🏷️ Basic Information Identification Make: Polaris Model: ATV Xpress 400 Year: 1996 Type: All-Terrain Vehicle (ATV) 👋 Introduction Market Position Target Audience: Professional technicians and DIY mechanics. Key Features Feature Highlight 1: Instant download availability. Feature Highlight 2: Detailed illustrations, drawings, and photos. Feature Highlight 3: Integrated troubleshooting and wiring diagrams. 📋 Manual Details Coverage Areas Main Coverage: Full Service Repair, Maintenance, Rebuild, Refurbish, Restoration Page Count Estimated Page Count: Unknown (PDF format, printable) Manual Type Type: Full Service Repair Manual Language Language: English Format File Format: PDF Download 📖 Manual Coverage Systems Covered Engine Service: Complete engine overhaul, diagnostics, repair, carburetor tuning, cooling system. Transmission Service: Clutch adjustment, belt inspection/replacement, gearcase service, torque converter. Electrical System: Wiring diagrams, troubleshooting, ignition system, charging system, lighting, starter. Chassis And Suspension: Front and rear suspension, steering, wheel bearings, shocks, A-arms, ball joints. Braking System: Brake pad replacement, caliper service, master cylinder, brake line bleeding, hydraulic system. Fuel System: Fuel tank, fuel pump, fuel lines, carburetor maintenance and cleaning. Cooling System: Radiator, fan, coolant, hoses, thermostat. Body And Frame: Body panel removal/installation, frame inspection, fenders, seat. Procedures Included Diagnostic Procedures: Detailed troubleshooting guides for common and uncommon issues. Maintenance Procedures: Scheduled maintenance, fluid changes, filter replacements, lubrication. Rebuild Procedures: Step-by-step instructions for component rebuilds (e.g., engine, carburetor). Installation Procedures: Instructions for installing common accessories or replacement parts. Technical Depth Depth Level: Comprehensive (suitable for professional technicians and advanced DIY users). Detail Level: Detailed sub-steps, notes, cautions, and warnings. 📊 Manual Specifications File Format Format: PDF Print Quality Printability: Full Printable Binding Type Binding: Digital Download (N/A for physical binding) Paper Type Paper Type: N/A (Digital) Software Requirements Reader Requirement: Adobe PDF Reader Extraction Requirement: WinRAR (for potential compressed files) Compatibility Operating Systems: All Versions of Windows & Mac ⚙️ Engine Specifications Primary Engine Engine Type: Two-stroke, liquid-cooled (typical for this model/era). Engine Displacement: 340cc (approximate, specific engine code needed for exact confirmation). Engine Configuration: Single-cylinder Performance Horsepower: Approx. 28 HP (estimate based on typical 340cc two-stroke ATV engines of the era). Torque: Not specified, but typically in the 25-30 lb-ft range. Fuel System Carburetor: Mikuni VM34 (common for this model, but requires confirmation). Fuel Type: Unleaded gasoline with 2-stroke oil mixture (e.g., 40:1). Ignition System Ignition Type: CDI (Capacitor Discharge Ignition) Cooling System Cooling Method: Liquid-cooled 🔧 Transmission Standard Transmission Type: CVT (Continuously Variable Transmission) with automatic clutch. Drive System: 2WD (Rear Wheel Drive) Features Gear Reduction: High and Low range (typical for utility ATVs). Fluid Specifications Gearcase Oil Type: Polaris recommended ATV gearcase lubricant (e.g., SAE 80W-90 GL-4, specific part number needed from manual). 📐 Dimensions Exterior Wheelbase: Approx. 49 inches (124.5 cm) - typical for this class. Weights Dry Weight: Approx. 420 lbs (190 kg) - estimate. Ground Clearance: Approx. 7.5 inches (19 cm) - estimate. 🛡️ Safety Features Features Braking System: Hydraulic disc brakes front and rear. Lighting: Headlights and taillight. Parking Brake: Integrated parking brake mechanism. 💡 Technology Features Infotainment Infotainment System: N/A (Basic utility ATV, no advanced infotainment). Driver Assistance Assistance Features: N/A (No electronic driver assistance features). 🔧 Maintenance Service Intervals Oil Change Engine: Two-stroke, pre-mix fuel, no separate engine oil change required (oil is mixed with fuel). Gearcase Oil Interval: Every 6 months or 100 operating hours (typical, refer to manual for exact interval). Air Filter Cleaning: Regular inspection and cleaning, depending on operating conditions (e.g., every 20-40 operating hours). Spark Plug Replacement: Every 1-2 years or as needed, depending on usage and plug condition. Fluid Specifications Coolant Type: Ethylene Glycol based antifreeze/coolant, 50/50 mix with distilled water. Brake Fluid Type: DOT 3 or DOT 4 hydraulic brake fluid. Known Issues Common Wear Item: Drive belt for CVT, can wear over time and require replacement. Carburetor Issues: Carburetors can be prone to clogging if fuel is not fresh or if the vehicle sits for extended periods. Engine Performance: Loss of power or rough running can indicate issues with the ignition, fuel delivery, or exhaust. 📚 Vehicle History Brand Heritage Brand Origin: Polaris Industries, Inc. is an American manufacturer of powersports vehicles, founded in 1954. Model Evolution Xpess Series: The Xpress series was Polaris's entry-level to mid-range ATV offering, known for its utility and value. Production Production Era: Mid-to-late 1990s, with the Xpress 400 being a significant model in this lineup. 🏆 Awards & Recognition Recognitions Industry Awards: Not specifically documented for this model year, but Polaris ATVs generally received positive reception for their performance and utility in their class.