2006 Arctic Cat DVX 400 ATV Service Manual (P/N 2257-485)

• Factory coverage: Built for the 2006 Arctic Cat DVX 400, this factory repair publication is supplied as a 164-page PDF and corresponds to the cataloged CD edition, P/N 2257-485.
• Engine and transmission repair: Covers power-unit removal and installation, cylinder-head and piston work, crankcase separation, crankshaft and transmission inspection, clutch service, cam timing, and final adjustment.
• Fuel, lubrication, and cooling: Details Mikuni BSR37 carburetor disassembly and cleaning, fuel-valve service, oil-pressure testing, radiator and thermostat checks, and water-pump repair.
• Electrical diagnosis: Provides component-level testing for the ignition coil, magneto, starter and relay, CDI unit, regulator/rectifier, TPS, switches, lighting, and cooling controls, plus the complete wiring diagram.
• Chassis procedures: Includes rear axle and bearing service, chain and sprocket replacement, swing-arm and A-arm work, steering-post and tie-rod repair, toe adjustment, hydraulic brake bleeding, and pad replacement.
• Shop reference data: Supplies maintenance schedules, valve-shim charts, component torque tables, fluid and lubrication data, wear limits, clearance specifications, electrical test values, troubleshooting charts, and labeled exploded views.

This manual is specific to the 2006 Arctic Cat DVX 400 and the configuration documented throughout: a Mikuni BSR37 carburetor, CDI ignition with throttle-position input, liquid cooling, electric starting, a manual clutch, and a five-speed transmission with reverse. It is suited to experienced mechanics and advanced owners who have proper support equipment, precision measuring tools, electrical test gear, and engine-service tooling; the procedures assume shop-level judgment rather than teaching basic repair practice.

Engine and Transmission Service

The engine chapter is organized around actual service access. The starter clutch, starter torque limiter, starter motor, water pump, top end, and side components can be serviced with the engine in the frame. Center-crankcase work requires removal of the complete engine/transmission assembly.

Coverage runs from camshafts, valves, guides, seats, piston, rings, and the plated cylinder through the primary clutch, oil pump, crankshaft, balancer, driveshaft, countershaft, reverse mechanism, shift cam, and shift forks. Factory procedures cover teardown, inspection, measurement, reassembly, and installation, supported by compression data, runout checks, journal and bushing clearances, wear limits, and valve-shim selection tables. Tool callouts include Compression Gauge P/N 0444-096 and Crankcase Separator/Crankshaft Remover P/N 0444-009.

Fuel, Cooling, and Electrical Diagnosis

The BSR37 section goes beyond routine adjustment. It documents carburetor removal, diaphragm and float-bowl disassembly, jet and passage cleaning, pilot-circuit service, float inspection, reassembly, and cable and idle setup. Lubrication and cooling coverage includes the oil-flow circuit, oil-pump pressure testing, oil tank and lines, radiator, thermostat, fan, temperature switches, and water-pump seals.

Electrical diagnosis is connector-specific, with resistance, voltage, charging-output, and peak-voltage tests for the starting, charging, ignition, lighting, indicator, and cooling-fan circuits. The specified test setup uses the Fluke Model 73 Multimeter P/N 0644-191 with Peak Voltage Reading Adapter P/N 0644-307. Ignition timing is checked for fault isolation but is not adjustable, an important distinction when tracing rotor, trigger-coil, CDI, or TPS faults.

Chassis, Brakes, and Technical Views

The chassis chapters cover the rear drive axle and housing, axle bearings and seals, front and rear suspension, shock preload and damping settings, swing-arm and A-arm bearings, steering post, tie rods, wheel alignment, brake master cylinders, and control cables. Separate troubleshooting tables sort engine, fuel, electrical, steering/suspension, and brake symptoms into likely causes and repair areas.

Named visual references include the Carburetor Schematic, Oil Flow Chart, Valve Seat/Guide Servicing Flow Chart, the wiring diagram for harness P/N 3509-007, Left and Right Rear Wheel Assembly Schematics, and Front and Rear Suspension Assembly Schematics with a separate swing-arm view. Exploded assembly drawings support the repair chapters, but replacement-part ordering remains the job of the separate Illustrated Parts Manual.

The manual flags assembly errors that can cause real damage: misaligned transmission-bushing oil passages can interrupt lubrication, while a backward oil-filter element blocks oil flow. For chassis or powertrain work, the ATV must be solidly supported before the wheels are raised; the shock absorbers contain high-pressure nitrogen and are treated as non-serviceable units.