The ATV 400 2x4 is a robust 2x4 utility ATV designed for reliable performance in varied terrain, making it a popular choice for outdoor enthusiasts, farmers, hunters, and recreational riders. Produced for the 1994 and 1995 model years, this vehicle offers a four-stroke, single-cylinder engine with an approximate displacement of 340cc to 375cc and an estimated 20-25 horsepower, coupled with an automatic CVT transmission and shaft drive to the rear wheels. Its engineering emphasizes durability and functionality, positioning it as a capable machine for work and recreation, comparable to other utility ATVs of its era. This comprehensive workshop repair service manual provides essential information for maintaining and repairing the ATV 400 2x4. It covers all variants and engines for the 1994 and 1995 model years, detailing procedures for engine overhaul, transmission service, drivetrain, suspension, steering, brakes, electrical systems, fuel systems, cooling systems, body, and frame. The manual includes routine maintenance, troubleshooting guides, repair instructions, disassembly and assembly procedures, diagnostics, and adjustments, offering detailed explanations, diagrams, and specifications to assist owners and technicians in keeping the vehicle in optimal condition. 🏷️ Basic Information Identification Make: Polaris Model: ATV 400 2x4 Model Variant: 400 2x4 Product Type: Workshop Repair Service Manual Codes Product Identifier: Polaris ATV 400 2x4 1994 1995 Workshop Repair Service Manual PDF Download 👋 Introduction Market Position Segment: Utility ATV Target Audience: Outdoor enthusiasts, farmers, hunters, recreational riders Competitive Analysis Competitors: Honda FourTrax, Yamaha Timberwolf, Suzuki QuadRunner, Kawasaki Bayou Key Features Vehicle Focus: Robust 2x4 utility ATV designed for reliable performance in varied terrain Manual Value: Essential resource for maintaining and repairing a classic Polaris ATV model 📋 Manual Details Coverage Areas Covered Model Years: 1994, 1995 Covered Models: All 400 2x4 variants Covered Engines: All engines for 400 2x4 models Covered Trims: All trim levels for 400 2x4 models Page Count Estimated Page Count: Likely 300-500 pages (typical for a comprehensive workshop manual of this era) Manual Type Type: Workshop Repair Service Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine: Complete engine overhaul, diagnosis, component testing, specifications, torque values, timing procedures, carburetion tuning Transmission: Clutch service, gear inspection, lubrication, linkage adjustment, repair procedures Drivetrain: Drive shaft maintenance, U-joints, differential service, axle inspection and repair Suspension: Front and rear suspension component inspection, repair, shock absorber service, pivot point lubrication Steering: Handlebar assembly, steering linkage, tie rods, steering column maintenance, alignment procedures Brakes: Hydraulic system bleeding, caliper service, brake pad replacement, drum brake adjustment (if applicable), master cylinder inspection Electrical System: Wiring diagrams, lighting system diagnosis, starter system, ignition system troubleshooting, battery maintenance, charging system (stator, regulator/rectifier) Fuel System: Fuel tank maintenance, fuel lines, fuel pump operation, carburetor disassembly, cleaning, and adjustment Cooling System: Radiator inspection, coolant specifications, fan operation (if applicable), thermostat service Body And Frame: Fender repair, seat removal, rack service, chassis inspection, frame straightening (if applicable) Exhaust System: Muffler inspection, pipe mounting, gasket replacement Procedures Included Maintenance: Routine servicing, lubrication points, filter replacements, spark plug replacement, fluid checks and changes Troubleshooting: Diagnostic flowcharts for common problems, symptom-based troubleshooting guides Repair: Step-by-step instructions for component replacement and repair of all major systems Disassembly Assembly: Detailed instructions for the removal and reinstallation of major assemblies and components Diagnostics: Electrical testing procedures, mechanical checks, component testing Adjustments: Carburetor synchronization, brake adjustments, clutch engagement settings Technical Depth Level: Comprehensive workshop level, suitable for professional mechanics and advanced DIY users Detail Level: Detailed explanations, diagrams, exploded views, torque specifications, clearances 📊 Manual Specifications File Format Format: PDF Searchability: Likely text-searchable PDF Print Quality Quality: Digital reproduction of original manual; quality may vary but aims for clarity of text and diagrams Binding Type Binding: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Type: Four-stroke, single-cylinder Displacement: Approximately 340cc to 375cc (Specific designation '400' often indicates a rating or marketing term, actual displacement may vary slightly) Bore X Stroke: Refer to manual for precise specifications. Cooling System: Air-cooled Performance Horsepower: Estimated 20-25 HP (Actual figures depend on specific tuning and model year variations) Torque: Refer to manual for precise specifications. Fuel System Carburetor: Single carburetor (likely Mikuni or Keihin, specific model in manual) Fuel Type: Unleaded gasoline (Octane rating to be specified in manual) Engine Oil Oil Type: SAE 10W-40 or 20W-50 motorcycle-specific oil (Verify with manual, often API SG or higher) Oil Capacity: Refer to manual for specific quantity, typically around 2-3 quarts 🔧 Transmission Standard Type: Automatic CVT (Continuously Variable Transmission) with 2WD Drive System: Shaft drive to rear wheels Optional Optional Transmissions: N/A for this specific model designation (2x4 implies rear-wheel drive, CVT is standard) Features Gear Reduction: Yes, typically with High/Low range and Reverse Transmission Fluid Fluid Type: Refer to manual; often a specific gear oil or automatic transmission fluid (ATF) 📐 Dimensions Exterior Length: Refer to...