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Sportsman 2004
Polaris Sportsman 2004 User Manual
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W
ARNING
The engine exhaust from this
product contains chemicals known
to cause cancer
, birth defects or
other reproductive harm.
A card containing important A
TV 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.
2
4
Table of Contents
Welcome
6
Vehicle Identification Numbers
7
Table of Contents
8
Safety
9
Safety Decals and Locations
10
Safe Riding Gear
13
Operator Safety
14
Know Your Vehicle
14
Age Restrictions
14
Safety Training
14
Equipment Modifications
18
Controls
39
Throttle Lever
40
Brake Lever
41
Light Switches
41
Master Cylinder
42
Parking Brake
43
Setting the Parking Brake
43
Auxiliary Brake
44
Fuel Valve
45
Fuel Tank
45
Fuel Filter
45
Belt Life
46
Engaging Front Gearcase
47
Features
47
Instrument Cluster
48
Rider Information Center
49
Diagnostic Mode
51
Fuel Safety
53
Operation
53
Break-In Period
54
Pre-Ride Inspection
55
Starting the Engine
56
Starting a Cold Engine
56
Starting a Warm Engine
57
Cold Weather Operation
57
Hauling Cargo
58
Driving Safely
60
Driving Procedures
60
Making Turns
61
Driving on Slippery Surfaces
62
Traveling Uphill
63
Traveling Downhill
65
Turning Around on a Hill
66
Driving through Water
67
Driving over Obstacles
68
Driving in Reverse
69
Parking on an Incline
70
Noise Emission Control System
71
Exhaust Emission Control System
71
Crankcase Emission Control System
71
Emission Control Systems
71
Maintenance and Lubrication
72
Periodic Maintenance Schedule
73
Lubrication Guide
77
Premium 4 Synthetic Lubricant
79
Oil Check
80
Oil and Filter Change
81
Oil Pump Priming
82
Oil Change
84
Front Gearcase Oil
85
Engine Cooling System
88
Coolant Level
88
Radiator Coolant Level
89
Toe Alignment
92
Steering Assembly
92
Side Panel Removal
93
Wheel Removal
94
Wheel Installation
95
Wheel Nut Torque Specifications
95
Front Wheel Hub Tightening
95
Filter Systems
96
Air Filter Service
96
Headlight Lamp Replacement
97
High Beam Adjustment
98
Headlight Housing Replacement
99
Spark Plugs
101
Vehicle Immersion
102
Spark Arrestor
103
High Range
104
Pvt System
104
Low Range
104
Pvt Drying
105
Battery Removal
107
Battery Installation
107
Battery Storage
108
Cleaning and Storage
110
Fluid Levels
111
Breather Filter
111
Storage Tips
112
Transporting the Atv
114
Rear Spring
115
Camber and Caster
115
Adjustments
115
Carburetor/Idle Rpm
116
Throttle Cable Freeplay
117
Polaris Products
118
Troubleshooting
119
Engine Overheating
122
Specifications
123
Jetting Chart
124
Clutching Chart
124
Warranty
131
Engine Oil
133
Index
136
5
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Polaris Sportsman 2004 Specifications
General
Brand
Polaris
Model
Sportsman 2004
Category
Offroad Vehicle
Language
English
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