Polaris ATV 400 6x6 1985-1995 Workshop Manual

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The ATV 400 6x6, produced between 1985 and 1995, stands as a testament to a pioneering spirit in the utility all-terrain vehicle market. Engineered for robust performance and exceptional traction,...

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Taper: Atv

Distributeur:

UGS: 56984

Mots clés: 1985 1986 1987 1988 1989 1990 1991 1992 1993 1994 1995 400 6x6 ATV Misc Polaris Powersports

Variantes de produits

Description

The ATV 400 6x6, produced between 1985 and 1995, stands as a testament to a pioneering spirit in the utility all-terrain vehicle market. Engineered for robust performance and exceptional traction, this model excels in demanding off-road conditions and heavy-duty tasks, thanks to its distinctive 6x6 drivetrain. Known for its ruggedness and capability, the ATV 400 6x6 was designed to provide reliable service for work and recreation, solidifying a reputation for durable and innovative ATVs. This comprehensive workshop and service manual provides detailed guidance for the maintenance and repair of your ATV 400 6x6. Covering a wide array of systems including the engine, transmission, chassis, braking, and electrical components, the manual offers step-by-step procedures for everything from routine servicing and fluid changes to complex overhauls and troubleshooting. With clear diagrams, exploded views, and essential technical specifications, this manual is an indispensable resource for owners, mechanics, and technicians seeking to ensure the optimal performance and longevity of their vehicle.

🏷️ Basic Information

Identification

Make:

Polaris

Model:

ATV 400 6x6

Generation

Model Years:

1985-1995

Codes

Vin Decoder Scope:

Not applicable for this manual; covers a range of years.

👋 Introduction

Market Position

Segment:

Heavy-duty utility ATV segment.

Target User:

Owners, mechanics, and technicians performing maintenance and repairs.

Competitive Analysis

Competitors:

Other utility ATVs of the era, e.g., early Honda FourTrax, Yamaha Timberwolf.

Key Features

Vehicle Selling Points:

6x6 drivability for traction and load carrying, Polaris's reputation for ruggedness.

Manual Value Proposition:

Enables DIY repairs, cost savings, proper maintenance for longevity.

📋 Manual Details

Coverage Areas

Primary Coverage:

Workshop repair and maintenance for Polaris ATV 400 6x6 models.

Secondary Coverage:

Troubleshooting, diagnostics, specifications, diagrams.

Page Count

Estimated Pages:

Likely extensive; typical workshop manuals for this era are 300-600+ pages.

Manual Type

Type:

Workshop Manual / Service Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Powertrain:

Engine, transmission, drivetrain (6x6 system).

Chassis:

Frame, suspension (front and rear), steering.

Braking:

Brake system components, hydraulics, adjustment.

Electrical:

Ignition, lighting, charging system, starter, battery, wiring diagrams.

Fuel System:

Carburetor, fuel lines, fuel pump, tank.

Cooling System:

Radiator, fan, coolant (if applicable).

Exhaust System:

Muffler, pipes, gaskets.

Body And Frame:

Body panels, fenders, frame inspection and repair.

Procedures Included

Maintenance:

Scheduled maintenance, fluid changes, lubrication, filter replacement.

Troubleshooting:

Diagnosis of common problems, diagnostic flowcharts.

Repair:

Component disassembly, reassembly, and adjustment procedures.

Rebuilds:

Engine overhaul, transmission rebuild, carburetor rebuild.

Inspections:

Pre-ride checks, component wear inspections, safety checks.

Specifications Torque:

Torque specifications for critical fasteners.

Technical Depth

Level:

Comprehensive: Covers from basic maintenance to complete engine and transmission overhauls.

Diagnostics:

Detailed diagnostic procedures for electrical and mechanical issues.

Illustrations:

Includes diagrams, exploded views, and schematics.

📊 Manual Specifications

File Format

Type:

Searchability:

Typically searchable text within PDF.

Print Quality

Resolution:

High resolution for clear diagrams and text (expected for professional PDF).

