Product Category:
Heavy-duty utility ATV
Target User:
Professional technicians, agricultural users, hunters, and outdoor enthusiasts requiring robust off-road capability.
Competitors Era:
Competed against other utility-focused 6x6 ATVs from brands like John Deere, Yamaha, and Kawasaki during the mid-to-late 1990s.
Traction Advantage:
The 6x6 drivetrain provides exceptional traction and load-carrying capability, distinguishing it from 4x4 counterparts.
Utility Focus:
Designed for work and utility, featuring a sturdy frame, rack capacity, and towing potential.
Covered Systems:
Engine, Transmission, Drivetrain (6x6), Suspension, Brakes, Steering, Electrical System, Fuel System, Cooling System, Exhaust System, Chassis, Bodywork, Maintenance, Troubleshooting, Specifications
Estimated Page Count:
Likely 200-400 pages (typical for comprehensive service manuals of this era)
Manual Type:
Repair Service Manual
Engine Mechanical:
Detailed procedures for top-end rebuild (cylinder, piston, rings), valve adjustments, camshaft service, crankshaft inspection, oil pump operation, and component replacement.
Engine Fuel System:
Carburetor disassembly, cleaning, adjustment (idle speed, mixture), fuel pump troubleshooting, fuel filter replacement, and fuel line inspection.
Transmission Drivetrain:
Manual gearbox service (shifting mechanisms, gear inspection), CVT (if applicable, though this model likely uses a different system for 6x6), driveshaft maintenance, differential inspection and repair for all six wheels, and hub assembly service.
Suspension Steering:
Front and rear suspension component inspection (shocks, springs, bushings, control arms), steering linkage and tie rod end service, wheel bearing replacement, and steering column maintenance.
Brakes:
Hydraulic brake system service (master cylinder, calipers, brake lines, brake fluid flushing), brake pad replacement, rotor inspection, and parking brake adjustment.
Electrical System:
Wiring diagrams, ignition system troubleshooting (spark plug, coil, CDI unit), lighting system repair, starter motor and solenoid service, battery maintenance, and charging system diagnostics.
Routine Maintenance:
Oil change intervals and specifications, filter replacements (oil, air, fuel), spark plug gap and type, tire pressure recommendations, lubrication points and schedule.
Diagnostic Troubleshooting:
Systematic diagnostic flowcharts for common issues like starting problems, poor performance, braking issues, and electrical faults.
Component Rebuild Overhaul:
In-depth procedures for disassembling, inspecting, cleaning, and reassembling major vehicle components like the engine, transmission, and differentials.
Technical Adjustments:
Precise instructions for carburetor tuning, ignition timing (if adjustable), throttle cable slack, and brake lever free play.
Depth Of Coverage:
Comprehensive, covering everything from basic fluid changes and bolt checks to complete engine and transmission overhauls. Designed for professional technicians but accessible to serious DIY mechanics with mechanical aptitude.
Engine Type:
Single-cylinder, 4-stroke
Displacement:
Approximately 360cc (common for Polaris 400cc models)
Bore X Stroke:
Typically around 83mm x 65mm for this engine family
Cooling System:
Liquid-cooled
Ignition System:
CDI (Capacitor Discharge Ignition)
Horsepower:
Estimated 20-25 HP at peak RPM (subject to specific tuning)
Torque:
Estimated 25-30 lb-ft (subject to specific tuning)
Fuel Delivery:
Carburetor (likely a Mikuni VM series or similar)
Fuel Type:
Unleaded gasoline
Fuel Tank Capacity:
Typically around 3.5-4.0 gallons
Transmission Type:
Automatic transmission with shaft drive to all six wheels.
Gear Selection:
High/Low range forward, Neutral, Reverse.
Drivetrain Engagement:
Selectable AWD/6WD engagement system.
Final Drive:
Shaft drive with differentials on each axle and a potentially locking center differential for the 6x6 system.
Engine Oil Change:
Every 100 hours or annually, whichever comes first.
Air Filter Cleaning:
Check every 20-40 operating hours, clean or replace as needed.
Spark Plug Replacement:
Recommended every 12 months or 100 hours.
Engine Oil Type:
SAE 10W-40 or SAE 20W-50 motorcycle-specific or high-quality API SG or higher engine oil. Check manual for exact specifications.
Engine Oil Capacity:
Approximately 1.7-2.0 quarts (1.6-1.9 liters).
Brake Fluid Type:
DOT 3 or DOT 4 hydraulic brake fluid.
Carburetor Fouling:
Common issue with older carburetors, requiring regular cleaning and tuning, especially if the vehicle sits for extended periods.
Suspension Wear:
Bushing and ball joint wear can occur with heavy use and off-road conditions.
Electrical Connections:
Corrosion or looseness in electrical connectors can lead to intermittent issues. The manual will guide on inspection and cleaning.
Maintenance Schedule Type
Schedule Detail:
The manual will provide a detailed, mileage-based and/or time-based maintenance schedule covering all critical components.
Polaris Heritage:
Polaris has a long history in powersports, starting with snowmobiles and expanding into ATVs and motorcycles, known for innovation and ruggedness.
Atv 400 Lineage:
The 400cc engine was a mainstay for Polaris in the utility ATV segment, evolving through various chassis and feature updates. The 6x6 variant offered a significant increase in utility and traction.
Manufacturing Location:
Primarily manufactured by Polaris Industries in the United States.
