Polaris ATV 400 6x6 1996 1997 Service Repair Workshop Manual

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Basic Information Identification Make: Polaris Model: ATV 400 6x6 Years Covered: 1996, 1997 Product Type: Service Repair Workshop Manual Format: PDF Download Introduction Market Position Niche: Specialized utility ATV market, known for its 6x6 capability and ruggedness for hauling and off-road work. Competitive Analysis Competitors: Competed against other utility ATVs from manufacturers like Yamaha (e.g., Big Bear 4x4 variants), Honda (e.g., FourTrax 300/350 variants), and Kawasaki (e.g., Bayou variants) in the utility segment, though the 6x6 configuration offered a distinct advantage in traction and load-carrying. Key Features Traction Advantage: The 6x6 drive system provides superior traction in mud, sand, and on uneven terrain compared to 4x4 models. Utility Focus: Designed for work and recreational use, with features like cargo racks, towing capacity, and robust construction. Versatility: Capable of handling a variety of tasks from farm work and hunting to trail riding. Manual Details Coverage Areas Engine Service: Complete engine overhaul, disassembly, assembly, inspection, and adjustment. Drivetrain Service: All aspects of the 6x6 drivetrain, including differentials, driveshafts, and axle maintenance. Suspension And Steering: Front and rear suspension components, steering linkage, and related adjustments. Braking System: Hydraulic brake system service, including master cylinder, calipers, pads, and bleeding procedures. Electrical System: Wiring diagrams, troubleshooting of lighting, ignition, charging systems, and accessories. Fuel And Emission Control: Fuel delivery system, carburetor service, and emission control components. Chassis And Body: Frame inspection, body panel removal/installation, and seat servicing. Troubleshooting Guide: Diagnostic procedures for common mechanical and electrical faults. Page Count Estimated Pages: Extensive, covering all service and repair aspects (exact page count varies based on PDF optimization). Manual Type Type: Comprehensive Service Repair Workshop Manual Language Language: English Format File Format: PDF Manual Coverage Systems Covered Engine: All internal and external engine components, cooling system, lubrication system. Transmission: Transmission unit, clutch, gear shifting mechanisms, and related components. Drivetrain: 6x6 drive system, differentials (front, center, rear), driveshafts, universal joints, and axles. Steering: Handlebar assembly, steering shaft, tie rods, and steering knuckle components. Suspension: Front and rear independent suspension, shock absorbers, A-arms, bushings, and bearings. Brakes: Front and rear hydraulic disc brakes, master cylinder, brake lines, calipers, pads, and rotor specifications. Electrical: Battery, starter motor, alternator, ignition system (CDI), lighting (headlights, taillight, brake light), wiring harness, fuses, switches, and starter solenoid. Fuel System: Fuel tank, fuel lines, fuel pump (if applicable), and carburetor (Mikuni VM34-346 or equivalent). Cooling System: Radiator, fan, coolant hoses, and thermostat. Exhaust System: Exhaust pipe, muffler, and heat shields. Body And Frame: Frame construction, front and rear racks, fenders, body panels, seat, and storage compartments. Procedures Included Maintenance: Routine maintenance checks, oil changes, filter replacements, lubrication, and adjustments. Diagnosis: Systematic troubleshooting for performance issues, starting problems, electrical faults, and driveability. Repair: Detailed step-by-step instructions for component removal, repair, and reinstallation. Rebuilds: Complete engine and transmission rebuild procedures, including specifications and tolerances. Adjustments: Carburetor tuning, valve clearance adjustment, brake adjustments, and steering alignment. Electrical Troubleshooting: Using wiring diagrams to diagnose and repair electrical system faults. Suspension Repair: Replacement of ball joints, tie rod ends, wheel bearings, and shock absorbers. Brake Service: Brake pad replacement, caliper service, brake line replacement, and bleeding. Technical Depth Depth: Comprehensive, suitable for both novice mechanics performing basic maintenance and experienced technicians undertaking major repairs and overhauls. Manual Specifications File Format Quality: High-resolution PDF, ensuring clarity of text and diagrams. Searchability: Searchable text for quick access to specific information. Print Quality Printable: Printable pages for on-site workshop use. Binding Type Digital Binding: N/A (Digital PDF format) Paper Type Digital Paper Simulation: N/A (Digital PDF format) Engine Specifications Primary Engine Type: 4-stroke, Liquid-Cooled, Single-Cylinder Displacement: 376 cc (approx.) Bore X Stroke: Information typically found within the manual, specific to the engine design. Compression Ratio: Information typically found within the manual, specific to the engine design. Performance Horsepower: Approx. 26-28 HP (estimated, actual may vary). Torque: Information typically found within the manual, specific to the engine design. Fuel System Carburetor: Mikuni VM34-346 (or similar variant), single downdraft carburetor. Fuel Type: Unleaded gasoline Fuel Capacity: Typically around 3.7 US gallons (14 L). Ignition System: CDI (Capacitor Discharge Ignition) Cooling System Type: Liquid-cooled Lubrication System: Wet sump Oil Type: API SG or higher, SAE 10W-40 or 20W-50 motorcycle-specific engine oil recommended (refer to manual for exact specification). Transmission Standard Type: Automatic (CVT - Continuously Variable Transmission) with 2WD/4WD/6WD selector. Gear Reduction: Varies with CVT ratio, low range gearing typically available for towing and steep inclines. Features Drive Selector: Dash-mounted lever for selecting 2WD, 4WD, or 6WD engagement. Gear Selection: Forward, Neutral, Reverse (F-N-R) automatic gearbox. Fluid Specifications Cvt Fluid: Specific CVT fluid (refer to manual for Polaris P/N or equivalent specification). Dimensions Exterior Length: Approx. 105 inches (2667 mm) Width: Approx. 46 inches (1168 mm) Height: Approx. 44 inches (1118 mm) Wheelbase: Approx. 76 inches (1930 mm) Weights Dry Weight: Approx. 660 lbs (300 kg)...

