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Polaris ATV 400 6x6 1994 1995 Workshop Service Repair Manual PDF Download
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Basic Information Identification Make: Polaris Model: ATV 400 6x6 Model Variant: 400 6x6 Production Years: 1994-1995 Codes Vin Character Engine: N/A (ATVs typically do not use VINs in the same...
Tipo: Powersports
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SKU: 58947
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| Basic Information | |
| Identification | |
| Make: | Polaris |
| Model: | ATV 400 6x6 |
| Model Variant: | 400 6x6 |
| Production Years: | 1994-1995 |
| Codes | |
| Vin Character Engine: | N/A (ATVs typically do not use VINs in the same way as cars for engine identification within the manual context) |
| Introduction | |
| Market Position | |
| Market Position: | The Polaris ATV 400 6x6 was positioned as a utility-focused all-terrain vehicle, emphasizing its all-wheel-drive capability for tackling difficult terrain and hauling loads, targeting recreational users and those with practical work needs in rugged environments. |
| Competitive Analysis | |
| Competitive Landscape: | Competed with other utility ATVs from brands like Yamaha, Honda, and Kawasaki, differentiating itself with its standard 6x6 drivetrain, which offered superior traction and load-carrying capacity compared to 4x4 models of the era. |
| Key Features | |
| Key Features: | 6x6 Drivetrain, Automatic Transmission, Robust Utility Design, Long-travel Suspension, High Ground Clearance. |
| Manual Details | |
| Coverage Areas | |
| Systems Covered: | Engine, Fuel System, Ignition System, Cooling System, Drivetrain, Transmission, Differential, Suspension, Steering, Brakes, Electrical System, Chassis, Bodywork, Troubleshooting, Maintenance |
| Page Count | |
| Estimated Page Count: | Hundreds (as per product description, specific count not provided but implies comprehensive coverage) |
| Manual Type | |
| Manual Type: | Workshop Service Repair Manual |
| Language | |
| Language: | English |
| Format | |
| Format: | PDF Download |
| Manual Coverage | |
| Systems Covered | |
| Engine Systems: | Complete engine overhaul, including disassembly, inspection, repair, and reassembly of all internal components (pistons, rings, valves, crankshaft, connecting rods, bearings), cylinder head, and lubrication system. |
| Fuel System Coverage: | Carburetor service and adjustment, fuel pump operation, fuel lines, fuel filter replacement, and fuel tank maintenance. |
| Ignition System Coverage: | Spark plug inspection and replacement, ignition coil testing, CDI unit diagnostics, and timing adjustments. |
| Drivetrain Coverage: | Detailed procedures for the 6x6 drivetrain, including front and rear differentials, driveshafts, U-joints, and the engagement mechanism for the six-wheel drive. |
| Transmission Coverage: | Automatic transmission service, including fluid changes, filter replacement, torque converter inspection, and internal component repair/rebuild procedures. |
| Suspension Coverage: | Front and rear suspension component inspection, repair, and replacement, including shock absorbers, springs, control arms, and bushings. |
| Steering Coverage: | Steering column assembly, tie rod ends, steering linkage, and handlebar component servicing and adjustment. |
| Brake System Coverage: | Front and rear brake caliper service, brake pad replacement, rotor inspection, hydraulic system bleeding, and parking brake adjustment. |
| Electrical System Coverage: | Wiring diagrams, lighting system diagnostics, battery testing and replacement, starter motor service, charging system (stator, regulator) inspection, and accessory wiring. |
| Chassis And Bodywork Coverage: | Frame inspection, plastic body panel removal and installation, seat service, and rack/carrier mounting. |
| Procedures Included | |
| Maintenance Procedures: | Routine maintenance tasks such as oil changes, filter replacements, spark plug changes, lubrication points, drive belt inspection and replacement, and tire pressure checks. |
| Troubleshooting Procedures: | Systematic diagnostic procedures for common and uncommon problems, fault finding guides based on symptoms, and electrical diagnostic trees. |
| Repair Procedures: | Detailed, step-by-step repair instructions for virtually all mechanical and electrical components, from minor adjustments to major component rebuilds. |
| Special Tool Requirements: | Identification and usage of specialized tools required for specific repair or maintenance tasks. |
| Technical Depth | |
| Depth Of Coverage: | Comprehensive factory-level repair information suitable for professional technicians and experienced DIY mechanics, covering everything from basic tune-ups to complete engine and transmission rebuilds. |
| Manual Specifications | |
| File Format | |
| File Format: | |
| Print Quality | |
| Print Quality: | High-resolution, designed for clear printing of all diagrams, illustrations, and text. |
