2004 Polaris Sportsman 400 Parts Manual

E 2003 Polaris Sales Inc. PARTS MANUAL PN 9918725 and MICROFICHE PN 9918726 7/03 SPORTSMAN 400 Model #A04CH42AQ Model #A04CH42AT Model #A04CH42AV Model #A04CH42AS Model #A04CH42AR Rev. 01

TABLE OF CONTENTS SPORTSMAN 400 A04CH42AQ and SPORTSMAN 400 A04CH42AT and SPORTSMAN 400 A04CH42AV and SPORTSMAN 400 A04CH42AR and SPORTSMAN 400 A04CH42AS A A -ARM C3 ............................ AIR BOX B2 ........................... B BUMPER MOUNTING A7-8 ................. C CALIPER, REAR B9 ..................... CARBURETOR D5-6 ....................... CLUTCH COVER C8 ..................... CONTROLS - MASTER CYLINDER/BRAKE LINE B5 ............ CONTROLS - THROTTLE ASM./CABLE B6 .... COOLING SYSTEM A12 ................... CRANKCASE D2 ........................ CRANKSHAFT and PISTON D4 ............. CYLINDER D3 .......................... D DECALS A10-11 ........................... DRIVE CLUTCH C6 ...................... DRIVE SHAFT B10 ....................... DRIVE SHAFT, REAR B11 ................. DRIVEN CLUTCH C7 ..................... E ELECTRICAL/TAILLIGHT C12 ............... ENGINE MOUNTING A13-14 .................. EXHAUST SYSTEM B1 ................... F FOOT PEDAL B8 ........................ FRONT CAB A5 ........................ FRONT HOUSING D1 .................... FUEL PUMP D9 ......................... FUEL TANK B3 ......................... G GEAR SELECTOR C5 .................... GEARCASE C13-14 ......................... H HANDLEBAR C1-2 ........................ HEADLIGHT POD C1-2 ..................... I INTAKE and EXHAUST D7 ................. M MAGNETO D14 .......................... MASTER CYLINDER, REAR B8 ............ O OIL FILTER D11 ......................... OIL PUMP D10 .......................... OIL TANK B4 ........................... P PROP SHAFT B12 ....................... R RACK MOUNTING, FRONT A7-8 ............. REAR CAB and SEAT A3-4 ................. REAR RACK MOUNTING A6 ............... REAR SUSPENSION C9-10 .................. REAR WHEEL DRIVE C11 .................. RECOIL STARTER D12 .................... S STARTING MOTOR D13 ................... STEERING POST C4 ..................... STRUT MOUNTING C3 ................... STRUT, FRONT B13 ...................... T TOOL KIT E1 ........................... W WATER PUMP D8 ....................... WHEEL, FRONT B14 ...................... WINCH ASM. A9 ........................ The illustrations used in this Parts Manual are for reference to replacement parts only. This manual is not to be used for assembly.

A3 REAR CAB and SEAT SPORTSMAN 400 A04CH42AQ and SPORTSMAN 400 A04CH42AT and SPORTSMAN 400 A04CH42AV and SPORTSMAN 400 A04CH42AR and SPORTSMAN 400 A04CH42AS 1 6 2 5 8 9 14 13 15 16 17 32 12 19 28 35 37 38 33 30 11 3 31 18 2 20 26 24 25 20 7 23 22 21 27 29 5 20 22 23 E 2003 Polaris Sales Inc. 4 10 34 36

