Segment:
Utility ATV, popular for recreational riding and light work.
Target Audience:
ATV owners, DIY mechanics, and professional service technicians working on Polaris ATVs of this era.
Competitors:
Competed with models from brands like Yamaha (e.g., Wolverine), Honda (e.g., FourTrax), and Suzuki (e.g., QuadRunner) in the mid-size utility ATV segment.
Vehicle Purpose:
Designed for versatile use, including trail riding, hunting, and light farm work, with emphasis on 4x4 capability.
Engine:
Detailed diagnostics, disassembly, assembly, inspection, and repair procedures for the engine.
Transmission:
Service and repair of the transmission, including gearbox, clutch, and drive components.
Drivetrain:
Maintenance and repair of the 4x4 system, including differentials, driveshafts, and CV joints.
Suspension:
Service and adjustment of front and rear suspension systems, shocks, and A-arms.
Brakes:
Repair, bleeding, and maintenance of the braking system (hydraulic, disc/drum depending on specific model configuration).
Steering:
Service and repair of the steering system, including tie rods, ball joints, and steering column.
Electrical System:
Wiring diagrams, troubleshooting for ignition, lighting, charging system, starter, and accessories.
Fuel System:
Carburetor service, fuel lines, fuel pump, and fuel tank maintenance.
Cooling System:
Radiator, fan, thermostat, and coolant management.
Exhaust System:
Inspection and replacement of exhaust components.
Frame And Bodywork:
Inspection, repair, and maintenance of the ATV frame and body panels.
Routine Maintenance:
Oil changes, filter replacements, spark plug service, lubrication points, and general inspections.
Troubleshooting:
Diagnostic charts and guided steps to identify and resolve common issues.
Engine Rebuild:
Complete procedures for engine disassembly, inspection of internal components (pistons, rings, valves, bearings), and reassembly.
Transmission Overhaul:
Detailed steps for transmission disassembly, component inspection, and reassembly.
Carburetor Tuning:
Adjustment and overhaul procedures for the carburetor to ensure optimal performance.
Electrical Diagnostics:
Step-by-step troubleshooting for electrical faults using wiring diagrams.
Suspension Adjustment:
Procedures for adjusting suspension settings and replacing worn components.
Brake System Service:
Brake pad replacement, caliper service, brake line inspection, and bleeding procedures.
Wheel And Tire Service:
Tire changes, wheel balancing (if applicable), and hub inspection.
Depth:
Comprehensive, covering everything from basic owner maintenance to complete engine and transmission rebuilds.
Diagnostic Capability:
Advanced diagnostic procedures, including troubleshooting charts and specific symptom-based solutions.
Specification Data:
Includes detailed specifications for all components, torque values, clearances, and fluid capacities.
Engine Type:
Two-stroke, liquid-cooled, single-cylinder.
Displacement:
Approximately 340cc to 350cc (specific model variation may exist, but '400' designation often refers to classification).
Bore X Stroke:
Technical specifications usually available in the manual.
Horsepower:
Typically in the range of 20-25 HP, depending on specific tuning and model year.
Torque:
Specifications usually detailed in the manual.
Carburetor:
Single carburetor, typically a Mikuni or Keihin, with specific model number in manual.
Fuel Type:
Unleaded gasoline.
Ignition Type:
CDI (Capacitor Discharge Ignition).
Cooling Method:
Liquid-cooled.
Length:
Specifications vary slightly by year; typical around 70-75 inches.
Width:
Typical around 44-48 inches.
Height:
Typical around 45-48 inches.
Dry Weight:
Typically in the range of 500-550 lbs.
Towing Capacity:
Typically around 750-1000 lbs.
Payload Capacity:
Typically around 200-300 lbs for racks.
Front Tire Size:
Commonly 22x7-10 or 23x7-10.
Rear Tire Size:
Commonly 22x10-10 or 23x10-10.
Wheel Bolt Pattern:
Typically 4/110mm or similar for ATVs.
Safety Certifications:
ATVs of this era did not have standardized crash ratings like automobiles. Safety features are inherent to design.
Braking System:
Hydraulic disc brakes (front and rear) are standard.
4X4 Engagement:
Selectable 2WD/4WD for enhanced traction and control.
Hand Guards:
Often equipped with basic handguards for rider protection.
Footwells:
Full floorboards with heel guards for foot protection.
Lighting:
Headlights, taillight, and brake light for visibility.
Engine Oil Change:
Typically every 50-100 operating hours or annually. Specifics in manual.
Air Filter Cleaning:
Check and clean frequently, replace as needed (e.g., every 25-50 operating hours).
Spark Plug Replacement:
Typically every 100-200 operating hours or annually. Specific part number and gap in manual.
Transmission Fluid:
Check fluid level regularly, change according to manual recommendations (e.g., annually or every 100 hours).
Engine Oil Type:
Typically a 2-stroke oil pre-mix or oil injection system. Specific oil grade (e.g., SAE 10W-30 or 10W-40 for transmission/crankcase) will be detailed in the manual.
Coolant Type:
Ethylene glycol-based antifreeze, typically a 50/50 mix with distilled water. Specific capacity in manual.
Brake Fluid:
DOT 3 or DOT 4 hydraulic brake fluid, depending on system specification. Check manual for exact type.
Carburetor Clogging:
Common with older carbureted engines due to fuel varnish.
Cv Joint Wear:
Can occur with heavy use or improper lubrication.
Suspension Bushings:
Wear and tear on rubber bushings is common over time.
Starter Solenoid:
Can fail over time, leading to starting issues.
Filters:
Specific part numbers for air filters, oil filters (if applicable), and fuel filters will be listed.
