2004 arctic cat dvx 400 service manual

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Remove the gas tank see Section 4. Remove the engine sprocket cover; then remove the engine sprocket with the drive chain. Remove the spark plug cap 1 , oil tank overflow hose 2 , and the breather hose 3. SP Page Left-Side Components Support the engine with a suitable floor jack; then remove the engine mounting brackets in the follow- ing order: A. Upper front: Four cap screws C , one nut B , bolt, and two mounting brackets.

Lower front not shown : One nut and through bolt directly under the alternator housing. Cover B. Drive Gear C. Neutral Switch 1. Remove the cap screws securing the starter drive cover; then remove the cover and drive gear.

Account for two thrust washers and the large O-ring. Remove the alignment pins 5 and the gasket 6. Page 37 8.

Remove the cam chain tensioner 4 and the cam chain 5 ; then remove the oil pipe 6. Using an appropriate clutch sleeve hub holder, secure the clutch sleeve hub and remove the hub nut; SP then remove the clutch sleeve hub. Remove the two screws securing the shift pawl lifter Remove the primary drive gear nut, washer, and pri- 3 and the shift cam driven gear 4. Remove the mary drive gear; then remove the key 1 , balancer shift cam stopper arm 5. The technician should use discretion and sound judgment.

Page 40 1. Remove the cap screw on the end of the tensioner; then remove the two Allen-head cap screws securing the tensioner adjuster assembly and remove the assembly. Account for a gasket and spring. Page Center Crankcase Components 9. Using an awl, remove one piston-pin circlip.

Push out the piston pin; then remove the piston. Account for the second piston-pin circlip. SP 7. Remove the cam chain guide 3 ; then remove the remaining two nuts 4 securing the cylinder to the crankcase. Servicing Top-Side Components Page 44 6.

Check the gasket surface of the cylinder head for dis- tortion using a straightedge and feeler gauge. Take clearance readings at several places. If any clearance reading exceeds the service limit specifications, replace the cylinder head with a new one.

SP 4. Page 45 3. Push the valve from side to side; then from top to bottom. Measuring Valve Guide Inside Diameter 1. Insert an exhaust valve seat pilot shaft into an exhaust valve guide. Slide an exhaust valve seat grinding tool onto the pilot shaft; then using light pressure on a driver handle and a deep socket, grind the exhaust valve seat until within specifications.

Page Piston Assembly 4. Rotate the valve until the valve and seat are evenly polished. Clean all compound residue from the valve and seat.

Installing Valves 1. Apply grease to the inside surface of the valve seals; then place a lower spring seat and valve guide seal over each valve guide. Place each piston ring in the wear portion of the cyl- 1. Measure the cylinder front to back in six places. Use the piston to position each ring squarely in 2. Wash the cylinder in parts-cleaning solvent. Inspect the cylinder for pitting, scoring, scuffing, and 1.

If marks are found, the cylinder must be replaced. Inspect the cylinder for pitting, scoring, scuffing, warpage, and corrosion. Page Servicing Left-Side Components 2. The lobe heights must not exceed minimum specifi- cations. Inspecting Camshaft Bearing Journal 1. Inspect the bearing journal for scoring, seizure marks, or pitting. If excessive scoring, seizure marks, or pitting is found, the cylinder head assembly must be replaced.

Measuring Camshaft to Cylinder Head Clearance 1. It is not serviceable. Page Oil Pump Nut 1. Primary Driven Gear Release Pin Lock Wash 2. Washer Camshaft Push Rod 3. Spacer Release Arm Retainer 4. Sleeve Hub Washer 5. Drive Plate 1 Bearing Bearing 6. Drive Plate 2 7. Remove the nut and large flat washer from the crank balancer shaft; then remove the driven gear. Crankcase Components 9. Nut 6. Page Crankshaft Assembly 3.

Install the oil pump idler gear shaft 1 ; then apply red Loctite to the shift arm stopper 2 and tighten to specification. Install the new bearing using the bearing installer; then apply a small amount of red Loctite to the bearing retainer screws and tighten securely.

Page Driveshaft Measuring Connecting Rod 3. Zero the indicator and rotate the crankshaft slowly. Small End Deflection! Place the crankshaft on a set of V-blocks and mount a dial indicator and base on the surface plate. Position Care should be taken to support the connecting the indicator contact point against the center of the rod when rotating the crankshaft. Page 56 4. Remove the reverse driven gear from the driveshaft.

Remove the 4th driven circlip and gear from the driveshaft. Remove the reverse driven bushing; then remove the 5th driven gear from the driveshaft. In order, remove the 2nd driven circlip, washer, gear, and bushing from the driveshaft.

If not aligned, engine damage will result. Install the 3rd driven gear onto the driveshaft. Page Countershaft 7.

Install the reverse dog onto the driveshaft making sure the four small dogs are facing toward the 1st driven gear as noted in disassembling. Install the 1st driven washer right side onto the shoulder of the splined shaft; then install the 1st driven bushing and gear.

Remove the remaining 5th drive washer from the 5. Install the 2nd drive gear and washer onto the countershaft. Assembling 1. Install the first 5th drive washer onto the counter- shaft. Install the 5th drive gear; then install the second 5th drive washer onto the countershaft. Install the crank balancer shaft. Simultaneously, install the driveshaft and counter- shift cam to ensure all gears shift properly.

Primary Drive Gear B. This is done to provide a means of holding shafts for tightening right-side shaft SP 4. Apply engine oil to the threads; then install the pri- C.

