Positioning:
Essential resource for owners and technicians of 1996-1998 Polaris 400 6x6 ATVs seeking to perform maintenance, repairs, and diagnostics.
Competitors:
Generic repair guides, owner's manuals (less detailed), potentially specialized online forums.
Value Proposition:
Provides in-depth technical information, detailed diagrams, and step-by-step procedures to maintain and repair the specific Polaris ATV model, saving on labor costs.
Comprehensiveness:
Covers all major mechanical and electrical systems of the ATV.
Engine:
Engine disassembly, inspection, assembly, torque specifications, troubleshooting
Transmission:
Transmission operation, inspection, repair, clutch service
Drivetrain:
4WD/6x6 system operation, driveshafts, differentials, chain drive maintenance
Suspension:
Front and rear suspension components, shocks, bushings, alignment
Brakes:
Brake system components, hydraulic lines, master cylinder, caliper service, bleeding procedures
Electrical System:
Wiring diagrams, ignition system, charging system, lighting, battery service, starter, alternator
Fuel System:
Carburetor service, fuel pump, fuel lines, fuel tank maintenance
Cooling System:
Radiator, fan, thermostat, coolant specifications, flushing procedures
Chassis And Frame:
Frame inspection, welds, steering components, wheel bearings
Bodywork:
Body panel removal, installation, plastic components
Scheduled Maintenance:
Oil changes, filter replacements, spark plug service, air filter cleaning/replacement, lubrication points
Troubleshooting:
Diagnostic charts for common problems, symptom-based troubleshooting
Repair Procedures:
Step-by-step instructions for component disassembly, repair, and reassembly
Diagnostic Procedures:
Testing electrical components, checking engine compression, identifying system faults
Special Tools:
Identification and usage of specialized tools required for certain repairs
Depth:
Comprehensive, from basic maintenance to major overhaul and diagnostics
Searchability:
Likely text-searchable PDF, enabling quick navigation to specific topics
Quality:
High-resolution scans, suitable for printing individual pages or the entire manual
Binding:
N/A (Digital PDF download)
Paper Type:
N/A (Digital PDF download)
Engine Type:
2-stroke, liquid-cooled
Displacement:
Approximately 340cc - 398cc (specific to the 400 designation)
Bore X Stroke:
Specific data will be detailed in the manual.
Cylinder Arrangement:
Single Cylinder
Horsepower:
Typically in the range of 25-30 HP (exact figures in manual)
Torque:
Specific figures to be detailed in manual.
Carburetor:
Single Mikuni carburetor (specific model number to be found in manual)
Fuel Type:
Unleaded gasoline (specific octane rating in manual)
Fuel Delivery:
Gravity feed or fuel pump (depending on model variant, manual will specify)
Ignition Type:
CDI (Capacitor Discharge Ignition)
Cooling Method:
Liquid-cooled
Oil Type:
2-stroke engine oil (specific API/JASO rating and mix ratio in manual)
Transmission Type:
Automatic (CVT - Continuously Variable Transmission)
Drive System:
Shaft drive to all 6 wheels (6x6)
Gear Selection:
High, Low, Neutral, Reverse
Clutch:
Drive and driven clutches, belt maintenance and replacement procedures
Transmission Fluid:
Specific type and capacity for the CVT and differentials (detailed in manual)
Wheelbase:
Extended wheelbase due to 6x6 configuration (specific measurement in manual)
Overall Length:
Typical for a utility ATV of its era (specifics in manual)
Overall Width:
Typical for a 6x6 ATV (specifics in manual)
Dry Weight:
Significant due to 6x6 configuration (specifics in manual)
Towing Capacity:
Refer to manual for specific rating and towing recommendations
Rack Capacity:
Front and rear racks (specific weight limits in manual)
Safety Standards:
Adherence to ATV safety guidelines of the era.
Braking System:
Hydraulic disc brakes (front and rear), detailed service procedures in manual.
Lighting:
Headlights, taillight, brake light (wiring diagrams and bulb types in manual).
Hand Grips:
Ergonomic hand grips for control.
Footwells:
Wide footwells for rider stability.
Infotainment Features:
N/A (Utility ATV of this era typically focused on function over entertainment features).
Driver Assistance Features:
N/A (No electronic driver assistance systems typical for this model year).
Connectivity Features:
N/A (No electronic connectivity features).
Oil Change:
Typically every 20-30 hours of operation or annually, check manual for specifics.
Air Filter Service:
Check every 10-15 hours, clean or replace as needed. Manual will provide detailed procedures.
Spark Plug Service:
Inspect at regular intervals, replace as per manual recommendations.
Belt Inspection:
Inspect CVT belt for wear and damage at recommended intervals.
Engine Oil Type:
Polaris recommends specific 2-stroke oil meeting certain API/JASO standards. Refer to manual for exact part numbers/specifications.
Coolant Type:
Ethylene glycol-based antifreeze. Manual will specify capacity and type.
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid. Manual will specify.
Gear Oil Type:
Specific gear oil for differentials and transmission. Manual will list specifications.
Common Issues:
Overheating due to cooling system inefficiencies, carburetor tuning issues, CVT belt wear, front differential leaks (common on many 6x6 models of this era).
Preventative Maintenance:
Regular cleaning of radiator fins, proper coolant levels, and timely CVT belt replacement are crucial.
Polarishistory:
Polaris has a long-standing history in powersports, beginning with snowmobiles and expanding into ATVs in the late 1980s.
Atv400 Evolution:
The 400 6x6 series represented Polaris's commitment to utility-focused ATVs, offering enhanced traction and carrying capacity.
Production Period:
These models were produced during a period of significant growth and innovation for Polaris ATVs.
Manufacturing Location:
United States (Polaris manufacturing facilities)
