Segment:
Utility ATV, specifically a 6x6 model designed for work and rugged terrain.
Target Audience:
Owners requiring in-depth knowledge for maintenance, repair, and troubleshooting of their Polaris 400 6x6 ATV.
Era Competitors:
Competed against other utility ATVs from brands like Yamaha (e.g., Big Bear 4x4), Honda (e.g., FourTrax), Suzuki, and Kawasaki, with the 6x6 configuration being a niche offering emphasizing hauling and traction.
Unique Selling Points:
The 6x6 drivetrain provides superior traction and load-carrying capacity compared to traditional 4x4 ATVs of the era.
Manual Value Proposition:
An 'inexpensive way to keep your vehicle' running, offering significant cost savings over professional servicing for DIY enthusiasts.
Engine:
Comprehensive coverage including disassembly, inspection, assembly, troubleshooting, and repair of the 400cc engine, cooling system, lubrication system, and fuel system.
Transmission:
Detailed procedures for the automatic transmission (likely PVT - Polaris Variable Transmission), including belt inspection/replacement, clutch service, and gearbox maintenance.
Drivetrain:
Extensive coverage of the 6x6 drivetrain, including front and rear differentials, driveshafts, universal joints, and the engaging mechanism for the front axle. Specific attention to the 6-wheel drive system.
Suspension:
Service and adjustment procedures for front and rear suspension components, including A-arms, shocks, springs, and bushings.
Brakes:
Maintenance and repair of the hydraulic brake system, including master cylinders, calipers, brake lines, pads, and bleeding procedures. May also cover parking brake systems.
Steering:
Service and alignment for the steering system, including tie rods, steering column, and steering linkage.
Electrical:
Wiring diagrams, component testing, troubleshooting for ignition, lighting, starter system, charging system (stator/regulator/rectifier), and any onboard instrumentation.
Bodywork Chassis:
Procedures for body panel removal/installation, frame inspection, and mounting hardware.
Cooling System:
Radiator, fan, coolant, hoses, and thermostat service.
Fuel System:
Carburetor (likely Mikuni), fuel lines, fuel pump, and fuel tank maintenance.
Routine Maintenance:
Oil changes, filter replacements (air, oil, fuel), spark plug service, lubrication points, and battery care.
Troubleshooting:
Diagnostic flowcharts and symptom-based problem solving for common issues across all systems.
Repair Procedures:
Step-by-step instructions for component removal, overhaul, and reinstallation.
Disassembly Assembly:
Detailed exploded views and specific instructions for taking apart and putting back together major components and assemblies.
Technical Specifications:
Torque values, clearances, fluid capacities, electrical values (resistance, voltage), and wear limits.
Special Tools:
Identification of any specialized tools required for specific repairs or adjustments.
Depth Level:
Comprehensive, covering from basic maintenance to complete engine and transmission rebuilds. Suitable for both home mechanics and professional technicians.
Engine Type:
Likely a 2-stroke or 4-stroke single-cylinder gasoline engine, based on Polaris ATV designs of this period.
Displacement:
Approximately 400cc (as indicated by the model name).
Bore X Stroke:
Specific dimensions would be detailed in the manual, typical for a 400cc class engine.
Cooling System:
Likely liquid-cooled, given the performance demands of an ATV.
Horsepower:
Estimated to be in the range of 25-35 HP, depending on the specific engine configuration.
Torque:
Torque figures tailored for low-end grunt and pulling power, characteristic of utility ATVs.
Fuel Delivery:
Carbureted. Likely a Mikuni VM series or similar.
Fuel Type:
Unleaded Gasoline (e.g., 87 octane).
Transmission Type:
Automatic (Polaris Variable Transmission - PVT).
Drive Modes:
Selectable 2WD/4WD/6WD engagement.
Gear Selection:
High, Low, Neutral, Reverse.
Clutch Type:
Centrifugal clutch and drive/driven pulleys for the PVT system.
Transmission Fluid:
Specific Polaris PVT fluid or a compatible SAE 10W-30 transmission oil, as per the manual.
Length:
Approximate: 85-95 inches (typical for this class).
Width:
Approximate: 45-55 inches.
Height:
Approximate: 45-50 inches.
Wheelbase:
Not specified, but significantly longer than a 4x4 to accommodate the extra axle.
Ground Clearance:
Likely in the range of 7-10 inches.
Dry Weight:
Estimated: 550-650 lbs.
Towing Capacity:
Typically around 1500 lbs for this class of ATV.
Rack Capacity Front:
Estimated: 50-75 lbs.
Rack Capacity Rear:
Estimated: 150-200 lbs.
Fuel Capacity:
Approximately 3-4 gallons.
Safety Standards:
ATVs of this era are subject to specific industry safety guidelines, but formal crash ratings like passenger cars are not applicable.
Braking System:
Hydraulic disc brakes (likely front and rear).
Traction Control:
The 6x6 configuration inherently provides advanced traction capabilities.
Frame Construction:
Robust steel frame designed for durability and load-bearing.
Lighting:
Headlights, taillight, and brake light for visibility.
Dashboard Features:
Basic instrumentation: speedometer, odometer, fuel gauge, indicator lights (e.g., neutral, high beam).
Transmission Assist:
The automatic PVT system provides a seamless power delivery and assists the rider in varied terrain.
Charging System:
12V electrical system with a charging system (stator, regulator/rectifier) to power accessories and maintain battery charge.
Engine Oil Change:
Typically every 100-200 hours or annually, as specified in the manual.
Air Filter Cleaning:
Frequent checks and cleaning/replacement recommended, especially in dusty conditions.
Transmission Fluid Change:
Intervals typically around 200-300 hours or annually.
Spark Plug Replacement:
As recommended, often based on hours or performance degradation.
Belt Inspection:
Regular inspection for wear and tension on the PVT belt is critical.
Engine Oil Type:
SAE 10W-30 or 10W-40 API SG or higher, specific grade and capacity detailed in manual.
Cooling Fluid:
Ethylene glycol-based antifreeze mixed with distilled water (typically 50/50).
Brake Fluid:
DOT 3 or DOT 4 hydraulic brake fluid, as specified.
Common Wear Items:
PVT belt wear, U-joints in driveshafts, suspension bushings, and brake pad wear are common for ATVs of this vintage.
Carburetor Issues:
Clogged jets or diaphragm issues in the carburetor can affect performance and starting.
Electrical Gremlins:
Wiring harness degradation or connection issues can cause intermittent electrical problems.
