The Polaris Sportsman, available in 400, 500, 600, and 700cc model variants for the 2004 model year, represents a robust line of all-terrain vehicles designed for a variety of demanding tasks. Known for its strong heritage in powersports and commitment to innovation, the Sportsman has been engineered to deliver reliable performance and utility. These ATVs are built to handle challenging terrain, offering features such as a Variable Transmission with engine braking, and often an all-wheel-drive system, making them suitable for work, recreation, and exploration. The engineering quality ensures durability and a capable ride, reflecting a dedication to producing high-performance powersports equipment.
This comprehensive English-language service manual, approximately 130 pages, provides in-depth technical information for the 2004 Sportsman. It covers essential areas including detailed engine diagnosis and overhaul, drivetrain components, chassis systems, and electrical systems, complete with clear illustrations and wiring diagrams. The manual outlines scheduled maintenance procedures, fluid specifications for engine oil, coolant, brake fluid, and gearcase oil, and offers systematic troubleshooting guidance for common issues. This resource is invaluable for owners and technicians alike, enabling accurate maintenance, effective repairs, and confident operation of the vehicle by providing factory-level accuracy and detailed step-by-step instructions.
Written for 2004 POLARIS SPORTSMAN 400 500 600 700 dealership mechanics, this reprint of the dealer manual shows you how to work on your vehicle. With step-by-step instructions, clear pictures, exploded view illustrations, schematics, and specifications, you will have the information you need to get your project on the road and keep it there. This manual covers 2004 POLARIS SPORTSMAN 400 500 600 700 models . Buy now to own the best shop manual for your vehicle.
TABLE OF CONTENTS
WELCOME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
VEHICLE IDENTIFICATION NUMBERS . . . . . . . . . . . . . . . 4
TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
EMISSION CONTROL SYSTEMS . . . . . . . . . . . . . . . . . . . 68
MAINTENANCE AND LUBRICATION . . . . . . . . . . . . . . . . 69
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
POLARIS PRODUCTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Written for 2004 POLARIS SPORTSMAN 400 500 600 700 dealership mechanics, this reprint of the dealer manual shows you how to work on your vehicle. With step-by-step instructions, clear pictures, exploded view illustrations, schematics, and specifications, you will have the information you need to get your project on the road and keep it there. This manual covers 2004 POLARIS SPORTSMAN 400 500 600 700 models . Buy now to own the best shop manual for your vehicle.
TABLE OF CONTENTS
WELCOME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
VEHICLE IDENTIFICATION NUMBERS . . . . . . . . . . . . . . . 4
TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
EMISSION CONTROL SYSTEMS . . . . . . . . . . . . . . . . . . . 68
MAINTENANCE AND LUBRICATION . . . . . . . . . . . . . . . . 69
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
POLARIS PRODUCTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
