2004 Polaris Sportsman 400 Specs and Review 2022

2004 Polaris Sportsman 400: Sporting an older, Trail Boss/Magnum-style body and a slicker interior, the Polaris Sportsman 400 had been in circulation since. 

2004 Polaris Sportsman 400

After its introduction, the four-wheeler was redesigned and was distinguished by a distinctive body, distinctive headlight, and instrument pods, as well as a more efficient transmission. These features remained the same for the year model year 2004 Polaris Sportsman 400.

The year 2004’s Polaris Sportsman 400 was the 9th edition of the Sportsman 400 lineup since its debut back in 1996. 

With On-Demand AWD/2WD driveline mode with aggressive styling, huge capacity in terms of fuel consumption, and the Lock & Ride attachment it was, without doubt, the most affordable ATV available that was available.

With an MSRP that is less than $6,000 the Polaris Sportsman 400 in 2004 Polaris Sportsman 400 offers a great value for the cost. 

Some consumers, however, have a different opinion about the car and claim that it’s simply a Sportsman 500 with a smaller engine and lots of brake issues. The question of whether or not this assertion is accurate remains to be seen. However, if you’d like to determine for yourself read this article.

2004 Polaris Sportsman 400

A Dated Sportsman

Although the design differences and function between the 2004 Polaris Sportsman 400 and its 500-class brother is not that impressive, many off-road enthusiasts and riders believe that the 4×4 has fallen in comparison to its rivals. 

In reality, the model has been in a state of naught since. The design that has been a hit for riders in the past might not be applicable or appropriate for the present enthusiasts.

Its inability to not come with a High Output powerplant as its counterparts do is one reason. Another reason is that it’s still carbureted. Carburetors aren’t necessarily a negative thing. 

However, with the introduction of more stringent emission guidelines and more informed customers who are looking for a fuel-efficient machine, fuel injection could have been a welcomed feature.

The brake system was one that many people feel Polaris should have paid greater focus on. From all the Sportsman models that were tested, the “04 Sportsman 400 seemed to be the one most afflicted with issues with the brakes. If this weren’t sufficient, a resolution to the issues was also rather unclear.


There was just one model that had three trims that were released in 2004 as the following:

Trim Model
2004 Polaris Sportsman 400 (green trim) A04CH42AA
2004 Polaris Sportsman 400 (red trim) A04CH42AB
2004 Polaris Sportsman 400 (yellow trim) A04CH42AC

The trim count of this model is significantly lower than that of the higher-displacement Sportsman models. Dealerships also offered hunting-themed accessories and body panels the trim count didn’t appear to be a factor.

Despite the shortcomings of this four-wheeler, it’s a loved and respected off-road partner. Farmers particularly love this sturdy and sturdy workhorse. 

Because of its tough appearance and sturdy engine, The Sportsman 400 became a favorite mode of transport for those who ride through rough roads and trails that are wooded. The towing capacity of 850 pounds is very useful in performing yard chores and other chores.

