This manual covers the ATV 400 4x4, a versatile all-terrain vehicle produced from 1985 to 1995. Renowned for its robust chassis and capable 4x4 system, this ATV was designed for utility and recreational trail riding, offering a reliable performance that made it a competitive option in its market segment. Its engineering emphasized durability and practicality, making it a workhorse for various tasks and adventures. The vehicle typically featured a liquid-cooled, 2-stroke engine with a displacement around 360-400cc, paired with an automatic CVT transmission and selectable 2WD/4WD modes. This comprehensive factory service manual provides essential information for the maintenance, repair, and troubleshooting of your ATV 400 4x4. It details procedures for all major systems, including the engine, cooling, fuel, ignition, transmission, drivetrain, suspension, steering, brakes, and electrical systems. The manual covers routine maintenance, detailed engine and transmission overhauls, brake servicing, electrical diagnostics, and suspension component replacement. With step-by-step instructions and diagnostic charts, this guide is an indispensable resource for owners and technicians alike to ensure the continued optimal performance and longevity of the vehicle. 🏷️ Basic Information Identification Make: Polaris Model: ATV 400 4x4 Model Variant: 4x4 Years Covered: 1985-1995 Codes Vin Decoder Info: VIN information and decoding specific to 1985-1995 Polaris ATVs is detailed within the manual. 👋 Introduction Market Position Segment: Early model, 4x4 utility/recreational All-Terrain Vehicle (ATV). Target Audience: Owners and technicians performing service, repair, and maintenance on Polaris ATV 400 4x4 models. Competitive Analysis Era Competitors: Competed with models from brands like Yamaha (Grizzly), Honda (FourTrax), and Suzuki during its production run. Key Features Atv Focus: Known for its 4x4 capability, robust chassis, and a focus on utility and trail riding. 📋 Manual Details Coverage Areas Primary Coverage: Complete factory service and repair for Polaris ATV 400 4x4 models from 1985 to 1995. Specific Years Covered: 1985, 1986, 1987, 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995 Page Count Estimated Page Count: Highly comprehensive, likely exceeding 500 pages based on the breadth of coverage and model years. Manual Type Type: Factory Service Manual / Repair Manual Language Language: English Format Format: Downloadable PDF 📖 Manual Coverage Systems Covered Engine: Detailed inspection, diagnosis, repair, and overhaul procedures for the Polaris 400cc engine. Cooling System: Radiator, fan, coolant hoses, thermostat, and water pump maintenance and repair. Fuel System: Carburetor adjustment, cleaning, and overhaul; fuel pump, fuel tank, and fuel lines. Ignition System: Spark plugs, ignition coil, CDI unit, timing, and troubleshooting. Transmission: CVT (Continuously Variable Transmission) operation, belt inspection/replacement, clutch maintenance, and gearbox service. Drivetrain: Front and rear differentials, driveshafts, U-joints, and 4x4 engagement mechanisms. Suspension: Front and rear suspension components, shock absorbers, control arms, bushings, and alignment. Steering: Handlebar assembly, steering shaft, tie rods, and steering linkage. Brakes: Hydraulic brake system, brake calipers, master cylinder, brake lines, pads, and rotors; bleeding procedures. Electrical System: Wiring diagrams, battery, charging system (stator, voltage regulator), lighting, starter motor, and switches. Body And Frame: Frame inspection, body panels, fenders, seat, racks, and mounting hardware. Wheels And Tires: Tire pressure, wear inspection, wheel removal/installation, and hub maintenance. Procedures Included Routine Maintenance: Oil changes, filter replacements, lubrication points, chain adjustment (if applicable), and pre-ride inspections. Troubleshooting: Diagnostic charts and flowcharts for common starting, running, and electrical issues. Engine Repair: Top-end rebuilds (cylinder, piston, rings), valve adjustments, and complete engine disassembly/reassembly. Transmission Repair: CVT clutch component service, gearbox seal replacement, and differential repairs. Brake Service: Brake pad replacement, caliper overhaul, master cylinder service, and brake bleeding. Electrical Diagnostics: Using a multimeter, testing circuits, component replacement (starter, stator, regulator). Suspension And Steering Repair: Replacement of bearings, bushings, tie rods, and shock absorber service. Assembly And Disassembly: Step-by-step instructions for component removal and installation. Technical Depth Depth: Comprehensive; covers everything from basic maintenance to complete engine and drivetrain overhauls and advanced electrical diagnostics. Diagnostic Tools: Details on using standard tools and potentially specific Polaris diagnostic procedures. 📊 Manual Specifications File Format Format: PDF Searchability: Typically searchable text within PDF format, allowing for quick access to specific topics. Print Quality Quality: High-resolution, suitable for printing specific sections or the entire manual. Binding Type Type: N/A (Digital Download - PDF) Paper Type Type: N/A (Digital Download - PDF) ⚙️ Engine Specifications Primary Engine Type: 2-stroke, single-cylinder (specific engine code/designation typically found in manual, e.g., Fuji-based engine). Displacement: Approximately 360-400cc (exact displacement varies by specific model year within the range). Performance Horsepower: Estimated 20-30 HP (actual figures vary by year and specific tuning). Torque: Moderate torque suitable for low-speed hauling and trail climbing. Fuel System Carburetion: Single carburetor (e.g., Mikuni VM series or similar), with specific jetting and adjustment procedures detailed in the manual. Ignition Type: CDI (Capacitor Discharge Ignition). Cooling System: Liquid-cooled (most models in this range). 🔧 Transmission Standard Type: Automatic CVT (Continuously Variable Transmission) with a centrifugal clutch. Optional Type: Not typically offered for this model. Features...