Polaris 400 6x6 1985-1995 Online Service Repair Manual

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Taper: Atv

Distributeur:

UGS: 52615

Mots clés: 1985 1986 1987 1988 1989 1990 1991 1992 1993 1994 1995 ATV Misc Polaris Polaris 400 6x6 Powersports

Variantes de produits

Description

This manual covers the 400 6x6 All-Terrain Vehicle (ATV) produced between 1985 and 1995. Renowned for its robust 6x6 drivetrain, the 400 6x6 offered exceptional traction and load-carrying capabilities, making it a versatile choice for utility tasks and off-road exploration. Its reliable two-stroke engine, combined with a durable chassis and automatic transmission with selectable 2WD, 4WD, and 6WD modes, established it as a capable machine in its market segment. The engineering quality focused on providing dependable performance in challenging terrains, a hallmark of utility ATV offerings during this period. This comprehensive service and repair manual provides detailed information essential for the maintenance and repair of your 400 6x6. It covers all major systems, including the engine, fuel system, drivetrain, suspension, brakes, and electrical system. Within its pages, you will find step-by-step procedures for routine maintenance, in-depth troubleshooting guides for common issues, and complete overhaul instructions for mechanical components. This manual is an invaluable resource for owners and technicians alike, ensuring the longevity and optimal performance of the vehicle through accurate and thorough guidance.

🏷️ Basic Information

Identification

Make:

Polaris

Model:

400 6x6

Model Variant:

All-Terrain Vehicle (ATV)

Year:

1985-1995

👋 Introduction

Market Position

Market Segment:

Utility ATV; positioned for off-road work, recreation, and utility tasks requiring robust 6-wheel drive capability.

Competitive Analysis

Competitors:

Competed against other utility ATVs of the era, emphasizing its unique 6x6 configuration for enhanced traction and load-carrying capacity.

Key Features

Distinctive Features:

6x6 drivetrain for superior traction in varied terrain, durable 2-stroke engine, reliable for work and exploration.

📋 Manual Details

Coverage Areas

General Coverage:

Comprehensive service and repair information for the Polaris 400 6x6 ATV across specified model years.

Page Count

Estimated Page Count:

Varies by specific edition; typically 200-400 pages for detailed service manuals of this era and complexity.

Manual Type

Type:

Service and Repair Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine:

Detailed breakdown of the Polaris 2-stroke engine, including top-end (cylinder, piston, rings), bottom-end (crankshaft, bearings), cooling system, and lubrication.

Fuel System:

Carburetor service (cleaning, adjustment, jetting), fuel lines, fuel pump, and fuel tank maintenance.

Drivetrain:

Coverage of the 6x6 drivetrain, including transmissions, drive shafts, differentials (front and rear), clutches (drive and driven), and chain drives.

Suspension:

Front and rear suspension components, including shocks, springs, control arms, bushings, and adjustment procedures.

Brakes:

Hydraulic brake system components, including master cylinder, calipers, brake pads, brake lines, and bleeding procedures.

Electrical System:

Ignition system (CDI, spark plugs), lighting (headlights, taillights), battery, starter motor, charging system (alternator/stator), and wiring diagrams.

Steering:

Steering column, tie rods, ball joints, and steering linkage maintenance and adjustment.

Body And Frame:

Body panel removal/installation, frame inspection and repair, seat, handle bar, and rack mounting.

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, spark plug checks, drive chain lubrication and adjustment, air filter cleaning/replacement.

Troubleshooting:

Diagnostic charts for common running issues, electrical problems, starting difficulties, and braking system malfunctions.

Engine Repair:

Top-end rebuild (piston replacement, decarbonizing), bottom-end overhauls (crankshaft seal replacement), cylinder head gasket replacement (if applicable).

Transmission Repair:

Clutch adjustment and replacement, transmission fluid change, internal transmission component inspection and repair.

Brake Service:

Brake pad replacement, caliper servicing, brake line replacement, system bleeding.

Electrical Diagnostics:

Testing ignition coils, charging system output, starter solenoid function, and using wiring diagrams for fault finding.

Suspension Overhaul:

Replacement of shocks, bushings, and control arms.

Technical Depth

Depth:

Comprehensive, covering everything from basic adjustments and fluid changes to complete engine and transmission overhauls. Suitable for amateur mechanics and professional technicians.

📊 Manual Specifications

File Format

File Format:

Print Quality

Scan Quality:

High-resolution scans ensuring clarity of text and diagrams. Searchable text functionality is typical for professionally produced PDFs.

Binding Type

Binding Type:

N/A (Digital Download)

Paper Type

Paper Type:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Two-stroke, air-cooled

Displacement:

Approximately 340cc (specific engine variant may vary slightly across years, often a derivative of Polaris's fan-cooled 2-stroke engines).

