2004 Polaris Sportsman 500 Specs and Review 2022

2004 Polaris Sportsman 500: It is clear it is true that it is a fact that the Sportsman 500 series only gets better and better. 

The development stage of the line was apparent in the year 2004’s Polaris Sportsman 500. 

The model featured an improved appearance and fit, a set of tires that we’re able to handle different terrains, a fantastic suspension, as well as a powerful engine designed to cruise off-pavement without difficulty. 

2004 Polaris Sportsman 500

It gave the type of force that you’d expect from a hybrid of the sportbike and an SUV, but with the added benefit of a twist.

In 2004, the Polaris Sportsman 500 was the 9th edition from the Sportsman 500 lineup since its debut back in 1996. This utilitarian ATV maintained its robust H.O. base model but also included a brand new feature called that is the Sportsman 500 ATP (All-Terrain Pickup) which was then named The ATV of the Year in 2004. ATV of the Year.

In terms of style terms design, comfort, and creativity In terms of design, comfort and style, the Polaris Sportsman 500 of 2004 was a masterpiece in terms of design, comfort, and style Polaris Sportsman 500 was one amazing vehicle that was designed to be a play and work vehicle.

Let this guide us on a journey to look closer at the massively powerful and versatile vehicle that created Polaris an off-roader’s powerhouse.

2004 Polaris Sportsman 500

Royalty Meets Innovation

In 2004 ATV-royalty Polaris was back on their drawing table and created a unique idea to revamp its highly successful Sportsman 500 lineup. The market wasn’t tired of the 500-cc model, but it was a lot to provide. 

It was the very character of an American manufacturer to develop something innovative and practical to the benefit of their customers. Therefore the H.O. base models were maintained as did it was the ATP (or All-Terrain Pickup trim was born.

While Sportsman fans were content with the space they had on their four-wheeler, Polaris thought they could enhance it. In keeping the H.O. base model The company then began to work on the Magnum chassis to create the ATP trim and to incorporate additional storage options within the. 

The result was the Sportsman model that has the wheelbase is slightly longer and front racks-cum-storage boxes and a rear mini-bed with a manual tilt as well as the possibility of dropping the tailgate.

The changes were logical particularly for outdoor enthusiasts who often feel that storage space isn’t sufficient. Additionally, the ATP version had a “Turf” mode, which was ideal for riding on lawns and golf courses without breaking the surface. 

This added feature resulted in the quad sporting the ability to driveline in three different positions that were the first for an ATV at the moment. These incredible additions were enough to cause ATV Magazine to give the four-wheeler the title of ATV to Watch.

