Segment:
Entry-level to mid-range utility ATV segment.
Target User:
Recreational riders, farmers, hunters, and individuals needing a reliable 4x4 ATV for various tasks.
Key Competitors Era:
Honda FourTrax, Yamaha Big Bear, Suzuki QuadRunner, Kawasaki Bayou.
Powertrain Highlight:
Polaris's proprietary engine and transmission technology, with a focus on reliable 4x4 capability.
Design Philosophy:
Robust, functional design prioritizing utility and durability for off-road conditions.
Primary Coverage:
Repair, maintenance, and troubleshooting for the Polaris ATV 400 4x4 (1994-1995).
Secondary Coverage:
Diagnostic procedures, specifications, and component descriptions.
Estimated Page Count:
Typically 300-500 pages for comprehensive service manuals covering multiple model years and variations. Exact count depends on publication.
Manual Classification:
Service Manual / Repair Manual
Primary Language:
English
Delivery Format:
PDF (Digital Download)
File Format Quality:
High-resolution PDF, ensuring clear text and legible diagrams. Searchable functionality is often a feature of well-digitized manuals.
Printability:
Designed for easy printing of individual pages or sections as needed for workshop use.
Binding Type:
N/A (Digital Format)
Paper Type:
N/A (Digital Format)
Engine Mechanical:
Detailed overhaul, inspection, and repair of the engine components (cylinder head, piston, crankshaft, camshaft, valve train).
Fuel System:
Carburetor tuning, cleaning, and overhaul; fuel pump and lines; fuel tank service.
Ignition System:
Ignition coil, spark plug, CDI unit, stator testing and replacement; timing specifications.
Transmission Drivetrain:
Service and repair of the automatic transmission, including belt inspection and replacement, clutch operation, and gear case maintenance.
4X4 System:
Operation and service of the four-wheel-drive engagement system, including drive shafts, differentials, and engagement mechanisms.
Suspension Steering:
Front and rear suspension component inspection, replacement (shocks, A-arms), and steering linkage adjustments.
Braking System:
Hydraulic brake system service (master cylinder, calipers, brake lines), brake pad replacement, and bleeding procedures.
Electrical System:
Wiring diagrams, troubleshooting for lighting, starting system, charging system, and accessory circuits.
Cooling System:
Radiator, fan, thermostat, and coolant line service (if applicable - some 400 models were air-cooled, others liquid-cooled, manual should clarify).
Body Chassis:
Frame inspection, plastic body panel removal and installation, seat service.
Routine Maintenance:
Oil changes, filter replacements, spark plug service, lubrication points, and general inspections.
Troubleshooting:
Systematic diagnostic steps for common and uncommon performance issues, component failures, and starting problems.
Disassembly Reassembly:
Step-by-step instructions for removing, overhauling, and reinstalling major components and sub-assemblies.
Torque Specifications:
Precise torque values for critical fasteners across all serviced systems.
Special Tools:
Identification and usage of specialized tools required for specific repair procedures.
Diagnostic Capability:
Advanced diagnostic procedures for electrical and mechanical systems, including fault code interpretation (if applicable).
Rebuild Procedures:
Comprehensive instructions for rebuilding engines, transmissions, carburetors, and other complex assemblies.
Adjustment Calibration:
Detailed procedures for adjusting carburetors, valve clearances, brake systems, and steering components.
Engine Type:
Single-cylinder, 2-stroke, liquid-cooled (some variants, check specific model year specification) or air-cooled.
Displacement:
Typically around 350-400cc. The exact displacement for the 400 4x4 model should be confirmed in the manual, but the '400' designation strongly suggests this range.
Bore X Stroke:
Specifications vary by exact engine variant. The manual will provide precise measurements.
Compression Ratio:
Details specific to the engine will be in the manual, crucial for performance diagnosis.
Horsepower:
Estimated 20-30 HP range, depending on exact engine tune and cooling system. Manual will provide exact figures.
Torque:
Specifications detailed in the manual, critical for understanding low-end pulling power.
Carburetion:
Single carburetor, likely a Mikuni or Keihin unit. Manual provides specific model and tuning/jetting information.
Fuel Type:
Unleaded gasoline. Manual will specify octane rating requirements.
Lubrication Type:
Premix for 2-stroke engines or oil sump for 4-stroke. Manual will clarify if 2-stroke and the required oil mixture ratio, or 4-stroke oil type and capacity.
Wheelbase:
Approx. 48-50 inches. Specific measurement provided in the manual.
Ground Clearance:
Around 7-9 inches. Exact spec in manual is crucial for off-road assessment.
Dry Weight:
Likely in the 500-600 lb range. Manual will provide exact curb weight.
Towing Capacity:
Typically rated for around 500-1000 lbs. Manual provides definitive rating.
Front Tire Size:
Commonly 24x8-12 or similar. Manual confirms exact size and recommended pressures.
Rear Tire Size:
Commonly 24x11-10 or similar. Manual confirms exact size and recommended pressures.
Engine Oil Change:
Typically every 100 hours or annually. Manual will provide precise intervals and conditions.
Air Filter Cleaning:
Check every 20-40 hours of operation, clean or replace as needed. Manual will specify cleaning procedures.
Spark Plug Replacement:
Recommended every 100-200 hours or annually. Manual will list correct spark plug type and gap.
Transmission Belt Inspection:
Inspect drive belt for wear and damage every 50-100 hours. Replace if cracks or excessive wear are present. Manual details inspection criteria.
Engine Oil Type:
Specific to 2-stroke pre-mix (e.g., API TC rated 2-stroke oil) or 4-stroke oil. Manual will specify SAE viscosity and API classification (e.g., SAE 10W-40, API SG).
Coolant Type:
If liquid-cooled, a specific ethylene glycol-based coolant is required. Manual will provide type and mixture ratio.
Gearcase Oil:
Specific gear oil type and capacity for front and rear differentials and gear cases. Manual will specify GL-4 or GL-5 classification and viscosity.
Cvt Belt Wear:
Common for older CVT systems; belt slippage or breakage can occur with age or heavy use. Manual details belt inspection and replacement.
Carburetor Maintenance:
Carburetors can become gummed up with stale fuel, leading to starting or running issues. Manual provides cleaning and adjustment procedures.
Electrical Connections:
Corrosion or loose connections can affect lighting, ignition, and starter systems. Manual aids in troubleshooting wiring.
Suspension Bushings:
Wear on suspension bushings can lead to play and handling issues. Manual provides replacement instructions.
Polarís History:
Polaris Industries Inc. has a long history in powersports, beginning with snowmobiles and expanding into ATVs in the late 1980s.
Atv 400 Lineage:
The 400 4x4 was a significant model for Polaris, offering a blend of utility, performance, and the highly sought-after 4-wheel-drive capability for its era.
Mid 90S Atv Market:
This period saw rapid development in ATV technology, with 4x4 becoming increasingly popular. Polaris was a key player in this growth.
Manufacturing Location:
Polaris ATVs are primarily manufactured in the United States, with key facilities in Minnesota and Iowa.
