🏷️ Basic Information Identification Make: Polaris Model: ATV 400 6x6 Product Name: Polaris ATV 400 6x6 1985-1995 Service Repair Manual Download PDF Vehicle Type: All-Terrain Vehicle (ATV) Generation Production Years: 1985-1995 Codes Vin Code: N/A (ATVs typically do not have VINs in the same manner as automobiles, but component serial numbers are critical) 👋 Introduction Market Position Market Segment: Heavy-duty utility ATV, designed for work, hauling, and off-road capability with its 6x6 drivetrain. Competitive Analysis Competitors: During its production run, the Polaris 400 6x6 competed with other utility-focused ATVs from brands like Kawasaki, Yamaha, Suzuki, and Can-Am, particularly those offering 6-wheel configurations or high towing capacities. Key Features Vehicle Features: 6x6 all-wheel drive for superior traction and load-carrying, robust chassis, ample towing and cargo capacity, utility-focused design. Manual Value Proposition Value: Essential for owners seeking to perform maintenance, repairs, and diagnostics, ensuring longevity and optimal performance of their vintage Polaris ATV. Manual Target Audience Audience: Polaris ATV 400 6x6 owners, mechanics, and enthusiasts performing maintenance and repairs. 📋 Manual Details Coverage Areas Primary Coverage: Complete factory service and repair for Polaris ATV 400 6x6 models Specific Years Covered: 1985, 1986, 1987, 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995 Page Count Estimated Pages: Variable, but comprehensive factory manuals typically range from 300-700+ pages depending on specific model updates and detail. Manual Type Type: Service Repair Manual (Factory Authorized) Language Language: English Format Format: Downloadable PDF 📖 Manual Coverage Systems Covered Powertrain: Engine disassembly, assembly, tuning, lubrication, cooling system, exhaust system, fuel system (carburetor, fuel pump, lines), ignition system (magneto, spark plugs, timing), starting system (starter motor, solenoid), charging system (alternator/stator, regulator). Drivetrain: Transmission (gearbox, shifting mechanisms, bearings, seals), differential gears, drive shafts, U-joints, final drive (sprockets, chains), front and rear axle assemblies, braking system (hydraulic lines, calipers, master cylinders, brake shoes/pads, parking brake). Chassis And Suspension: Frame inspection and repair, front suspension (A-arms, shocks, springs, steering components), rear suspension (swingarm, shocks, springs, linkage), wheel bearings, steering system (handlebars, tie rods, steering knuckles), hitch/towing components. Electrical System: Wiring diagrams, battery service, lighting systems (headlights, taillights, brake lights), accessory circuits, switches, fuses, relays, instrument cluster functionality. Body And Controls: Body panels, seat, fenders, floorboards, controls (throttle, brake levers, shifter), operator safety features, lubrication points. Procedures Included Maintenance: Scheduled maintenance intervals, oil changes, filter replacements (air, oil, fuel), spark plug service, brake adjustments, chain lubrication and adjustment, lubrication of pivot points. Troubleshooting: Diagnostic charts and procedures for common issues related to engine starting, running, braking, electrical faults, and drivetrain operation. Repair And Rebuild: Detailed step-by-step instructions for disassembly, inspection, repair, and reassembly of all major components and systems. Technical Adjustments: Carburetor tuning and adjustment, ignition timing verification, valve clearance adjustment (if applicable), brake system bleeding, suspension adjustments. Technical Depth Depth: Comprehensive, covering routine maintenance to complete engine and transmission rebuilds. Includes detailed torque specifications, clearances, and diagnostic procedures. 📊 Manual Specifications File Format Format: PDF Searchability: Likely text-searchable, allowing for quick access to specific topics and procedures. Print Quality Quality: Dependent on source scan quality, but factory manuals are generally high quality with clear diagrams and text. Binding Type Type: N/A (Downloadable PDF format) Paper Type Type: N/A (Downloadable PDF format) ⚙️ Engine Specifications Primary Engine Type: Likely a 2-stroke, air-cooled or liquid-cooled engine, common for Polaris ATVs of this era. Specific displacement details often varied. Displacement Cc: Typically around 350-400cc. Specific figures vary by exact model year and variant. Bore X Stroke: Refer to specific model year within the manual for precise measurements. Horsepower Hp: Estimated 20-30 HP, depending on exact engine configuration and tuning. Torque Lb-Ft: Torque figures would be model-specific and geared towards low-end grunt for utility. Performance Top Speed: Approximately 35-45 mph, prioritizing torque and stability over high speed. Fuel System Induction: Carburetor (e.g., Mikuni or Keihin) – Manual will detail specific carburetor model, jetting, and adjustment procedures. Fuel Type: Unleaded gasoline (typically 87 octane, but manual will confirm). Ignition System Type: Magneto ignition system with CDI (Capacitor Discharge Ignition) unit. Cooling System Type: Air-cooled, possibly with fan assist or limited liquid cooling on later models. Manual specifies. 🔧 Transmission Standard Type: Automatic transmission with a torque converter and a CVT (Continuously Variable Transmission) belt system, offering variable gear ratios. Drive Modes: 2WD, 4WD, and 6WD selectable modes. Optional Type: N/A (Typically a single automatic transmission setup for this model). Features Reduction Gears: Low and High range gearing for towing and general use. Fluid Specifications Transmission Fluid Type: Refer to manual for specific SAE viscosity grade and type (e.g., SAE 30, SAE 80W-90 gear oil for differentials, specific CVT fluid if applicable). 📐 Dimensions Exterior Length: Refer to specific model year data in manual; typically around 80-90 inches. Width: Refer to specific model year data in manual; typically around 40-50 inches. Height: Refer to specific model year data in...