Historical Context:
The 1995 Polaris 400 2x4 was a popular mid-range ATV in its era, known for its utility and recreational capabilities. This service manual is essential for maintaining and repairing this specific model.
Segment Competitors:
Competed with models from Yamaha (e.g., Kodiak), Suzuki (e.g., QuadSport), and Honda (e.g., FourTrax) in the utility ATV segment.
Vehicle Strengths:
Reliable 2WD system, capable engine for its class, balanced suspension for various terrains.
Manual Value Proposition:
Provides owners and technicians with the authoritative information needed to keep the 1995 Polaris 400 2x4 operating at peak performance and reliability.
Engine Service:
Full disassembly, inspection, reassembly, tuning, and troubleshooting
Fuel System:
Carburetor service, fuel pump, fuel lines, fuel tank maintenance
Ignition System:
CDI, spark plugs, ignition timing, troubleshooting
Transmission Drivetrain:
Automatic transmission (CVT) service, clutch, differential, driveshaft maintenance
Suspension Steering:
Front and rear suspension, shock absorbers, steering system components, linkage adjustments
Brakes:
Hydraulic brake system, calipers, master cylinders, brake fluid, bleeding procedures
Electrical System:
Wiring diagrams, lighting, battery, stator, starter, troubleshooting electrical faults
Cooling System:
Air-cooled engine specifications and maintenance (if applicable, or oil cooling system for relevant models)
Frame Chassis:
Frame inspection, repairs, mounting points
Bodywork Plastics:
Fairing removal, installation, plastic component care
Wheels Tires:
Tire pressure specifications, wheel removal and installation
Preventative Maintenance:
Scheduled maintenance, fluid changes, lubrication, filter replacement
Troubleshooting Diagnostics:
Step-by-step diagnostic procedures for common and uncommon issues, fault code interpretation (if applicable)
Repair Rebuild:
Detailed instructions for component repair, overhaul, and complete engine or transmission rebuilds
Carburetor Adjustment:
Comprehensive guidance on cleaning, tuning, and synchronizing the carburetor
Electrical Diagnostics:
Troubleshooting electrical system faults using multimeter and wiring diagrams
Brake Bleeding:
Proper procedures for bleeding the hydraulic brake system
Depth Of Information:
Factory-level detail suitable for professional mechanics and experienced DIY enthusiasts
Diagnostic Tools:
References to required special tools and diagnostic equipment
Engine Type:
2-stroke, 1-cylinder
Engine Displacement:
340cc - 400cc (approximate, specific variant may vary slightly, refer to manual for precise designation)
Cooling System:
Air-cooled or Oil-cooled (refer to manual for specific cooling type)
Horsepower Estimated:
Approximately 25-30 HP (typical for the class and engine size)
Torque Estimated:
Refer to manual for specific torque figures
Carburetor Model:
Single Mikuni (common, specific model number in manual)
Fuel Type:
Unleaded gasoline (87 octane recommended)
Fuel Mixture:
Pre-mix 2-stroke oil and gasoline (refer to manual for precise ratio, typically 40:1 or 50:1)
Bore X Stroke:
Refer to manual for exact specifications
Compression Ratio:
Refer to manual for exact specifications
Transmission Type:
Automatic (CVT - Continuously Variable Transmission)
Number Of Gears:
Variable (CVT)
Gear Selection:
Forward, Neutral, Reverse (FN R)
Clutch Type:
Automatic centrifugal clutch system
Transmission Fluid Type:
Refer to manual for specific fluid type (often SAE 10W-30 or specific ATV transmission fluid)
Transmission Fluid Capacity:
Refer to manual for exact capacity
Overall Length:
Approx. 72-78 inches (refer to manual for exact figures)
Overall Width:
Approx. 42-46 inches (refer to manual for exact figures)
Overall Height:
Approx. 42-46 inches (refer to manual for exact figures)
Dry Weight:
Approx. 400-450 lbs (refer to manual for exact figures)
Ground Clearance:
Approx. 7-9 inches (refer to manual for exact figures)
Towing Capacity:
Refer to manual for specific towing capacity
Wheelbase:
Refer to manual for exact wheelbase
Tire Size Front:
Typically 23x8-12 or similar (refer to manual for exact specification)
Tire Size Rear:
Typically 24x11-10 or similar (refer to manual for exact specification)
Atv Safety Considerations:
Designed for off-road use; rider training and protective gear are essential. No formal crash ratings for ATVs.
Braking System:
Hydraulic disc brakes front and rear, or drum brakes depending on specific variant (manual will detail)
Handlebars Grip:
Throttle control, brake levers
Operator Awareness:
Manual emphasizes safe riding practices and proper ATV operation.
Oil Change Interval:
Refer to manual for specific interval, typically every 50-100 operating hours or annually
Spark Plug Replacement:
Refer to manual for specific interval, usually based on operating hours or when fouled
Air Filter Cleaning:
Frequent cleaning recommended, replacement based on condition and operating environment
Cv Boot Inspection:
Regular inspection for tears and damage
Engine Oil Type:
Refer to manual for specific 2-stroke oil type and pre-mix ratio (e.g., API TC, JASO FD)
Brake Fluid Type:
DOT 3 or DOT 4 (refer to manual for precise specification)
Common Wear Items:
CVT belt wear, carburetor jetting issues, starter motor reliability, exhaust seal leaks
Preventative Measures:
Regular cleaning of the carburetor bowl, maintaining correct fuel/oil mixture, proper CVT belt care.
