Polaris ATV 400 2x4 1985-1995 Workshop Manual

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The Polaris ATV 400 2x4, produced from 1985 to 1995, is a robust and practical all-terrain vehicle designed for utility and recreational use. Known for its dependable 400cc single-cylinder engine...

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Tipo: Atv

Proveedor:

SKU: 56981

Etiquetas: 1985 1986 1987 1988 1989 1990 1991 1992 1993 1994 1995 400 2x4 ATV Misc Polaris Powersports

Variantes de producto

Descripción

The Polaris ATV 400 2x4, produced from 1985 to 1995, is a robust and practical all-terrain vehicle designed for utility and recreational use. Known for its dependable 400cc single-cylinder engine and a simple, durable design, this two-wheel-drive ATV offered a reliable solution for various tasks and terrains. Its engineering emphasized ease of maintenance and a strong chassis, making it a workhorse in its class, competing with other prominent manufacturers of the era. The ATV 400 2x4 was built to withstand demanding conditions, solidifying its reputation as a pioneer in the ATV market. This comprehensive workshop manual provides complete repair and maintenance guidance for the Polaris ATV 400 2x4 across its production years. It covers all essential systems, including detailed procedures for engine mechanicals, fuel and ignition systems, transmission, drivetrain, brakes, suspension, steering, and the electrical system. The manual also offers in-depth troubleshooting advice, routine maintenance schedules, and component replacement instructions. With its extensive coverage of routine tasks to major overhauls, this manual serves as an indispensable resource for owners, mechanics, and technicians seeking to maintain and repair their vehicle efficiently and effectively.

🏷️ Basic Information

Identification

Make:

Polaris

Model:

ATV 400 2x4

Model Years Covered:

1985, 1986, 1987, 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995

Vehicle Type:

All-Terrain Vehicle (ATV)

Drive Type:

2x4 (Two-Wheel Drive)

👋 Introduction

Market Position

Original Target Market:

Utility and recreational ATV market, known for its ruggedness and practicality in its era.

Competitive Analysis

Contemporary Competitors:

Competed with models from Yamaha (e.g., Moto-4), Suzuki (e.g., QuadSport), and Honda (e.g., FourTrax) in the mid-size utility ATV segment.

Key Features Of Vehicle

Robust Chassis:

Designed for durability and off-road use, often featuring a robust steel frame.

Dependable Engine:

Known for its reliable 400cc class engine, offering a good balance of power and usability.

Simplicity Of Design:

Engineered for ease of maintenance and repair, a hallmark of Polaris ATVs from this period.

Manual Value Proposition

Problem Solving:

Aids in determining the cause of vehicle-related problems and provides recommended repair/maintenance procedures.

Diy Support:

Empowers owners and technicians with the knowledge to perform effective maintenance and repairs, saving time and money.

📋 Manual Details

Coverage Areas

General Coverage:

Complete workshop repair and maintenance

Page Count

Estimated Page Count:

Estimated 300-500 pages (typical for comprehensive workshop manuals of this era)

Manual Type

Type:

Workshop Manual / Service Manual / Repair Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Full engine teardown, inspection, assembly, tuning, valve adjustments, piston and cylinder work, crankshaft and connecting rod service.

Fuel System:

Carburetor disassembly, cleaning, adjustment, jetting information, fuel pump, fuel tank, fuel lines.

Ignition System:

CDI ignition system components, troubleshooting, timing, spark plug specifications.

Cooling System:

Radiator, fan, thermostat, coolant specifications, flushing procedures (if applicable to specific 400 2x4 variants).

Transmission:

Gearbox disassembly, inspection, reassembly, gear selection mechanisms, lubrication requirements.

Drivetrain:

Drive shaft, differential (if applicable), rear axle, wheel bearings, U-joints, maintenance and lubrication.

Brakes:

Hydraulic brake system, brake calipers, master cylinder, brake lines, pads/shoes replacement, bleeding procedures, rotor specifications.

Suspension:

Front and rear suspension components, shock absorbers, springs, bushings, alignment procedures, adjustments.

Steering:

Steering column, tie rods, steering linkage, wheel alignment, troubleshooting steering play.

Electrical System:

Wiring diagrams, battery, charging system (stator, regulator/rectifier), starter motor, lighting, switches, fuses.

Bodywork And Frame:

Body panel removal/installation, seat, fenders, handlebars, frame inspection, mounts.

Troubleshooting:

Diagnostic flowcharts, common problems and their solutions, symptom-based troubleshooting.

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, air filter cleaning/replacement, spark plug checks, lubrication points, chain/belt adjustment.

Major Repairs:

Engine rebuilds, transmission overhauls, suspension component replacement, brake system overhauls.

Diagnostics:

Systematic diagnosis of performance issues, electrical faults, and mechanical failures.

Component Replacement:

Step-by-step instructions for replacing virtually all wear items and serviceable components.

Specifications And Tolerances:

Detailed torque specifications, clearances, and measurements for all critical engine and chassis components.

Technical Depth

Depth:

Comprehensive, from basic user maintenance to full engine and transmission overhauls. Suitable for experienced DIY mechanics and professional technicians.

