Category:
All-Terrain Vehicle (ATV)
Segment:
Heavy-duty, multi-purpose utility ATV
Competitors Era:
Polaris faced competition from manufacturers like Yamaha (Grizzly), Honda (FourTrax), and Suzuki (King Quad) in the utility ATV segment during the mid-to-late 1990s.
Six Wheel Drive:
The defining feature, offering superior traction and load-carrying capability in challenging terrain compared to 4x4 models.
Utility Focus:
Designed for work, hunting, and off-road exploration rather than sport riding.
Powertrain:
Engine, transmission, drive axles, clutch, exhaust system
Chassis:
Suspension (front and rear), steering system, braking system, frame and body construction
Electrical:
Ignition system, charging system, lighting, starting system, wiring diagrams, instruments and controls
Fuel System:
Fuel tank, fuel pump, carburetor (likely specific model), fuel lines
Cooling System:
Radiator, fan, thermostat, coolant hoses, water pump
Lubrication System:
Oil pump, oil filter, oil pan, lubrication points
Maintenance:
Scheduled maintenance, oil changes, filter replacements, lubrication, general upkeep
Engine Repair:
Engine disassembly, inspection, reassembly, component replacement (pistons, rings, valves, gaskets)
Transmission Repair:
Transmission inspection, clutch adjustment/replacement, gear engagement, torque converter service (if applicable)
Brake Service:
Brake pad replacement, rotor resurfacing/replacement, brake caliper service, bleeding brake lines
Suspension Service:
Shock absorber replacement, spring inspection, ball joint and tie rod end service, wheel bearing replacement
Electrical Troubleshooting:
Diagnostic procedures for charging system, ignition system faults, lighting issues, starter problems
Carburetor Adjustment And Rebuild:
Detailed steps for tuning and overhauling the carburetor for optimal performance and fuel efficiency.
Troubleshooting Guides:
Systematic diagnostic trees for common and uncommon issues, symptom-based problem solving.
Diagnostic Codes:
Explanation of any diagnostic trouble codes or fault indicators (if applicable to this model).
Depth:
Comprehensive (from basic maintenance to complete engine and transmission overhauls)
Diagnostic Capabilities:
Advanced diagnostics with detailed troubleshooting procedures and wiring diagrams.
Rebuild Procedures:
Detailed instructions for major component rebuilds, including engine and transmission.
Engine Type:
2-stroke, liquid-cooled, single-cylinder
Displacement:
340cc to 400cc (Specific model year dependent, commonly around 340cc for early models and potentially larger for later ones, but the '400' in the name suggests this displacement class.)
Bore X Stroke:
Varies by specific 400cc engine variant, detailed in manual.
Power Output:
Approx. 25-30 HP (Estimates, actual figures vary by year and tuning; manual will provide precise specs.)
Torque Output:
Approx. 28-32 lb-ft (Estimates, actual figures vary by year and tuning; manual will provide precise specs.)
Fuel Delivery:
Carburetor (likely Mikuni or Keihin, specific model detailed in manual)
Fuel Type:
Unleaded gasoline (91 octane recommended, refer to manual for exact octane rating)
Ignition System:
CDI (Capacitor Discharge Ignition)
Transmission Type:
Automatic (CVT - Continuously Variable Transmission)
Gear Selection:
High, Low, Neutral, Reverse
Drive System:
6x6 with selectable 4x4 engagement for front and rear driveshafts independently (or combined through differential). Specific engagement mechanism detailed in manual.
Clutch Type:
Automatic centrifugal clutch
Belt Drive:
CVT belt drive system with primary and secondary drive clutches.
Length:
Varies, typically around 80-90 inches (203-229 cm), precise measurements in manual.
Width:
Varies, typically around 45-50 inches (114-127 cm), precise measurements in manual.
Height:
Varies, typically around 40-45 inches (102-114 cm), precise measurements in manual.
Dry Weight:
Approx. 550-650 lbs (250-295 kg), specific weight varies by configuration.
Payload Capacity:
Significant due to 6x6 configuration, often 500 lbs+ for racks and moderate towing capacity (detailed in manual).
Safety Standards:
ATV safety standards of the era; specific certifications not typically rated like automobiles.
Braking System:
Hydraulic disc brakes, likely on all wheels or select axles, detailed in manual.
Chassis Design:
Sturdy frame construction for stability and durability.
Operator Safety:
Emphasizes safe riding practices, use of protective gear (PPE) as per manufacturer guidelines.
Infotainment System:
Basic, typically limited to essential gauges (speedometer, odometer, warning lights) and controls. No advanced infotainment features like stereos or screens.
Driver Assistance Features:
None. Focus is on mechanical systems and operator control.
Connectivity Features:
None. This is a purely mechanical vehicle from an era before widespread digital connectivity in ATVs.
Oil Change Engine:
Typically every 50-100 operating hours or annually. Refer to specific interval charts in the manual.
Air Filter Cleaning Or Replacement:
Regular inspection (every 20-40 hours) and cleaning/replacement as needed, especially in dusty conditions.
Spark Plug Replacement:
Recommended at 100-150 operating hours or annually, specific plug type in manual.
Cv Boot Inspection:
Frequent inspection for tears or damage is crucial for drivetrain longevity.
Engine Oil:
Polaris recommends specific 2-stroke oil injection or pre-mix ratios. For the oil injection system, a high-quality 2-stroke synthetic or semi-synthetic oil meeting API-TC, JASO FD, or ISO-L-EGD standards is typically required. Manual will specify exact grade and capacity.
Coolant:
Ethylene glycol-based antifreeze mixture (50/50 with distilled water recommended). Specific type and capacity in manual.
Gearcase Oil:
Polaris Gearcase Lube or equivalent SAE 80W-90 hypoid gear oil for differentials and final drives. Manual will specify quantities.
Brake Fluid:
DOT 3 or DOT 4 hydraulic brake fluid (check manual for precise specification).
Carburetor Clogging:
Common in older vehicles due to fuel degradation, requires regular cleaning and proper fuel storage.
Cv Joint Wear:
Due to the demanding nature of 6x6 operation and potential for abuse, CV joints and boots can wear out. Regular inspection and proper maintenance are key.
Cooling System Maintenance:
Overheating can occur if the radiator is blocked or coolant levels are low. Regular flushing and inspection are recommended.
Drive Belt Wear:
CVT belts can stretch or break over time, especially under heavy load or if worn. Inspection and timely replacement are essential.
Polarish Heritage:
Polaris Industries is a long-standing American manufacturer known for its snowmobiles, ATVs, and UTVs, with a reputation for innovation and rugged off-road vehicles.
6X6 Development:
The 6x6 platform was a significant development in the ATV market, expanding capability for utility and work-related tasks. The 400 6x6 was a key model in this line.
Production Period:
Mid-to-late 1990s, with the product focusing on 1996-1998, but the platform existed earlier.
