Positioning:
Targeted at owners and independent repair shops seeking to maintain and repair their Polaris ATV 400 6x6 models from the late 1990s.
Value Proposition:
Provides essential technical data and procedural guidance to empower DIY maintenance and repair, reducing reliance on dealership service.
Features:
Detailed diagrams, step-by-step repair instructions, diagnostic flowcharts, torque specifications, and maintenance schedules.
Engine:
Engine overhaul, disassembly, assembly, tuning, lubrication, cooling system, fuel system, exhaust system.
Transmission:
Clutch, gearbox, drive shafts, differential, maintenance, repair, adjustments.
Drivetrain:
6x6 drive system, differentials, axle assemblies, U-joints, CV joints, lubrication.
Suspension:
Front and rear suspension components, shock absorbers, springs, bushings, alignment.
Brakes:
Hydraulic brake system, calipers, master cylinder, brake lines, pads, rotors, bleeding procedure.
Electrical System:
Ignition system, starting system, charging system, battery, lighting, wiring diagrams, troubleshooting.
Frame And Body:
Chassis, body panels, racks, seat, fenders, repair and replacement.
Steering:
Steering column, tie rods, steering linkage, adjustments.
Wheels And Tires:
Wheel specifications, tire pressure, replacement.
Maintenance:
Scheduled maintenance, lubrication points, fluid changes, filter replacements, pre-ride inspections.
Troubleshooting:
Diagnostic procedures for common problems, symptom-based troubleshooting guides.
Repair:
Detailed step-by-step instructions for component removal, repair, and reinstallation.
Rebuild:
Complete engine and transmission rebuild procedures, including specifications.
Adjustments:
Carburetor tuning, brake adjustments, cable adjustments.
Specifications:
Torque specifications, clearances, fluid capacities, engine timing.
Depth:
Comprehensive: Covers everything from basic maintenance and adjustments to complete engine and transmission overhauls and diagnostics.
Engine Type:
2-stroke, Liquid-Cooled, Single Cylinder
Displacement:
375cc (approximate, actual can vary slightly by year/sub-model)
Bore X Stroke:
Refer to manual for exact specifications; typical for this era 2-stroke.
Carburetion:
Single Carburetor (e.g., Mikuni VM Series or similar)
Horsepower:
Approx. 25-30 HP (varies by model year and tuning)
Torque:
Refer to manual for specific torque figures.
Fuel Type:
Unleaded Gasoline (typically 87 octane minimum), mixed with 2-stroke oil
Oil Mixture:
Refer to manual for specific oil-to-fuel ratio (commonly 40:1 or 50:1)
Oil Type:
2-stroke engine oil meeting API TC specifications or manufacturer recommendation.
Cooling Method:
Liquid-Cooled
Coolant Type:
Ethylene glycol based antifreeze/coolant (e.g., 50/50 mix with distilled water)
Type:
Automatic (PVT - Polaris Variable Transmission) with Hi/Lo range and Reverse.
Drive System:
Shaft drive to all six wheels.
Gear Reduction:
Yes, for off-road capability.
Transmission Fluid Type:
Polaris Synthetic Gearcase Lubricant or equivalent (refer to manual for specific part number/viscosity).
Gearcase Capacity:
Refer to manual for exact capacity; typically around 300-400 ml.
Length:
Refer to manual; generally around 80-90 inches.
Width:
Refer to manual; typically around 46-50 inches.
Height:
Refer to manual; typically around 45-50 inches.
Dry Weight:
Approx. 600-700 lbs (varies)
Towing Capacity:
Typically rated for 1500 lbs.
Rack Capacity Front:
Refer to manual; usually around 50 lbs.
Rack Capacity Rear:
Refer to manual; usually around 100-200 lbs.
Classification:
ATV (All-Terrain Vehicle) - Not street legal in most jurisdictions without modification and registration.
Braking System:
Hydraulic disc brakes on all wheels.
Roll Over Protection:
None inherently, operator safety relies on skill and adherence to use guidelines.
Lighting:
Headlights, taillight/brakelight.
Oil Change Engine:
Refer to manual; typically every 25-50 operating hours for 2-stroke oil injection, or as per premix ratio.
Spark Plug Replacement:
Refer to manual; typically every 100-200 operating hours or as needed.
Air Filter Cleaning:
Refer to manual; recommended every 25-50 operating hours or more frequently in dusty conditions.
Transmission Fluid Change:
Refer to manual; typically every 100-200 operating hours or annually.
Brake Fluid Flush:
Refer to manual; typically every 2 years.
Engine Oil Type:
API TC 2-Stroke Oil (premix or injection)
Gearcase Oil Type:
Polaris Synthetic Gearcase Lubricant or SAE 80W-90 Gear Oil (verify with manual)
Coolant Type:
50/50 mixture of Ethylene Glycol antifreeze and distilled water.
Common Wear Items:
Drive belts (PVT), spark plugs, air filters, brake pads, tie rod ends, ball joints, wheel bearings due to demanding use.
Carburetor Issues:
Can be prone to clogging from old fuel or debris; requires periodic cleaning and adjustment.
2 Stroke Engine Care:
Requires proper fuel/oil mixture or functioning oil injection system to prevent engine damage.
Heritage:
Polaris Industries has a long history of manufacturing powersports vehicles, including ATVs and snowmobiles, known for innovation and off-road performance.
Evolution Lineage:
The 400 6x6 was part of Polaris's growing ATV lineup, emphasizing utility and all-wheel drive capability, building on earlier models.
Manufacturing Location:
USA (Polaris manufacturing facilities).
Production Era:
Mid to late 1990s, a period of significant growth and technological advancement for ATVs.
