The ATV 400 4x4, produced for the 1994 and 1995 model years, is a capable all-terrain vehicle designed for recreational trail riding and utility tasks. Known for its robust 4x4 capability and reliable engine, this mid-size ATV offered a comfortable ride and a utility-focused design that made it competitive in its segment. Its key features include dependable 4-wheel drive and a design optimized for various outdoor activities. This comprehensive factory service repair manual provides in-depth information essential for maintaining, diagnosing, and repairing your ATV 400 4x4. It covers all major systems, including engine mechanicals, fuel, ignition, cooling, transmission, 4x4 system, suspension, steering, brakes, and electrical systems. Detailed procedures for routine maintenance, troubleshooting, adjustments, and rebuilds are included, along with essential technical specifications and wiring diagrams, ensuring owners and technicians have the resources to keep the vehicle in optimal condition. 🏷️ Basic Information Identification Make: Polaris Model: ATV 400 4x4 Model Years Covered: 1994, 1995 Vehicle Type: All-Terrain Vehicle (ATV) Chassis Code: Not specified in product info, typical for ATVs 👋 Introduction Market Position Market Segment: Mid-size utility ATV, popular for recreational trail riding and light farm work. Competitive Analysis Competitors 1994 1995: Competed with models from Honda (e.g., FourTrax 300/400), Yamaha (e.g., Kodiak 400), Suzuki (e.g., King Quad 300), and Kawasaki (e.g., Bayou 300/400). Key Features Key Features Vehicle: 4x4 capability, reliable Polaris engine, comfortable ride for its era, utility focused design. Manual Value Proposition Manual Value: Essential resource for owners and technicians to maintain, diagnose, and repair the ATV, ensuring longevity and optimal performance. 📋 Manual Details Coverage Areas Manual Coverage: Comprehensive Factory Service Repair Page Count Page Count: Hundreds of pages Manual Type Manual Type: Factory Service Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine Mechanical: Detailed disassembly, inspection, and reassembly of engine components including cylinder, piston, crankshaft, connecting rod, and valve train. Fuel System: Carburetor service (cleaning, adjustment, jetting), fuel pump operation, fuel tank, and fuel lines. Ignition System: CDI unit, ignition coil, spark plug specifications, timing checks, and troubleshooting. Cooling System: Radiator, coolant, fan operation, and associated plumbing (if applicable). Transmission Drivetrain: Clutch operation, gearbox disassembly and assembly, final drive, and driveshaft maintenance. 4X4 System: Operation of the 4-wheel drive system, front differential, and engagement mechanisms. Suspension System: Front and rear suspension components, shock absorbers, control arms, and lubrication points. Steering System: Handlebar assembly, tie rods, steering linkage, and wheel alignment. Braking System: Front and rear brake calipers, master cylinders, brake lines, pads, rotors, and bleeding procedures. Electrical System: Wiring diagrams, battery, starter, lighting, charging system (stator, rectifier/regulator), and accessory connections. Body Chassis: Frame inspection, body panels, racks, and seat removal/installation. Procedures Included Routine Maintenance: Oil changes, filter replacements, lubrication, spark plug checks, and air filter cleaning/replacement. Troubleshooting Diagnostics: Systematic diagnostic flowcharts and symptom-based troubleshooting guides for common issues. Rebuild Procedures: Detailed instructions for complete engine, transmission, and differential rebuilds. Adjustment Procedures: Carburetor jetting, throttle cable slack, brake lever free play, and chain tension (if applicable). Testing Procedures: Electrical component testing, compression testing, and ignition system performance checks. Wiring Diagrams: Color-coded, system-specific wiring schematics for accurate electrical diagnosis. Technical Depth Depth Of Coverage: Factory-level repair and overhaul, suitable for experienced DIY mechanics and professional technicians. 📊 Manual Specifications File Format File Format: PDF Print Quality Print Quality: High-resolution, suitable for printing all pages. Binding Type Binding Type: Not applicable (PDF Download) Paper Type Paper Type: Not applicable (PDF Download) Searchability Searchable Text: Likely searchable text within the PDF for efficient information retrieval. Organizational Structure Organizational Structure: Typically organized by system with clear chapter breaks and an index. ⚙️ Engine Specifications Primary Engine Engine Type: 4-stroke, liquid-cooled, single-cylinder (typical for this model, confirm with manual) Displacement: Approximately 375-400cc (exact figure to be confirmed with manual) Bore X Stroke: Specific dimensions required from manual. Compression Ratio: Specific ratio required from manual. Performance Horsepower: Estimated 20-25 HP (exact figure to be confirmed with manual) Torque: Specific torque figures required from manual. Fuel System Carburetor Type: Likely Mikuni or Keihin (specific model number required from manual). Fuel Type: Unleaded gasoline (Octane rating to be confirmed). Ignition System Ignition Timing: Specific ignition timing specifications required from manual. 🔧 Transmission Standard Transmission Type: Automatic with Variable Transmission (CVT) or Polaris Variable Transmission (PVT). Gear Selection: Forward, Neutral, Reverse. Features Drive System: Shaft drive with automatic engagement of front differential for 4x4 operation. Maintenance Transmission Fluid Type: Specific Polaris transmission fluid or equivalent SAE 10W-30/SAE 30 motorcycle oil (verify with manual). Transmission Fluid Capacity: Specific capacity to be confirmed with manual. 📐 Dimensions Exterior Wheelbase: Approximate 48-50 inches (exact measurement required from manual). Ground Clearance: Approximate 8-10 inches (exact measurement required from manual). Weights Dry Weight: Approximate 500-550 lbs (exact weight required from manual). Cargo Capacity Rack Front: Specific capacity to be confirmed with manual. Cargo...