Arctic Cat DVX 400 2004

Questions and Answers

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traviscrawfordAug 31, 2025
Why is my Arctic Cat DVX 400 2004 engine noisy (noise seems to come from piston)?
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  Nancy NicholsAug 31, 2025
  If the noise seems to come from the piston area in your Arctic Cat Offroad Vehicle, the piston or cylinder may be worn (replace or service the piston and cylinder). Other potential causes include carbon buildup in the combustion chamber (clean the chamber), a worn piston pin or piston pin bore (replace or service the pin and bore), or worn piston rings or ring grooves (replace the rings or piston).
X
xmooreSep 9, 2025
How to fix handling too heavy or stiff on Arctic Cat Offroad Vehicle?
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  Ana KeySep 9, 2025
  If the handling of your Arctic Cat Offroad Vehicle feels too heavy or stiff, it could be due to incorrect front wheel alignment (adjust the alignment). Other potential causes include inadequate lubrication (lubricate the appropriate components), incorrect tire inflation pressure (adjust the pressure), seizing tie rod ends (replace the tie rod ends), or seizing linkage connections (repair or replace the connections).
M
Mr. Philip WilliamsAug 30, 2025
How to fix a charging unstable on Arctic Cat Offroad Vehicle?
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  Katherine PhillipsAug 30, 2025
  If the charging is unstable on your Arctic Cat Offroad Vehicle, it may be due to a lead wire intermittently shorting (replace the lead wire). Other potential causes include a magneto internally shorted or a defective regulator/rectifier (replace these components if defective).
J
jonesmatthewSep 23, 2025
What causes my Arctic Cat DVX 400 2004 Offroad Vehicle starting impaired?
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  Julie PierceSep 23, 2025
  If the starting is impaired on your Arctic Cat Offroad Vehicle, the starter jet may be obstructed (clean the jet). Other potential causes include an obstructed starter jet passage (clean the passage), the starter body or carburetor leaking air (tighten, adjust, or replace the gasket), or the starter valve not operating properly (check or adjust the valve).
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Jane SchultzSep 10, 2025
Why Arctic Cat DVX 400 2004 tire wear rapid or uneven?
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  John GraySep 12, 2025
  Rapid or uneven tire wear on your Arctic Cat Offroad Vehicle can be caused by worn or loose wheel hub bearings (replace the bearings). Another potential cause is incorrect front wheel alignment (adjust the alignment).
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Thomas CummingsSep 14, 2025
What causes my Arctic Cat DVX 400 2004 Offroad Vehicle brake lever/pedal travel excessive?
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  Nicole NguyenSep 14, 2025
  Excessive brake lever or pedal travel in your Arctic Cat Offroad Vehicle can be caused by air in the hydraulic system (bleed the hydraulic system). Other potential causes include low brake fluid (add fluid to the proper level), incorrect brake fluid (replace with the correct fluid), or a worn piston seal or cup (replace the seal or cup).
M
Michele TurnerSep 22, 2025
Why is Arctic Cat Offroad Vehicle starter button not effective?
- S
  smithkatherineSep 22, 2025
  If the starter button is not effective on your Arctic Cat Offroad Vehicle, the battery charge may be low (recharge or replace the battery). Other potential causes include defective switch contacts (replace the switch), starter motor brushes not seating (repair or replace the brushes), a defective starter relay (replace the relay), the emergency stop or ignition switch being off (turn on the switches), loose or disconnected wiring connections (connect, tighten, or repair the connections), or a defective clutch position switch (replace the switch).
D
Dawn JohnsonAug 27, 2025
Why is my Arctic Cat DVX 400 2004 Offroad Vehicle clutch slipping?
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  Patricia WagnerAug 27, 2025
  Clutch slippage in your Arctic Cat Offroad Vehicle can occur if the clutch cable is out of adjustment (adjust the cable). Other causes include weak clutch springs (replace the springs), a worn or distorted pressure disc (replace the disc), or distorted clutch plates (replace the plates).
A
Alicia AndersonAug 27, 2025
What causes my Arctic Cat DVX 400 2004 to overheat?
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  pcareyAug 27, 2025
  Your Arctic Cat Offroad Vehicle may overheat due to excessive carbon deposits on the piston crown (clean the piston). Other causes include low oil (add oil), poor gasoline (drain and replace), or a defective oil pump (replace the pump). An obstructed oil circuit (clean the circuit), low gasoline level in the float chamber (adjust float height), or air leaking into the intake manifold (tighten or replace the manifold) can also cause overheating. Check for low coolant level (fill and check for leaks), a malfunctioning fan (check the fuse or replace the fan), a malfunctioning fan switch (replace the switch), or a thermostat stuck closed (replace the thermostat). Damaged or obstructed radiator hoses or cap should be cleared or replaced.
C
Collin JohnsonAug 26, 2025
Why does my Arctic Cat DVX 400 2004 engine stall easily?
- D
  Derek HenryAug 26, 2025
  Your Arctic Cat Offroad Vehicle engine might stall easily due to a fouled spark plug (clean the plug). Other potential causes include a defective magneto or CDI unit (replace if defective), obstructed carburetor jets (clean the jets), or valve clearance that is out of adjustment (adjust the clearance).

