Polaris ATV 400 4x4 1985-1995 Workshop Manual

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Taper: Atv

Distributeur:

UGS: 56982

Mots clés: 1985 1986 1987 1988 1989 1990 1991 1992 1993 1994 1995 400 4x4 ATV Misc Polaris Powersports

Variantes de produits

Description

The Polaris ATV 400 4x4, produced between 1985 and 1995, represents a robust and capable all-terrain vehicle designed for demanding off-road use. This model is characterized by its reliable 2-stroke, single-cylinder engine, typically around 300-400cc, and an air-cooled system, delivering approximately 20-25 horsepower. Its engineering emphasizes durability and performance, featuring a shaft-driven 4WD system with selectable engagement, an automatic CVT transmission with Hi/Lo range and reverse, and hydraulic disc brakes for effective stopping power. The ATV 400 4x4 was a significant step in Polaris's ATV development, offering enhanced traction and utility for its intended users. This comprehensive workshop repair manual provides essential guidance for the diagnosis and repair of the Polaris ATV 400 4x4. It covers a wide array of systems, including detailed procedures for engine mechanics, transmission and drivetrain, chassis and suspension, brakes, and the electrical system. The manual includes instructions for routine maintenance, disassembly and assembly of major components, and troubleshooting common issues such as carburetor fouling and CVT belt wear. This resource is invaluable for ATV owners, home mechanics, and independent repair shops seeking to maintain and repair their vehicles, offering in-depth technical information that far exceeds the scope of an owner's manual.

🏷️ Basic Information

Identification

Make:

Polaris

Model:

ATV 400 4x4

Model Variant:

Generation

Production Years:

1985-1995

👋 Introduction

Market Position

Target User:

ATV owners, home mechanics, independent repair shops

Value Proposition:

Essential tool for maintaining and repairing Polaris 400 4x4 ATVs from 1985-1995, saving on dealership service costs.

Competitive Analysis

Vs Owner Manual:

Significantly more in-depth than an owner's manual, focusing on repair procedures rather than basic operation.

Key Features

Diagnostic Focus:

Emphasis on identifying and resolving mechanical and electrical issues.

Comprehensiveness:

Covers all major systems for the specified model range.

📋 Manual Details

Coverage Areas

Manual Type:

Workshop Repair Manual

Primary Purpose:

Diagnosis and repair of vehicle-related problems, recommended repair/maintenance procedures

Page Count

Estimated Page Count:

Varies by specific edition, typically 300-600 pages for comprehensive workshop manuals of this era

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine Mechanics:

Engine overhaul, cylinder head, pistons, crankshaft, lubrication, cooling system, fuel system, ignition system

Transmission Drivetrain:

Gearbox, clutch, drive shafts, differentials, 4-wheel drive system operation and repair

Chassis Suspension:

Front and rear suspension, steering system, shock absorbers, control arms, bushings

Brakes:

Brake system inspection, hydraulic components, brake pads, rotors, calipers, bleeding procedures

Electrical System:

Wiring diagrams, lighting, battery, starter, alternator, ignition switch, sensors, fuses, relays

Bodywork Frame:

Body panel removal/installation, frame inspection, fenders, seat, handlebars

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, spark plug checks, lubrication points, air filter cleaning/replacement

Troubleshooting:

Diagnostic charts, common problem identification, step-by-step fault finding

Repair Procedures:

Detailed, step-by-step instructions for component removal, repair, and reinstallation

Disassembly Assembly:

Complete breakdown and reassembly instructions for major components and systems

Technical Depth

Depth Of Coverage:

Comprehensive, covering routine maintenance to complete engine and drivetrain rebuilds

Diagnostic Capabilities:

Includes diagnostic flowcharts and specifications for identifying and resolving mechanical and electrical issues

📊 Manual Specifications

File Format

File Type:

Portable Document Format (PDF)

Searchability:

Typically text-searchable, allowing for quick finding of specific topics or keywords

Print Quality

Print Readability:

High-resolution, suitable for printing individual pages or the entire manual

Binding Type

Binding:

N/A (Digital Download)

Paper Type

Paper Quality:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Typically a 2-stroke, single-cylinder engine

