🏷️ Basic Information

Make:

Polaris

Model:

Sportsman 400

Year:

2004

Model Codes Covered:

A04CH42AQ, A04CH42AT, A04CH42AV, A04CH42AR, A04CH42AS

Product Type:

Parts Manual

Format:

PDF Download

👋 Introduction

Atv Segment:

Mid-size utility ATV, known for its balance of capability and maneuverability.

Key Competitors 2004:

Honda FourTrax Foreman 400, Yamaha Kodiak 400, Suzuki Vinson 500 (indirectly due to displacement differences, but market segment overlap).

Design Philosophy:

Reliable design, simple construction, and ease of repair for home mechanics.

Utility:

Essential tool for DIY maintenance, repair, and parts sourcing.

Benefit To Owner:

Empowers owners to perform routine maintenance and repairs, saving costs and extending vehicle life.

📋 Manual Details

Primary Coverage:

All components and assemblies for the 2004 Polaris Sportsman 400 ATV.

Specific Assemblies Covered:

Front cab, rear cab and seat, rear rack mounting, front rack and bumper mounting, engine mounting, cooling system, exhaust system, fuel tank, oil tank, air box, front drive, front tightener, front strut, CV joint – BTB, front wheel, front brake, controls (throttle, master cylinder, brake line), steering post, handlebar and headlight pod, A-arm/strut mounting, center tightener, swing arm/shock mounting, drive clutch, driven clutch, clutch cover, gearcase/brake and chain cover mounting, rear brake, rear wheel drive, electrical/taillight, gearcase, gear selector, piston and crankshaft, crankcase and cylinder, recoil starter, carburetor, oil pump, magneto, starting motor, tool kit.

Total Pages:

59

Type:

Parts Manual with Exploded Diagrams and Part Number Lists

Language:

English

Digital Format:

PDF

Printable Options:

Allows printing of specific sections only.

📖 Manual Coverage

Powertrain:

Engine (piston, crankshaft, crankcase, cylinder, oil pump, magneto, recoil starter, carburetor), clutch system (drive clutch, driven clutch), gearcase, rear wheel drive.

Chassis And Suspension:

Front drive, front tightener, front strut, CV joints, front wheel, front brake, A-arm/strut mounting, center tightener, swing arm/shock mounting, rear brake, rear wheel drive.

Body And Controls:

Front cab, rear cab and seat, rear rack mounting, front rack and bumper mounting, engine mounting, cooling system, exhaust system, fuel tank, oil tank, air box, controls (throttle assembly, cables, master cylinder, brake lines), steering post, handlebar, headlight pod, clutch cover, gear selector.

Electrical:

Electrical system components including taillight and headlight pod.

Part Identification:

Detailed exploded diagrams for precise identification of all ATV components.

Part Ordering:

Comprehensive part number listings for all components, facilitating efficient ordering.

Assembly Disassembly:

Visual guidance through exploded views aids in understanding component relationships for assembly and disassembly.

Depth:

Comprehensive for parts identification and replacement, supporting DIY maintenance and repair.

📊 Manual Specifications

File Type:

Portable Document Format (PDF)

Searchability:

Likely text-searchable within the PDF, enabling quick location of specific part numbers or descriptions.

Print Capability:

High resolution, allowing for clear printing of diagrams and text.

Binding:

N/A (Digital PDF Download)

Recommended Paper:

Standard copier paper for printing specific pages.

⚙️ Engine Specifications

Engine Type:

Single-cylinder, 4-stroke

Engine Displacement:

Approximately 375cc - 400cc (exact displacement may vary slightly by specific sub-model, typical for this era's Polaris 400 class).

Cooling System:

Liquid-cooled

Horsepower Estimated:

Around 24-28 HP (typical for this class of engine at the time).

Torque Estimated:

Around 25-28 lb-ft (estimated).

Fuel Delivery:

Carburetor

Fuel Type:

Unleaded gasoline (typically 87 octane).

Oil Type Specification:

API SG or higher, SAE 10W-40 motorcycle-specific or ATV oil recommended. Manual would list exact Polaris specification.

Oil Capacity:

Approx. 2.0-2.5 quarts (refer to manual for exact capacity).

🔧 Transmission

Transmission Type:

Automatic (CVT - Continuously Variable Transmission)

Drive System:

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

Gear Selection:

Automatic with High/Low range and Reverse.

Clutch Type:

High-performance CVT drive and driven clutches.

Gearcase Oil Type:

Polaris Demand Drive Fluid or equivalent SAE 80W-90 gear oil (refer to manual for specific Polaris part number or specification).

📐 Dimensions

Length:

Approx. 81 inches (refer to specific sub-model data).

Width:

Approx. 46 inches (refer to specific sub-model data).

Height:

Approx. 47 inches (refer to specific sub-model data).

Dry Weight:

Approx. 630 lbs (refer to specific sub-model data).

Towing Capacity:

650 lbs

Rack Capacity Front:

100 lbs

Rack Capacity Rear:

200 lbs

🛡️ Safety Features

Atv Safety Standards:

Complies with ANSI standards for All-Terrain Vehicles.

Braking System:

Hydraulic disc brakes on all four wheels, foot-operated rear brake, handlebar-operated front brakes.

Throttle Control:

Thumb-activated throttle lever.

Lighting:

Dual headlights, taillight with brake light.

Seatbelt Provision:

N/A (ATVs typically do not have seatbelts; rider use of helmet and protective gear is paramount).

💡 Technology Features

Infotainment Features:

N/A (Utility ATV focused on function, not typically equipped with infotainment systems).

Atv Assistance Features:

On-Demand AWD system provides enhanced traction and stability.

Connectivity Features:

N/A

🔧 Maintenance

Oil Change Recommendation:

Every 100 hours or annually, whichever comes first (refer to manual for exact intervals).

Air Filter Maintenance:

Regular inspection and cleaning, replacement as needed (frequency depends on operating conditions).

Spark Plug Replacement:

Recommended at intervals of 1,000-1,500 miles or annually (refer to manual).

Belt Inspection:

Periodic inspection of drive belt for wear and damage, replacement as necessary.

Coolant Type:

Ethylene glycol-based antifreeze (50/50 mix with distilled water). Refer to manual for Polaris specific coolant part number.

Brake Fluid Type:

DOT 3 or DOT 4 brake fluid (refer to manual).

Common Wear Items:

Drive belts, CV joint boots, wheel bearings, brake pads, suspension bushings are common wear items on ATVs of this era.

Electrical Connection Corrosion:

Corrosion in electrical connectors can be an issue in wet or muddy environments, requiring inspection and cleaning.

📚 Vehicle History

Polarisfamily:

Polaris has a long history in powersports, particularly with ATVs, known for innovation and performance.

Sportsman Lineage:

The Sportsman line is Polaris's flagship utility ATV series, known for its comfort, capability, and versatility since its introduction.

Manufacturing Location:

Typically manufactured in Polaris facilities in the USA.

🏆 Awards & Recognition

Industry Awards:

The Polaris Sportsman line has historically received numerous accolades for its performance, comfort, and utility in the ATV market.