Target Audience:
Owners and technicians performing maintenance, repair, and troubleshooting on 2004 Polaris Sportsman 400 and 500 ATVs.
Competitive Advantage Of Manual:
Comprehensive coverage of two popular models and engine variants, offering detailed technical information essential for proper upkeep and repair.
Product Value Proposition:
Empowers users with the knowledge to maintain their ATVs effectively, diagnose issues, and perform repairs, saving time and money.
Ease Of Use:
PDF format allows for easy navigation, searching, and printing of specific sections.
Completeness:
Aims to provide complete documentation for all repair and maintenance aspects of the covered models.
Authoritative Information:
Based on factory service manual standards, providing accurate and reliable technical data.
Engine Systems:
Engine overhaul, top-end and bottom-end components, cooling system, lubrication system, fuel system, ignition system, starting system, exhaust system.
Drivetrain Systems:
Transmission (PVT - Polaris Variable Transmission), drive shafts, differential, final drive, clutch system (drive and driven clutches).
Chassis Suspension Steering:
Frame, front and rear suspension (including shocks, control arms, bushings), steering system (handlebars, tie rods, steering post, rack and pinion assembly), wheels, tires.
Braking Systems:
Front and rear hydraulic disc brakes, brake calipers, master cylinders, brake lines, brake pads, parking brake mechanism.
Electrical Systems:
Battery, charging system (stator, voltage regulator), lighting system (headlights, taillights, brake lights), ignition switch, starter motor, wiring harnesses, fuses, relays, DC accessory outlet.
Fuel And Emission Controls:
Carburetor (Mikuni BSR42 for 500, specific carb for 400), fuel pump, fuel lines, fuel filter, emissions control components (if applicable).
Body And Trim:
Body panels, racks (front and rear), fenders, seat, storage compartments.
Routine Maintenance:
Oil changes, filter replacements (oil, air), spark plug checks and replacement, drive belt inspection and replacement, chain adjustment and lubrication (if applicable), lubrication points, coolant checks and changes.
Troubleshooting:
Diagnostic charts for common problems (e.g., starting issues, poor performance, braking problems, electrical faults), symptom-based troubleshooting guides.
Component Disassembly Reassembly:
Detailed step-by-step instructions for removing, inspecting, servicing, and reinstalling all major and minor components across all systems.
Torque Specifications:
Precise torque values for all critical fasteners, bolts, and nuts to ensure proper assembly and prevent damage.
Special Tool Requirements:
Identification of specialized tools required for specific maintenance or repair procedures, with potential references to Polaris part numbers for these tools.
Diagnostic Procedures:
In-depth diagnostic procedures for electrical systems, fuel delivery, and engine performance, including identification of common failure points and testing methods.
Engine Rebuild:
Comprehensive guides for engine teardown, inspection of internal components (pistons, rings, cylinders, crankshaft, valves), reassembly, and break-in procedures.
Transmission Overhaul:
Detailed instructions for servicing the Polaris Variable Transmission (PVT), including clutch inspection, belt replacement, sheave maintenance, and gearcase service.
Wiring Diagrams:
Complete and detailed electrical wiring diagrams for all model variations, illustrating component connections, wire colors, and fuse locations.
Specifications And Tolerances:
Extensive listing of all essential technical specifications, including engine clearances, bearing tolerances, fluid capacities, and electrical system parameters.
Sportsman 400 Engine Type:
Single-cylinder, 4-stroke, liquid-cooled, SOHC
Sportsman 400 Engine Displacement:
Approximately 375cc (specific displacement may vary slightly by sub-model or internal Polaris designation)
Sportsman 500 Engine Type:
Single-cylinder, 4-stroke, liquid-cooled, SOHC
Sportsman 500 Engine Displacement:
499cc
Sportsman 400 Horsepower:
Estimated 28-30 HP (varies by specific model and tuning)
Sportsman 500 Horsepower:
Estimated 32-34 HP (varies by specific model and tuning)
Sportsman 400 Fuel Delivery:
Carbureted (e.g., Mikuni BSR40 or similar, specific model dependent)
Sportsman 500 Fuel Delivery:
Carbureted (typically Mikuni BSR42)
Fuel Type:
Unleaded gasoline, 87 octane minimum.
Engine Oil Change Interval:
Every 100 hours or 6 months, whichever comes first (consult manual for exact intervals based on usage).
Air Filter Inspection:
Inspect every 25 hours, clean/replace as needed. More frequent cleaning in dusty conditions.
Spark Plug Replacement Interval:
Approximately every 100-200 hours or annually.
Drive Belt Inspection Replacement:
Inspect every 50 hours, replace based on wear and tear, typically recommended every 2 years or 200 hours.
Engine Oil Type And Capacity:
Polaris PS-4 Full Synthetic 5W-50 Engine Oil. Capacity approx. 2.3 US quarts (2.2 liters) with filter change.
Gearcase Lubricant:
Polaris AGL Premium Synthetic Gearcase Lubricant. Capacity approx. 10 US fluid ounces (0.3 liters) for rear differential and approx. 6.7 US fluid ounces (0.2 liters) for front differential (if applicable).
Coolant Type:
Ethylene glycol-based antifreeze (e.g., 50/50 mix of coolant and distilled water). Total capacity approx. 3.3 US quarts (3.1 liters).
Common Wear Items:
Drive belts, ball joints, tie rod ends, wheel bearings, bushings, and brake pads are common wear items due to off-road use.
Electrical Connector Issues:
Corrosion or loose connections in electrical connectors can sometimes cause intermittent electrical problems.
Fuel System Maintenance:
Regular fuel system cleaning and fuel stabilizer use are recommended, especially during storage, to prevent carburetor issues.
Polaris Atv Legacy:
Polaris has a long-standing history of producing ATVs, dating back to the early 1980s, with the Sportsman line becoming a cornerstone of their off-road offerings.
Sportsman Line Introduction:
The Polaris Sportsman line was introduced in 1993 and has since evolved significantly, becoming known for its comfort, capability, and four-wheel-drive systems.
2004 Model Updates:
The 2004 models represent an iteration within the second generation of Sportsman ATVs, often featuring refinements in suspension, engine tuning, and ergonomics. The 500cc engine was a popular and robust powerplant.
Manufacturing Location:
Polaris ATVs are typically manufactured in the United States, primarily at their facilities in Minnesota and Iowa.