2004 Polaris Sportsman 400 Specs & Features

2004 Polaris Sportsman

  • Engine The 2004 Polaris Sportsman 400 is brought to life with a four-stroke single-cylinder, liquid-cooled single-cylinder engine. It has a bore-stroke proportion of 87.9 70 millimeters (3.461 in x 2.756 inches) and a 9.2:1 compression ratio. 
  • The engine’s displacement is 425 cubic centimeters (25.94 in3) and is delivered through a 34-mm Mikuni BST carburetor and coupled to a lubrication system (dry-sump). It comes with the 5.25 US gallon (19.9 liters) tank capacity for fuel which is higher than its counterpart in the 500 class that is fuel-injected. The recommended fuel is regular unleaded or leaded gasoline with the minimum PSN rating of 85 (oxygenated) (oxygenated) or 90 (non-oxygenated).
  • Lubrication – The capacity of the oil will be 2 US quarts/1.89 milliliters of Polaris 0W-40 Synthetic Engine Lubricant or SJ-certified API engine oil. 
  • For the best performance, be sure that the type of oil you prefer conforms to the specifications of the manufacturer as well as JASO the T903MA standards in addition to being of the proper API classification. Castrol 03101 Edge 0W-40 Advanced Full Synthetic Motor Oil (view on Amazon) is a good alternative in lieu of the manufacturer-recommended engine oil.
  • Drivetrain A 30mm automated Belt of Polaris Variable Transmission controlled Helix is able to handle power. It’s a direct rear driveshaft and a Hilliard-type clutch. An H-shifter that is gated (with a H/L/N/R/P pattern for gearshifts) regulates wheel spin. 
  • Similar to other Sportsman models it is also available in 2004. Polaris 400 Sportsman offers AWD/2WD modes that can be controlled with a switch on the left handlebar. Because this model of Sportsman 400 is carbureted, it requires adjustment of the jetting for driving at altitudes higher than 6,000 feet.
  • Ignition The four-wheeler features a CDI (Capacitor Discharge Ignition) electric start system, which includes a recoil start to provide backup. The auxiliary outlet as well as other electronic components make use of a 12V 12-AH 220-CCA (Cold Cranking Amps) 2004 Polaris Sportsman 400 battery. 
  • Current YTX14AH-BS batteries like Yuasa YTX14AHL-BS batteries (view at Amazon) can be used in the 2004 Sportsman 400. Many owners fear replacing the battery due to its position within the quad.
  • tires and Brakes The rear and front steel wheels are equipped with a prescribed tires pressure that is 5 PSI. Similar to the 500cc Sportsman 400, the front brakes feature hydraulic discs. The rear brakes are hydraulic, opposed-piston caliper, and fixed discs and secured in the driveline.
  • Suspension – A MacPherson front suspension strut with 6.7 inches (170 millimeters) of movement, two-inch tubular shock absorbers, and 9.5 inches (241 millimeters) of travel adds a 2004 Sportsman 400’s incredible control and maneuverability. 
  • Its total turn distance at 5.42 feet (165.1 centimeters) allows for a more precise turning.
  • Dimensions the 2004 Polaris 400 Sportsman’s total dimensions are 81x 46 and 47 inches, with the height at 41 inches (1,041 millimeters) in the distance from the ground until the saddle. 
  • The minimum ground clearance not loaded to the ground is 9.25 inches (235 millimeters) while the width of the wheels is 50.5 inches (1,283 millimeters). Dry weight is 697 lbs/316 kg and the seat’s size is 34 inches (864 mm). The towing capacity of the hitch is 850 pounds (386 kg) and 1200 lbs (544 Kg) using a brakeless trailer. 
  • Tongue capacity is 30 lbs (13 kg) and shouldn’t exceed 180 pounds (81 kg) when coupled with the rear rack weight. GVWR is 1,200. This is an amalgamation of curb weight, the 270-lb total rack capacity, the weight of the passenger, and other accessories.
  • Exterior The Gen IV type steel frame features a black medium gloss finish and comes with a polymer body panel that is available in red, green, and yellow. 
  • The standard features include rear and front fenders as well as mudguards, front and back composite utility racks as well as side panels that have vents, handgrips, handlebars, floorboards that are full, and a complete-length skid plate. 
  • Mossy Oak Camouflage, Mossy Oak Break-Up as well as Ducks Unlimited Wetlands accessories were available from dealerships and may be found in the kit of a brand new Sportsman 400.
  • Lighting 60-watt Halogen pod light, 8.26-watt taillight as well as 26.9-watt brake light offer the 4×4 with superior light distribution. 
  • It is possible to replace the light bulbs with LEDs for better visibility in late-night driving and outdoor activities. Led Light Bar Nilight 2PCS 9 96w Red Spot Light (view on Amazon) is a great match with the Red 2004 Polaris Sportsman 400.

2004 Polaris Sportsman 400 Value

The 2004 Polaris Sportsman 400 base model’s list price is $5,899 (exclusive of special-edition-themed accessories). T,

he is $700 lower than its larger displacement counterpart. With the inclusions of the package, the MSRP of the car can increase by as much as $2,000, which makes the 400-cc Sportsman costlier than the 2005 Sportsman 500 with High Output (Mossy Oak Camouflage) trim.

