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.
Arctic Cat Models Covered & Key Technical Specifications
Models: Arctic Cat DVX 400 2x4
Model Years: 2004–2008
Technical Data:
- Engine displacement: 398 cc
- Cylinder bore and stroke: 90.0 × 62.6 mm
- Compression ratio: 11.3:1
- Dry weight: 169 kg (373 lb)
- Engine oil capacity: 2.1 L (2.2 U.S. qt)
- Cooling system capacity: 1.2 L (1.3 U.S. qt)
- Fuel tank capacity: 10.0 L (2.6 U.S. gal)
- Tire inflation pressure: Front 0.30 kg/cm² (4.4 psi), Rear 0.275 kg/cm² (4.0 psi)
- Oil pressure at 60°C (140°F): 0.2–0.6 kg/cm² (2.8–8.5 psi)
Arctic Cat Manual Features & Content Preview
2004–2008 Arctic Cat DVX 400 2x4 Service & Maintenance Manual
- Covers all 2004–2008 Arctic Cat DVX 400 2x4 models, providing exact technical specifications for the 398cc liquid-cooled engine
- Contains 150 pages of pure technical reference, including lubrication points, complete electrical wiring diagrams, and fuel-delivery diagnostics
- Includes 52 high-resolution exploded-view schematics for the drive system, engine and transmission assembly, and fuel/cooling components
- Fully searchable PDF format—allowing you to find specific chapters, tear-down procedures, and torque specs instantly
- Available for immediate download directly to your device right after checkout
Service and Maintenance Overview
This manual outlines essential maintenance routines for the DVX 400, taking you from periodic inspection charts and engine break-in procedures to long-term storage prep. Chapters clearly detail the inspection of air cleaners, spark plug maintenance, and drive chain adjustments to keep the ATV running at factory standards. You will find complete documentation for the disassembly and assembly of top-end components, crankshaft units, and transmission shafts for the 398cc platform.
Additional sections explain how factory workshop documentation is structured, focusing heavily on electrical and fuel system troubleshooting. The guide walks through testing procedures for the magneto coils, starter motor, coolant temperature switches, and the throttle position sensor (TPS). Maintenance chapters also cover hydraulic brake system inspections, laying out the exact pad replacement criteria for both front and rear discs.
Technical Specification Preview
Mechanics will find highly detailed tolerance charts for valves, guides, and piston-ring end gaps. Cylinder head distortion limits are firmly set at 0.05 mm, and the engine oil capacity is specified at 2.1 liters. The guide lists all transmission gear ratios for the five-speed manual, including the 2.153 reverse gear ratio. Electrical data outlines charging coil resistance at 0.1–1.5 ohms (brown to brown) for the magneto system, alongside operational specs for coolant temperature switches and the cooling fan thermostat. Working on high-performance ATV drivelines and electrical systems requires strict precision; always verify your setup against these factory specs and consult a certified shop if an issue falls outside standard mechanical maintenance parameters.
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