The ATV 400 6x6, manufactured for the 1996, 1997, and 1998 model years, represents a robust utility all-terrain vehicle designed for demanding off-road applications. Known for its reliable 2-stroke, liquid-cooled engine and the advantage of its 6x6 drivetrain, this model offers enhanced traction and carrying capacity. The heritage in powersports is evident in the engineering of this ATV, which was built to provide dependable performance in challenging environments, making it a capable tool for work and recreation. This comprehensive service and repair manual provides essential technical data and step-by-step procedural guidance for owners and technicians. It covers all aspects of maintenance, troubleshooting, and repair for the ATV 400 6x6, including detailed information on the engine, transmission, drivetrain, suspension, brakes, and electrical systems. With clear instructions and diagrams, this manual is an invaluable resource for ensuring the longevity and optimal performance of your vehicle. 🏷️ Basic Information Identification Make: Polaris Model: ATV 400 6x6 Model Years Covered: 1996, 1997, 1998 Product Type: Service & Repair Manual 👋 Introduction Market Position Positioning: Targeted at owners and independent repair shops seeking to maintain and repair their Polaris ATV 400 6x6 models from the late 1990s. Competitive Analysis Value Proposition: Provides essential technical data and procedural guidance to empower DIY maintenance and repair, reducing reliance on dealership service. Key Features Features: Detailed diagrams, step-by-step repair instructions, diagnostic flowcharts, torque specifications, and maintenance schedules. 📋 Manual Details Coverage Areas Coverage Scope: All service and repair for the specified model years. Page Count Estimated Page Count: Refer to actual manual documentation for precise count; typically 300-500 pages for this era of service manual. Manual Type Type: Comprehensive Service & Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine: Engine overhaul, disassembly, assembly, tuning, lubrication, cooling system, fuel system, exhaust system. Transmission: Clutch, gearbox, drive shafts, differential, maintenance, repair, adjustments. Drivetrain: 6x6 drive system, differentials, axle assemblies, U-joints, CV joints, lubrication. Suspension: Front and rear suspension components, shock absorbers, springs, bushings, alignment. Brakes: Hydraulic brake system, calipers, master cylinder, brake lines, pads, rotors, bleeding procedure. Electrical System: Ignition system, starting system, charging system, battery, lighting, wiring diagrams, troubleshooting. Frame And Body: Chassis, body panels, racks, seat, fenders, repair and replacement. Steering: Steering column, tie rods, steering linkage, adjustments. Wheels And Tires: Wheel specifications, tire pressure, replacement. Procedures Included Maintenance: Scheduled maintenance, lubrication points, fluid changes, filter replacements, pre-ride inspections. Troubleshooting: Diagnostic procedures for common problems, symptom-based troubleshooting guides. Repair: Detailed step-by-step instructions for component removal, repair, and reinstallation. Rebuild: Complete engine and transmission rebuild procedures, including specifications. Adjustments: Carburetor tuning, brake adjustments, cable adjustments. Specifications: Torque specifications, clearances, fluid capacities, engine timing. Technical Depth Depth: Comprehensive: Covers everything from basic maintenance and adjustments to complete engine and transmission overhauls and diagnostics. 📊 Manual Specifications File Format Format: PDF Searchability: Searchable text (typically in official PDFs), allowing for quick access to information. Print Quality Quality: High-resolution scans ensuring clear diagrams and text. Binding Type Type: N/A (Digital PDF) Paper Type Type: N/A (Digital PDF) ⚙️ Engine Specifications Primary Engine Engine Type: 2-stroke, Liquid-Cooled, Single Cylinder Displacement: 375cc (approximate, actual can vary slightly by year/sub-model) Bore X Stroke: Refer to manual for exact specifications; typical for this era 2-stroke. Carburetion: Single Carburetor (e.g., Mikuni VM Series or similar) Performance Horsepower: Approx. 25-30 HP (varies by model year and tuning) Torque: Refer to manual for specific torque figures. Fuel System Fuel Type: Unleaded Gasoline (typically 87 octane minimum), mixed with 2-stroke oil Oil Mixture: Refer to manual for specific oil-to-fuel ratio (commonly 40:1 or 50:1) Lubrication Oil Type: 2-stroke engine oil meeting API TC specifications or manufacturer recommendation. Cooling System Cooling Method: Liquid-Cooled Coolant Type: Ethylene glycol based antifreeze/coolant (e.g., 50/50 mix with distilled water) 🔧 Transmission Standard Type: Automatic (PVT - Polaris Variable Transmission) with Hi/Lo range and Reverse. Features Drive System: Shaft drive to all six wheels. Gear Reduction: Yes, for off-road capability. Fluid Specifications Transmission Fluid Type: Polaris Synthetic Gearcase Lubricant or equivalent (refer to manual for specific part number/viscosity). Fluid Capacity Gearcase Capacity: Refer to manual for exact capacity; typically around 300-400 ml. 📐 Dimensions Exterior Length: Refer to manual; generally around 80-90 inches. Width: Refer to manual; typically around 46-50 inches. Height: Refer to manual; typically around 45-50 inches. Weights Dry Weight: Approx. 600-700 lbs (varies) Towing Capacity: Typically rated for 1500 lbs. Cargo Rack Capacity Front: Refer to manual; usually around 50 lbs. Rack Capacity Rear: Refer to manual; usually around 100-200 lbs. 🛡️ Safety Features Ratings Classification: ATV (All-Terrain Vehicle) - Not street legal in most jurisdictions without modification and registration. Active Features Braking System: Hydraulic disc brakes on all wheels. Passive Features Roll Over Protection: None inherently, operator safety relies on skill and adherence to use guidelines. Lighting: Headlights, taillight/brakelight. 💡 Technology Features Infotainment Features: Basic...