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2004 SPORTSMAN
Polaris 2004 SPORTSMAN User Manual
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Owner's Manual
for V
ehicle Maintenance
and Safety
Owner's Manual
for V
ehicle Maintenance
and Safety
2004
2004
R
ead this manual carefully
. It contains impor
tant safety infor
mation.
This is an adult vehicle only
.
Operation is prohibited for those under 16 years of age.
SPORTSMAN
SPORTSMAN
2
Table of Contents
Welcome
5
Vehicle Identification Numbers
6
Table of Contents
7
Safety
8
Safety Decals and Locations
9
Safe Riding Gear
12
Age Restrictions
13
Know Your Vehicle
13
Operator Safety
13
Safety Training
13
Equipment Modifications
17
Controls
38
Throttle Lever
39
Brake Lever
40
Light Switches
40
Master Cylinder
41
Parking Brake
42
Setting the Parking Brake
42
Auxiliary Brake
43
Fuel Valve
44
Fuel Tank
44
Fuel Filter
44
Features
46
Engaging Front Gearcase
46
Instrument Cluster
47
Rider Information Center
48
Operation
52
Fuel Safety
52
Break-In Period
53
Pre-Ride Inspection
54
Starting the Engine
55
Starting a Cold Engine
55
Starting a Warm Engine
56
Cold Weather Operation
56
Hauling Cargo
57
Driving Safely
59
Driving Procedures
59
Making Turns
60
Driving on Slippery Surfaces
61
Traveling Uphill
62
Traveling Downhill
64
Turning Around on a Hill
65
Driving through Water
66
Driving over Obstacles
67
Driving in Reverse
68
Parking on an Incline
69
Emission Control Systems
70
Noise Emission Control System
70
Exhaust Emission Control System
70
Crankcase Emission Control System
70
Maintenance and Lubrication
71
Periodic Maintenance Schedule
72
Lubrication Guide
78
Premium 4 Synthetic Lubricant
80
Oil Check
81
Oil and Filter Change
82
Oil Change
85
Coolant Level
90
Engine Cooling System
90
Radiator Coolant Level
91
Front Brake
92
Rear Brake
93
Steering Assembly
94
Toe Alignment
94
Side Panel Removal
95
Wheel Removal
96
Front Wheel Hub Tightening
97
Wheel Installation
97
Wheel Nut Torque Specifications
97
Air Filter Service
98
Filter Systems
98
Headlight Lamp Replacement
99
High Beam Adjustment
100
Headlight Housing Replacement
101
Spark Plugs
103
Vehicle Immersion
104
Spark Arrestor
105
High Range
106
Low Range
106
Pvt System
106
Pvt Drying
107
Battery Installation
109
Battery Removal
109
Battery Storage
110
Cleaning and Storage
112
Storage Tips
113
Transporting the Atv
115
Camber and Caster
116
Rear Spring
116
Carburetor/Idle Rpm
117
Throttle Cable Freeplay
118
Troubleshooting
119
Engine Overheating
122
Polaris Products
123
Specifications
124
Warranty
132
4
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Polaris 2004 SPORTSMAN Specifications
General
Brand
Polaris
Model
2004 SPORTSMAN
Category
Offroad Vehicle
Language
English
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