🏷️ Basic Information

Make:

Polaris

Model:

Sportsman 400 / 500

Year:

2004

Vehicle Type:

All-Terrain Vehicle (ATV)

Product Name:

2004 Polaris Sportsman 400 500 ATV Repair Manual Download PDF

👋 Introduction

Market Position:

Targets Polaris Sportsman 400 and 500 owners seeking professional-grade repair and maintenance information for their 2004 models. Positioned as an OEM source, emphasizing factory accuracy.

Competitive Analysis:

Competes with other aftermarket repair manuals and potentially official Polaris service resources. The key differentiator here is the convenient digital PDF format and instant download, catering to modern repair needs and mobile accessibility.

Key Features:

Instant PDF download, OEM content, comprehensive coverage of 2004 Sportsman 400/500 models, lifetime protection policy, mobile-friendly access for on-trail repairs.

📋 Manual Details

Covered Models:

2004 Polaris Sportsman 400 ATVs, 2004 Polaris Sportsman 500 ATVs

Page Count:

Not specified, but implied to be comprehensive OEM content.

Manual Type:

OEM Shop/Service/Repair Manual

Language:

English (presumed based on product description and typical manual languages)

Format:

Downloadable PDF

📖 Manual Coverage

Systems Covered:

General Information, Routine Maintenance, Engine Removal and Installation, Fuel System, Lubrication and Cooling System, Engine Specifications, Transmission, Drive Chain & Sprockets, Steering System, Shocks, Body Work, Intake & Exhaust, Electrical System, Advanced Troubleshooting

Procedures Included:

Repair, routine maintenance, parts lookup, troubleshooting, diagnostics, component removal and installation, adjustments, rebuilds.

Technical Depth:

Comprehensive, covering routine maintenance to advanced troubleshooting and repair procedures, consistent with OEM factory service information.

📊 Manual Specifications

File Format:

PDF

Print Quality:

High-resolution, suitable for printing individual pages as needed.

Binding Type:

N/A (Digital Download)

Paper Type:

N/A (Digital Download)

⚙️ Engine Specifications

Engine Type 400:

4-stroke, SOHC, 4-valve, Single Cylinder

Engine Displacement 400:

375cc (actual displacement may vary slightly by source, typically around 375.4cc)

Engine Type 500:

4-stroke, SOHC, 4-valve, Single Cylinder

Engine Displacement 500:

499cc

Horsepower 400:

Approx. 28-30 HP (varies with tuning and conditions)

Horsepower 500:

Approx. 35-38 HP (varies with tuning and conditions)

Fuel Delivery 400:

Carbureted (likely Mikuni BSR series)

Fuel Delivery 500:

Carbureted (likely Mikuni BSR series)

🔧 Transmission

Transmission Type:

Automatic (CVT - Continuously Variable Transmission) with High/Low range and Reverse.

Drive System:

On-Demand All-Wheel Drive (AWD) / 2WD selectable.

📐 Dimensions

Length Approx:

211.8 cm (83.4 in)

Width Approx:

117.5 cm (46.3 in)

Height Approx:

121.9 cm (48 in)

Dry Weight 400:

Approx. 273 kg (602 lbs)

Dry Weight 500:

Approx. 277 kg (610 lbs)

Ground Clearance Approx:

29.2 cm (11.5 in)

💡 Technology Features

Infotainment System:

Basic instrument cluster with speedometer, odometer, trip meter, tachometer, gear indicator (P-R-N-L-H), fuel gauge, and indicator lights. No advanced infotainment features.

Driver Assistance Features:

On-Demand AWD system, engine braking through CVT.

🔧 Maintenance

Initial Service:

Typically around 10-20 operating hours or 1 month for initial break-in service (oil change, filter check, general inspection).

Routine Oil Change Interval:

Every 100 operating hours or 6 months, whichever comes first (check manual for specific grade).

Air Filter Cleaning Interval:

Every 25 operating hours or more frequently in dusty conditions.

Engine Oil Type:

SAE 5W-50 Synthetic (typically, consult manual for exact specification and viscosity grades for ambient temperature ranges). Polaris branded oils often recommended.

Engine Oil Capacity:

Approx. 2.2 L (2.3 US qt) without filter, 2.4 L (2.5 US qt) with filter.

Transmission Fluid Type:

Polaris AGL Synthetic Gearcase Lubricant or equivalent API GL-4 (check manual for specific Polaris part number or equivalence).

Transmission Fluid Capacity:

Approx. 0.65 L (0.69 US qt) - fill to level plug.

Brake Fluid Type:

DOT 3 or DOT 4 (check manual for specific recommendation).

Known Issues:

Common issues can include CVT belt wear and slippage, carburetor tuning issues, electrical connector corrosion, and occasional issues with the AWD engagement system. Regular maintenance as outlined in the manual is key to mitigating these.

📚 Vehicle History

Brand Heritage:

Polaris is a long-standing manufacturer of powersports vehicles, known for its innovation and diverse product lines including ATVs, snowmobiles, and motorcycles.

Model Evolution:

The Sportsman line is Polaris's flagship ATV series, characterized by comfortable ride, capable suspension, and versatility for work and recreation. The 2004 models represent a mature iteration of this successful platform, incorporating features developed over several years.

Production Years:

The Sportsman 400 and 500 models have been in continuous production for many years, with significant updates and refinements occurring throughout their lineage.

🏆 Awards & Recognition

Recognitions:

The Polaris Sportsman series consistently receives positive reviews for its off-road capability, comfort, and durability, often cited as a benchmark in the utility ATV market.