Arctic Cat 400 TRV User manual

FOREWORD
This Arctic Cat Service Manual contains service, maintenance, and troubleshooting information for certain 2010
Arctic Cat ATV models (see cover). The complete manual is designed to aid service personnel in service-oriented
applications.
Arctic Cat offers additional publications (when they become available) to aid in servicing other ATV models. To
service models not included in this manual, please refer to the following publications:
• 2010 Y-12+ Service Manual
• 2010 T-14 Service Manual
• 2010 300 DVX/Utility Service Manual
• 2010 366 Service Manual
• 2010 700 Diesel Service Manual
This manual is divided into sections. Each section covers a specific ATV component or system and, in addition to
the standard service procedures, includes disassembling, inspecting, and assembling instructions. When using this
manual as a guide, the technician should use discretion as to how much disassembly is needed to correct any given
condition.
The service technician should become familiar with the operation and construction of each component or system
by carefully studying the complete manual. This manual will assist the service technician in becoming more aware
of and efficient with servicing procedures. Such efficiency not only helps build consumer confidence but also saves
time and labor.
All Arctic Cat ATV publications and decals display the words Warning, Caution, Note, and At This Point to
emphasize important information. The symbol ! WARNING identifies personal safety-related information.
Be sure to follow the directive because it deals with the possibility of severe personal injury or even death. A
CAUTION identifies unsafe practices which may result in ATV-related damage. Follow the directive because it
deals with the possibility of damaging part or parts of the ATV. The symbol NOTE: identifies supplementary
information worthy of particular attention. The symbol AT THIS POINT directs the technician to certain
and specific procedures to promote efficiency and to improve clarity.
At the time of publication, all information, photographs, and illustrations were technically correct. Some photo-
graphs used in this manual are used for clarity purposes only and are not designed to depict actual conditions.
Because Arctic Cat Inc. constantly refines and improves its products, no retroactive obligation is incurred.
All materials and specifications are subject to change without notice.
Keep this manual accessible in the shop area for reference.
Product Service and
Warranty Department
Arctic Cat Inc.
© 2009 Arctic Cat Inc. September 2009
®™ Trademarks of Arctic Cat Inc., Thief River Falls, MN 56701
Manual
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TABLE OF CONTENTS
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Foreword
1. General Information/Specifications
2. Periodic Maintenance
3. Engine/Transmission
4. Fuel/Lubrication/Cooling
5. Electrical System
6. Drive System
7. Suspension
8. Steering/Frame
9. Controls/Indicators
1
2
3
4
5
6
7
8
9

1-1
1
SECTION 1 - GENERAL INFORMATION/
SPECIFICATIONS
TABLE OF
CONTENTS
General Specifications ............................................ 1-2
Torque Specifications .............................................. 1-3
Torque Conversions (ft-lb/N-m) ............................... 1-5
Tightening Torque (General Bolts) .......................... 1-5
Break-In Procedure ................................................. 1-5
Gasoline - Oil - Lubricant ........................................ 1-5
Genuine Parts ......................................................... 1-6
Preparation For Storage.......................................... 1-6
Preparation After Storage........................................ 1-7
Manual
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1-2
General Specifications*
* Specifications subject to change without notice.
** One inch below plug threads.
*** At the plug threads.
400 TRV
CHASSIS
Brake Type Hydraulic w/Brake Lever Lock
and Auxiliary Brake
Tire Size Front - 25 x 8-12
Rear - 25 x 11-12
Tire Inflation Pressure 0.35 kg/cm² (5 psi)
MISCELLANY
Gas Tank Capacity 20.0 L (5.3 U.S. gal.)
Rear Drive Capacity 250 ml (8.5 fl oz)**
Front Differential Capacity 275 ml (9.3 fl oz)***
Engine Oil Capacity 3.3 L (3.5 U.S. qt) - Overhaul
2.8 L (3.0 U.S. qt) - Change
Gasoline (recommended) 87 Octane Regular Unleaded
Engine Oil (recommended) Arctic Cat ACX All Weather
(Synthetic)
Differential/Rear Drive Lubricant SAE Approved 80W-90 Hypoid
Drive Belt Width (minimum) 28.5 mm (1.12 in.)
Brake Fluid DOT 4
Taillight/Brakelight 12V/8W/27W
Headlight 12V/37W (2)
H1
CHASSIS
Brake Type Hydraulic w/Brake Lever Lock and
Auxiliary Brake
Tire Size
(Mud Pro)
(Mud Pro)
Front - 25 x 8-12
Rear - 25 x 10-12
Front - 28 x 9-14
Rear - 28 x 9-14
Tire Inflation Pressure 0.35 kg/cm² (5 psi)
MISCELLANY
Gas Tank Capacity 21.6 L (5.7 U.S. gal.) - FIS
21.9 L (5.8 U.S. gal.) - TBX
20.0 L (5.3 U.S. gal.) - TRV/Cruiser
Coolant Capacity 2.9 L (3.0 U.S. qt)
Differential Capacity 275 ml (9.3 fl oz)**
Rear Drive Capacity 250 ml (8.5 fl oz)***
Engine Oil Capacity 2.5 L (2.6 U.S. qt) - Overhaul
1.9 L (2.0 U.S. qt) - Change
Gasoline (recommended) 87 Octane Regular Unleaded
Engine Oil (recommended) Arctic Cat ACX All Weather (Synthetic)
Differential/Rear Drive
Lubricant
SAE Approved 80W-90 Hypoid
Drive Belt Width (minimum) 35.6 mm (1.40 in.)
