2004 Polaris Sportsman 400 Problems and Repair Information
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Free 2004 Polaris Sportsman 400 manuals!
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Popular 2004 Polaris Sportsman 400 Manual Pages
Owners Manual - Page 6
...We proudly produce an exciting line of your vehicle, be performed only by a Factory Certified Master Service Dealer (MSD) Technician. Your manual contains instructions for purchasing a Polaris vehicle, and welcome to your service needs during, and after, the warranty period. We also take great pride in this owner's manual. Have your accessories and clothing delivered right to our world...
Owners Manual - Page 14
... follow the recommended maintenance program outlined in your owner's manual. Know Your Vehicle
As the operator of the vehicle, you are thoroughly inspected at specific intervals.
11
You were also provided with all laws and regulations concerning the operation of vehicle safety.
Read and understand your owner's manual, which includes valuable information about all aspects of...
Owners Manual - Page 49
...indicates the gear the transmission is in the LCD, and the speedometer needle will blink. This indicator illuminates when the electrical portion of fuel in the instrument ... at idle and high electrical load (lights, cooling fan, accessories) is activated. Service Interval/Diagnostic Mode Indicator 5. Check Engine Warning Indicator - Do not continue to your Polaris dealer for...
Owners Manual - Page 55
...use. Tires - Check for free operation and closing. 5. Loose parts - Check operation, adjustment and fluid levels (includes auxiliary brake). 4. clean or replace. 9. Fuel tank and engine oil... level - Throttle - Check for proper function. 7. Headlight/Taillight/Brakelight - Check for any area. 10. All brakes - check that your vehicle is not done...
Owners Manual - Page 66
... the transmission in the owner's manual. Use extreme caution when operating on the left . 5. If the vehicle stalls while climbing a hill, never back it 's pointing across the hill or slightly downward. 6.
Dismount on the uphill side of the vehicle, or on hills, and follow proper operating procedures outlined in forward and shut off the engine. 3.
Owners Manual - Page 67
... engine damage can operate through water: 1. NOTE: Avoid operating the vehicle through deep or fast-flowing water. Do not make sudden turns or stops, and do not make sudden throttle changes. Have the vehicle serviced by applying light pressure to your weight carefully, avoid sudden movements, and maintain a slow and steady forward motion. Perform the services...
Owners Manual - Page 73
...,Pre-cleaner Pre-Ride Pre-Ride
L
Coolant level Fuel tank and engine oil Throttle Lights Engine stop switch Steering
" Air box sediment
Pre-Ride...Service (California)
J Dealer service item
70 Have an authorized Polaris dealer perform these services.
apply Polaris dielectric grease to connector when replaced Check operation daily; Item Brake System Auxiliary Brake Tires Wheels Hours/ Miles...
Owners Manual - Page 75
... hoses J Clutches (drive and driven) Engine mounts
J Brake fluid J Front wheel bear- MAINTENANCE AND LUBRICATION
Periodic Maintenance Schedule
WARNING
Improperly performing the procedures marked with a J could result...an authorized Polaris dealer perform these services. lube Inspect; adjust and lubricate if needed Check for leaks at tank cap, lines, fuel valve, filter, pump and carburetor;
Owners Manual - Page 77
... (U Joint) (Fig. 2) Ball Joint (Fig. 3)
Grease fittings (3 pumps maximum) Locate grease fitting and grease with grease gun. Every 3 months or 50 hours Every 3 months or 50 hours Every 3 months or 50 hours
FGrease
"LGrease
74 Perform all services at whichever reading is due at 100 hours
Transmission Oil
Polaris Premium Synthetic Gearcase Lube Premium...
Owners Manual - Page 81
... the mark (4) on the drain plug and the oil tank should be clean and free of the engine. 2. Severe use includes continuous duty in oil change the oil filter whenever changing the oil. Install ... miles, or one month, whichever comes first. Allow the oil to 14-17 ft. lbs. (19-23 Nm) 6. Position the vehicle on the oil drain plug. Severe use operation requires more frequent service....
Owners Manual - Page 94
... slightly. 3. Elevate the side of the vehicle by placing a suitable stand under the footrest frame. 4. See illustration.
