The 2004 Polaris Sportsman represents a pivotal year for this iconic utility ATV, known for its rugged body style and robust capabilities. Part of the long-standing Sportsman line, this model year offered popular trims like the Sportsman 400, 500 HO, 600, and 700, with new prices ranging from approximately $6,000 to $8,000. Its full-time AWD, independent rear suspension, and powerful engines made it stand out as a highly capable and comfortable choice for both work and recreational riders.
The Good
The 2004 Polaris Sportsman offers significant advantages, including its class-leading independent rear suspension for superior comfort and traction, robust performance from its powerful engines, and a practical reputation as a workhorse. Emotionally, it provides the thrill of adventure and confidence in challenging terrains, making it a strong value proposition for both utilitarian tasks and spirited trail riding.
The Bad
Potential weaknesses for the 2004 Polaris Sportsman include known issues with the AWD system's Hilliard clutch, occasional electrical gremlins, and some reports of premature wear on suspension bushings and wheel bearings. Buyers should also inspect for frame cracks, especially on higher-mileage or heavily used units, and check for consistent fluid leaks.
2004 Polaris Sportsman: Quick Overview
- Engine Options: The 2004 Sportsman lineup featured a range of liquid-cooled, 4-stroke engines to suit various needs. These included:
- Sportsman 400: 425cc single-cylinder engine.
- Sportsman 500 HO: 499cc high-output single-cylinder engine, renowned for its strong, reliable power.
- Sportsman 600: 597cc parallel-twin engine, offering increased torque and smoother power delivery.
- Sportsman 700: 697cc parallel-twin engine, providing the top-tier power and performance for the lineup.
- Horsepower: Exact horsepower figures were not always officially published but generally ranged from approximately 25-30 HP for the 400, around 35-40 HP for the 500 HO, and up to 45-50 HP for the 600 and 700 models, offering robust power for their respective classes.
- Fuel Economy: Fuel economy for ATVs varies significantly based on riding style, terrain, and load. Owners typically report averages ranging from 15-25 MPG for the smaller engines and 12-20 MPG for the larger 600/700 twins under mixed conditions.
- 0-60 Times: 0-60 MPH acceleration is not a standard performance metric for utility ATVs like the Sportsman. Their design prioritizes low-end torque, traction, and hauling capabilities over outright speed. Top speeds generally range from 50-65 MPH depending on the model.
- Towing Capacity: All Sportsman models were designed with utility in mind. The 2004 models offered impressive towing capacities, typically rated around 1,225 pounds (555.7 kg) on a level surface, making them excellent choices for hauling trailers, logs, or other heavy equipment.
- Trim-Level Features: Key features across the 2004 Sportsman lineup that differentiated it included:
- Independent Rear Suspension (IRS): A hallmark feature across all models, providing superior ride comfort, ground clearance, and traction over rough terrain.
- On-Demand True All-Wheel Drive (AWD): Polaris's signature system automatically engages all four wheels when the rear wheels slip, reverting to 2WD once traction is regained.
- Engine Braking System (EBS): Standard on many models, providing controlled descent on steep grades.
- Automatic PVT Transmission: A continuously variable transmission (CVT) with high/low range, neutral, reverse, and park for ease of use.
- Standard Front and Rear Racks: Ample cargo capacity for gear.
- Front Storage Box: Integrated, watertight storage for smaller items.
- Hydraulic Disc Brakes: Reliable stopping power.
- Ground Clearance: Excellent ground clearance (typically 11 inches or more) for navigating obstacles.
2004 Polaris Sportsman Specifications
Vehicle Information
| Year | 2004 |
| Make | Polaris |
| Model | Sportsman |
| Trim | - |
| Style | 4x4 |
| Type | Motorcycle |
| Category | Low Speed Vehicle |
Manufacturing Details
| Made In | Taiwan |
| Manufacturing City | TAINAN |
Dimensions
| Doors | - |
| Curb Weight | - |
| Gross Vehicle Weight Rating | - |
| Overall Height | - |
| Overall Length | - |
| Overall Width | - |
| Wheelbase Length | - |
| Standard Seating | - |
Engine & Performance
| Engine | 89cc 1cyl |
| Engine Size | 89L |
| Engine Cylinders | 1 |
| Transmission | - |
| Transmission Type | Motorcycle - Chain Drive Off-Road |
| Transmission Speeds | - |
| Drivetrain | Four-Wheel Drive |
Additional Features
| Anti-Brake System | - |
| Steering Type | - |
Pricing
| Manufacturer Suggested Retail Price (MSRP) | - |
| Invoice Price | - |
| Delivery Charges | - |
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What Problems Does the 2004 Polaris Sportsman Have?
