I have a 2004.5 400 and asked the same question before. From what I can tell the only difference is that the 2004 has the fuel gauge on the tank, and the 2004.5 has it on the digital gauge.
So far no issues, but then I haven't owned it very long. Mine does have a lift on it, and it sits just as high as the new 500's, so I would recommend that.
As I understand it the 04 had the fluid filled hubs and the locking-unlocking occured there, in 04.5 they switched over to the central Hilliard system where the action occurs in the front diff. and these have no fluid in there hubs.
Thats a pretty serious drive just to ride. The 2004.5 sportsmans have a fuel gage with I think a little smaller fuel tank. The 2004 does not have a fuel gage and i think a little bigger fuel gage.
Hello, I have a 2004.5 Polaris sportsman 400 and I need the wiring harness. Does anyone know were i can get a used one for this model?
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