Brake Fluid DOT 4
Taillight/Brakelight 12V/8W/27W
Headlight 12V/27W (2)
H2
CHASSIS
Brake Type Hydraulic w/Brake Lever Lock and
Auxiliary Brake
Tire Size
(Mud Pro)
(Mud Pro)
Front - 25 x 8-12
Rear - 25 x 10-12
Front - 28 x 9-14
Rear - 28 x 9-14
Tire Inflation Pressure 0.35 kg/cm² (5 psi)
MISCELLANY
Gas Tank Capacity 21.6 L (5.7 U.S. gal.) - FIS
20.0 L (5.3 U.S. gal.) - Cruiser/TRV
Coolant Capacity 3.3 L (3.5 U.S. qt)
Differential Capacity 275 ml (9.3 fl oz)**
Rear Drive Capacity 250 ml (8.5 fl oz)***
Engine Oil (Gen. I)
Capacity
(Gen. II)
2.8 L (3.0 U.S. qt) - Overhaul
2.4 L (2.5 U.S. qt) - Change
2.6 L (2.75 U.S. qt) - Overhaul
2.1 L (2.25 U.S. qt) - Change
Gasoline (recommended) 87 Octane Regular Unleaded
Engine Oil (recommended) Arctic Cat ACX All Weather (Synthetic)
Front Differential/Rear Drive
Lubricant
SAE Approved 80W-90 Hypoid
Drive Belt Width (minimum) 35.6 mm (1.40 in.)
Brake Fluid DOT 4
Taillight/Brakelight 12V/8W/27W
Headlight 12V/27W (2)
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1-3
1
Torque Specifications
* w/Blue Loctite #243
** w/Red Loctite #271
*** w/Green Loctite #609
EXHAUST COMPONENTS
Part Part Bolted To Torque
ft-lb N-m
Exhaust Pipe Engine 20 27
Spark Arrester Muffler 48
in.-lb
5.5
ELECTRICAL COMPONENTS
Engine/Harness Ground Cap
Screw
Crankcase 8 11
Coil (400 TRV/650)* Frame 12 16
Coil (EFI) Air Filter Housing 7 10
STEERING COMPONENTS
Steering Post Bearing
Housing
Frame 20 27
Steering Post Bearing Flange Frame 20 27
Lower Steering Bearing
Washer Cap Screw***
Steering Post 40 54
Tie Rod End Knuckle/Steering Post 30 41
BRAKE COMPONENTS
Brake Disc* Hub 15 20
Brake Hose Caliper 20 27
Brake Hose Master Cylinder 20 27
Brake Hose Auxiliary Brake Cylinder 20 27
Master Cylinder (Rear) Frame 12 16
Hydraulic Caliper Knuckle 20 27
Master Cylinder Clamp Master Cylinder 6 8
Brake Pedal Brake Pedal Axle 25 34
CHASSIS COMPONENTS
Footrest Frame (8 mm) 20 27
Footrest Frame (10 mm) 40 54
SUSPENSION COMPONENTS (Front)
A-Arm (400 TRV/H1) Frame 35 47
A-Arm (H2) Frame 50 68
Knuckle Ball Joint 35 47
Shock Absorber Frame 35 47
Shock Absorber Upper A-Arm 35 47
Knuckle A-Arm 35 47
SUSPENSION COMPONENTS (Rear)
Shock Absorber (Upper) Frame 35 47
Shock Absorber (Upper) (H2) Frame 50 68
Shock Absorber (Lower) Lower A-Arm 20 27
A-Arm Frame 35 47
A-Arm (H2) Frame 50 68
Knuckle A-Arm 35 47
Knuckle (H2) A-Arm 50 68
DRIVE TRAIN COMPONENTS
(400 TRV)
Part Part Bolted To Torque
ft-lb N-m
Engine Mounting Through-Bolt Frame 38 52
Front Differential Frame/Differential
Bracket
38 52
Output Flange Rear Flange Output
Joint
20 27
Pinion Housing Differential Housing 23 31
Differential Housing Cover*** Differential Housing 23 31
Drive Bevel Gear Nut** Shaft 59 80
Driven Bevel Gear Nut** Driven Shaft 59 80
Lock Collar Differential Housing 125 169
Hub Nut Shaft/Axle (max) 200 272
Oil Drain Plug Front Differential/ Rear
Drive
45
in.-lb
5
Oil Fill Plug Front Differential/ Rear
Drive
16 22
Oil Drain Plug Engine 20 27
Rear Drive Input Shaft/Housing Differential Housing 23 31
Wheel Hub 40 54
Rear Drive Gear Case Frame 38 52
Engine Output Shaft** Rear Gear Case Input
Flange
20 27
DRIVE TRAIN COMPONENTS
(H1)
Engine Mounting Through-Bolt Frame 40 54
Engine (TRV) Engine Cradle 40 54
Engine Cradle (TRV)** Rubber Mount 25 34
Rubber Mount (TRV) Frame Bracket 35 47
Front Differential* Frame/Differential
Bracket
38 52
Output Flange Rear Flange Output
Joint
20 27
Pinion Housing Differential Housing 23 31
Differential Housing Cover*** Differential Housing 23 31
Drive Bevel Gear Nut*** Shaft 72 98
Differential Gear Case*** Hub 19 26
Lock Collar Differential Housing 125 169
Hub Nut Shaft/Axle (max) 200 272
Oil Drain Plug Front Differential/ Rear
Drive
45
in.-lb
5
Oil Fill Plug Front Differential/ Rear
Drive
16 22
Oil Drain Plug Engine 16 22
Rear Drive Input Shaft/Housing Differential Housing 23 31
Wheel Hub 40 54
Rear Drive Gear Case Frame 38 52
Engine Output Shaft ** Rear Gear Case Input
Flange
20 27
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1-4
* w/Blue Loctite #243
** w/Red Loctite #271
*** w/Green Loctite #609
* w/Blue Loctite #243 ** w/Red Loctite #271
*** w/Green Loctite #609
DRIVE TRAIN COMPONENTS
(H2)
Part Part Bolted To Torque
ft-lb N-m
Engine Mount (Rear) Frame 45 61
Front Differential Frame/Differential
Bracket
38 52
Rear Gear Case Frame 38 52
Pinion Housing Differential Housing 23 31
Differential Housing Cover*** Differential Housing 23 31