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Sku: 59218

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Tags: 1996 1997 400 6x6 ATV Misc Polaris Powersports

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Description

Basic Information
Identification
Make:	Polaris
Model:	ATV 400 6x6
Years Covered:	1996, 1997
Product Type:	Service Repair Workshop Manual
Format:	PDF Download

Introduction
Market Position
Niche:	Specialized utility ATV market, known for its 6x6 capability and ruggedness for hauling and off-road work.
Competitive Analysis
Competitors:	Competed against other utility ATVs from manufacturers like Yamaha (e.g., Big Bear 4x4 variants), Honda (e.g., FourTrax 300/350 variants), and Kawasaki (e.g., Bayou variants) in the utility segment, though the 6x6 configuration offered a distinct advantage in traction and load-carrying.
Key Features
Traction Advantage:	The 6x6 drive system provides superior traction in mud, sand, and on uneven terrain compared to 4x4 models.
Utility Focus:	Designed for work and recreational use, with features like cargo racks, towing capacity, and robust construction.
Versatility:	Capable of handling a variety of tasks from farm work and hunting to trail riding.

Manual Details
Coverage Areas
Engine Service:	Complete engine overhaul, disassembly, assembly, inspection, and adjustment.
Drivetrain Service:	All aspects of the 6x6 drivetrain, including differentials, driveshafts, and axle maintenance.
Suspension And Steering:	Front and rear suspension components, steering linkage, and related adjustments.
Braking System:	Hydraulic brake system service, including master cylinder, calipers, pads, and bleeding procedures.
Electrical System:	Wiring diagrams, troubleshooting of lighting, ignition, charging systems, and accessories.
Fuel And Emission Control:	Fuel delivery system, carburetor service, and emission control components.
Chassis And Body:	Frame inspection, body panel removal/installation, and seat servicing.
Troubleshooting Guide:	Diagnostic procedures for common mechanical and electrical faults.
Page Count
Estimated Pages:	Extensive, covering all service and repair aspects (exact page count varies based on PDF optimization).
Manual Type
Type:	Comprehensive Service Repair Workshop Manual
Language
Language:	English
Format
File Format:	PDF

