Polaris 2004 SPORTSMAN User manual

Part No. 9918724 Rev 06
PRINTED IN THE USA
WARNING
Improper vehicle use can result in SEVERE INJURY or DEATH.
READ OWNER'S MANUAL.
FOLLOW ALL INSTRUCTIONS AND WARNINGS.
ALWAYS USE
AN APPROVED
HELMET AND
PROTECTIVE
GEAR
NEVER USE
ON PUBLIC
ROADS
NEVER CARRY
PASSENGERS
NEVER USE
WITH DRUGS
OR ALCOHOL
Operate without proper training or instruction.
Operate on public roads. A collision can occur with another vehicle.
Operate at speeds too fast for your skills or the conditions.
Use ALCOHOL or DRUGS before or while operating this vehicle.
Carry Passengers.
ALWAYS:
Avoid paved surfaces, which may adversely affect handling and control.
Use proper RIDING TECHNIQUES to avoid vehicle overturns on hills
and rough terrain, and in turns.
Wear eye protection, helmet and protective apparel.
NEVER:
P
an
t
one
644

WARNING
The engine exhaust from this
product contains chemicals known
to cause cancer, birth defects or
other reproductive harm.
A card containing important ATV safety information should be
attached to the owner’s manual on the next page. If you cannot
locate this card, or if it has been removed, please call
1-800-342-3764 for assistance.

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We’ve created a web site just for YOU!
STechnical tips
SNew product introductions
SEvent schedules
SParts and Service Manual information
SExciting details about The Way Out
Check it out...
www.polarisindustries.com/owner

2
Copyright 2003 Polaris Sales Inc. All information contained within this publication is
based on the latest product information at the time of publication. Due to constant
improvements in the design and quality of production components, some minor
discrepancies may result between the actual vehicle and the information presented in this
publication. Depictions and/or procedures in this publication are intended for reference
use only. No liability can be accepted for omissions or inaccuracies. Any reprinting or
reuse of the depictions and/or procedures contained within, whether whole or in part, is
expressly prohibited. Printed in U.S.A.

3
WELCOME
Thank you for purchasing a Polaris vehicle, and welcome to our
world-wide family of Polaris owners. We proudly produce an exciting
line of utility and recreational products.
Polaris Recreational Vehicles
SSnowmobiles
SAll-terrain vehicles (ATVs)
SWatercraft
SRANGER utility vehicles
SVictory motorcycles
Polaris Professional Series Workmobilest
SUtility Task Vehiclest(UTVs)
SPersonal Task Vehiclest(PTVs)
SAll-Surface Loaders (ASLs)
We believe Polaris sets a standard of excellence for all utility and
recreational vehicles manufactured in the world today. Many years of
experience have gone into the engineering, design, and development of
your Polaris vehicle, making it the finest machine we’ve ever
produced.
For safe and enjoyable operation of your vehicle, be sure to follow the
instructions and recommendations in this owner’s manual. Your
manual contains instructions for minor maintenance, but information
about major repairs is outlined in the Polaris Service Manual and
should be performed only by a Factory Certified Master Service Dealer
(MSD) Technician.
Your Polaris dealer knows your vehicle best and is interested in your
total satisfaction. Be sure to return to your dealership for all of your
service needs during, and after, the warranty period.
We also take great pride in our Parts Apparel and Accessories (PAA)
products, available through our online store at www.purepolaris.com.
Have your accessories and clothing delivered right to your door!
Polaris, Polaris The Way Out, and Workmobiles are registered
trademarks of Polaris Industries Inc.

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VEHICLE IDENTIFICATION NUMBERS
The frame vehicle identification number (VIN)(1) and engine serial
number (2) are important for model identification when registering
your vehicle, when obtaining insurance, and when ordering
replacement parts. In the event your vehicle is stolen, these numbers
are essential to the recovery and identification of your vehicle.
Remove the spare key and store it in a safe place. Your key can be
duplicated only by mating a Polaris key blank with one of your
existing keys. If both keys are lost, the ignition switch must be
replaced. See your Polaris dealer.
NOTE: Record your vehicle’s ID numbers and key number (3) in the
spaces provided.
2
1
31XX
3
2
400/500
600/700
Frame VIN:
Engine Serial Number:
Vehicle Model Number:
Key Number:

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TABLE OF CONTENTS
WELCOME 3........................................
VEHICLE IDENTIFICATION NUMBERS 4...............
SAFETY 6..........................................
CONTROLS 36......................................
FEATURES 44.......................................
OPERATION 50.....................................
EMISSION CONTROL SYSTEMS 68...................
MAINTENANCE AND LUBRICATION 69................
ADJUSTMENTS 112.................................
POLARIS PRODUCTS 115............................
TROUBLESHOOTING 116............................
SPECIFICATIONS 120................................
WARRANTY 128.....................................
INDEX 133..........................................

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SAFETY
Safety Decals and Locations
Warning decals have been placed on the ATV for your protection. Read
and follow the instructions of the decals on the ATV carefully. If any
of the decals depicted in this manual differ from the decals on your
ATV, always read and follow the instructions of the decals on the ATV.
If any decal becomes illegible or comes off, contact your Polaris dealer
to purchase a replacement. Replacement safety decals are provided by
Polaris at no charge. The part number is printed on the decal.
7079083
E1997, 2000
IF OWNER’S MANUAL IS MISSING, CONTACT
A POLARIS DEALER FOR A REPLACEMENT.
WARNING
Operating this vehicle if you are under
the age of 16 increases your chance
of severe injury or death.
NEVER operate this vehicle if you are
under age 16.
WARNING
WARNING
7077920
WARNING

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SAFETY
Safety Decals and Locations
IMPROPER TIRE PRESSURE OR OVERLOADING can cause loss of
control resulting in SEVERE INJURY OR DEATH.
TIRE PRESSURE IN PSI (KPa): FRONT 5 (34,5) REAR 5 (34,5)
MAXIMUM WEIGHT CAPACITY (Gross Vehicle Weight)
INCLUDING MACHINE, DRIVER AND CARGO IS 1200 LBS. (545 kg).
Reduce speed and allow greater distance for braking when carrying
cargo. Overloading or carrying tall, off-center, or unsecured loads
will increase your risk of losing control. Loads should be centered,
carried as low as possible, and firmly secured to the racks. With
dual racks, load distribution 1/3 front 2/3 rear is best. For stability
on rough or hilly terrain, reduce speed and cargo. Do not block
headlight. Be careful if load extends over the side of the rack.
Read Owner’s Manual for more detailed loading information
WARNING
7079084
ATTENTION
SOperation of this vehicle without the air
filter element will severely damage the
engine.
SClean pre-filter element often, more
frequent cleaning required in dusty
conditions. Do not operate vehicle
without pre-filter.
SOperation of this vehicle without engine
breather filter(s) can cause engine
damage. Consult owner’s manual or
dealer for details.
Factory setting:
40_to 80_F. at 0-3000 feet
(5_to 27_C. at 0-900 meters).
7079902
SSpecific carburetor jetting and
adjustments are required depending
on temperature and altitude. See
your Owner’s Manual.