Binding Type

Binding:

N/A (Digital PDF download)

Paper Type

Paper:

N/A (Digital PDF download)

⚙️ Engine Specifications

Primary Engine

Type:

2-stroke, piston-ported gasoline engine.

Displacement:

Approximately 300-340cc (specific variant dependent on exact model year within range).

Bore X Stroke:

Typical for this class: e.g., 70mm x 76mm (specifics in manual).

Cooling:

Liquid-cooled (common for this performance level).

Ignition:

CDI (Capacitor Discharge Ignition).

Performance

Horsepower:

Estimated 22-28 HP (typical for a 2-stroke of this displacement).

Torque:

Not typically published for ATVs of this era, but critical for low-end pull.

Fuel System

Carburetor:

Single barrel carburetor (e.g., Mikuni VM or similar).

Fuel Type:

Unleaded gasoline.

Oil Mixture:

2-stroke pre-mix or oil injection system (manual will specify).

🔧 Transmission

Standard

Type:

Automatic (CVT - Continuously Variable Transmission).

Drive System:

6x6 (all-wheel drive), with selectable 2WD/4WD/6WD.

Features

Gear Reduction:

High and low range gear selection (typical for utility ATVs).

Transmission Fluid:

Specific CVT fluid or gear oil (manual to specify).

📐 Dimensions

Exterior

Length:

Approx. 70-80 inches (specifics vary by year).

Width:

Approx. 40-45 inches.

Height:

Approx. 40-45 inches.

Weights

Dry Weight:

Approx. 550-650 lbs (specific to configuration).

Ground Clearance:

Approx. 6-8 inches.

🛡️ Safety Features

Ratings

Safety Standards:

Industry standards for ATVs of the era; specific agency ratings less common.

Active Features

Braking System:

Hydraulic disc brakes (front and rear), often drum brakes on rear wheels in early models.

Passive Features

Frame Design:

Steel frame providing structural integrity.

Lighting:

Headlights, taillight, brakelight.

💡 Technology Features

Infotainment

Features:

Basic; primarily functional instrumentation (speedometer, odometer, warning lights).

Driver Assistance

Features:

None in the modern sense; reliance on mechanical systems and rider skill.

Connectivity

Features:

Not applicable.

🔧 Maintenance

Service Intervals

Oil Change Engine:

e.g., Every 50 hours or annually for 2-stroke models (details in manual).

Air Filter Cleaning:

Frequent checks and cleaning/replacement based on operating conditions (e.g., every 25 hours).

Spark Plug Replacement:

e.g., Annually or every 100 hours.

Cv Belt Inspection:

Regular inspection for wear and damage.

Fluid Specifications

Engine Oil:

Specific 2-stroke engine oil (e.g., Polaris Premium 2-Stroke Oil) or specified pre-mix ratio.

Transmission Fluid:

Manual will specify appropriate gear oil or CVT fluid (e.g., SAE 80W-90 gear oil for differentials if applicable).

Coolant:

Ethylene glycol-based antifreeze mixture (specific type and ratio in manual).

Known Issues

Common Wear Items:

CVT belt failure, carburetor gumming/fouling, rear suspension wear, braking component wear.

2 Stroke Care:

Importance of proper fuel/oil mixture, avoiding carbon buildup, regular decarbonization.

📚 Vehicle History

Brand Heritage

Polaris Atv Legacy:

Polaris was a pioneer in the ATV market, known for its innovative 6x6 designs and utility focus.

Model Evolution

400 6X6 Development:

Evolved from earlier Polaris models, emphasizing increased traction and load capacity for work and recreation.

Production

Manufacturing Era:

1985-1995 marked a significant period of development and sales for this model line.

🏆 Awards & Recognition

Recognitions

Industry Impact:

Polaris's 6x6 models were highly regarded for their off-road capability and utility in their prime.

Ratings

Consumer Reviews:

Generally positive for ruggedness and traction, with typical 2-stroke maintenance demands.

Certifications

Safety Certification:

Compliant with relevant national ATV safety guidelines of the period.