Model:
Sportsman 400, 500, 600, 700
Product Type:
Owners Manual PDF Download
Product Name:
2004 Polaris Sportsman 400 500 600 700 ATV Owners Manual PDF Download
Segment:
Polaris Sportsman models are positioned as versatile, reliable utility ATVs known for their comfort, handling, and robust performance in a variety of terrain.
Target Audience:
Enthusiasts, farmers, hunters, recreational riders seeking a reliable and capable utility ATV.
Competitors:
• Can-Am Outlander
• Honda Foreman/Rancher
• Kawasaki Brute Force
• Yamaha Kodiak/Grizzly
Features Of Atvs:
• Independent Rear Suspension (IRS)
• On-Demand All-Wheel Drive (AWD)
• Powerful Engine Options (400, 500, 600, 700cc)
• Comfortable Ergonomics
• Integrated Storage
Value:
Provides essential knowledge for owners to maintain, troubleshoot, and perform basic repairs on their 2004 Polaris Sportsman ATV, ensuring longevity and optimal performance. The digital format offers immediate access and ease of use in field conditions.
Lifetime Policy:
Includes a lifetime protection policy for lost or damaged files.
Engine:
General Information, Engine Removal and Installation, Engine Specifications, Lubrication and Cooling System, Intake & Exhaust
Drivetrain:
Transmission, Drive Chain & Sprockets
Chassis:
Steering System, Shocks, Body Work
Electrical:
Electrical System
Suspension:
Shocks, front and rear suspension components, adjustment procedures.
Bodywork And Frame:
Body panels, fenders, seat, handlebars, frame inspection.
Ignition System:
Ignition system components, ignition timing specifications (if adjustable), troubleshooting electrical faults related to ignition.
Maintenance:
Routine Maintenance, Lubrication, Fluid Checks, Filter Replacements, Spark Plug Service
Troubleshooting:
Advanced Troubleshooting
Repair Tasks:
• Engine Removal and Installation
• Fuel System Servicing
• Cooling System Maintenance
• Steering System Adjustments
• Shock Absorber Inspection
Diagnostics:
Troubleshooting guides for common starting, running, and electrical issues.
Wheel And Tire:
Tire pressure recommendations, wheel specifications, lug nut torque values.
Battery And Charging:
Battery specifications, charging system testing, starter motor information.
Depth:
Comprehensive coverage for owner-level maintenance and basic repairs, as well as detailed specifications for advanced diagnostics and troubleshooting.
Diagnostic Charts:
Likely includes diagnostic flowcharts and symptom-based troubleshooting tables.
Searchability:
Likely searchable text for efficient information retrieval, typical of professionally produced PDFs.
Accessibility:
Instant download post-payment, no complex software or plugins required.
Software Requirement:
Requires a standard PDF reader application (e.g., Adobe Acrobat Reader).
Printability:
Designed for easy printing of specific pages for use in a workshop environment.
Binding:
N/A (Digital Download)
Paper Type:
N/A (Digital Download)
Engine Configurations:
• Sportsman 400: Typically a 375-400cc class engine.
• Sportsman 500: Typically a 499cc class engine.
• Sportsman 600: Typically a 589cc class engine.
• Sportsman 700: Typically a 683cc class engine.
Horsepower Torque:
Specific horsepower and torque figures vary by engine size. The manual will provide detailed specifications for each model. Generally, these engines offer ample power for utility work and trail riding.
Fuel Delivery:
Likely carbureted for most models in this year, though some might have featured early fuel injection depending on trim. Manual will detail specific system components and maintenance.
Cooling Type:
Liquid-cooled
Oil Type Capacity:
The manual will specify the exact SAE viscosity grade and API classification for engine oil, along with the correct oil capacity for each engine variant. Common recommendations for this era include 10W-40 or 20W-50 synthetic or conventional motorcycle/ATV specific oils.
Engine Type:
Typically single-cylinder, 4-stroke OHV engines.
Transmission Type:
Automatic (Polaris Variable Transmission - PVT)
Gear Selection:
Typically High, Low, Neutral, Reverse, and Park.
Drive System:
On-Demand All-Wheel Drive (AWD) with 2WD/4WD engagement options.
Transmission Fluid:
The manual will specify the exact type and quantity of transmission fluid required, which is often a proprietary Polaris fluid or a compatible CVT fluid.
General Dimensions:
Dimensions vary slightly between models. The manual will provide exact length, width, and height for each specific Sportsman variant (e.g., Sportsman 500 HO, Sportsman 700 EFI).
Dry Weight:
Dry weights typically range from approximately 600-750 lbs (272-340 kg) depending on the model and configuration.
Towing Capacity:
Towing capacities are generally around 1500 lbs (680 kg) for models equipped with a receiver hitch. Consult manual for exact specifications.
Ground Clearance:
Typical ground clearance is around 10.5 to 11.25 inches (267-286 mm), depending on the model.
Safety Standards:
ATVs manufactured during this period typically met ANSI standards for recreational off-highway vehicles. Specific ratings not usually provided in this format.
Braking System:
Hydraulic disc brakes, typically on all wheels. The manual will detail brake fluid type and bleeding procedures.
Operator Safety:
Manual will emphasize safe operating practices, protective gear recommendations (helmet, eye protection, etc.), and hazard awareness.
Lighting System:
Dual headlights, taillight/brake light. Manual covers bulb types and replacement.
Routine Maintenance Schedule:
The manual will detail recommended service intervals for tasks such as oil changes, filter replacements, spark plug checks, drive belt inspection, and lubrication points, typically on a per-hour or mileage basis (e.g., every 100 hours or 6 months for oil changes).
Coolant Type:
The manual will specify the correct type and mixture ratio for engine coolant (typically an ethylene glycol-based antifreeze).
Brake Fluid Type:
Typically DOT 3 or DOT 4 hydraulic brake fluid.
Gearcase Oil:
The manual will specify the recommended SAE viscosity grade for the transmission/gearcase oil.
Common Wear Items:
Common wear items for ATVs of this era include the drive belt (PVT), suspension bushings, tie-rod ends, and brake pads. The manual will provide guidance on inspection and replacement.
Tune Up Components:
Includes specifications for spark plug gap, idle speed, and carburetor adjustment (if applicable), as well as air filter cleaning/replacement.
Polaris Atv History:
Polaris has been a pioneer in the ATV industry since the 1980s, consistently developing innovative and market-leading models. The Sportsman line, introduced in the mid-1990s, quickly became one of their most popular and recognized offerings.
Sportsman Line Development:
The Sportsman line evolved significantly throughout the late 1990s and early 2000s, with engine sizes increasing and features like IRS and AWD becoming standard. The 2004 models represent a mature iteration of this popular platform, offering various engine displacements to cater to different user needs.
Manufacturing Location:
Polaris Industries vehicles are primarily manufactured in the United States.
