2004–2008 Arctic Cat DVX 400 2x4 Service 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
• Details the Mikuni BSR36 carburetor, starter torque limiter, swing arm, steering knuckles, and water pump
• Explores front A-arms, shock absorbers, tie rods, master cylinders, cam chain tensioners, and stator assemblies

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. Instead of paying premium dealership labor rates, DIYers and professional mechanics can follow step-by-step instructions for tasks like adjusting valve/tappet clearances, bleeding the hydraulic brake system, rebuilding the carburetor, and dialing in the suspension's rebound and compression damping forces.

Having this PDF on your workshop device lets you instantly pull up vital data right beside the ATV, ensuring you don't strip delicate aluminum engine case threads or miscalculate critical tolerances. To further accelerate any repair, the documentation incorporates specific visual aids, including the Tappet Shim Selection Table, an Oil Flow Chart, the Carburetor Schematic, Rear Drive Assembly Schematics, and the Valve Seat/Guide Servicing Flow Chart.

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.

When overhauling this 398cc powerplant, technicians frequently encounter a few notorious pitfalls documented for this model. Installing the oil filter element backward is a common trap that instantly blocks flow and causes catastrophic top-end oil starvation. Additionally, failing to perfectly align the oil feed holes in the driven gear bushings with the driveshaft oil supply holes during transmission assembly will quickly destroy the gearbox. Working on high-performance ATV drivelines, electrical circuits, and pressurized suspension components carries inherent physical risks; always safely relieve nitrogen gas pressure before servicing shocks and strictly verify your mechanical work against these factory parameters to prevent severe injury.