Target Audience:
Primarily professional technicians, but also suitable for experienced ATV enthusiasts undertaking their own maintenance and repairs.
Value Proposition:
Provides essential, in-depth technical knowledge for maintaining and repairing the 1996 Polaris ATV 400 6x6, enabling cost-effective upkeep and maximizing vehicle longevity.
Manual Uniqueness:
Focuses specifically on the 1996 model year and the 6x6 configuration, offering granular detail often absent in broader ATV manuals.
Instant Access:
Available for immediate download, allowing users to access critical information without delay.
Detail Orientation:
Emphasizes comprehensive data, including diagrams, specifications, and procedures, as stated in the product description.
Engine Mechanical:
Disassembly, inspection, assembly, and testing of engine components (cylinder, piston, crankshaft, connecting rod, valves, camshaft).
Engine Fuel System:
Carburetor (Mikuni VM series likely) identification, adjustment, cleaning, and rebuild procedures; fuel pump operation and service.
Engine Ignition System:
CDI ignition system troubleshooting, component testing (coil, stator, ignition module), spark plug specifications.
Cooling System:
Radiator, coolant hoses, thermostat, water pump maintenance and replacement; coolant specifications.
Transmission Gearbox:
Clutch operation, adjustment, and replacement; gearbox disassembly, inspection, and reassembly; gear shift mechanism service; differential maintenance.
Drivetrain Axles:
Front and rear driveshaft service, U-joints inspection and replacement; front differential service; rear axle drive and lubrication.
Suspension Steering:
Front and rear suspension component inspection (shocks, springs, control arms); steering linkage adjustment and service; wheel bearing replacement.
Braking System:
Hydraulic brake system bleeding; brake caliper service; brake pad inspection and replacement; brake line inspection; parking brake adjustment.
Electrical System:
Wiring diagrams; battery testing and maintenance; starter motor service; lighting system troubleshooting; accessory wiring.
Frame Chassis:
Frame inspection for damage or corrosion; mounting bolt torque specifications; attachment points for components.
Bodywork Trim:
Removal and installation of plastic body panels, fenders, seat, handlebars; fastener identification.
Routine Maintenance:
Oil changes, filter replacements, air filter cleaning, spark plug checks, lubrication points, tire pressure checks, brake adjustments.
Troubleshooting Diagnostics:
Step-by-step diagnostic procedures for common issues related to starting, running, braking, and electrical systems.
Component Rebuild:
Detailed instructions for the complete disassembly, cleaning, inspection, replacement of parts, and reassembly of major engine and transmission components.
Assembly Disassembly:
Comprehensive instructions for removing and reinstalling all major assemblies and components, with torque specifications.
Electrical Testing:
Testing procedures for battery voltage, alternator output, ignition system components, starter draw, and lighting circuits using a multimeter.
Carburetor Tuning:
Specific instructions for adjusting idle speed, fuel-air mixture, and jetting for optimal performance and emissions.
Depth Level:
Comprehensive - Suitable for professional technicians and advanced DIY mechanics, covering all aspects from routine maintenance to complete engine and transmission overhauls.
Diagnostic Capability:
Includes detailed diagnostic flowcharts and troubleshooting trees for identifying and resolving mechanical and electrical issues.
Special Tool Requirements:
Identifies any special tools or equipment required for specific repair or diagnostic procedures.
Engine Type:
Likely a 2-stroke, single-cylinder, liquid-cooled engine, characteristic of Polaris ATVs of this era.
Displacement:
Approximately 398cc (specific bore and stroke would be detailed in the manual).
Bore X Stroke:
Actual figures not provided, but typical for this displacement class.
Compression Ratio:
Specific ratio not provided, but essential for performance tuning and diagnostics.
Horsepower:
Estimated 28-32 HP (typical for this engine size and type in 1996).
Torque:
Torque figures not provided but would be critical for understanding low-end pulling power.
Carburetor Model:
Likely a Mikuni VM series carburetor (e.g., VM34 or similar), specific model number detailed in the manual.
Fuel Type:
Unleaded gasoline, octane rating specified in manual.
Fuel Tank Capacity:
Typical capacity around 3.7 gallons (14 liters), specific capacity detailed in manual.
Overall Length:
Approx. 95 inches (2413 mm) - specific dimensions detailed in manual.
Overall Width:
Approx. 46 inches (1168 mm) - specific dimensions detailed in manual.
Overall Height:
Approx. 43 inches (1092 mm) - specific dimensions detailed in manual.
Wheelbase:
Specific wheelbase not provided, but 6x6 configurations typically have longer wheelbases for stability.
Dry Weight:
Approx. 530 lbs (240 kg) - specific dry weight detailed in manual.
Ground Clearance:
Typically around 8-10 inches (203-254 mm), specific clearance detailed in manual.
Rack Capacity Front:
Approx. 100 lbs (45 kg) - specific capacity detailed in manual.
Rack Capacity Rear:
Approx. 200 lbs (90 kg) - specific capacity detailed in manual.
Towing Capacity:
Typically around 1,500 lbs (680 kg), specific towing capacity detailed in manual.
Atv Safety Standards:
Adheres to applicable ANSI/SVIA safety standards for ATVs of the era.
Braking System:
Hydraulic disc brakes on all wheels, providing strong stopping power and all-wheel braking capability.
Drive Modes:
Selectable 2WD, 4WD, and 6WD modes allow the rider to adapt traction to varying terrain.
Handlebars:
Wide handlebars for improved control and stability.
Chassis Design:
6x6 chassis provides enhanced stability and load-carrying capacity compared to 4x4 models.
Engine Oil Change:
Typically every 50-100 hours or annually, depending on usage. Specific interval and oil type detailed in manual.
Air Filter Cleaning:
Recommended every 25-50 hours or when visibly dirty. Manual will specify cleaning procedure and filter element type.
Spark Plug Replacement:
Recommended every 100-200 hours or as needed based on condition. Manual will provide correct plug type and gap.
Brake Fluid Change:
Recommended every 1-2 years to maintain optimal braking performance. Manual will specify fluid type (DOT 3 or DOT 4).
Engine Oil:
Likely a 2-stroke oil, pre-mix or oil injection system. Manual will specify exact oil type and ratio/viscosity (e.g., SAE 10W-30 or specific 2T oil).
Transmission Fluid:
Specific transmission fluid type and capacity would be detailed. Likely a gear oil or specific ATV transmission fluid.
Coolant:
Antifreeze coolant mixture (ethylene glycol based) with distilled water. Manual will specify the correct type and mixture ratio.
Carburetor Fouling:
Common for older ATVs, requiring regular cleaning and adjustment.
Cvt Belt Wear:
CVT belts can wear over time and require periodic inspection and replacement to maintain performance.
Electrical Connections:
Corrosion or looseness in electrical connectors can cause intermittent issues.
Suspension Bushings:
Wear on suspension bushings can lead to noise and affect handling.
Polaris Atv History:
Polaris Industries has a long history of manufacturing ATVs, dating back to the late 1980s, known for innovation in the utility and off-road segments.
Atv 400 Series:
The 400cc class was a popular offering, with the 6x6 variant introduced to provide superior traction and carrying capacity for demanding work and recreational use.
1996 Features:
The 1996 model likely incorporated refinements from previous years, focusing on reliability and enhanced off-road performance.
Manufacturing Location:
Polaris ATVs are primarily manufactured in the United States.
