2004 Bombardier Outlander 400 Problems(With Fixes)

The 2004 Bombardier Outlander 400 is one of the most popular models available, but like all vehicles, it has its own set of common problems. 

In this article, we’ll discuss some of the most frequently reported problems of the 2004 Bombardier Outlander 400 and provide helpful solutions. 

2004 Bombardier Outlander 400 Problems

Bombardier Outlander 400 Problems

1. Poor Starting Reliability

The 2004 Bombardier Outlander 400 had an issue with poor starting reliability due to the engine having difficulty receiving sufficient fuel. 

This was caused by a lack of fuel pressure and air leakages in the carburetor. 


To fix this issue, it is necessary to check the fuel pump and filter for any blockages or damages, as well as inspect the carburetor for any air leaks. 

Replacing the spark plugs may also improve starting reliability if needed.

2. Poor Durability of Plastic Bodywork

The Bombardier Outlander 400 was known to have poor durability of its plastic bodywork, making it prone to cracking and fading in the sun. 

This led to dissatisfaction among customers and saw many turn to other models for their offroad needs. 


Fortunately, Bombardier responded by introducing tougher polyesters that could withstand UV rays, chemical substances, and temperatures up to 300°C (572°F). 

In addition, these materials were also lightweight and able to retain their shape even after being bent or twisted. 

This improved the overall toughness of the bodywork while also reducing the amount of maintenance required on a regular basis.

3. Weak Front Suspension

The Bombardier Outlander 400 has had reports of weak front suspension. This can be an issue for riders, as it presents a safety hazard. 

The weak front suspension can cause the ATV to bounce more than normal, resulting in reduced stability and responsiveness when riding on uneven terrain. 


To fix this problem, the front shock absorbers must be replaced with new ones that are capable of adequately absorbing impact and shock from uneven surfaces. 

Additionally, upgrading the suspension to aftermarket shocks designed for off-road use can further improve the ATV’s overall durability and performance on rough terrain.

4. Erratic Ignition System

The erratic ignition system in the 2004 Bombardier Outlander 400 can be a major cause for concern. 

This issue is typically caused by faulty spark plugs, a weak battery or a poor electrical connection. 

The most common symptom of an erratic ignition system is difficulty starting the engine, resulting in misfiring and sputtering. 


To diagnose this problem, it is best to check the spark plugs for wear and tear, inspect the battery for any potential failure and make sure all wiring connections are tight and secure.

 If these solutions do not solve your problem, you may need to replace your ignition system components with those designed specifically for your vehicle model.

5. Overheating Issues

The Bombardier Outlander 400 is known to sometimes suffer from overheating issues due to a combination of factors, such as insufficient airflow and blockages in the cooling system. 

Insufficient airflow can be caused by clogged air filters or blocked fins on the radiator. Blockages in the cooling system may be caused by a buildup of debris or mud in the radiator or hoses. 

If left unchecked, this can lead to significant damage to critical engine components, such as pistons, cylinders, and gaskets. 


To avoid an overheating issue, it is important to regularly service your Outlander 400 and ensure that all air filters are clean and free of obstructions. 

It is also important to inspect the cooling system for any debris or blockages that could inhibit proper airflow.

6. Clutch Slippage

Clutch slippage can be one of the most frustrating problems to experience with a 2004 Bombardier Outlander 400. 

It occurs when the clutch does not properly disengage, causing the engine to rev up without accelerating as it should. This can lead to stalling or power loss while driving. 

The cause of clutch slippage is usually attributed to improper adjustment and alignment of the clutch cable, worn-out parts, too much oil in the system, or simply wear and tear on the clutch components over time.


To fix this problem, it is recommended that you have your Bombardier Outlander inspected by a qualified technician who can properly adjust and replace the necessary parts. 

In addition to that, regular maintenance such as changing out fluids and lubrication will help ensure your 2004 Bombardier Outlander 400 functions properly for years to come.

7. Clogged Fuel Filters

Clogged fuel filters are a common problem in the Bombardier Outlander 400. 

These clogs can occur when dirt and other contaminants get into the fuel system, restricting the flow of gasoline through the engine. 

This can cause a decrease in performance – power will be lost, acceleration will be sluggish, and fuel economy will suffer. 


The best way to prevent this from happening is by changing out your fuel filter regularly according to manufacturer instructions. 

If you do experience any of these symptoms, it’s important to take immediate action to clean or replace your fuel filter before further damage is done.


The 2004 Bombardier Outlander 400 is a dependable ATV, but it’s also prone to certain issues. 

If you own one of these models or are considering purchasing one in the future, make sure you understand and keep an eye out for potential problems. 

Technical Specification of Bombardier Outlander 400:

Engine400cc, Single-Cylinder, 4-stroke
HorsepowerVaries by model/year
TransmissionAutomatic CVT with Reverse
Drive SystemSelectable 2WD/4WD with Visco-Lok QE
Suspension (Front)Independent Double A-arm
Suspension (Rear)Torsional Trailing Arm Independent
Brakes (Front)Dual Hydraulic Disc
Brakes (Rear)Hydraulic Disc

Pros and Cons of Bombardier Outlander 400:


  1. Reliable Engine: The engine used in the Outlander series is known for its reliability and performance.
  2. Comfortable Ride: The ATV is equipped with an independent rear suspension system, making it comfortable even on rugged terrains.
  3. Versatility: The Outlander 400 is suitable for a variety of tasks including recreation, hunting, and light utility work.
  4. Selectable 2WD/4WD: This feature allows riders to switch between two-wheel drive and four-wheel drive depending on the conditions.
  5. Storage: The front and rear racks offer practical storage options for gear or games.
  6. Safety: The ATVs in this series often come with features like a digital security system to prevent theft.


  1. Weight: The Outlander series tends to be heavier compared to some competing models, which might affect maneuverability for some riders.
  2. Fuel Efficiency: While the engine is powerful, it may not be the most fuel-efficient in its class.

Frequently Asked Questions

How much is a 2004 Bombardier worth?

Generally, a good-condition 2004 Bombardier Outlander 400 can be worth anywhere from $2,000 to $3,500 USD.

How much horsepower does a 2004 Bombardier Outlander 400 have?

The 2004 Bombardier Outlander 400 has a 340cc engine producing 36 horsepower

This provides enough power to reach speeds of up to 45 mph, making it an ideal vehicle for exploring tough terrain. 

Who makes Bombardier Outlander 400?

Bombardier Outlander 400 is made by Bombardier Recreational Products, a Canadian company that specializes in the manufacturing of ATVs and snowmobile vehicles.

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