Arctic Cat 2015 400 Service Manual

SERVICE MANUAL
www.arcticcat.com
400

Arctic Cat 2015 400 Specifications

General

Brand	Arctic Cat
Model	2015 400
Category	Offroad Vehicle
Language	English

Summary

Torque Specifications

Engine/Transmission

Lists torque values for clutch, crankcase, cylinder head, and oil pump components.

Drive Train Components

Specifies torque values for engine mounting, differentials, and drive shaft components.

Brake Components

Lists torque values for brake discs, hoses, calipers, and master cylinders.

Periodic Maintenance

Air Filter

Provides instructions for cleaning and inspecting the air filter.

Valve/Tappet Clearance

Details the procedure for checking and adjusting valve/tappet clearance.

Feeler Gauge Procedure

Valve Adjuster Procedure

Step-by-step guide for adjusting valve clearance using the adjuster dial.

Testing Engine Compression

Adjusting Throttle Cable

Adjusting Engine RPM (Idle)

Engine/Transmission Oil - Filter

Ignition Timing

Shift Lever

Details how to check and adjust the shift lever linkage.

Hydraulic Brake Systems

Checking/Bleeding

Procedure for checking and bleeding the hydraulic brake system.

Checking/Replacing Pads

Burnishing Brake Pads

Procedure for properly burnishing new brake pads for effective braking.

Checking/Replacing V-Belt

Steering Post/Tie Rods

LCD Gauge

Replacing

Procedure for replacing the LCD gauge assembly.

Throttle Control

Adjusting

Instructions for adjusting the throttle cable free-play.

Steering Knuckles

Removing and Disassembling

Steps to remove and disassemble the steering knuckles.

Assembling and Installing

Steps for assembling and installing steering knuckles.

Measuring/Adjusting Toe-Out

Lights

Headlights

Instructions for replacing headlight bulbs.

Taillights-Brakelights

Procedure for replacing taillight and brakelight bulbs.

Running Lights/Back-Up Lights

Instructions for replacing running and back-up light bulbs.

Checking/Adjusting Headlight Aim

Troubleshooting

Problem: Handling too heavy or stiff

Lists conditions and remedies for stiff or heavy handling.

Problem: Starting impaired

Lists conditions and remedies for starting issues.

Problem: Spark absent or weak

Lists conditions and remedies for absent or weak spark.

Problem: Alternator overcharges

Lists conditions and remedies for alternator overcharging.

Problem: Steering oscillation

Lists conditions and remedies for steering oscillation issues.

Problem: Idling or low speed impaired

Lists conditions and remedies for poor idling or low speed performance.

Problem: Spark plug fouled with carbon

Lists conditions and remedies for carbon-fouled spark plugs.

Problem: Charging unstable

Lists conditions and remedies for unstable charging.

Problem: Steering pulling to one side

Lists conditions and remedies for the ATV pulling to one side.

Problem: Medium or high speed impaired

Lists conditions and remedies for impaired medium/high speed operation.

Problem: Spark plug electrodes overheat or burn

Lists conditions and remedies for overheated or burnt spark plug electrodes.

Problem: Starter button inoperative

Lists conditions and remedies for inoperative starter button.

Problem: Tire wear rapid or uneven

Lists conditions and remedies for rapid or uneven tire wear.

Problem: Overflow and fuel level fluctuations

Problem: Alternator does not charge

Lists conditions and remedies for alternator charging failure.

Problem: Battery “sulfation”

Lists conditions and remedies for battery sulfation.

Problem: Steering noise

Lists conditions and remedies for noise originating from the steering system.

Problem: Alternator charges, but charging rate is below the specification

Lists conditions and remedies for low alternator charging rate.

Problem: Battery discharges too rapidly

Lists conditions and remedies for rapid battery discharge.

Problem: Battery polarity reversed

Lists conditions and remedies for reversed battery polarity.

Engine/Transmission

Removing Engine/Transmission

Detailed procedure for removing the engine/transmission assembly from the frame.

Top-Side Components

A. Cylinder Head Cover/Rocker Arms

Procedure for removing the cylinder head cover and rocker arms.

B. Cylinder Head/Camshaft

Steps for removing the cylinder head and camshaft.

Servicing Top-Side Components

Valve Assembly

Instructions for inspecting and servicing the valve assembly.

Measuring Piston-Ring End Gap (Installed)

Cleaning/Inspecting Cylinder Head

C. Cylinder Head/Camshaft

Measuring Piston Pin, Connecting Rod Small End, and Piston-Pin Bore

Measuring Cylinder Head Distortion

D. Cylinder Head Cover/Rocker Arms

Removing Valves

Steps for removing valve springs, keepers, and valves.

Installing Valves

Measuring Piston Skirt/Cylinder Clearance

Cleaning/Inspecting Cylinder

Measuring Camshaft Runout

Installing Piston Rings

Measuring Camshaft Lobe Height

A. Piston

Inspecting Piston

B. Cylinder

Removing Piston Rings

C. Cylinder

D. Piston

Steps for removing the piston.

