Market Segment:
Mid-range utility ATV with enhanced traction due to 6x6 drivetrain.
Competitors:
Similar models from John Deere, Yamaha (e.g., Big Bear 6x6), and Kawasaki during the mid-to-late 1990s.
Drivetrain Advantage:
6x6 drive system provides superior traction and load-carrying capability in challenging terrain.
Engine Power:
375cc engine offers a balance of power and efficiency for utility tasks.
Manual Benefit:
Empowers owners and technicians to perform repairs and maintenance, saving on professional service costs.
General Coverage:
Comprehensive repair, maintenance, and rebuilding procedures for Polaris Magnum 400 6x6 ATVs.
Estimated Pages:
N/A (Digital format, comprehensive coverage implies extensive content)
Type:
Digital Workshop Repair Manual
Delivery Format:
PDF Download
Engine:
Complete engine disassembly, assembly, diagnosis, and repair of the 375cc engine.
Transmission:
Automatic transmission (PVT), drive clutch, driven clutch, belt replacement, and drivetrain component service.
Drivetrain:
6x6 drive system, differentials, driveshafts, U-joints, and axle service.
Suspension:
Front and rear suspension systems, shocks, A-arms, bushings, and wheel bearing service.
Brakes:
Hydraulic brake system, brake calipers, master cylinder, brake lines, pads, and rotor service.
Steering:
Handlebar assembly, tie rods, steering shaft, and related components.
Electrical:
Ignition system, starting system, charging system, lighting, wiring diagrams, and component testing.
Fuel System:
Carburetor removal, cleaning, adjustment, fuel pump, fuel lines, and fuel tank service.
Cooling System:
Engine cooling system, radiator, fan, coolant flush and fill procedures.
Bodywork:
Fender removal, body panel repair, seat maintenance, and rack systems.
Maintenance:
Scheduled maintenance, oil changes, filter replacements, lubrication, and general upkeep.
Troubleshooting:
Diagnostic flowcharts and procedures for identifying and resolving common issues.
Repair:
Step-by-step instructions for component repair and replacement.
Rebuild:
Detailed instructions for complete engine, transmission, and component overhauls.
Diagnostics:
Advanced diagnostic techniques for electrical and mechanical systems.
Depth:
Professional-level, A-Z coverage from basic maintenance to complete engine and drivetrain rebuilding.
Engine Type:
4-stroke, liquid-cooled
Displacement:
375 cc (approx.)
Bore X Stroke:
N/A (Specifics typically found within the manual)
Horsepower:
N/A (Typically around 20-25 HP for this class of engine)
Torque:
N/A (Specifics typically found within the manual)
Fuel Delivery:
Carburetor (e.g., Mikuni)
Fuel Type:
Unleaded gasoline
Ignition System:
CDI (Capacitor Discharge Ignition)
Transmission Type:
Automatic Variable Transmission (PVT - Polaris Variable Transmission)
Drive System:
Shaft drive, 6x6 selectable
Gear Selection:
High, Low, Neutral, Reverse
Clutch System:
Centrifugal drive clutch and variable driven clutch with V-belt.
Length:
N/A (Specifics typically found within the manual or owner's manual)
Width:
N/A (Specifics typically found within the manual or owner's manual)
Height:
N/A (Specifics typically found within the manual or owner's manual)
Dry Weight:
Approx. 550-600 lbs (Varies slightly by year/trim)
Towing Capacity:
N/A (ATVs typically not rated for towing in the same way as vehicles)
Rack Capacity Front:
Approx. 50 lbs
Rack Capacity Rear:
Approx. 100 lbs
Safety Standards:
Designed to meet ANSI standards for ATVs.
Braking System:
Hydraulic disc brakes front and rear.
Lighting:
Headlights, taillight, brake light.
General Caution:
Always wear appropriate safety gear (helmet, eye protection, protective clothing) when operating.
Oil Change Engine:
Refer to manual (typically every 50-100 hours or annually)
Air Filter Cleaning:
Refer to manual (frequent cleaning recommended in dusty conditions)
Spark Plug Inspection:
Refer to manual (typically every 100-200 hours)
Engine Oil Type:
SAE 20W-50 motorcycle oil or equivalent meeting API SG/SH/SJ specifications (refer to manual for exact specs).
Transmission Fluid Type:
Polaris recommended gearcase lubricant or SAE 80W-90 GL-5 gear oil (refer to manual).
Coolant Type:
Ethylene glycol-based antifreeze/coolant (50/50 mix with distilled water).
Clutch Wear:
Wear on drive/driven clutches and belts is common due to operational use.
Carburetor Issues:
Carburetors can be prone to clogging if fuel is not fresh or if the machine sits for extended periods.
Suspension Bushings:
Rubber bushings in suspension and A-arms can wear over time, leading to looseness.
Drive Chain Tension:
Maintaining proper drive chain tension is crucial for longevity (if applicable, though shaft drive is prevalent).
Manufacturer:
Polaris Industries, a long-standing manufacturer of powersports vehicles.
Magnum Series:
The Magnum line was a popular utility ATV offering from Polaris, known for its robust design and capability.
6X6 Introduction:
Polaris was an early pioneer in the 6x6 ATV segment, offering increased traction and versatility.
Production Period:
1996-1998, indicating a stable production run for this configuration.
