Vehicle Segment:
Utility ATV (All-Terrain Vehicle)
Target Audience:
Hobbyists, farmers, hunters, outdoor enthusiasts requiring rugged, all-terrain capability.
Key Competitors:
Yamaha Big Bear, Kawasaki Bayou, Suzuki King Quad, John Deere Gator (depending on specific use case).
Unique Selling Proposition:
The 6x6 drivetrain provides superior traction and load-carrying capacity, differentiating it from 4x4 counterparts.
Drivetrain:
6x6 All-Wheel Drive system for maximum traction.
Engine Type:
Robust, liquid-cooled engine suitable for demanding tasks.
Utility Focus:
Designed for hauling, towing, and navigating challenging terrain.
Manual Value:
Essential for owners to maintain optimal performance and longevity of their vintage ATV.
Engine Maintenance:
Complete
Transmission Service:
Complete
Electrical System Diagnostics:
Comprehensive
Chassis And Suspension:
Full Repair
Bodywork And Plastics:
Repair and Replacement Procedures
Troubleshooting Guides:
Extensive
Technical Specifications Section:
Included
Torque Specifications:
Detailed
Wiring Diagrams:
Included
Special Tools Required:
Listed
Recommended Maintenance Schedule:
Provided
Estimated Pages:
Likely 300-500+ pages (typical for full service manuals)
Type:
Full Service Repair Manual
Content Focus:
Repair, Maintenance, Rebuilding, Troubleshooting
Primary Language:
English
Download Format:
PDF Download
Searchability:
Typically Searchable Text within PDF
Printable:
Yes (standard PDF functionality)
Engine Mechanical:
Top end, bottom end, cylinder head, pistons, crankshaft, timing components, lubrication system, cooling system, fuel injection system (if applicable), carburetor (if applicable), starting system, ignition system.
Transmission Drivetrain:
All-wheel drive (6x6) system, differential locks, drive shafts, universal joints, final drives, gearbox, clutch, belt drive system (CVT if applicable), brake systems (front and rear).
Electrical System:
Battery, charging system (alternator/stator), ignition system, lighting (headlights, taillights, brake lights), instrumentation, starter motor, wiring harnesses, fuses, relays, sensors.
Suspension Steering:
Front and rear suspension components, shocks, springs, control arms, bushings, steering mechanism, tie rods, steering column.
Fuel System:
Fuel tank, fuel lines, fuel pump, carburetor (or fuel injection components), fuel filter.
Body Frame:
Frame construction, body panels, fenders, racks, seat, handlebars, controls, plastics.
Maintenance:
Scheduled maintenance, oil changes, filter replacements, lubrication, tune-ups, spark plug replacement, air filter cleaning/replacement, coolant checks.
Repair:
Engine rebuilds, transmission overhauls, brake caliper service, suspension component replacement, steering system repairs, electrical component diagnosis and replacement.
Troubleshooting:
Diagnostic flowcharts for common problems, symptom-based troubleshooting, error code interpretation (if applicable).
Disassembly Assembly:
Step-by-step instructions for component removal and reinstallation.
Wiring Diagram Interpretation:
Guidance on understanding and using electrical schematics.
Depth:
Comprehensive (covers from basic maintenance to complex engine and drivetrain rebuilds).
Diagnostic Capabilities:
Advanced diagnostics for electrical and mechanical systems.
Rebuild Procedures:
Detailed instructions for complete engine and transmission rebuilds.
Diagnostic Codes:
Likely to include diagnostic procedures but not necessarily OBD-II style codes for this era.
Engine Type:
4-stroke, Liquid-Cooled, SOHC (Single Overhead Cam)
Displacement:
375cc - 400cc (approximate, commonly cited as 375cc or 400cc for this generation)
Bore X Stroke:
Refer to manual for exact specifications
Compression Ratio:
Refer to manual for exact specifications
Horsepower:
Approximately 20-25 HP (engine dependent)
Torque:
Refer to manual for exact specifications
Fuel Delivery:
Carburetor (likely Mikuni or Keihin)
Fuel Type:
Unleaded Gasoline (87 Octane recommended)
Fuel Tank Capacity:
Approximately 3.3 - 4.0 Gallons
Crash Safety Ratings:
N/A (ATVs are not typically rated by organizations like NHTSA or IIHS)
Braking System:
Hydraulic disc brakes (front and rear)
Parking Brake:
Usually a hand lever or thumb lever system
Operator Controls:
Handlebar steering, thumb throttle, hand brake levers.
Lighting:
Headlights, taillight, brake light for visibility.
Infotainment System:
N/A (Minimal to no infotainment features typical for this era and utility focus).
Assistance Features:
N/A (No electronic driver assistance features like ABS or traction control).
Connectivity Options:
N/A (No integrated connectivity features).
Dashboard Features:
Basic instrumentation including speedometer, odometer, fuel gauge, indicator lights (e.g., oil pressure, battery, 4WD engagement).
Engine Oil Change:
Every 50-100 hours or annually (refer to manual for precise interval based on usage).
Air Filter Cleaning Or Replacement:
Check every 25-50 hours, clean or replace as needed depending on operating conditions.
Spark Plug Replacement:
Every 100-200 hours or annually.
Transmission Oil Change:
Every 100-200 hours or annually.
Coolant Flush And Refill:
Every 1-2 years or as recommended.
Engine Oil:
Polaris recommendations or SAE 10W-40 API SG or higher. Refer to manual for exact specification.
Transmission Fluid:
Polaris recommended synthetic gear oil or SAE 80W-90 gear oil. Refer to manual for exact specification.
Coolant:
Ethylene glycol-based antifreeze (50/50 mix with distilled water).
Brake Fluid:
DOT 3 or DOT 4 brake fluid.
Cv Belt Wear:
CVT belts can wear over time and require replacement, especially with heavy use. Proper belt tension is crucial.
Carburetor Tuning:
Carburetors can require periodic adjustment or cleaning to maintain optimal performance, especially due to fuel variations or debris.
Suspension Bushings:
Rubber bushings in suspension and steering components can degrade and wear, leading to looseness and noise.
Electrical Connections:
Corrosion or loose connections in wiring can lead to intermittent electrical issues. Regular inspection is recommended.
Polaris History:
Polaris Industries Inc. is a long-standing American manufacturer known for its off-road vehicles, including snowmobiles and ATVs, with a reputation for innovation and durability.
Atv 400 6X6 Lineage:
Part of Polaris's early expansion into the utility ATV market, emphasizing its 6x6 capability for demanding work and terrain.
Predecessors Successors:
Built upon the success of earlier Polaris ATVs, it paved the way for more advanced 6x6 models and continued development of their utility ATV line.
Manufacturing Location:
Primarily manufactured in the United States by Polaris Industries.
Market Impact:
The 6x6 model was a significant player in the utility ATV segment, offering a unique advantage in traction and load-carrying.