Manual Coverage
Systems Covered
Engine:	All internal and external engine components, cooling system, lubrication system.
Transmission:	Transmission unit, clutch, gear shifting mechanisms, and related components.
Drivetrain:	6x6 drive system, differentials (front, center, rear), driveshafts, universal joints, and axles.
Steering:	Handlebar assembly, steering shaft, tie rods, and steering knuckle components.
Suspension:	Front and rear independent suspension, shock absorbers, A-arms, bushings, and bearings.
Brakes:	Front and rear hydraulic disc brakes, master cylinder, brake lines, calipers, pads, and rotor specifications.
Electrical:	Battery, starter motor, alternator, ignition system (CDI), lighting (headlights, taillight, brake light), wiring harness, fuses, switches, and starter solenoid.
Fuel System:	Fuel tank, fuel lines, fuel pump (if applicable), and carburetor (Mikuni VM34-346 or equivalent).
Cooling System:	Radiator, fan, coolant hoses, and thermostat.
Exhaust System:	Exhaust pipe, muffler, and heat shields.
Body And Frame:	Frame construction, front and rear racks, fenders, body panels, seat, and storage compartments.
Procedures Included
Maintenance:	Routine maintenance checks, oil changes, filter replacements, lubrication, and adjustments.
Diagnosis:	Systematic troubleshooting for performance issues, starting problems, electrical faults, and driveability.
Repair:	Detailed step-by-step instructions for component removal, repair, and reinstallation.
Rebuilds:	Complete engine and transmission rebuild procedures, including specifications and tolerances.
Adjustments:	Carburetor tuning, valve clearance adjustment, brake adjustments, and steering alignment.
Electrical Troubleshooting:	Using wiring diagrams to diagnose and repair electrical system faults.
Suspension Repair:	Replacement of ball joints, tie rod ends, wheel bearings, and shock absorbers.
Brake Service:	Brake pad replacement, caliper service, brake line replacement, and bleeding.
Technical Depth
Depth:	Comprehensive, suitable for both novice mechanics performing basic maintenance and experienced technicians undertaking major repairs and overhauls.

Manual Specifications
File Format
Quality:	High-resolution PDF, ensuring clarity of text and diagrams.
Searchability:	Searchable text for quick access to specific information.
Print Quality
Printable:	Printable pages for on-site workshop use.
Binding Type
Digital Binding:	N/A (Digital PDF format)
Paper Type
Digital Paper Simulation:	N/A (Digital PDF format)

Engine Specifications
Primary Engine
Type:	4-stroke, Liquid-Cooled, Single-Cylinder
Displacement:	376 cc (approx.)
Bore X Stroke:	Information typically found within the manual, specific to the engine design.
Compression Ratio:	Information typically found within the manual, specific to the engine design.
Performance
Horsepower:	Approx. 26-28 HP (estimated, actual may vary).
Torque:	Information typically found within the manual, specific to the engine design.
Fuel System
Carburetor:	Mikuni VM34-346 (or similar variant), single downdraft carburetor.
Fuel Type:	Unleaded gasoline
Fuel Capacity:	Typically around 3.7 US gallons (14 L).
Ignition
System:	CDI (Capacitor Discharge Ignition)
Cooling System
Type:	Liquid-cooled
Lubrication
System:	Wet sump
Oil Type:	API SG or higher, SAE 10W-40 or 20W-50 motorcycle-specific engine oil recommended (refer to manual for exact specification).

Transmission
Standard
Type:	Automatic (CVT - Continuously Variable Transmission) with 2WD/4WD/6WD selector.
Gear Reduction:	Varies with CVT ratio, low range gearing typically available for towing and steep inclines.
Features
Drive Selector:	Dash-mounted lever for selecting 2WD, 4WD, or 6WD engagement.
Gear Selection:	Forward, Neutral, Reverse (F-N-R) automatic gearbox.
Fluid Specifications
Cvt Fluid:	Specific CVT fluid (refer to manual for Polaris P/N or equivalent specification).

