The ATV 400 6x6, produced between 1985 and 1995, stands as a testament to a pioneering spirit in the utility all-terrain vehicle market. Engineered for robust performance and exceptional traction, this model excels in demanding off-road conditions and heavy-duty tasks, thanks to its distinctive 6x6 drivetrain. Known for its ruggedness and capability, the ATV 400 6x6 was designed to provide reliable service for work and recreation, solidifying a reputation for durable and innovative ATVs. This comprehensive workshop and service manual provides detailed guidance for the maintenance and repair of your ATV 400 6x6. Covering a wide array of systems including the engine, transmission, chassis, braking, and electrical components, the manual offers step-by-step procedures for everything from routine servicing and fluid changes to complex overhauls and troubleshooting. With clear diagrams, exploded views, and essential technical specifications, this manual is an indispensable resource for owners, mechanics, and technicians seeking to ensure the optimal performance and longevity of their vehicle. 🏷️ Basic Information Identification Make: Polaris Model: ATV 400 6x6 Generation Model Years: 1985-1995 Codes Vin Decoder Scope: Not applicable for this manual; covers a range of years. 👋 Introduction Market Position Segment: Heavy-duty utility ATV segment. Target User: Owners, mechanics, and technicians performing maintenance and repairs. Competitive Analysis Competitors: Other utility ATVs of the era, e.g., early Honda FourTrax, Yamaha Timberwolf. Key Features Vehicle Selling Points: 6x6 drivability for traction and load carrying, Polaris's reputation for ruggedness. Manual Value Proposition: Enables DIY repairs, cost savings, proper maintenance for longevity. 📋 Manual Details Coverage Areas Primary Coverage: Workshop repair and maintenance for Polaris ATV 400 6x6 models. Secondary Coverage: Troubleshooting, diagnostics, specifications, diagrams. Page Count Estimated Pages: Likely extensive; typical workshop manuals for this era are 300-600+ pages. Manual Type Type: Workshop Manual / Service Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Powertrain: Engine, transmission, drivetrain (6x6 system). Chassis: Frame, suspension (front and rear), steering. Braking: Brake system components, hydraulics, adjustment. Electrical: Ignition, lighting, charging system, starter, battery, wiring diagrams. Fuel System: Carburetor, fuel lines, fuel pump, tank. Cooling System: Radiator, fan, coolant (if applicable). Exhaust System: Muffler, pipes, gaskets. Body And Frame: Body panels, fenders, frame inspection and repair. Procedures Included Maintenance: Scheduled maintenance, fluid changes, lubrication, filter replacement. Troubleshooting: Diagnosis of common problems, diagnostic flowcharts. Repair: Component disassembly, reassembly, and adjustment procedures. Rebuilds: Engine overhaul, transmission rebuild, carburetor rebuild. Inspections: Pre-ride checks, component wear inspections, safety checks. Specifications Torque: Torque specifications for critical fasteners. Technical Depth Level: Comprehensive: Covers from basic maintenance to complete engine and transmission overhauls. Diagnostics: Detailed diagnostic procedures for electrical and mechanical issues. Illustrations: Includes diagrams, exploded views, and schematics. 📊 Manual Specifications File Format Type: PDF Searchability: Typically searchable text within PDF. Print Quality Resolution: High resolution for clear diagrams and text (expected for professional PDF). Binding Type Binding: N/A (Digital PDF download) Paper Type Paper: N/A (Digital PDF download) ⚙️ Engine Specifications Primary Engine Type: 2-stroke, piston-ported gasoline engine. Displacement: Approximately 300-340cc (specific variant dependent on exact model year within range). Bore X Stroke: Typical for this class: e.g., 70mm x 76mm (specifics in manual). Cooling: Liquid-cooled (common for this performance level). Ignition: CDI (Capacitor Discharge Ignition). Performance Horsepower: Estimated 22-28 HP (typical for a 2-stroke of this displacement). Torque: Not typically published for ATVs of this era, but critical for low-end pull. Fuel System Carburetor: Single barrel carburetor (e.g., Mikuni VM or similar). Fuel Type: Unleaded gasoline. Oil Mixture: 2-stroke pre-mix or oil injection system (manual will specify). 🔧 Transmission Standard Type: Automatic (CVT - Continuously Variable Transmission). Drive System: 6x6 (all-wheel drive), with selectable 2WD/4WD/6WD. Features Gear Reduction: High and low range gear selection (typical for utility ATVs). Transmission Fluid: Specific CVT fluid or gear oil (manual to specify). 📐 Dimensions Exterior Length: Approx. 70-80 inches (specifics vary by year). Width: Approx. 40-45 inches. Height: Approx. 40-45 inches. Weights Dry Weight: Approx. 550-650 lbs (specific to configuration). Ground Clearance: Approx. 6-8 inches. 🛡️ Safety Features Ratings Safety Standards: Industry standards for ATVs of the era; specific agency ratings less common. Active Features Braking System: Hydraulic disc brakes (front and rear), often drum brakes on rear wheels in early models. Passive Features Frame Design: Steel frame providing structural integrity. Lighting: Headlights, taillight, brakelight. 💡 Technology Features Infotainment Features: Basic; primarily functional instrumentation (speedometer, odometer, warning lights). Driver Assistance Features: None in the modern sense; reliance on mechanical systems and rider skill. Connectivity Features: Not applicable. 🔧 Maintenance Service Intervals Oil Change Engine: e.g., Every 50 hours or annually for 2-stroke models (details in manual). Air Filter Cleaning: Frequent checks and cleaning/replacement based on operating conditions (e.g., every 25 hours). Spark Plug Replacement: e.g., Annually or every 100 hours. Cv Belt Inspection: Regular inspection for wear and damage. Fluid Specifications Engine Oil: Specific 2-stroke engine oil (e.g., Polaris Premium...