Bore X Stroke:

Typical for this displacement class, refer to manual for exact figures.

Power Output:

Estimated 20-25 horsepower (actual figures depend on specific engine tune and year).

Torque Output:

Designed for low-end torque for utility applications.

Performance

Top Speed:

Generally limited for utility use, typically around 35-45 mph.

Fuel System

Carburetor:

Single carburetor, likely a Mikuni VM series or similar, with manual choke.

Fuel Type:

Unleaded gasoline, mixed with 2-stroke oil (e.g., 40:1 or 50:1 ratio, consult manual for exact specification).

Cooling System

Cooling Method:

Forced air cooling via fan, often belt-driven or directly from the crankshaft.

🔧 Transmission

Standard

Transmission Type:

Automatic transmission with continuously variable transmission (CVT) clutch system.

Drive Modes:

2WD, 4WD, 6WD selectable via a lever or mechanism.

Optional

Optional Transmissions:

None typically offered for this model.

Features

Gear Reduction:

Low-range gear reduction for enhanced pulling power and slow-speed control.

Drive Shafts:

Driveshafts connecting transmission to front and rear differentials.

📐 Dimensions

Exterior

Length:

Varies slightly by year, generally around 80-90 inches.

Width:

Approximately 40-45 inches.

Height:

Approximately 40-45 inches to handlebars.

Weights

Dry Weight:

Around 500-600 lbs, depending on exact configuration.

Towing Capacity:

Typically rated for towing around 1000-1500 lbs.

Cargo Capacity:

Front and rear racks with significant load-bearing capabilities, consult manual for specific weight limits.

Wheels And Tires

Tire Size Front:

Commonly 22x8-10 or similar.

Tire Size Rear:

Commonly 22x11-10 or similar.

Wheel Bolt Pattern:

Typically 4/110 or 4/115 mm, refer to manual for exact specifications.

🛡️ Safety Features

Ratings

Atv Safety Standards:

Adherence to industry safety standards of the time; comprehensive owner's manual supplements are crucial for safe operation.

Active Features

Braking System:

Hydraulic disc brakes on multiple wheels (specific configuration varies by year and model).

Lighting:

Headlights, taillight, and stop light for visibility.

Passive Features

Handlebar Design:

Ergonomically designed handlebars with handgrips and controls.

Chassis Design:

Robust frame and chassis designed for off-road durability.

💡 Technology Features

Infotainment

Infotainment System:

No integrated infotainment system; basic functionality focused on operation and utility.

Driver Assistance

Driver Assistance Features:

None; designed for mechanical operation rather than electronic driver aids.

Connectivity

Connectivity Features:

None.

🔧 Maintenance

Service Intervals

Engine Oil Change:

Refer to manual; typically every 20-30 hours of operation or annually.

Spark Plug Inspection:

Inspect every 10-15 hours, replace as needed.

Air Filter Cleaning:

Clean every 10-20 hours of operation, depending on operating conditions.

Drive Chain Lubrication:

Lubricate chain every 5-10 hours of operation.

Fluid Specifications

Transmission Fluid Type:

Polaris specified gear oil or equivalent high-quality gear oil. Consult manual for specific viscosity grade (e.g., SAE 80W-90).

Brake Fluid Type:

DOT 3 or DOT 4 hydraulic brake fluid, as specified by Polaris.

2 Stroke Oil Mix:

High-quality 2-stroke oil for air-cooled engines, mixed at specified ratio (e.g., 40:1 or 50:1). Refer to manual for exact ratio and oil type.

Known Issues

Carburetor Fouling:

Common with older 2-stroke engines; requires regular cleaning and adjustment.

Drive Clutch Wear:

CVT drive clutches can experience wear over time, leading to performance degradation.

Suspension Bushings:

Rubber bushings in suspension components can degrade with age, leading to play and reduced handling.

Electrical Connections:

Corrosion or loose connections in the electrical system can cause intermittent faults.

📚 Vehicle History

Brand Heritage

Brand History:

Polaris is a well-established American manufacturer of powersports vehicles, with a strong reputation for innovation in the ATV market.

Model Evolution

400 6X6 Development:

The 400 6x6 was a significant model in Polaris's lineup, building on their expertise in multi-wheel drive systems and 2-stroke engine technology.

Production

Production Period:

Produced throughout the late 1980s and early 1990s, contributing to the growth of the utility ATV segment.

🏆 Awards & Recognition

Recognitions

Industry Awards:

Specific awards for this model are not widely documented, but it contributed to Polaris's reputation for utility ATVs.

Ratings

Consumer Ratings:

Generally well-regarded for its off-road capability and durability in its class and era.

Certifications

Certification Standards:

Manufactured to meet the safety and environmental standards applicable in its production years and markets.