Target User:
ATV owners, home mechanics, independent repair shops
Value Proposition:
Essential tool for maintaining and repairing Polaris 400 4x4 ATVs from 1985-1995, saving on dealership service costs.
Vs Owner Manual:
Significantly more in-depth than an owner's manual, focusing on repair procedures rather than basic operation.
Diagnostic Focus:
Emphasis on identifying and resolving mechanical and electrical issues.
Comprehensiveness:
Covers all major systems for the specified model range.
Engine Mechanics:
Engine overhaul, cylinder head, pistons, crankshaft, lubrication, cooling system, fuel system, ignition system
Transmission Drivetrain:
Gearbox, clutch, drive shafts, differentials, 4-wheel drive system operation and repair
Chassis Suspension:
Front and rear suspension, steering system, shock absorbers, control arms, bushings
Brakes:
Brake system inspection, hydraulic components, brake pads, rotors, calipers, bleeding procedures
Electrical System:
Wiring diagrams, lighting, battery, starter, alternator, ignition switch, sensors, fuses, relays
Bodywork Frame:
Body panel removal/installation, frame inspection, fenders, seat, handlebars
Routine Maintenance:
Oil changes, filter replacements, spark plug checks, lubrication points, air filter cleaning/replacement
Troubleshooting:
Diagnostic charts, common problem identification, step-by-step fault finding
Repair Procedures:
Detailed, step-by-step instructions for component removal, repair, and reinstallation
Disassembly Assembly:
Complete breakdown and reassembly instructions for major components and systems
Depth Of Coverage:
Comprehensive, covering routine maintenance to complete engine and drivetrain rebuilds
Diagnostic Capabilities:
Includes diagnostic flowcharts and specifications for identifying and resolving mechanical and electrical issues
Engine Type:
Typically a 2-stroke, single-cylinder engine
Displacement:
Around 300-400cc, specific displacement varied slightly across the years and sub-models (e.g., often referred to as the 'XPL 400' or similar)
Cooling System:
Air-cooled
Horsepower Range:
Approx. 20-25 HP (figures varied by specific year and tuning)
Torque Range:
Approx. 25-30 lb-ft (figures varied)
Carburetion:
Single carburetor (e.g., Mikuni VM series common)
Fuel Type:
Unleaded gasoline
Ignition Type:
CDI (Capacitor Discharge Ignition)
Transmission Type:
Automatic (CVT - Continuously Variable Transmission) with Hi/Lo range and Reverse
Manual Transmission:
Not typically offered for this model
Drive System:
Shaft drive to all four wheels, with selectable 2WD/4WD engagement
Differential Lock:
May feature a locking front differential on certain sub-models or years
Length:
Approx. 75-80 inches (Varies by specific model/year)
Width:
Approx. 40-45 inches (Varies by specific model/year)
Height:
Approx. 45-50 inches (Varies by specific model/year)
Dry Weight:
Approx. 450-550 lbs (Varies by specific model/year)
Towing Capacity:
Typically rated for light towing, consult specific model documentation
Rack Capacity:
Front and rear racks capable of carrying moderate loads (e.g., 25-50 lbs front, 50-75 lbs rear)
Crash Safety Rating:
N/A (ATVs are not typically crash-tested by regulatory bodies like NHTSA)
Braking System:
Hydraulic disc brakes (front and rear)
Suspension Stability:
Independent front suspension (IFS) and swingarm rear suspension (on later models) contribute to stability.
Roll Over Protection:
Not equipped with standard roll-over protection structures (ROPS); operator awareness and safe riding practices are paramount.
Lighting:
Headlights and taillight for visibility.
Engine Oil Change:
Every 50-100 operating hours or annually, whichever comes first (consult manual for exact spec).
Air Filter Cleaning:
Inspect and clean every 20-40 operating hours, replace as needed.
Spark Plug Inspection:
Inspect and gap every 100 operating hours.
Engine Oil Type:
Typically SAE 10W-40 or 20W-50 motorcycle-specific or ATV engine oil meeting API SG or higher specifications.
Gearcase Oil Type:
GL-4 or GL-5 gear oil, often SAE 75W-90 or 80W-90.
Brake Fluid Type:
DOT 3 or DOT 4 hydraulic brake fluid.
Carburetor Fouling:
Common issue with older 2-stroke engines, requiring regular cleaning and adjustment.
Cvt Belt Wear:
CVT belts can wear over time and require inspection and replacement.
Electrical Connections:
Corroded or loose electrical connections are a common cause of intermittent faults.
Suspension Bushings:
Worn suspension bushings can lead to handling issues and noise.
Polarisk History:
Polaris Industries, founded in 1954, has a long history of producing off-road vehicles, including snowmobiles and ATVs.
Atv 400 Development:
The 400 4x4 model was a significant offering in Polaris's early ATV lineup, evolving from earlier two-wheel drive models and introducing key 4WD capabilities. It paved the way for more advanced models.
Manufacturing Location:
Primarily manufactured in the United States by Polaris Industries.
