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Arctic Cat
Offroad Vehicle
DVX 400 2004
Arctic Cat DVX 400 2004 User Manual
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VX 400
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Table of Contents
Table of Contents
3
General Specifications
5
Break-In Procedure
5
Engine/Transmission
6
Gasoline - Oil - Lubricant
6
Genuine Parts
6
Preparation for Storage
6
Preparation after Storage
7
Section 2 - Periodic Maintenance/Tune-Up
8
Periodic Maintenance Chart
9
Battery
10
Fuses
10
Lubrication Points
10
Air Cleaner
11
Valve/Tappet Clearance
13
Muffler/Spark Arrester
17
Spark Plug
17
Testing Engine Compression
17
Adjusting Engine RPM (Idle)
18
Adjusting Throttle Cable
18
Gas/Vent Hoses
18
Engine/Transmission Oil - Filter
19
Adjusting Clutch Lever Cable
20
Tires
20
Headlight/Taillight-Brakelight
21
Nuts/Bolts/Cap Screws
21
Steering Components
21
Suspension/Shock Absorbers/Bushings
21
Indicator Lights
22
Switches
22
Electrical Connections
23
Frame/Welds
23
Hydraulic/Parking Brake Systems
23
Burnishing Brake Pads
27
Coolant
27
Drive Chain
28
Table of Contents
32
Left-Side Components
34
Removing Left-Side Components
35
Removing Right-Side Components
36
Right-Side Components
36
Removing Top-Side Components
39
Top-Side Components
39
Center Crankcase Components
41
Separating Crankcase Halves
41
Disassembling Crankcase Half
42
Servicing Components
43
Piston Assembly
47
Cylinder/Cylinder Head Assembly
48
Servicing Left-Side Components
50
Starter Clutch
50
Starter Torque Limiter
51
Servicing Right-Side Components
51
Primary Clutch Assembly
51
Oil Pump
52
Crank Balancer Driven Gear
53
Servicing Center Crankcase Components
53
Crankcase
53
Crankshaft Assembly
54
Driveshaft
55
Countershaft
58
Assembling Crankcase Half
59
Joining Crankcase Halves
60
Installing Right-Side Components
61
Installing Left-Side Components
65
Installing Top-Side Components
65
Installing Engine/Transmission
69
Section 4 - Fuel/Lubrication/Cooling
72
Fuel/Lubrication/Cooling
72
Carburetor Specifications
73
Carburetor Schematic
73
Carburetor
74
Cleaning and Inspecting Carburetor
77
Throttle Cable Free-Play
77
Engine RPM (Idle)
77
Gas Tank
78
Fuel Valve
78
Gas/Vent Hoses
79
Oil Flow Chart
80
Oil Filter/Oil Pump
81
Testing Oil Pump Pressure
81
Oil Tank
81
Liquid Cooling System
83
Radiator
83
Hoses/Thermostat
84
Fan
84
Servicing Water Pump
85
Engine Coolant Temperature Switch
87
Cooling Fan Thermo-Switch
88
Section 5 - Electrical System
90
Electrical System
90
Specifications
91
Battery
91
Testing Electrical Components
91
Brakelight Switch (Front Brake)
92
Brakelight Switch (Rear Brake)
92
Coolant Temperature and Cooling Fan Switches
92
Fan Motor
93
Fuse Holder
93
Fuse
93
Ignition Coil
94
Indicator Lights
94
Ignition Switch
95
Neutral Indicator Light
95
Handlebar Control Switches
96
Neutral Switch
96
Clutch Lever Position Switch
97
Magneto Coils
97
Starter Motor
98
Starter Relay
100
CDI Unit
101
Regulator/Rectifier
101
Headlights
101
Taillight - Brakelight
101
Ignition Timing
102
Wiring Diagram
103
Drive System
104
Section 7 - Suspension
110
Front and Rear Suspension Assembly Schematics
111
Shock Absorbers
111
Swing Arm
114
Front A-Arms
119
Wheels and Tires
124
Steering/Frame
126
Section 9 - Controls/Indicators
136
Controls/Indicators
136
Front Brake Lever/Master Cylinder Assembly
137
Rear Brake Pedal/Master Cylinder Assembly
138
Throttle Control
140
Gearshift Pedal
141
Reverse Selector/Lock
141
Aids for Maintenance
142
Torque Specifications
143
Tightening Torque
144
Troubleshooting
145
Engine
146
Fuel System
149
Electrical
150
Steering/Suspension
151
Brakes
152
4
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Arctic Cat DVX 400 2004 Specifications
General
Brand
Arctic Cat
Model
DVX 400 2004
Category
Offroad Vehicle
Language
English
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