Segment:
Mid-size utility ATV for recreational and light-duty work applications.
Target Audience:
Owners and technicians seeking to maintain, repair, and troubleshoot the 1994 Polaris ATV 400 2x4.
Competitors Era:
Competed with models from Yamaha (Grizzly), Honda (FourTrax), Kawasaki (Bayou), and Suzuki (QuadRunner) in the mid-size ATV segment.
Vehicle Focus:
Reliable performance, utility-oriented design, 2x4 drivetrain for maneuverability and lighter weight.
Manual Value Proposition:
Provides factory-accurate repair and maintenance procedures, essential for preserving the longevity and performance of this vintage ATV.
Engine:
Detailed engine overhaul, tuning, diagnostics, including combustion chamber, piston, connecting rod, crankshaft, valve train, cooling system, lubrication system.
Fuel System:
Carburetor assembly, fuel pump, fuel lines, fuel tank, and related components, including jetting and adjustment procedures.
Transmission Drivetrain:
Primary clutch, secondary clutch (drive and driven), belt inspection and replacement, gearcase overhaul, differential, and drive shafts.
Brakes:
Hydraulic brake system, caliper overhaul, master cylinder, brake lines, pads, rotors, bleeding procedures.
Suspension Steering:
Front and rear suspension components, shock absorbers, springs, control arms, tie rods, steering column, and related adjustments.
Electrical System:
Ignition system, lighting, battery, starter motor, charging system (stator, regulator/rectifier), wiring diagrams, fuses, relays, and switches.
Cooling System:
Radiator, fan, coolant hoses, thermostat, coolant specifications and capacity.
Exhaust System:
Muffler, exhaust pipe, heat shields, and gasket specifications.
Frame Chassis:
Frame inspection, maintenance, and repair, including bolt torque specifications.
Bodywork Plastics:
Fender, seat, handlebar, and plastic component removal, installation, and care.
Preventative Maintenance:
Routine inspections, lubrication points, filter replacements, spark plug service, and fluid changes.
Troubleshooting:
Diagnostic charts and procedures for identifying and resolving common mechanical and electrical issues.
Repair Overhaul:
Step-by-step instructions for component disassembly, inspection, repair, reassembly, and adjustment for all major systems.
Technical Specifications:
Torque specifications, clearances, fluid capacities, electrical resistance values, and engine timing.
Wiring Diagrams:
Comprehensive electrical schematics for easy diagnosis and repair of the electrical system.
Depth:
Comprehensive factory-level detail, suitable for professional mechanics and serious DIY enthusiasts. Covers everything from basic maintenance to complete engine and transmission rebuilds.
Configuration:
Likely a single-cylinder, two-stroke, liquid-cooled engine. Specific displacement is '400', suggesting around 350-400cc range.
Bore X Stroke:
Specifics not provided, but typical for the era would be in the range of 80-90mm bore and 70-80mm stroke.
Compression Ratio:
Likely in the range of 6.5:1 to 7.5:1 for a two-stroke, as specified by Polaris service documentation.
Ignition System:
CDI (Capacitor Discharge Ignition) system, likely with electronic timing advance.
Cooling Method:
Liquid-cooled
Horsepower:
Estimated 25-30 HP, typical for a 400cc two-stroke ATV of this era. Exact figures would be in the manual.
Torque:
Estimated 25-30 lb-ft. Exact figures would be in the manual.
Carburetor Type:
Likely a single Mikuni or Keihin carburetor, e.g., Mikuni VM34 or similar. Specific model and jetting would be detailed.
Fuel Type:
Unleaded gasoline, likely with a specific octane rating recommended by Polaris (e.g., 87 or 89 octane).
Fuel Mixture:
Two-stroke oil/gasoline mixture (premix) or automatic oil injection system. The 1994 400 likely featured automatic oil injection.
Length:
Approx. 75-80 inches (specifics in manual).
Width:
Approx. 42-45 inches (specifics in manual).
Height:
Approx. 45-48 inches (specifics in manual).
Wheelbase:
Approx. 50-52 inches (specifics in manual).
Dry Weight:
Approx. 450-500 lbs (specifics in manual).
Payload Capacity:
Typically around 200-250 lbs for racks. Specifics in manual.
Front Tire Size:
Likely 25x8-12 or similar. Specifics in manual.
Rear Tire Size:
Likely 25x10-12 or similar. Specifics in manual.
Tire Pressure:
Typically 5-7 PSI for off-road use. Exact recommendations in manual.
Safety Standards:
Designed to meet ATV safety standards of the time. No formal crash test ratings as with passenger vehicles.
Braking System:
Hydraulic disc brakes front and rear.
Throttle Limiter:
May have had adjustable throttle limiter for new riders, common in this era.
Lighting:
Headlights, taillight, and brake light.
Handlebars:
Handlebar grip design and placement for rider control.
Footwells:
Aggressive footwell designs with heel guards for rider foot security.
Oil Change Engine:
Every 50-100 hours of operation or annually. Specific recommendation for 2-stroke mix or oil injection reservoir refill would be in the manual.
Spark Plug Service:
Inspect every 20-40 hours, replace as needed. Specific plug type and gap in manual.
Air Filter Cleaning:
Clean every 20-40 hours, depending on operating conditions. Replacement intervals also specified.
Clutch Belt Inspection:
Inspect CVT belt condition and tension every 50-100 hours. Replace if worn or damaged.
Gear Case Oil Change:
Every 100-200 hours or annually. Specific fluid type and capacity in manual.
Engine Oil Type:
For the 2-stroke engine, this refers to the specific 2-stroke oil for the injection system or premix. Polaris brand oil or equivalent meeting specifications (e.g., API-TC, JASO FD) would be recommended. Specific Polaris part numbers for oil and coolant would be listed.
Coolant Type:
Ethylene glycol based antifreeze, mixed 50/50 with distilled water. Specific Polaris coolant part number would be detailed.
Gear Oil:
Likely SAE 90W gear oil. Specific Polaris gear oil part number or equivalent would be listed.
Common Problems Era:
Potential issues for 1990s 2-stroke ATVs can include carburetor gumming, CVT belt wear, exhaust leaks, and occasional electrical component failures (stator, rectifier). Clutch alignment and wear are also critical.
Manual Utility For Issues:
The manual's troubleshooting section is crucial for diagnosing and rectifying these common issues.
Polariss Atv History:
Polaris was a pioneering force in the ATV market, introducing innovative designs and popularizing the utility ATV segment.
Polaris 400 Lineage:
The 400cc engine size was a popular displacement in Polaris's ATV lineup throughout the 1990s, evolving through various chassis and feature updates.
1990S Atv Market:
The 1990s saw significant growth and technological advancement in the ATV industry, with manufacturers focusing on engine power, suspension comfort, and utility features.
Manufacturing Location:
Polaris Industries vehicles are primarily manufactured in the United States.