Summary

Section 1 - General Information

General Specifications

Detailed technical specifications for the ATV model.

Break-In Procedure

Guidelines for the initial operating period to ensure ATV longevity.

Gasoline - Oil - Lubricant

Recommended fuel, oil types, and lubricant specifications.

Preparation For Storage

Steps to prepare the ATV for extended storage.

Preparation After Storage

Steps to prepare the ATV after it has been stored.

Section 2 - Periodic Maintenance;Tune-Up

Periodic Maintenance Chart

Schedule and tasks for regular ATV maintenance.

Battery

Maintenance, charging, and removal procedures for the ATV battery.

Air Cleaner

Procedures for cleaning and inspecting the air filter assembly.

Hydraulic;Parking Brake Systems

Procedures for checking, bleeding, and maintaining brake systems.

Section 3 - Engine;Transmission

Specifications*

Detailed engine and transmission specifications and tolerances.

Servicing Left-Side Components

Procedures for servicing components on the left side of the engine.

Servicing Right-Side Components

Procedures for servicing components on the right side of the engine.

Separating Crankcase Halves

Steps to separate the engine crankcase halves.

Disassembling Crankcase Half

Disassembly procedures for a crankcase half.

Section 4 - Fuel;Lubrication;Cooling

Carburetor

Procedures for removing, disassembling, and assembling the carburetor.

Oil Filter;Oil Pump

Servicing the oil filter and oil pump for lubrication.

Liquid Cooling System

Maintenance and operation of the ATV's liquid cooling system.

Servicing Water Pump

Procedures for servicing the water pump.

Section 5 - Electrical System

Battery

Maintenance, charging, and removal procedures for the battery.

Testing Electrical Components

General guidelines and procedures for testing electrical components.

Ignition Coil

Testing and resistance checks for the ignition coil.

Starter Motor

Procedures for starter motor removal, disassembly, and inspection.

WIRING DIAGRAM

Fold-out wiring diagram for the ATV's electrical system.

Section 6 - Drive System

Rear Drive Assembly Schematics

Diagrams illustrating the rear drive assembly components.

Rear Drive Axle

Procedures for removing and inspecting the rear drive axle.

Installing Bearings

Steps for installing new bearings into the axle housing.

Section 7 - Suspension

Shock Absorbers

Procedures for shock absorber removal, cleaning, inspection, and installation.

Swing Arm

Procedures for swing arm removal, disassembly, cleaning, and inspection.

Front A-Arms

Procedures for front A-arm removal, cleaning, inspection, and installation.

Wheels and Tires

Information on tire size, inflation, and wheel maintenance.

Section 8 - Steering;Frame

Steering Post;Tie Rods

Procedures for removing and servicing the steering post and tie rods.

Measuring;Adjusting Toe-In;Toe-Out

How to measure and adjust wheel alignment (toe-in/toe-out).

Body

Procedures for removing, cleaning, and installing body panels.

Section 9 - Controls;Indicators

Front Brake Lever;Master Cylinder Assembly

Procedures for front brake lever and master cylinder removal and inspection.

Rear Brake Pedal;Master Cylinder Assembly

Procedures for rear brake pedal and master cylinder removal and inspection.

Throttle Control

Procedures for throttle control removal, installation, and adjustment.

Section 10 - Aids for Maintenance

Torque Specifications

Specific torque values for various ATV components.

Tightening Torque (General Bolts)

General torque specifications based on bolt size and type.

Section 11 - Troubleshooting

Engine

Common engine problems and their remedies.

Fuel System

Common fuel system issues and solutions.

Electrical

Troubleshooting common electrical problems.

Brakes

Troubleshooting common braking problems.