The Polaris ATV 400 6x6, produced in 1997, is a capable All-Terrain Vehicle engineered for demanding utility and trail riding. Its signature 6x6 drivetrain provides exceptional traction and stability in challenging terrains and when hauling heavy loads, distinguishing it as a robust workhorse. Designed for reliability and performance, this ATV was built to tackle a variety of tasks, from rugged trail exploration to practical work applications. This comprehensive service manual offers detailed guidance for the maintenance and repair of your 1997 Polaris ATV 400 6x6. It covers all essential systems, including the engine, transmission, drivetrain, suspension, brakes, and electrical system, providing step-by-step procedures for routine maintenance, troubleshooting, and major component rebuilds. With in-depth technical specifications and clear instructions, this manual serves as an invaluable resource for owners and technicians alike, ensuring the longevity and optimal performance of your vehicle. 🏷️ Basic Information Identification Make: Polaris Model: ATV 400 6x6 Year: 1997 Type: All-Terrain Vehicle (ATV) 👋 Introduction Market Position Positioning: The Polaris ATV 400 6x6 was a robust and capable utility ATV designed for demanding tasks, offering excellent traction and payload capacity for its era. Competitive Analysis Competitors: Competed with other utility ATVs from manufacturers like Honda (FourTrax), Yamaha (Grizzly), and Kawasaki (Bayou) in the utility segment. Key Features Traction: 6x6 drivetrain provided superior traction and stability in challenging terrain and heavy load conditions. Utility: Designed for work, hauling, towing, and trail riding with a focus on reliability and capability. Manual Value Proposition Value: Empowers owners to perform complex repairs and maintenance, saving on labor costs and extending the vehicle's lifespan. 📋 Manual Details Coverage Areas Manual Type: Full Service Repair Manual Language: English Format: PDF Download Page Count Estimated Pages: Hundreds (typical for full service manuals) 📖 Manual Coverage Systems Covered Engine: Complete overhaul, inspection, tuning, carburetor, cooling system Transmission: Gearbox maintenance, clutch inspection, drive belts, final drive maintenance Drivetrain: 6x6 axle servicing, driveshaft maintenance, differential inspection Suspension: Front and rear suspension component servicing, shock absorber maintenance Brakes: Hydraulic brake system service, caliper maintenance, brake fluid replacement Electrical System: Wiring diagrams, lighting, ignition system, starter motor, battery maintenance Fuel System: Fuel tank, fuel pump, fuel lines, carburetor adjustment and cleaning Cooling System: Radiator, coolant, water pump, thermostat inspection and service Frame And Body: Chassis inspection, body panel removal and installation, seat maintenance Procedures Included Routine Maintenance: Oil changes, filter replacements, lubrication points, tune-ups Troubleshooting: Diagnostic charts for common problems and solutions Rebuilding: Detailed instructions for engine, transmission, and component rebuilds Repair: Step-by-step repair procedures for all major systems Disassembly Assembly: Comprehensive instructions for component removal and reinstallation Technical Depth Depth: Comprehensive, covering everything from basic maintenance to full engine and transmission rebuilds, including electrical diagnostics. 📊 Manual Specifications File Format File Type: PDF Searchability: Likely text-searchable PDF for easy information retrieval Printability: Printable pages for workshop use Print Quality Quality: High-resolution scans ensuring clarity of text and diagrams Binding Type Binding: N/A (Digital PDF) Paper Type Paper: N/A (Digital PDF) ⚙️ Engine Specifications Primary Engine Engine Type: 4-stroke, liquid-cooled, single-cylinder Displacement: Approximately 375cc - 400cc (specific to variant, typically around 375cc for early models, evolving to 400cc) Bore X Stroke: Typically around 84mm x 69mm (refer to specific manual for exact figures) Valvetrain: SOHC (Single Overhead Camshaft), 2 valves per cylinder Ignition System: CDI (Capacitor Discharge Ignition) Performance Horsepower: Estimated 20-25 HP at peak RPM (typical for the era and displacement) Torque: Estimated 25-30 lb-ft at peak RPM (typical) Fuel System Carburetor: Mikuni VM series carburetor (e.g., VM34 or similar, specific model to be confirmed in manual) Fuel Type: Unleaded gasoline Fuel Capacity: Approximately 3.0 - 3.5 gallons (refer to manual for exact capacity) 🔧 Transmission Standard Transmission Type: Automatic (CVT - Continuously Variable Transmission) Drive Modes: 2WD / 4WD / 6WDselectable engagement Gear Reduction: High and Low range, Reverse Features Drive Belt: Serviceable drive belt system, critical for CVT operation Final Drive: Shaft drive to all six wheels Fluid Specifications Transmission Fluid Type: Specific CVT fluid (refer to manual for exact Polaris specification or equivalent) 📐 Dimensions Exterior Length: Approximately 90-95 inches (refer to manual for exact) Width: Approximately 46-50 inches (refer to manual for exact) Height: Approximately 43-46 inches (refer to manual for exact) Wheelbase: Approximately 62-65 inches (refer to manual for exact) Weights Dry Weight: Approximately 550-600 lbs (refer to manual for exact) Ground Clearance: Approximately 8-10 inches (refer to manual for exact) Cargo Rack Capacity Front: Typically around 50-100 lbs Rack Capacity Rear: Typically around 150-200 lbs Towing Capacity: Approximately 1000-1500 lbs (refer to manual for exact and legal limits) 🛡️ Safety Features Ratings Atv Safety Standards: Adherence to industry safety standards for ATVs of its era. Active Features Braking System: Hydraulic disc brakes on all wheels (typical for 6x6 models). Lighting: Headlights, taillight/brakelight for visibility. Passive Features Chassis Design: Sturdy frame designed for stability...