Segment:
Entry-level to mid-range recreational ATV for utility and trail riding.
Competitors:
Competed with models from Honda (e.g., TRX300FW), Yamaha (e.g., Kodiak 400), Suzuki (e.g., QuadRunner 300), and Kawasaki (e.g., Bayou 300).
Features:
Reliable two-stroke engine, selectable 2WD, rugged chassis, utility rack system, comfortable seating for its class.
Primary Coverage:
Factory Service Repair
Secondary Coverage:
Maintenance, Troubleshooting, Adjustments, Repair, Disassembly, Assembly, Installation, Removal
Estimated Pages:
Likely between 300-500 pages, typical for a comprehensive factory service manual of this era.
Type:
Service Manual / Repair Manual
Engine:
Detailed overhaul, tuning, carburetor, cooling system, lubrication.
Transmission Drivetrain:
Clutch, drive shafts, differential, gearbox, chain/belt drive maintenance.
Brakes:
Hydraulic system, caliper, master cylinder, pad/shoe replacement, bleeding procedures.
Electrical System:
Ignition system, battery, charging system, lighting, starter, wiring diagrams, component testing.
Chassis Suspension:
Front and rear suspension components, steering system, shocks, bearings, ball joints.
Body Frame:
Frame inspection, body panel removal/installation, guards, racks.
Fuel System:
Fuel tank, fuel lines, fuel filter, fuel pump (if applicable).
Cooling System:
Radiator, hoses, fan, coolant specifications.
Maintenance:
Regular service checks, lubrication points, fluid changes, filter replacements.
Troubleshooting:
Diagnostic charts for common symptoms and their resolutions.
Repair:
Detailed step-by-step instructions for component repair and replacement.
Disassembly Assembly:
Comprehensive instructions for dismantling and reassembling major vehicle components.
Installation Removal:
Guidance on removing and installing various parts and accessories.
Adjustments:
Carburetor tuning, throttle cable adjustment, brake lever adjustment.
Depth:
Comprehensive, covering from basic routine maintenance to complete engine and transmission rebuilds. Includes torque specifications, tolerances, and diagnostic procedures.
Searchability:
Typically searchable text within the PDF for quick information retrieval.
Quality:
High-resolution scans of original factory documentation, ensuring clarity of text and diagrams.
Binding:
N/A (Digital PDF Download)
Type:
N/A (Digital PDF Download)
Type:
2-stroke, 2-cylinder, liquid-cooled
Bore X Stroke:
Typically around 63mm x 63mm (specifics should be confirmed in manual).
Compression Ratio:
Around 6.5:1 (typical for this era's 2-strokes).
Power Output:
Estimated 20-25 HP at peak RPM (specific output not usually listed in manual, but implied by engine type).
Ignition:
CDI (Capacitor Discharge Ignition)
Carburetion:
Dual Mikuni VM series carburetors (e.g., VM32SS or similar). Specifics confirmed in manual.
Fuel Type:
Unleaded gasoline, typically 87 octane minimum.
Fuel Mixture:
Requires 2-stroke oil pre-mixed with gasoline at a ratio specified by Polaris (commonly 40:1 or 50:1). Manual will specify exact ratio.
Top Speed:
Not typically published, but in the range of 40-50 mph depending on conditions and rider weight.
Type:
CVT (Continuously Variable Transmission) with automatic clutch
Drive System:
Shaft drive to rear differential
Gears:
Forward, Neutral, Reverse
Clutch Type:
Primary and Secondary Drive Clutch System
Belt Maintenance:
CVT belt inspection, tension adjustment, and replacement procedures are detailed.
Length:
Approx. 77 inches (specifics in manual)
Width:
Approx. 42 inches (specifics in manual)
Height:
Approx. 45 inches (specifics in manual)
Dry Weight:
Approx. 450-470 lbs (specifics in manual)
Ground Clearance:
Approx. 8-10 inches (specifics in manual)
Rack Capacity Front:
Approx. 25 lbs (typical for this class)
Rack Capacity Rear:
Approx. 50 lbs (typical for this class)
Towing Capacity:
Typically around 1500 lbs for this class, but check manual for exact rating.
Atv Safety:
ATVs require responsible operation and appropriate safety gear. The manual will emphasize safe riding practices.
Brakes:
Hydraulic disc brakes front and rear.
Parking Brake:
Mechanical parking brake, typically integrated with the rear brake system.
Lighting:
Headlights, taillight, brake light for visibility.
Throttle Limiter:
Some models had a throttle limiter screw for beginner riders, covered in the manual.
Features:
Basic instrumentation: speedometer, odometer, neutral and reverse indicator lights. No advanced infotainment systems on this model.
Features:
No electronic driver assistance features. Operation relies on rider skill.
Features:
No connectivity features.
Oil Change Engine:
Regular checks and top-offs of the 2-stroke oil reservoir are crucial. The manual will specify when to change the gearbox oil.
Spark Plug Inspection:
Recommended inspection and cleaning/replacement every few hundred miles or annually, as detailed in the manual.
Air Filter Cleaning:
Frequent cleaning or replacement, especially in dusty conditions, as per manual recommendations.
Brake Fluid Flush:
Recommended every 1-2 years, or as per manual, to maintain braking performance.
Engine Oil:
Specific 2-stroke synthetic or semi-synthetic oil, pre-mixed with fuel. Manual will specify exact type and ratio (e.g., Polaris Premium 2-Cycle Oil or equivalent API-TC rated oil).
Gearbox Oil:
Gearbox oil specification (e.g., SAE 80W-90 hypoid gear oil) and capacity will be detailed in the manual.
Brake Fluid:
DOT 3 or DOT 4 hydraulic brake fluid, as specified by Polaris.
Coolant:
Ethylene glycol-based antifreeze coolant, typically a 50/50 mix with distilled water.
Common Wear Items:
CVT belt wear, carburetor gumming, suspension bushings, rear brake pads, and 2-stroke top-end wear are common concerns.
Carburetor Issues:
Fuel delivery issues, idling problems due to carburetor settings or cleanliness are frequent. Manual provides tuning and cleaning guides.
2 Stroke Engine:
Proper oil/fuel mixture and maintenance are critical for longevity of 2-stroke engines. Manual covers top-end inspection and rebuilds.
Polarise Heritage:
Polaris is a long-standing American manufacturer known for snowmobiles, ATVs, and off-road vehicles, established in 1954.
Atv Development:
The 400 2x4 was part of Polaris's early to mid-90s ATV lineup, transitioning from simpler designs to more powerful and feature-rich models.
Production Period:
The Polaris 400 2x4 was produced throughout the mid-1990s. The '95 model is a specific iteration within this period.
