Segment:
Heavy-duty utility ATV segment.
Target User:
Owners, mechanics, and technicians performing maintenance and repairs.
Competitors:
Other utility ATVs of the era, e.g., early Honda FourTrax, Yamaha Timberwolf.
Vehicle Selling Points:
6x6 drivability for traction and load carrying, Polaris's reputation for ruggedness.
Manual Value Proposition:
Enables DIY repairs, cost savings, proper maintenance for longevity.
Primary Coverage:
Workshop repair and maintenance for Polaris ATV 400 6x6 models.
Secondary Coverage:
Troubleshooting, diagnostics, specifications, diagrams.
Estimated Pages:
Likely extensive; typical workshop manuals for this era are 300-600+ pages.
Type:
Workshop Manual / Service Manual
Powertrain:
Engine, transmission, drivetrain (6x6 system).
Chassis:
Frame, suspension (front and rear), steering.
Braking:
Brake system components, hydraulics, adjustment.
Electrical:
Ignition, lighting, charging system, starter, battery, wiring diagrams.
Fuel System:
Carburetor, fuel lines, fuel pump, tank.
Cooling System:
Radiator, fan, coolant (if applicable).
Exhaust System:
Muffler, pipes, gaskets.
Body And Frame:
Body panels, fenders, frame inspection and repair.
Maintenance:
Scheduled maintenance, fluid changes, lubrication, filter replacement.
Troubleshooting:
Diagnosis of common problems, diagnostic flowcharts.
Repair:
Component disassembly, reassembly, and adjustment procedures.
Rebuilds:
Engine overhaul, transmission rebuild, carburetor rebuild.
Inspections:
Pre-ride checks, component wear inspections, safety checks.
Specifications Torque:
Torque specifications for critical fasteners.
Level:
Comprehensive: Covers from basic maintenance to complete engine and transmission overhauls.
Diagnostics:
Detailed diagnostic procedures for electrical and mechanical issues.
Illustrations:
Includes diagrams, exploded views, and schematics.
Type:
2-stroke, piston-ported gasoline engine.
Displacement:
Approximately 300-340cc (specific variant dependent on exact model year within range).
Bore X Stroke:
Typical for this class: e.g., 70mm x 76mm (specifics in manual).
Cooling:
Liquid-cooled (common for this performance level).
Ignition:
CDI (Capacitor Discharge Ignition).
Horsepower:
Estimated 22-28 HP (typical for a 2-stroke of this displacement).
Torque:
Not typically published for ATVs of this era, but critical for low-end pull.
Carburetor:
Single barrel carburetor (e.g., Mikuni VM or similar).
Fuel Type:
Unleaded gasoline.
Oil Mixture:
2-stroke pre-mix or oil injection system (manual will specify).
Type:
Automatic (CVT - Continuously Variable Transmission).
Drive System:
6x6 (all-wheel drive), with selectable 2WD/4WD/6WD.
Gear Reduction:
High and low range gear selection (typical for utility ATVs).
Transmission Fluid:
Specific CVT fluid or gear oil (manual to specify).
Safety Standards:
Industry standards for ATVs of the era; specific agency ratings less common.
Braking System:
Hydraulic disc brakes (front and rear), often drum brakes on rear wheels in early models.
Frame Design:
Steel frame providing structural integrity.
Lighting:
Headlights, taillight, brakelight.
Oil Change Engine:
e.g., Every 50 hours or annually for 2-stroke models (details in manual).
Air Filter Cleaning:
Frequent checks and cleaning/replacement based on operating conditions (e.g., every 25 hours).
Spark Plug Replacement:
e.g., Annually or every 100 hours.
Cv Belt Inspection:
Regular inspection for wear and damage.
Engine Oil:
Specific 2-stroke engine oil (e.g., Polaris Premium 2-Stroke Oil) or specified pre-mix ratio.
Transmission Fluid:
Manual will specify appropriate gear oil or CVT fluid (e.g., SAE 80W-90 gear oil for differentials if applicable).
Coolant:
Ethylene glycol-based antifreeze mixture (specific type and ratio in manual).
Common Wear Items:
CVT belt failure, carburetor gumming/fouling, rear suspension wear, braking component wear.
2 Stroke Care:
Importance of proper fuel/oil mixture, avoiding carbon buildup, regular decarbonization.
Polaris Atv Legacy:
Polaris was a pioneer in the ATV market, known for its innovative 6x6 designs and utility focus.
400 6X6 Development:
Evolved from earlier Polaris models, emphasizing increased traction and load capacity for work and recreation.
Manufacturing Era:
1985-1995 marked a significant period of development and sales for this model line.