For the 2004 Polaris Sportsman, several frequently reported problems and long-term reliability concerns have been noted by owners over the years. One of the most common issues revolves around the AWD Hilliard clutch system. Owners often report the AWD not engaging reliably, or engaging intermittently. This can sometimes be traced to worn sprague cages, faulty armature plates, or wiring issues to the front differential. Inspection of the front differential fluid and components is crucial.
Electrical problems are another area of concern. These can manifest as inconsistent starting, issues with lights, or problems with the instrument cluster. Wiring harnesses can degrade over time, connections can become corroded, and voltage regulator/rectifier failures are not uncommon, leading to battery charging problems. A thorough check of all electrical grounds and connections is recommended.
The Engine Braking System (EBS), while beneficial, can sometimes experience issues, often related to the one-way bearing in the clutch assembly. If the EBS isn't working or is making grinding noises, the clutch primary or secondary could be worn or damaged.
Suspension components, particularly bushings and wheel bearings, are wear items on any ATV, but some owners report earlier-than-expected wear on the Sportsman. Regular greasing and inspection can mitigate this. Ball joint wear is also a common issue with older ATVs, impacting steering precision.
Regarding recalls, specific information for the 2004 model year should always be checked with Polaris directly or via NHTSA records, though major recalls directly impacting structural safety or core engine components that early are less common. However, smaller service bulletins addressing specific components or procedures might exist.
Finally, the carburetor on the carbureted models (like the 500 HO) can be prone to clogging or requiring frequent cleaning, especially if fuel is left untreated over storage periods, leading to rough idling or poor performance. Regular maintenance, including fuel stabilizer use, is crucial for preventing these fuel system issues.
Electrical problems are another area of concern. These can manifest as inconsistent starting, issues with lights, or problems with the instrument cluster. Wiring harnesses can degrade over time, connections can become corroded, and voltage regulator/rectifier failures are not uncommon, leading to battery charging problems. A thorough check of all electrical grounds and connections is recommended.
The Engine Braking System (EBS), while beneficial, can sometimes experience issues, often related to the one-way bearing in the clutch assembly. If the EBS isn't working or is making grinding noises, the clutch primary or secondary could be worn or damaged.
Suspension components, particularly bushings and wheel bearings, are wear items on any ATV, but some owners report earlier-than-expected wear on the Sportsman. Regular greasing and inspection can mitigate this. Ball joint wear is also a common issue with older ATVs, impacting steering precision.
Regarding recalls, specific information for the 2004 model year should always be checked with Polaris directly or via NHTSA records, though major recalls directly impacting structural safety or core engine components that early are less common. However, smaller service bulletins addressing specific components or procedures might exist.
Finally, the carburetor on the carbureted models (like the 500 HO) can be prone to clogging or requiring frequent cleaning, especially if fuel is left untreated over storage periods, leading to rough idling or poor performance. Regular maintenance, including fuel stabilizer use, is crucial for preventing these fuel system issues.
How long will the 2004 Polaris Sportsman last?
The 2004 Polaris Sportsman, with diligent maintenance, can easily provide 10-15 years or more of reliable service, often accumulating 5,000-10,000 miles or several hundred engine hours. Its long-term durability is a strong point, especially concerning the robust powertrain if oil changes and air filter cleanings are consistent. However, the independent rear suspension, while comfortable, means more moving parts prone to wear over time. Bushings, ball joints, and wheel bearings will likely require replacement at some point, particularly with heavy use. Electrical systems can become finicky as wiring ages and connections corrode. The AWD system's Hilliard clutch is another common long-term wear item. Regular fluid changes in all differentials and the transmission are vital for maximizing lifespan.
What Technology & Safety Features are Included?
As a utility ATV from 2004, the Polaris Sportsman's "tech" is primarily focused on functionality rather than entertainment or advanced driver assistance. The built-in tech typically includes a basic but informative instrumentation cluster, often featuring a speedometer, odometer, trip meter, hour meter, and indicator lights for oil pressure, high beam, and neutral/reverse gears. Some models might have a simple digital display providing additional information.
For entertainment, there are no factory-installed features like radios or infotainment screens; the primary "entertainment" comes from the riding experience itself.
