Basic Information Identification Make: Polaris Model: 400 4x4 Model Variant: All-Terrain Vehicle (ATV) Product Name: Polaris 400 4x4 1994 1995 Workshop Service Manual PDF Download Codes Model Code 1994: Likely begins with 'A94' or similar Polaris internal coding Model Code 1995: Likely begins with 'A95' or similar Polaris internal coding Introduction Market Position Segment: Mid-size utility ATV Target User: Recreational riders, farmers, hunters, and general utility users requiring 4x4 capability Competitive Analysis Competitors 1994 1995: Honda FourTrax 300/350 4x4, Yamaha Big Bear 350 4x4, Kawasaki Bayou 300 4x4, Suzuki QuadRunner 300 4x4 Key Features Powertrain: 400cc class liquid-cooled 2-stroke engine, Shaft-driven 4WD Suspension: Independent front suspension (IFS), Swingarm rear suspension Transmission: Polaris Variable Transmission (PVT) with Hi/Lo range Braking: Hydraulic disc brakes front and rear Manual Details Coverage Areas Primary Coverage: Repair and overhaul of Polaris 400 4x4 1994 and 1995 models Page Count Estimated Page Count: Estimated 400-600 pages (typical for a comprehensive workshop manual of this era) Manual Type Type: Workshop Service Manual Purpose: Technical repair and maintenance guidance for technicians and advanced DIY users Language Language: English Format Format: PDF Download Manual Coverage Systems Covered Engine: Detailed disassembly, assembly, diagnosis, and repair of the 2-stroke engine Fuel System: Carburetor overhaul, fuel pump, fuel lines, fuel tank service Cooling System: Liquid cooling system, radiator, water pump, thermostat Ignition System: CDI unit, stator, ignition coil, spark plug service Drive System: CVT (Continuously Variable Transmission) service, belt inspection and replacement, roller inspection, clutch assembly service Drivetrain: Front and rear differentials, driveshafts, U-joints, axle boots Suspension: Front and rear suspension components, shocks, springs, bushings, A-arms Brakes: Hydraulic brake system, calipers, master cylinder, brake lines, pads, rotors, bleeding procedures Steering: Steering column, tie rods, ball joints, steering linkage Electrical System: Wiring diagrams, lighting system, battery service, starter, charging system (alternator/stator) Chassis And Frame: Frame inspection, welding points, body panels Bodywork: Fenders, racks, seat, handlebar assembly Procedures Included Maintenance: Regular maintenance procedures, lubrication, filter changes, fluid level checks Troubleshooting: Diagnostic charts and procedures for common problems Repair: Step-by-step repair instructions for all major components Overhaul: Complete engine, transmission, and differential rebuild procedures Specifications: Torque specifications, clearances, tolerances, electrical values Wiring Diagrams: Comprehensive electrical system schematics Technical Depth Depth: Comprehensive; covers from basic maintenance to full engine and transmission rebuilds Target Audience: Professional mechanics, experienced ATV technicians, and knowledgeable DIY enthusiasts Manual Specifications File Format Format: PDF Searchability: Likely text-searchable PDF (depending on scan quality) Print Quality Quality: High-resolution scans suitable for printing Binding Type Binding: N/A (Digital PDF) Paper Type Paper: N/A (Digital PDF) Engine Specifications Primary Engine Engine Type: 2-stroke, liquid-cooled, single-cylinder Displacement: Approx. 398 cc Bore X Stroke: Not explicitly stated in product info, but typically around 80mm x 79mm for similar engines Fuel Delivery: Carburetor (likely a Mikuni VM series) Ignition: CDI (Capacitor Discharge Ignition) Performance Horsepower: Estimated 20-25 HP (typical for this class and era) Torque: Not explicitly stated in product info, but generally strong low-end torque for utility Fuel System Carburetor Model: Likely Mikuni VM34 or similar Fuel Type: Unleaded gasoline (typically 87 octane minimum) Lubrication Oil System: Pre-mix oil/gasoline for the 2-stroke engine, separate oil for transmission/drivetrain Transmission Standard Type: Polaris Variable Transmission (PVT) - automatic CVT Drive Modes: 2WD/4WD selectable Features Gear Ranges: High, Low, Neutral, Reverse Clutch: Centrifugal clutch, Drive and Driven pulleys Fluid Specifications Transmission Fluid Type: Likely SAE 30W or SAE 75W-90 gear oil for the final drives, CVT belt/pulley requires specific alignment and torque settings Dimensions Exterior Length: Approx. 77-80 inches Width: Approx. 46-48 inches Height: Approx. 42-45 inches (seat height) Weights Dry Weight: Approx. 500-550 lbs Ground Clearance: Approx. 8-10 inches Cargo Front Rack Capacity: Approx. 50 lbs Rear Rack Capacity: Approx. 100 lbs Wheels Tires Wheelbase: Approx. 48-50 inches Tire Size Front: AT 23x8-12 or similar Tire Size Rear: AT 24x11-10 or similar Wheel Bolt Pattern: 4-stud, typically 4x110 or 4x115mm Safety Features Ratings Safety Standards: Adherence to ATV safety guidelines of the era; designed for responsible operation Active Features Braking System: Hydraulic disc brakes front and rear for reliable stopping power 4Wd System: Provides enhanced traction and control in challenging terrain Passive Features Chassis Design: Robust frame construction to withstand off-road conditions Lighting: Headlights and taillight for visibility Operation Recommendations: Always wear a helmet, eye protection, and appropriate protective clothing. Read manual thoroughly before operation. Technology Features Infotainment Features: N/A - Basic utility ATV of the era, no complex infotainment systems Driver Assistance Features: N/A - Relies on rider skill and basic mechanical systems Connectivity Features: N/A Maintenance Service Intervals Oil Change Engine: For 2-stroke, regular checking of oil levels in the autolube system; oil/filter change for crankcase if applicable, follow manual for specific intervals. Transmission Fluid Change: Check and change differential and final drive fluids at specified intervals (e.g., every 6 months or 100 hours of operation, consult...