20 Most Recent Polaris 2004 Sportsman 400 Questions & Answers


did you check the float height?

Polaris 2004... | Answered on May 22, 2017


Hi ! for an informantion,, please visit the website below. If you need more information about a specific electrical issue you can reach me at motor@motorpartstore.com. Motor Part Store Motor Parts Wholesale

Polaris 2004... | Answered on May 07, 2016


may need topping up with oil

Polaris 2004... | Answered on Nov 03, 2015


replace the battery as there is not enough charge to start and provide power for the ignition
when you pull start the max power is provided to the ignition system

Polaris 2004... | Answered on Mar 23, 2015


0w-40 synthetic, I get mine at auto zone. 2 quarts in, and run the machine a few seconds and check and top off with third quart if needed. You also have to prime the oil pump by pinching off the oil hose.

Polaris 2004... | Answered on Mar 17, 2015


Get codes from the dianbostic computer reader at Pep Boys/ Autozone etc. or the dealer.
This should tell you which sensor is out

Polaris 2004... | Answered on Mar 17, 2015


Just a suggestion but you should consider soldering all your electrical connections to insure they are weather and vibration proof. Additionally, I added a small 3 amp circuit breaker, but a 1.5 to 2 Amp automotive fuse and fuse holder will do nicely.

Process:

1- Disassemble the 'Instrument/Light' cluster cover.

2- Remove the 'Radiator access' panel.

>>>Perform This Test BEFORE Proceeding and make SURE all power is OFF!<<<

3-On the drivers LEFT side of the radiator access area, locate two (2) connectors, each with SOLID GREY wires and BROWN wires with a WHITE Stripe on top and smaller diameter Solid Grey and Brown wires with a White stripe leading down.
--a) Disconnect both connectors by pulling the top and bottom sections away from each other. (DO NOT pull the WIRES, use the connector body to pull).
--b) Test EACH of the two (2) connectors with the SMALL DIAMETER wires leading down. (see Hub Coil Connectors pix)
--c) Using an OHM meter, measure the resistance across the two pins (one connector at a time) for each connector. Depending on the accuracy and sensitivity of the meter, each connector should read between 25 and 28 OHMS. NOTE: If EITHER of the two (2) Hub Coils reads ZERO (0) or less than 25 or Greater than 28 OHMS STOP!!! The Hub Coil itself OR the wires OR the connectors may be defective or in need of repair!
--d) Using an OHM meter, on EACH of the two connectors, measure the resistance between one pin of each connector and GROUND (any bare metal point on the ATV frame). NOTE: If EITHER of the two (2) connectors resistance to GROUND reads anything GREATER/ABOVE than ZERO ( 0 ) OHMS STOP!!! The Hub Coil itself OR the wires OR the connectors may be defective or in need of repair!

>>>If the test in 'c)' or 'd)' FAIL STOP, DO NOT proceed!! The Hub Coil itself OR the wires OR the connectors may be defective and MUST be repaired before ANYTHING else is done!<<<

4-(For my model) On the right handlebar, check the lamp in the AWD switch to make sure it is not burned out or missing. Replace lamp if necessary. (Not essential to the AWD operation, just nice to have to confirm voltage is being applied to the front wheel Hub Coils)

5-In the 'Radiator Access' area, locate the Red/White stripe wires providing (switched) full time + (battery plus) voltage (accessory power) via a ΒΌ" female connector. "Accessory Leads" - in the wiring diagram.

6-Using a volt meter (or continuity light), CONFIRM that the terminal is OFF (NO voltage) when the ignition switch and the 'Engine STOP/START switch (on the left handlebar) are both OFF, and has + (positive) battery voltage, when the ignition switch and 'Engine STOP/START switch are both ON, with the engine NOT running.

Polaris 2004... | Answered on Mar 17, 2015


Could possibly be the cdi unit is overheating/going bad.

Polaris 2004... | Answered on Nov 24, 2014


Test your battery to make sure your voltage regulator is working.Plows do drain batteries,but they are supposed to recharge.

Polaris 2004... | Answered on Sep 29, 2014


If this modle has a fuel pump try rebuilding it.

Polaris 2004... | Answered on Sep 29, 2014


You either have the wrong drive belt on it,or the clutch is not totally disengauging.

Polaris 2004... | Answered on Sep 29, 2014


You can check a solenoid by using an ohm meter. Or just take it to a auto shop and ask them to check it for you if you don't have one. They can check it real quick and shouldn't charge you anything.

Polaris 2004... | Answered on Sep 12, 2014


sounds like you need a new camshaft and exhaust rocker arm. they are a very common problem and i had 2 sportsmans that did exactly the same thing. you can buy high quality forged camshafts on ebay that will not wear out like stock polaris or cheap aftermarket cams.

Polaris 2004... | Answered on Jun 05, 2014

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