Target User:
DIY mechanics, ATV enthusiasts, and professional technicians working on Polaris 400 6x6 ATVs.
Value Proposition:
Provides comprehensive, factory-level repair and maintenance information for owners who prefer hands-on work, ensuring quality and cost savings.
Uniqueness:
A singular resource offering detailed, model-specific repair data for this particular 1996 6x6 model, often scarce in generic ATV manuals.
Content Focus:
Emphasizes practical repair and maintenance, covering the 'how-to' for virtually every component.
Engine Mechanical:
Engine disassembly, inspection, reassembly, valve adjustments, piston/ring replacement, cylinder head service, crankshaft/connecting rod inspection.
Engine Fuel System:
Carburetor (Mikuni) removal, cleaning, adjustment, fuel pump, fuel filter, fuel lines.
Engine Ignition System:
Ignition coil, stator, CDI unit, spark plug specifications, timing checks.
Cooling System:
Radiator, fan, coolant, thermostat, hoses, water pump.
Transmission And Drivetrain:
Transmission disassembly, inspection, reassembly, gear shifting mechanisms, drive shafts, differentials (front and rear), chain drive, universal joints, AWD engagement system.
Braking System:
Hydraulic brake system, brake caliper service, brake pads, brake lines, master cylinder, bleeding procedures, parking brake.
Suspension System:
Front and rear suspension components, shock absorbers, springs, A-arms, bushings, wheel bearings.
Steering System:
Handlebar assembly, steering shaft, tie rods, steering linkage, U-joints.
Electrical System:
Wiring diagrams, battery specifications, starter motor, alternator (stator), lighting system (headlights, taillights, brake lights), electrical connectors, fuses, relays.
Frame And Bodywork:
Frame inspection, body panel removal/installation, fenders, racks, seat assembly.
Routine Maintenance:
Oil changes, filter replacements (oil, air), spark plug replacement, lubrication points, tire pressure checks, battery maintenance.
Troubleshooting:
Step-by-step diagnostic procedures for common starting, running, electrical, and mechanical issues.
Repair Procedures:
Detailed, illustrated instructions for component removal, repair, and reinstallation.
Rebuild Instructions:
Complete engine and transmission rebuild guides with torque specifications and clearances.
Adjustments:
Carburetor adjustment, ignition timing, valve clearance adjustments, brake adjustments.
Wiring Diagrams:
Comprehensive, high-resolution electrical system schematics.
Depth Level:
Expert-level, covering complete overhauls and advanced diagnostics.
Detail Level:
Highly detailed, with step-by-step instructions, torque specifications, clearances, and diagnostic charts.
Visual Aids:
Includes diagrams, illustrations, and exploded views to clarify procedures.
Engine Type:
4-stroke, Liquid-Cooled, SOHC
Engine Displacement:
375 cc (approximate, often referred to as 400cc)
Bore X Stroke:
Specifics detailed in manual
Compression Ratio:
Specifics detailed in manual
Horsepower:
Approximately 26-30 HP (variations may exist)
Torque:
Specifics detailed in manual
Carburetor Model:
Mikuni VM34SS (typical)
Fuel Type:
Unleaded gasoline
Fuel Capacity:
Approximately 4.5 gallons (17 L)
Oil Type:
SAE 20W-50 motorcycle oil (typically)
Oil Capacity:
Specifics detailed in manual (e.g., ~1.9 quarts with filter change)
Engine Oil Change:
Every 100 hours or annually, whichever comes first (refer to manual for exact hours).
Air Filter Cleaning Or Replacement:
Check every 25 hours, clean/replace as needed.
Spark Plug Inspection:
Inspect every 50 hours, replace as needed based on condition.
Valve Adjustment:
Recommended every 200-400 hours or annually (critical for performance).
Brake Fluid Flush:
Recommended every 2 years or as per manual.
Engine Oil:
SAE 20W-50 Motorcycle Oil (API SG or higher)
Coolant:
Ethylene glycol based antifreeze (50/50 mix with distilled water)
Brake Fluid:
DOT 3 or DOT 4 Hydraulic Brake Fluid
Carburetor Fouling:
Common with infrequent use or poor fuel quality; manual details cleaning and adjustment.
Cvtsuspension Wear:
Belt wear and suspension bushing wear are common with high mileage; manual covers replacement.
Electrical Connector Corrosion:
Exposure to elements can lead to corrosion; manual provides guidance on inspection and cleaning.
Oil Filter Pnp:
Part numbers vary, consult manual for specific cross-references (e.g., HiFlofiltro HF145, K&N KN-145 often fit).
Air Filter Pnp:
Part numbers vary, consult manual for specific cross-references (e.g., UNI Filter NU-4131ST often fits).