Lock Collar Differential Housing 125 169
Hub Nut Shaft/Axle (max) 200 272
Oil Drain Plug Front Differential/
Rear Drive
45
in.-lb
5
Oil Fill Plug Front Differential/
Rear Drive
16 22
Oil Drain Plug Engine 16 22
Wheel Hub 40 54
Rear Drive Input Shaft/Housing Differentail Housing 23 31
Rear Output Drive Flange Rear Yoke Flange 20 27
Shift Cam Stopper Shift Stopper 8 11
Shift Cam Plate Shift Cam Shaft 8 11
Shifter Housing Crankcase 8 11
Engine Output Shaft** Rear Gear Case
Input Flange
20 27
ENGINE/TRANSMISSION
(400 TRV)
Clutch Shoe** Crankshaft 147 199
Clutch Cover/Housing Assembly Crankcase 8 11
Left-Side Cover Crankcase 8 11
Crankcase Half (6 mm) Crankcase Half 10 13.5
Crankcase Half (8 mm) Crankcase Half 21 28
Cylinder Nut Crankcase Half 8 11
Cylinder Head (Cap Screw) Crankcase 28 38
Cylinder Head (6 mm) Cylinder 8 11
Cylinder Head (8 mm) Cylinder 20 27
Cylinder Head Cover Cylinder Head 8 11
Oil Pump Drive Gear** Crankshaft 63 86
Driven Pulley Nut** Driveshaft 147 199
Ground Cable Engine 8 11
Output Shaft Flange Nut Output Shaft 59 80
Magneto Rotor Nut Crankshaft 107 146
Cam Sprocket** Camshaft 11 15
Starter Motor Crankcase 8 11
V-Belt Cover Crankcase 8 11
Valve Adjuster Jam Nut Valve Adjuster 7 9.5
Oil Fitting Engine 8 11
Oil Pump* Crankcase 8 11
Movable Drive Face Nut** Clutch Shaft 147 199
Oil Cooler Hose Clamps Engine/Oil Cooler 30
in.-lb
3.4
Valve Cover Crankcase 8 11
ENGINE/TRANSMISSION (H1)
Part Part Bolted To Torque
ft-lb N-m
Crankshaft Spacer Crankshaft 25 34
Speed Sensor Housing Crankcase 8 11
Clutch Shoe** Crankshaft 221 300
Clutch Cover/Housing Assembly Crankcase 8 11
Crankcase Half (6 mm) Crankcase Half 8 11
Crankcase Half (8 mm) Crankcase Half 20 27
Cylinder Head (Cap Screw) Crankcase 40 54
Cylinder Head (6 mm) Cylinder 8 11
Cylinder Head (8 mm) Cylinder 18 24
Valve Cover Cylinder Head 8.5 11.5
Driven Pulley Nut Driveshaft 80 108
Ground Wire Engine 8 11
Magneto Cover Crankcase 8 11
Oil Pump Drive Gear** Crank Balancer Shaft 63 85
Output Shaft Nut Output Shaft 59 80
Outer Magneto Cover Left-Side Cover 6 8
Magneto Rotor Nut Crankshaft 107 145
Cam Sprocket** Camshaft 10 13.5
Starter Motor Crankcase 8 11
V-Belt Cover Clutch Cover 8 11
Drive Pulley Nut** Clutch Shaft 165 224
Movable Drive Face Nut** Clutch Shaft 165 224
Output Yoke Nut Driven Output Shaft 74 100
Secondary Shaft Bearing
Housing
Crankcase Half 28 38
ENGINE/TRANSMISSION (H2)
Clutch Shoe** Crankshaft 221 300
Clutch Cover/Housing Assembly Crankcase 8 11
Crankcase Half Crankcase Half 8 11
Crankcase Lower Cover (6 mm) Crankcase 8 11
Crankcase Lower Cover (8 mm) Crankcase 20 27
Cylinder Head (Cap Screw) Crankcase 37 50
Cylinder Head (6 mm) Cylinder 8 11
Cylinder Head (8 mm) Cylinder 18 24
Cylinder Head Cover Cylinder Head 8.5 11.5
Driven Pulley Nut** Driveshaft 80 108
Ground Wire Engine 8 11
Magneto Cover Crankcase 8 11
Oil Filler Cover Crankcase 8 11
Speed Sensor Housing Crankcase 8 11
Starter Motor Crankcase 8 11
V-Belt Housing Crankcase 8 11
Intake Manifold Cylinder 8 11
Output Shaft Yoke Nut Output Shaft 59 80
Rotor/Flywheel Nut Crankshaft 107 145
Cam Sprocket** Camshaft 10 13.5
V-Belt Cover Clutch Cover 8 11
Movable Drive Face Nut** Clutch Shaft 165 224
Oil Pump Cover* Crankcase 8 11
Oil Strainer Cap Crankcase 8 11
Shift Cam Stopper Crankcase 8 11
Shift Cam Stopper Spring Shift Cam Stopper 8 11
Shift Cam Plate Shift Cam Shaft 8 11
Shifter Housing Crankcase 8 11
Secondary Drive Gear Nut Driven Output Shaft 74 100
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1-5
1
Torque Conversions
(ft-lb/N-m)
Tightening Torque
(General Bolts)
Break-In Procedure
A new ATV and an overhauled ATV engine require a
“break-in” period. The first 10 hours (or 200 miles) are
most critical to the life of this ATV. Proper operation
during this break-in period will help assure maximum
life and performance from the ATV.
During the first 10 hours (or 200 miles) of operation,
always use less than 1/2 throttle. Varying the engine
RPM during the break-in period allows the compo-
nents to “load” (aiding the mating process) and then
“unload” (allowing components to cool). Although it
is essential to place some stress on the engine compo-
nents during break-in, care should be taken not to
overload the engine too often. Do not pull a trailer or
carry heavy loads during the 10-hour break-in period.
When the engine starts, allow it to warm up properly.