2004 Polaris Sportsman

2004 Polaris Sportsman 500 Specs & Features

  • Engine The four-stroke single-cylinder liquid-cooled SOHC engine makes the Sportsman to life. Bore-stroke is x75 mm (3.625 inches) x 2.955 inches) and the compression ratio of 10:2. Its engine displacement is 498 cubic centimeters (30.45 in3) which are delivered via a 40-mm Mikuni BST carburetor. 
  • It features a dry-sump system for lubrication. The capacity of the fuel tank is reduced by 4.75 US gallons/18.1 liters for the H.O. as well as 3.3 US gallons/12.49 liters for the ATP in comparison to models from previous years. Regular or unleaded gasoline with an optimum PON value at 85 (oxygenated) and 89 (non-oxygenated) is suggested for use. The maximum power of the 2005 Polaris Sportsman 500 HO is 41.5 HP (30.94 kW/35.28 WHP calculated based on a loss of 15% to the drivetrain). Incorporating hot cams (view at Amazon) inside your four-wheeler can give you some more horsepower.
  • Lubrication Two US quarts/1.89 Liters is the capacity of oil. Make use of SAE’s 0.W-40 Polaris Premium Synthetic Lubricant, or any API-certified SJ oil. To get the best results, you should use synthetic oil that has the appropriate API classification and that is in compliance with specifications of the manufacturer and the T903 MA standards of JASO, for example, Castrol’s EDGE Synthetic 0W-40 Motor oil (view the full review on Amazon). 
  • Be aware that you might need to perform oil changes more often if you are not making use of Premium 4-Synthetic Lubricant. If you’re using other versions make sure to choose an oil that does not contain molybdenum.
  • Drivetrain An automatic belt-driven Polaris Variable Transmission with compound EBS regulates the power and a direct rear driveshaft provides it. The side lever (with an incline of neutral, high, low, and reverse gearshift pattern) regulates the shifting. Similar to older models like the H.O. comes with two driveline options (AWD 2WD) operated by an on the handlebar to the right. 
  • To extend the life of the belt make sure to use a lower forward gear when transporting or operating at lower than 7 mph for a prolonged time. Equally, jetting adjustments are necessary when operating at elevations higher than 6,000 feet.
  • ignition: The four-wheeler has a CDI (Capacitor Discharge Ignition) electric start system, which includes a recoil start to backup. In the ignition, it operates at 30deg 2deg at 5,000 RPM and it requires spark plugs (NGK BKR6E) with a 0.036 inch (0.9 millimeter) gap. It comes with an alternator charging system that has a capacity of 250W. 
  • A 12V 12-AH 220-CCA (Cold Cranking Amps) battery that has dimensions of 5.31 3.50 x 3.50 6.56 inches. 6.56 inches (134 in x 89 in x 166 millimeters, (L x WxH) can power electronic devices as well as a 12-volt DC power outlet. The current YTX14AH battery models work perfectly with the 2004 Sportsman 500.
  • Brakes and Tires: Front and back steel wheels have the same Rawhide and Titan 25×8-12/205/80 tires, and 25 X 11-12/270/60 R12 tires, both of which have the suggested tire pressure of five psi (34.47 kPa/0.35 kg/cm2). 
  • The front brakes use hydraulic discs and the rear brakes are pistons that are opposed to hydraulic brakes, fixed discs all connected on the driveline. To be safe it is advised not to use your quad on slopes greater than 25deg. Also, keep away from abrupt stopping.
  • Suspension This year’s Sportsman 500 uses a MacPherson front suspension with a strut that offers 6.7 inches of movement. the fully-independent rear suspension, which is progressive-rate and fully independent. that includes a stabilizer bar, tubular shock absorbers, as well as 9.5 inches of suspension travel. This. These contribute to the 2004 Polaris Sportsman 500‘s exceptional handling. 
  • Furthermore, its overall turn diameter at 5.42 feet (165.1 millimeters) ensures precise turning angles. In the Sportsman 500 ATP, rear-wheel travel is reduced by 6 inches (152.4 millimeters) to accommodate a swingarm in the rear as well as a dump bed.
  • Dimensions the 2004 Polaris Sportsman 500 HO’s overall dimensions are 81 x 47 inches (85 x 46 and 46 inches for ATP LxWxH). The minimum ground clearance empty is 11.5 inches (279 millimeters) while the width of its wheelbase measures 50.5 inches (1,283 millimeters). It weighs a dry amount at 697 lbs/316.4 Kg, and the seat height is 34 inches (863.6 mm). Towing capacity for the Hitch is 1,225 pounds (556 kg) and 1,786 pounds (810 kg) with the brakeless trailer. 
  • Tongue capacity is 120 lbs (54 kg) and shouldn’t exceed 180 pounds (81.6 kg) when coupled with the rear rack weight. GVWR is 1200-1500 lbs. combined with 740-lb/347.23 Kg 740-lb/336.3 kg (ATP 740-lb/336.3 Kg (ATP – 765.52-lb/347.23 kg) curb weight, the total rack weight of 270 pounds (122.5 Kg) as well as passengers (either one or two up).
  • Exterior Its Gen IV type steel frame features a black medium gloss finish and comes with the body of the frame made of plastic and available in yellow as well as Mossy Oak Break-Up brand camo.
  •  Other features that are standard include rear and front composite utility racks and fenders, as well as handgrips and handles, complete floorboards, and a complete-length skid plate. A National Cycle Lexan ATV Windshield (view on Amazon) is an ideal option for those who frequently take a ride on snow.
  • Lighting Two 27-watt grille-mounted single-beam lighting fixtures and 50-watt Halogen pod headlight offer superior light distribution in the 4×4. Lighting comes with the 8.26-watt light for the tail, 26.9-watt brake lights, as well as single-watt indicators. 
  • Installing LED lights in place of stock lights is ideal for nighttime and outdoor activities. Trail Tech 752-114 Black Vapor Digital Speedometer and Tachometer Gauge Kit (view on Amazon) is useful in the event that your instrument cluster is damaged.
  • On-Demand Drive System AWD/WD This feature exclusive to Polaris activates by means of a switch on the left handlebar. It lets the front axles immediately engage, at whatever point that rear wheels lose their traction. This reverses when rear wheels get back their traction. 
  • The override switch is activated AWD while in reverse. If you have those with the ATP model, it’s a three-position switch that incorporates the recently added “Turf” option.
  • Lock and Ride Cargo Systems This technology allows being installed with ease and without tools. It is quick to attach or remove rear cargo boxes, as well as other accessories when you require access to the composite racks on the four-wheeler.