The average retail price and auction listings could range from $1,125-$3,300. The majority of these resales units are owned by a farm with very low mileage and mechanical issues. 

Some are equipped with gun scabbards, closed front storage ITP wheels, a recovery winch, and a glacier blade system as well as a glacier blade system. 

The quality of the maintenance carried out by its previous owners the second-hand Sportsman might have damaged resistors, ripped seats and damaged CV joints or even a faulty cooling fan. Contrarily, some vehicles could be in excellent condition.

2004 Polaris Sportsman 400 Problems Belt Problems

It is possible that your quad may abruptly stop working, followed by the noise of the belt hitting the gear housing. If you notice this it is a sign that you are experiencing PVT belt problems with your Sportsman.

It is possible it is because the belt has become in a loose state. To determine whether the belt has become stretched or glazed or stretched, owners must take the car apart. Sometimes it can be difficult to know what is going on in the clutch that causes the problem or whether the sheaves are grooved.

From this point, you’ll be required to keep your service manual on hand, since it’s your most reliable source for tackling this issue (more especially if it’s the first time you’ve attempted to do it). In addition, you should find out if the issue originates from the rear or front clutch. 

Inject the front clutch and check if it retracts out. If it does, the issue might be in the clutch in your rear. You will require the clutch puller to take out from the clutch drive (or forward) clutch as well as an instrument to remove it. In reverse, the back clutch is able to be removed and dismantled by hand.

Brake Noise

The most likely causes are plugged or embedded material on discs or brake pads and excessive or premature pad/brake disc wear, loose wheels hubs or bearings, as well as damaged or warped brake discs. 

It could also result caused by the other Polaris Sportsman 400 parts, like the axle, chain disc, hub, or wheel. Typically, the first step is to cleanse your brake system components. Spraying pads and discs using CRC Brakeleen or similar can help remove any foreign material that might be trapped in the discs or pads.

If this first method is not working check the front calipers, ports switches, and controls to determine any areas that need to be adjusted or replaced. 

In the worst case, you may need to replace the wheel hub or discs for your brakes if are sure the problem isn’t due to misalignment or dirt. In the end, you should look at other components in the quad if replacement is not enough to eliminate the brake sound.

Parking Brake Not Holding Pressure

Based on Sportsman users, this issue is usually encountered when they use the parking brake when they are on a slope. While the brakes stop at a moment’s notice but the four-wheeler will start to move after a few minutes. 

The hand brake press provides ample resistance initially. After a few squeezes, the lever finally closes to the grip of the handlebar. This has puzzled many Sportsman users who couldn’t quite pin their fingers at the source of the issue.

Lines that are clogged with air, leaky seals, or worn-down pads the pistons and calipers are pushing out until they leak or bleeding master cylinder seals are among the reasons that the Sportsman 400 brakes not holding pressure. If the problem is due to an air leak in your lines bleeding the brakes in order to get rid of air could be a simple solution to this. 

However, leaks of seals in master cylinders or the calipers will require reconstruction. Unfortunately, rebuild kits don’t exist for the Sportsman model. So, you’d be required to replace the affected by purchasing an aftermarket replacement or a less expensive Chinese alternative. In contrast, piston seal kits for calipers are available for the rear and front calipers, if you require these.

Many riders believe that they’d see evidence of leaks if their brakes were pushing too far. However, however, there are times when seals (especially tiny worn-out piston seals inside the master piston) alter their shape only to allow air to enter – which prevents leaks from showing up. 

In addition, the master cylinder that is located on the brake’s foot is thought to suffer from seals drying out or cracking because of non-use. You should check if you suspect there’s something wrong with the parking brake.

Polaris Sportsman 400 Top Speed

Without any upgrades, the advertised top speed of the 2004 Sportsman 400 is 54mph. Incorporating the HMF Engineering Titan LX Slip-On Exhaust Muffler (view the product on Amazon) as well as a brand new clutch, a less restrictive air filter, and higher tires could result in a quad improvement of 3-4 miles per hour. 

