Market Segment:
Entry-level to mid-range utility ATV for recreational and light-duty work.
Competitors 1994:
Competed against models from Honda (e.g., FourTrax 300), Yamaha (e.g., Kodiak 400), Suzuki (e.g., QuadRunner 4x4), and Kawasaki (e.g., Bayou 400).
Feature 1:
True 4x4 capability for enhanced traction.
Feature 2:
Reliable 2-stroke engine known for its power-to-weight ratio.
Feature 3:
Automatic transmission for ease of operation.
Engine:
Detailed coverage of the 2-stroke engine, including disassembly, assembly, tuning, and troubleshooting.
Transmission Drivetrain:
Includes repair and maintenance for the automatic transmission, drive shafts, CV joints, and 4x4 engagement system.
Suspension Steering:
Covers front and rear suspension components, shock absorbers, bushings, steering linkage, and wheel alignment.
Brakes:
Explains hydraulic brake system components, including master cylinders, calipers, brake lines, pads, and bleeding procedures.
Electrical System:
Details the ignition system, lighting, charging system (stator, regulator/rectifier), starter motor, battery, and wiring diagrams.
Fuel System:
Includes carburetor service, fuel pump operation, fuel lines, and fuel tank maintenance.
Cooling System:
Information on the liquid cooling system, radiator, fan, thermostat, and coolant specifications.
Body Chassis:
Covers frame inspection, body panel removal/installation, and seat maintenance.
Routine Maintenance:
Covers oil changes, filter replacements, spark plug service, chain adjustment, and lubrication points.
Troubleshooting:
Provides diagnostic charts and symptom-based troubleshooting for common issues.
Engine Rebuild:
Detailed step-by-step instructions for complete engine disassembly, inspection, part replacement, and reassembly.
Transmission Repair:
Guidance on repairing and servicing the CVT (Continuously Variable Transmission) and clutch systems.
Electrical Diagnostics:
Instructions for testing electrical components, diagnosing faults using wiring diagrams, and multimeter usage.
Carburetor Tuning:
Procedures for cleaning, adjusting, and rebuilding the carburetor for optimal performance.
Suspension Overhaul:
Steps for replacing wear items like ball joints, tie rod ends, wheel bearings, and shock absorbers.
Depth:
Comprehensive, covering everything from basic adjustments to complete engine and transmission overhauls.
Engine Type:
2-Stroke, Liquid-Cooled
Engine Displacement:
340cc (approx.) - Often referred to as a '400' class due to marketing or stroke volume, but displacement is closer to 340cc for the 2-stroke.
Bore X Stroke:
Refer to manual for exact dimensions, typically around 72mm x 80mm for this class.
Cylinder Configuration:
Single Cylinder
Horsepower Estimate:
Approx. 25-30 HP (at flywheel, specific rating varies).
Torque Estimate:
Refer to manual for precise torque figures.
Fuel Delivery:
Carburetor (e.g., Mikuni VM34 or similar).
Fuel Type:
Unleaded Gasoline (91 octane recommended).
Oil Mixture:
Premix or Oil Injection System (check specific model designation, 50:1 or 40:1 oil-to-gas ratio typically).
Transmission Type:
Automatic (CVT - Continuously Variable Transmission)
Drive System:
Shaft Drive (2WD/4WD selectable)
Optional Gearbox:
N/A for this model; standard CVT operation.
Transmission Fluid:
Refer to manual for specific SAE viscosity and Polaris part numbers (often a specific ATF or gear oil).
Gear Reduction:
High/Low range gear selector, plus Reverse.
Length:
Refer to manual for exact dimensions (typically around 75-80 inches).
Width:
Refer to manual for exact dimensions (typically around 42-46 inches).
Height:
Refer to manual for exact dimensions (typically around 42-46 inches).
Dry Weight:
Approx. 400-450 lbs (dry).
Ground Clearance:
Approx. 7-9 inches (check specific model variation).
Safety Standards:
ATVs of this era did not have standardized crash test ratings like automobiles. Safety primarily relies on operator skill and adherence to safe riding practices.
Active Safety Features:
4x4 traction control, engine braking.
Passive Safety Features:
Handgrips, footwells, throttle limiter (often adjustable).
Oil Change Interval:
Refer to manual, typically every 20-40 operating hours or annually. Transmission fluid check more frequently.
Spark Plug Replacement:
Refer to manual, typically every 6-12 months or as needed based on condition.
Air Filter Cleaning:
Check and clean every 10-20 operating hours, especially in dusty conditions.
Engine Oil:
Refer to manual for specific 2-stroke oil type and premix ratio. For transmission, often SAE 10W-30 or 10W-40 (check manual for exact spec).
Coolant Type:
Ethylene Glycol based antifreeze, typically 50/50 mix with distilled water.
Brake Fluid:
DOT 3 or DOT 4 (check manual for exact specification).
Common Issue 1:
Carburetor gumming/clogging due to fuel degradation if stored with fuel.
Common Issue 2:
Wear on CV joint boots leading to damage.
Common Issue 3:
Potential for starter motor issues or solenoid failure.
Common Issue 4:
Carburetor intake manifold cracking.
Common Issue 5:
Water pump seal leaks.
Brand Legacy:
Polaris is a long-standing manufacturer of powersports vehicles, known for pioneering the modern snowmobile and expanding into ATVs.
Model Line Context:
The Polaris 400 4x4 was a significant model in the early development of Polaris's ATV lineup, offering a robust 4-wheel drive system.
Production Period:
The '400' designation was used across several years and iterations of Polaris ATVs, with the 1994 model representing a specific generation.