Driver-assistance features are rudimentary by modern automotive standards but were advanced for ATVs of its era. The most significant is the On-Demand True All-Wheel Drive (AWD) system, which automatically engages the front wheels when the rear wheels slip, providing critical traction without driver intervention. This acts as a basic form of traction assistance. The Engine Braking System (EBS), standard on many models, provides controlled deceleration on downhills, effectively assisting the rider in maintaining control without constantly applying the brakes.
Safety features are fundamental for an ATV. These include bright halogen headlamps for visibility, taillights and brake lights, and a robust braking system typically consisting of hydraulic disc brakes on all four wheels. A parking brake is standard. The sturdy frame and wide stance contribute to stability. Safety warnings are typically displayed on the machine regarding helmet use, rider age, and safe operating practices. There are no crash-test ratings available for ATVs from agencies like NHTSA or IIHS, as these are off-road vehicles not subject to the same road vehicle safety standards. Optional features were mostly utilitarian, such as winches, plows, cargo boxes, and brush guards, all designed to enhance the vehicle's utility and protection rather than tech or entertainment.
For entertainment, there are no factory-installed features like radios or infotainment screens; the primary "entertainment" comes from the riding experience itself.
Driver-assistance features are rudimentary by modern automotive standards but were advanced for ATVs of its era. The most significant is the On-Demand True All-Wheel Drive (AWD) system, which automatically engages the front wheels when the rear wheels slip, providing critical traction without driver intervention. This acts as a basic form of traction assistance. The Engine Braking System (EBS), standard on many models, provides controlled deceleration on downhills, effectively assisting the rider in maintaining control without constantly applying the brakes.
Safety features are fundamental for an ATV. These include bright halogen headlamps for visibility, taillights and brake lights, and a robust braking system typically consisting of hydraulic disc brakes on all four wheels. A parking brake is standard. The sturdy frame and wide stance contribute to stability. Safety warnings are typically displayed on the machine regarding helmet use, rider age, and safe operating practices. There are no crash-test ratings available for ATVs from agencies like NHTSA or IIHS, as these are off-road vehicles not subject to the same road vehicle safety standards. Optional features were mostly utilitarian, such as winches, plows, cargo boxes, and brush guards, all designed to enhance the vehicle's utility and protection rather than tech or entertainment.
What Colors Options are Available?
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In the meantime, feel free to explore the other sections for more content.
In the meantime, feel free to explore the other sections for more content.
2004 Polaris Sportsman Prices and Market Value
When new in 2004, the Polaris Sportsman models typically ranged from approximately $6,000 for the Sportsman 400 to around $8,000 for the top-tier Sportsman 700. Like most powersports vehicles, ATVs experience significant depreciation, especially in the initial years. Today, a used 2004 Polaris Sportsman can be found anywhere from $2,000 to $4,500, heavily dependent on condition, mileage/hours, and trim level. Models like the 500 HO and 700 often hold their value better due to their desirable performance. Factors affecting current resale value include overall mechanical condition, evidence of regular maintenance, tire wear, cosmetic damage, presence of accessories (like a winch or plow), and whether it comes with a clear title. Well-maintained units with lower hours and no major known issues command higher prices, reflecting the model's reputation for durability.
2004 Polaris Sportsman Cost of Ownership
Long-term ownership of a 2004 Polaris Sportsman can be moderately economical if well-maintained, but costly if neglected. Insurance for ATVs is generally affordable, especially for older models, often ranging from $100-$300 annually for basic coverage. Fuel costs are moderate; while not extremely fuel-efficient, it's typically used for specific tasks or recreational rides, not daily commuting. Maintenance involves regular oil changes, air filter cleaning, and greasing, which are DIY-friendly and reasonably priced. However, repairs, especially for the AWD system, suspension components, or electrical issues, can become costly due to parts and labor. Tires are a significant consumable expense. Overall, it's an economical vehicle for its capabilities, provided preventative maintenance is consistently performed to avoid major repairs.
2004 Polaris Sportsman Fuel Efficiency
Fuel Type
Gasoline
Fuel Capacity
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Highway Mileage
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2004 Polaris Sportsman Insurance
Insurance for a 2004 Polaris Sportsman is moderately priced, reflecting its status as a Motorcycle with strong safety ratings and
reasonable repair costs.
reasonable repair costs.
How Does the 2004 Polaris Sportsman Compare to Other Motorcycle?
The 2004 Polaris Sportsman competed fiercely with several key rivals in the utility ATV segment, most notably the Honda Rancher/Rubicon, Yamaha Grizzly, and Kawasaki Prairie/Brute Force.