Idle the engine several minutes until the engine has
reached normal operating temperature. Do not idle the
engine for excessively long periods of time.
During the break-in period, a maximum of 1/2 throttle
is recommended; however, brief full-throttle accelera-
tions and variations in driving speeds contribute to
good engine break-in.
After the completion of the break-in period, the engine
oil and oil filter should be changed. Other maintenance
after break-in should include checking of all pre-
scribed adjustments and tightening of all fasteners (see
Periodic Maintenance Chart in Section 2).
Gasoline - Oil -
Lubricant
RECOMMENDED GASOLINE
The recommended gasoline to use is 87 minimum
octane regular unleaded. In many areas, oxygenates
(either ethanol or MTBE) are added to the gasoline.
Oxygenated gasolines containing up to 10% ethanol,
5% methane, or 5% MTBE are acceptable gasolines.
When using ethanol blended gasoline, it is not neces-
sary to add a gasoline antifreeze since ethanol will pre-
vent the accumulation of moisture in the fuel system.
ft-lb N-m ft-lb N-m ft-lb N-m ft-lb N-m
11.4 26 35.4 51 69.4 76 103.4
22.7 27 36.7 52 70.7 77 104.7
34.1 28 38.1 53 72.1 78 106.1
45.4 29 39.4 54 73.4 79 107.4
56.8 30 40.8 55 74.8 80 108.8
68.2 31 42.2 56 76.2 81 110.2
79.5 32 43.5 57 77.5 82 111.5
810.9 33 44.9 58 78.9 83 112.9
912.2 34 46.2 59 80.2 84 114.2
10 13.6 35 47.6 60 81.6 85 115.6
11 15 36 49 61 83 86 117
12 16.3 37 50.3 62 84.3 87 118.3
13 17.7 38 51.7 63 85.7 88 119.7
14 19 39 53 64 87 89 121
15 20.4 40 54.4 65 88.4 90 122.4
16 21.8 41 55.8 66 89.8 91 123.8
17 23.1 42 57.1 67 91.1 92 125.1
18 24.5 43 58.5 68 92.5 93 126.5
19 25.8 44 59.8 69 93.8 94 127.8
20 27.2 45 61.2 70 95.2 95 129.2
21 28.6 46 62.6 71 96.6 96 130.6
22 29.9 47 63.9 72 97.9 97 131.9
23 31.3 48 65.3 73 99.3 98 133.3
24 32.6 49 66.6 74 100.6 99 134.6
25 34 50 68 75 102 100 136
Type of Bolt Thread Diameter
A (mm)
Tightening
Torque
(Conventional or 4 Marked Bolt) 5 12-36 in.-lb
6 36-60 in.-lb
8 7-11 ft-lb
10 16-25 ft-lb
(7 Marked Bolt) 5 24-48 in.-lb
6 6-8 ft-lb
8 13-20 ft-lb
10 29-43 ft-lb
CAUTION
Do not use white gas. Only Arctic Cat approved gaso-
line additives should be used.
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1-6
RECOMMENDED ENGINE/
TRANSMISSION OIL
The recommended oil to use is Arctic Cat ACX All
Weather synthetic engine oil, which has been specifi-
cally formulated for use in this Arctic Cat engine.
Although Arctic Cat ACX All Weather synthetic
engine oil is the only oil recommended for use in this
engine, use of any API certified SM 5W-50 oil is
acceptable.
OILCHARTI
RECOMMENDED FRONT
DIFFERENTIAL/REAR DRIVE
LUBRICANT
The recommended lubricant is Arctic Cat Gear Lube
or an equivalent gear lube which is SAE approved
80W-90 hypoid. This lubricant meets all of the lubrica-
tion requirements of the Arctic Cat ATV front differen-
tials and rear drives.
FILLING GAS TANK
Since gasoline expands as its temperature rises, the gas
tank must be filled to its rated capacity only. Expan-
sion room must be maintained in the tank particularly
if the tank is filled with cold gasoline and then moved
to a warm area.
ATV0049B
Tighten the gas tank cap securely after filling the tank.
Genuine Parts
When replacement of parts is necessary, use only gen-
uine Arctic Cat ATV parts. They are precision-made to
ensure high quality and correct fit. Refer to the appro-
priate Illustrated Parts Manual for the correct part
number, quantity, and description.
Preparation For Storage
Arctic Cat recommends the following procedure to
prepare the ATV for storage.
1. Clean the seat cushion (cover and base) with a
damp cloth and allow it to dry.
2. Clean the ATV thoroughly by washing dirt, oil,
grass, and other foreign matter from the entire
ATV. Allow the ATV to dry thoroughly. DO NOT
get water into any part of the engine or air intake.
3. Either drain the gas tank or add Fuel Stabilizer to
the gas in the gas tank. Remove the air filter hous-
ing cover and air filter. Start the engine and allow
it to idle; then using Arctic Cat Engine Storage
Preserver, rapidly inject the preserver into the air
filter opening for a period of 10 to 20 seconds;
then stop the engine. Install the air filter and hous-
ing cover.
CAUTION
Any oil used in place of the recommended oil could
cause serious engine damage. Do not use oils which
contain graphite or molybdenum additives. These oils
can adversely affect clutch operation. Also, not recom-
mended are racing, vegetable, non-detergent, and cas-
tor-based oils.
CAUTION
Any lubricant used in place of the recommended lubri-
cant could cause serious front differential/rear drive
damage.
! WARNING
Always fill the gas tank in a well-ventilated area. Never
add fuel to the ATV gas tank near any open flames or
with the engine running. DO NOT SMOKE while filling
the gas tank.
! WARNING
Do not overflow gasoline when filling the gas tank. A
fire hazard could materialize. Always allow the engine
to cool before filling the gas tank.
! WARNING
Do not over-fill the gas tank.
CAUTION
Prior to storing the ATV, it must be properly serviced
to prevent rusting and component deterioration.
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1-7
1
4. On the 400/650 drain the carburetor float chamber.
5. Plug the exhaust hole in the exhaust system with a
clean cloth.