📊 Manual Specifications

File Format

Digital Format:

Print Quality

Readability:

High-resolution scans ensuring clear text and diagrams. Searchable text for easy navigation.

Binding Type

Binding:

N/A (Digital Download)

Paper Type

Paper Quality:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Single-cylinder, 4-stroke, OHV (Overhead Valve)

Displacement:

Approximately 400cc (specific bore/stroke may vary slightly by year within the range, but consistently around 400cc).

Bore X Stroke:

Typical for this era might be around 82mm x 75mm (actual figures should be verified in manual).

Cooling System:

Air-cooled (most common for this model/era, though liquid-cooled variants may exist and should be checked in the manual).

Performance

Horsepower:

Estimated 15-20 HP (specific output varies by year and tuning).

Torque:

Moderate torque output suitable for utility tasks and trail riding.

Fuel System

Carburetor Type:

Single carburetor (likely Mikuni or Keihin, e.g., VM series).

Fuel Type:

Unleaded gasoline

Ignition System

Ignition Type:

CDI (Capacitor Discharge Ignition)

🔧 Transmission

Standard

Transmission Type:

Automatic Transmission with High/Low range and Reverse

Drive Mechanism:

Shaft drive to rear differential

Optional

Clutch Type:

Torque converter automatic transmission

Features

Gear Selection:

Selector lever for Park, Reverse, Neutral, Drive (High/Low)

📐 Dimensions

Exterior

Length:

Approx. 75-80 inches (190-203 cm) (varies slightly by model year)

Width:

Approx. 40-45 inches (102-114 cm)

Height:

Approx. 40-45 inches (102-114 cm)

Weights

Dry Weight:

Approx. 450-500 lbs (204-227 kg)

Towing Capacity:

Typically around 1500 lbs (680 kg) for hitch-equipped models.

Ground Clearance:

Approx. 6-8 inches (15-20 cm) (varies by tire size and suspension).

🛡️ Safety Features

Ratings

Crash Test Ratings:

N/A (ATVs are not typically subjected to standardized crash tests like passenger vehicles).

Active Features

Braking System:

Hydraulic disc brakes front and rear, providing robust stopping power.

Throttle Governor:

May incorporate a throttle limiter or governor for controlled speed, especially for younger riders or specific models.

Passive Features

Lighting:

Headlights and taillights for visibility.

Handlebars:

Ergonomic handlebars with hand grips and control levers.

Footwells:

Aggressively treaded footwells for secure footing.

💡 Technology Features

Infotainment

Features:

N/A (Basic utility ATV, no complex infotainment systems).

Driver Assistance

Features:

N/A (No electronic driver assistance features typical of modern vehicles).

Connectivity

Features:

N/A (No connectivity features).

🔧 Maintenance

Service Intervals

Engine Oil Change:

Every 100 hours or annually, whichever comes first (typical interval).

Air Filter Cleaning:

Clean every 20-30 hours, replace as needed.

Spark Plug Inspection:

Inspect every 50 hours, replace as needed based on condition.

Gearbox Oil Change:

Every 200 hours or annually.

Fluid Specifications

Engine Oil Type:

SAE 20W-40 or 10W-40 motorcycle-specific or ATV oil (refer to manual for exact viscosity and API classification).

Engine Oil Capacity:

Approximately 1.5 - 2.0 liters (refer to manual for exact capacity).

Gearbox Oil Type:

Gear oil, e.g., SAE 80W-90 GL-4 (check manual for specific grade).

Brake Fluid Type:

DOT 3 or DOT 4 hydraulic brake fluid.

Known Issues

Carburetor Fouling:

Common issue with older carbureted engines; requires periodic cleaning and adjustment.

Electrical Connection Corrosion:

In humid or wet environments, electrical connections can corrode, leading to intermittent faults. Manual provides troubleshooting for these.

Suspension Component Wear:

Bushing and ball joint wear over time; manual details inspection and replacement procedures.

Drive Belt Wear:

If equipped with a CVT (Continuously Variable Transmission), belt wear is a maintenance item. However, the 400 2x4 often used a more conventional transmission. If CVT, belt inspection/replacement is critical.

📚 Vehicle History

Brand Heritage

Polariss Atv Legacy:

Polaris was an early pioneer in the ATV market, establishing a reputation for rugged, utility-focused machines.

Model Evolution

400 Series Development:

The 400cc engine was a popular displacement for Polaris, appearing in various iterations and chassis configurations throughout the late 80s and early 90s.

Production

Manufacturing Location:

Manufactured by Polaris Industries in the USA.

Production Run Significance:

This generation of Polaris ATVs solidified the brand's presence in the growing ATV market, known for their workhorse capabilities.

🏆 Awards & Recognition

Recognitions

Industry Awards:

N/A (Specific awards for this model are not widely documented; its reputation was built on practical performance and reliability).

Ratings

Consumer Satisfaction:

Generally high for its utilitarian capabilities and durability in demanding conditions during its production run.

Certifications

Safety Certifications:

Manufactured to meet applicable safety standards for ATVs of its era.