Market Position:
The Polaris Sportsman series has historically been a dominant force in the ATV market, known for its versatility, ruggedness, and rider comfort, particularly appealing to hunters and utility users.
Competitive Analysis:
Competed against other major utility ATV manufacturers such as Can-Am (Outlander), Yamaha (Grizzly), and Honda (Rancher/Foreman) in the mid-size to large displacement utility segment.
Key Features:
Independent Rear Suspension (IRS) for improved ride quality, Polaris Variable Transmission (PVT) with engine braking, powerful engine options (400cc and 500cc), and the 'Hunter Edition' typically includes features like enhanced tires, racks, and possibly a winch or gun scabbard.
Systems Covered:
Engine, drivetrain, transmission, suspension, steering, brakes, electrical system, fuel system, cooling system, exhaust system, chassis, bodywork, maintenance procedures, troubleshooting, diagnostic procedures.
Procedures Included:
Routine maintenance, scheduled servicing, disassembly, assembly, inspection, adjustment, repair, troubleshooting, component replacement, wiring diagrams, torque specifications, diagnostic flowcharts.
Technical Depth:
In-depth, covering from basic adjustments and fluid changes to complete engine and transmission overhauls, electrical system diagnostics, and major component repairs. Suitable for professional technicians and advanced DIY enthusiasts.
Primary Engine:
Polaris 4-stroke, liquid-cooled, SOHC engine
Engine Displacement:
400cc (approx. 375cc actual) and 500cc (approx. 499cc actual) variants
Bore X Stroke 400:
68.5mm x 64.4mm (typical for this era)
Bore X Stroke 500:
94mm x 71mm (typical for this era)
Compression Ratio 400:
10.0:1 (approx.)
Compression Ratio 500:
9.0:1 (approx.)
Horsepower 400:
Estimated 25-30 HP
Horsepower 500:
Estimated 35-40 HP
Torque 400:
Estimated 25-30 lb-ft
Torque 500:
Estimated 35-40 lb-ft
Fuel System:
Carbureted (likely Mikuni BSR series)
Carburetor Size 400:
30mm (typical)
Carburetor Size 500:
34mm (typical)
Ignition System:
CDI (Capacitor Discharge Ignition)
Cooling System:
Liquid-cooled with fan
Spark Plug Type:
NGK CR9EB (typical, verify with manual)
Standard:
Polaris Variable Transmission (PVT) with Engine Braking
Optional:
N/A for this model year and trim
Drive System:
Shaft drive, AWD (All-Wheel Drive) with automatic engagement
Gear Selection:
High, Low, Neutral, Reverse, Park
Clutch Type:
Centrifugal automatic clutch with drive and driven pulleys
Transmission Fluid Type:
Polaris Synthetic 2-Cycle Oil or equivalent SAE 10W-30 API SG, JASO MA (verify with manual)
Ratings:
ATVs are not typically rated by agencies like NHTSA or IIHS; safety relies on operator adherence to safe riding practices and manufacturer recommendations.
Active Features:
Engine braking system (part of PVT), all-wheel-drive engagement, powerful hydraulic disc brakes on all wheels.
Passive Features:
Handlebar handgrips, thumb throttle with safety cover, integrated floorboards with heel guards, headlights and taillight, stoplight.
Braking System:
Hydraulic disc brakes front and rear
Service Intervals Oil Change
Service Intervals Oil Change:
Every 100 hours or annually, whichever comes first (verify with manual).
Service Intervals Air Filter
Service Intervals Air Filter:
Inspect every 50 hours, clean or replace as needed (more frequently in dusty conditions).
Service Intervals Spark Plug
Service Intervals Spark Plug:
Inspect every 100 hours, replace as needed or at recommended interval (e.g., every 1,000-2,000 hours or 1-2 years).
Service Intervals Valve Adjustment
Service Intervals Valve Adjustment:
Every 100 hours or annually (crucial for engine performance).
Fluid Specifications Engine Oil
Fluid Specifications Engine Oil:
SAE 10W-30, API SG or higher, JASO MA certified synthetic (e.g., Polaris Synthetic 4-Stroke)
Fluid Capacities Engine Oil
Fluid Capacities Engine Oil:
Approximately 1.8 quarts (1.7 L) with filter change (verify with manual).
Fluid Specifications Coolant
Fluid Specifications Coolant:
50/50 mixture of ethylene glycol antifreeze and distilled water
Fluid Specifications Brake Fluid
Fluid Specifications Brake Fluid:
DOT 4 hydraulic brake fluid
Known Issues:
Common issues for this era can include starter solenoid failure, voltage regulator issues, carburetor gumming if not run regularly, and potential wear on suspension components over time. Clutch belt wear is also a regular maintenance item.
Filter Part Numbers Oil Filter
Filter Part Numbers Oil Filter:
Polaris 3089239 or 3088034 (verify with manual)
Filter Part Numbers Air Filter
Filter Part Numbers Air Filter:
Polaris 7080003 (verify with manual)
Brand Heritage:
Polaris Industries Inc. has been a pioneer in the powersports industry since its founding in 1954, known for innovation in snowmobiles, ATVs, and UTVs.
Model Evolution:
The Sportsman line, introduced in 1993, revolutionized ATVs with its independent rear suspension (IRS) and continues to be a benchmark for comfort and utility. The 400 and 500 models were consistently popular mid-size utility options.
Production:
Manufactured by Polaris Industries in the United States (Roseau, Minnesota and Spirit Lake, Iowa).
Recognitions:
The Polaris Sportsman line has consistently received positive reviews and recognition for its ride quality, performance, and utility capabilities throughout its production history.
Ratings:
User reviews often praise its durability, comfortable ride, and capability in various terrain types. Specific industry awards for this 2004 model are not readily available but it was part of a highly successful and well-regarded product line.
Certifications:
Meets all relevant EPA and CARB emissions standards for its model year.