6. Apply light oil to the upper steering post bushing
and plungers of the shock absorbers.
7. Tighten all nuts, bolts, cap screws, and screws.
Make sure rivets holding components together are
tight. Replace all loose rivets. Care must be taken
that all calibrated nuts, cap screws, and bolts are
tightened to specifications.
8. On liquid-cooled models, fill the cooling system to
the bottom of the stand pipe in the radiator neck
with properly mixed coolant.
9. Disconnect the battery cables; then remove the
battery, clean the battery posts and cables, and
store in a clean, dry area.
10. Store the ATV indoors in a level position.
Preparation After
Storage
Taking the ATV out of storage and correctly preparing
it will assure many miles and hours of trouble-free rid-
ing. Arctic Cat recommends the following procedure
to prepare the ATV.
1. Clean the ATV thoroughly.
2. Clean the engine. Remove the cloth from the
exhaust system.
3. Check all control wires and cables for signs of
wear or fraying. Replace if necessary.
4. Change the engine/transmission oil and filter.
5. On liquid-cooled models, check the coolant level
and add properly mixed coolant as necessary.
6. Charge the battery; then install. Connect the bat-
tery cables.
7. Check the entire brake systems (fluid level, pads,
etc.), all controls, headlights, taillight, brakelight,
and headlight aim; adjust or replace as necessary.
8. Tighten all nuts, bolts, cap screws, and screws
making sure all calibrated nuts, cap screws, and
bolts are tightened to specifications.
9. Check tire pressure. Inflate to recommended pres-
sure as necessary.
10. Make sure the steering moves freely and does not
bind.
11. Check the spark plug(s). Clean or replace as nec-
essary.
CAUTION
If the interior of the air filter housing is dirty, clean the
area before starting the engine.
CAUTION
Avoid storing outside in direct sunlight and avoid
using a plastic cover as moisture will collect on the
ATV causing rusting.
CAUTION
The ignition switch must be in the OFF position prior
to installing the battery or damage may occur to the
ignition system.
CAUTION
Connect the positive battery cable first; then the nega-
tive.
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2-1
2
SECTION 2 -
PERIODIC MAINTENANCE
TABLE OF
CONTENTS
Periodic Maintenance Chart.................................... 2-2
Periodic Maintenance.............................................. 2-3
Lubrication Points.................................................... 2-3
Air Filter................................................................... 2-3
Valve/Tappet Clearance
(Feeler Gauge Procedure) ................................... 2-4
Valve/Tappet Clearance
(Valve Adjuster Procedure) (400/H1) ................... 2-5
Valve/Tappet Clearance
(Valve Adjuster Procedure) (H2) .......................... 2-6
Testing Engine Compression .................................. 2-6
Spark Plug(s) .......................................................... 2-7
Muffler/Spark Arrester ............................................. 2-7
Engine/Transmission Oil - Filter - Strainer .............. 2-8
Front Differential/Rear Drive Lubricant .................. 2-10
Driveshaft/Coupling............................................... 2-10
Nuts/Bolts/Cap Screws.......................................... 2-10
Headlights/Taillight-Brakelight ............................... 2-11
Shift Lever ............................................................. 2-12
Frame/Welds/Racks .............................................. 2-12
Hydraulic Brake Systems ...................................... 2-12
Burnishing Brake Pads.......................................... 2-15
Checking/Replacing V-Belt ................................... 2-15
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2-2
Periodic Maintenance
Chart
A = Adjust I = Inspect
C = Clean L = Lubricate
D = Drain R = Replace
T = Tighten
* Service/Inspect more frequently when operating in adverse conditions.
** When using an API certified SM 5W-50 oil.
*** When using Arctic Cat ACX All Weather synthetic oil, oil change interval and strainer inspection can be increased to every
1,000 miles or every year.
Item
Initial Service
After Break-In
(First Mo or 100
Mi)
Every
Day
Every
Month or
Every 100
Miles
Every 3
Months or
Every 300
Miles
Every 6
Months or
Every 500
Miles
Every Year
or Every
1500 Miles
As Needed
Battery I I C
Fuses IR
Air Filter/Drain Tube I I C* R
Valve/Tappet Clearance I I A
Engine Compression I
Spark Plug(s) I I R
(4000 Mi or 18 Mo)
Muffler/Spark Arrester CR
Gas/Vent Hoses I I R (2 Yrs)
Throttle Cable I I C-L A-R
Carburetor Float Chamber
(400/650)
D*
Engine Idle RPM (400/650) I I A
Engine-Transmission Oil Level I A
Engine-Transmission Oil/Filter R R*/R**/R*** R
Oil Strainer I I C
Front Differential/Rear Drive Lubricant I I R (4 Yrs)
Tires/Air Pressure I I R
Steering Components I I I R
V-Belt I l R
Suspension (Ball joint boots, drive axle
boots front and rear, tie rods,
differential and rear drive bellows)
II R
Nuts/Cap Screws/Screws I I T
Ignition Timing I
Headlight/Taillight-Brakelight I I R
Switches I I R
Shift Lever IA-L
Handlebar Grips I R
Handlebar I I R
Gauges/Indicators I I R
Frame/Welds/Racks I l
Electrical Connections I l C
Complete Brake System
(Hydraulic & Auxiliary)
II C L-R
Brake Pads I I* R
Brake Fluid I I R (2 Yrs)
Brake Hoses I I R (4 Yrs)
Coolant (Liquid-Cooled Models)/
Cooling System
II R(2Yrs)
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2-3
2
Periodic Maintenance
This section has been organized into sub-sections
which show common maintenance procedures for the
Arctic Cat ATV.
NOTE: Arctic Cat recommends the use of new
gaskets, lock nuts, and seals and lubricating all
internal components when servicing the
engine/transmission.
NOTE: Some photographs and illustrations used
in this section are used for clarity purposes only
and are not designed to depict actual conditions.
NOTE: Critical torque specifications are located
in Section 1.
