Description
This Used 2004 Polaris Sportsman 400 / 500 Factory Service Repair Manual provides detailed service information, step-by-step repair instruction and maintenance specifications for 2004 Sportsman 400 and 500 ATVs.
Table of contents includes:
GENERAL INFORMATION – 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, Lubricant and Maintenance Product Numbers, Special Tools, Lubrication Charts, Transmission Lubrication, Front Gearcase Lubrication, Front Hub Maintenance, Transmission Linkage Adjustment, Throttle / Carburetor Adjustments, Fuel System, Compression Test, Battery Maintenance, Coolant System Maintenance, Air Filter Service, Airbox Sediment Tube Service, Breather Filter, Recoil Housing, Oil Change/Filter, Valve Clearance, Steering and Toe Alignment, Exhaust System Maintenance, Brake System Service, Suspension Service, Controls, Wheel Removal/Installation, Tire Inspection, Warn Winch/Hand Warmer Operation
ENGINE – Torque Specifications, Special Tools, EH50PL Service Data, Torque Patterns, Piston Identification, Cooling System Pressure Test, Cooling System Specifications, Engine Removal, Engine Installation Notes, Cylinder Honing, Crankshaft Runout Inspection, EH50PL Engine Lubrication, EH50PLOil Pump Priming Procedure, EH50PL Lubrication/Oil Flow, EH50PL Engine Exploded View, EH50PL Engine Top End Disassembly, EH50PL Valve Seat Service, EH50PLCylinder Head Assembly, EH50PL Engine Bottom End Disassembly, EH50PL Crankcase and Bearing Assembly, EH50PL Crankcase End Play Inspection, EH50PLCounter Balancer End Play Inspection, EH50PL Engine Assembly/Inspection, Sealed Recoil Disassembly/Inspection, Sealed Recoil Assembly, Spark Plug Fouling Checklist, Troubleshooting
FUEL/CARBURETION – Exploded View, Mikuni BST 34/40 Carburetor, Fuel Tank Asm. Exploded View, Fuel Flow Diagram, Ruel Sender Remove/Install, Special Tools & Jetting Guidelines, Carburetor Jetting, Main Jet/ Pilot Jet Part numbers, CV Carburetor System Function (4 Cycle), CV Carburetor Vent System(4 Cycle), CV Carburetor Operation, Disassembly Notes – CV Carburetor, Cleaning – CV Carburetor, Inspection – CV Carburetor, Assembly – CV Carburetor, Float Adjustment – CV Carburetor, Needle & Seat Leakage Test, Fuel Level, Fuel Pump Service, Troubleshooting
BODY AND STEERING – Torque Specifications and Special Tools, Cover/Panel Removal, Side Panel Removal, Front Rack/Grill Removal, Body Assembly Exploded View, Headlight Pod Exploded View, Steering Assembly Exploded View, A-Arm Replacement, Rear Suspension Assembly, Strut Assembly Exploded View, Front Strut Cartridge Replacement, Front Strut Ball Joint Replacement, Steering Post Assembly, Decal Replacement
CLUTCHING – Service Tools Supplies & Torques, PVT System Operation, PVT Maintenance/Inspection, PVT Disassembly, PVT Assembly, PVT Sealing and Ducting Components, Drive Clutch Exploded View, Drive Clutch Spring Specifications, Shift Weights, Drive Clutch Inspection, Drive Clutch Disassembly, Drive Clutch Assembly, Drive Belt Tension, Drive Belt Removal/Inspection, Drive Belt Installation, Clutch Alignment /Offset, Drive Clutch Bushing Service, Driven Clutch Disassembly/Inspection, Driven Clutch Assembly, Driven Clutch Bushing Service, EBS Exploded View, EBS Drive Clutch Disassembly/Inspection, Early 2004 EBS Driven Clutch Disassembly/Inspection, All 2004 EBS Drive Clutch Bushing Service, Early 2004 EBS Driven Clutch Bushing Service, Late 2004 EBS Driven Clutch Disassembly/Inspection, Late 2004 EBS Driven Clutch Bushing Service, Troubleshooting
FINAL DRIVE – Final Drive Torque Specifications, AWD Operation Overview, AWD Front Hub Removal, AWD Hub/Bearing Installation, AWD Front Hub Bearing Adjustment, AWD Front Hub Exploded View, AWD Hub Seal Replacement, AWD Magnetic Coil Service, AWD Hilliard Clutch Disassembly/Inspection, AWD Armature Plate Inspection
Early AWD Front Axle Removal/Installation, Late AWD Front Axle Removal/Installation, AWD Front CV Joint Boot Replace, AWD Front Drive Axle Exploded View, Early AWD Strut Casting Seal Replace, Early AWD Strut Seal Sleeve Replace, Late Front Hub Disassembly/Assembly, AWD Front Prop Shaft Removal, U-Joint Disassembly/Assembly, Early Front Gearcase Service, Late AWD Front Gearcase Operation, Late AWD Front Gearcase Service, Rear Hub Remove/Install, Rear Hub Disassembly/Assembly, Rear Driveshaft Removal, Driveshaft/CV Joint Tips, Rear Driveshaft Installation, Rear Driveshaft Service
TRANSMISSION SERVICE – Early 2004 Transmission Info, Late 2004 Transmission Info
BRAKES – Rear Auxiliary Master Cylinder Exploded View, Main Brake System, Front Caliper Exploded View, Rear Caliper Exploded View, Special Tools/Specifications/Torques, Brake System Service Notes, Brake Noise Troubleshooting, Hydraulic Brake System Overview, Hydraulic Caliper Bleeding, Brake Bleeding Fluid Change, Master Cylinder Removal, Master Cylinder Installation, Front Pad Removal, Front Pad Assembly, Brake Burnishing, Front Disc Inspection, Front Disc Removal/Replacement, Front Caliper Removal, Front Caliper Disassembly, Front Caliper Inspection, Front Caliper Reassembly, Front Caliper Installation, Rear Pad Removal, Rear Pad Installation, Rear Caliper Removal/Inspection, Rear Caliper Assembly, Rear Disc Inspection, Rear (Auxiliary) Brake Remove/Install, Troubleshooting
ELECTRICAL – Special Tools / Service Notes, Timing Check Procedure, Gear Position Switch Testing, Late 2004 ECM Operation, Instrument Cluster Operation, Speedometer Removal/Installation, Speedometer Troubleshooting, Coolant Sensor Tests, Fan Motor Tests, Late Coolant Sensor Test, Electronic Throttle Circuit System Operation, Ignition System Information, Ignition System Testing Flow Chart, Ignition System Troubleshooting, CDI Output Test, Charging System Testing, Battery Activation/ Service, Headlight/Brake light Lamp Service, Fuel Sender Test, Hand/Thumb Warmer, Warn Winch Information, Starter System Troubleshooting, Starter Motor Service, Starter Drive, Starter Assembly Exploded View , Starter System Testing Flow Chart
Wiring Diagram