Left-Side Components

Replacing Starter Clutch Assembly

A. Cover/Stator Assembly

C. Starter Motor

Inspecting Starter Clutch/Gear

Replacing Starter Gear Bearing

A. Starter Idler Gears

B. Rotor/Flywheel

C. Cover

Right-Side Components

D. Centrifugal Clutch Assembly

Inspecting Oil Pump

A. V-Belt Cover

E. Oil Pump Drive Gear

Inspecting Centrifugal Clutch Shoe

B. Driven Pulley

F. Oil Pump Driven Gear

C. Clutch Cover

G. Oil Pump

Inspecting Primary One-Way Drive

A. Oil Pump

Center Crankcase Components

Separating Crankcase Halves

Detailed procedure for separating the crankcase halves.

Correcting Tooth Contact

Instructions for correcting tooth contact patterns on bevel gears.

Joining Crankcase Halves

Detailed procedure for joining the crankcase halves.

Checking Backlash

Procedure for checking gear backlash in the rear shaft/bevel gear.

Correcting Backlash

Steps for correcting gear backlash by adjusting shims.

Measuring Connecting Rod (Small End Inside Diameter)

Checking Tooth Contact

Procedure for checking tooth contact on bevel gears.

Measuring Connecting Rod (Small End Deflection)

Measuring Connecting Rod (Big End Side-to-Side)

Center Crankcase Components

Disassembling Crankcase Half

Measuring Connecting Rod (Big End Width)

Assembling Crankcase Half

Measuring Crankshaft (Runout)

Measuring Crankshaft (Web-to-Web)

Installing Engine/Transmission

Fuel/Lubrication/Cooling

Carburetor

Assembling

Electric Choke

Throttle Cable Free-Play

Gas Tank

Removing

Steps to remove the ATV gas tank.

Installing

Steps for installing the gas tank assembly.

Oil Filter/Oil Pump

Testing Oil Pump Pressure

Procedure for testing oil pump pressure.

Electrical System

Charging

Detailed steps for charging the ATV battery.

Resistance (Switch)

Resistance (Fan Motor Connector)

Voltage (Headlights)

Oil Temperature and Cooling Fan Switches

Fuse Block/Power Distribution Module

Instructions for testing fuses and the power distribution module.

Regulator/Rectifier

Procedure for testing the regulator/rectifier output voltage.

Voltage (Running Lights)

Accessory Receptacle/Connector

Fan Motor

Lights

Taillights - Brakelights

Maintenance Charging

Brakelight Switch (Pressure)

Voltage (Taillights)

Voltage (Brakelights)

Back-Up Lights

Voltage

Ignition Coil

Resistance

Primary Winding

Secondary Winding

Spark Plug Cap

Primary/CDI

Ignition Coil

Speed Sensor

Procedure for testing speed sensor voltage and resistance.

Ignition Switch

Procedures for testing ignition switch voltage and resistance.

Handlebar Control Switches

Resistance (HI Beam)

Resistance (LO Beam)

Resistance (Emergency Stop)

Resistance (Reverse Override)

Gear Position Switch

Stator Coil

Voltage (AC Generator - Regulated Output)

Procedure for testing AC generator output voltage.

Electrical System

Voltage (Charging Coil - No Load)

Procedure for testing charging coil voltage without load.

Resistance (Charging Coil)

Resistance (Trigger Coil)

Trigger Coil

Starter Relay

Procedure for testing the starter relay.

Starter Motor

Procedure for testing starter motor voltage.

Drive System

Disassembling Input Shaft

Assembling Input Shaft

Disassembling Pinion Gear

Ring Gear/Thrust Button

Removing/Installing Axle Seal

Removing Rear Drive Axle

Rear Gear Case

Hub

Hydraulic Brake Caliper

Assembling Differential Assembly

Installing Differential

Front Differential

Removing Differential

Installing Rear Drive Axle

Installing Front Drive Axle

Drive System

Shimming Procedure/Shim Selection

Procedure for selecting and installing shims for proper gear tolerance.

Ring Gear End-Play

Procedure for adjusting ring gear end-play.

Hand Brake Lever/Master Cylinder Assembly

Hydraulic Brake Caliper

Steps for installing the brake caliper and bleeding the system.

Backlash

Steps for checking and adjusting gear backlash.

Troubleshooting Drive System

Problem: Power not transmitted from engine to wheels

Lists conditions and remedies for lack of power transmission to wheels.

Problem: Power not transmitted from engine to either front wheel

Lists conditions and remedies for no power to front wheels.

Troubleshooting Brake System

Problem: Braking poor

Lists conditions and remedies for poor braking performance.

Problem: Brake lever travel excessive

Lists conditions and remedies for excessive brake lever travel.

Problem: Brake fluid leaking

Lists conditions and remedies for brake fluid leaks.

Suspension

Front A-Arms

Rear A-Arms

Shock Absorbers

Wheels and Tires

Checking/Inflating

Troubleshooting

Lists conditions and remedies for suspension issues.

Problem: Suspension too soft

Lists conditions and remedies for a soft suspension.

Problem: Suspension too stiff

Lists conditions and remedies for a stiff suspension.

Problem: Suspension noisy

Lists conditions and remedies for suspension noise.

Problem: Rear wheel oscillation

Lists conditions and remedies for rear wheel oscillation.