1/8I (.3 cm)
Wheel Removal
1. Remove the wheel nuts and remove the wheel.
91 Stop the engine, place the transmission in PARK and lock the parking brake. 2. Tire Tread Depth
Always replace tires when tread depth is worn to...
Owners Manual - Page 102
...engine. Turn the fuel valve on page 102 for service as soon as possible, whether you succeed in starting it or not. Attempt to water below . 1. If it if water is evident. 3. Turn the fuel...Tighten the carburetor drain screw. 9. Take the ATV to your ATV to your vehicle becomes immersed, major engine damage can result if the machine is not thoroughly inspected. Filter replacement is ...
Owners Manual - Page 105
...Extensive engineering and testing has been conducted to dry it in the owner's manual. Use the following responsibilities to drain. Start the engine and shift the transmission into the PVT system. See your dealer for service as...the PVT housing is accidently ingested into neutral. Take the vehicle to your dealer as the owner, you have the following instructions to ensure the safety of ...
Owners Manual - Page 110
... be waxed with any water that may have entered the engine or exhaust system.
If a high pressure system is with a chamois to the wheel bearings, transmission seals, body panels, brakes and warning labels. Cleaning and Storage
See page 115 for your Polaris dealer. Accessory outlets are damaged, contact your ATV is used, exercise...
Owners Manual - Page 122
.... Use a garden hose to 12.5 VDC Replace with recommended fuel Inspect and clean or replace See your Polaris dealer See your Polaris dealer See your Polaris dealer Clean radiator screen and core Clean engine exterior See your Polaris dealer Set gap to specs or replace plugs Check all connections and tighten Recharge battery...
Owners Manual - Page 123
SPECIFICATIONS
SPORTSMAN 400
Gross Vehicle Weight Towing Capacity Hitch Tongue Capacity Front Rack Capacity Rear Rack Capacity Overall Length Overall Width Overall Height Wheelbase Ground Clearance Dry Weight Minimum Turning Radius Fuel Capacity Engine Oil Capacity Coolant Capacity Engine ... @ 5000 RPM NGK BKR5E / .035 in. (0.9 mm) Dry Sump Automatic PVT (Polaris Variable Transmission)
120
Owners Manual - Page 125
SPECIFICATIONS
SPORTSMAN 500
Gross Vehicle Weight Hitch Towing Rating Unbraked Trailer Towing Capacity* Hitch Tongue Capacity Front Rack Capacity Rear Rack Capacity Overall Length Overall Width Overall Height Wheelbase Ground Clearance Dry Weight Minimum Turning Radius Fuel Capacity Engine Oil Capacity Coolant Capacity Engine... (Polaris Variable Transmission)
* Based on EU Directive 76/432/EC
122
Owners Manual - Page 127
SPECIFICATIONS
SPORTSMAN 600
Gross Vehicle Weight Fuel Capacity Towing Capacity Hitch Tongue Capacity Front Rack Capacity Rear Rack Capacity Overall Length Overall Width Overall Height Wheelbase Ground Clearance Dry Weight Minimum Turning Radius Engine Oil Capacity Coolant Capacity Engine Displacement Bore x Stroke Pilot Jet Main Jet Needle Jet Jet Needle Pilot Screw Alternator Output Compression ...
Owners Manual - Page 129
SPECIFICATIONS
SPORTSMAN 700
Gross Vehicle Weight Fuel Capacity Towing Rating Unbraked Trailer Towing Capacity* Front Rack Capacity Rear Rack Capacity Hitch Tongue Capacity Overall Length Overall Width Overall Height Wheelbase Ground Clearance Dry Weight Minimum Turning Radius Engine Oil Capacity Coolant Capacity Engine Displacement Bore x Stroke Pilot Jet Main Jet Needle Jet Jet Needle Pilot ...
Owners Manual - Page 133
...). HOW TO OBTAIN WARRANTY SERVICE
If your copy of Polaris engine oil for your dealer to resolve any Polaris Servicing Dealer to repair Polaris ATVs. If any additional assistance they will remain in effect. When requesting warranty service you must present your ATV requires warranty service, you must take it to a Polaris dealer authorized to perform warranty service. Please work with...
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