🏷️ Basic Information Identification Make: Polaris Model: ATV 400 2x4 Model Years Covered: 1985, 1986, 1987, 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995 Vehicle Type: All-Terrain Vehicle (ATV) Drive Type: 2x4 (Two-Wheel Drive) 👋 Introduction Market Position Original Target Market: Utility and recreational ATV market, known for its ruggedness and practicality in its era. Competitive Analysis Contemporary Competitors: Competed with models from Yamaha (e.g., Moto-4), Suzuki (e.g., QuadSport), and Honda (e.g., FourTrax) in the mid-size utility ATV segment. Key Features Of Vehicle Robust Chassis: Designed for durability and off-road use, often featuring a robust steel frame. Dependable Engine: Known for its reliable 400cc class engine, offering a good balance of power and usability. Simplicity Of Design: Engineered for ease of maintenance and repair, a hallmark of Polaris ATVs from this period. Manual Value Proposition Problem Solving: Aids in determining the cause of vehicle-related problems and provides recommended repair/maintenance procedures. Diy Support: Empowers owners and technicians with the knowledge to perform effective maintenance and repairs, saving time and money. 📋 Manual Details Coverage Areas General Coverage: Complete workshop repair and maintenance Page Count Estimated Page Count: Estimated 300-500 pages (typical for comprehensive workshop manuals of this era) Manual Type Type: Workshop Manual / Service Manual / Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine Mechanical: Full engine teardown, inspection, assembly, tuning, valve adjustments, piston and cylinder work, crankshaft and connecting rod service. Fuel System: Carburetor disassembly, cleaning, adjustment, jetting information, fuel pump, fuel tank, fuel lines. Ignition System: CDI ignition system components, troubleshooting, timing, spark plug specifications. Cooling System: Radiator, fan, thermostat, coolant specifications, flushing procedures (if applicable to specific 400 2x4 variants). Transmission: Gearbox disassembly, inspection, reassembly, gear selection mechanisms, lubrication requirements. Drivetrain: Drive shaft, differential (if applicable), rear axle, wheel bearings, U-joints, maintenance and lubrication. Brakes: Hydraulic brake system, brake calipers, master cylinder, brake lines, pads/shoes replacement, bleeding procedures, rotor specifications. Suspension: Front and rear suspension components, shock absorbers, springs, bushings, alignment procedures, adjustments. Steering: Steering column, tie rods, steering linkage, wheel alignment, troubleshooting steering play. Electrical System: Wiring diagrams, battery, charging system (stator, regulator/rectifier), starter motor, lighting, switches, fuses. Bodywork And Frame: Body panel removal/installation, seat, fenders, handlebars, frame inspection, mounts. Troubleshooting: Diagnostic flowcharts, common problems and their solutions, symptom-based troubleshooting. Procedures Included Routine Maintenance: Oil changes, filter replacements, air filter cleaning/replacement, spark plug checks, lubrication points, chain/belt adjustment. Major Repairs: Engine rebuilds, transmission overhauls, suspension component replacement, brake system overhauls. Diagnostics: Systematic diagnosis of performance issues, electrical faults, and mechanical failures. Component Replacement: Step-by-step instructions for replacing virtually all wear items and serviceable components. Specifications And Tolerances: Detailed torque specifications, clearances, and measurements for all critical engine and chassis components. Technical Depth Depth: Comprehensive, from basic user maintenance to full engine and transmission overhauls. Suitable for experienced DIY mechanics and professional technicians. 📊 Manual Specifications File Format Digital Format: PDF Print Quality Readability: High-resolution scans ensuring clear text and diagrams. Searchable text for easy navigation. Binding Type Binding: N/A (Digital Download) Paper Type Paper Quality: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: Single-cylinder, 4-stroke, OHV (Overhead Valve) Displacement: Approximately 400cc (specific bore/stroke may vary slightly by year within the range, but consistently around 400cc). Bore X Stroke: Typical for this era might be around 82mm x 75mm (actual figures should be verified in manual). Cooling System: Air-cooled (most common for this model/era, though liquid-cooled variants may exist and should be checked in the manual). Performance Horsepower: Estimated 15-20 HP (specific output varies by year and tuning). Torque: Moderate torque output suitable for utility tasks and trail riding. Fuel System Carburetor Type: Single carburetor (likely Mikuni or Keihin, e.g., VM series). Fuel Type: Unleaded gasoline Ignition System Ignition Type: CDI (Capacitor Discharge Ignition) 🔧 Transmission Standard Transmission Type: Automatic Transmission with High/Low range and Reverse Drive Mechanism: Shaft drive to rear differential Optional Clutch Type: Torque converter automatic transmission Features Gear Selection: Selector lever for Park, Reverse, Neutral, Drive (High/Low) 📐 Dimensions Exterior Length: Approx. 75-80 inches (190-203 cm) (varies slightly by model year) Width: Approx. 40-45 inches (102-114 cm) Height: Approx. 40-45 inches (102-114 cm) Weights Dry Weight: Approx. 450-500 lbs (204-227 kg) Towing Capacity: Typically around 1500 lbs (680 kg) for hitch-equipped models. Ground Clearance: Approx. 6-8 inches (15-20 cm) (varies by tire size and suspension). 🛡️ Safety Features Ratings Crash Test Ratings: N/A (ATVs are not typically subjected to standardized crash tests like passenger vehicles). Active Features Braking System: Hydraulic disc brakes front and rear, providing robust stopping power. Throttle Governor: May incorporate a throttle limiter or governor for controlled speed, especially for younger riders or specific models. Passive Features Lighting: Headlights and taillights for visibility. Handlebars: Ergonomic handlebars with hand grips and control levers. Footwells: Aggressively treaded footwells for secure footing. 💡 Technology...