Target Audience:
Owners, technicians, and enthusiasts performing maintenance and repairs on Polaris 400 6x6 models.
Key Competitors Era:
Other 6x6 utility ATVs from brands like Yamaha, Suzuki, and Kawasaki, as well as other Polaris models.
Vehicle Utility:
Known for its 6x6 drivetrain providing enhanced traction and load-carrying capability, suitable for work and recreational off-roading.
Manual Utility:
A crucial resource for maintaining the longevity and performance of the ATV, covering all essential service and repair aspects.
Powertrain:
Engine, transmission, drive axles, final drive, 6x6 drive system.
Chassis:
Frame, suspension (front and rear), steering system, wheels, tires.
Electrical:
Ignition system, charging system (stator, regulator/rectifier), lighting, starter motor, battery, wiring diagrams, sensors.
Fuel System:
Carburetor (type and adjustments), fuel pump, fuel lines, fuel tank, fuel filter.
Braking System:
Hydraulic brake system (front and rear), brake calipers, master cylinders, brake lines, pads/shoes.
Cooling System:
Liquid-cooled engine, radiator, fan, coolant hoses, thermostat.
Exhaust System:
Exhaust manifold, muffler, exhaust pipes.
Bodywork And Trim:
Body panels, fenders, racks, seat, controls, lighting components.
Maintenance:
Scheduled maintenance tasks, oil changes, filter replacements, lubrication, valve adjustments, spark plug replacement.
Troubleshooting:
Diagnostic procedures for common and uncommon problems, symptom-based troubleshooting guides.
Repair:
Step-by-step repair instructions for all major components and systems, including disassembly, inspection, and reassembly.
Diagnostics:
Detailed diagnostic procedures for electrical and mechanical issues.
Engine Rebuild:
Complete engine overhaul procedures, including cylinder head, piston, crankshaft, and camshaft service.
Transmission Overhaul:
Procedures for servicing and rebuilding the transmission and differential components.
Suspension Service:
Ball joint replacement, shock absorber service, bushing replacement, alignment procedures (where applicable).
Electrical Component Testing:
Testing procedures for stator, CDI unit, voltage regulator, starter solenoid, and other electrical parts.
Depth Level:
Comprehensive (covers basic maintenance to complete engine/transmission rebuilds).
Diagrams And Illustrations:
Includes exploded views, schematics, and detailed illustrations for clarity.
Torque Specifications:
Detailed torque values for all critical fasteners.
Clearances And Tolerances:
Specifications for engine internal component clearances (piston-to-wall, bearing clearances, etc.).
Engine Type:
4-stroke, liquid-cooled, SOHC
Displacement:
375cc to 400cc (specific engine designation varies slightly across production years for the '400' designation).
Bore X Stroke:
Typically around 84.0 mm x 70.0 mm (common for engines in this displacement class).
Compression Ratio:
Around 8.5:1 to 9.5:1 (typical for this era).
Horsepower Estimated:
Approximately 25-30 HP (peak output).
Torque Estimated:
Around 20-25 ft-lbs (peak torque).
Carburetor Type:
Mikuni BSR32 or similar single-barrel carburetor.
Fuel Type:
Unleaded gasoline (87 octane recommended).
Fuel Tank Capacity Estimated:
Approximately 4.5-5.0 gallons.
Ignition Type:
Electronic ignition (CDI - Capacitor Discharge Ignition).
Cooling Method:
Liquid-cooled with thermostatically controlled fan.
Transmission Type:
Automatic (CVT - Continuously Variable Transmission) with engine braking.
Drive Modes:
2WD, 6x6 (shaft-driven, with lockable differentials on some models/years).
Optional Transmission:
N/A for this model and configuration.
Gear Reduction:
Includes high and low range gearing for versatile performance.
Transmission Fluid Type:
Refer to manual for specific Polaris AGL Gearcase Lubricant or equivalent.
Final Drive Fluid Type:
Refer to manual for specific Polaris AGL Gearcase Lubricant or equivalent.
Length Estimated:
Approximately 90-100 inches.
Width Estimated:
Approximately 44-48 inches.
Height Estimated:
Approximately 40-45 inches.
Front Rack Capacity Estimated:
Approximately 50 lbs.
Rear Rack Capacity Estimated:
Approximately 100-200 lbs.
Dry Weight Estimated:
Approximately 550-650 lbs.
Towing Capacity Estimated:
Typically around 1,000-1,500 lbs.
Front Tire Size Typical:
AT 25x8-12 or similar.
Rear Tire Size Typical:
AT 25x10-12 or similar.
Wheel Bolt Pattern:
Likely 4x110mm or 4x115mm (common for Polaris).
Engine Oil Change:
Typically every 100 hours or annually, whichever comes first. Refer to manual for exact interval.
Air Filter Cleaning Inspection:
Inspect every 20-40 operating hours; clean or replace as needed.
Spark Plug Replacement:
Recommended every 500-1000 hours or based on condition.
Transmission Fluid Change:
Typically every 200 hours or annually.
Engine Oil Type And Viscosity:
SAE 10W-40 or 20W-50, API SG or higher (refer to manual for exact specification).
Engine Oil Capacity:
Approx. 1.7-2.0 quarts (refer to manual).
Coolant Type:
Ethylene glycol-based antifreeze (50/50 mix with distilled water).
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid.
Common Wear Items:
Brake pads, wheel bearings, CV boots, tie rod ends, suspension bushings, drive belts (CVT).
Electrical Concerns:
Potential for stator or voltage regulator failure, wiring harness issues due to vibration and environmental exposure.
Carburetor Issues:
Can become clogged with debris or varnish if not maintained, leading to poor running conditions.
Cooling System Concerns:
Overheating due to radiator blockage, fan motor failure, or coolant leaks.
Brand Origin:
Polaris Inc. is an American manufacturer founded in 1954, known for powersports vehicles.
400 6X6 Lineage:
Part of Polaris's pioneering work in the ATV market, particularly with multi-wheel drive configurations.
Era Context:
The mid-to-late 1990s were a period of significant growth and technological advancement in the ATV industry, with Polaris being a major player.
Production Period:
The 400 6x6 model was produced throughout the latter half of the 1990s, including the specified 1996-1998 years.
