This manual covers the ATV 400 6x6 models manufactured between 1996 and 1998. These versatile all-terrain vehicles are equipped with a robust 398cc, liquid-cooled, 2-stroke, single-cylinder engine, offering reliable performance for a variety of demanding tasks. The 6x6 drive system, coupled with hydraulic disc brakes and a capable suspension, provides enhanced traction and control across diverse terrains, making it a dependable choice for utility and recreational use. A respected name in off-road vehicle manufacturing, the brand has a heritage of producing durable and innovative ATVs, and the 400 6x6 exemplifies this commitment to quality and functionality. This comprehensive service manual is designed to assist professional ATV repair technicians and advanced DIY enthusiasts in maintaining and repairing their ATV 400 6x6. It provides in-depth coverage of all major systems, including detailed procedures for engine mechanics, fuel and ignition systems, cooling, transmission, drivetrain, suspension, braking, steering, and electrical systems. The manual includes routine maintenance schedules, troubleshooting guides, component-level repair instructions, and critical technical specifications such as torque values. By following the systematic diagnostics and rebuild procedures outlined within, users can ensure accurate repairs, optimize vehicle performance, and extend the lifespan of their ATV. 🏷️ Basic Information Identification Make: Polaris Model: ATV 400 6x6 Model Variant: 400cc 6x6 Codes Vin Code Engine Type: Likely 2-stroke, liquid-cooled, single-cylinder (typical for this era Polaris 400) 👋 Introduction Market Position Target Audience: Professional ATV repair technicians and serious DIY enthusiasts. Value Proposition: Enables accurate diagnostics, efficient repairs, and proper maintenance, saving time and money while ensuring vehicle longevity. Competitive Analysis Differentiation: This manual provides the in-depth, technical detail required for genuine Polaris service, superior to generic guides. Key Features Delivery Method: Instant download for immediate access. Content Focus: Emphasizes repair procedures and technical specifications critical for service. 📋 Manual Details Coverage Areas Applicable Model Years: 1996, 1997, 1998 Coverage Scope: Complete service and repair for Polaris ATV 400 6x6 models from 1996-1998 Page Count Estimated Page Count: Likely 300-500 pages (typical for comprehensive service manuals) Manual Type Manual Type: Service Manual / Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine Mechanics: Engine disassembly, assembly, inspection, overhaul procedures for the 398cc liquid-cooled 2-stroke engine. Fuel System: Carburetor (likely Mikuni VM series) tuning, cleaning, rebuilding, fuel pump, fuel lines, and tank servicing. Ignition System: CDI ignition system, stator, coil, spark plug specifications, troubleshooting. Cooling System: Radiator, fan, thermostat, coolant capacity, flushing, and leak testing. Transmission And Drivetrain: Automatic transmission (CVT - Continuously Variable Transmission) service, belt inspection/replacement, clutch operation, gearbox lubrication, and the 6x6 drive system engagement and maintenance. Suspension System: Front and rear suspension components, shock absorbers, springs, bushings, travel specifications, and adjustment procedures. Braking System: Hydraulic disc brakes (front and rear), brake fluid type and bleeding procedures, caliper overhaul, pad replacement, rotor inspection. Steering System: Handlebar, steering shaft, tie rods, wheel alignment, and front knuckle servicing. Electrical System: Wiring diagrams, lighting, battery specifications, starter motor, charging system (stator/regulator), fuses, and switches. Body And Chassis: Frame inspection, body panel removal/installation, seat, racks, and fender servicing. Procedures Included Routine Maintenance: Oil changes, filter replacements, spark plug checks, air filter cleaning/replacement, chain lubrication (if applicable for drive shafts), general inspection checklists. Troubleshooting: Diagnostic flowcharts for common problems related to starting, running, electrical systems, and drivetrain. Engine Repair: Top-end rebuilds (piston, rings, cylinder), bottom-end overhauls, bearing replacement, seal replacement. Transmission Overhaul: CVT clutch disassembly/reassembly, gearbox internal inspection and repair. Electrical Diagnostics: Testing of ignition components, charging system, starter, and accessory circuits. Suspension Repair: Shock absorber replacement, spring installation, bushing replacement, and linkage servicing. Brake System Maintenance: Brake pad and rotor replacement, brake line bleeding, caliper servicing. Torque Specifications: Detailed torque values for critical fasteners across all systems. Technical Depth Depth Of Information: Comprehensive, suitable for professional technicians and advanced DIY mechanics. Covers detailed diagnostics, component-level repair, and overhaul procedures. Diagnostic Procedures: Includes systematic troubleshooting guides and diagnostic trees for identifying faults. Rebuild Instructions: Detailed step-by-step instructions for rebuilding major components like the engine and transmission. 📊 Manual Specifications File Format File Format: PDF Searchability: Likely text-searchable PDF for efficient information retrieval. Print Quality Print Quality: High-resolution scans suitable for printing individual pages or the entire manual. Binding Type Binding Type For Printed Version: N/A (Digital Download) Paper Type Paper Type For Printed Version: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: 2-stroke, liquid-cooled, single-cylinder Displacement: 398cc (approximately) Bore X Stroke: Typically around 80mm x 79mm (specifics in manual) Compression Ratio: Typically 6.5:1 to 7.0:1 (specifics in manual) Performance Horsepower: Estimated 28-32 HP (specifics in manual) Torque: Estimated 28-32 lb-ft (specifics in manual) Fuel System Carburetor Model: Likely Mikuni VM34 or similar Fuel Type: Unleaded gasoline (87 octane or higher) Fuel Mixture: Requires 2-stroke oil mixed with gasoline (ratio specified in manual, typically 40:1 or 50:1) Lubrication 2 Stroke Oil Type: High-quality...