2013 Arctic Cat 400 TRV ATV Service Manual (P/N 2259-675)

This service manual covers the 2013 Arctic Cat 400 TRV ATV equipped with the Keihin CVK36 carburetor and 25-inch tires. Publication P/N 2259-675 is structured across eight sections covering general specifications, periodic maintenance, troubleshooting, and vehicle repair. The standard 400 model has a separate service manual.

Text search, bookmarks, and wiring detail: Service text is searchable, with embedded bookmarks for all eight sections and the appended wiring sheet. Labels within the wiring diagram are not searchable, and some small connector numbers and wire codes remain difficult to read even when enlarged.

• Engine and transmission: Engine removal, top-end repair, cam timing, crankcase separation and reassembly, centrifugal clutch inspection, and countershaft service.

• Fuel and lubrication: Keihin CVK36 carburetor rebuilding, electric choke testing, vacuum pulse fuel-pump diagnosis, and oil-pressure testing.

• Drive system: Front differential and rear gear case disassembly, pinion-bearing work, gear shimming, axle-seal replacement, and drive axle removal.

• Electrical diagnosis: Stator and ignition-coil tests, CDI peak-voltage checks, starter-circuit troubleshooting, regulator/rectifier testing, and the main-harness wiring diagram.

• Brakes and suspension: Hydraulic brake bleeding, caliper repair, pad replacement and burnishing, shock absorber inspection, and front/rear A-arm service.

• Maintenance and steering: Factory maintenance intervals and inspection routines, valve clearance adjustment, compression testing, V-belt replacement, steering-knuckle service, and toe-out alignment.

Written for service personnel, this manual assumes familiarity with ATV systems and the workshop tools used for component inspection and electrical diagnosis.

Engine and Transmission Repair

Top-side, left-side, and right-side procedures identify work that can be done with the engine still in the frame; center-crankcase work requires removal. This distinction helps a technician plan the teardown around the component that actually needs repair.

Cylinder-head and piston inspection are backed by wear limits and clearance specifications. Countershaft repair covers the high, low, and reverse gears; secondary-bevel-gear work includes tooth-contact illustrations and the Backlash Measurement/Shim Correction and Tooth Contact/Shim Correction charts.

Reference tables provide component-specific torque values, fluid capacities, and hot/cold compression test data.

The V-belt procedure warns that incomplete engagement of the movable drive face on the clutch-shaft splines can produce a false torque reading and damage the shaft and face plate. The crankcase section specifies Crankcase Separator/Crankshaft Remover 0444-152.

The driven pulley and crankshaft/connecting-rod assemblies are specified for complete replacement if defective.

Carburetor and Lubrication Tests

The Carburetor Schematics exploded view identifies the vacuum piston, jet needle, float valve, and pump diaphragm. Electric choke testing includes plunger-travel checks using Electric Choke Test Harness 0444-247.

Oil-pressure testing and vacuum pulse fuel-pump pressure checks have separate procedures. Both pumps are specified for replacement as assemblies.

Ignition, Charging, and Wiring

CDI diagnosis covers peak-voltage and harness-continuity checks before unit replacement. The electrical section specifies a Fluke Model 77 multimeter and Peak Voltage Reading Adapter 0644-307, with test values linked to the specified equipment.

The appended color Main Harness (p/n 0486-464) diagram shows connector pin layouts and wire-color codes. Troubleshooting tables include Spark absent or weak and Battery does not charge; speed-sensor testing is paired with LCD gauge replacement guidance.

Differential, Brake, and Chassis Service

Differential service distinguishes case-side backlash shims from cover-side end-play shims and includes rear gear case thrust-button adjustment. Internal drive axle disassembly is referred to the applicable boot repair kit's instructions. Axle-removal cautions explain how an unsupported shaft can damage the inner CV joint.

Brake coverage includes caliper disassembly, piston/seal inspection, and reassembly. Arctic Cat recommends that hydraulic brake service be performed by authorized Arctic Cat ATV dealers.

Suspension and steering procedures cover shock spring removal, steering-post and tie-rod inspection, knuckle-bearing replacement, and toe-out measurement. Frame/weld inspections, TRV seat removal, and wheel/tire checks are also covered.

PDF Contents and Included Wiring Sheet

Supplied as one printable, English-language 147-page PDF: 140 pages across the eight service sections (including three notes pages), five front-matter pages (cover, foreword, contents, and two blank pages), one back cover, and one appended color wiring-diagram page. All are included in the total.