Dimensions
Exterior
Length:	Approx. 105 inches (2667 mm)
Width:	Approx. 46 inches (1168 mm)
Height:	Approx. 44 inches (1118 mm)
Wheelbase:	Approx. 76 inches (1930 mm)
Weights
Dry Weight:	Approx. 660 lbs (300 kg)
Towing Capacity:	Typically rated at 1500 lbs (680 kg).
Cargo
Rack Capacity Front:	Approx. 50 lbs (23 kg)
Rack Capacity Rear:	Approx. 100 lbs (45 kg)
Wheels And Tires
Front Tire Size:	25 x 8-12 (Commonly)
Rear Tire Size:	25 x 11-10 (Commonly)
Wheel Type:	Steel wheels
Bolt Pattern:	Information typically found within the manual, specific to wheel hub design.

Safety Features
Ratings
Design Standard:	Designed for off-road use, not street legal without modification.
Active Features
Braking:	Hydraulic disc brakes on all wheels (or configurable via 6x6 system).
Traction Control:	Integral 6x6 drive system for enhanced stability and traction.
Passive Features
Rollover Protection:	None (typical for ATVs of this era; operator assumes risk).
Seatbelt:	None (operator restraint is typically foot and leg grip).
Warning Information
Operator Training:	Manual emphasizes operator safety training, protective gear, and understanding of ATV limitations.

Technology Features
Infotainment
System:	Basic instrumentation panel (speedometer, odometer, basic indicator lights). No complex infotainment systems.
Driver Assistance
Features:	No electronic driver assistance systems typical of modern vehicles.
Connectivity
Features:	No connectivity features.

Maintenance
Service Intervals
Oil Change Engine:	Every 100 hours or annually (whichever comes first); refer to manual for specific recommendations.
Air Filter:	Inspect every 25 hours, clean or replace as needed; replace annually.
Spark Plug:	Inspect annually or every 100 hours, replace as needed.
Brake Fluid:	Flush and replace every 2 years.
Lubrication:	Lubricate all pivot points, suspension components, and linkages at intervals specified in the manual (typically every 50 hours or annually).
Fluid Specifications
Engine Oil:	API SG or higher, SAE 10W-40 or 20W-50 motorcycle-specific engine oil.
Coolant:	Ethylene glycol-based antifreeze mixed 50/50 with distilled water.
Brake Fluid:	DOT 3 or DOT 4 hydraulic brake fluid.
Cvt Fluid:	Polaris recommended CVT fluid or equivalent specified in the manual.
Known Issues
Drive Belt Wear:	CVT drive belts can wear over time, especially with heavy use; proper tension and alignment are crucial.
Carburetor Tuning:	Carburetors may require periodic cleaning and adjustment to maintain optimal performance due to fuel quality or debris.
Electrical Connections:	Corrosion on electrical connectors can lead to intermittent faults; regular inspection and dielectric grease application are recommended.
Suspension Bushings:	Rubber suspension bushings can degrade over time, leading to play and potential alignment issues.

Vehicle History
Brand Heritage
Polarisfamily:	Polaris is a well-established American manufacturer with a long history of producing recreational and utility vehicles, including snowmobiles and ATVs.
Model Evolution
Progression:	The 400 6x6 was part of Polaris's expanding ATV lineup in the mid-to-late 1990s, focusing on utility and off-road capability. The 6x6 configuration represented a significant step in traction and load-bearing for the brand.
Production
Era:	Produced during the peak of ATV popularity and technological development in the 1990s.

Awards & Recognition
Recognitions
Industry Impact:	The 6x6 configuration, while not unique, solidified Polaris's reputation for rugged utility ATVs in the 1990s, influencing competitors and market perception.