🏷️ Basic Information Identification Make: Polaris Model: 400 6x6 Product Type: Workshop Service Manual 👋 Introduction Market Position Category: All-Terrain Vehicle (ATV) Segment: Heavy-duty, multi-purpose utility ATV Competitive Analysis Competitors Era: Polaris faced competition from manufacturers like Yamaha (Grizzly), Honda (FourTrax), and Suzuki (King Quad) in the utility ATV segment during the mid-to-late 1990s. Key Features Six Wheel Drive: The defining feature, offering superior traction and load-carrying capability in challenging terrain compared to 4x4 models. Utility Focus: Designed for work, hunting, and off-road exploration rather than sport riding. 📋 Manual Details Coverage Areas Applicable Years: 1996, 1997, 1998 Extended Coverage Mention: 1985-1995 (Note: Original product description mentions a broader range, but the primary focus of the product name is 1996-1998. Manual coverage for earlier years may vary in detail or accuracy.) Page Count Page Count: 633 Manual Type Manual Type: Workshop Service Manual / Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Powertrain: Engine, transmission, drive axles, clutch, exhaust system Chassis: Suspension (front and rear), steering system, braking system, frame and body construction Electrical: Ignition system, charging system, lighting, starting system, wiring diagrams, instruments and controls Fuel System: Fuel tank, fuel pump, carburetor (likely specific model), fuel lines Cooling System: Radiator, fan, thermostat, coolant hoses, water pump Lubrication System: Oil pump, oil filter, oil pan, lubrication points Maintenance: Scheduled maintenance, oil changes, filter replacements, lubrication, general upkeep Procedures Included Engine Repair: Engine disassembly, inspection, reassembly, component replacement (pistons, rings, valves, gaskets) Transmission Repair: Transmission inspection, clutch adjustment/replacement, gear engagement, torque converter service (if applicable) Brake Service: Brake pad replacement, rotor resurfacing/replacement, brake caliper service, bleeding brake lines Suspension Service: Shock absorber replacement, spring inspection, ball joint and tie rod end service, wheel bearing replacement Electrical Troubleshooting: Diagnostic procedures for charging system, ignition system faults, lighting issues, starter problems Carburetor Adjustment And Rebuild: Detailed steps for tuning and overhauling the carburetor for optimal performance and fuel efficiency. Troubleshooting Guides: Systematic diagnostic trees for common and uncommon issues, symptom-based problem solving. Diagnostic Codes: Explanation of any diagnostic trouble codes or fault indicators (if applicable to this model). Technical Depth Depth: Comprehensive (from basic maintenance to complete engine and transmission overhauls) Diagnostic Capabilities: Advanced diagnostics with detailed troubleshooting procedures and wiring diagrams. Rebuild Procedures: Detailed instructions for major component rebuilds, including engine and transmission. 📊 Manual Specifications File Format File Format: PDF Searchability: Likely searchable text within the PDF for quick information retrieval. Print Quality Print Quality: High-resolution, suitable for printing specific sections or the entire manual. Binding Type Binding Type: N/A (Digital PDF Download) Paper Type Paper Type: N/A (Digital PDF Download) ⚙️ Engine Specifications Primary Engine Engine Type: 2-stroke, liquid-cooled, single-cylinder Displacement: 340cc to 400cc (Specific model year dependent, commonly around 340cc for early models and potentially larger for later ones, but the '400' in the name suggests this displacement class.) Bore X Stroke: Varies by specific 400cc engine variant, detailed in manual. Power Output: Approx. 25-30 HP (Estimates, actual figures vary by year and tuning; manual will provide precise specs.) Torque Output: Approx. 28-32 lb-ft (Estimates, actual figures vary by year and tuning; manual will provide precise specs.) Fuel System Fuel Delivery: Carburetor (likely Mikuni or Keihin, specific model detailed in manual) Fuel Type: Unleaded gasoline (91 octane recommended, refer to manual for exact octane rating) Engine Management Ignition System: CDI (Capacitor Discharge Ignition) 🔧 Transmission Standard Transmission Type: Automatic (CVT - Continuously Variable Transmission) Gear Selection: High, Low, Neutral, Reverse Drive System: 6x6 with selectable 4x4 engagement for front and rear driveshafts independently (or combined through differential). Specific engagement mechanism detailed in manual. Features Clutch Type: Automatic centrifugal clutch Belt Drive: CVT belt drive system with primary and secondary drive clutches. 📐 Dimensions Exterior Length: Varies, typically around 80-90 inches (203-229 cm), precise measurements in manual. Width: Varies, typically around 45-50 inches (114-127 cm), precise measurements in manual. Height: Varies, typically around 40-45 inches (102-114 cm), precise measurements in manual. Weights Dry Weight: Approx. 550-650 lbs (250-295 kg), specific weight varies by configuration. Payload Capacity: Significant due to 6x6 configuration, often 500 lbs+ for racks and moderate towing capacity (detailed in manual). 🛡️ Safety Features Ratings Safety Standards: ATV safety standards of the era; specific certifications not typically rated like automobiles. Active Features Braking System: Hydraulic disc brakes, likely on all wheels or select axles, detailed in manual. Passive Features Chassis Design: Sturdy frame construction for stability and durability. Operator Safety: Emphasizes safe riding practices, use of protective gear (PPE) as per manufacturer guidelines. 💡 Technology Features Infotainment Infotainment System: Basic, typically limited to essential gauges (speedometer, odometer, warning lights) and controls. No advanced infotainment features like stereos or screens. Driver Assistance Driver Assistance Features: None. Focus is on mechanical systems and operator control. Connectivity Connectivity Features: None. This is a purely mechanical...