What is the price of the 2005 Sportsman 500 Cost?

The 9th edition of the Polaris Sportsman 500 lineup saw an increase of $400 in the price of the base H.O. model, which was sold at $6,599. The limited-edition Mossy Oak Break-Up brand camo trim cost only $300 more at $6,899 — nevertheless, it was less expensive than the listed cost of the. Its ATP trim is an absolute bargain at just $6,999. 

The resale price can be as high as $8,499 based on the trim, and whether buyers get an entire accessory package that includes the addition of an exhaust system with high-performance and an AM/FM Radio-CD that has speakers.

Retail prices for average units can be between $1,490 and $2,060. Trader and auction listing sites evaluate second-hand units between $927 to $3,900. The most common defects from these used wheelers are AWD not functioning and damaged seat covers. Some are available as part of building projects. 

There are quads that are in great operating condition, recently cleaned and serviced. Some are even fitted with a new camshaft, as well as an upper toolbox. The average mileage is 4,500 miles. Total hours are minimal and 480 hours are the longest. Incredibly, all units offered being offered for sale don’t have titles.

Get on the Qui Vive

Be on the Qui Vive


A few of the 2004 Polaris Sportsman 500 HO models mostly suffered from the issue because of malfunctioning electronic control modules, or ECMs that were known to overheat and could cause the risk of burning and fire. 

Sportsman 500 500 models like A04CH50AO A04CH50AR and A04CH50AS were recalled to protect any serious injury to a rider and another large displacement scrambler as well as Sportsman vehicles.

In addition to this recall, typical causes of overheating are:

  • Poorly maintained or low-voltage battery, or engine operation that is not proper jetting (especially relevant when operating at different altitudes)
  • A damaged cooling unit, malfunctioning control for the fan, or even a hot light circuit
  • Filled or dirty radiator screen and the core
  • Inattention to warning light for Check Engine warning light

Regularly maintaining your quad is usually able to prevent overheating from occurring. If not, you’ll be required to consult an expert for resolution.

Leaking Carburetor

In some instances, symptoms associated with this issue can be confused with leaks of gasoline into the oil. A little confusing because it can appear in different ways, such as hydro-locks, running too rich, or even when starting the engine. The real culprit is a leaky needle valve in the carburetor. 

If the valve fails to stop the flow of fuel to the bowl it expands and causes the excess to flow via the primary jet holder into the manifold, finally, the motor. Even with an engine and the motor is shut off, fuel continues to flow. 

Also, a blocked vent in the tank will result in pressure building up within the tank, preventing the needle from sitting. It is a must to do the use of carbs after having completed all the initial steps.