A4 REAR CAB and SEAT SPORTSMAN 400 A04CH42AQ and SPORTSMAN 400 A04CH42AT and SPORTSMAN 400 A04CH42AV and SPORTSMAN 400 A04CH42AR and SPORTSMAN 400 A04CH42AS Ref. Part No. Qty. Description Ref. Part No. Qty. Description 1 7511930 2 Bolt 2 7555792 4 Washer 3 5811107 1 Foil, Rear Cab, Rear 4 5432117-400 5435164-455 5435164-456 5432117-341 5432117-053 1 1 1 1 1 Cab, Rear, Camo Green Metallic (AQ) Cab, Rear, Break-Up (AT) Cab, Rear, Shadowgrass (AV) Cab, Rear, Sonic Blue Met. (AS) Cab, Rear, Med. Yellow (AR) 5 7541925 4 Nut, Nylok 6 5224592 1 Retainer, Seat Latch 7 5811308 1 Foil, Tape, Rear Cab 8 7512242 4 Screw 9 7555859 4 Washer, Flat 10 7556034 4 Washer 11 7512085 2 Screw 12 5431786 1 Box, Tool 13 7621403 2 Rivet 14 5211033 2 Bracket, Lever Retainer 15 1040387 1 Latch, Seat 16 7041370 1 Spring, Latch 17 2683222-070 2683418-070 2682958-070 1 1 1 Asm., Seat, Black (AQ)(AR)(AS) Asm., Seat, Black w/Gold Polaris (AT)(AV) Covering, Seat, Black 18 5412067 8 Bumper, Rubber 19 5431787 1 Cover, Tool Box 20 7542122 8 Nut, Nylok 21 ------- 1 Front Housing (See Front Housing Pg. D1 for Details) 22 7552603 7 Washer, Spring Lock 23 7512492 7 Screw 24 5432280 2 Spacer, Footwell 25 7517377 4 Screw 26 1014189-067 1 Frame, Main, Black 27 7170911 1 Decal, Hitch 28 7517376 8 Screw 29 5432221-070 5433219-070 1 1 Footwell, Black, LH Footwell, Black, RH 30 5811111 1 Foil, Foam, Rear Fender 31 5811106 2 Foil, Rear Cab, Front 32 7079902 1 Decal, Carb/Filter Information 33 5811087 1 Foil, Foam 34 7517312 2 Screw 35 7512232 22 Screw 36 7555832 2 Washer 37 7670057 22 Nut, U-Type Speed 38 5434704-070 5434705-070 1 1 Guard, Mud, Rear, LH Guard, Mud, Rear, RH 7/03

A5 FRONT CAB SPORTSMAN 400 A04CH42AQ and SPORTSMAN 400 A04CH42AT and SPORTSMAN 400 A04CH42AV and SPORTSMAN 400 A04CH42AR and SPORTSMAN 400 A04CH42AS 3 4 2 6 8 15 21 22 13 20 19 24 6 23 1 1 9 1 12 16 5 10 18 14 E 2003 Polaris Sales Inc. 7 17 11 11 11 Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly. Ref. Part No. Qty. Description Ref. Part No. Qty. Description 1 7517312 2 Screw 2 2632748-400 2632818-455 2632818-456 2632748-053 2632748-341 1 1 1 1 1 Cab, Front, Camo Green Met (AQ) Cab, Front, Break-Up (AT) Cab, Front, Shadowgrass (AV) Cab, Front, Med. Yellow (AR) Cab, Front, Sonic Blue Met (AS) 3 5435110-400 5435166-455 5435166-456 5435110-053 5435110-341 1 1 1 1 1 Cover, Front, Camo Green Met (AQ) Cover, Front, Break-Up (AT) Cover, Front, Shadowgrass (AV) Cover, Front, Med. Yellow (AR) Cover, Front, Sonic Blue Met. (AS) 4 7670085 2 Clip, Spring 5 7621509 2 Rivet, Plasti-Loc 6 7670057 12 Nut, U-Type Speed 7 5246872 1 Guard, Splash, LH/Pump Mount 8 7670135 2 Nut, Speed 9 7512232 10 Screw 10 7670156 2 Clip, Retaining 11 7542122 3 Nut, Nylok 12 4020139 1 Clip, Rosebud 13 7556034 2 Washer 14 7555859 2 Washer, Flat 15 5434702-070 5434703-070 1 1 Guard, Mud, Front, LH Guard, Mud, Front, RH 16 5246021-067 1 Guard, Splash, RH 17 7512126 1 Screw 18 7515158 2 Screw 19 7541925 2 Nut, Nylok 20 7555792 2 Washer 21 5435322-400 2622471-400 5435335-455 2632819-455 5435335-456 2632819-456 5435322-053 2622471-053 5435322-341 2622471-341 5812138 1 1 1 1 1 1 1 1 1 1 1 Panel, Side, Green Met, LH (AQ) Panel/Foil, Green Met, RH (AQ) Panel, Side, Break-Up, LH (AT) Panel/Foil, Break-Up, RH (AT) Panel, Side, Shadowgrass, LH (AV) Panel/Foil, Shadowgrass, RH (AV) Panel, Side, Med. Yellow, LH (AR) Panel/Foil, Med. Yellow, RH (AR) Panel, Side, Sonic Blue Met., LH (AS) Panel/Foil, Sonic Blue Met., RH (AS) Foam, LH 22 5812329 5812326 1 1 Foil, Side Panel, RH Foil, Side Panel, RH (AT)(AV) 23 5811491 1 Foil, Side Panel, RH 24 7512085 2 Screw 7/03

