The Polaris ATV 400 2x4, produced from 1985 to 1995, is a robust and practical all-terrain vehicle designed for utility and recreational use. Known for its dependable 400cc single-cylinder engine and a simple, durable design, this two-wheel-drive ATV offered a reliable solution for various tasks and terrains. Its engineering emphasized ease of maintenance and a strong chassis, making it a workhorse in its class, competing with other prominent manufacturers of the era. The ATV 400 2x4 was built to withstand demanding conditions, solidifying its reputation as a pioneer in the ATV market. This comprehensive workshop manual provides complete repair and maintenance guidance for the Polaris ATV 400 2x4 across its production years. It covers all essential systems, including detailed procedures for engine mechanicals, fuel and ignition systems, transmission, drivetrain, brakes, suspension, steering, and the electrical system. The manual also offers in-depth troubleshooting advice, routine maintenance schedules, and component replacement instructions. With its extensive coverage of routine tasks to major overhauls, this manual serves as an indispensable resource for owners, mechanics, and technicians seeking to maintain and repair their vehicle efficiently and effectively. 🏷️ 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...