The 2004 Sportsman 400 is a mid-size utility ATV designed for a balance of capability and maneuverability. Built with a reliable and simple construction philosophy, this model is known for its ease of repair, making it a practical choice for various tasks and recreational activities. It features a liquid-cooled, single-cylinder engine with an approximate displacement of 375cc to 400cc, delivering an estimated 24-28 horsepower and 25-28 lb-ft of torque. The vehicle is equipped with an automatic CVT transmission, on-demand all-wheel drive, and hydraulic disc brakes on all four wheels. With a towing capacity of 650 lbs and rack capacities of 100 lbs front and 200 lbs rear, the Sportsman 400 is a versatile machine.
This comprehensive parts manual serves as an essential tool for owners and technicians, providing detailed exploded diagrams and part number listings for all components and assemblies of the 2004 Sportsman 400 ATV, covering model codes A04CH42AQ, A04CH42AT, A04CH42AV, A04CH42AR, and A04CH42AS. It covers critical systems including the engine, powertrain, chassis, suspension, body, controls, and electrical systems. The manual's utility lies in its ability to facilitate precise part identification, aid in assembly and disassembly, and empower users to perform routine maintenance and repairs, thereby extending the vehicle's lifespan and ensuring optimal performance.
2004 Polaris Sportsman 400 Parts Manual for Models SPORTSMAN 400 A04CH42AQ, SPORTSMAN 400 A04CH42AT, SPORTSMAN 400 A04CH42AV, SPORTSMAN 400 A04CH42AR and SPORTSMAN 400 A04CH42AS.
Because of their reliable design, relatively simple construction, and ease of repair; ATVs are the ideal machine for maintenance and repair at home. With proper care and routine maintenance, your ATV will provide many years of reliable use. When repairing an ATV, most home mechanics will find them easy to work with and repairs quick and trouble-free.
Scheduled ATV maintenance should occur frequently at regular intervals. This routine maintenance should include changing the oil, inspecting the shift linkage - steering - suspension - coolant system - fuel system - drive belts - engine mounts, changing the spark plugs, and replacing the fuel and air filters. Having a quality parts manual specific to your ATV will help you identify the parts of your ATV and assist you during routine maintenance and repair.
Doing routine maintenance on your ATV at home provides many benefits. It is less expensive than having an ATV shop do the maintenance. It prolongs the life of your ATV. And, it provides you a better understanding of the working components of your ATV.
Even with diligent routine maintenance, ATVs may require periodic repairs. In the event that you need to repair your ATV, it will likely be easier if you have been doing your own routine maintenance as you will be more familiar with the mechanics of your engine. Another asset that makes ATV engine repair easier, is access to service manuals and parts catalogues. Since you already have a maintenance manual that youve been using for routine maintenance, you need only assure that you have on hand a parts catalogue for any repairs that are necessary.
Your ATV will provide you with many years of service. Routine maintenance and periodic repairs at home will save you money and prolong the life of your ATV engine.
59 pages in english pdf format that enables you to print only what you need.
Contents include the following topics with exploded diagrams and part number lists.
SPECIFICATIONS, FRONT CAB, REAR CAB and SEAT, REAR RACK MOUNTING, DECALS, 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 ASM./CABLE, CONTROLS – 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, PART NUMBER INDEX
2004 Polaris Sportsman 400 Parts Manual for Models SPORTSMAN 400 A04CH42AQ, SPORTSMAN 400 A04CH42AT, SPORTSMAN 400 A04CH42AV, SPORTSMAN 400 A04CH42AR and SPORTSMAN 400 A04CH42AS.
Because of their reliable design, relatively simple construction, and ease of repair; ATVs are the ideal machine for maintenance and repair at home. With proper care and routine maintenance, your ATV will provide many years of reliable use. When repairing an ATV, most home mechanics will find them easy to work with and repairs quick and trouble-free.
Scheduled ATV maintenance should occur frequently at regular intervals. This routine maintenance should include changing the oil, inspecting the shift linkage - steering - suspension - coolant system - fuel system - drive belts - engine mounts, changing the spark plugs, and replacing the fuel and air filters. Having a quality parts manual specific to your ATV will help you identify the parts of your ATV and assist you during routine maintenance and repair.
Doing routine maintenance on your ATV at home provides many benefits. It is less expensive than having an ATV shop do the maintenance. It prolongs the life of your ATV. And, it provides you a better understanding of the working components of your ATV.
Even with diligent routine maintenance, ATVs may require periodic repairs. In the event that you need to repair your ATV, it will likely be easier if you have been doing your own routine maintenance as you will be more familiar with the mechanics of your engine. Another asset that makes ATV engine repair easier, is access to service manuals and parts catalogues. Since you already have a maintenance manual that youve been using for routine maintenance, you need only assure that you have on hand a parts catalogue for any repairs that are necessary.
Your ATV will provide you with many years of service. Routine maintenance and periodic repairs at home will save you money and prolong the life of your ATV engine.
59 pages in english pdf format that enables you to print only what you need.
Contents include the following topics with exploded diagrams and part number lists.
SPECIFICATIONS, FRONT CAB, REAR CAB and SEAT, REAR RACK MOUNTING, DECALS, 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 ASM./CABLE, CONTROLS – 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, PART NUMBER INDEX
