Model Years Covered:
1985, 1986, 1987, 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995
Engine Type:
2-Stroke, Air-Cooled
Drive Type:
2WD (Two-Wheel Drive)
Chassis Codes:
Likely varies by specific year, but often referred to by the model name itself.
Atv Segment:
Utility and recreational ATV, popular for its robust design and capability during its production run.
Key Competitors Era:
Competed with other manufacturers' 300-400cc class ATVs from brands like Honda, Yamaha, Kawasaki, and Suzuki.
Engine Configuration:
Known for its reliable, albeit somewhat basic, 2-stroke engine, offering good power for its class and time.
Utility Focus:
Designed for practical use, including work around the farm or ranch, trail riding, and general recreational purposes.
Durability:
Polaris ATVs from this era were generally regarded for their robust construction and ability to withstand demanding conditions.
Coverage Scope:
Comprehensive factory service and repair for Polaris ATV 400 2x4 models from 1985-1995.
Specific Years Detailed:
1985, and all subsequent model years up to 1995.
Estimated Page Count:
Variable, typically 300-600 pages for a comprehensive factory service manual of this era and scope. Specific count not provided, but expected to be substantial.
Manual Category:
Factory Service Manual / Repair Manual
Intended Audience:
Professional Technicians and Experienced DIY Mechanics
Engine System:
Complete engine overhaul, top-end and bottom-end assembly, lubrication system, cooling system (air-cooling specifics), fuel system, ignition system, starting system, exhaust system.
Transmission Drivetrain:
Clutch operation and adjustment, transmission disassembly and reassembly, final drive, drive shafts, universal joints, differential (if applicable).
Electrical System:
Wiring diagrams, lighting system, charging system (alternator/stator), battery maintenance, starter motor, ignition switch, fuses, relays, switches, sensors.
Braking System:
Hydraulic brake system, brake caliper service, brake pad replacement, brake fluid specifications and bleeding procedures, parking brake system.
Suspension Steering:
Front and rear suspension systems (likely solid axle rear, independent front suspension variations), shock absorber service, steering linkage, tie rod ends, wheel alignment.
Body Chassis:
Frame inspection and repair, body panel removal and installation, seat, handlebars, fenders, racks, plastics.
Routine Maintenance:
Oil changes, filter replacements, spark plug service, air filter cleaning/replacement, chain adjustment (if applicable), lubrication points.
Troubleshooting:
Diagnostic charts, common problems and their solutions, symptom-based troubleshooting guides for engine, electrical, and mechanical issues.
Repair Rebuild:
Step-by-step instructions for component disassembly, cleaning, inspection, repair, and reassembly for all major vehicle systems.
Technical Specifications:
Torque specifications for all fasteners, engine timing, valve clearances (if applicable), fluid capacities, electrical system voltages, diagnostic trouble codes (DTCs) if applicable to the era.
Special Tools:
Listing and description of any specialized tools required for specific repair procedures.
Diagnostic Capabilities:
Detailed diagnostic procedures for identifying and resolving performance issues, electrical faults, and mechanical failures.
Rebuild Guidance:
Comprehensive instructions for complete engine rebuilds, transmission overhauls, and other major component restorations.
Adjustment Procedures:
Precise instructions for adjusting clutches, carburetors, brakes, and other critical systems for optimal performance.
Engine Displacement:
Typically around 350cc to 400cc for the '400' model designation. Specific displacement may vary slightly by year.
Engine Description:
Single-cylinder, 2-stroke, reed valve induction, air-cooled engine.
Horsepower Estimate:
Estimated 20-25 HP, typical for a 400cc 2-stroke of the period.
Torque Estimate:
Torque figures would be moderate, suitable for utility tasks and moderate acceleration.
Carburetor Type:
Single Mikuni carburetor, likely 30-34mm range, with specific jetting per year and altitude.
Fuel Type:
Unleaded gasoline with a specific octane rating (refer to manual for exact specification, typically 87 or higher).
Oil Mixture:
Requires a 2-stroke oil and gasoline mixture, usually 40:1 or 50:1 ratio. The manual will specify the exact ratio and approved oil types.
Transmission Type:
Automatic (CVT - Continuously Variable Transmission) with a belt-driven system.
Gear Selection:
Typically High (H), Low (L), Neutral (N), and Reverse (R).
Optional Transmission:
N/A, CVT was standard for this model.
Drive System:
Shaft drive to the rear axle.
Transmission Fluid:
Specific CVT fluid required. Manual will specify type and capacity.
Length:
Varies slightly by year, typically around 75-80 inches.
Width:
Varies slightly by year, typically around 40-45 inches.
Height:
Varies slightly by year, typically around 45-50 inches.
Dry Weight:
Approximately 450-500 lbs, varies by year and specific features.
Ground Clearance:
Typically around 7-9 inches, depending on suspension setup and tire size.
Rack Capacity Front:
Typically rated for around 50-75 lbs.
Rack Capacity Rear:
Typically rated for around 100-150 lbs.
Infotainment System:
Basic, primarily analog instrumentation: speedometer, odometer, engine hour meter (if equipped), indicator lights for neutral, oil, etc.
Driver Assistance Features:
None beyond the fundamental mechanical and electrical systems designed for safe operation.
Connectivity Options:
N/A. No electronic connectivity features.
Engine Oil Change:
Typically every 100 hours of operation or annually, whichever comes first. Manual will specify exact interval and fluid type.
Air Filter Service:
Check every 20-40 hours, clean/replace as needed. More frequent service in dusty conditions.
Spark Plug Service:
Inspect and clean/gap every 50-100 hours, replace as needed. Manual will specify correct plug type and gap.
Transmission Belt Inspection:
Inspect periodically for wear and damage, typically every 50-100 hours. Replacement based on condition.
Engine Oil Type:
Specific 2-stroke oil blend. Manual will specify SAE viscosity grade and API classification (e.g., TC-W3 rated).
Gear Lube Type:
Specific gear oil for final drive. Manual will specify viscosity (e.g., SAE 80W-90) and API GL-4 or GL-5 rating.
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid, depending on the specific hydraulic system used. Manual will confirm.
Common Wear Items:
CVT belt wear, carburetor jetting issues due to age/fuel quality, spark plug fouling (typical for 2-strokes), suspension bushings and ball joints.
Electrical Gremlins:
Corrosion on electrical connectors, aging starter solenoids, and stator issues can occur over time.
Cooling System Considerations:
Air-cooled engines can overheat if not properly maintained, especially in hot weather or under heavy load. Ensuring fins are clean is crucial.
