This manual covers the 400 6x6 ATV, produced for the model years 1996, 1997, and 1998. Designed as a utility ATV, it is engineered for recreational riders, farmers, hunters, and utility users who require exceptional traction in challenging terrain. Key features include a robust 4-stroke, single-cylinder engine known for its reliability, and the Variable Transmission (PVT) with high and low range gearing for automatic shifting and engine braking. The full-time 6x6 drive system provides superior capability in difficult conditions, making it ideal for hauling, towing, and navigating off-road environments. This comprehensive service and repair manual provides detailed guidance for maintaining and repairing your 400 6x6. It encompasses a wide range of topics, including engine assembly and tuning, transmission service, drivetrain maintenance, suspension and brake system overhauls, and electrical system diagnostics. The manual offers step-by-step procedures for routine maintenance, troubleshooting common issues, and complete component rebuilds, ensuring owners and technicians have the necessary information to keep the vehicle in optimal working condition. It includes essential technical specifications, wiring diagrams, and exploded-view illustrations for accurate repairs. 🏷️ Basic Information Identification Make: Polaris Model: 400 6x6 Model Variant: ATV Years Covered: 1996, 1997, 1998 Codes Chassis Code: N/A (ATV specific, typically VIN based) 👋 Introduction Market Position Segment: Utility ATV Target Audience: Recreational riders, farmers, hunters, utility users requiring 6x6 traction. Competitive Analysis Competitors: Similar 6x6 ATVs from brands like Yamaha, Honda, Suzuki, and Kawasaki during the mid-to-late 1990s. Key Features Traction: Full-time 6x6 drive system for exceptional traction in challenging terrain. Engine: Reliable 4-stroke, single-cylinder engine, known for its workhorse capabilities. Transmission: Polaris Variable Transmission (PVT) with high and low range gearing, offering automatic shifting and engine braking. Utility: Designed for hauling, towing, and navigating difficult off-road conditions. 📋 Manual Details Coverage Areas Coverage Scope: Comprehensive Service and Repair Page Count Estimated Pages: Refer to actual manual for exact count; typically 300-500 pages for this era of ATV service manual Manual Type Type: Service and Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine: Engine assembly, disassembly, tuning, lubrication, cooling system, ignition system, carburetor service. Transmission: Automatic transmission (PVT - Polaris Variable Transmission) operation, maintenance, clutch service, belt inspection and replacement. Drivetrain: Front and rear driveshafts, differentials (if applicable to model variant), 6x6 drive system engagement and maintenance, universal joints. Suspension: Front and rear suspension systems, shocks, springs, A-arms, pivot points, bushings, bearings. Brakes: Hydraulic brake system, brake fluid, master cylinder, calipers, brake pads, brake lines, parking brake. Electrical: Battery, charging system (stator, regulator/rectifier), starting system (starter motor, solenoid), lighting (headlights, taillights), ignition switch, wiring diagrams. Fuel System: Fuel tank, fuel lines, fuel filter, carburetor, choke operation. Cooling System: Air-cooling system, cooling fins, engine shroud, thermal considerations. Frame And Body: Frame structure, fenders, racks, seat, handlebars, controls. Procedures Included Maintenance: Regular scheduled maintenance, oil changes, filter replacements, lubrication points, battery care, tire pressure checks. Troubleshooting: Diagnostic procedures for common starting, running, and performance issues. Symptom-based troubleshooting guides. Repair: Step-by-step instructions for component removal, disassembly, cleaning, inspection, repair, reassembly, and installation. Engine Rebuild: Detailed instructions for engine top-end and bottom-end overhauls, including piston, rings, cylinder, and crankshaft service. Carburetor Tuning: Carburetor adjustment, cleaning, jetting information, and synchronization (if applicable). Electrical Diagnostics: Wiring diagram interpretation, voltage drop testing, continuity checks, component testing for electrical circuits. Wheel Bearing Service: Inspection, greasing, and replacement of wheel bearings. Tire And Wheel Service: Tire mounting, balancing, and wheel torque specifications. Steering System Service: Tie rod ends, steering linkage, handlebar assembly maintenance and adjustment. Body Panel Removal Installation: Instructions for removing and refitting fenders, racks, seat, and other body components for access to mechanical parts. Lighting And Switch Replacement: Procedures for replacing bulbs, switches, and troubleshooting electrical circuits related to lights. Graphics And Decals: Information on the application and care of vehicle graphics and decals. Technical Depth Depth: Comprehensive, covering everything from basic adjustments to complete engine and transmission overhauls, including detailed electrical schematics. 📊 Manual Specifications File Format Format: PDF Print Quality Quality: Digital reproduction, quality dependent on original source; typically includes clear diagrams and text. Binding Type Binding: N/A (Digital Download) Paper Type Paper: N/A (Digital Download) Searchability Text Search: Typically searchable PDF, allowing for quick keyword access to information. Completeness Content Scope: Complete Service and Repair Manual, including all necessary diagrams, specifications, and procedures for maintenance and repair. Usability Diagram Quality: Expect clear, detailed exploded-view diagrams and wiring schematics essential for accurate work. ⚙️ Engine Specifications Primary Engine Type: 4-Stroke, Single Cylinder Displacement: 375cc to 400cc (Specific variant may differ slightly, common range for this model line) Cooling: Air-Cooled Bore X Stroke: Refer to specific model year for exact dimensions. Compression Ratio: Refer to specific model year for exact ratio. Performance Horsepower: Approximately 25-30 HP (estimated based on engine size and era) Torque: Refer to specific model year for exact...