This manual provides comprehensive information for the ATV 400 6x6, covering model years 1996, 1997, and 1998. Renowned for its robust 6x6 drivetrain, this utility All-Terrain Vehicle offers exceptional traction and load-carrying capabilities, making it suitable for demanding work and recreational off-road excursions. An established American manufacturer, engineered these ATVs to be reliable and performant in various conditions, with the 400 6x6 line representing a significant contribution to the utility ATV market during its production era. The scope of this workshop manual is extensive, detailing all essential aspects of maintenance, repair, and diagnostics. It covers critical systems including the powertrain, chassis, electrical components, fuel system, braking system, and cooling system. Within its pages, you will find step-by-step procedures for routine maintenance, in-depth troubleshooting guides, complete engine and transmission overhaul instructions, and all necessary technical specifications, clearances, and torque values. This resource is designed to empower owners, mechanics, and technicians in effectively maintaining and repairing their ATV 400 6x6, ensuring its optimal performance and longevity. 🏷️ Basic Information Identification Make: Polaris Model: ATV 400 6x6 Model Variant: 400 Generation Code: Not explicitly stated, but refers to a specific design era for the 400 6x6. 👋 Introduction Market Position Category: Utility ATV Target Audience: Owners, technicians, and enthusiasts performing maintenance and repairs on Polaris 400 6x6 models. Competitive Analysis Key Competitors Era: Other 6x6 utility ATVs from brands like Yamaha, Suzuki, and Kawasaki, as well as other Polaris models. Key Features Vehicle Utility: Known for its 6x6 drivetrain providing enhanced traction and load-carrying capability, suitable for work and recreational off-roading. Manual Utility: A crucial resource for maintaining the longevity and performance of the ATV, covering all essential service and repair aspects. 📋 Manual Details Coverage Areas Years Covered: 1996, 1997, 1998 Vehicle Types Covered: All-Terrain Vehicle (ATV) Regions Covered: Global (based on typical Polaris distribution) Page Count Estimated Page Count: Likely 300-600 pages (typical for comprehensive workshop manuals of this era). Manual Type Type: Workshop Manual / Service Manual / Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Powertrain: Engine, transmission, drive axles, final drive, 6x6 drive system. Chassis: Frame, suspension (front and rear), steering system, wheels, tires. Electrical: Ignition system, charging system (stator, regulator/rectifier), lighting, starter motor, battery, wiring diagrams, sensors. Fuel System: Carburetor (type and adjustments), fuel pump, fuel lines, fuel tank, fuel filter. Braking System: Hydraulic brake system (front and rear), brake calipers, master cylinders, brake lines, pads/shoes. Cooling System: Liquid-cooled engine, radiator, fan, coolant hoses, thermostat. Exhaust System: Exhaust manifold, muffler, exhaust pipes. Bodywork And Trim: Body panels, fenders, racks, seat, controls, lighting components. Procedures Included Maintenance: Scheduled maintenance tasks, oil changes, filter replacements, lubrication, valve adjustments, spark plug replacement. Troubleshooting: Diagnostic procedures for common and uncommon problems, symptom-based troubleshooting guides. Repair: Step-by-step repair instructions for all major components and systems, including disassembly, inspection, and reassembly. Diagnostics: Detailed diagnostic procedures for electrical and mechanical issues. Engine Rebuild: Complete engine overhaul procedures, including cylinder head, piston, crankshaft, and camshaft service. Transmission Overhaul: Procedures for servicing and rebuilding the transmission and differential components. Suspension Service: Ball joint replacement, shock absorber service, bushing replacement, alignment procedures (where applicable). Electrical Component Testing: Testing procedures for stator, CDI unit, voltage regulator, starter solenoid, and other electrical parts. Technical Depth Depth Level: Comprehensive (covers basic maintenance to complete engine/transmission rebuilds). Diagrams And Illustrations: Includes exploded views, schematics, and detailed illustrations for clarity. Torque Specifications: Detailed torque values for all critical fasteners. Clearances And Tolerances: Specifications for engine internal component clearances (piston-to-wall, bearing clearances, etc.). 📊 Manual Specifications File Format File Type: PDF Searchability: Likely text-searchable PDF for efficient information retrieval. Print Quality Print Recommendation: Optimized for digital viewing; printable for workshop use. Binding Type Binding For Physical Copy: N/A (Digital Format) Paper Type Paper Type For Physical Copy: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Engine Type: 4-stroke, liquid-cooled, SOHC Displacement: 375cc to 400cc (specific engine designation varies slightly across production years for the '400' designation). Bore X Stroke: Typically around 84.0 mm x 70.0 mm (common for engines in this displacement class). Compression Ratio: Around 8.5:1 to 9.5:1 (typical for this era). Horsepower Estimated: Approximately 25-30 HP (peak output). Torque Estimated: Around 20-25 ft-lbs (peak torque). Fuel System Carburetor Type: Mikuni BSR32 or similar single-barrel carburetor. Fuel Type: Unleaded gasoline (87 octane recommended). Fuel Tank Capacity Estimated: Approximately 4.5-5.0 gallons. Ignition System Ignition Type: Electronic ignition (CDI - Capacitor Discharge Ignition). Cooling System Cooling Method: Liquid-cooled with thermostatically controlled fan. 🔧 Transmission Standard Transmission Type: Automatic (CVT - Continuously Variable Transmission) with engine braking. Drive Modes: 2WD, 6x6 (shaft-driven, with lockable differentials on some models/years). Optional Optional Transmission: N/A for this model and configuration. Features Gear Reduction: Includes high and low range gearing for versatile performance. Transmission Fluid Type: Refer to manual for specific Polaris AGL...