Positioning:
The Polaris ATV 400 6x6 was positioned as a capable utility and recreational ATV, emphasizing its 6x6 drivetrain for enhanced traction and load-carrying capacity, making it suitable for work on farms, ranches, and demanding off-road terrain.
Competitors:
Competed with other utility ATVs from manufacturers like John Deere, Yamaha, Honda, and Kawasaki, particularly those offering larger displacement engines and 4x4 or 6x6 drive options.
Features:
6x6 full-time 4-wheel drive system with automatic locking front differential, a powerful 2-stroke engine, automatic transmission, robust suspension for rough terrain, and a utility rack system.
Benefit To Owner:
Empowers owners to perform maintenance and repairs themselves, ensuring optimal performance, longevity, and cost savings. Provides confidence in tackling common issues and understanding the machine's mechanics.
Systems Covered:
Engine, fuel system, ignition, cooling, transmission, drivetrain, suspension, steering, brakes, electrical system, bodywork, chassis, maintenance procedures, troubleshooting, diagnostics, specifications, torque values.
Page Count:
Estimated 300-500 pages (typical for comprehensive service manuals of this era and type). Specific count not provided in product information.
Manual Type:
Service and Repair Manual
Format:
Downloadable Digital Format (PDF implied by 'Download')
Engine:
Comprehensive coverage of the 400cc 2-stroke engine, including disassembly, assembly, inspection, and repair of all internal components.
Fuel System:
Carburetor tuning, fuel pump, fuel lines, fuel filter replacement, and troubleshooting.
Ignition System:
CDI ignition, spark plug specifications, coil testing, and troubleshooting.
Cooling System:
Radiator, fan, coolant specifications, thermostat, and related component service.
Transmission Drivetrain:
Automatic transmission (PVT - Polaris Variable Transmission), belt inspection and replacement, clutch service, differential inspection and repair for all six wheels.
Suspension:
Front and rear suspension component inspection, shock absorber service, spring replacement, and alignment.
Steering:
Handlebar assembly, tie rod ends, steering column, and linkage service.
Braking System:
Hydraulic brake system, caliper service, master cylinder, brake pads, brake fluid specifications, and bleeding procedures.
Electrical System:
Battery specifications, charging system (stator, regulator/rectifier), starter motor, lighting, wiring diagrams, and component testing.
Bodywork Chassis:
Frame inspection, plastic body panel removal and installation, seat, fender, and rack service.
Maintenance:
Detailed schedules for oil changes, filter replacements, spark plug checks, lubrication points, and general upkeep.
Troubleshooting:
Systematic diagnostic charts and procedures for identifying and resolving common performance issues and failures.
Repair Rebuild:
Step-by-step instructions for component disassembly, cleaning, inspection, repair, and reassembly for most major systems.
Technical Specifications:
Torque specifications for fasteners, fluid capacities, clearances, and critical measurements for engine and chassis components.
Wiring Diagrams:
Includes comprehensive electrical wiring diagrams for fault finding and component identification.
Depth:
Comprehensive, covering everything from routine maintenance and minor adjustments to major component overhauls and complete engine rebuilds.
File Format:
Likely PDF. Searchable text, bookmarked sections, and printable pages are expected for a quality digital manual.
Print Quality:
Digital format implies excellent clarity of diagrams and text. If printable, quality depends on the source file.
Binding Type:
Not applicable (Digital Download)
Paper Type:
Not applicable (Digital Download)
Engine Type:
2-stroke, Liquid-Cooled, Single Cylinder
Displacement:
Approximately 399cc (often referred to as 400cc)
Bore X Stroke:
Specifics not detailed in product info, but typical for this class.
Compression Ratio:
Specifics not detailed in product info.
Horsepower:
Estimated 28-32 HP (typical for this engine size and configuration in 1997).
Torque:
Estimated 30-35 lb-ft (typical for this engine size and configuration in 1997).
Carburetor:
Single Carburetor (likely Mikuni or Keihin, size specific to model, typically 34-38mm).
Fuel Type:
Unleaded gasoline (octane rating specified in manual)
Fuel Mixture:
2-stroke oil-gasoline pre-mix ratio specified in manual (e.g., 40:1 or 50:1).
