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Arctic Cat ALTERRA 400 User Manual

Arctic Cat ALTERRA 400
76 pages
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2016
OPERATOR’S MANUAL
ALTERRA 400/ALTERRA 450
www.arcticcat.com
UNDER
16
!
WARNING
Operating this ATV if you are under
the age of 16 increases your chance
of severe injury or death.
NEVER operate this ATV if you are
under 16.
Do not remove this Operator’s Manual from this ATV
according to the guidelines and agreement with the U.S.
Consumer Product Safety Commission.
Read this manual carefully.
It contains important safety
information.
/
/

Table of Contents

Questions and Answers:

Arctic Cat ALTERRA 400 Specifications

General IconGeneral
BrandArctic Cat
ModelALTERRA 400
CategoryOffroad Vehicle
LanguageEnglish

Summary

Torque Specifications

Engine/Transmission Torque

Lists torque values for engine and transmission components.

Drive Train Components Torque

Lists torque values for drive train components.

Brake Components Torque

Lists torque values for brake system components.

Gasoline, Oil, and Lubricant Recommendations

Engine Performance Checks

Testing Engine Compression

Provides a step-by-step procedure to test engine compression.

Engine and Transmission Servicing

Engine and Transmission Oil and Filter Change

Outlines the procedure for changing the engine oil and filter.

Brake System Service

Hydraulic Brake System Check and Bleeding

Covers checking fluid levels and bleeding hydraulic brake systems.

Brake Pad and V-Belt Service

V-Belt Removal and Installation

V-Belt Installation (Continued)

Throttle Control and Steering Knuckles

Steering Knuckle Removal and Disassembly

Steps for removing and disassembling steering knuckles.

Front Wheel Alignment and Front Rack

Measuring and Adjusting Toe-Out

Details how to measure and adjust front wheel toe-out.

Lighting System Service

Headlight Aim Adjustment

Headlight Aim Checking and Adjustment

Details how to check and adjust headlight aim for proper illumination.

Vehicle Troubleshooting Guides

Handling and Steering Troubleshooting

Lists conditions and remedies for handling, steering oscillation, and noise issues.

Tire Wear and Steering Pull Troubleshooting

Lists conditions and remedies for rapid tire wear and steering pull.

Engine Troubleshooting

Transmission and Secondary Gear Noise Troubleshooting

Lists conditions and remedies for noise from the transmission and secondary gears.

Engine Idle, Speed, and Smoke Troubleshooting

Lists conditions and remedies for poor idling, high-speed issues, and smoke.

Engine Power and Exhaust Troubleshooting

Lists conditions and remedies for lack of engine power and exhaust issues.

Engine Overheating Troubleshooting

Engine Overheating Conditions and Remedies

Lists conditions and remedies for engine overheating.

Engine/Transmission Removal

Engine/Transmission Removal Procedure

Provides steps to remove the engine/transmission assembly from the frame.

Top-Side Engine Component Service

Removing Top-Side Components

Details the process of removing top-side engine components.

Engine Component Removal Steps

Cylinder and Piston Service

Engine Internal Component Service

Valve and Piston Service Details

Piston Assembly Inspection

Procedure for inspecting the piston for damage.

Piston and Ring Measurement Procedures

Measuring Piston Ring End Gap

How to measure installed piston ring end gap.

Measuring Piston Pin, Connecting Rod, and Bore

How to measure piston pin, connecting rod, and bore.

Measuring Piston Skirt/Cylinder Clearance

How to measure piston skirt to cylinder clearance.

Installing Piston Rings

Steps for installing new piston rings correctly.

Cylinder and Cylinder Head Assembly

Cylinder Head Cleaning and Inspection

Procedure for cleaning and inspecting the cylinder head.

Measuring Cylinder Head Distortion

How to measure cylinder head distortion.

Cylinder Cleaning and Inspection

Procedure for cleaning and inspecting the cylinder bore.

Camshaft Measurement and Inspection

Engine Top-End Assembly

Cylinder Head/Camshaft Installation

Steps for installing cylinder head and camshaft.

Cylinder Head and Camshaft Installation Steps

Camshaft Installation and Timing

Camshaft Installation and Timing (Continued)

Left-Side Engine Components

Removing Left-Side Components

Steps to remove left-side engine components.

Rotor, Flywheel, and Starter Motor Removal

Rotor/Flywheel Removal

Steps to remove the rotor/flywheel assembly.

Left-Side Component Service

Starter Clutch and Gear Inspection

Procedure to inspect the starter clutch and gear.

Starter Component Replacement

Starter Clutch Assembly Replacement

Steps to replace the starter clutch assembly.

Left-Side Component Installation

Rotor/Flywheel Installation

Steps to install the rotor/flywheel assembly.

Left-Side Cover Installation

Steps to install the left-side cover and outer magneto cover.

Right-Side Engine Components

Removing Right-Side Components

Steps to remove right-side engine components.

Right-Side Component Removal Details

Centrifugal Clutch Assembly Removal

Details removing the centrifugal clutch assembly.

Right-Side Component Service

Centrifugal Clutch Shoe Inspection

Procedure to inspect centrifugal clutch shoes.

Primary One-Way Drive Inspection

Procedure to inspect the primary one-way drive.

Oil Pump and Driven Pulley Service

Oil Pump Inspection

Procedure to inspect the oil pump for damage.

