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
Table of Contents

TM
SHARE OUR PASSION.
ATV
ATV
Service Manual
Service Manual
400 TRV
550 FIS/TRV
650 FIS
700 FIS/TBX/TRV
Thundercat
1000 TRV
Cruiser
Mud Pro
TABLE OF CONTENTS
Click on blue text to go.
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
Table of Contents

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)
Next
Section
Table of Contents
Manual
Table of Contents

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
NextBack Section
Table of Contents
Manual
Table of Contents