Professional race outfitters make additional adjustments that let them boost the Sportsman’s top speed up to 65 mph:

  • The power mill that came with the machine can be swapped to get a larger carburetor
  • Hot Cams to boost power and torque at low RPM
  • Porting the head of the cylinder
  • Increase the compression ratio of the quad without exceeding 10:1.

About Polaris

Polaris Inc. is an American company that has been recognized for introducing people and enthusiasts to cutting-edge technologies like auto transmission, Independent Rear Suspension (IRS) as well as Electronic Fuel Injection (EFI). 

The creator of the Polaris Sportsman 400 of 2004 Polaris Sportsman 400 traces its humble beginnings in the production of agricultural machinery before successfully spawning the snowmobile market in 1954 before unveiling its Sno Traveler in 1956. 

With its top-selling utility line of products as well as other off-road innovations The American manufacturer has managed to expand its presence within the ATV market.

Conclusion – 2004 Polaris Sportsman 400 Review

With the lack of the H.O. engine and an EFI fueling system in the background 2004, the Polaris Sportsman is one powerful and powerful mean machine. 

The drivetrain and braking system was not perfect, and it had some distance to travel, however by 2009, it was able to reach. 

While the car’s shortcomings were the subject of much discussion in 2004, in the present they’re close to being negligible given the variety of performance and upgrades that can be incorporated into ATVs.

Online tutorials, great service from the riding and aftermarket communities, and a rise in savvy people who own ATVs could certainly revive the cult Sportsman 400.

Is Polaris Sportsman 400 a good ATV?

Farmers are particularly fond of farmers especially love this sturdy and sturdy workhorse. Due to its rugged appearance and powerful engine, The Sportsman 400 became a favorite mode of transport for those who ride through rough roads and wooded trails. Its towing capacity of 850 pounds is beneficial for performing yard chores and other chores.

How much does a 2004 Polaris Sportsman 400 weight?

In 2004, the Polaris Sportsman 400 ATV weighed 697 pounds and was 12.94 percent more than other Utility models.

What is a Polaris Sportsman 400?

The most affordable ATV is available with excellent handling and smooth riding. With an integrated storage box and on-demand AWD, and the legendary soft, independently rear suspension. Some features may include. SPORTSMAN(r) 400 H.O. FULL-SIZE best-value ATV. This full-size Sportsman(r) 400 H.O. is the most valuable ATV available.

How much does a 2005 Polaris Sportsman 400 weight?

The model 2005 Polaris Sportsman 400 ATV weighs 715 pounds, which is 14.78 percent higher than other Utility models.

Where are Polaris Sportsman ATVs made?

Polaris is headquartered in Roseau, Minnesota, USA. Components are mainly produced at Osceola, Wisconsin, and the vehicle’s assembly is done in Roseau, Minnesota. This is what we refer to as an American manufactured ATV. A lot more people than before are worried about where their machines are manufactured.

Where is the fuse box on a 570 Polaris Ranger?

1:06 Fuse box and Battery situated beneath in the back of the car. 1:14 Front of vehicle (hood latch lever and under-hood components: terminal block cooler overflow bottle, the cap for radiators; brake master cylinder; the cap on fuel)

2004 Polaris Sportsman 400 FAQ

1. Is Polaris Sportsman 400 a good ATV?

This reliable and capable workhorse is a favorite among farmers. The Sportsman 400 is a popular mode of transport for riding on dirt roads and trails. The Sportsman 400’s 850-pound towing weight makes it ideal for yard work and chores.

2. What kind of oil does a Polaris Sportsman 400 take?

Oil Change Kit with Polaris PS-4 Plus 5W-50 to Polaris SPORTSMAN 400 H.O. 2008-2014 – Walmart.com.

3. How much compression should a Polaris Sportsman 400 have?

The overall compression should be between 210 and 250 psi/cylinder.

4. How much oil does a 2013 Polaris Sportsman 400?

Take out the dipstick, and fill your tank with 2 Quarts (1.9 L) Polaris Premium4 Synthetic Oil.

5. How much horsepower does a 400 Polaris Sportsman have?

Beefy 800 EFI power – This proven twin-cylinder 800 engine produces 54HP. It also features EFI for reliable, fast starting at any temperature and automatic adjustments for altitude.

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