Oil Pump Installation

Steps to install the oil pump.

Right-Side Component Installation

Clutch Cover and Drive Face Installation

Clutch Cover Installation

Steps to install the clutch cover.

Right-Side Component Installation (Final)

Crankcase Halves Separation

Separating Crankcase Halves Procedure

Steps to separate the crankcase halves.

Crankcase Disassembly

Crankcase Half Disassembly

Steps to disassemble a crankcase half.

Center Crankcase Component Service

Secondary Gears: Backlash and Tooth Contact

Notes on checking and correcting secondary gear backlash and tooth contact.

Gear Backlash Checking and Correction

Procedure to check and correct gear backlash.

Gear Tooth Contact Checking

Procedure to check gear tooth contact.

Crankshaft Assembly Measurements

Correcting Gear Tooth Contact

Procedure to correct gear tooth contact.

Connecting Rod Measurements

How to measure connecting rod dimensions.

Crankshaft and Countershaft Measurements

Countershaft Assembly

Countershaft Assembly (Continued)

Crankcase Assembly

Crankcase Half Assembly Procedure

Steps to assemble a crankcase half.

Engine/Transmission Installation

Engine/Transmission Installation into Frame

Steps to install the engine/transmission into the frame.

Engine/Transmission Installation Steps

Engine/Transmission Installation (Continued)

Continues installation steps for engine/transmission.

Engine/Transmission Installation (Final)

Engine/Transmission Installation (Final Steps)

Completes installation steps for engine/transmission.

Carburetor Service

Carburetor Removal Procedure

Steps to remove the carburetor assembly.

Carburetor Disassembly

Carburetor Disassembly Steps

Steps to disassemble the carburetor.

Carburetor Cleaning and Assembly

Carburetor Assembly (Continued)

Carburetor Installation

Carburetor Installation Steps

Steps to install the carburetor.

Gas Tank Removal

Oil Filter and Oil Pump Service

Oil Pump Pressure Testing

Procedure to test oil pump pressure.

Oil Cooler and Troubleshooting

Starting System Troubleshooting

Lists conditions and remedies for starting system issues.

Fuel System Troubleshooting

Lists conditions and remedies for fuel system issues.

Ignition Coil and Primary/CDI Testing

Ignition Coil Resistance Test

Testing ignition coil resistance.

Handlebar Switches and Gear Position Switch

Gear Position Switch Troubleshooting

Procedure to troubleshoot the gear position switch.

Stator Coil Voltage Test (AC Output)

Testing AC generator regulated output voltage.

Stator Coil, Trigger Coil, and Starter System

Stator Coil Voltage Test (Charging Coil)

Testing charging coil voltage without load.

Starter Relay Testing

Testing the starter relay.

Starter Motor Voltage Test

Testing starter motor voltage.

Starter Motor, CDI Unit, and Regulator/Rectifier

Regulator/Rectifier Testing

Procedure to test the regulator/rectifier.

Lights System Testing

General Troubleshooting Guide

Spark and Alternator Troubleshooting

Lists conditions and remedies for spark and alternator issues.

Spark Plug and Alternator Charging Troubleshooting

Lists conditions and remedies for spark plug and charging issues.

Charging System and Starter Troubleshooting

Alternator Overcharging and Unstable Charging Troubleshooting

Lists conditions for overcharging and unstable charging.

Starter Button and Battery Troubleshooting

Lists conditions and remedies for starter button and battery issues.

Drive System

Front Differential Removal

Steps to remove the front differential assembly.

Input Shaft Service

Input Shaft Assembly

Pinion Gear Disassembly

Pinion Gear Shimming and Backlash

Shimming Procedure and Shim Selection

Procedure and selection guide for shimming gears.

Gear Backlash Adjustment

Steps to check and adjust gear backlash.

Ring Gear End-Play Adjustment

Ring Gear End-Play Adjustment Procedure

Procedure to adjust ring gear end-play.

Ring Gear and Thrust Button Service

Front Differential Installation

Front Differential Installation Procedure

Steps to install the front differential assembly.

Hub Service and Rear Gear Case Removal

Rear Gear Case Removal Procedure

Steps to remove the rear gear case.

Rear Gear Case Installation and Hub Removal

Rear Gear Case Installation Procedure

Steps to install the rear gear case.

Hydraulic Brake Caliper Service

Brake Caliper Cleaning and Assembly

Brake Caliper Assembly and Installation

Steps to assemble and install the brake caliper.

Brake Caliper Assembly and Installation (Continued)

Brake Caliper Assembly and Installation Steps

Continues steps to assemble and install the brake caliper.

Drive System Troubleshooting

Power Transmission Troubleshooting

Lists conditions and remedies for power transmission issues.

Braking Performance Troubleshooting

Lists conditions and remedies for poor braking.

Brake System Troubleshooting

Hydraulic Brake Caliper Removal and Disassembly

Steps to remove and disassemble the hydraulic brake caliper.

Tire Checking and Inflation

Tire Checking and Inflation Procedure

Procedure for checking and inflating tires.

Suspension and Wheel Troubleshooting

Suspension Softness/Stiffness Troubleshooting

Lists conditions and remedies for suspension softness/stiffness.

Rear Wheel Oscillation Troubleshooting

Lists conditions and remedies for rear wheel oscillation.

Tire Checking and Inflation (Continued)

Suspension and Wheel Troubleshooting (Continued)

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