The ATV 400 6x6, produced between 1996 and 1998, is a robust utility all-terrain vehicle engineered for demanding work and recreational applications. Its distinctive 6x6 drivetrain offers exceptional traction and superior load-carrying capacity, making it ideal for challenging terrains, agricultural tasks, and hunting expeditions. Known for its durability and reliable performance, this model embodies a commitment to building capable off-road machines. The ATV 400 6x6 features a 4-stroke, liquid-cooled, SOHC engine with an approximate displacement of 377cc, paired with an Automatic Variable Transmission for smooth power delivery and on-demand 6WD. This comprehensive workshop service manual provides all necessary information for the maintenance, repair, and troubleshooting of the ATV 400 6x6 (1996-1998). It covers essential systems including the engine, fuel, ignition, drivetrain, suspension, steering, brakes, and electrical components. Detailed procedures for routine maintenance, major repairs, and component disassembly/reassembly are included, along with critical torque specifications and diagnostic guides to address common issues. This manual serves as an indispensable resource for owners, mechanics, and technicians to ensure the optimal performance, longevity, and safe operation of their vehicle. 🏷️ Basic Information Identification Make: Polaris Model: ATV 400 6x6 Production Years: 1996-1998 Codes Chassis Code: Not specified in product info Engine Code: Not specified in product info 👋 Introduction Market Position Segment: Utility All-Terrain Vehicle (ATV) Target User: Workhorse users, recreational riders requiring significant hauling and off-road capability, agricultural and hunting applications. Competitive Analysis Competitors: Concurrent models from John Deere, Yamaha, Kawasaki, Can-Am, Suzuki in the 6x6 utility ATV segment. Key Features Articulation: 6x6 drivetrain providing superior traction and load-carrying capacity in challenging terrain. Utility Focus: Designed for hauling, towing, and navigating difficult terrain, making it a versatile tool for work and recreation. Durability: Known for robust construction and reliable performance in demanding conditions. 📋 Manual Details Coverage Areas Primary Coverage: All aspects of service, repair, and maintenance for Polaris ATV 400 6x6 (1996-1998) Specific Systems: Engine, drivetrain, suspension, steering, brakes, electrical, chassis, bodywork Page Count Estimated Page Count: Detailed page count not provided in product information, but typical workshop manuals of this era range from 300-600 pages. Manual Type Type: Workshop Service Manual / Repair Manual Language Language: English (presumed, standard for Polaris service documentation) Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine Mechanical: Engine removal/installation, cylinder head, pistons, crankshaft, valve train, lubrication system, cooling system, compression testing, engine diagnostics. Fuel System: Carburetor disassembly, cleaning, adjustment, fuel pump, fuel lines, fuel filter, fuel tank. Ignition System: Ignition coil, spark plug, CDI unit, timing, troubleshooting. Drivetrain Transmission: Automatic transmission (PVT - Polaris Variable Transmission) operation, clutch service, belt replacement, gearcase lubrication, differential service (front and rear), driveshafts, CV joints. Suspension Steering: Front and rear suspension components, shock absorbers, A-arms, bushings, wheel bearings, steering column, tie rods, ball joints, steering linkage. Braking System: Hydraulic brake system, brake calipers, brake pads, brake discs, master cylinder, brake fluid flush and bleeding, parking brake. Electrical System: Battery, charging system (stator, regulator/rectifier), starter motor, lighting system, wiring diagrams, fuses, relays, switches, instrument cluster. Chassis Frame: Frame inspection, welding, component mounting. Bodywork Plastics: Fender removal/installation, seat, handlebars, body panel repair and replacement. Procedures Included Routine Maintenance: Oil changes, filter replacements, spark plug checks, air filter cleaning/replacement, chain/belt adjustments, lubrication points. Troubleshooting: Diagnostic charts for common starting, running, and electrical issues, symptoms and causes analysis. Major Repairs: Engine overhauls, transmission rebuilds, suspension component replacement, brake system overhauls, electrical component replacement. Component Disassembly Reassembly: Detailed step-by-step instructions for taking apart and putting back together all major vehicle systems and components. Torquing Specifications: Essential torque values for critical fasteners across all systems, ensuring proper assembly and preventing component failure. Technical Depth Depth: Comprehensive; covers basic maintenance to complete engine and transmission rebuilds, including detailed diagnostics and specifications. Diagnostic Capability: Includes troubleshooting guides, symptom-to-cause charts, and diagnostic procedures to identify and resolve performance issues. Rebuild Procedures: Detailed instructions for rebuilding key components such as the engine and transmission, suitable for experienced mechanics. 📊 Manual Specifications File Format Digital Format: PDF Searchable Text: Typically yes for professionally produced PDF service manuals, enabling quick information retrieval. Print Quality Printability: Designed for printing, allowing users to create hard copies for workshop use. Binding Type Digital Binding: N/A (Digital file) Paper Type Digital Paper Simulation: Simulates professional workshop manual pages for clarity and ease of use. ⚙️ Engine Specifications Primary Engine Type: 4-stroke, liquid-cooled, SOHC Displacement: 377cc (approx.) - Specific engine code/variant would provide exact displacement. Bore X Stroke: Not specified in product info, but typical for this era's Polaris engines. Compression Ratio: Not specified in product info. Power Output: Estimated 20-25 HP (typical for this displacement and application). Torque Output: Not specified in product info. Performance Carburetion: Single Mikuni carburetor (likely 36mm or 40mm) - Specific model number would be in the manual. Ignition: CDI (Capacitor Discharge Ignition) Fuel System Fuel Type: Unleaded gasoline (minimum...