The Polaris 400 4x4, produced between 1985 and 1995, is a utility all-terrain vehicle engineered for reliable performance in varied terrain and light-duty work. Known for its robust chassis, capable 4x4 system, and a dependable engine, this model offered a solid platform for recreational riding and practical applications. Its design emphasized durability and functionality, making it a competitive choice within the utility ATV segment of its era, and a valuable asset for those seeking a capable off-road machine. This comprehensive service and repair manual provides essential information for maintaining and servicing the Polaris 400 4x4. It covers a wide range of topics, including detailed procedures for engine overhaul, drivetrain and transmission maintenance, suspension and brake system repairs, and electrical system troubleshooting. With step-by-step instructions, diagrams, and technical specifications, this manual is an indispensable resource for owners and technicians aiming to ensure the longevity and optimal performance of their vehicle. 🏷️ Basic Information Identification Make: Polaris Model: 400 4x4 Generation Model Years Covered: 1985-1995 👋 Introduction Market Position Segment: Utility ATV, designed for recreational and light-duty work applications. Competitive Analysis Competitors: Competed against other 300-400cc class ATVs from manufacturers like Yamaha (Banshee 350, Warrior 350 - though Banshee was more sport-oriented), Suzuki (LT4WD series), and Honda (FourTrax 300). Key Features Features: 4x4 capability, robust chassis, reliable engine, capable suspension for varied terrain, often equipped with racks for utility. 📋 Manual Details Coverage Areas Primary Coverage: Comprehensive service and repair information for the Polaris 400 4x4 ATV Page Count Estimated Pages: Varies by specific manual version, typically 300-600 pages for comprehensive coverage Manual Type Type: Service and Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine: Complete engine overhaul, disassembly, inspection, assembly, lubrication, cooling system, ignition system, fuel system (carburetor tuning, fuel pump, fuel tank), exhaust system. Drivetrain: All-wheel drive system, differentials (front and rear), driveshafts, U-joints, CV joints, axle bearings. Transmission: Clutch system, gearbox operation, maintenance, repair, gear selection, chain drive maintenance (if applicable). Suspension: Front and rear suspension components, shock absorbers, springs, control arms, bushings, steering linkage, wheel bearings. Brakes: Hydraulic brake system, brake master cylinder, brake calipers, brake pads, brake shoes, brake drums, brake lines, bleeding procedures. Electrical: Battery, starter, charging system (stator, regulator/rectifier), lighting system, ignition switch, wiring diagrams, fuses, troubleshooting electrical faults. Body Chassis: Frame inspection and repair, body panels, fenders, handlebars, seating, storage racks, plastic components. Procedures Included Maintenance: Routine maintenance checks, oil changes, filter replacements, chain adjustment, lubrication points, spark plug service, air filter cleaning/replacement. Troubleshooting: Diagnostic procedures for common issues, symptom analysis, fault finding for engine performance, electrical problems, and drivability. Repair: Step-by-step repair instructions for all major systems, including component replacement, adjustments, and reassembly. Disassembly Assembly: Detailed instructions for complete disassembly and reassembly of all major mechanical and electrical components. Technical Depth Depth Level: Comprehensive, covering basic maintenance to complete engine and transmission rebuilds. Includes detailed diagrams and specifications. 📊 Manual Specifications File Format File Type: PDF Print Quality Quality: High-resolution scans, ensuring clarity of text, diagrams, and images. Searchable text functionality is highly probable. Binding Type Binding: N/A (Digital Download) Paper Type Paper Quality: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: 2-stroke, liquid-cooled (or air-cooled depending on exact variant, but often liquid-cooled for this class and era) Displacement: Approximately 300-400cc (specific engine model would clarify exact CC) Bore X Stroke: To be confirmed by specific model variant in manual (e.g., 72mm x 73mm is common for similar displacements) Compression Ratio: Typical range 6.5:1 - 7.5:1 for 2-stroke utility engines. Performance Horsepower: Estimated 20-25 HP at peak RPM. Torque: Estimated 20-25 lb-ft. Fuel System Carburetion: Single carburetor, likely a Mikuni VM series or similar (e.g., VM34 or VM36). Fuel Type: Unleaded gasoline, octane rating to be specified (likely 87 or 89 octane). Fuel Tank Capacity: Typically 3-4 gallons (approx. 11-15 liters). 🔧 Transmission Standard Transmission Type: Automatic (Continuously Variable Transmission - CVT) with high/low range and reverse. Drive System: Shaft-driven 4x4 with automatic engagement or selectable 2WD/4WD. Features Gear Reduction: High and Low range gear ratios for varied terrain and towing. Transmission Fluid Type: Specific CVT fluid (e.g., Polaris brand or equivalent, often a specialized fluid). 📐 Dimensions Exterior Length: Approx. 75-80 inches (190-203 cm). Width: Approx. 40-45 inches (102-114 cm). Height: Approx. 45-50 inches (114-127 cm). Wheelbase: Approx. 48-50 inches (122-127 cm). Weights Dry Weight: Approx. 450-550 lbs (204-250 kg). Ground Clearance: Approx. 8-10 inches (20-25 cm). Cargo Front Rack Capacity: Typically 50-75 lbs (23-34 kg). Rear Rack Capacity: Typically 100-150 lbs (45-68 kg). Towing Capacity: Typically 500-1000 lbs (227-454 kg). 🛡️ Safety Features Ratings Atv Safety Standards: Designed to meet industry safety standards of its time; adherence to modern standards may vary. Active Features Braking System: Hydraulic disc brakes (front and rear) or drum brakes on some early models. All-wheel braking. 4X4...