The ATV 400 6x6 is a robust all-terrain vehicle produced for the 1996 and 1997 model years, recognized for its exceptional utility and capability in challenging environments. Its defining feature is the advanced 6x6 drivetrain, which provides superior traction and enhanced load-carrying capacity, setting it apart from conventional 4x4 ATVs. Engineered for demanding tasks, this model is a favored choice for individuals involved in farming, hunting, and general outdoor work, where reliability and performance in rugged terrain are paramount. The vehicle's design prioritizes functionality and durability, ensuring it can handle demanding conditions effectively. This comprehensive workshop repair service manual is designed to be an indispensable resource for maintaining and repairing your ATV 400 6x6. It covers all models and engines from 1996 and 1997, offering detailed guidance on service, maintenance, repair, and troubleshooting procedures. Within its pages, you will find step-by-step instructions for engine mechanicals, drivetrain systems, transmission, brakes, suspension, steering, electrical components, and bodywork. The manual includes essential technical specifications, diagnostic charts, and routine maintenance schedules, empowering owners and technicians to keep the vehicle in optimal working condition and address any potential issues efficiently. 🏷️ Basic Information Identification Make: Polaris Model: ATV 400 6x6 Model Variant: 400 6x6 Years Covered: 1996, 1997 Codes Vin Code Digit 10: S for 1995, T for 1996, V for 1997 👋 Introduction Market Position Positioning: A robust and versatile all-terrain vehicle designed for utility and recreational purposes, particularly effective in challenging terrain due to its 6x6 drivetrain. Competitive Analysis Competitors: Competed with other utility ATVs of similar displacement and configuration from brands like Yamaha (Kodiak, Big Bear), Kawasaki (Bayou), and Suzuki (King Quad). Key Features Drivetrain Advantage: The 6x6 drive system provides exceptional traction and load-carrying capability, distinguishing it from traditional 4x4 ATVs. Utility Focus: Designed for hauling, towing, and working in demanding environments, often favored by hunters, farmers, and outdoorsmen. 📋 Manual Details Coverage Areas Primary Coverage: Service, Maintenance, Repair, Troubleshooting Model Coverage: All Models, All Engines, All Trim Levels for Polaris ATV 400 6x6 (1996-1997) Page Count Estimated Pages: 300+ Manual Type Type: Workshop Repair Service Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine Mechanical: Engine assembly, disassembly, inspection, repair, tuning, cooling system, lubrication system, fuel delivery system, ignition system. Drivetrain: 6x6 drive system, AWD engagement, differential service, driveshafts, universal joints, PTO (if applicable). Transmission: Automatic transmission operation, maintenance, and repair, including belt inspection, clutch assembly, and gearcase service. Brakes: Hydraulic brake system, caliper service, master cylinder, brake lines, brake fluid specifications, bleeding procedures. Suspension Steering: Front and rear suspension components, shocks, springs, bushings, ball joints, steering linkage, tie rods, steering column. Electrical: Wiring diagrams, lighting system, starting system, charging system (stator, regulator/rectifier), battery specifications, fuses, relays, starter motor, ignition coil. Bodywork Frame: Frame inspection, body panel removal and installation, fenders, racks, seat assembly. Controls: Throttle controls, brake levers, shifter mechanisms, parking brake. Procedures Included Maintenance: Routine inspections, oil changes, filter replacements, lubrication points, valve adjustments, belt service, tire pressure checks. Troubleshooting: Diagnostic charts for common problems, symptom-based troubleshooting guides, electrical diagnostics, engine performance issues. Repair: Step-by-step instructions for component disassembly, repair, reassembly, and adjustment for all major systems. Diagnostics: Identification of potential issues, checking tolerances, testing electrical components, reading diagnostic codes (if applicable). Rebuilds: Detailed procedures for engine rebuilds, transmission overhauls, and differential rebuilding. Technical Depth Depth Level: Comprehensive; covers basic maintenance to complete engine and transmission overhauls. Diagnostic Capability: Advanced troubleshooting guides and component testing procedures. Specifications Accuracy: Includes precise torque specifications, clearances, fluid capacities, and electrical resistances. 📊 Manual Specifications File Format File Type: PDF Searchability: Text-searchable for quick information retrieval. Print Quality Quality: High-resolution scans for clear diagrams and text. Binding Type Binding: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: 2-stroke, liquid-cooled, single-cylinder Displacement: 340cc (approx.) Bore X Stroke: 70mm x 60mm (approx.) Compression Ratio: 6.8:1 (approx.) Performance Horsepower: Approximately 28-30 HP (estimated based on era and displacement) Torque: Not explicitly specified in product description, but designed for low-end grunt for utility. Fuel System Carburetor: Mikuni VM34 (common for this model year, refer to manual for exact spec) Fuel Type: Unleaded gasoline (91 octane or higher recommended) Lubrication Oil Type: 2-stroke engine oil, pre-mix or injection system (refer to manual for specific system and grade) Ignition Ignition System: CDI (Capacitor Discharge Ignition) Cooling Cooling Method: Liquid-cooled 🔧 Transmission Standard Transmission Type: Automatic (CVT - Continuously Variable Transmission) with Hi/Lo range and Reverse Optional Optional Transmission: N/A Features Drive Modes: 2WD / 4WD / 6WD (all-wheel drive engagement system) Clutch Type: CVT belt drive system Fluid Specifications Transmission Fluid Type: Refer to manual for specific Polaris transmission fluid or equivalent (e.g., Polaris Demand Drive Fluid for front diffs if applicable, CVT fluid) 📐 Dimensions Exterior Length: Approx. 100-105 inches (refer to manual...