In terms of performance, the Sportsman, especially the 500 HO, 600, and 700 models, offered strong power and torque, often matching or exceeding competitors like the Honda Rubicon 500 or Yamaha Grizzly 660 in outright grunt. Its true On-Demand AWD system was a significant advantage over some rivals' selectable 4WD.
For features, the Sportsman truly stood out with its legendary Independent Rear Suspension (IRS), providing a significantly smoother and more comfortable ride over rough terrain compared to the solid rear axle designs still found on many Honda models (like the Rancher) or some Kawasaki models. This made it a favorite for long rides and uneven landscapes. The storage capacity, particularly the integrated front box, was also a practical bonus.
Reliability is where the competition often had a slight edge in some areas. Honda's reputation for bulletproof reliability with its simpler designs (e.g., solid axle, conventional automatic transmission) was formidable. The Sportsman's more complex IRS, AWD system, and sometimes finicky electricals meant it might require more attention to maintenance to maintain peak reliability. Yamaha's Grizzly 660 was also known for strong reliability but had a more traditional feel.
Regarding price, new, the Sportsman was competitively priced within the mid-to-high end of the utility ATV market. On the used market, a well-maintained Sportsman often holds its value well due to its features, but older Honda models might command a premium for their perceived bulletproof nature.
Similar Alternatives:
The Sportsman was often considered a "comfort king" among its peers due to the IRS, making it a better choice for riders prioritizing ride quality over absolute bulletproof simplicity.
In terms of performance, the Sportsman, especially the 500 HO, 600, and 700 models, offered strong power and torque, often matching or exceeding competitors like the Honda Rubicon 500 or Yamaha Grizzly 660 in outright grunt. Its true On-Demand AWD system was a significant advantage over some rivals' selectable 4WD.
For features, the Sportsman truly stood out with its legendary Independent Rear Suspension (IRS), providing a significantly smoother and more comfortable ride over rough terrain compared to the solid rear axle designs still found on many Honda models (like the Rancher) or some Kawasaki models. This made it a favorite for long rides and uneven landscapes. The storage capacity, particularly the integrated front box, was also a practical bonus.
Reliability is where the competition often had a slight edge in some areas. Honda's reputation for bulletproof reliability with its simpler designs (e.g., solid axle, conventional automatic transmission) was formidable. The Sportsman's more complex IRS, AWD system, and sometimes finicky electricals meant it might require more attention to maintenance to maintain peak reliability. Yamaha's Grizzly 660 was also known for strong reliability but had a more traditional feel.
Regarding price, new, the Sportsman was competitively priced within the mid-to-high end of the utility ATV market. On the used market, a well-maintained Sportsman often holds its value well due to its features, but older Honda models might command a premium for their perceived bulletproof nature.
Similar Alternatives:
- Yamaha Grizzly 660 (2002-2008): Excellent all-around performance, good reliability, similar IRS, and strong utility. A very close rival.
- Honda Rubicon 500 (2001-2004): Known for exceptional reliability and Honda's unique "Hondamatic" transmission. Less comfortable ride due to swingarm rear suspension, but incredibly durable.
- Kawasaki Prairie 650/700 (2002-2006): Offered V-twin power, which was unique at the time, and a spirited ride. Also featured IRS.
The Sportsman was often considered a "comfort king" among its peers due to the IRS, making it a better choice for riders prioritizing ride quality over absolute bulletproof simplicity.
Final Verdict: Is the 2004 Polaris Sportsman a Good Motorcycle?
The 2004 Polaris Sportsman is an excellent used ATV ideal for riders prioritizing comfort, ground clearance, and robust utility capabilities. It's particularly suited for those who tackle challenging trails, use their ATV for demanding work like plowing or hauling, or simply desire a smooth ride over rough terrain thanks to its independent rear suspension. It's definitely worth buying as a used machine, offering significant value for its current market price. However, buyers should seek out a unit with a well-documented maintenance history and perform a thorough pre-purchase inspection, paying close attention to the AWD system, electrical components, and suspension wear. The Sportsman 500 HO and 700 trims offer the best balance of power and features for most users. Avoid heavily abused or poorly maintained examples unless you're prepared for potential repair costs. Overall, it's a capable and comfortable workhorse that still delivers adventure.
Simon A
Simon is a contributor to VinCheck, where he provides articles and reviews on various automotive topics. His work focuses on delivering accurate and up-to-date information about used cars, helping readers make informed decisions.