🏷️ Basic Information Identification Make: Polaris Model: ATV 400 6x6 Model Years Covered: 1996, 1997, 1998 Product Type: Service & Repair Manual 👋 Introduction Market Position Positioning: Targeted at owners and independent repair shops seeking to maintain and repair their Polaris ATV 400 6x6 models from the late 1990s. Competitive Analysis Value Proposition: Provides essential technical data and procedural guidance to empower DIY maintenance and repair, reducing reliance on dealership service. Key Features Features: Detailed diagrams, step-by-step repair instructions, diagnostic flowcharts, torque specifications, and maintenance schedules. 📋 Manual Details Coverage Areas Coverage Scope: All service and repair for the specified model years. Page Count Estimated Page Count: Refer to actual manual documentation for precise count; typically 300-500 pages for this era of service manual. Manual Type Type: Comprehensive Service & Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine: Engine overhaul, disassembly, assembly, tuning, lubrication, cooling system, fuel system, exhaust system. Transmission: Clutch, gearbox, drive shafts, differential, maintenance, repair, adjustments. Drivetrain: 6x6 drive system, differentials, axle assemblies, U-joints, CV joints, lubrication. Suspension: Front and rear suspension components, shock absorbers, springs, bushings, alignment. Brakes: Hydraulic brake system, calipers, master cylinder, brake lines, pads, rotors, bleeding procedure. Electrical System: Ignition system, starting system, charging system, battery, lighting, wiring diagrams, troubleshooting. Frame And Body: Chassis, body panels, racks, seat, fenders, repair and replacement. Steering: Steering column, tie rods, steering linkage, adjustments. Wheels And Tires: Wheel specifications, tire pressure, replacement. Procedures Included Maintenance: Scheduled maintenance, lubrication points, fluid changes, filter replacements, pre-ride inspections. Troubleshooting: Diagnostic procedures for common problems, symptom-based troubleshooting guides. Repair: Detailed step-by-step instructions for component removal, repair, and reinstallation. Rebuild: Complete engine and transmission rebuild procedures, including specifications. Adjustments: Carburetor tuning, brake adjustments, cable adjustments. Specifications: Torque specifications, clearances, fluid capacities, engine timing. Technical Depth Depth: Comprehensive: Covers everything from basic maintenance and adjustments to complete engine and transmission overhauls and diagnostics. 📊 Manual Specifications File Format Format: PDF Searchability: Searchable text (typically in official PDFs), allowing for quick access to information. Print Quality Quality: High-resolution scans ensuring clear diagrams and text. Binding Type Type: N/A (Digital PDF) Paper Type Type: N/A (Digital PDF) ⚙️ Engine Specifications Primary Engine Engine Type: 2-stroke, Liquid-Cooled, Single Cylinder Displacement: 375cc (approximate, actual can vary slightly by year/sub-model) Bore X Stroke: Refer to manual for exact specifications; typical for this era 2-stroke. Carburetion: Single Carburetor (e.g., Mikuni VM Series or similar) Performance Horsepower: Approx. 25-30 HP (varies by model year and tuning) Torque: Refer to manual for specific torque figures. Fuel System Fuel Type: Unleaded Gasoline (typically 87 octane minimum), mixed with 2-stroke oil Oil Mixture: Refer to manual for specific oil-to-fuel ratio (commonly 40:1 or 50:1) Lubrication Oil Type: 2-stroke engine oil meeting API TC specifications or manufacturer recommendation. Cooling System Cooling Method: Liquid-Cooled Coolant Type: Ethylene glycol based antifreeze/coolant (e.g., 50/50 mix with distilled water) 🔧 Transmission Standard Type: Automatic (PVT - Polaris Variable Transmission) with Hi/Lo range and Reverse. Features Drive System: Shaft drive to all six wheels. Gear Reduction: Yes, for off-road capability. Fluid Specifications Transmission Fluid Type: Polaris Synthetic Gearcase Lubricant or equivalent (refer to manual for specific part number/viscosity). Fluid Capacity Gearcase Capacity: Refer to manual for exact capacity; typically around 300-400 ml. 📐 Dimensions Exterior Length: Refer to manual; generally around 80-90 inches. Width: Refer to manual; typically around 46-50 inches. Height: Refer to manual; typically around 45-50 inches. Weights Dry Weight: Approx. 600-700 lbs (varies) Towing Capacity: Typically rated for 1500 lbs. Cargo Rack Capacity Front: Refer to manual; usually around 50 lbs. Rack Capacity Rear: Refer to manual; usually around 100-200 lbs. 🛡️ Safety Features Ratings Classification: ATV (All-Terrain Vehicle) - Not street legal in most jurisdictions without modification and registration. Active Features Braking System: Hydraulic disc brakes on all wheels. Passive Features Roll Over Protection: None inherently, operator safety relies on skill and adherence to use guidelines. Lighting: Headlights, taillight/brakelight. 💡 Technology Features Infotainment Features: Basic instrumentation: Speedometer, odometer, fuel gauge (if equipped), indicator lights. Driver Assistance Features: Limited to the inherent mechanical systems of the ATV, no electronic driver assistance features. Connectivity Features: None. 🔧 Maintenance Service Intervals Oil Change Engine: Refer to manual; typically every 25-50 operating hours for 2-stroke oil injection, or as per premix ratio. Spark Plug Replacement: Refer to manual; typically every 100-200 operating hours or as needed. Air Filter Cleaning: Refer to manual; recommended every 25-50 operating hours or more frequently in dusty conditions. Transmission Fluid Change: Refer to manual; typically every 100-200 operating hours or annually. Brake Fluid Flush: Refer to manual; typically every 2 years. Fluid Specifications Engine Oil Type: API TC 2-Stroke Oil (premix or injection) Gearcase Oil Type: Polaris Synthetic Gearcase Lubricant or SAE 80W-90 Gear Oil (verify with manual) Coolant Type: 50/50 mixture of Ethylene Glycol antifreeze and...