🏷️ 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 2-Stroke Oil) or specified pre-mix ratio. Transmission Fluid: Manual will specify appropriate gear oil or CVT fluid (e.g., SAE 80W-90 gear oil for differentials if applicable). Coolant: Ethylene glycol-based antifreeze mixture (specific type and ratio in manual). Known Issues Common Wear Items: CVT belt failure, carburetor gumming/fouling, rear suspension wear, braking component wear. 2 Stroke Care: Importance of proper fuel/oil mixture, avoiding carbon buildup, regular decarbonization. 📚 Vehicle History Brand Heritage Polaris Atv Legacy: Polaris was a pioneer in the ATV market, known for its innovative 6x6 designs and utility focus. Model Evolution 400 6X6 Development: Evolved from earlier Polaris models, emphasizing increased traction and load capacity for work and recreation. Production Manufacturing Era: 1985-1995 marked a significant period of development and sales for this model line. 🏆 Awards & Recognition Recognitions Industry Impact: Polaris's 6x6 models were highly regarded for their off-road capability and utility in their prime. Ratings Consumer Reviews: Generally positive for ruggedness and...