🏷️ Basic Information Identification Make: Polaris Model: ATV 400 6x6 Model Variant: 400 6x6 Model Years Covered: 1996, 1997, 1998 Codes Engine Code: Likely derived from engine displacement (e.g., 400cc class) Chassis Code: Not explicitly provided, but would pertain to the 6x6 platform 👋 Introduction Market Position Segment: Utility ATV, specifically a 6x6 model designed for work and rugged terrain. Target Audience: Owners requiring in-depth knowledge for maintenance, repair, and troubleshooting of their Polaris 400 6x6 ATV. Competitive Analysis Era Competitors: Competed against other utility ATVs from brands like Yamaha (e.g., Big Bear 4x4), Honda (e.g., FourTrax), Suzuki, and Kawasaki, with the 6x6 configuration being a niche offering emphasizing hauling and traction. Key Features Unique Selling Points: The 6x6 drivetrain provides superior traction and load-carrying capacity compared to traditional 4x4 ATVs of the era. Manual Value Proposition: An 'inexpensive way to keep your vehicle' running, offering significant cost savings over professional servicing for DIY enthusiasts. 📋 Manual Details Coverage Areas Manual Type: Workshop Service Repair Manual Language: English Format: PDF Download Page Count: Not explicitly stated, but typical for this era and type of manual is 200-400 pages. 📖 Manual Coverage Systems Covered Engine: Comprehensive coverage including disassembly, inspection, assembly, troubleshooting, and repair of the 400cc engine, cooling system, lubrication system, and fuel system. Transmission: Detailed procedures for the automatic transmission (likely PVT - Polaris Variable Transmission), including belt inspection/replacement, clutch service, and gearbox maintenance. Drivetrain: Extensive coverage of the 6x6 drivetrain, including front and rear differentials, driveshafts, universal joints, and the engaging mechanism for the front axle. Specific attention to the 6-wheel drive system. Suspension: Service and adjustment procedures for front and rear suspension components, including A-arms, shocks, springs, and bushings. Brakes: Maintenance and repair of the hydraulic brake system, including master cylinders, calipers, brake lines, pads, and bleeding procedures. May also cover parking brake systems. Steering: Service and alignment for the steering system, including tie rods, steering column, and steering linkage. Electrical: Wiring diagrams, component testing, troubleshooting for ignition, lighting, starter system, charging system (stator/regulator/rectifier), and any onboard instrumentation. Bodywork Chassis: Procedures for body panel removal/installation, frame inspection, and mounting hardware. Cooling System: Radiator, fan, coolant, hoses, and thermostat service. Fuel System: Carburetor (likely Mikuni), fuel lines, fuel pump, and fuel tank maintenance. Procedures Included Routine Maintenance: Oil changes, filter replacements (air, oil, fuel), spark plug service, lubrication points, and battery care. Troubleshooting: Diagnostic flowcharts and symptom-based problem solving for common issues across all systems. Repair Procedures: Step-by-step instructions for component removal, overhaul, and reinstallation. Disassembly Assembly: Detailed exploded views and specific instructions for taking apart and putting back together major components and assemblies. Technical Specifications: Torque values, clearances, fluid capacities, electrical values (resistance, voltage), and wear limits. Special Tools: Identification of any specialized tools required for specific repairs or adjustments. Technical Depth Depth Level: Comprehensive, covering from basic maintenance to complete engine and transmission rebuilds. Suitable for both home mechanics and professional technicians. 📊 Manual Specifications File Format File Type: PDF Searchability: Assumed to be text-searchable PDF, allowing for quick access to specific topics. Printability: Typically, PDF manuals are printable for workshop use. Digital Features: Hyperlinked table of contents and cross-references for ease of navigation. Print Quality Image Resolution: High resolution for clear diagrams and illustrations, crucial for accurate assembly. Binding Type Digital Binding: N/A (PDF) Paper Type Digital Paper Type: N/A (PDF) ⚙️ Engine Specifications Primary Engine Engine Type: Likely a 2-stroke or 4-stroke single-cylinder gasoline engine, based on Polaris ATV designs of this period. Displacement: Approximately 400cc (as indicated by the model name). Bore X Stroke: Specific dimensions would be detailed in the manual, typical for a 400cc class engine. Cooling System: Likely liquid-cooled, given the performance demands of an ATV. Performance Horsepower: Estimated to be in the range of 25-35 HP, depending on the specific engine configuration. Torque: Torque figures tailored for low-end grunt and pulling power, characteristic of utility ATVs. Fuel System Fuel Delivery: Carbureted. Likely a Mikuni VM series or similar. Fuel Type: Unleaded Gasoline (e.g., 87 octane). 🔧 Transmission Standard Transmission Type: Automatic (Polaris Variable Transmission - PVT). Drive Modes: Selectable 2WD/4WD/6WD engagement. Gear Selection: High, Low, Neutral, Reverse. Features Clutch Type: Centrifugal clutch and drive/driven pulleys for the PVT system. Transmission Fluid: Specific Polaris PVT fluid or a compatible SAE 10W-30 transmission oil, as per the manual. 📐 Dimensions Exterior Length: Approximate: 85-95 inches (typical for this class). Width: Approximate: 45-55 inches. Height: Approximate: 45-50 inches. Wheelbase: Not specified, but significantly longer than a 4x4 to accommodate the extra axle. Ground Clearance: Likely in the range of 7-10 inches. Weights Dry Weight: Estimated: 550-650 lbs. Towing Capacity: Typically around 1500 lbs for this class of ATV. Rack Capacity Front: Estimated: 50-75 lbs. Rack Capacity Rear: Estimated: 150-200 lbs. Fuel Capacity: Approximately 3-4 gallons. 🛡️ Safety Features Ratings Safety Standards: ATVs...