Basic Information Identification Make: Polaris Model: ATV 400 6x6 Years Covered: 1996, 1997 Product Type: Service Repair Workshop Manual Format: PDF Download Introduction Market Position Niche: Specialized utility ATV market, known for its 6x6 capability and ruggedness for hauling and off-road work. Competitive Analysis Competitors: Competed against other utility ATVs from manufacturers like Yamaha (e.g., Big Bear 4x4 variants), Honda (e.g., FourTrax 300/350 variants), and Kawasaki (e.g., Bayou variants) in the utility segment, though the 6x6 configuration offered a distinct advantage in traction and load-carrying. Key Features Traction Advantage: The 6x6 drive system provides superior traction in mud, sand, and on uneven terrain compared to 4x4 models. Utility Focus: Designed for work and recreational use, with features like cargo racks, towing capacity, and robust construction. Versatility: Capable of handling a variety of tasks from farm work and hunting to trail riding. Manual Details Coverage Areas Engine Service: Complete engine overhaul, disassembly, assembly, inspection, and adjustment. Drivetrain Service: All aspects of the 6x6 drivetrain, including differentials, driveshafts, and axle maintenance. Suspension And Steering: Front and rear suspension components, steering linkage, and related adjustments. Braking System: Hydraulic brake system service, including master cylinder, calipers, pads, and bleeding procedures. Electrical System: Wiring diagrams, troubleshooting of lighting, ignition, charging systems, and accessories. Fuel And Emission Control: Fuel delivery system, carburetor service, and emission control components. Chassis And Body: Frame inspection, body panel removal/installation, and seat servicing. Troubleshooting Guide: Diagnostic procedures for common mechanical and electrical faults. Page Count Estimated Pages: Extensive, covering all service and repair aspects (exact page count varies based on PDF optimization). Manual Type Type: Comprehensive Service Repair Workshop Manual Language Language: English Format File Format: PDF Manual Coverage Systems Covered Engine: All internal and external engine components, cooling system, lubrication system. Transmission: Transmission unit, clutch, gear shifting mechanisms, and related components. Drivetrain: 6x6 drive system, differentials (front, center, rear), driveshafts, universal joints, and axles. Steering: Handlebar assembly, steering shaft, tie rods, and steering knuckle components. Suspension: Front and rear independent suspension, shock absorbers, A-arms, bushings, and bearings. Brakes: Front and rear hydraulic disc brakes, master cylinder, brake lines, calipers, pads, and rotor specifications. Electrical: Battery, starter motor, alternator, ignition system (CDI), lighting (headlights, taillight, brake light), wiring harness, fuses, switches, and starter solenoid. Fuel System: Fuel tank, fuel lines, fuel pump (if applicable), and carburetor (Mikuni VM34-346 or equivalent). Cooling System: Radiator, fan, coolant hoses, and thermostat. Exhaust System: Exhaust pipe, muffler, and heat shields. Body And Frame: Frame construction, front and rear racks, fenders, body panels, seat, and storage compartments. Procedures Included Maintenance: Routine maintenance checks, oil changes, filter replacements, lubrication, and adjustments. Diagnosis: Systematic troubleshooting for performance issues, starting problems, electrical faults, and driveability. Repair: Detailed step-by-step instructions for component removal, repair, and reinstallation. Rebuilds: Complete engine and transmission rebuild procedures, including specifications and tolerances. Adjustments: Carburetor tuning, valve clearance adjustment, brake adjustments, and steering alignment. Electrical Troubleshooting: Using wiring diagrams to diagnose and repair electrical system faults. Suspension Repair: Replacement of ball joints, tie rod ends, wheel bearings, and shock absorbers. Brake Service: Brake pad replacement, caliper service, brake line replacement, and bleeding. Technical Depth Depth: Comprehensive, suitable for both novice mechanics performing basic maintenance and experienced technicians undertaking major repairs and overhauls. Manual Specifications File Format Quality: High-resolution PDF, ensuring clarity of text and diagrams. Searchability: Searchable text for quick access to specific information. Print Quality Printable: Printable pages for on-site workshop use. Binding Type Digital Binding: N/A (Digital PDF format) Paper Type Digital Paper Simulation: N/A (Digital PDF format) Engine Specifications Primary Engine Type: 4-stroke, Liquid-Cooled, Single-Cylinder Displacement: 376 cc (approx.) Bore X Stroke: Information typically found within the manual, specific to the engine design. Compression Ratio: Information typically found within the manual, specific to the engine design. Performance Horsepower: Approx. 26-28 HP (estimated, actual may vary). Torque: Information typically found within the manual, specific to the engine design. Fuel System Carburetor: Mikuni VM34-346 (or similar variant), single downdraft carburetor. Fuel Type: Unleaded gasoline Fuel Capacity: Typically around 3.7 US gallons (14 L). Ignition System: CDI (Capacitor Discharge Ignition) Cooling System Type: Liquid-cooled Lubrication System: Wet sump Oil Type: API SG or higher, SAE 10W-40 or 20W-50 motorcycle-specific engine oil recommended (refer to manual for exact specification). Transmission Standard Type: Automatic (CVT - Continuously Variable Transmission) with 2WD/4WD/6WD selector. Gear Reduction: Varies with CVT ratio, low range gearing typically available for towing and steep inclines. Features Drive Selector: Dash-mounted lever for selecting 2WD, 4WD, or 6WD engagement. Gear Selection: Forward, Neutral, Reverse (F-N-R) automatic gearbox. Fluid Specifications Cvt Fluid: Specific CVT fluid (refer to manual for Polaris P/N or equivalent specification). Dimensions Exterior Length: Approx. 105 inches (2667 mm) Width: Approx. 46 inches (1168 mm) Height: Approx. 44 inches (1118 mm) Wheelbase: Approx. 76 inches (1930 mm) Weights Dry Weight: Approx. 660 lbs (300 kg)...