A6 REAR RACK MOUNTING SPORTSMAN 400 A04CH42AQ and SPORTSMAN 400 A04CH42AT and SPORTSMAN 400 A04CH42AV and SPORTSMAN 400 A04CH42AR and SPORTSMAN 400 A04CH42AS 1 2 3 5 8 9 7 10 11 12 6 2 7 4 E 2003 Polaris Sales Inc. 4 Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly. Ref. Part No. Qty. Description Ref. Part No. Qty. Description 1 1040510-418 1 Extender, Rack, Rear (AT)(AV) 2 7517983 2 Screw 3 7517685 2 Screw 4 7555916 2 Washer, Nylon 5 2632669-070 2632837-070 1 1 Asm., Rack, Rear (Incl. Warning Decal) (If built before 2/03/03) Asm., Rack, Rear (Incl. Warning Decal) (If built after 2/03/03) 6 5334092 2 Spacer 7 7558402 8 Washer, Flat 8 7512329 4 Bolt 9 ------- 1 Bracket, Silencer, Frame (See Ex- haust System Pg. B1, Ref. 6) 10 7542324 4 Nut, Nylok 11 1013724-067 1 Support, Rear Rack 12 7517208 6 Screw (AT)(AV) 5/03

A7 FRONT RACK and BUMPER MOUNTING SPORTSMAN 400 A04CH42AQ and SPORTSMAN 400 A04CH42AT and SPORTSMAN 400 A04CH42AV and SPORTSMAN 400 A04CH42AR and SPORTSMAN 400 A04CH42AS 27 6 22 7 26 9 10 14 5 20 4 24 13 17 16 21 15 11 14 21 21 8 7 18 22 7 7 8 27 12 25 23 19 8 E 2003 Polaris Sales Inc. 3 1 2 7

A8 FRONT RACK and BUMPER MOUNTING SPORTSMAN 400 A04CH42AQ and SPORTSMAN 400 A04CH42AT and SPORTSMAN 400 A04CH42AV and SPORTSMAN 400 A04CH42AR and SPORTSMAN 400 A04CH42AS Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly. Ref. Part No. Qty. Description Ref. Part No. Qty. Description 1 1013972-418 1 Extention, Front Rack (AT)(AV) 2 7081085 2 Plug, Barbed (AT)(AV) 3 7517208 4 Screw 4 7517685 4 Screw 5 5434697-070 5435240-070 1 1 Rack, Front, Black (If built before 2/03/03) Rack, Front, Black (If built after 2/03/03) 6 2431017 4030059 2 2 Headlight Bulb, Replacement, 27W 7 7558402 10 Washer, Flat 8 7542324 8 Nut, Nylok (Qty 10 for AT,AV) 9 2632758-070 1 Asm., Bumper, Front, Black (Incl. Warning Decal) 10 7515306 4 Screw 11 5434699-070 1 Panel 12 7512094 2 Screw 13 1013366-067 1 Guard, Brush 14 5434314 5434315 1 1 Shield, Side, Radiator, LH Shield, Side, Radiator, RH 15 5412504 4 Grommet 16 5435046 1 Cover, Radiator 17 5247507-067 1 Grill, Brush Guard 18 7522021 4 Screw 19 7670094 6 Nut, U-Type 20 7512097 6 Screw 21 7515399 4 Screw 22 7512329 2 Screw 23 7171474 7171475 1 1 Decal, Reflector, Amber, LH Decal, Reflector, Amber, RH 24 1014020-067 1 Support, Front Rack 25 5810467 1 Plug, Frame 26 1014261-067 1014262-067 1 1 Support, Front Rack, LH Support, Front Rack, RH 27 7512232 6 Screw 7/03