To address this issue:

  1. Drain the float completely using the drain screw, and then start the gas. This will open the needle to the fullest extent and permit the fuel to flush dust (or any other blockage) from the seat and needle.
  2. If you want to be sure to Replace the needle valve, float the seat O-ring along with the needle valve. The float level tolerances are important as well. A combination of hard and cold needle surfaces and decrease in tension of the spring of the needle and a slight increase in the float level is all you require to cause an overflow.
  3. However, you must measure the height of the float from the bowl’s mating surface up to where the bottom of the float is in the center and with the float bowl removed, and then laid on the flat surface.
  4. When both floats are adjacent to each other but without compressing the float’s spring The measure should be 13mm (.51 millimeter) +/- 1 millimeter.

Other Problems

The possible causes and solutions for misfiring or backfiring on the 2004 Sportsman 500 are the same as the issues that riders have to face in older models. The 2004 Polaris Sportsman 500 service manual pdf is an ideal source for these issues and provides troubleshooting guides that are easy to read and use. 

The spark plugs may be damaged or damaged or air filters that are blocked and fuel vent lines are some of the first places to check. The owner’s manual provides specific guidelines for contacting your Polaris dealer if the issue causes:

  • Unsufficient wiring of the plug wires
  • Incorrect timing of ignition
  • Reverse speed limiter/electronic control problem
  • And any other mechanical problem

2004 Polaris Sportsman 500 Pros and Cons

If you’re considering purchasing a Sportsman It is important to be aware of both the positive and negative qualities of this legendary off-road car. 

Its 2004 version of the Polaris Sportsman 500 has undergone certain changes in its design but isn’t quite at the level of perfection in its overall design and operation.


  • Attention to detail is excellent regarding aesthetics and construction. The materials fit better with the previous year’s releases.
  • A new, modern pod that has an industry-first tachometer has been added to this model for 2004. It houses the instruments of the quad as well as the choke knob, which greatly aids when you are cold-starting.
  • The continued use of the PVT is good news for novice cyclists and those who do like shifting.
  • Features such as the throttle, the high seat height, and the full floorboards make this quad ideal for long trails.
  • The On-Demand AWD/2WD drive system works well and will let you out of any circumstance.
  • The stock Rawhide/Titan tires are fantastic general-purpose tires, whether on a forest trail or slick slippery surfaces. They ensure that handling is predictable regardless of the terrain.
  • It is possible to access both the oil dipstick and the filter without having to remove any additional panels before doing so.
  • The 4×4 also has an installation area for a winch that was built by the factory.
  • Nothing can beat an Independent Rear Suspension on the trails.
  • It is a great powerhouse for a mid-sized, 500-class ATV.
  • In the 2004 ATP model, noteworthy points include the wider wheelbase and front racks that include storage boxes as well as rear cubbies incorporated into the rear fenders as well as the minidump bed.
  • “Turf” Mode is only available only to ATP trim, which makes the 4×4 ride more comfortable on rough terrains.


  • IRS could not be the most suitable for hauling because of the squats you’ll get in the rear.
  • The tachometer is generally slow to react, particularly when it is at lower RPMs.
  • A single lever brake system for all four wheels is very difficult.
  • You must be at or near 2,800 RPM in order to achieve the required throttle response.
  • The On-Demand All-Wheel-Drive System only works with 4WD and reverses when you press the override button.
  • EBS functions can be detrimental in difficult, hard-to-see descents. The result is that riders have no choice but to use brakes in this circumstance.
  • A rear swingarm is replacing the independent rear Suspension in the 2004 ATP trim since only a swingarm has the capacity to be used to support this specific version’s ability to pull. The drawback of this modification is that it will have lower rear-wheel travel.
  • “Turf” mode on the ATP trim “Turf” mode of the ATP trim allows the four-wheeler to take a ride on the trails.

About Polaris

Polaris Inc. is an American company that is famous for its role in the birth of an industry called snowmobiling. It was acquired through Textron, Inc. in 1968, the company was initially an agricultural equipment maker before entering the world of snowmobiles in the year 1954.

 In 1956, the firm was already acknowledged for its successes in the field of Sno Traveler and amid increasing the range of its products. Since the time, Polaris has become a major actor in the ATV market and has successfully brought its customers in the U.S. its first-ever American-made ATV in the year 1985. 