Shift Cam Driven Gear mary drive gear nut and tighten to specifications. Oil Pump E. Apply engine oil to the moving parts of the oil pump Install the cam chain 1 onto the sprocket; then and all mating surfaces. SPA 9. Install the spacer 3 , primary driven gear assembly Bend the washer over securely engaging the flat of 1 , washer 2 , clutch sleeve hub 4 , lock washer the nut. Install the starter driven gear 1 , dowel pins 2 , and Install the alignment pins 1 and a new gasket 2 ; a new gasket 3 ; then install the cover and tighten then install the clutch cover using a new washer gas- the cap screws securely.

Do not allow the spacer ends to overlap. B is correct. Apply engine oil to the sliding surface of the piston and the big end of the connecting rod; then install the alignment pins 2 and a new gasket 3 onto the ATV crankcase. Page 67 8. Install the cylinder head on the cylinder. Lightly oil the threads of the 10 mm cap screws and the washers; then install and tighten in two steps to specifications using a diagonal pattern.

Page 68 SP SP Making sure that the piston position is top-dead-cen- the camshaft steady and pull up the cam chain to ter on the compression stroke, tighten the camshaft remove any slack; Install the exhaust pipe and muffler; then tighten the exhaust pipe nut 1 , muffler mounting bolts 2 , and the connector bolt 3 to specifications.

Page 70 Fill the oil tank. See Section 2. Fill the cooling system with the appropriate mix of Arctic Cat anti-freeze and water. See Section 2 for all adjustments.

Page 71 Connect all remaining electrical connections; then Carburetor Schematic Page Carburetor Carburetor! WARNING Whenever any maintenance or inspection is per- formed on the fuel system during which there may be fuel leakage, there should be no welding, smok- ing, open flames, etc.

Remove the two screws securing the primer housing. Account for the primer diaphragm assembly 11 and spring. SPA SP 6. Secure the needle jet holder with a wrench; then remove the main jet. Page 76 D. After cleaning, install the pilot screw with a 5. Place the float chamber into position making sure the new O-ring to the original position by turning O-ring is properly positioned; then secure with the Phillips-head screws.

Page Cleaning And Inspecting Carburetor 6. Position the carburetor in the air cleaner and intake pipe boots; then secure with the clamps. Throttle Cable Free-Play 7. Connect the hose at the fuel valve connection. Secure the air-intake snorkel. Remove the gas tank. Whenever any maintenance or inspection is made on 1. Remove the hose from the fuel valve by releasing the spring clamp; then remove the vacuum hose. Remove the two nuts securing the fuel valve; then remove the valve.

Account for the gasket. Spring Rotors 1. Page 82 SP SP 2. Install new O-rings to the upper and lower tank fit- 4. Remove the oil lines from the tank. Account for the tings; then secure the fittings to the tank and tighten two O-rings 7 and two alignment pins 8. Page Liquid Cooling System Radiator for leakage and damage. While the cooling system is being filled, air pockets may develop; therefore, run the 1. Radiator 2. Remove the fan assembly from the radiator. O-Ring 1. Water Pump Housing Drain Plug 2.

Gasket 3. Mechanical Seal Cap Screw 4. Oil Seal Cap Screw 5. O-Ring 6. E-Ring Circlip 7. O-Ring Driven Gear 8. Clean all oil-pump components in cleaning solvent. Place the new oil seal into the housing; then using a seal driver, gently tap the seal down until it is fully seated. Install the washer 1 , drive pin 2 , and driven gear 2. Install the clutch cover and tighten the cap screws 3 ; then install the circlip 4.

Make sure the circlip securely; then install the master cylinder mounting is properly seated. Page Cooling Fan Thermo-Switch 2. Disconnect the engine coolant temperature lead wire 2. Disconnect the cooling fan thermo-switch lead wire coupler 1 ; then remove the engine coolant tempera- coupler 1 ; then remove the cooling fan thermo- ture switch 2. Page Specifications 2. Remove the negative battery cable; then remove the positive cable. Remove the battery from the ATV.

The switch connector is the two-prong one located in front of the steering post. Page Fan Motor 6. If the readings are not as indicated, the switch must be replaced. Page Ignition Coil 5. The meter reading must be within specification. Page Ignition Switch 2. Connect the red tester lead to the orange wire; then connect the black tester lead to ground. The meter must show battery voltage. After testing procedures are completed, use the following procedure. Page Handlebar Control Switches The switch harness.

The meter must show less than 1 ohm. Page Starter Motor 3. Set the meter selector to the OHMS position. Connect the red tester lead to the green wire; then connect the black tester lead to the blue wire. Page 99 8. Slide the armature free of the starter housing. Remove the nut from the positive post. Account for the lock washer, flat washer, a fiber washer, and an O-ring. Bend the two positive brushes outward; then remove the brush holder.

Account for two brush springs and brushes. If there is still no meter indication, replace the brush assembly. Align the tab on the brush holder with the notch in the right-side cover; Page Ignition Timing Also, the ignition switch should be in the ON position and the brake either foot 2.

SPB 4. Remove the rear wheel hubs; then remove the left- side axle nuts 1. Account for two concave washers 2. Pack the new bearings with a good quality wheel bearing grease; then install the right bearing 1 first using an appropriate bearing installer.

The sealed side of the bearing must be directed outward. Install the spacer; then install the left bearing 2. ATV 3. Page SP SP 4. Front Arm Assy 1. Shock Absorber 2. Bearing 2. Cap Screw 3. Bearing 3. Grease Fitting 4. Nut 5. Spacer 5. A-Arm 6.