2004–2008 Arctic Cat DVX 400 2x4 ATV Service & Repair Manual

This service manual covers the 2004–2008 Arctic Cat DVX 400 2x4 ATV, with maintenance, diagnostic, and internal engine/transmission repair procedures.

• Engine and transmission: Engine removal, cylinder-head and crankshaft inspection, cam timing, clutch service, and driveshaft/countershaft disassembly.

• Fuel and lubrication: Mikuni BSR36 carburetor teardown and reassembly, fuel-valve inspection, oil-pump service, and oil-pressure testing.

• Cooling system: Radiator and fan removal, thermostat inspection, water-pump seal replacement, and coolant-temperature and cooling-fan switch tests.

• Electrical diagnosis: Ignition, magneto-coil and stator checks, starter-motor overhaul, charging-system troubleshooting, TPS resistance tests, and a color wiring diagram.

• Drive system and suspension: Rear-axle bearing replacement, swing-arm and front A-arm service, steering-knuckle inspection, and shock preload and damping adjustments.

• Brakes and controls: Hydraulic-system bleeding, front and rear pad replacement, master-cylinder inspection, parking-brake adjustment, and throttle/reverse-selector service.

The procedures suit mechanics and experienced owners familiar with precision measurements and electrical testing; internal engine work requires the specialized tools identified in the manual.

Maintenance, Valve Work, and Internal Engine Repair

Periodic inspection charts cover lubrication points, air-cleaner and spark-plug maintenance, drive-chain adjustment, engine break-in, and preparation for storage and return to service.

The valve section includes separate intake and exhaust Tappet Shim Selection Tables, plus a Valve Seat/Guide Servicing Flow Chart. Cylinder-head distortion, camshaft journals, piston-ring end gaps, and crankshaft measurements have dedicated inspection procedures and tolerance data.

Top-side and side-cover work can be performed with the engine in the frame; center-crankcase service requires engine/transmission removal. Crankcase separation uses the Crankcase Separator/Crankshaft Remover, P/N 0444-009.

Clutch and geartrain: Coverage extends to clutch-plate inspection, cam-chain tensioners, gear engagement, and transmission-shaft assembly. Cross-sectional views show gear, washer, and circlip positions. Starter-clutch replacement and starter torque-limiter testing are included; the torque limiter is replaced as a unit rather than internally repaired.

Oil-filter service warnings explain how a reversed element can interrupt oil flow and damage the engine. Transmission assembly cautions address oil-feed-hole alignment in the driven-gear bushings and the engine damage associated with misalignment.

Carburetor, Oil Circuit, and Cooling Components

The Carburetor Schematic identifies the BSR36's jets, needle, float, and diaphragm components alongside cleaning, inspection, and assembly procedures. The fuel-system section also addresses the automatic-off diaphragm fuel valve and gas/vent hoses.

An Oil Flow Chart accompanies pump and filter documentation. Cooling coverage goes beyond hose inspection to water-pump impeller/shaft and seal work, radiator/fan removal, and thermostat testing.

Starting, Charging, and Fault Diagnosis

Electrical testing specifies the Fluke Model 73 Multimeter, P/N 0644-191, and Peak Voltage Reading Adapter, P/N 0644-307. Connector and wire-color references support ignition-coil, magneto, starter-relay, regulator/rectifier, temperature-switch, and TPS checks. The TPS and ignition timing are not adjustable.

The no-start charts separate compression, spark, and fuel-delivery causes, helping you select the relevant diagnostic section before dismantling the engine. Other condition/remedy charts address poor running, shifting faults, charging problems, steering, suspension, and brakes.

Rear Axle, Steering, Suspension, and Brakes

Rear Drive Assembly Schematics support axle, hub, bearing, and dust-seal work. The axle installation section includes the torque-wrench correction required when using the offset axle-nut adapter. Component-specific torque tables cover engine, chassis, electrical, and brake fasteners.

Steering procedures address the steering post, tie rods, knuckles, and toe-in/toe-out measurement. Suspension instructions distinguish front and rear spring preload, rebound, and compression settings. The shocks contain high-pressure nitrogen and are not internally serviceable; the manual includes pressure-release warnings for disposal.

Brake sections provide front and rear pad replacement criteria, hydraulic bleeding, and master-cylinder procedures. The front master cylinder is identified as an assembly-replacement component; rear master-cylinder instructions include internal inspection and reassembly.

A Preview of Powertrain Specifications and Coil Tests

These examples are a small selection of the manual's inspection and electrical specifications.

For the cylinder head, maximum distortion is 0.05 mm. The cold-engine valve/tappet clearance ranges are 0.10–0.20 mm for intake and 0.20–0.30 mm for exhaust, with separate shim-selection tables supporting adjustment.

The transmission table lists all five forward gear ratios and a reverse ratio of 2.153.

The electrical specifications list charging-coil resistance at 0.1–1.5 ohms between brown wires, with testing specified at room temperature, 68°F.

PDF Search, Bookmarks, and Wiring Detail

Finding text and diagram detail: Most service text is searchable. The intake/exhaust shim tables and final wiring diagram lack searchable content. Embedded bookmarks cover the main sections and wiring diagram, but “Contents” has no valid destination and “Controls / Indicators” opens the torque-reference section. Small wiring labels require zooming.

Supplied as one printable, English-language PDF download with 150 pages: 149 service-manual pages plus one appended color wiring-diagram page, already included in the total.