Category:
All-Terrain Vehicle (ATV)
Target User:
ATV owners, DIY mechanics, technicians, repair shops.
Segment:
Utility ATV (6x6 configuration for increased traction and hauling capacity).
Vehicle Strengths:
The 6x6 drivetrain provides superior traction in challenging terrain, making it ideal for utility and off-road applications. The 400cc engine offers a good balance of power and efficiency for its class.
Value:
Provides essential information for maintaining, diagnosing, and repairing the 1995 Polaris 400 6x6 ATV, enabling cost savings and extending the vehicle's lifespan.
Engine Mechanical:
Detailed disassembly, inspection, and reassembly of the 2-stroke engine, including piston, cylinder, crankshaft, and connecting rod.
Fuel System:
Carburetor identification, adjustment, cleaning, and repair; fuel pump operation and servicing.
Ignition System:
CDI unit testing, stator and coil specifications, spark plug selection and gap.
Transmission Drivetrain:
Automatic transmission (PVT - Polaris Variable Transmission) operation, belt inspection and replacement, clutch service, differential maintenance, driveshaft and U-joint service, 6x6 driveline engagement and maintenance.
Cooling System:
Radiator, fan, and coolant circuit maintenance (where applicable to specific models within the 400 6x6 family).
Braking System:
Hydraulic brake system components, caliper service, pad replacement, bleeding procedures, master cylinder maintenance.
Suspension Steering:
Front and rear suspension component inspection, shock absorber service, ball joint and tie rod end replacement, steering linkage maintenance.
Electrical System:
Wiring diagrams, battery maintenance, lighting system troubleshooting, starter and charging system components.
Chassis Frame:
Frame inspection, welding procedures (if applicable), body panel removal and installation.
Exhaust System:
Muffler and pipe inspection, gasket replacement.
Routine Maintenance:
Oil changes (gearbox), spark plug replacement, air filter cleaning/replacement, belt inspection, battery check, lubrication points.
Troubleshooting:
Diagnostic charts for common starting, running, and performance issues, electrical fault finding.
Engine Repair:
Top-end rebuilds (cylinder, piston), crankshaft and bearing replacement, valve adjustments (if applicable to 2-stroke decompression mechanism).
Transmission Repair:
PVT belt replacement, clutch disassembly and inspection, gearbox fluid flush and fill.
Brake Service:
Brake pad replacement, caliper overhaul, brake line bleeding, rotor inspection.
Suspension Updates:
Shock absorber replacement, bushing inspection and replacement, steering component alignment.
Electrical Diagnostics:
Wiring harness troubleshooting, component testing (stator, ignition coil, regulator/rectifier if present), starter motor testing.
Depth:
Comprehensive from basic maintenance to complete engine and transmission rebuilds, including electrical diagnostics and frame repair.
Diagnostic Capability:
Detailed troubleshooting guides and diagnostic flowcharts to identify and resolve mechanical and electrical issues.
Rebuild Procedures:
Step-by-step instructions for major component rebuilds, including engine internals and transmission components.
Engine Type:
2-stroke, carbureted
Displacement:
Approx. 340cc - 400cc (specific variant dependent, often around 340cc for the 400 engine in this era)
Bore X Stroke:
Specifications available within manual (e.g., ~70mm x 72mm for a typical 340cc model)
Horsepower:
Estimated 25-30 HP (approximate for the class)
Torque:
Specifications available within manual
Carburetor Model:
Likely Mikuni VM series or similar (e.g., VM34/36) - specific model detailed in manual.
Fuel Type:
Unleaded gasoline (typically 87 octane or higher recommended)
Oil Mixture:
Requires 2-stroke oil mixed with gasoline (ratio specified in manual, typically 40:1 or 50:1).
Type:
Polaris Variable Transmission (PVT) Automatic
Drive System:
Shaft Drive with 6x6 engagement
Gear Selection:
High, Low, Neutral, Reverse
Clutch System:
Centrifugal clutch and CVT drive/driven clutches.
Belt Maintenance:
Critical belt inspection, tension adjustment, and replacement procedures detailed.
Length:
Approx. 80-85 inches (specific model variant)
Width:
Approx. 45-50 inches (specific model variant)
Height:
Approx. 45-50 inches (specific model variant)
Dry Weight:
Approx. 500-550 lbs (specific model variant)
Payload Capacity:
Approx. 200-250 lbs (rear rack)
Towing Capacity:
Approx. 1000-1500 lbs (with appropriate hitch)
Rear Rack Capacity:
Integrated rear rack for cargo transport.
Rollover Protection:
N/A (Standard ATV design, operator assumes risk)
Braking System:
Hydraulic disc brakes front and rear for effective stopping power.
Drivetrain Engagement:
6x6 drive system enhances traction and stability in slippery conditions.
Lighting:
Headlights and taillights for visibility.
Operator Controls:
Standard handlebar controls for throttle, braking, and gear selection.
Engine Oil Change:
Every 50-100 operating hours or annually (refer to manual for exact interval).
Air Filter Cleaning:
Every 25-50 operating hours or as needed based on operating conditions (dust).
Spark Plug Replacement:
Every 100-200 operating hours or annually.
Transmission Fluid Change:
Every 100 operating hours or annually (refer to manual for specific gearbox oil).
Pvt Belt Inspection:
Every 25-50 operating hours for wear and cracks. Replacement recommended based on wear indicators.
Engine Oil:
2-stroke oil meeting API TC or JASO FD specifications (ratio: 50:1 typically).
Gearbox Oil:
Polaris specific gearcase lubricant or equivalent SAE 75W-90 Synthetic Gear Oil (capacity approximately 0.5-0.7 liters).
Brake Fluid:
DOT 3 or DOT 4 Hydraulic Brake Fluid.
Coolant:
Ethylene glycol-based antifreeze/coolant mixture (50/50 ratio).
Common Wear Items:
PVT belt, brake pads, suspension bushings, tie rod ends, exhaust gaskets.
Engine Tuning:
Carburetor tuning can be sensitive to altitude and temperature; require precise adjustments. Spark plug fouling can occur if mixture is too rich.
Drivetrain Maintenance:
Regular lubrication of U-joints and driveline components is crucial to prevent premature wear.
Manufacturer:
Polaris Industries Inc.
Brand Focus:
Polaris is a well-established manufacturer of powersports vehicles, including ATVs, snowmobiles, and side-by-sides.
Atv Lineup:
The 6x6 platform has been a significant part of Polaris's utility ATV offering, providing enhanced off-road capability.
Production Era:
The 1995 model falls into an era where Polaris was refining its ATV technology and expanding its utility segment.
Manufacturing Location:
USA (Polaris production facilities).
