Positioning:
The Polaris ATV 400 6x6 was a robust and capable utility ATV designed for demanding tasks, offering excellent traction and payload capacity for its era.
Competitors:
Competed with other utility ATVs from manufacturers like Honda (FourTrax), Yamaha (Grizzly), and Kawasaki (Bayou) in the utility segment.
Traction:
6x6 drivetrain provided superior traction and stability in challenging terrain and heavy load conditions.
Utility:
Designed for work, hauling, towing, and trail riding with a focus on reliability and capability.
Value:
Empowers owners to perform complex repairs and maintenance, saving on labor costs and extending the vehicle's lifespan.
Engine:
Complete overhaul, inspection, tuning, carburetor, cooling system
Transmission:
Gearbox maintenance, clutch inspection, drive belts, final drive maintenance
Drivetrain:
6x6 axle servicing, driveshaft maintenance, differential inspection
Suspension:
Front and rear suspension component servicing, shock absorber maintenance
Brakes:
Hydraulic brake system service, caliper maintenance, brake fluid replacement
Electrical System:
Wiring diagrams, lighting, ignition system, starter motor, battery maintenance
Fuel System:
Fuel tank, fuel pump, fuel lines, carburetor adjustment and cleaning
Cooling System:
Radiator, coolant, water pump, thermostat inspection and service
Frame And Body:
Chassis inspection, body panel removal and installation, seat maintenance
Routine Maintenance:
Oil changes, filter replacements, lubrication points, tune-ups
Troubleshooting:
Diagnostic charts for common problems and solutions
Rebuilding:
Detailed instructions for engine, transmission, and component rebuilds
Repair:
Step-by-step repair procedures for all major systems
Disassembly Assembly:
Comprehensive instructions for component removal and reinstallation
Depth:
Comprehensive, covering everything from basic maintenance to full engine and transmission rebuilds, including electrical diagnostics.
Engine Type:
4-stroke, liquid-cooled, single-cylinder
Displacement:
Approximately 375cc - 400cc (specific to variant, typically around 375cc for early models, evolving to 400cc)
Bore X Stroke:
Typically around 84mm x 69mm (refer to specific manual for exact figures)
Valvetrain:
SOHC (Single Overhead Camshaft), 2 valves per cylinder
Ignition System:
CDI (Capacitor Discharge Ignition)
Horsepower:
Estimated 20-25 HP at peak RPM (typical for the era and displacement)
Torque:
Estimated 25-30 lb-ft at peak RPM (typical)
Carburetor:
Mikuni VM series carburetor (e.g., VM34 or similar, specific model to be confirmed in manual)
Fuel Type:
Unleaded gasoline
Fuel Capacity:
Approximately 3.0 - 3.5 gallons (refer to manual for exact capacity)
Transmission Type:
Automatic (CVT - Continuously Variable Transmission)
Drive Modes:
2WD / 4WD / 6WDselectable engagement
Gear Reduction:
High and Low range, Reverse
Drive Belt:
Serviceable drive belt system, critical for CVT operation
Final Drive:
Shaft drive to all six wheels
Transmission Fluid Type:
Specific CVT fluid (refer to manual for exact Polaris specification or equivalent)
Length:
Approximately 90-95 inches (refer to manual for exact)
Width:
Approximately 46-50 inches (refer to manual for exact)
Height:
Approximately 43-46 inches (refer to manual for exact)
Wheelbase:
Approximately 62-65 inches (refer to manual for exact)
Dry Weight:
Approximately 550-600 lbs (refer to manual for exact)
Ground Clearance:
Approximately 8-10 inches (refer to manual for exact)
Rack Capacity Front:
Typically around 50-100 lbs
Rack Capacity Rear:
Typically around 150-200 lbs
Towing Capacity:
Approximately 1000-1500 lbs (refer to manual for exact and legal limits)
Atv Safety Standards:
Adherence to industry safety standards for ATVs of its era.
Braking System:
Hydraulic disc brakes on all wheels (typical for 6x6 models).
Lighting:
Headlights, taillight/brakelight for visibility.
Chassis Design:
Sturdy frame designed for stability and durability.
Operator Controls:
Ergonomically placed controls for safe operation.
Operator Warnings:
Included in the manual are critical warnings regarding safe operation, protective gear, and environmental considerations.
Engine Oil Change:
Typically every 50-100 hours of operation or annually (refer to manual for precise interval and condition-based maintenance).
Air Filter Cleaning:
Check and clean every 20-40 hours or as needed based on operating conditions (dusty environments require more frequent checks).
Spark Plug Replacement:
Inspect every 100 hours, replace as needed.
Brake Fluid Flush:
Recommended every 1-2 years to prevent moisture absorption and corrosion.
Cvt Belt Inspection:
Inspect for wear and damage at every oil change or every 50 hours.
Engine Oil Type:
API SG or higher, SAE 10W-40 or 20W-50 (refer to manual for specific Polaris recommendation, e.g., PS-4).
Engine Oil Capacity:
Approximately 1.7 - 2.0 liters (refer to manual for exact capacity).
Coolant Type:
Ethylene glycol based antifreeze, 50/50 mix with distilled water.
Brake Fluid Type:
DOT 3 or DOT 4 hydraulic brake fluid.
Gearcase Oil Type:
Specific gearcase lubricant (refer to manual for Polaris specification).
Carburetor Tuning:
Carburetors can be prone to clogging due to fuel quality or age, requiring cleaning and proper jetting.
Cvt Belt Wear:
Aggressive riding or heavy loads can accelerate CVT belt wear, necessitating regular inspection and timely replacement.
Cooling System Leaks:
Hose connections and radiator integrity should be periodically checked for leaks, especially on older units.
Electrical Connections:
Corrosion or loose connections can affect lighting and ignition systems; dielectric grease is recommended for connectors.
Starter Solenoid:
The starter solenoid can fail over time; proper diagnosis is key.
Brand:
Polaris Industries is a well-established American manufacturer of powersports vehicles, known for its innovation in ATVs and snowmobiles.
Lineage:
The 400 6x6 was part of Polaris's expanding line of utility ATVs, building upon their experience with 4x4 models and introducing the extended-traction 6x6 platform.
Production Era:
The 6x6 platform, including the 400 variant, was produced throughout the late 1990s and early 2000s, with various engine displacements and feature updates.
