Market Position:
The Polaris ATV 400 2x4 from the mid-1990s was positioned as a capable and versatile utility and recreational ATV, catering to a broad range of users from trail riding to light work tasks.
Competitors:
Competed with other manufacturers' mid-size utility ATVs of the era, such as models from Honda, Yamaha, Kawasaki, and Suzuki, often focusing on Polaris's reputation for power and robust build.
Key Features:
Two-wheel drive configuration, liquid-cooled engine, comfortable suspension for its time, utility-focused design with racks, and a reputation for reliability.
Target Audience:
Enthusiasts and owners seeking to perform maintenance, repairs, and diagnostics on their 1994-1995 Polaris ATV 400 2x4. Also valuable for mechanics and technical service departments.
Engine Systems:
Engine assembly, disassembly, tuning, troubleshooting, lubrication, cooling system, fuel system (carburetor, fuel pump), ignition system, exhaust system.
Transmission Drivetrain Systems:
Clutch, gearbox, drive shafts, differential (if applicable), final drive, maintenance, repair, and troubleshooting.
Chassis Suspension Steering:
Front and rear suspension components, shock absorbers, springs, control arms, steering system components, steering column, tie rods, alignment procedures.
Braking Systems:
Hydraulic brake system, brake calipers, master cylinder, brake lines, brake pads, brake discs, bleeding procedures, maintenance, and repair.
Electrical Systems:
Wiring diagrams, charging system (stator, regulator/rectifier), starting system (starter motor, solenoid), lighting system, ignition system, battery, fuses, switches, troubleshooting electrical faults.
Bodywork Frame:
Frame inspection and repair, body panel removal and installation, seat, fenders, handle bars, graphics, plastics.
Maintenance Procedures:
Routine maintenance tasks, oil changes, filter replacements, spark plug checks, air filter cleaning/replacement, lubrication points, battery maintenance.
Diagnostic Procedures:
Troubleshooting guides for common problems, diagnostic charts, symptom-based troubleshooting, fault finding for engine, electrical, and mechanical issues.
Repair Procedures:
Step-by-step instructions for component removal, disassembly, inspection, repair, reassembly, and installation for all major systems.
Technical Specifications:
Detailed specifications for all components, including torque values, clearances, tolerances, fluid capacities, and electrical specifications.
Technical Depth:
Full factory-level repair and maintenance procedures, suitable for professional mechanics and advanced DIY enthusiasts. Covers everything from basic adjustments to complete engine and transmission rebuilds.
File Format:
PDF (Portable Document Format)
Print Quality:
High resolution, ensuring clarity of text, diagrams, and illustrations when printed.
Binding Type:
N/A (Digital download - user printable)
Paper Type:
N/A (Digital download - user printable)
Searchable Text:
Likely includes searchable text for quick navigation to specific topics or components.
Completeness:
Complete official factory service repair manual, encompassing all aspects of maintenance and repair.
Engine Type:
Four-stroke, Liquid-cooled, Single-cylinder
Displacement:
Approximately 375cc to 400cc (exact figure often varied slightly by specific model designation, but 400 denotes the class)
Bore X Stroke:
Specifics typically detailed within the manual, crucial for rebuilds.
Compression Ratio:
Specifics typically detailed within the manual.
Horsepower:
Estimates range from 20-25 HP (actual figures vary and are often not explicitly advertised for utility ATVs).
Torque:
Torque figures are typically detailed within the manual and critical for understanding low-end pulling power.
Fuel Delivery:
Carburetor (likely a Mikuni or similar Japanese brand), with specific model number detailed in the manual.
Fuel Type:
Unleaded Gasoline (Octane rating as specified in manual)
Oil Type:
Specific SAE Viscosity grade and API service classification for engine oil provided in the manual (e.g., SAE 10W-40, API SG or higher).
Oil Capacity:
Engine oil capacity with filter change specified in the manual (e.g., approx. 1.5-2.0 liters).
Transmission Type:
Automatic CVT (Continuously Variable Transmission) with engine braking.
Gear Reduction Stages:
Specific gear reduction ratios for forward and reverse, detailed in the manual.
Clutch Type:
Centrifugal clutch mechanism within the CVT system.
Transmission Fluid Type:
Specific CVT fluid or appropriate gear oil as per Polaris specifications (detailed in manual).
Drive Modes:
Forward, Neutral, Reverse.
Length:
Specific dimensions (e.g., approx. 70-75 inches) would be found in the manual.
Width:
Specific dimensions (e.g., approx. 40-45 inches) would be found in the manual.
Height:
Specific dimensions (e.g., approx. 45-50 inches) would be found in the manual.
Front Rack Capacity:
Typically rated for a specified weight (e.g., 50-75 lbs).
Rear Rack Capacity:
Typically rated for a specified weight (e.g., 100-150 lbs).
Dry Weight:
Specific dry weight (e.g., approx. 450-500 lbs) detailed in the manual.
Ground Clearance:
Typical ground clearance for utility ATVs of this era (e.g., 8-10 inches) would be specified.
Atv Safety Standards:
Adherence to industry safety standards of the time, with specific warnings and operation guidelines detailed in the manual.
Braking System Type:
Hydraulic disc brakes on front and rear wheels for reliable stopping power.
Engine Braking:
Integrated engine braking from the CVT system aids in controlled descents.
Handlebar Design:
Ergonomically designed handlebars with grip heaters (possibly optional) for control and comfort.
Lighting:
Headlights and taillight for visibility in various conditions.
Footwells:
Spacious and protected footwells with integrated floorboards for rider safety.
Engine Oil Change:
Recommended every 100 hours of operation or annually, whichever comes first. Specific interval detailed in the manual.
Air Filter Cleaning:
Recommended every 50 hours or more frequently in dusty conditions. Manual will specify exact procedure and frequency.
Spark Plug Inspection:
Recommended every 100 hours or annually. Manual will provide correct gap and type.
Brake System Inspection:
Regular inspection of brake pads, fluid level, and lines at recommended intervals (detailed in manual).
Suspension Lubrication:
Grease points on suspension and steering components should be serviced regularly as per manual recommendations.
Engine Oil Spec:
SAE 10W-40 API SG or higher recommended. Refer to manual for precise specifications and capacity.
Brake Fluid Spec:
DOT 3 or DOT 4 Hydraulic Brake Fluid. Manual will specify correct type and bleeding procedure.
Coolant Spec:
Ethylene glycol-based antifreeze with corrosion inhibitors. Manual will specify mixture ratio and capacity.
Carburetor Tuning:
Carburetors on older ATVs can sometimes require periodic cleaning and adjustment due to fuel deposits.
Cvt Belt Wear:
CVT drive belts can wear over time and require replacement to maintain performance. Manual will specify belt part number and replacement procedure.
Electrical Connections:
Corrosion or loosening of electrical connectors can cause intermittent issues. Manual's wiring diagrams are crucial for troubleshooting.
Polarishistory:
Polaris has a long-standing history in powersports, originating in the mid-20th century and growing to become a major manufacturer of ATVs, snowmobiles, and motorcycles.
Atv Evolution:
The ATV 400 2x4 represents a period of significant development in Polaris's ATV lineup, building on earlier models and introducing refinements in performance, comfort, and durability.
Manufacturing Era:
Mid-1990s (1994-1995 model years).
Production Location:
Typically manufactured in the United States by Polaris Industries.
