Basic Information Identification Make: Polaris Model: ATV 400 4x4 Model Variant: 400 4x4 Model Years Covered: 1994, 1995 Product Name: Polaris ATV 400 4x4 1994 1995 Service Repair Workshop Manual PDF Download Codes Vin Decoder Note: VIN information not provided in product data, but typically found on the vehicle's frame. Engine Code Note: Specific engine codes not detailed in product data; engine identification typically via displacement and configuration. Introduction Market Position Market Position: The Polaris ATV 400 4x4 was a significant player in the mid-size utility ATV market during the mid-1990s, offering a capable 4WD system for recreational and light utility use. Competitive Analysis Competitive Analysis: Competed against models from manufacturers like Yamaha (Grizzly, Kodiak), Honda (FourTrax), and Suzuki (QuadRunner) in the 350-400cc class. Key Features Vehicle Key Features Vehicle: Automatic transmission (likely PVT or similar), shaft-driven 4x4 system, independent front suspension (IFS) on some variants, robust build quality for its era. Key Features Manual Key Features Manual: Provides detailed, actionable information used by professional technicians, ensuring accuracy and completeness for repairs and maintenance. Manual Value Proposition Manual Value Proposition: Essential resource for maintaining the performance, reliability, and longevity of the 1994-1995 Polaris ATV 400 4x4, enabling cost-effective DIY repairs and professional service. Manual Details Coverage Areas Coverage Overview: Comprehensive service, repair, and workshop instructions for Polaris ATV 400 4x4 models from 1994 and 1995. Target Audience: Professional mechanics and experienced DIY enthusiasts. Page Count Page Count Estimate: Estimated 300-500 pages (typical for a comprehensive workshop manual of this era). Manual Type Manual Type: Service Repair Workshop Manual Language Language: English Format Format: PDF Download Manual Coverage Systems Covered Engine Systems: Engine overhaul, top-end rebuild (cylinder head, piston, valves), bottom-end assembly (crankshaft, connecting rod), cooling system, lubrication system, fuel delivery (carburetor tuning, fuel pump), ignition system (spark plug, ignition coil, timing), starting system, exhaust system. Drivetrain Systems: Transmission (gearbox) removal, disassembly, assembly, and repair; final drive and differential service; drive shaft and CV joint maintenance; 4x4 engagement system (transfer case, hubs). Chassis Suspension Steering: Front and rear suspension (shocks, springs, control arms), steering system (tie rods, steering column, rack and pinion), wheel bearings, ball joints, bushings. Braking System: Hydraulic brake system service (master cylinder, calipers, brake lines), brake pad and rotor replacement, bleeding procedure, parking brake adjustment. Electrical System: Wiring diagrams, battery maintenance, charging system (stator, voltage regulator), lighting system, starter motor, ignition switch, fuses, relays, diagnostic procedures. Body Frame Components: Frame inspection and repair, body panel removal and installation, seat, handlebars, fenders, racks, bumpers. Procedures Included Maintenance Procedures: Scheduled maintenance (oil changes, filter replacements, spark plug checks), lubrication points, chain adjustment (if applicable), tire pressure checks. Diagnostic Procedures: Troubleshooting common issues, symptom-based diagnostics, component testing procedures. Repair Procedures: Step-by-step instructions for component removal, disassembly, cleaning, inspection, repair, reassembly, and installation. Special Tools And Techniques: Identification and usage of specialized tools required for specific repairs. Technical Depth Technical Depth: In-depth coverage from basic maintenance and adjustments to complete engine and transmission overhauls, electrical system diagnostics, and frame repairs. Designed for comprehensive workshop application. Manual Specifications File Format File Format: PDF (Portable Document Format) Print Quality Print Quality: High-resolution scans optimized for clarity and readability of text, diagrams, and illustrations. Binding Type Binding Type: N/A (Digital PDF download) Paper Type Paper Type: N/A (Digital PDF download) Searchability Searchability: Likely text-searchable PDF, allowing users to quickly find specific information. Illustrations Illustrations: Includes diagrams, schematics, and exploded views to aid in disassembly and reassembly. Engine Specifications Primary Engine Engine Type: Liquid-cooled, 2-stroke, single-cylinder Displacement: Approximately 340cc (actual displacement may vary slightly based on specific model year sub-variant; often referred to as 340, 350, or 400 class). Bore X Stroke: Specific figures not in product data, but typical for this displacement range. Compression Ratio: Typical 6.0:1 - 7.0:1 for 2-stroke engines of this era. Performance Horsepower Estimate: Estimated 20-25 HP (Horsepower), indicative of performance for its class. Torque Estimate: Estimated 25-30 lb-ft (Torque), optimized for low-end grunt. Fuel System Fuel System Type: Carbureted Carburetor Model: Likely a Mikuni or Keihin single carburetor (e.g., VM34 or similar). Fuel Type: Unleaded gasoline (Octane rating typically 87 or higher). Fuel Mixture: Requires 2-stroke oil mixed with gasoline (check manual for exact ratio, typically 32:1 or 40:1). Ignition System Ignition Type: CDI (Capacitor Discharge Ignition) Cooling System Cooling Type: Liquid-cooled Coolant Type: Ethylene glycol based antifreeze/coolant (check manual for specific blend and capacity). Transmission Standard Transmission Type: Automatic (Polaris Variable Transmission - PVT) Drive System: Shaft Drive, 4WD Gear Selection: High, Low, Neutral, Reverse (often via a single shifter) Features Clutch Type: CVT (Continuously Variable Transmission) primary and secondary clutch system. Transmission Fluid Type: Specific CVT fluid required (check manual for Polaris specification, often SAE 10W-30 or similar for the transmission/gearbox). Transmission Fluid Capacity: Check manual for specific capacity, typically around 1-2 liters. Dimensions Exterior Length: Approx. 75-80...