SPECIAL TOOLS
A number of special tools must be available to the
technician when performing service procedures in this
section.
NOTE: Special tools are available from the Arctic
Cat Service Parts Department.
Lubrication Points
It is advisable to lubricate certain components periodi-
cally to ensure free movement. Apply light oil to the
components using the following list as reference.
A. Throttle Lever Pivot/Cable Ends
B. Brake Lever Pivot/Cable Ends
C. Auxiliary Brake Cable Ends
D. Shift Lever Cable End
E. Idle RPM Screw (400/650)
Air Filter
Use the following procedure to remove the filter and
inspect and/or clean it.
CLEANING AND INSPECTING
FILTER
1. Remove the seat; then remove the appropriate
reinstallable rivets securing the storage compart-
ment.
CF260A
2. Raise the storage compartment cover; then slide
the cover forward and off the compartment.
Remove the storage compartment.
FI467
FI468
3. Unsnap the four spring-clip fasteners; then remove
the air filter cover.
Description p/n
Compression Tester Kit 0444-213
Oil Filter Wrench 0644-389
Tachometer 0644-275
Timing Light 0644-296
Valve Clearance Adjuster 0444-255
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2-4
CD675A
4. Remove the air filter element/screen assembly and
separate the element from the screen.
5. Fill a wash pan larger than the element with a
non-flammable cleaning solvent; then dip the ele-
ment in the solvent and wash it.
NOTE: Foam Air Filter Cleaner and Foam Air Fil-
ter Oil are available from Arctic Cat.
6. Dry the element.
7. Put the element in a plastic bag; then pour in air
filter oil and work the oil into the element. Attach
the element to the filter screen.
NOTE: Carefully squeeze excessive oil from the
filter element. Do not twist foam to remove oil.
8. Clean any dirt or debris from inside the air cleaner.
Be sure no dirt enters the carburetor (if equipped).
9. Place the filter assembly in the air filter housing
making sure it is properly positioned and properly
seated with the filter screen down.
CD674
10. Install the air filter housing cover and secure with
the retaining clips.
11. Install the storage compartment; then secure with
the reinstallable rivets.
CHECKING AND CLEANING
DRAINS
1. Inspect the drains beneath the main housing for
debris and for proper sealing.
KX045A
2. Replace any drain that is cracked or shows any
signs of hardening or deterioration.
3. Wipe any accumulation of oil or gas from the filter
housing and drains.
Valve/Tappet Clearance
(Feeler Gauge Procedure)
To check and adjust valve/tappet clearance, use the
following procedure.
1. Remove the timing inspection plug; then remove
the tappet covers and spark plug(s) (for more
detailed information, see Section 3 - Servicing
Top-Side Components).
NOTE: On the H2 models, remove the crankshaft
end cap and install the special cap screw
(left-hand threads) to rotate the engine.
2. Rotate the crankshaft to the TDC position on the com-
pression stroke (front cylinder on the H2 models).
NOTE: At this point, the rocker arms and adjuster
screws must not have pressure on them.
3. Using a feeler gauge, check each valve/tappet
clearance. If clearance is not within specifications,
loosen the jam nut and rotate the tappet adjuster
screw until the clearance is within specifications.
Tighten each jam nut securely after completing the
adjustment.
CAUTION
A torn air filter element can cause damage to the ATV
engine. Dirt and dust may get inside the engine if the
element is torn. Carefully examine the element for
tears before and after cleaning it. Replace the element
with a new one if it is torn.
CAUTION
The drain to the right is the clean air section of the fil-
ter housing. Any leak of this drain will allow dirt into
the engine intake causing severe engine damage.
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2-5
2
CC007DC
4. On the H2 models, rotate the engine 270° to the
TDC position of the rear cylinder; then repeat step
3.
GZ059
5. Install the timing inspection plug; then on the H2
models, remove the cap screw and install the
crankcase end cap.
6. Place the two tappet covers into position making
sure the proper cap screws are with the proper
cover. Tighten the cap screws securely.
7. Install the spark plug(s).
Valve/Tappet Clearance
(Valve Adjuster Procedure)
(400/H1)
To check and adjust valve/tappet clearance, use the
following procedure.
NOTE: The seat, storage compartment cover
assembly, compartment box, air filter/filter hous-
ing, and left-side/right-side splash panels must be
removed for this procedure.
1. Remove the timing inspection plug; then remove
the tappet covers and spark plug (for more detailed
information, see Section 3 - Servicing Top-Side
Components).
CF005
2. Rotate the crankshaft to the TDC position on the
compression stroke.
NOTE: At this point, the rocker arms and adjuster
screws must not have pressure on them.
NOTE: Use Valve Clearance Adjuster for this pro-
cedure.
3. Place the valve adjuster onto the jam nut securing
the tappet adjuster screw; then rotate the valve
adjuster dial clockwise until the end is seated in
the tappet adjuster screw.
4. While holding the valve adjuster dial in place, use
the valve adjuster handle and loosen the jam nut;
then rotate the tappet adjuster screw clockwise
until friction is felt.
5. Align the valve adjuster handle with one of the
marks on the valve adjuster dial.
6. While holding the valve adjuster handle in place,
rotate the valve adjuster dial counterclockwise
until proper valve/tappet clearance is attained.
NOTE: Refer to the appropriate specifications in
Feeler Gauge Procedure sub-section for the
proper valve/tappet clearance.
CAUTION
The feeler gauge must be positioned at the same angle
as the valve and valve adjuster for an accurate mea-
surement of clearance. Failure to measure the valve
clearance accurately could cause valve component
damage.
VALVE/TAPPET CLEARANCE (400)
Intake 0.076-0.127 mm (0.003-0.005 in.)
Exhaust 0.152-0.203 mm (0.006-0.008 in.)
VALVE/TAPPET CLEARANCE (H1/H2)
Intake 0.1016 mm (0.004 in.)
Exhaust 0.1524 mm (0.006 in.)
