The ATV 400 6x6, produced between 1996 and 1998, is a robust utility all-terrain vehicle engineered for demanding tasks and challenging terrains. Its distinctive 6x6 drivetrain provides exceptional traction for mud, snow, and steep inclines, making it ideal for farmers, hunters, and recreational riders. Featuring a powerful 2-stroke, liquid-cooled engine and the reliable Variable Transmission (PVT), this ATV offers efficient power delivery and adaptability. The durable chassis and suspension system, coupled with integrated racks for cargo, underscore its design for heavy-duty work and off-road capability, establishing it as a capable and versatile machine in its segment. This comprehensive service and repair manual provides factory-level detail for the ATV 400 6x6, covering all production years from 1996 to 1998. It offers in-depth guidance on routine maintenance, troubleshooting common issues, and performing complex repairs across all major vehicle systems, including the engine, transmission, drivetrain, suspension, brakes, and electrical components. With step-by-step instructions, diagnostic charts, and essential technical specifications, this manual is an indispensable resource for owners and technicians alike, ensuring the proper upkeep and longevity of the vehicle. 🏷️ Basic Information Identification Make: Polaris Model: ATV 400 6x6 Model Variant: 400 6x6 Generation Production Years: 1996-1998 👋 Introduction Market Position Segment: Utility ATV, 6x6 configuration for enhanced traction and load-carrying capacity. Target User: Hobbyists, farmers, hunters, recreational riders requiring robust performance in challenging terrain. Competitive Analysis Competitors: John Deere Gator (early models), Cub Cadet, other utility-focused ATVs of the era. Key Features Feature 1: 6x6 Drivetrain for superior traction in mud, snow, and steep inclines. Feature 2: Powerful Polaris Variable Transmission (PVT) for seamless gear changes and optimal power delivery. Feature 3: Robust chassis and suspension designed for heavy-duty work and off-road capability. Feature 4: Utility-focused design with integrated racks for carrying gear and equipment. 📋 Manual Details Coverage Areas Primary Coverage: Factory Service and Repair Specific Models Covered: Polaris ATV 400 6x6 (1996, 1997, 1998) Page Count Estimated Pages: 300+ Manual Type Type: Service Manual / Repair Manual Language Language: English Format Format: Downloadable PDF 📖 Manual Coverage Systems Covered Engine: Complete engine overhaul, diagnostics, tuning, lubrication system, cooling system, fuel system (carburetor details, fuel pump), exhaust system, ignition system (CDI, spark plugs). Transmission: PVT (Polaris Variable Transmission) system, drive clutch, driven clutch, belt inspection and replacement, high/low range operation, reverse gear, transmission oil specifications and change procedures. Drivetrain: 6x6 drive system operation, front differential, rear differentials, driveshafts, U-joints, gear case lubrication, maintenance of all six drive wheels. Suspension: Front and rear suspension systems, shock absorbers, springs, control arms, bushings, steering linkage, alignment procedures. Brakes: Hydraulic brake system, brake caliper maintenance, brake pad replacement, brake fluid type and bleeding procedures, master cylinder, brake lines. Electrical: Wiring diagrams, battery maintenance and testing, charging system (stator, regulator/rectifier), lighting system (headlights, taillights, brake lights), starting system (starter motor, solenoid), ignition switch, switches, fuses, troubleshooting electrical faults. Bodywork: Body panel removal and installation, fenders, racks, seat, storage compartments, frame inspection and repair. Steering: Handlebar assembly, steering shaft, tie rods, steering linkage maintenance and adjustment. Wheels Tires: Wheel lug nut torque specifications, tire pressure recommendations, tire replacement. Procedures Included Maintenance: Routine maintenance checks, lubrication points, oil and filter changes, spark plug replacement, air filter cleaning/replacement, battery care, brake inspection, chain/belt adjustment (if applicable), general inspection points. Troubleshooting: Diagnostic charts, symptom-based troubleshooting guides for common problems (engine starting issues, power loss, braking problems, electrical malfunctions). Repair: Step-by-step instructions for component removal, disassembly, inspection, repair, reassembly, and installation for all major systems. Diagnostics: Methods for diagnosing mechanical and electrical faults, using basic tools, interpreting symptoms. Technical Depth Depth: Comprehensive factory-level detail, suitable for both amateur mechanics and professional technicians. Covers everything from basic maintenance to complete engine and transmission rebuilds. 📊 Manual Specifications File Format Format: PDF Searchability: Searchable text content for quick information retrieval. Printability: Printable pages for easy workshop use. Print Quality Resolution: High-resolution scans ensuring clarity of diagrams and text. Binding Type Type: N/A (Digital Download) Paper Type Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Type: 2-stroke, Reed Valve, Liquid-Cooled Displacement: 340 cc (approximate) Bore X Stroke: Refer to manual for specific dimensions Cooling System: Liquid-cooled with radiator and fan Performance Horsepower: Approximately 26-30 HP (estimated) Torque: Refer to manual for specific torque curves Fuel System Carburetor: Single Mikuni carburetor (specific model and jetting detailed in manual) Fuel Type: Unleaded gasoline (refer to manual for octane rating) Fuel Capacity: Approx. 3.7 gallons (14 L) Lubrication Oil Type: 2-stroke oil premix or autolube system (details in manual) 🔧 Transmission Standard Type: Polaris Variable Transmission (PVT) Automatic Gearing: High, Low, Neutral, Reverse Features Drive System: Shaft drive to all six wheels. Clutch System: Centrifugal drive clutch and weighted driven clutch. Transmission Oil Type: SAE 10W-30 or 10W-40 API SG or higher (refer to manual for precise specification) Transmission Oil Capacity: Refer to manual for specific...