The 400 6x6 is a robust All-Terrain Vehicle (ATV) produced between 1996 and 1998. Engineered for demanding utility and recreational off-road use, this model is distinguished by its signature six-wheel-drive system, providing exceptional traction and superior load-carrying capabilities in challenging terrains such as mud and sand. Its design prioritizes durability and versatility, making it a reliable choice for tasks like hauling, towing, and navigating difficult environments, reflecting an established heritage in the powersports industry. This comprehensive Service & Shop Manual provides essential information for the maintenance and repair of your 400 6x6. Covering a wide array of systems including the engine, fuel, cooling, drivetrain, transmission, braking, suspension, steering, and electrical systems, it offers detailed procedures for everything from routine service and lubrication to complete component overhauls. The manual includes troubleshooting guides, disassembly and assembly instructions, repair techniques, and information on special tools, empowering owners and technicians to ensure the optimal performance and longevity of their vehicle. 🏷️ Basic Information Identification Make: Polaris Model: 400 6x6 Model Variant: All-Terrain Vehicle (ATV) Generation Production Years: 1996-1998 👋 Introduction Market Position Market Segment: Utility ATV, designed for work, hunting, and recreational off-road use, particularly in challenging terrain. Competitive Analysis Competitors: Competed with other utility-focused ATVs from brands like Yamaha (Grizzly), Honda (FourTrax), and Suzuki (King Quad) during its production era. Key Features Six Wheel Drive: The signature 6x6 drivetrain provides exceptional traction and load-carrying capability in mud, sand, and rough terrain. Utility Focus: Designed for hauling, towing, and navigating difficult environments, making it a popular choice for outdoor enthusiasts and workers. Durability: Known for its robust construction and ability to withstand demanding operational conditions. 📋 Manual Details Coverage Areas Manual Type: Service & Shop Manual Page Count Page Count: 663 Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Engine Maintenance: Detailed overhaul, inspection, and repair procedures for the 400cc engine. Fuel System: Carburetor adjustment, fuel pump, fuel tank, and fuel lines. Cooling System: Radiator, fan, coolant circulation, and thermostat. Ignition System: Spark plug, ignition coil, CDI unit, and timing. Exhaust System: Muffler and exhaust pipe maintenance. Drivetrain Front Axle: Front differential, drive shafts, and CV joints. Drivetrain Rear Axle: Rear differential, drive shafts, and suspension linkages. Transmission System: Automatic transmission (PVT - Polaris Variable Transmission) service, belt inspection, and clutch adjustments. Braking System: Hydraulic brake system, brake caliper overhaul, pad replacement, and bleeding procedures. Suspension System: Front and rear suspension components, shock absorbers, and steering knuckles. Steering System: Handlebar, tie rods, steering shaft, and universal joints. Electrical System: Wiring diagrams, battery, charging system (stator, rectifier/regulator), starter motor, lighting, and instrumentation. Body And Frame: Frame inspection, body panels, fenders, racks, and seat assembly. Wheels And Tires: Wheel bearing service, tire pressure specifications, and rim compatibility. Procedures Included Preventive Maintenance: Regular service checks, lubrication points, and filter replacement intervals. Troubleshooting Guides: Diagnostic charts and symptom-based troubleshooting for common issues. Disassembly And Assembly: Step-by-step instructions for component removal and reinstallation. Repair Techniques: Specific repair methods for various components, including wear limits and specifications. Special Tools: Identification and usage of specialized tools required for certain procedures. Technical Depth Technical Depth: Comprehensive coverage from basic maintenance to complete engine and transmission overhauls, suitable for professional mechanics and experienced DIY enthusiasts. 📊 Manual Specifications File Format File Format: PDF File Size File Size: 50MB Print Quality Print Quality: High-resolution, designed for clear printing of diagrams and text. Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: 2-stroke, liquid-cooled, single-cylinder Displacement: 340 cc (approx.) Bore X Stroke: Refer to manual for specific dimensions Compression Ratio: Refer to manual for specific ratios Performance Horsepower: Approximately 25-30 HP (estimated, actual figures vary) Torque: Refer to manual for torque specifications Fuel System Fuel Delivery: Carburetor (e.g., Mikuni VM34 or similar) Fuel Type: Unleaded gasoline Oil Mixture: Premix (50:1 ratio for 2-stroke oil recommended in manual) 🔧 Transmission Standard Transmission Type: Polaris Variable Transmission (PVT) - Automatic CVT Drive Modes: 2WD / 6WD (selectable) Features Clutch Type: Centrifugal clutch and drive/driven clutches Transmission Fluid: Refer to manual for specific fluid type and capacity (typically specialized CVT fluid or SAE 10W-30 engine oil for some gearcases) 📐 Dimensions Exterior Length: Refer to manual for exact dimensions Width: Refer to manual for exact dimensions Height: Refer to manual for exact dimensions Weights Dry Weight: Approximately 570-600 lbs (estimated) Ground Clearance: Refer to manual for specific clearance Cargo Rack Capacity Front: Refer to manual for specifications Rack Capacity Rear: Refer to manual for specifications Towing Capacity: Refer to manual for towing capacity and hitch specifications 🛡️ Safety Features Ratings Safety Ratings: ATVs are not subject to traditional automotive crash safety ratings. User manual details safe operating practices. Active Features Braking System: Hydraulic disc brakes front and rear. Throttle Limiter: May include throttle...