|
Introduction
|
|
Market Position
|
|
Segment:
|
Utility ATV (All-Terrain Vehicle) with 6x6 capability for enhanced traction and load carrying.
|
|
Target Audience:
|
Owners, mechanics, and technicians performing maintenance, repairs, and diagnostics on Polaris ATV 400 6x6 models of the specified years.
|
|
Competitive Analysis
|
|
Competitors:
|
Competitors in the utility ATV segment of this era included models from brands like Yamaha (Kodiak, Timberwolf), Honda (FourTrax), Kawasaki (Bayou), and Suzuki (QuadRunner).
|
|
Key Features
|
|
All Wheel Drive:
|
The signature 6x6 drivetrain provided superior traction in challenging terrain and increased hauling capacity.
|
|
Utility Focus:
|
Designed for work and off-road exploration, emphasizing durability and functional capability.
|
|
Manual Details
|
|
Coverage Areas
|
|
Systems Covered:
|
Engine, drivetrain (6x6 system), transmission, suspension, steering, brakes, electrical system, fuel system, cooling system, exhaust system, chassis, body panels, frame, maintenance procedures, troubleshooting, diagnostics, component removal/installation.
|
|
Page Count
|
|
Page Count:
|
Estimated 300-500 pages (typical for a comprehensive workshop manual of this era and complexity).
|
|
Manual Type
|
|
Manual Type:
|
Workshop Repair Service Manual
|
|
Language
|
|
Language:
|
English
|
|
Format
|
|
Format:
|
PDF Download
|
|
Manual Coverage
|
|
Systems Covered
|
|
Engine:
|
Detailed coverage of the 400cc class engine, including disassembly, assembly, component specifications, and troubleshooting.
|
|
Drivetrain 6X6:
|
Specific procedures for the engageable 6-wheel drive system, including differentials, drive shafts, and U-joints.
|
|
Transmission:
|
Coverage of the automatic transmission, including shift mechanisms and fluid service.
|
|
Suspension Steering:
|
Front and rear suspension components, steering linkage, tie rods, and alignment specifications.
|
|
Brakes:
|
Hydraulic brake system, including master cylinder, calipers, brake lines, fluid specifications, and bleeding procedures.
|
|
Electrical System:
|
Wiring diagrams, ignition system, lighting, starter, charging system (stator, regulator/rectifier), battery specifications, and troubleshooting electrical faults.
|
|
Fuel System:
|
Carburetor disassembly, cleaning, and adjustment, fuel pump operation, fuel lines, and tank service.
|
|
Cooling System:
|
Radiator, hoses, coolant specifications, and thermostat operation.
|
|
Procedures Included
|
|
Maintenance:
|
Regular service tasks, fluid changes, filter replacements, lubrication points, and pre-ride inspections.
|
|
Troubleshooting:
|
Diagnostic charts and procedures for common and uncommon problems across all major systems.
|
|
Repair Rebuild:
|
Step-by-step instructions for component disassembly, overhaul, and reassembly for major vehicle systems.
|
|
Adjustment:
|
Carburetor tuning, throttle cable adjustments, brake lever free play, and other critical adjustments.
|
|
Diagnostic Charts:
|
Systematic approaches to identify and resolve issues based on symptoms.
|
|
Technical Depth
|
|
Depth:
|
Comprehensive, covering everything from basic owner maintenance to full engine and transmission rebuilds. Includes detailed torque specifications and clearances.
|
|
Engine Specifications
|
|
Primary Engine
|
|
Engine Type:
|
Two-stroke, liquid-cooled, single-cylinder gasoline engine.
|
|
Displacement:
|
Approximately 340cc to 400cc (specific variant may differ slightly, but marketed as '400').
|
|
Bore X Stroke:
|
Specific dimensions would be detailed in the manual, e.g., typical for a 340cc Polaris engine.
|
|
Compression Ratio:
|
To be detailed in the manual, critical for performance and tuning.
