Polaris 400 6x6 1996-1998 PDF Service & Repair Manual Download

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This manual covers the 400 6x6 ATV, produced for the model years 1996, 1997, and 1998. Designed as a utility ATV, it is engineered for recreational riders, farmers, hunters, and...

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Type: Atv

Vendor:

Sku: 70050

Tags: 1996 1997 1998 ATV Misc Polaris Polaris 400 6x6 Powersports

Product variants

Description

This manual covers the 400 6x6 ATV, produced for the model years 1996, 1997, and 1998. Designed as a utility ATV, it is engineered for recreational riders, farmers, hunters, and utility users who require exceptional traction in challenging terrain. Key features include a robust 4-stroke, single-cylinder engine known for its reliability, and the Variable Transmission (PVT) with high and low range gearing for automatic shifting and engine braking. The full-time 6x6 drive system provides superior capability in difficult conditions, making it ideal for hauling, towing, and navigating off-road environments. This comprehensive service and repair manual provides detailed guidance for maintaining and repairing your 400 6x6. It encompasses a wide range of topics, including engine assembly and tuning, transmission service, drivetrain maintenance, suspension and brake system overhauls, and electrical system diagnostics. The manual offers step-by-step procedures for routine maintenance, troubleshooting common issues, and complete component rebuilds, ensuring owners and technicians have the necessary information to keep the vehicle in optimal working condition. It includes essential technical specifications, wiring diagrams, and exploded-view illustrations for accurate repairs.

🏷️ Basic Information

Identification

Make:

Polaris

Model:

400 6x6

Model Variant:

Years Covered:

1996, 1997, 1998

Codes

Chassis Code:

N/A (ATV specific, typically VIN based)

👋 Introduction

Market Position

Segment:

Utility ATV

Target Audience:

Recreational riders, farmers, hunters, utility users requiring 6x6 traction.

Competitive Analysis

Competitors:

Similar 6x6 ATVs from brands like Yamaha, Honda, Suzuki, and Kawasaki during the mid-to-late 1990s.

Key Features

Traction:

Full-time 6x6 drive system for exceptional traction in challenging terrain.

Engine:

Reliable 4-stroke, single-cylinder engine, known for its workhorse capabilities.

Transmission:

Polaris Variable Transmission (PVT) with high and low range gearing, offering automatic shifting and engine braking.

Utility:

Designed for hauling, towing, and navigating difficult off-road conditions.

📋 Manual Details

Coverage Areas

Coverage Scope:

Comprehensive Service and Repair

Page Count

Estimated Pages:

Refer to actual manual for exact count; typically 300-500 pages for this era of ATV service manual

Manual Type

Type:

Service and Repair Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine:

Engine assembly, disassembly, tuning, lubrication, cooling system, ignition system, carburetor service.

Transmission:

Automatic transmission (PVT - Polaris Variable Transmission) operation, maintenance, clutch service, belt inspection and replacement.

Drivetrain:

Front and rear driveshafts, differentials (if applicable to model variant), 6x6 drive system engagement and maintenance, universal joints.

Suspension:

Front and rear suspension systems, shocks, springs, A-arms, pivot points, bushings, bearings.

Brakes:

Hydraulic brake system, brake fluid, master cylinder, calipers, brake pads, brake lines, parking brake.

Electrical:

Battery, charging system (stator, regulator/rectifier), starting system (starter motor, solenoid), lighting (headlights, taillights), ignition switch, wiring diagrams.

Fuel System:

Fuel tank, fuel lines, fuel filter, carburetor, choke operation.

Cooling System:

Air-cooling system, cooling fins, engine shroud, thermal considerations.

Frame And Body:

Frame structure, fenders, racks, seat, handlebars, controls.

Procedures Included

Maintenance:

Regular scheduled maintenance, oil changes, filter replacements, lubrication points, battery care, tire pressure checks.

Troubleshooting:

Diagnostic procedures for common starting, running, and performance issues. Symptom-based troubleshooting guides.

Repair:

Step-by-step instructions for component removal, disassembly, cleaning, inspection, repair, reassembly, and installation.

Engine Rebuild:

Detailed instructions for engine top-end and bottom-end overhauls, including piston, rings, cylinder, and crankshaft service.

Carburetor Tuning:

Carburetor adjustment, cleaning, jetting information, and synchronization (if applicable).

Electrical Diagnostics:

Wiring diagram interpretation, voltage drop testing, continuity checks, component testing for electrical circuits.

Wheel Bearing Service:

Inspection, greasing, and replacement of wheel bearings.

Tire And Wheel Service:

Tire mounting, balancing, and wheel torque specifications.

Steering System Service:

Tie rod ends, steering linkage, handlebar assembly maintenance and adjustment.

Body Panel Removal Installation:

Instructions for removing and refitting fenders, racks, seat, and other body components for access to mechanical parts.

Lighting And Switch Replacement:

Procedures for replacing bulbs, switches, and troubleshooting electrical circuits related to lights.

Graphics And Decals:

Information on the application and care of vehicle graphics and decals.

Technical Depth

Depth:

Comprehensive, covering everything from basic adjustments to complete engine and transmission overhauls, including detailed electrical schematics.

