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Polaris ATV 400 6x6 1996 1997 Workshop Service Repair Manual

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This document provides comprehensive service and repair information for the ATV 400 6x6, covering the 1996 and 1997 model years. Engineered as a robust utility all-terrain vehicle, the ATV 400...
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Type: Atv
Vendor:
Sku: 58844
Polaris ATV 400 6x6 1996 1997 Workshop Service Repair ManualPolaris ATV 400 6x6 1996 1997 Workshop Service Repair ManualPolaris ATV 400 6x6 1996 1997 Workshop Service Repair ManualPolaris ATV 400 6x6 1996 1997 Workshop Service Repair Manual
This document provides comprehensive service and repair information for the ATV 400 6x6, covering the 1996 and 1997 model years. Engineered as a robust utility all-terrain vehicle, the ATV 400 6x6 is renowned for its selectable 6x6 all-wheel-drive capability, substantial cargo capacity, and reliable performance across various demanding applications, including work, farm tasks, trail riding, and general utility duties. Its design prioritizes durability and functionality, making it a capable machine for both recreational and professional use, often compared favorably to competitors of its era for its specific utility features. This workshop service repair manual offers factory-level detail on all major systems, including the engine, transmission, drivetrain, suspension, brakes, steering, electrical system, and fuel system. It provides detailed step-by-step instructions for maintenance, diagnostics, troubleshooting, repair, overhaul, and rebuilding of components. Essential technical data, torque specifications, fluid recommendations, and wiring diagrams are included to assist owners, mechanics, and technicians in maintaining the optimal performance, reliability, and safety of their ATV 400 6x6.
🏷️ Basic Information
Identification
Make:
Polaris
Model:
ATV 400 6x6
Model Years Covered:
1996, 1997
👋 Introduction
Market Position
Category:
Utility All-Terrain Vehicle (ATV)
Competitive Analysis
Competitors 1996 1997:
Honda TRX400, Yamaha Big Bear 400, Kawasaki Bayou 400
Key Features
Wheel Drive:
6x6 selectable AWD
Cargo Capacity:
High, designed for utility and hauling
Intended Use:
Work, farm, trail riding, utility tasks
📋 Manual Details
Coverage Areas
Coverage Scope:
Complete official factory service and repair
Page Count
Estimated Pages:
Hundreds
Manual Type
Type:
Workshop Service Repair Manual
Language
Language:
English
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Engine:
Yes, detailed diagnostics, repair, and overhaul
Transmission:
Yes, including gear case and drive systems
Drivetrain:
Yes, covering 6x6 drive system, differentials, and driveshafts
Suspension:
Yes, front and rear suspension systems, shocks, and components
Brakes:
Yes, hydraulic brake system, calipers, master cylinders, and bleeding procedures
Steering:
Yes, steering column, tie rods, and knuckle assembly
Electrical System:
Yes, wiring diagrams, ignition, lighting, charging system, starter
Fuel System:
Yes, carburetor, fuel lines, and fuel tank
Cooling System:
Yes, radiator, fan, and coolant flow
Frame And Body:
Yes, chassis, body panels, and mounting points
Wheels And Tires:
Yes, wheel mounting, tire specifications, and pressure
Procedures Included
Maintenance:
Yes, routine checks, lubrication, adjustments
Troubleshooting:
Yes, diagnostic flowcharts and common problem solutions
Repair:
Yes, detailed step-by-step repair instructions for all systems
Overhaul:
Yes, complete engine and transmission overhaul procedures
Rebuilding:
Yes, carburetor rebuilding and other component rebuilds
Assembly Disassembly:
Yes, comprehensive instructions for component removal and installation
Torque Specifications:
Yes, critical torque values for all fasteners
Technical Depth
Depth:
Comprehensive factory-level detail
📊 Manual Specifications
File Format
File Type:
PDF
Print Quality
Printability:
Printable in its entirety or selected sections
Binding Type
Binding:
Digital (N/A for PDF, but implies printable pages)
Paper Type
Paper Quality:
Digital (N/A for PDF, but implies clear, readable text and diagrams)
⚙️ Engine Specifications
Primary Engine
Engine Type:
4-stroke, liquid-cooled
Displacement:
Approximately 375cc - 400cc (specific designation may vary slightly)
Bore X Stroke:
Refer to manual for exact specifications
Compression Ratio:
Refer to manual for exact specifications
Performance
Horsepower:
Estimated 20-25 HP (refer to manual for precise figures)
Torque:
Refer to manual for exact specifications
Fuel System
Carburetor Type:
Single Carburetor (e.g., Mikuni or similar, specific model in manual)
Fuel Type:
Unleaded Gasoline
Fuel Tank Capacity:
Refer to manual for exact specifications
🔧 Transmission
Standard
Transmission Type:
Automatic (CVT - Continuously Variable Transmission)
Optional
Gear Reduction:
Yes, for low-speed torque and hauling
Features
Drive Modes:
2WD, 4WD, 6WD (selectable)
Final Drive:
Shaft drive to all axles
📐 Dimensions
Exterior
Length:
Refer to manual for exact specifications
Width:
Refer to manual for exact specifications
Height:
Refer to manual for exact specifications
Weights
Dry Weight:
Refer to manual for exact specifications
Ground Clearance:
Refer to manual for exact specifications
🛡️ Safety Features
Ratings
Safety Standards:
Designed to meet relevant ATV safety standards of the era
Active Features
Braking System:
Hydraulic disc brakes, front and rear
Passive Features
Lighting:
Headlights, taillight, brake light
💡 Technology Features
Infotainment
Display Features:
Basic instrument cluster: speedometer, odometer, neutral indicator, high beam indicator
Driver Assistance
Adc Features:
None (ATV of this era)
Connectivity
Connectivity Features:
None
🔧 Maintenance
Service Intervals
Oil Change:
Refer to manual for specific mileage/hours
Spark Plug Inspection:
Refer to manual for specific mileage/hours
Air Filter Cleaning:
Refer to manual for specific mileage/hours, often more frequent in dusty conditions
Fluid Specifications
Engine Oil Type:
Refer to manual for specific viscosity (e.g., SAE 10W-40, JASO MA)
Engine Oil Capacity:
Refer to manual for exact capacity
Coolant Type:
Ethylene glycol-based antifreeze (specific mix ratio in manual)
Brake Fluid Type:
DOT 3 or DOT 4 hydraulic brake fluid (confirm with manual)
Gearcase Oil Type:
Refer to manual for specific gear oil specification
Known Issues
Common Wear Items:
Brake pads, wheel bearings, CVT belt, suspension bushings
Electrical Issues:
Wiring harness wear, corrosion on connectors (common in wet environments)
Carburetor Performance:
Can be susceptible to clogging if fuel quality is poor or fuel system is not clean
📚 Vehicle History
Brand Heritage
Manufacturer:
Polaris Industries
Model Evolution
Predecessors:
Polaris 350L, other Polaris utility ATVs
Production
Production Period:
1996-1997 for this specific 400 6x6 model
🏆 Awards & Recognition
Recognitions
Industry Accolades:
Generally well-regarded for its utility and 6x6 capability in its class during its production years.
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