|
|
Performance
|
|
Horsepower:
|
Estimated 20-25 HP (typical for a utility ATV of this displacement in the mid-90s).
|
|
Torque:
|
Estimated 25-30 lb-ft (specific figures detailed in manual).
|
|
Fuel System
|
|
Carburetor:
|
Likely a Mikuni or Keihin single carburetor (e.g., VM34 or similar), manual will detail specifications and tuning.
|
|
Fuel Type:
|
Unleaded gasoline (87 octane recommended, specific grade in manual).
|
|
Ignition System
|
|
Ignition Type:
|
Electronic Ignition (CDI), manual will cover components and timing.
|
|
Transmission
|
|
Standard
|
|
Transmission Type:
|
Automatic (CVT - Continuously Variable Transmission) with high/low range and reverse.
|
|
Drive System:
|
Shaft-driven, 6x6 with selectable front differential lock.
|
|
Features
|
|
Gear Selection:
|
High, Low, Neutral, Reverse, Park (common for Polaris automatic transmissions of the era).
|
|
Clutch Type:
|
CVT belt drive system, manual will detail belt inspection, replacement, and roller weights/springs.
|
|
Transmission Fluid:
|
Specific Polaris AGL Gearcase Lubricant or equivalent. Capacity and change intervals detailed.
|
|
Maintenance
|
|
Service Intervals
|
|
Oil Change:
|
Engine oil and filter change every 25-50 operating hours or annually, as specified in the manual.
|
|
Air Filter Cleaning:
|
Inspect and clean air filter every 10-20 operating hours, replace as needed.
|
|
Spark Plug:
|
Inspect and gap spark plug every 25-50 operating hours, replace as needed.
|
|
Cv Belt Inspection:
|
Inspect CVT belt for wear, cracks, and proper tension at 25-50 operating hours. Replace as necessary.
|
|
Fluid Specifications
|
|
Engine Oil Type:
|
API TC-W3 outboard motor oil or equivalent two-stroke injector oil (for pre-mix if applicable) and gearcase oil (Polaris AGL or equivalent).
|
|
Engine Oil Capacity:
|
Specific capacity for the two-stroke engine and separate gearcase will be detailed.
|
|
Brake Fluid:
|
DOT 3 or DOT 4 hydraulic brake fluid. Manual specifies which and capacity.
|
|
Coolant Type:
|
Ethylene glycol-based antifreeze (e.g., SAE J1034) with distilled water in a 50/50 mix.
|
|
Known Issues
|
|
Carburetor Fouling:
|
Common issue on older carbureted engines, requiring regular cleaning and adjustment. Manual covers jetting and settings.
|
|
Cvt Belt Wear:
|
CVT belts wear over time and can slip or break, impacting acceleration and power transfer. Manual details inspection and replacement procedures.
|
|
Electrical Connections:
|
Corrosion or looseness in electrical connectors can lead to intermittent issues or component failure. Manual provides wiring diagrams for troubleshooting.
|
|
Suspension Bushings:
|
Wear and tear on suspension bushings can lead to sloppy handling and noise. Manual covers replacement.
|
|
Vehicle History
|
|
Brand Heritage
|
|
Polarishistory:
|
Polaris Industries has a long history dating back to 1954, initially known for snowmobiles before expanding into ATVs in the late 1980s. They were pioneers in the ATV market, particularly with their Ranger utility vehicles and Sportsman models.
|
|
Model Evolution
|
|
Atv400 6X6 Evolution:
|
The 400 6x6 represented Polaris's commitment to utility and versatility in the ATV market, building on the success of earlier models. The 6x6 configuration was a key differentiator, offering enhanced off-road capability.
|
|
Production
|
|
Production Years:
|
The Polaris ATV 400 6x6 was produced through the mid-to-late 1990s, with 1994 and 1995 being specifically covered by this manual.
|
|
Manufacturing Location:
|
Polaris vehicles are typically manufactured in the United States, primarily at their facilities in Minnesota and Iowa.
|
