Lighting:
Dual Halogen headlights, Taillight/Brake light.
Operator Warnings:
Manual would contain critical safety warnings regarding riding techniques, protective gear, and operational limits.
Oil Change Interval:
Typically every 3-6 months or 50-100 hours of operation (refer to specific service manual for exact intervals).
Air Filter Maintenance:
Regular inspection and cleaning/replacement based on operating conditions (e.g., dusty environments require more frequent checks).
Spark Plug Replacement:
Recommended replacement based on mileage or hours, or as needed if fouled.
Engine Oil Type:
SAE 5W-50 or SAE 10W-40 Synthetic ATV Oil (verify specific viscosity and API service classification from an actual service manual).
Engine Oil Capacity:
Approx. 2.0-2.5 quarts (1.9-2.4 liters) with filter change.
Coolant Type:
Ethylene Glycol-based Antifreeze (50/50 mix with distilled water).
Brake Fluid Type:
DOT 3 or DOT 4 Hydraulic Brake Fluid.
Common Wear Items:
CV boots, ball joints, tie rod ends, brake pads, wheel bearings, and suspension bushings are common wear items on ATVs of this era.
Carburetor Maintenance:
Carburetors can require periodic cleaning and adjustment due to fuel quality or debris ingress.
Cooling System Checks:
Regular checks for coolant leaks and thermostat operation are important for preventing overheating.
Polaris Atv Legacy:
Polaris has a long history in the ATV market, originating from snowmobiles and pioneering many features in the ATV industry.
Sportsman Lineage:
The Sportsman line has been a core offering for Polaris, known for its comfortable ride and utility features. The 400cc class models have consistently provided a balance of power and affordability.
Manufacturing Location:
Polaris vehicles are typically manufactured in the USA (e.g., Spirit Lake, Iowa; Roseau, Minnesota).
