Market Segment:
Heavy-duty utility ATV, designed for work, hauling, and off-road capability with its 6x6 drivetrain.
Competitors:
During its production run, the Polaris 400 6x6 competed with other utility-focused ATVs from brands like Kawasaki, Yamaha, Suzuki, and Can-Am, particularly those offering 6-wheel configurations or high towing capacities.
Vehicle Features:
6x6 all-wheel drive for superior traction and load-carrying, robust chassis, ample towing and cargo capacity, utility-focused design.
Value:
Essential for owners seeking to perform maintenance, repairs, and diagnostics, ensuring longevity and optimal performance of their vintage Polaris ATV.
Audience:
Polaris ATV 400 6x6 owners, mechanics, and enthusiasts performing maintenance and repairs.
Primary Coverage:
Complete factory service and repair for Polaris ATV 400 6x6 models
Specific Years Covered:
1985, 1986, 1987, 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995
Estimated Pages:
Variable, but comprehensive factory manuals typically range from 300-700+ pages depending on specific model updates and detail.
Type:
Service Repair Manual (Factory Authorized)
Powertrain:
Engine disassembly, assembly, tuning, lubrication, cooling system, exhaust system, fuel system (carburetor, fuel pump, lines), ignition system (magneto, spark plugs, timing), starting system (starter motor, solenoid), charging system (alternator/stator, regulator).
Drivetrain:
Transmission (gearbox, shifting mechanisms, bearings, seals), differential gears, drive shafts, U-joints, final drive (sprockets, chains), front and rear axle assemblies, braking system (hydraulic lines, calipers, master cylinders, brake shoes/pads, parking brake).
Chassis And Suspension:
Frame inspection and repair, front suspension (A-arms, shocks, springs, steering components), rear suspension (swingarm, shocks, springs, linkage), wheel bearings, steering system (handlebars, tie rods, steering knuckles), hitch/towing components.
Electrical System:
Wiring diagrams, battery service, lighting systems (headlights, taillights, brake lights), accessory circuits, switches, fuses, relays, instrument cluster functionality.
Body And Controls:
Body panels, seat, fenders, floorboards, controls (throttle, brake levers, shifter), operator safety features, lubrication points.
Maintenance:
Scheduled maintenance intervals, oil changes, filter replacements (air, oil, fuel), spark plug service, brake adjustments, chain lubrication and adjustment, lubrication of pivot points.
Troubleshooting:
Diagnostic charts and procedures for common issues related to engine starting, running, braking, electrical faults, and drivetrain operation.
Repair And Rebuild:
Detailed step-by-step instructions for disassembly, inspection, repair, and reassembly of all major components and systems.
Technical Adjustments:
Carburetor tuning and adjustment, ignition timing verification, valve clearance adjustment (if applicable), brake system bleeding, suspension adjustments.
Depth:
Comprehensive, covering routine maintenance to complete engine and transmission rebuilds. Includes detailed torque specifications, clearances, and diagnostic procedures.
Type:
Likely a 2-stroke, air-cooled or liquid-cooled engine, common for Polaris ATVs of this era. Specific displacement details often varied.
Displacement Cc:
Typically around 350-400cc. Specific figures vary by exact model year and variant.
Bore X Stroke:
Refer to specific model year within the manual for precise measurements.
Horsepower Hp:
Estimated 20-30 HP, depending on exact engine configuration and tuning.
Torque Lb-Ft:
Torque figures would be model-specific and geared towards low-end grunt for utility.
Top Speed:
Approximately 35-45 mph, prioritizing torque and stability over high speed.
Induction:
Carburetor (e.g., Mikuni or Keihin) – Manual will detail specific carburetor model, jetting, and adjustment procedures.
Fuel Type:
Unleaded gasoline (typically 87 octane, but manual will confirm).
Type:
Magneto ignition system with CDI (Capacitor Discharge Ignition) unit.
Type:
Air-cooled, possibly with fan assist or limited liquid cooling on later models. Manual specifies.
Type:
Automatic transmission with a torque converter and a CVT (Continuously Variable Transmission) belt system, offering variable gear ratios.
Drive Modes:
2WD, 4WD, and 6WD selectable modes.
Type:
N/A (Typically a single automatic transmission setup for this model).
Reduction Gears:
Low and High range gearing for towing and general use.
Transmission Fluid Type:
Refer to manual for specific SAE viscosity grade and type (e.g., SAE 30, SAE 80W-90 gear oil for differentials, specific CVT fluid if applicable).
Length:
Refer to specific model year data in manual; typically around 80-90 inches.
Width:
Refer to specific model year data in manual; typically around 40-50 inches.
Height:
Refer to specific model year data in manual; typically around 40-50 inches.
Rear Rack Capacity Lbs:
Typically rated for significant load, often 100-200+ lbs. Manual will provide exact spec.
Dry Weight Lbs:
Estimated 500-600 lbs. Manual will provide precise dry weight.
Towing Capacity Lbs:
High, often in the 900-1200+ lb range due to 6x6 configuration and robust chassis. Manual will confirm exact rating.
Front Tire Size:
Commonly 25x8-12 or similar. Manual will list exact specifications and recommended pressures.
Rear Tire Size:
Commonly 25x10-12 or similar. Manual will list exact specifications and recommended pressures.
Bolt Pattern:
Refer to manual for specific wheel bolt pattern and offset.
Crash Test Ratings:
N/A (ATVs are not subject to the same crash testing standards as automobiles).
Braking System:
Hydraulically actuated disc brakes (front and rear) and mechanical parking brake. Manual details operation and maintenance.
Engine Braking:
CVT system provides some engine braking effect.
Operator Presence Control:
Throttle and brake lever interlocks typical for ATVs of this era.
Lighting:
Headlights, taillight, and brake light for visibility and signaling.
Oil Change Interval Hours:
Typically every 30-50 hours of operation or annually, whichever comes first. Manual provides definitive schedule.
Air Filter Cleaning Hours:
Recommend checking and cleaning every 20-30 hours, replacing as needed. Manual specifics are crucial.
Spark Plug Replacement Hours:
Typically every 100-150 hours, or when performance degrades. Manual will list correct spark plug type and gap.
Engine Oil Type:
Refer to manual for recommended oil viscosity (e.g., SAE 10W-30, SAE 30) and API service classification. Often a 2-stroke oil/gas mixture for pre-mix engines or specific oil for oil-injected 2-strokes.
Engine Oil Capacity Liters:
Refer to manual; oil capacity is dependent on whether it's a premix or oil-injected system.
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid, depending on system requirements. Manual will specify.
Common Problems:
Wear items like CVT belts, carburetor issues (clogging, tuning), starter solenoid failures, wheel bearing wear, and potential chain/sprocket wear are common on older ATVs. The manual addresses these directly.
Troubleshooting Focus:
The manual provides systematic approaches to diagnose and resolve these common problems, including electrical continuity tests, fuel delivery checks, and mechanical component inspections.
Polarishistory:
Polaris Industries, founded in 1954, has a long history of producing snowmobiles and later expanding into ATVs, pioneering many innovations in the off-road vehicle market.
400 6X6 Evolution:
The 6x6 platform represented a significant step in utility ATVs, offering enhanced traction and carrying capacity. Continuous refinement occurred throughout the 1985-1995 production run, with minor updates to engine, suspension, and styling.
Manufacturing Location:
Polaris vehicles are typically manufactured in the United States.