The manufacturer of the year 2004’s Polaris Sportsman 500 did not stop there and continued to venture into other fields, leading to the introduction of an automated transmission and the Independent Rear Suspension (IRS) as well as Electronic Fuel Injection (EFI).

Conclusion 2004 Polaris Sportsman 500 Review

This year’s Polaris Sportsman 500 model may be the crucial pivotal moment in the Sportsman lineage. It’s a demonstration of foresight as well as the strength that the company’s brand. 

While it is sensible not to reinvent something that is already working, however, it is the most strategic approach (for any company) to be prepared for risk. When it came to this All-Terrain Pickup trim, Polaris made sure to keep the High Output basic models to customers who are more conventional.

There are very few or no ATP models are for auction or sale which proves it’s indeed a good investment. If you happen to see one, seize the opportunity and don’t think twice. If you can’t endure a shorter rear-wheel journey as well as IRS The H.O. trim is the best way to move. 

The two quads share a motorcycle-like style and offer excellent traction on hard surfaces, and are perfect for hard work and enjoyment. Both are great options to get a taste of the many features Polaris can offer.

Are Polaris Sportsman 500 any good?

The Sportsman 500 H.O. is a highly great ATV in any way. We’re yet to discover anything that it could not do, similar to most Sportsman owners, and it’ll get to work every day and then be ready to enjoy the weekend.

Is a 2004 Polaris Sportsman 500 fuel injected?

The company behind the 2004 Polaris Sportsman 500 did not stop there. It continued to venture into different industries, which led to the development of automated transmission as well as independent rear suspension (IRS) as well as electronic fuel injection (EFI).

Which is better ATV Honda or Polaris?

The Honda is well-known for its dependability, ease to operate an excellent ride, comfort of riding, and capability to move quickly. The Polaris is more smooth than glass in rough terrain. It has tremendous power, and the EBS performs well, is exceptionally comfortable to ride as well as the steering power is top-of-the-line.

Is Sportsman 500 fuel injected?

The brand new electronic fuel injection engine has a large quantity of smooth power and is much more responsive than its predecessor, which was carbureted. Another benefit of the electronically injected fuel is that one doesn’t need to mess around with the choke, making it easy to start the Polaris(r) Sportsman(r) the 570 easy to begin.

How much can a Polaris Sportsman 500 HO pull?

The wheelbase is 50.5 inches. The dry mass of the ATV is 696lbs. The tank for fuel can hold 4.1 gallons of regular gasoline, which is unleaded. The front rack can accommodate 90 pounds. And the rear rack can hold 180 pounds. The ATV can pull 1,225 pounds.

How do you tell what year my Polaris Sportsman 500 is?

— Examine the 10th letter of the identification number of the vehicle. The 10th character is used to identify the year model of the four-wheeler.

2004 Polaris Sportsman 500 FAQ

1. What kind of oil does a Polaris 500 take?

Polaris suggests the Premium Synthetic 4 0W40 for use as engine oil since it is specifically designed to be compatible with Polaris four-cycle engines. It is a synthetic multi-viscosity, multi-viscosity engine oil that has good film strength in a wide temperature range of minus-40 to 120°F.

2. What does HO stand for on Polaris Sportsman?

HO = High Output. As mentioned earlier, Polaris changed its engine to make more horsepower from the same displacement of the engine.

3. How do you tell what year my Polaris Sportsman 500 is?

How can I determine which year I have my Polaris ATV has? Find the 17-character Identification number in the frame of your four-wheeler. It is important to Take a look at the 10th letter of the number of identification for your vehicle. Use the 10th character to determine the year of manufacture of the four-wheeler.

4. What is the top speed of a Polaris 500?

the two sportsman 500s I had previously approximately 58 100 mph tops. It was new belts and everything else stock.

5. How many ccs is a Polaris 500?

Polaris Scrambler 500 Specs & Features. Engine – Power is generated by the four-valve, liquid-cooled SOHC engine (2004 models and higher were equipped with DOHC). Its bore measures 92 millimeters and 75 millimeters of stroke. The displacement of the engine is four hundred cubic centimeters.

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