The 1995 400 6x6 ATV is a robust and versatile all-terrain vehicle engineered for demanding utility and off-road applications. Its distinctive 6x6 drivetrain provides exceptional traction and stability, making it ideal for challenging terrains and hauling tasks. Combining a reliable 2-stroke engine with a capable automatic transmission, this model offers a practical blend of power and efficiency, supporting recreational use and work-related activities with its inherent durability and functional design. This comprehensive service and repair manual provides essential information for owners, mechanics, and technicians to maintain, diagnose, and repair the 1995 400 6x6 ATV. It covers a wide range of topics, including detailed procedures for engine mechanicals, fuel and ignition systems, transmission and drivetrain, braking, suspension, and electrical systems. The manual also includes routine maintenance schedules, troubleshooting guides, and step-by-step instructions for component-level repairs and rebuilds, ensuring the vehicle's optimal performance and longevity. 🏷️ Basic Information Identification Make: Polaris Model: 400 6x6 ATV Year: 1995 Product Type: Service Repair Manual 👋 Introduction Market Position Category: All-Terrain Vehicle (ATV) Target User: ATV owners, DIY mechanics, technicians, repair shops. Competitive Analysis Segment: Utility ATV (6x6 configuration for increased traction and hauling capacity). Key Features Vehicle Strengths: The 6x6 drivetrain provides superior traction in challenging terrain, making it ideal for utility and off-road applications. The 400cc engine offers a good balance of power and efficiency for its class. Manual Value Proposition Value: Provides essential information for maintaining, diagnosing, and repairing the 1995 Polaris 400 6x6 ATV, enabling cost savings and extending the vehicle's lifespan. 📋 Manual Details Coverage Areas Primary Coverage: Comprehensive service and repair for the 1995 Polaris 400 6x6 ATV. Secondary Coverage: Maintenance, troubleshooting, diagnostics, and component-level repair procedures. Page Count Estimated Pages: 250-300 Manual Type Type: Factory Service Manual / Repair Manual Language Language: English Format Format: Digital (PDF) 📖 Manual Coverage Systems Covered Engine Mechanical: Detailed disassembly, inspection, and reassembly of the 2-stroke engine, including piston, cylinder, crankshaft, and connecting rod. Fuel System: Carburetor identification, adjustment, cleaning, and repair; fuel pump operation and servicing. Ignition System: CDI unit testing, stator and coil specifications, spark plug selection and gap. Transmission Drivetrain: Automatic transmission (PVT - Polaris Variable Transmission) operation, belt inspection and replacement, clutch service, differential maintenance, driveshaft and U-joint service, 6x6 driveline engagement and maintenance. Cooling System: Radiator, fan, and coolant circuit maintenance (where applicable to specific models within the 400 6x6 family). Braking System: Hydraulic brake system components, caliper service, pad replacement, bleeding procedures, master cylinder maintenance. Suspension Steering: Front and rear suspension component inspection, shock absorber service, ball joint and tie rod end replacement, steering linkage maintenance. Electrical System: Wiring diagrams, battery maintenance, lighting system troubleshooting, starter and charging system components. Chassis Frame: Frame inspection, welding procedures (if applicable), body panel removal and installation. Exhaust System: Muffler and pipe inspection, gasket replacement. Procedures Included Routine Maintenance: Oil changes (gearbox), spark plug replacement, air filter cleaning/replacement, belt inspection, battery check, lubrication points. Troubleshooting: Diagnostic charts for common starting, running, and performance issues, electrical fault finding. Engine Repair: Top-end rebuilds (cylinder, piston), crankshaft and bearing replacement, valve adjustments (if applicable to 2-stroke decompression mechanism). Transmission Repair: PVT belt replacement, clutch disassembly and inspection, gearbox fluid flush and fill. Brake Service: Brake pad replacement, caliper overhaul, brake line bleeding, rotor inspection. Suspension Updates: Shock absorber replacement, bushing inspection and replacement, steering component alignment. Electrical Diagnostics: Wiring harness troubleshooting, component testing (stator, ignition coil, regulator/rectifier if present), starter motor testing. Technical Depth Depth: Comprehensive from basic maintenance to complete engine and transmission rebuilds, including electrical diagnostics and frame repair. Diagnostic Capability: Detailed troubleshooting guides and diagnostic flowcharts to identify and resolve mechanical and electrical issues. Rebuild Procedures: Step-by-step instructions for major component rebuilds, including engine internals and transmission components. 📊 Manual Specifications File Format Format: PDF Searchable: Yes (typically searchable text within the PDF) Printable: Yes Print Quality Resolution: High-resolution (suitable for clear viewing of diagrams and text) Binding Type Binding: N/A (Digital PDF) Paper Type Paper: N/A (Digital PDF) ⚙️ Engine Specifications Primary Engine Engine Type: 2-stroke, carbureted Displacement: Approx. 340cc - 400cc (specific variant dependent, often around 340cc for the 400 engine in this era) Cooling: Liquid-cooled Bore X Stroke: Specifications available within manual (e.g., ~70mm x 72mm for a typical 340cc model) Performance Horsepower: Estimated 25-30 HP (approximate for the class) Torque: Specifications available within manual Fuel System Carburetor Model: Likely Mikuni VM series or similar (e.g., VM34/36) - specific model detailed in manual. Fuel Type: Unleaded gasoline (typically 87 octane or higher recommended) Oil Mixture: Requires 2-stroke oil mixed with gasoline (ratio specified in manual, typically 40:1 or 50:1). 🔧 Transmission Standard Type: Polaris Variable Transmission (PVT) Automatic Drive System: Shaft Drive with 6x6 engagement Gear Selection: High, Low, Neutral, Reverse Features Clutch System: Centrifugal clutch and CVT drive/driven clutches. Belt Maintenance: Critical belt inspection, tension adjustment,...