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2004 Polaris Sportsman 400, Sportsman 500 ATV manual Preview image 1
2004 Polaris Sportsman 400, Sportsman 500 ATV manual Preview image 2
2004 Polaris Sportsman 400, Sportsman 500 ATV manual Preview image 3
2004 Polaris Sportsman 400, Sportsman 500 ATV manual Preview image 4
2004 Polaris Sportsman 400, Sportsman 500 ATV manual Preview image 5
2004 Polaris Sportsman 400, Sportsman 500 ATV manual Preview image 6

2004 Polaris Sportsman 400, Sportsman 500 ATV manual

Models covered in this manual:

Sportsman 400, Sportsman 500 / Polaris Industries Inc

  • Sportsman 400
    • Standard model with 425cc engine.
    • Available in different color options.
  • Sportsman 500 H.O. (High Output)
    • Enhanced 499cc high-output engine.
    • Features improved suspension and handling.
  • Sportsman 500 DUSE (Ducks Unlimited Special Edition)
    • Special edition with unique camouflage graphics.
    • Includes additional accessories like gun scabbards.
  • Sportsman 500 RSE (Remington Special Edition)
    • Remington Edition with exclusive green color and Remington branding.
    • Comes with upgraded wheels and additional features.

Production/model years: 2004

File specifications

File size: 25.63 MB
File type: PDF
Language: English

Printable: Yes
Estimated download time: 0.52 Minutes
$18.99 Instant Download

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Product Information

Table of Contents

GENERAL

  • Model Identification
  • Serial Number Location
  • Publication Numbers
  • Paint Codes
  • Replacement Keys
  • 2004 Model Identification
  • General Specifications - Sportsman 400/500
  • Early 2004 Specs Sportsman 400/500
  • Late 2004 Specs Sportsman 400/500
  • Standard Torque Specifications
  • Decimal Equivalent Chart
  • Conversion Table
  • Tap Drill Charts
  • Glossary of Terms

MAINTENANCE

  • Periodic Maintenance Chart
  • Lubrication
  • Maintenance Schedule
  • Maintenance Operations
  • Service Record

ENGINE

  • Engine Removal and Installation
  • Engine Specifications
  • Cylinder Head
  • Cylinder and Piston
  • Crankshaft and Crankcase
  • Camshaft and Valve Train
  • Timing Chain and Tensioner
  • Lubrication System
  • Cooling System

CARBURETION

  • Carburetor Specifications
  • Carburetor Removal and Installation
  • Carburetor Disassembly
  • Carburetor Inspection and Reassembly

BODY AND STEERING

  • Frame and Related Components
  • Steering System
  • Front Suspension
  • Rear Suspension

CLUTCHING

  • Drive Clutch
  • Driven Clutch
  • Clutch Specifications

FINAL DRIVE

  • Final Drive Removal and Installation
  • Final Drive Inspection
  • Final Drive Repair

TRANSMISSION

  • Transmission Removal and Installation
  • Transmission Disassembly
  • Transmission Inspection and Reassembly
  • Transmission Specifications

BRAKES

  • Brake System
  • Brake Specifications
  • Brake Maintenance and Inspection
  • Brake Service Procedures

ELECTRICAL

  • Electrical System
  • Wiring Diagrams
  • Electrical Troubleshooting
  • Battery
  • Charging System
  • Starting System
  • Ignition System
  • Lights and Switches
  • Instrument Cluster
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