Basic Information Identification Make: Polaris Model: ATV 400 6x6 Year: 1996, 1997 Codes Model Code 1996: A96CH40AA Model Code 1997: A97CH40AA Introduction Market Position Target Audience: Owners, technicians, and enthusiasts seeking to maintain, repair, or restore the Polaris ATV 400 6x6 (1996-1997). Competitive Analysis Value Proposition: Provides comprehensive factory-level information essential for accurate and efficient servicing, crucial for maintaining the performance and longevity of these vintage ATVs. Key Features Completeness: The 'COMPLETE official full factory service repair manual' designation ensures all relevant repair and maintenance data is included. Digital Format: PDF download offers instant access and portability, allowing for use on various devices or printing as needed. Manual Details Coverage Areas Manual Type: Factory Service Repair Manual Language: English Format: PDF Download Page Count Estimated Page Count: Hundreds of pages (exact count not specified but implied to be comprehensive) Manual Coverage Systems Covered Engine: Complete engine overhaul, disassembly, inspection, assembly, tuning, and troubleshooting Transmission: All aspects of the transmission, including lubrication, adjustments, and internal component repair Drivetrain: Front and rear driveshafts, differentials, axle components, and 6x6 engagement system Suspension: Front and rear suspension components, shock absorbers, bushings, and alignment Brakes: Hydraulic brake system, brake calipers, master cylinder, lines, fluid specifications, and bleeding procedures Electrical: Ignition system, charging system (stator, regulator/rectifier), battery, starter motor, lighting, wiring diagrams, and component testing Fuel System: Carburetor service, fuel pump, fuel lines, fuel filter, and tank maintenance Cooling System: Radiator, coolant, thermostat, hoses, and fan operation Frame And Body: Frame integrity, body panel removal and installation, plastics, and seat assembly Steering: Steering column, tie rods, steering rack, and wheel alignment Wheels And Tires: Tire pressure, wheel torque specifications, and tire replacement Procedures Included Routine Maintenance: Oil changes, filter replacements, spark plug checks, chain lubrication, and general inspection Troubleshooting: Diagnostic charts and procedures for common problems and symptoms Rebuild Procedures: Detailed step-by-step instructions for overhauling major components like the engine and transmission Adjustment Procedures: Carburetor, clutch, brake, and idle speed adjustments Diagnostic Procedures: Step-by-step guides for identifying and resolving mechanical and electrical issues Technical Depth Depth Of Information: Comprehensive, covering from basic maintenance to complete engine and transmission rebuilds Diagnostic Capabilities: Advanced diagnostics with detailed fault finding charts and wiring diagrams Specification Detail: Includes precise torque values, clearances, fluid capacities, and electrical resistance readings Manual Specifications File Format File Type: PDF Searchable Text: Typically PDFs from reputable sources are text-searchable, enhancing usability. Print Quality Printability: Designed for printing, allowing users to print the entire manual or specific sections. Binding Type Binding For Print: If printed, standard manual binding (stapled, spiral, or perfect bound) would apply. Paper Type Paper Quality For Print: For optimal use in a workshop environment, durable paper stock is recommended. Engine Specifications Primary Engine Engine Type: 4-stroke, liquid-cooled, SOHC, 2-valve Displacement: 375cc Bore X Stroke: 83 mm x 70 mm (approximate, to be confirmed by manual) Compression Ratio: 9.0:1 (typical for this era engine, confirm with manual) Performance Horsepower: Approx. 24-26 HP (estimated, specific figure in manual) Torque: Not readily available, detailed in manual Fuel System Carburetor Type: Mikuni VM34 (or similar single carburetor, confirm with manual) Fuel Type: Unleaded gasoline Transmission Standard Transmission Type: Automatic (CVT - Continuously Variable Transmission) Optional Gear Reduction: Two-speed transmission with Hi/Lo range, plus reverse Features Drive System: Selectable 6x6 with 2WD/4WD/6WD modes Clutch Type: Automatic centrifugal clutch Final Drive: Shaft drive, enclosed constant velocity (CV) joints Dimensions Exterior Length: Approx. 84 inches (213 cm) (typical for this model, confirm with manual) Width: Approx. 45 inches (114 cm) (typical for this model, confirm with manual) Height: Approx. 42 inches (107 cm) (typical for this model, confirm with manual) Cargo Front Rack Capacity: Not specified, but typical for utility ATVs Rear Rack Capacity: Approx. 100 lbs (45 kg) (typical for this model, confirm with manual) Weights Dry Weight: Approx. 575 lbs (261 kg) (typical for this model, confirm with manual) Towing Capacity: Not specified for this model, typically limited by chassis and drivetrain capabilities. Safety Features Ratings Rollover Protection: None inherent; ATVs require careful operation. Active Features Braking System: Hydraulic disc brakes front and rear, sealed drum brake rear (typical for this era, confirm with manual). Passive Features Lighting: Headlights, taillight/brake light. Throttle Limiter: Not typically featured, relies on rider skill and responsible use. Technology Features Infotainment Infotainment System: Basic; typically no advanced infotainment systems. Focus is on functional utility. Driver Assistance Driver Assistance Features: None; ATV operation relies on rider skill and awareness. Connectivity Connectivity Options: None. Maintenance Service Intervals Engine Oil Change: Recommended every 30-50 operating hours or annually (specific interval detailed in manual). Air Filter Cleaning: Inspect every 20-30 hours, clean/replace as needed, especially in dusty conditions (manual provides specifics). Spark Plug Replacement: Typically recommended every 100-200 operating hours or annually (confirm with manual). Fluid Specifications Engine Oil Type: API SG, SH, SJ SAE 10W-40...