2004-2008 Arctic Cat DVX 400 2x4 Service Manual
Complete service guide covers valve tappet clearance, clutch adjustment, hydraulic brake systems, engine rebuild procedures, and transmission servicing with detailed torque specifications throughout.
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Models Covered & Key Technical Specifications
Arctic Cat DVX 400 2x4 — 2004–2008 Operational Industrial Sourcebook | DVX 400 Series Set.
- Authorized Generation Capacity: The dry weight mass is set to 169 kg (373 lb), establishing the vehicle empty mass Specifications.
- Published Working Temperature: For optimal engine operation, the cooling system capacity corresponds to 1.2 L (1.3 U.S. qt) coolant volume Framework.
- Reference Operational Speed: The engine displacement dictates 90.0 × 62.6 mm (3.54 × 2.46 in.) cylinder bore and stroke Mapping.
- Established Addressable Resolution: The compression ratio specifies 11.3:1 for the combustion chamber configuration Requirements.
- Measured Reservoir Specs: Fuel tank capacity is standardized to 10.0 L (2.6 U.S. gal) liquid storage Threshold.
- Core Amperage Specs: Engine oil capacity limits 2.1 L (2.2 U.S. qt) for proper lubrication and system Range.
Professional Workshop Service Manual & Technical Specifications
Applied Calibration Manual: ATV Arctic Cat DVX 400 2x4 Service and Repair Manual (2004-2008) OEM-Documentation
Subsystem-Focus: DVX 400 (2004) // Coverage-Scope: Engine and transmission systems / Periodic maintenance procedures // Coverage-Scope: Complete specifications documentation for all ATV systems.
| Service-Nexus | Operational-Logic | Calibration-Spec |
|---|---|---|
| Engine rebuild and top-end servicing | Complete camshaft, valve, and piston procedures | Tappet shim selection tables included |
| Drivetrain and transmission operation | Shift fork and gear assembly sequencing | Torque specifications for all fasteners documented |
| Cooling system maintenance | Thermostat and water pump operation | Radiator capacity and coolant type specifications |
OEM specifications cover the engine and transmission systems, drivetrain procedures, and complete cooling system documentation, while addressing suspension components and frame assembly methods.
Engineered Standard
Rigorously requiring technical precision across multiple sections, the document includes comprehensive coverage of valve and tappet clearance procedures. The manual documents engine specifications for intake valve face diameter (36 mm) and exhaust valve face diameter (29 mm), with corresponding clearance reference data included. Valve/tappet clearance specifications are documented for both cold engine conditions and operational scenarios, enabling proper component evaluation. The document contains reference information for valve spring tension, camshaft journal clearance, and cylinder head distortion limits to support service technician decision-making.
Structured Protocol
Drivetrain specifications are addressed in extensive sections covering the primary reduction ratio (2.960), final reduction ratio (2.857), and individual gear ratios across all forward and reverse gears. The manual provides detailed driveshaft and countershaft assembly illustrations, with component identification and proper sequencing documented for complex transmission rebuilding. Service intervals are documented for drive chain slack measurement (30-40 mm), chain replacement procedures, and sprocket tooth wear assessment guidance. Component locations are identified for the oil pump assembly, clutch mechanisms, and balancer systems, with exploded diagrams showing all internal relationships.
Systematic Topology
Reassembly procedures are specified for the crankcase halves, including alignment pin positioning and Three Bond Sealant application points. The document contains specifications for connecting rod clearances, crankshaft web-to-web measurements (61.9-62.1 mm), and bearing installation depths with precise dial indicator measurement procedures documented. Oil flow diagrams illustrate the complete lubrication circuit, including oil pump pressure specifications (0.2-0.6 kg/cm²) and filter element installation orientation. The manual documents torque specifications for the engine to ensure proper fastener fatigue prevention.
Technical Parameters
The liquid cooling system section includes thermostat operating temperature ranges (75°C opening threshold), radiator capacity specifications (1.2 liters), and hose routing guidelines for both upper and lower coolant paths. Electrical system documentation addresses magneto coil resistance values (trigger: 350-670 ohms; charging: 0.1-1.5 ohms), ignition coil primary and secondary winding specifications, and CDI unit peak voltage requirements. The document provides comprehensive wiring diagrams with color-coded lead wire identification for all lighting, switching, and sensor circuits throughout the ATV.
Systematic Interface
Suspension assembly procedures document front shock absorber spring preload adjustment ranges (280.7-294.7 mm), rear shock preload settings (228.5-238 mm), and damping force adjuster screw positions with complete before-and-after specifications. Steering alignment documentation includes wheel toe-in measurement methodology (5 mm specification), A-arm pivot bearing installation depths (12 mm for upper pivots), and ball joint replacement sequencing. The document contains brake system specifications covering hydraulic disc brake specifications, bleeder screw locations, and brake pad thickness measurement guidelines (2.0 mm service limit).
The manual documents torque specifications for the engine, transmission, suspension, and brake components to ensure proper fastener fatigue prevention. Comprehensive electrical testing procedures are included for magneto coils, ignition system components, starter motor operation, and all indicator light circuits, with meter resistance and voltage ranges specified for diagnostic accuracy.
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