Segment:
Utility All-Terrain Vehicle (ATV)
Target User:
Workhorse users, recreational riders requiring significant hauling and off-road capability, agricultural and hunting applications.
Competitors:
Concurrent models from John Deere, Yamaha, Kawasaki, Can-Am, Suzuki in the 6x6 utility ATV segment.
Articulation:
6x6 drivetrain providing superior traction and load-carrying capacity in challenging terrain.
Utility Focus:
Designed for hauling, towing, and navigating difficult terrain, making it a versatile tool for work and recreation.
Durability:
Known for robust construction and reliable performance in demanding conditions.
Primary Coverage:
All aspects of service, repair, and maintenance for Polaris ATV 400 6x6 (1996-1998)
Specific Systems:
Engine, drivetrain, suspension, steering, brakes, electrical, chassis, bodywork
Estimated Page Count:
Detailed page count not provided in product information, but typical workshop manuals of this era range from 300-600 pages.
Type:
Workshop Service Manual / Repair Manual
Language:
English (presumed, standard for Polaris service documentation)
Engine Mechanical:
Engine removal/installation, cylinder head, pistons, crankshaft, valve train, lubrication system, cooling system, compression testing, engine diagnostics.
Fuel System:
Carburetor disassembly, cleaning, adjustment, fuel pump, fuel lines, fuel filter, fuel tank.
Ignition System:
Ignition coil, spark plug, CDI unit, timing, troubleshooting.
Drivetrain Transmission:
Automatic transmission (PVT - Polaris Variable Transmission) operation, clutch service, belt replacement, gearcase lubrication, differential service (front and rear), driveshafts, CV joints.
Suspension Steering:
Front and rear suspension components, shock absorbers, A-arms, bushings, wheel bearings, steering column, tie rods, ball joints, steering linkage.
Braking System:
Hydraulic brake system, brake calipers, brake pads, brake discs, master cylinder, brake fluid flush and bleeding, parking brake.
Electrical System:
Battery, charging system (stator, regulator/rectifier), starter motor, lighting system, wiring diagrams, fuses, relays, switches, instrument cluster.
Chassis Frame:
Frame inspection, welding, component mounting.
Bodywork Plastics:
Fender removal/installation, seat, handlebars, body panel repair and replacement.
Routine Maintenance:
Oil changes, filter replacements, spark plug checks, air filter cleaning/replacement, chain/belt adjustments, lubrication points.
Troubleshooting:
Diagnostic charts for common starting, running, and electrical issues, symptoms and causes analysis.
Major Repairs:
Engine overhauls, transmission rebuilds, suspension component replacement, brake system overhauls, electrical component replacement.
Component Disassembly Reassembly:
Detailed step-by-step instructions for taking apart and putting back together all major vehicle systems and components.
Torquing Specifications:
Essential torque values for critical fasteners across all systems, ensuring proper assembly and preventing component failure.
Depth:
Comprehensive; covers basic maintenance to complete engine and transmission rebuilds, including detailed diagnostics and specifications.
Diagnostic Capability:
Includes troubleshooting guides, symptom-to-cause charts, and diagnostic procedures to identify and resolve performance issues.
Rebuild Procedures:
Detailed instructions for rebuilding key components such as the engine and transmission, suitable for experienced mechanics.
Type:
4-stroke, liquid-cooled, SOHC
Displacement:
377cc (approx.) - Specific engine code/variant would provide exact displacement.
Bore X Stroke:
Not specified in product info, but typical for this era's Polaris engines.
Compression Ratio:
Not specified in product info.
Power Output:
Estimated 20-25 HP (typical for this displacement and application).
Torque Output:
Not specified in product info.
Carburetion:
Single Mikuni carburetor (likely 36mm or 40mm) - Specific model number would be in the manual.
Ignition:
CDI (Capacitor Discharge Ignition)
Fuel Type:
Unleaded gasoline (minimum 87 octane recommended)
Fuel Tank Capacity:
Approximately 4 gallons (15 liters) - Verifiable in manual.
Type:
Polaris Automatic Variable Transmission (PVT) with shaft drive.
Gear Selection:
High (H), Low (L), Neutral (N), Reverse (R), Park (P).
Drive System:
6WD with on-demand engagement for all six wheels, and locking front differential.
Transmission Options:
None for this model (PVT was standard).
Clutch Type:
Centrifugal clutch with drive and driven pulleys.
Belt Service:
Crucial component requiring regular inspection and replacement as per manual recommendations.
Length:
Approximately 100-110 inches (254-279 cm) - Exact length varies slightly by year and configuration.
Width:
Approximately 48-52 inches (122-132 cm).
Height:
Approximately 45-50 inches (114-127 cm).
Rack Capacity Front:
Approx. 100 lbs (45 kg).
Rack Capacity Rear:
Approx. 200-400 lbs (90-180 kg) - Verifiable in manual.
Dry Weight:
Approximately 600-700 lbs (272-318 kg).
Towing Capacity:
Typically rated around 1,000-1,500 lbs (454-680 kg).
Ground Clearance:
Approximately 9-11 inches (23-28 cm).
Crash Safety:
ATVs are not subject to the same crash test ratings as passenger vehicles. Safety relies on operator skill and adherence to guidelines.
Braking System:
Hydraulic disc brakes on all wheels for consistent stopping power.
Traction Control:
6x6 drivetrain provides enhanced traction in slippery conditions; locking front differential for extreme grip.
Handlebars:
Designed for ergonomic control and stability.
Lighting:
Headlights and taillight for visibility.
Operator Training:
Manual will emphasize safe operating practices, protective gear, and terrain awareness.
Engine Oil Change:
Every 50-100 operating hours or annually, whichever comes first (refer to manual for precise intervals).
Transmission Oil Change:
Annually or every 100-200 operating hours, depending on usage severity.
Air Filter Cleaning:
Frequent cleaning in dusty conditions, typically every 20-40 operating hours.
Spark Plug Inspection:
Check every 50 operating hours, replace as needed.
Pvt Belt Inspection:
Inspect for wear, cracks, and delamination every 50-100 operating hours. Replacement is critical for performance and preventing damage.
Engine Oil:
Polaris Premium 4 Synthetic 0W-40 or equivalent SAE 0W-40 API SG or higher (verify exact spec in manual).
Transmission Gearcase Oil:
Polaris 2W-40 Synthetic Gearcase Oil or equivalent SAE 0W-40 (verify exact spec in manual).
Brake Fluid:
DOT 3 or DOT 4 Hydraulic Brake Fluid.
Coolant:
Ethylene Glycol based antifreeze (50/50 mix with distilled water recommended).
Grease Points:
Regularly lubricate suspension pivot points, steering components, and driveshaft splines with a high-quality multi-purpose grease.
Common Wear Items:
PVT belt, wheel bearings, tie rod ends, ball joints, brake pads, and suspension bushings due to off-road use.
Potential Problems:
Carburetor adjustments can be sensitive to altitude and temperature; water intrusion into the PVT housing if seals are compromised.
Electrical Connections:
Corrosion on electrical connectors, especially in wet environments, can cause intermittent issues.
Polaris History:
Polaris Industries, founded in 1954, has a long history of producing off-road vehicles, snowmobiles, and powersports equipment, known for innovation and durability.
Atv Development:
The 6x6 models were developed to offer enhanced traction and load-carrying capabilities beyond traditional 4x4 ATVs, leveraging Polaris's engineering expertise in the powersports market.
400 Series:
The 400cc engine platform was a common and reliable workhorse for Polaris in this era, used across various ATV models.
Manufacturing Location:
Polaris vehicles are primarily manufactured in the United States.