Ignition System:
CDI (Capacitor Discharge Ignition)
Spark Plug:
Specific plug type and gap (e.g., NGK BR7ES, gap 0.028-0.032 inches) detailed in manual.
Cooling Method:
Liquid-cooled
Type:
Polaris Variable Transmission (PVT) - Automatic CVT (Continuously Variable Transmission)
Drive Modes:
2WD, 4WD, 6WD (selectable or automatic engagement of front axles).
Gear Selection:
High, Low, Neutral, Reverse.
Drive Belt:
CVT belt inspection, replacement intervals, and specifications covered in detail.
Differential Lock:
Automatic locking front differential for enhanced traction in 4WD and 6WD modes.
Transmission Fluid:
Specific type (e.g., Polaris AGL or equivalent synthetic gear oil) and capacity detailed in manual.
Length:
Approximately 95 inches (2413 mm) - typical for this model.
Width:
Approximately 48 inches (1219 mm) - typical for this model.
Height:
Approximately 46 inches (1168 mm) - typical for this model.
Wheelbase:
Approximately 70 inches (1778 mm) - typical for 6x6 models.
Dry Weight:
Approximately 600-650 lbs (272-295 kg) - typical for this configuration.
Payload Capacity:
Typically around 500-700 lbs (227-317 kg).
Rack Capacity Front:
Typically around 100 lbs (45 kg).
Rack Capacity Rear:
Typically around 200 lbs (90 kg).
Front Tire Size:
Commonly 25x8-12 or 25x8.00-12. Specifics in manual.
Rear Tire Size:
Commonly 25x10-12 or 25x10.00-12. Specifics in manual.
Wheel Bolt Pattern:
Specific pattern (e.g., 4/110 or 4/115) will be detailed in the manual.
Safety Standards:
ATVs are subject to specific safety standards; details on compliance or testing are not typically provided in service manuals but may touch on design considerations.
Braking System Type:
Hydraulic disc brakes on all wheels, with parking brake mechanism.
Throttle Limiter:
Some models may have adjustable throttle limiters for beginner riders, covered in owner's manuals, but service manuals focus on mechanics.
Rollover Protection:
No specific rollover protection systems like cages found on this era of ATV; rider safety relies on operator skill and proper riding gear.
Lighting:
Headlights, taillight, and brake light for visibility and signaling.
Engine Oil Change:
Typically every 100 hours or annually, as specified in the manual.
Air Filter Cleaning:
Recommended every 20-40 hours of operation, depending on conditions. Manual will detail specific cleaning/replacement procedure.
Transmission Fluid Change:
Typically every 200 hours or annually. Manual will detail procedure and fluid type.
Spark Plug Inspection:
Recommended at regular intervals, often with oil changes.
Brake Fluid Flush:
Recommended every 1-2 years or as per manual's recommendation.
Engine Oil Type:
2-stroke synthetic oil (specific brand and mix ratio to be confirmed in manual, e.g., SAE 50 or 10W-30 for pre-mix).
Transmission Fluid Type:
Polaris AGL or equivalent synthetic gear lubricant (SAE 75W-90 or similar) – specific specification in manual.
Brake Fluid Type:
DOT 3 or DOT 4 hydraulic brake fluid.
Coolant Type:
Ethylene glycol-based antifreeze (e.g., SAE 20 or 50/50 mix) – specific type and capacity in manual.
Common Wear Items:
CVT drive belt wear and breakage, spark plug fouling (common on 2-strokes), carburetor jetting issues, suspension component wear (bushings, ball joints).
Electrical Issues:
Potential for stator or voltage regulator failure, wiring harness degradation over time.
Engine Performance:
Loss of power can be due to carburetor, ignition, or exhaust port blockages. Manual will help diagnose these.
Polarisi Heritage:
Polaris Industries, founded in 1954, has a long history in powersports, evolving from snowmobiles to ATVs, UTVs, and motorcycles. They are known for innovation in the ATV market.
Atv Lineup Context:
The 400 6x6 was part of Polaris's expansion into the utility ATV segment, building on earlier models and technologies. The 6x6 configuration was a key differentiator for tasks requiring enhanced traction and stability.
Production Period:
The 400 6x6 model was produced through the late 1990s and early 2000s, with various updates and engine options over its lifespan.
Manufacturing Location:
Polaris vehicles are primarily manufactured in the United States, at facilities in Minnesota and other locations.