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2-6
NOTE: Rotating the valve adjuster dial counter-
clockwise will open the valve/tappet clearance by
0.05 mm (0.002 in.) per mark.
7. While holding the adjuster dial at the proper clear-
ance setting, tighten the jam nut securely with the
valve adjuster handle.
8. Place the two tappet covers with O-rings into posi-
tion; then tighten the covers securely.
9. Install the spark plug; then install the timing
inspection plug.
Valve/Tappet Clearance
(Valve Adjuster Procedure)
(H2)
To check and adjust valve/tappet clearance, use the
following procedure.
NOTE: The seat, storage compartment cover
assembly, compartment box, air filter/filter hous-
ing, and left-side/right-side engine panels must be
removed for this procedure.
1. Remove the timing inspection plug; then remove
the tappet covers and spark plugs (for more
detailed information, see Section 3 - Servicing
Top-Side Components).
CF005
2. Rotate the crankshaft to the TDC position on the
compression stroke of the front cylinder.
GZ063
NOTE: At this point, the rocker arms and adjuster
screws must not have pressure on them.
NOTE: Use Valve Clearance Adjuster for this pro-
cedure.
3. Place the valve adjuster onto the jam nut securing
the tappet adjuster screw; then rotate the valve
adjuster dial clockwise until the end is seated in
the tappet adjuster screw.
4. While holding the valve adjuster dial in place, use
the valve adjuster handle and loosen the jam nut;
then rotate the tappet adjuster screw clockwise
until friction is felt.
5. Align the valve adjuster handle with one of the
marks on the valve adjuster dial.
6. While holding the valve adjuster handle in place,
rotate the valve adjuster dial counterclockwise
until proper valve/tappet clearance is attained.
NOTE: Refer to the appropriate specifications in
Feeler Gauge Procedure sub-section for the
proper valve/tappet clearance.
NOTE: Rotating the valve adjuster dial counter-
clockwise will open the valve/tappet clearance by
0.05 mm (0.002 in.) per mark.
7. While holding the adjuster dial at the proper clear-
ance setting, tighten the jam nut securely with the
valve adjuster handle.
8. Rotate the engine 270° to the TDC position of the
rear cylinder; then repeat steps 4-7 for the rear
cylinder.
9. Place the tappet covers with O-rings into position;
then tighten the covers securely.
10. Install the spark plugs; then install the timing
inspection plug and crankshaft end cap.
Testing Engine
Compression
To test engine compression, use the following proce-
dure.
1. Remove the high tension lead(s) from the spark
plug(s).
2. Using compressed air, blow any debris from
around the spark plug(s).
! WARNING
Always wear safety glasses when using compressed
air.
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2-7
2
3. Remove the spark plug(s); then attach the high
tension lead(s) to the plug(s) and ground the
plug(s) on the cylinder head(s) well away from the
spark plug hole(s).
4. Attach the Compression Tester Kit.
NOTE: The engine should be warm (operating
temperature) and the battery full charged for an
accurate compression test. Throttle must be in the
wide-open throttle (WOT) position. In the event the
engine can not be run, cold values are included.
5. While holding the throttle lever in the full-open
position, crank the engine over with the electric
starter until the gauge shows a peak reading (five
to 10 compression strokes).
6. If compression is abnormally low, inspect the
following items.
A. Verify starter cranks engine over at normal
speed (approximately 400 RPM).
B. Gauge functioning properly.
C. Throttle lever in the full-open position.
D. Valve/tappet clearance correct.
E. Valve not bent or burned.
F. Valve seat not burned.
NOTE: To service valves, see Section 3.
7. Pour 29.5 ml (1 fl oz) of oil into the spark plug
hole, reattach the gauge, and retest compression.
8. If compression is now evident, service the piston
rings (see Section 3).
Spark Plug(s)
A light brown insulator indicates that a plug is correct.
A white or dark insulator indicates that the engine may
need to be serviced or the carburetor (if equipped) may
need to be adjusted. To maintain a hot, strong spark,
keep the plug free of carbon.
ATV-0051
Adjust the gap to 0.7-0.8 mm (0.028-0.032 in.) for
proper ignition. Use a feeler gauge to check the gap.
ATV0052C
When installing the spark plug, be sure to tighten it
securely. A new spark plug should be tightened 1/2
turn once the washer contacts the cylinder head. A
used spark plug should be tightened 1/8 - 1/4 turn once
the washer contacts the cylinder head.
Muffler/Spark Arrester
At the intervals shown in the Periodic Maintenance
Chart, clean the spark arrester using the following pro-
cedure.
1. Remove the three cap screws securing the spark
arrester assembly to the muffler; then loosen and
remove the arrester.
COMPRESSION
Model PSI Hot (WOT) PSI Cold (WOT)
400 95-115 N/A
550 120-140 80-120
650/700 125-145 100-140
1000 (Front) 125-145 80-120
(Rear) 165-185 150-190
CAUTION
Before removing a spark plug, be sure to clean the
area around the spark plug. Dirt could enter engine
when removing or installing the spark plug.
! WARNING
Wait until the muffler cools to avoid burns.
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2-8
CF105A
2. Using a suitable brush, clean the carbon deposits
from the screen taking care not to damage the
screen.
NOTE: If the screen or gasket is damaged in any
way, it must be replaced.
3. Install the spark arrester assembly with gasket;
then secure with the three cap screws. Tighten to
48 in.-lb.
CF104
Engine/Transmission
Oil - Filter - Strainer
OIL - FILTER
The engine should always be warm when the oil is
changed so the oil will drain easily and completely.
1. Park the ATV on level ground.
2. Remove the oil level stick/filler plug.
CF109M
GZ415A
3. Remove the drain plug from the bottom of the
engine and drain the oil into a drain pan.
733-441A
4. Remove the oil filter plug from the filter mounting
boss (located on the front side of the transmission
case) and allow the filter to drain completely.
Install the plug and tighten securely.
