Segment:
Utility ATV segment, emphasizing work and utility capabilities with its 6x6 drivetrain.
Target Audience:
Owners and mechanics of Polaris 300/400 6x6 ATVs requiring detailed repair and maintenance information.
Competitors Segment:
Competed with other utility-focused ATVs from brands like Yamaha, Honda, and Kawasaki, often emphasizing its 6-wheel drive advantage for traction and load carrying.
Comprehensiveness:
Offers exhaustive coverage for repair, maintenance, and rebuilding, making it an essential resource for DIY enthusiasts and professional mechanics.
Digital Accessibility:
Convenient PDF format allows for easy access, searching, and selective printing of necessary procedures.
Engine Mechanical:
Complete engine overhaul, disassembly, inspection, repair, and reassembly of all internal and external components.
Fuel System:
Carburetor adjustment, cleaning, and rebuilding; fuel pump operation; fuel tank and lines.
Cooling System:
Radiator, fan, thermostat, coolant flow, and maintenance.
Ignition System:
Spark plugs, ignition coils, CDI unit, timing adjustments.
Drivetrain Transmission:
Automatic transmission (PVT - Polaris Variable Transmission) operation, belt inspection and replacement, clutch service, and gearbox.
Drivetrain Axles Drive:
6x6 driveline system, drive shafts, differentials, and CV joints.
Suspension Steering:
Front and rear suspension components, shock absorbers, bushings, steering linkage, and wheel alignment.
Brakes:
Brake system diagnosis, hydraulic lines, master cylinders, calipers, brake pads, and bleeding procedures.
Electrical System:
Wiring diagrams, battery, starter, charging system, lighting, ignition switch, and accessories.
Bodywork Chassis:
Frame inspection, body panel removal and installation, fenders, racks, and seating.
Wheels Tires:
Tire pressure recommendations, wheel bearing service, and tire replacement.
Routine Maintenance:
Oil changes, filter replacements, lubrication points, spark plug checks, air filter servicing.
Troubleshooting:
Diagnostic procedures for common problems, fault codes (if applicable), and systematic diagnostic trees.
Rebuilds Overhauls:
Complete engine, transmission, and differential rebuild procedures.
Adjustments:
Carburetor tuning, throttle cable adjustment, brake adjustments.
Component Replacement:
Step-by-step guides for replacing major and minor components.
Depth:
Comprehensive, covering everything from basic user-level maintenance to full engine and transmission rebuilds.
Diagnostic Capabilities:
Includes troubleshooting guides and diagnostic information for identifying and resolving mechanical and electrical issues.
Specifications Data:
Detailed torque specifications, clearances, and measurement data for all components.
Type 300:
Likely a 2-stroke, single-cylinder, liquid-cooled engine (common for Polaris of this era).
Displacement 300:
Approximately 298cc (based on model designation)
Type 400:
Likely a 2-stroke, single-cylinder, liquid-cooled engine.
Displacement 400:
Approximately 375cc (based on model designation)
Horsepower Estimate:
Estimated 25-35 HP, dependent on specific engine tuning and model year.
Torque Estimate:
Torque figures are model-specific but emphasize low-end grunt for utility.
Carburetor:
Single carburetor (e.g., Mikuni or Keihin), requiring periodic cleaning and adjustment.
Fuel Type:
Unleaded gasoline
Oil Type:
Specific 2-stroke oil for pre-mix or oil injection system, as dictated by the engine design. Manual will specify grade (e.g., JASO FD).
Length Estimate:
Approx. 75-80 inches (190-203 cm)
Width Estimate:
Approx. 40-45 inches (102-114 cm)
Height Estimate:
Approx. 40-45 inches (102-114 cm)
Dry Weight Estimate:
Approx. 450-550 lbs (204-250 kg)
Ground Clearance Estimate:
Approx. 7-9 inches (18-23 cm)
Rack Capacity Estimate:
Front and rear racks typically rated for 50-100 lbs each.
Oil Change Interval:
Typically every 20-30 hours of operation or annually. Manual will specify exact interval.
Air Filter Service:
Check and clean every 10-20 hours, replace as needed. Manual will detail specific cleaning procedure.
Spark Plug Replacement:
Replace every 50-100 hours or annually. Manual will specify correct plug type and gap.
Pvt Belt Inspection:
Inspect belt condition and tension every 20-30 hours. Replace if showing signs of wear, fraying, or excessive glazing.
Engine Oil Type:
Specific 2-stroke oil injection (if equipped) or pre-mix oil. Manual will specify grade and ratio (e.g., SAE 0W-40 for some gearboxes, specific 2T oil for engine).
Transmission Oil Type:
Manual will specify a specific ATV transmission fluid or gear oil (e.g., SAE 80W-90 GL-4 for gearbox).
Coolant Type:
Ethylene glycol-based antifreeze coolant, typically a 50/50 mix with distilled water. Manual will specify type and capacity.
Pvt Belt Wear:
Drive belts can wear prematurely if ridden aggressively or if the PVT system is not maintained (e.g., clutch alignment, proper belt tension).
Carburetor Clogging:
Common in ATVs that sit for extended periods due to fuel degradation and sediment. Requires regular cleaning.
Electrical Connector Corrosion:
Exposure to elements can lead to corrosion in electrical connectors, causing intermittent faults. Manual's wiring diagrams are crucial for diagnosis.
Suspension Bushings:
Wear on rubber bushings in suspension and steering components can lead to play and degraded handling. Manual provides replacement procedures.