Displacement:

Around 300-400cc, specific displacement varied slightly across the years and sub-models (e.g., often referred to as the 'XPL 400' or similar)

Cooling System:

Air-cooled

Performance

Horsepower Range:

Approx. 20-25 HP (figures varied by specific year and tuning)

Torque Range:

Approx. 25-30 lb-ft (figures varied)

Fuel System

Carburetion:

Single carburetor (e.g., Mikuni VM series common)

Fuel Type:

Unleaded gasoline

Ignition System

Ignition Type:

CDI (Capacitor Discharge Ignition)

🔧 Transmission

Standard

Transmission Type:

Automatic (CVT - Continuously Variable Transmission) with Hi/Lo range and Reverse

Optional

Manual Transmission:

Not typically offered for this model

Features

Drive System:

Shaft drive to all four wheels, with selectable 2WD/4WD engagement

Differential Lock:

May feature a locking front differential on certain sub-models or years

📐 Dimensions

Exterior

Length:

Approx. 75-80 inches (Varies by specific model/year)

Width:

Approx. 40-45 inches (Varies by specific model/year)

Height:

Approx. 45-50 inches (Varies by specific model/year)

Weights

Dry Weight:

Approx. 450-550 lbs (Varies by specific model/year)

Towing Capacity:

Typically rated for light towing, consult specific model documentation

Cargo

Rack Capacity:

Front and rear racks capable of carrying moderate loads (e.g., 25-50 lbs front, 50-75 lbs rear)

🛡️ Safety Features

Ratings

Crash Safety Rating:

N/A (ATVs are not typically crash-tested by regulatory bodies like NHTSA)

Active Features

Braking System:

Hydraulic disc brakes (front and rear)

Suspension Stability:

Independent front suspension (IFS) and swingarm rear suspension (on later models) contribute to stability.

Passive Features

Roll Over Protection:

Not equipped with standard roll-over protection structures (ROPS); operator awareness and safe riding practices are paramount.

Lighting:

Headlights and taillight for visibility.

💡 Technology Features

Infotainment

Display Features:

Basic LCD display for speed, odometer, trip meter, and gear indicator.

Driver Assistance

Traction Control:

No electronic traction control; relies on mechanical 4WD system.

Connectivity

Connectivity Features:

🔧 Maintenance

Service Intervals

Engine Oil Change:

Every 50-100 operating hours or annually, whichever comes first (consult manual for exact spec).

Air Filter Cleaning:

Inspect and clean every 20-40 operating hours, replace as needed.

Spark Plug Inspection:

Inspect and gap every 100 operating hours.

Fluid Specifications

Engine Oil Type:

Typically SAE 10W-40 or 20W-50 motorcycle-specific or ATV engine oil meeting API SG or higher specifications.

Gearcase Oil Type:

GL-4 or GL-5 gear oil, often SAE 75W-90 or 80W-90.

Brake Fluid Type:

DOT 3 or DOT 4 hydraulic brake fluid.

Known Issues

Carburetor Fouling:

Common issue with older 2-stroke engines, requiring regular cleaning and adjustment.

Cvt Belt Wear:

CVT belts can wear over time and require inspection and replacement.

Electrical Connections:

Corroded or loose electrical connections are a common cause of intermittent faults.

Suspension Bushings:

Worn suspension bushings can lead to handling issues and noise.

📚 Vehicle History

Brand Heritage

Polarisk History:

Polaris Industries, founded in 1954, has a long history of producing off-road vehicles, including snowmobiles and ATVs.

Model Evolution

Atv 400 Development:

The 400 4x4 model was a significant offering in Polaris's early ATV lineup, evolving from earlier two-wheel drive models and introducing key 4WD capabilities. It paved the way for more advanced models.

Production

Manufacturing Location:

Primarily manufactured in the United States by Polaris Industries.

🏆 Awards & Recognition

Recognitions

Industry Awards:

While specific awards for this model may not be widely documented, Polaris ATVs of this era were generally well-regarded for their performance and 4WD capabilities in the utility ATV market.

Ratings

Consumer Satisfaction:

Based on owner feedback from the period, generally positive for its intended utility use.