A9 WINCH ASM. SPORTSMAN 400 A04CH42AT and SPORTSMAN 400 A04CH42AV E 2003 Polaris Sales Inc. 7 27 20 25 20 20 20 26 17 21 24 13 17 7 7 7 7 7 22 12 18 23 11 14 15 16 1 3 2 4 19 9 5 10 8 6 Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly. Ref. Part No. Qty. Description Ref. Part No. Qty. Description 1 2410423 1 Asm., Winch Switch 2 7518304 2 Screw 3 5247139 1 Plate, Switch Mount 4 5133010 2 Spacer, Master Cylinder Clamp 5 7512247 2 Bolt 6 2202254 1 Contactor 7 7558402 10 Washer, Flat 8 7512329 1 Bolt 9 5247570 1 Bracket, Contactor 10 7542122 2 Nut, Nylok 11 2202253 1 Asm., Hook, Warn Winch 12 2202643 1 Asm., Winch, Warn w/Cable 13 5247568 1 Plate, Fairlead Mount 14 2871462 1 Roller, Fairlead, Warn Winch 15 7515494 2 Screw 16 7542451 2 Nut, Nylok 17 7512392 4 Screw 18 2461220 1 Harness, Front 19 2461218 1 Harness, Main 20 7542324 10 Nut, Nylok 21 5434698-070 1 Bumper, Front 22 2431017 2 Asm., Headlight, Bottom Mount 23 1014020-067 1 Support, Rack, Front 24 5247569 1 Plate Mount 25 7515321 4 Bolt 26 7515317 4 Screw 27 7552901 4 Washer, Spring Lock 5/03

A10 DECALS SPORTSMAN 400 A04CH42AQ and SPORTSMAN 400 A04CH42AR and SPORTSMAN 400 A04CH42AS RH LH 10 11 19 20 21 7 8 18 13 6 4 5 17 16 9 2 1 2 9 3 14 15 E 2003 Polaris Sales Inc. 12 Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly. Ref. Part No. Qty. Description Ref. Part No. Qty. Description 1 7170991 2 Decal, Reflector, Red 2 7170021 2 Decal, Warning Front and Rear Rack 3 7170999 7171953 1 1 Decal, “4X4”, Side Panel, Lower, LH Decal, “4X4”, Side Panel, Lower, RH 4 7078253 1 Decal, Age Warning, 16 ATV 5 7170993 7170994 1 1 Decal, Tankside, LH Decal, Tankside, RH 6 7079780 1 Decal, Warning, AWD Switch, White 7 7078003 1 Decal, Headlight Adjustment 8 7078465 1 Logo, Polaris Star 9 7171474 7171475 1 1 Decal, Reflector, Amber, LH Decal, Reflector, Amber, RH 10 7078577 1 Decal, Drain Recoil 11 7079773 7079916 1 1 Decal, Front Cover, “POLARIS” (AQ)(AS) Decal, Front Cover, “POLARIS” (AR) 12 7079672 1 Decal, Foot Brake 13 7079604 1 Decal, Warning, Override, AWD 14 7170995 7170996 1 1 Decal, Side Panel, Top, LH Decal, Side Panel, Top, RH 15 7170997 7170998 1 1 Decal, Side Panel, Middle, LH Decal, Side Panel, Middle, RH 16 7079977 1 Decal, IRS, Rear 17 7079959 1 Decal, “POLARIS”, Rear 18 7079084 1 Decal, Tire Pressure/Load 19 7077920 1 Decal, Passenger Warning 20 7171383 1 Decal, Discretional Warning 21 7079083 1 Decal, Warning, General, CPSC 7/03

2004 Polaris Sportsman 400 Parts Manual

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