The Polaris ATV 400 4x4, produced between 1985 and 1995, represents a robust and capable all-terrain vehicle designed for demanding off-road use. This model is characterized by its reliable 2-stroke, single-cylinder engine, typically around 300-400cc, and an air-cooled system, delivering approximately 20-25 horsepower. Its engineering emphasizes durability and performance, featuring a shaft-driven 4WD system with selectable engagement, an automatic CVT transmission with Hi/Lo range and reverse, and hydraulic disc brakes for effective stopping power. The ATV 400 4x4 was a significant step in Polaris's ATV development, offering enhanced traction and utility for its intended users. This comprehensive workshop repair manual provides essential guidance for the diagnosis and repair of the Polaris ATV 400 4x4. It covers a wide array of systems, including detailed procedures for engine mechanics, transmission and drivetrain, chassis and suspension, brakes, and the electrical system. The manual includes instructions for routine maintenance, disassembly and assembly of major components, and troubleshooting common issues such as carburetor fouling and CVT belt wear. This resource is invaluable for ATV owners, home mechanics, and independent repair shops seeking to maintain and repair their vehicles, offering in-depth technical information that far exceeds the scope of an owner's manual. 🏷️ Basic Information Identification Make: Polaris Model: ATV 400 4x4 Model Variant: 4x4 Generation Production Years: 1985-1995 👋 Introduction Market Position Target User: ATV owners, home mechanics, independent repair shops Value Proposition: Essential tool for maintaining and repairing Polaris 400 4x4 ATVs from 1985-1995, saving on dealership service costs. Competitive Analysis Vs Owner Manual: Significantly more in-depth than an owner's manual, focusing on repair procedures rather than basic operation. Key Features Diagnostic Focus: Emphasis on identifying and resolving mechanical and electrical issues. Comprehensiveness: Covers all major systems for the specified model range. 📋 Manual Details Coverage Areas Manual Type: Workshop Repair Manual Primary Purpose: Diagnosis and repair of vehicle-related problems, recommended repair/maintenance procedures Page Count Estimated Page Count: Varies by specific edition, typically 300-600 pages for comprehensive workshop manuals of this era Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine Mechanics: Engine overhaul, cylinder head, pistons, crankshaft, lubrication, cooling system, fuel system, ignition system Transmission Drivetrain: Gearbox, clutch, drive shafts, differentials, 4-wheel drive system operation and repair Chassis Suspension: Front and rear suspension, steering system, shock absorbers, control arms, bushings Brakes: Brake system inspection, hydraulic components, brake pads, rotors, calipers, bleeding procedures Electrical System: Wiring diagrams, lighting, battery, starter, alternator, ignition switch, sensors, fuses, relays Bodywork Frame: Body panel removal/installation, frame inspection, fenders, seat, handlebars Procedures Included Routine Maintenance: Oil changes, filter replacements, spark plug checks, lubrication points, air filter cleaning/replacement Troubleshooting: Diagnostic charts, common problem identification, step-by-step fault finding Repair Procedures: Detailed, step-by-step instructions for component removal, repair, and reinstallation Disassembly Assembly: Complete breakdown and reassembly instructions for major components and systems Technical Depth Depth Of Coverage: Comprehensive, covering routine maintenance to complete engine and drivetrain rebuilds Diagnostic Capabilities: Includes diagnostic flowcharts and specifications for identifying and resolving mechanical and electrical issues 📊 Manual Specifications File Format File Type: Portable Document Format (PDF) Searchability: Typically text-searchable, allowing for quick finding of specific topics or keywords Print Quality Print Readability: High-resolution, suitable for printing individual pages or the entire manual Binding Type Binding: N/A (Digital Download) Paper Type Paper Quality: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: Typically a 2-stroke, single-cylinder engine Displacement: Around 300-400cc, specific displacement varied slightly across the years and sub-models (e.g., often referred to as the 'XPL 400' or similar) Cooling System: Air-cooled Performance Horsepower Range: Approx. 20-25 HP (figures varied by specific year and tuning) Torque Range: Approx. 25-30 lb-ft (figures varied) Fuel System Carburetion: Single carburetor (e.g., Mikuni VM series common) Fuel Type: Unleaded gasoline Ignition System Ignition Type: CDI (Capacitor Discharge Ignition) 🔧 Transmission Standard Transmission Type: Automatic (CVT - Continuously Variable Transmission) with Hi/Lo range and Reverse Optional Manual Transmission: Not typically offered for this model Features Drive System: Shaft drive to all four wheels, with selectable 2WD/4WD engagement Differential Lock: May feature a locking front differential on certain sub-models or years 📐 Dimensions Exterior Length: Approx. 75-80 inches (Varies by specific model/year) Width: Approx. 40-45 inches (Varies by specific model/year) Height: Approx. 45-50 inches (Varies by specific model/year) Weights Dry Weight: Approx. 450-550 lbs (Varies by specific model/year) Towing Capacity: Typically rated for light towing, consult specific model documentation Cargo Rack Capacity: Front and rear racks capable of carrying moderate loads (e.g., 25-50 lbs front, 50-75 lbs rear) 🛡️ Safety Features Ratings Crash Safety Rating: N/A (ATVs are not typically crash-tested by regulatory bodies like NHTSA) Active Features Braking System: Hydraulic disc brakes (front and rear) Suspension Stability: Independent front suspension (IFS) and swingarm rear suspension (on later models) contribute to stability. Passive Features Roll Over Protection: Not equipped with standard roll-over protection structures (ROPS); operator awareness...