Target Audience:
Polaris dealerships, certified repair shops, and dedicated enthusiasts undertaking significant maintenance and repair tasks.
Value Proposition:
Provides the definitive, factory-authorized information crucial for accurate and efficient servicing of the 1985 Polaris 400, ensuring optimal performance and longevity.
Manual Attributes:
Comprehensive diagnostic charts, detailed exploded views of components, precise torque specifications, and step-by-step procedural guidance.
Engine Systems:
Engine overhaul, top-end repair, bottom-end assembly, cooling system, lubrication, fuel system (carburetor, fuel pump, lines), ignition system (CDI, spark plugs, coils), exhaust system.
Drivetrain Systems:
Clutch systems (drive clutch, driven clutch - calibration, replacement, repair), chaincase (gearing, lubrication, seals), track system (suspension, idler wheels, bogies, track tension), skis, steering.
Electrical Systems:
Wiring diagrams, lighting, starter motor, battery, alternator/stator, kill switch, safety features, gauge cluster.
Chassis And Body:
Frame inspection, body panels, seat, handlebars, controls (throttle, brake lever), footrests, storage compartments.
Maintenance Procedures:
Routine servicing, pre-ride inspections, post-ride care, lubrication points, battery maintenance, track adjustment, clutch inspection, spark plug replacement, air filter cleaning/replacement.
Diagnostic Procedures:
Troubleshooting charts for common issues (e.g., no start, poor performance, overheating), electrical system diagnostics, carburetor tuning and diagnosis.
Repair Procedures:
Step-by-step instructions for component removal, disassembly, inspection, repair, reassembly, and installation. Includes engine rebuilds, clutch service, suspension repairs, electrical component replacement.
Technical Specifications:
Torque specifications for all fasteners, engine clearances, ignition timing, carburetor jetting, clutch weights and springs, chaincase gear ratios.
Depth Of Coverage:
In-depth, factory-level detail suitable for professional technicians and experienced DIY mechanics. Covers complete engine overhauls, transmission repairs, and complex electrical diagnostics.
Digital File Format:
N/A (Original product is print).
Original Print Quality:
High-quality, durable paper stock with clear diagrams and text, typical of OEM service manuals from the era.
Original Binding:
Likely bound (stapled or stitched and glued spine) for durability in a workshop environment.
Original Paper Type:
Durable, often coated paper to resist grease and dirt in a workshop.
Engine Type:
Two-stroke, liquid-cooled, twin-cylinder (configuration may vary based on specific 400 sub-model, but typical for Polaris of this era).
Displacement:
Approximately 398cc (may vary slightly).
Bore X Stroke:
Specifications would be detailed in the manual, crucial for rebuilds.
Horsepower Rating:
Estimated 40-50 HP (typical for this displacement and era).
Torque Rating:
Specifications would be detailed in the manual.
Carburetion:
Dual Mikuni carburetors (specific model number and jetting details in manual, e.g., VM30/32).
Fuel Type:
Unleaded gasoline mixed with 2-stroke oil (ratio specified in manual, e.g., 40:1 or 50:1).
Ignition Type:
CDI (Capacitor Discharge Ignition) system with breakerless ignition.
Cooling Method:
Liquid-cooled, with radiator, fan, and coolant hoses.
Drive System:
Arctic Drive System (ADS) utilizing a Variable Rate Drive (VRD) clutch system.
Drive Clutch Type:
Polaris P-85 or similar OEM variable speed drive clutch.
Driven Clutch Type:
Polaris Torque-sensing driven clutch.
Reduction Gearing:
Chaincase with reduction gears for track drive; specific gear ratios provided in manual.
Chaincase Oil Spec:
Specific chaincase oil type and viscosity (e.g., SAE 80W-90 gear oil or specialized chaincase lubricant) detailed in manual.
Overall Length:
Specifications would be detailed in the manual, but typically around 100-110 inches.
Overall Width:
Specifications would be detailed in the manual, but typically around 36-40 inches.
Dry Weight:
Estimated 450-500 lbs (will vary based on specific configuration).
Fuel Capacity:
Approximately 5-7 gallons (specified in manual).
Track Length:
Specifications would be detailed in the manual, typically around 114-121 inches.
Track Width:
Specifications would be detailed in the manual, typically around 15 inches.
Lug Height:
Specifications would be detailed in the manual, important for traction.
Oil Change Frequency:
2-stroke engine requires oil/gas mixture; no traditional oil change for engine lubrication, but chaincase oil should be checked and changed per manual schedule.
Clutch Service Interval:
Inspection recommended annually or every 500 miles; service/calibration as needed based on performance. Manual provides specific guidance.
Spark Plug Replacement:
Recommended annually or every 1000 miles, or as per manual's diagnostic recommendations.
Coolant Type:
Specific antifreeze/coolant mixture ratio and type (e.g., ethylene glycol-based) as specified in the manual for liquid-cooled engines.
Carburetor Cleaner:
Recommended cleaning solvents for carburetor jets and passages detailed in manual.
Common Wear Items:
Drive belts, clutch weights and springs, track wear, idler wheel bearings, carburetor jets/needles, and ignition components can be common wear items over time.
Carburetor Tuning Sensitivity:
Two-stroke engines of this era can be sensitive to altitude and temperature changes, requiring occasional carburetor adjustment. Manual provides detailed tuning procedures.
Engine Starting Problems:
Manual provides systematic troubleshooting for no-start conditions, including fuel, spark, and compression checks.
Polaris History:
Polaris Industries, founded in 1954, is a major American manufacturer of recreational vehicles, including snowmobiles, ATVs, and motorcycles. Known for innovation in the powersports industry.
1985 Polaris Lineup:
The 1985 Polaris 400 was part of a diversified snowmobile lineup, often positioned as a mid-range or performance-oriented trail machine, building on Polaris's reputation for robust and capable snowmobiles.
Manufacturing Location:
Typically manufactured in Roseau, Minnesota, USA by Polaris Industries.