📊 Manual Specifications

File Format

Format:

Print Quality

Quality:

Digital reproduction, quality dependent on original source; typically includes clear diagrams and text.

Binding Type

Binding:

N/A (Digital Download)

Paper Type

Paper:

N/A (Digital Download)

Searchability

Text Search:

Typically searchable PDF, allowing for quick keyword access to information.

Completeness

Content Scope:

Complete Service and Repair Manual, including all necessary diagrams, specifications, and procedures for maintenance and repair.

Usability

Diagram Quality:

Expect clear, detailed exploded-view diagrams and wiring schematics essential for accurate work.

⚙️ Engine Specifications

Primary Engine

Type:

4-Stroke, Single Cylinder

Displacement:

375cc to 400cc (Specific variant may differ slightly, common range for this model line)

Cooling:

Air-Cooled

Bore X Stroke:

Refer to specific model year for exact dimensions.

Compression Ratio:

Refer to specific model year for exact ratio.

Performance

Horsepower:

Approximately 25-30 HP (estimated based on engine size and era)

Torque:

Refer to specific model year for exact specifications.

Fuel System

Carburetor:

Mikuni (common for Polaris of this era), single barrel

Fuel Type:

Unleaded Gasoline

Fuel Capacity:

Approximately 3.7 US gallons (14 Liters)

🔧 Transmission

Standard

Type:

Polaris Variable Transmission (PVT)

Gearing:

High, Low, Neutral, Reverse

Drive System:

6x6, Shaft Drive

Optional

Type:

Features

Engine Braking:

Standard feature of the PVT system for downhill control.

Clutch System:

Centrifugal clutch with a drive and driven pulley system.

Fluid Specifications

Transmission Fluid:

Polaris Premium ATV 2-Cycle Oil (for pre-mix if applicable) and PVT Fluid (check manual for specific type, often a specialized CVT fluid or 0W-40 synthetic motor oil).

📐 Dimensions

Exterior

Length:

Approximately 85 inches (2159 mm)

Width:

Approximately 45 inches (1143 mm)

Height:

Approximately 43 inches (1092 mm)

Weights

Dry Weight:

Approximately 550 lbs (250 kg)

Towing Capacity:

Typically rated around 1500 lbs (680 kg)

Rack Capacity Front:

Approximately 50 lbs (23 kg)

Rack Capacity Rear:

Approximately 100 lbs (45 kg)

🛡️ Safety Features

Ratings

Crash Test Rating:

N/A (ATVs are not typically rated by standard automotive crash test organizations)

Active Features

Braking System:

Hydraulic disc brakes front and rear, providing reliable stopping power.

Engine Braking:

PVT system provides significant engine braking for controlled descents.

Passive Features

Rollover Protection:

N/A (Standard ATV design with no rollover protection)

Seatbelt:

N/A (Handlebar steering and footrests)

Lighting:

Headlights, taillight, brake light for visibility.

💡 Technology Features

Infotainment

Features:

N/A (Basic utility vehicle design focused on function, no infotainment system).

Driver Assistance

Features:

N/A (No electronic driver assistance features like ABS or traction control in this era/model).

Connectivity

Features:

N/A (No external connectivity options).

🔧 Maintenance

Service Intervals

Oil Change Engine:

Every 100 hours or annually (refer to manual for specific recommendation).

Air Filter Cleaning:

As needed, depending on operating conditions; typically every 25-50 hours.

Spark Plug Replacement:

Approximately every 1000 hours or annually (check manual for correct spark plug type and gap).

Transmission Belt Inspection:

Inspect every 50 hours, replace as needed based on wear.

Fluid Specifications

Engine Oil:

SAE 10W-40 or SAE 20W-50 (check manual for specific viscosity recommendations based on climate).

Engine Oil Capacity:

Approximately 1.8 US quarts (1.7 Liters).

Brake Fluid:

DOT 3 or DOT 4 Hydraulic Brake Fluid.

Known Issues

Carburetor Clogging:

Common issue with older ATVs due to fuel varnish; regular fuel stabilizer use and cleaning can mitigate.

Pvt Belt Wear:

The CVT belt can wear over time, leading to reduced performance or slippage; regular inspection and replacement are crucial.

Suspension Bushings:

Wear and tear on A-arm and shock bushings can lead to play and reduced handling.

📚 Vehicle History

Brand Heritage

Manufacturer:

Polaris Industries, a prominent American manufacturer of powersports vehicles.

Model Evolution

Lineage:

Part of Polaris's pioneering line of ATVs, building on earlier models like the original Sportsman. The 6x6 configuration offered enhanced traction for specific applications.

Updates:

During this period, Polaris ATVs saw continuous refinement in engine performance, suspension, and reliability.

Production

Manufacturing Location:

USA (Polaris manufacturing facilities)

Production Run:

The Polaris 400 6x6 was a popular model within the 1990s ATV market, with production spanning several years.

🏆 Awards & Recognition

Recognitions

Industry Awards:

While specific awards for this model are not readily publicized, Polaris ATVs of this era were generally well-regarded for their utility and innovation in the ATV market.

Ratings

Customer Satisfaction:

Generally positive among users who valued its 6x6 capability for demanding tasks and challenging terrain.