This document provides comprehensive service and repair information for the ATV 400 6x6, covering the 1996 and 1997 model years. Engineered as a robust utility all-terrain vehicle, the ATV 400 6x6 is renowned for its selectable 6x6 all-wheel-drive capability, substantial cargo capacity, and reliable performance across various demanding applications, including work, farm tasks, trail riding, and general utility duties. Its design prioritizes durability and functionality, making it a capable machine for both recreational and professional use, often compared favorably to competitors of its era for its specific utility features. This workshop service repair manual offers factory-level detail on all major systems, including the engine, transmission, drivetrain, suspension, brakes, steering, electrical system, and fuel system. It provides detailed step-by-step instructions for maintenance, diagnostics, troubleshooting, repair, overhaul, and rebuilding of components. Essential technical data, torque specifications, fluid recommendations, and wiring diagrams are included to assist owners, mechanics, and technicians in maintaining the optimal performance, reliability, and safety of their ATV 400 6x6. 🏷️ Basic Information Identification Make: Polaris Model: ATV 400 6x6 Model Years Covered: 1996, 1997 👋 Introduction Market Position Category: Utility All-Terrain Vehicle (ATV) Competitive Analysis Competitors 1996 1997: Honda TRX400, Yamaha Big Bear 400, Kawasaki Bayou 400 Key Features Wheel Drive: 6x6 selectable AWD Cargo Capacity: High, designed for utility and hauling Intended Use: Work, farm, trail riding, utility tasks 📋 Manual Details Coverage Areas Coverage Scope: Complete official factory service and repair Page Count Estimated Pages: Hundreds Manual Type Type: Workshop Service Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine: Yes, detailed diagnostics, repair, and overhaul Transmission: Yes, including gear case and drive systems Drivetrain: Yes, covering 6x6 drive system, differentials, and driveshafts Suspension: Yes, front and rear suspension systems, shocks, and components Brakes: Yes, hydraulic brake system, calipers, master cylinders, and bleeding procedures Steering: Yes, steering column, tie rods, and knuckle assembly Electrical System: Yes, wiring diagrams, ignition, lighting, charging system, starter Fuel System: Yes, carburetor, fuel lines, and fuel tank Cooling System: Yes, radiator, fan, and coolant flow Frame And Body: Yes, chassis, body panels, and mounting points Wheels And Tires: Yes, wheel mounting, tire specifications, and pressure Procedures Included Maintenance: Yes, routine checks, lubrication, adjustments Troubleshooting: Yes, diagnostic flowcharts and common problem solutions Repair: Yes, detailed step-by-step repair instructions for all systems Overhaul: Yes, complete engine and transmission overhaul procedures Rebuilding: Yes, carburetor rebuilding and other component rebuilds Assembly Disassembly: Yes, comprehensive instructions for component removal and installation Torque Specifications: Yes, critical torque values for all fasteners Technical Depth Depth: Comprehensive factory-level detail 📊 Manual Specifications File Format File Type: PDF Print Quality Printability: Printable in its entirety or selected sections Binding Type Binding: Digital (N/A for PDF, but implies printable pages) Paper Type Paper Quality: Digital (N/A for PDF, but implies clear, readable text and diagrams) ⚙️ Engine Specifications Primary Engine Engine Type: 4-stroke, liquid-cooled Displacement: Approximately 375cc - 400cc (specific designation may vary slightly) Bore X Stroke: Refer to manual for exact specifications Compression Ratio: Refer to manual for exact specifications Performance Horsepower: Estimated 20-25 HP (refer to manual for precise figures) Torque: Refer to manual for exact specifications Fuel System Carburetor Type: Single Carburetor (e.g., Mikuni or similar, specific model in manual) Fuel Type: Unleaded Gasoline Fuel Tank Capacity: Refer to manual for exact specifications 🔧 Transmission Standard Transmission Type: Automatic (CVT - Continuously Variable Transmission) Optional Gear Reduction: Yes, for low-speed torque and hauling Features Drive Modes: 2WD, 4WD, 6WD (selectable) Final Drive: Shaft drive to all axles 📐 Dimensions Exterior Length: Refer to manual for exact specifications Width: Refer to manual for exact specifications Height: Refer to manual for exact specifications Weights Dry Weight: Refer to manual for exact specifications Ground Clearance: Refer to manual for exact specifications 🛡️ Safety Features Ratings Safety Standards: Designed to meet relevant ATV safety standards of the era Active Features Braking System: Hydraulic disc brakes, front and rear Passive Features Lighting: Headlights, taillight, brake light 💡 Technology Features Infotainment Display Features: Basic instrument cluster: speedometer, odometer, neutral indicator, high beam indicator Driver Assistance Adc Features: None (ATV of this era) Connectivity Connectivity Features: None 🔧 Maintenance Service Intervals Oil Change: Refer to manual for specific mileage/hours Spark Plug Inspection: Refer to manual for specific mileage/hours Air Filter Cleaning: Refer to manual for specific mileage/hours, often more frequent in dusty conditions Fluid Specifications Engine Oil Type: Refer to manual for specific viscosity (e.g., SAE 10W-40, JASO MA) Engine Oil Capacity: Refer to manual for exact capacity Coolant Type: Ethylene glycol-based antifreeze (specific mix ratio in manual) Brake Fluid Type: DOT 3 or DOT 4 hydraulic brake fluid (confirm with manual) Gearcase Oil Type: Refer to manual for specific gear oil specification Known Issues Common Wear Items: Brake pads, wheel bearings, CVT belt, suspension bushings Electrical Issues: Wiring harness...