Atv Segment:
Utility ATV, designed for work and moderate recreational use. The 6x6 configuration provides enhanced traction and load-carrying capabilities.
Competitive Landscape 1998:
Competed with other utility ATVs from brands like Yamaha (Kodiak), Honda (FourTrax), Suzuki (King Quad), and Kawasaki (Bayou). The 6x6 offered a distinct advantage in challenging terrain and hauling.
Vehicle Highlights:
6x6 drive system for superior traction, robust utility design, Polaris's well-established reputation in the ATV market.
Target Audience:
Professional ATV technicians, mechanics, and experienced DIY enthusiasts.
Value To Owner:
Enables owners to perform complex repairs and maintenance, saving money on dealership service and extending the vehicle's lifespan.
Engine Service:
Engine overhaul, disassembly, assembly, component testing, lubrication system, cooling system (if applicable), cylinder head, piston, crankshaft, camshaft, valve train.
Fuel System:
Carburetor tuning and overhaul (likely Mikuni or Keihin), fuel pump, fuel lines, fuel tank, fuel filter.
Drivetrain Transmission:
Automatic transmission (likely PVT - Polaris Variable Transmission), clutch operation, belt inspection and replacement, gearcase lubrication, drive shaft service, differential maintenance.
Suspension Steering:
Front and rear suspension component inspection and replacement, shock absorber service, steering linkage geometry, tie rod ends, steering column.
Braking System:
Hydraulic brake system diagnosis and repair, brake caliper service, brake pad replacement, master cylinder service, brake fluid specifications, bleeding procedures.
Electrical System:
Ignition system (CDI, stator, coil), starting system (starter motor, solenoid, battery), charging system (alternator/stator), lighting system, wiring diagrams, fuse/relay identification, troubleshooting electrical faults.
Bodywork Chassis:
Frame inspection, body panel removal and installation, seat assembly, racks, fenders, guards.
Cooling System:
Radiator service (if liquid-cooled), fan operation, coolant type and capacity.
Routine Maintenance:
Oil change intervals, oil filter part numbers, spark plug specifications, air filter cleaning/replacement, chain/belt tension adjustment, grease points.
Troubleshooting:
Diagnostic procedures for common and uncommon issues, fault finding charts, symptom-based diagnostics.
Disassembly Reassembly:
Step-by-step instructions for component removal and reinstallation, including torque specifications for critical fasteners.
Diagnostic Charts:
Systematic guides to identify and resolve malfunctions.
Wiring Diagrams:
Detailed electrical schematics for all vehicle systems.
Depth Of Coverage:
Comprehensive. Covers everything from basic adjustments and fluid changes to complete engine rebuilds, transmission overhauls, and complex electrical diagnostics.
Diagnostic Capabilities:
Advanced diagnostic procedures for ignition, fuel, electrical, and mechanical systems.
Rebuild Instructions:
Detailed instructions for rebuilding major components like the engine, transmission, and carburetor.
Print Quality Notes:
Typically high resolution, allowing for clear viewing and printing of diagrams, schematics, and text. Quality depends on the original source scan.
Binding Type Notes:
N/A (Digital PDF download).
Paper Type Notes:
N/A (Digital PDF download). For printed versions, original manuals often used heavy-duty, gloss-coated paper.
Search Functionality:
PDF format typically allows for text searching of keywords (e.g., 'carburetor,' 'spark plug').
Engine Type:
2-stroke, liquid-cooled, single-cylinder (likely).
Displacement:
Approximately 340cc - 400cc. Specific model designation suggests around 400cc.
Bore X Stroke:
Specifics not provided, but typical for this displacement range.
Compression Ratio:
Typical for 2-stroke performance, likely in the range of 6.5:1 to 7.5:1.
Horsepower:
Estimated 25-35 HP. Exact figures vary by tuning and specific engine variant.
Torque:
Adequate for pulling and utility tasks, exact figures not provided but optimized for low-end grunt.
Carburetor Type:
Single Carburetor, likely Mikuni VM34 or similar.
Fuel Type:
Unleaded gasoline (typically 87 octane minimum).
Oil Type:
2-stroke oil, mixed with fuel or via oil injection system (check specific model configuration).
Ignition System:
CDI (Capacitor Discharge Ignition).
Cooling Method:
Liquid-cooled.
Length:
Typically around 90-100 inches for this class of ATV.
Width:
Typically around 45-50 inches.
Height:
Typically around 45-50 inches.
Dry Weight:
Likely in the range of 600-700 lbs, reflecting the 6x6 configuration.
Ground Clearance:
Expect around 8-10 inches.
Front Rack Capacity:
Typically rated for 50-100 lbs.
Rear Rack Capacity:
Typically rated for 100-200 lbs.
Towing Capacity:
Often rated for 1000-1500 lbs.
Atv Safety Standards:
Adheres to relevant industry safety standards for ATVs of its era. Specific crash test ratings are not applicable to ATVs in the same way as passenger cars.
Braking System Type:
Hydraulic disc brakes on at least two axles, possibly all. The manual will detail precise configuration.
Handlebar Design:
Handguards often included for protection.
Footwells:
Integrated footwells with floorboards for rider safety.
Operator Safety:
Manual will emphasize the importance of wearing helmets, eye protection, protective clothing, and following safe riding practices.
Engine Oil Change:
Typically every 50-100 operating hours or annually. Manual will provide precise interval.
Spark Plug Replacement:
Refer to manual for specific mileage or hours. Typically every 100-200 hours.
Air Filter Maintenance:
Inspect and clean every 20-40 operating hours, replace as needed.
Transmission Fluid Change:
Check and change according to manual's recommendations, typically annually or every 100 hours.
Engine Oil Grade:
Likely SAE 10W-40 or 20W-50 for the engine (check manual for specific application).
Brake Fluid Type:
DOT 3 or DOT 4 hydraulic brake fluid. Manual will confirm.
Coolant Type:
Ethylene glycol-based antifreeze with corrosion inhibitors. Manual specifies ratio and type.
Gearcase Oil Type:
Specific gear oil, e.g., SAE 80W-90 or Polaris-specific gearcase lubricant. Manual is essential for this.
Common Wear Items:
Drive belts (PVT), wheel bearings, ball joints, tie rod ends, brake pads, exhaust components. The manual details inspection and replacement for these.
Engine Tuning:
Carburetor adjustments are common for optimal performance and starting, especially in varying altitudes or temperatures. Manual covers this.
Electrical Connections:
Corrosion in electrical connectors can be an issue on older ATVs; manual helps in tracing and cleaning.
Polaristimeline:
Polaris Industries was founded in 1954 and has been a significant innovator in the powersports industry, including ATVs, snowmobiles, and motorcycles.
Atv Development:
Polaris was one of the early pioneers in the ATV market, developing models that catered to both recreational and utility users. The 6x6 models were developed to offer superior traction and load capacity.
Powertrain Advancements:
Polaris engines and PVT systems evolved significantly through the 1990s, with continuous improvements in reliability and performance.
Model Production Era:
The 400 6x6 was part of Polaris's successful utility ATV lineup in the late 1990s.