| Binding Type | |
| Binding Type: | Digital download (Printable pages allow for user to bind as needed) |
| Paper Type | |
| Paper Type: | N/A (Digital PDF) |
| Engine Specifications | |
| Primary Engine | |
| Engine Type: | 2-stroke, 1-cylinder |
| Engine Displacement: | 375 cc (23 cubic inches) |
| Bore X Stroke: | 67.5 mm x 64 mm |
| Cooling System: | Liquid-cooled |
| Performance | |
| Horsepower Estimated: | Approx. 27-30 HP (specific figures vary by tuning and source) |
| Torque Estimated: | N/A (Specifications for torque are less commonly published for this era of ATVs in readily accessible formats) |
| Fuel System | |
| Carburetor Type: | Mikuni VM34SS (typical) |
| Fuel Type: | Unleaded gasoline (minimum 87 octane) |
| Ignition System | |
| Ignition Type: | CDI (Capacitor Discharge Ignition) |
| Transmission | |
| Standard | |
| Transmission Type: | Automatic (PVT - Polaris Variable Transmission) |
| Transmission Gears: | Forward, Neutral, Reverse |
| Features | |
| Drive System: | Shaft drive to all six wheels; on-demand locking front differential; selectable 4x4 and 6x6 engagement. |
| Final Drive: | Gear reduction in each axle |
| Dimensions | |
| Exterior | |
| Length: | Approx. 83 inches (210.8 cm) |
| Width: | Approx. 42 inches (106.7 cm) |
| Height: | Approx. 44 inches (111.8 cm) |
| Wheelbase: | Approx. 59 inches (149.9 cm) |
| Ground Clearance: | Approx. 8 inches (20.3 cm) |
| Weights | |
| Dry Weight: | Approx. 550 lbs (249 kg) |
| Towing Capacity: | Approx. 1500 lbs (680 kg) |
| Rack Capacity Front: | Approx. 75 lbs (34 kg) |
| Rack Capacity Rear: | Approx. 150 lbs (68 kg) |
| Safety Features | |
| Ratings | |
| Safety Ratings: | N/A (ATVs are not typically subjected to standardized crash safety ratings like passenger vehicles; user responsibility for safe operation is emphasized in manuals.) |
| Active Features | |
| Active Safety Features: | Engine braking, 6x6 traction, responsive braking system, ergonomic controls. |
| Passive Features | |
| Passive Safety Features: | Handlebar protection, integrated lighting, robust chassis construction. |
| Technology Features | |
| Infotainment | |
| Infotainment System: | N/A (Basic utility ATV with no integrated infotainment features.) |
| Driver Assistance | |
| Driver Assistance Features: | N/A (No electronic driver assistance systems.) |
| Connectivity | |
| Connectivity Features: | N/A |
| Other Technology | |
| Pvtvariabletransmission: | Polaris's PVT (Polaris Variable Transmission) is a continuously variable transmission (CVT) system that automatically adjusts gear ratios based on engine speed and load, providing seamless power delivery and optimal performance across various terrains. |
| Maintenance | |
| Service Intervals | |
| Engine Oil Change: | Every 50 hours of operation or annually, whichever comes first (refer to manual for specific oil type and capacity). |
| Air Filter Cleaning: | Inspect every 25 hours, clean or replace as needed. More frequent cleaning in dusty conditions. |
| Spark Plug Inspection: | Inspect every 25 hours, replace as needed. Check gap. |
| Drive Belt Inspection: | Inspect every 50 hours for wear and damage. Replace if any signs of deterioration are present. |
| Fluid Specifications | |
| Engine Oil Type: | Polaris Premium 2-stroke oil or equivalent (refer to manual for precise specification, typically pre-mix ratio or injection) |
| Transmission Gear Oil Type: | Polaris AGMA 7 or 8 EP gear lubricant (refer to manual for exact specification and capacity). |
| Brake Fluid Type: | DOT 3 brake fluid |
| Known Issues | |
| Common Issues: | Drive belt wear, carburetor gumming due to fuel storage, occasional starter solenoid failure, wear on U-joints in the 6x6 driveline, cooling system leaks if not maintained. |
| Preventative Maintenance Focus: | Proper fuel stabilization for storage, regular cleaning of the air filter, and diligent lubrication of the driveline components are critical for longevity. |
| Vehicle History | |
| Brand Heritage | |
| Polaris Heritage: | Polaris began as a snowmobile manufacturer in 1954 and expanded into ATVs in the late 1980s, quickly establishing a reputation for innovative designs and rugged, capable machines. |
| Model Evolution | |
| 400 6X6 Evolution: | The 400 6x6 was a significant model in Polaris's utility ATV lineup, building on earlier 6x6 designs and contributing to the brand's dominance in the multi-axle ATV segment. It represented a progression in engine size and features from previous iterations. |
| Production | |
| Manufacturing Location: | Roseau, Minnesota, USA (Primary Polaris Manufacturing) |
| Awards & Recognition | |
| Recognitions | |
| Awards And Recognitions: | N/A (Specific awards for this model are not readily documented, but Polaris ATVs of this era were generally well-regarded for their utility and off-road capability, contributing to the brand's overall market success and reputation.) |