Basic Information Identification Make: Polaris Model: ATV 400 4x4 Years Covered: 1994, 1995 Codes Chassis Code: Likely specific to Polaris' internal designations, not commonly published as a universal code for this era. Engine Code Prefix: Likely Polaris' internal engine designations, e.g., referencing bore/stroke or engine family. Introduction Market Position Segment: Utility ATV Target Audience: Recreational riders, farmers, hunters, and general outdoor enthusiasts requiring reliable 4x4 capability. Competitive Analysis Key Competitors Era: Honda FourTrax, Yamaha Kodiak/Big Bear, Suzuki King Quad, Kawasaki Bayou. Key Features Vehicle Usp: Polaris' reputation for powerful engines and robust 4x4 systems in the mid-90s utility ATV market. Manual Value Proposition: Essential for owners seeking to maintain, repair, and optimize their vintage Polaris ATV for longevity and performance. Manual Details Coverage Areas General: Comprehensive factory service and repair information for the Polaris ATV 400 4x4. Specific Systems: Engine, drivetrain, suspension, brakes, electrical system, chassis, body, controls, maintenance, troubleshooting. Page Count Estimated Pages: Hundreds of pages (as per product description, typical for factory service manuals of this era). Manual Type Type: Workshop Service Repair Manual Language Language: English Format Format: PDF Download Manual Coverage Systems Covered Engine Mechanical: Detailed disassembly, assembly, inspection, and repair procedures for engine components (cylinder head, piston, crankshaft, valve train). Engine Fuel System: Carburetor overhaul, adjustment, fuel pump, fuel lines, and filter service. Engine Ignition System: Spark plug specifications, ignition timing, coil, and CDI unit testing and service. Cooling System: Radiator, coolant flow, fan operation, and associated plumbing. Drivetrain Transmission: Gearbox overhaul, clutch service, drive shaft maintenance, and differential procedures. Drivetrain 4Wd System: Operation and service of the four-wheel-drive engagement system, including front differential and driveshafts. Suspension Front: A-arm replacement, shock absorber servicing, steering linkage, and alignment specifications. Suspension Rear: Swingarm service, shock absorber replacement, and rear axle maintenance. Brakes Front: Hydraulic brake system, caliper overhaul, pad replacement, rotor service, and bleeding procedures. Brakes Rear: Rear brake system (likely drum or disc depending on specific configuration), adjustment, and service. Electrical System: Wiring diagrams, battery service, starter motor, lighting, charging system (stator, regulator/rectifier), and accessory circuits. Chassis Frame: Frame inspection, component mounting, and general chassis service. Bodywork Plastics: Removal and installation of body panels, fenders, and seat. Controls Steering: Handlebar assembly, throttle control, brake levers, and steering column service. Controls Throttle And Brake: Cable routing, adjustment, and lever service. Procedures Included Routine Maintenance: Oil changes, filter replacements, lubrication points, chain adjustment (if applicable), and general inspection. Troubleshooting: Systematic diagnostic procedures for common and uncommon problems, fault finding charts. Engine Rebuild: Complete engine overhaul procedures from disassembly to reassembly. Transmission Repair: Step-by-step instructions for gearbox and clutch component repair. Suspension Overhaul: Rebuilding or replacing suspension components, including shocks and bushings. Brake System Service: Bleeding, pad/shoe replacement, caliper/wheel cylinder service. Electrical Diagnosis: Wiring diagram interpretation, component testing (multimeter usage). Carburetor Tuning: Adjustment of fuel mixture, idle speed, and float levels for optimal performance. Component Torque Specifications: Crucial torque values for critical fasteners to ensure proper assembly and prevent damage. Technical Depth Depth: Comprehensive, factory-level detail suitable for professional mechanics and experienced DIY technicians. Diagnostic Capability: Includes detailed diagnostic trees and symptom-based troubleshooting guides. Rebuild Instructions: Covers complete engine, transmission, and suspension component rebuilds. Manual Specifications File Format Format: PDF Searchability: Likely text-searchable PDF, enabling quick access to specific topics. Print Quality Printability: Designed to be printable, allowing users to print specific sections or the entire manual. Binding Type Typical Binding: N/A (as it is a PDF download). Paper Type Typical Paper: N/A (as it is a PDF download). Engine Specifications Primary Engine Type: Liquid-cooled, 2-stroke, single-cylinder Displacement: Approximately 340cc (specific displacement might vary slightly, but this is typical for Polaris 400 models of that era). Bore X Stroke: Typically around 70mm x 72mm (exact figures in manual). Performance Horsepower: Estimated 25-30 HP (subject to specific tuning and model year variations). Torque: Likely in the range of 20-25 lb-ft (subject to specific tuning and model year variations). Fuel System Carburetor Model: Likely a Mikuni VM series (e.g., VM34 or similar), exact model and jetting details in manual. Fuel Type: Unleaded gasoline (octane rating specified in manual). Ignition System Ignition Type: CDI (Capacitor Discharge Ignition) Engine Oil Oil Type: 2-stroke oil, premix or injection (manual will specify type and ratio/system). Transmission Standard Type: Automatic (Continuously Variable Transmission - CVT) with High/Low range Drive System: Shaft drive to all four wheels (4x4). Features Transmission Fluid Type: Specific CVT fluid or gear oil, to be detailed in the manual (e.g., SAE 30 or 5W-50 for specific gearboxes). Clutch Type: Centrifugal clutch (part of the CVT system). Dimensions Exterior Length: Approximately 74-76 inches (specific dimensions in manual). Width: Approximately 46-48 inches (specific dimensions in manual). Height: Approximately 44-46 inches (specific dimensions in manual). Weights Dry Weight: Around 500-550 lbs (specific weight in manual). Ground Clearance: Typically 7-9 inches (specific clearance in manual). Towing...