5. Using the adjustable Oil Filter Wrench and a suit-
able wrench, remove the old oil filter.
NOTE: Clean up any excess oil after removing
the filter.
6. Apply oil to a new filter O-ring and check to make
sure it is positioned correctly; then install the new
oil filter. Tighten securely.
NOTE: Install a new O-ring each time the filter is
replaced.
400/H1
H2
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2-9
2
7. Install the engine drain plug and tighten to 16 ft-lb.
Pour the specified amount of the recommended oil
in the filler hole. Install the oil level stick/filler
plug.
8. Start the engine (while the ATV is outside on level
ground) and allow it to idle for a few minutes.
9. Turn the engine off and wait approximately one
minute.
10. Remove the oil level stick and wipe it with a clean
cloth.
11. Install the oil level stick and thread into the engine
case.
12. Remove the oil level stick; the oil level must be
within the operating range but not exceeding the
upper mark.
GZ461A
13. Inspect the area around the drain plug and oil filter
for leaks.
STRAINER
1. Remove the belly panel.
2. Remove the cap screws securing the oil strainer
cap; then remove the cap.
CC091D
3. Remove the two cap screws securing the strainer;
then remove the strainer.
NOTE: On the H1/H2 models, thoroughly clean
any sealant from the oil strainer cap.
CC163D
4. Place the oil strainer into position beneath the
crankcase and secure with the cap screws. Tighten
securely.
5. Place the strainer cap into position on the strainer
making sure silicone sealant is applied; then
secure with the cap screws. Tighten securely.
CC091D
6. Install the belly panel.
CAUTION
Any oil used in place of the recommended oil could
cause serious engine damage. Do not use oils which
contain graphite or molybdenum additives. These oils
can adversely affect clutch operation. Also, not recom-
mended are racing, vegetable, non-detergent, and cas-
tor-based oils.
CAUTION
Do not over-fill the engine with oil. Always make
sure that the oil level is not above the upper mark.
AT THIS POINT
To check/service oil strainer, see Section 3.
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2-10
Front Differential/Rear
Drive Lubricant
NOTE: On the H2, the rear drive incorporates a
shock-limiting clutch pack in the gear case input
assembly that is designed to cushion driveline
shock.
When changing the lubricant, use approved SAE
80W-90 hypoid gear lube.
To check lubricant, remove the fill plug; the lubricant
level should be 1 in. below the threads of the plug. If
low, add SAE approved 80W-90 hypoid gear lubricant
as necessary.
To change the lubricant, use the following procedure.
1. Place the ATV on level ground.
2. Remove each fill plug.
AL677C
3. Drain the lubricant into a drain pan by removing in
turn the drain plug from each.
ATV0082A
737-651B
4. After all the lubricant has been drained, install the
drain plugs and tighten to 45 in.-lb.
5. Pour the appropriate amount of approved SAE
80W-90 hypoid gear lubricant into the filler hole.
6. Install the fill plugs.
NOTE: If the differential/rear drive lubricant is
contaminated with water, inspect the drain plug,
fill plug, and/or bladder.
Driveshaft/Coupling
The following drive system components should be
inspected periodically to ensure proper operation.
A. Spline lateral movement (slop).
B. Coupling cracked, damaged, or worn.
Nuts/Bolts/Cap Screws
Tighten all nuts, bolts, and cap screws. Make sure riv-
ets holding components together are tight. Replace all
loose rivets. Care must be taken that all calibrated
nuts, bolts, and cap screws are tightened to specifica-
tions (see Section 1).
CAUTION
Any lubricant used in place of the recommended gear
case lubricant could result in premature failure of the
shock limiter. Do not use any lubricant containing
graphite or molybdenum additives or other fric-
tion-modified lubricants as these may cause severe
damage to shock limiter components.
CAUTION
Water entering the outer end of the axle will not be
able to enter the rear drive unless the seals are dam-
aged.
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2-11
2
Headlights/Taillight-
Brakelight
HEADLIGHTS
NOTE: The bulb portion of a headlight is fragile.
HANDLE WITH CARE. When replacing a headlight
bulb, do not touch the glass portion of the bulb. If
the glass is touched, it must be cleaned with a dry
cloth before installing. Skin oil residue on the bulb
will shorten the life of the bulb.
To replace a headlight bulb, use the following proce-
dure.
1. Rotate the bulb assembly counterclockwise and
remove from the headlight housing; then discon-
nect from the wiring harness.
2. Connect the new bulb assembly to the wiring har-
ness connector; then insert into the headlight hous-
ing and rotate fully clockwise.
TAILLIGHT-BRAKELIGHT
To replace the taillight-brakelight bulb, use the follow-
ing procedure.
1. Turn the bulb socket assembly counterclockwise
and remove from the housing.
CF135A
2. Pull the bulb straight out of the socket; then insert
a new bulb.
CF132A
3. Insert the bulb socket assembly into the housing
and turn it clockwise to secure.
CHECKING/ADJUSTING
HEADLIGHT AIM
The headlights can be adjusted vertically and horizon-
tally. The geometric center of the HIGH beam light
zone is to be used for vertical and horizontal aiming.
1. Position the ATV on a level floor so the headlights
are approximately 6.1 m (20 ft) from an aiming
surface (wall or similar aiming surface).
ATV-0070C
NOTE: There should be an average operating
load on the ATV when adjusting the headlight aim.
2. Measure the distance from the floor to the
mid-point of each headlight.
3. Using the measurements obtained in step 2, make
horizontal marks on the aiming surface.
4. Make vertical marks which intersect the horizontal
marks on the aiming surface directly in front of the
headlights.
5. Switch on the lights. Make sure the HIGH beam is
on. DO NOT USE LOW BEAM.
6. Observe each headlight beam aim. Proper aim is
when the most intense beam is centered on the ver-
tical mark 5 cm (2 in.) below the horizontal mark
on the aiming surface.
! WARNING
Do not attempt to remove a bulb when it is hot. Severe
burns may result.
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