Arctic Cat 2008 400 2x4 Owner'S Manual Download Page 12

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Warnings

RNIN

! WARNINGS

POTENTIAL HAZARD
Operating this ATV at excessive speeds.

WHAT CAN HAPPEN
Increases your chances or losing control of the ATV, which can
result in an accident.

HOW TO AVOID THE HAZARD
Always ride at a speed that is proper for the terrain, visibility and
operating conditions, and your experience.

Summary of Contents for 2008 400 2x4

Page 1: ...TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SERIOUS INJURY OR DEATH Particularly important information is distinguished in this manual by the following notations 77 17 21 87 21 127 The Safety Alert Symbol means ATTENTION BE ALERT YOUR SAFETY IS INVOLVED Failure to follow WARNING instructions could result in severe injury or death to the ATV operator a bystander or a per son inspe...

Page 2: ...emember only authorized Arctic Cat ATV dealers have the knowledge and facilities to provide you with the best service possible l Know all local state provincial riding laws l Respect vour ATV l Respect the environment and l You will gain the respect of others We also advise you to strictly follow the recommended maintenance program as outlined This preventive maintenance program is designed to ens...

Page 3: ...tive riding techniques 37 Tips 45 SOUND JUDGMENT 49 55 Environment 49 Those around you 51 Equipment 52 Maximum load capacity chart 53 SUPERVISION 49 55 Taking Responsibility 50 DIVISION II OPERATION MAINTENANCE PREFACE 57 PARTS AND ACCESSORIES 57 SPECIFICATIONS 58 59 GENERAL INFORMATION 60 69 ATV Identification Numbers 60 Ignition Switch Key 60 Control Locations and Functions 61 Gas Vent Hoses 66 ...

Page 4: ...ve Rubber Boots 78 Battery 78 Spark Plug 80 Engine Idle RPM Adjustment 81 Throttle Cable Adjustment 81 Air Filter Engine 81 Air Filter Housing Drain Tube 82 Tires 83 Wheel Removal 84 Light Bulb Replacement 84 Fuses 86 Tools 87 PREPARATION FOR STORAGE 88 PREPARATION AFTER STORAGE 89 WARRANTY 90 WARRANTY PROCEDURE OWNER RESPONSIBILITY 93 3 ...

Page 5: ...errain carefully before you start up any hill Never climb hills with slippery or loose surfaces Shift your weight forward Never open the throttle suddenly or make sudden gear changes Never go over the top of any hill at high speed Always follow proper procedures for going down hills and for braking on hills as described in this manual Check the terrain carefully before you start down any hill Shif...

Page 6: ...ly and be very cautious in order to reduce the chance of skidding or sliding out of control Never operate an ATV in fast flowing water or in water deeper than the footrests Remember that wet brakes may have reduced stopping capa bility Test your brakes after leaving water If necessary apply them lightly several times to let friction dry out the pads Always be sure there are no obstacles or people ...

Page 7: ... to the warnings contained in the manual and on all labels Never operate an ATV without proper instruction Take a training course Never operate an ATV without an approved motorcycle helmet eye protection boots gloves long pants and a long sleeved shirt or jacket Never operate an ATV at excessive speeds Go at a speed which is proper for the terrain visibility conditions and your experience Never at...

Page 8: ...containing important safety information Anyone who rides the ATV should read and understand this information before riding The labels should be considered as permanent parts of the ATV If a label comes off or becomes hard to read contact your Arctic Cat ATV dealer for a replacement labels 7 ...

Page 9: ...8 Warning Labels A C F E H ...

Page 10: ... Lever Lock 8 Key Switch 9 Shift Lever 10 Throttle Limiter 11 Drive Selector model 4x4 12 Throttle Lever 13 Engine Starter Button 14 Taillight Brakelight 15 Mirror 16 Operator s Manual Location 17 Headlight LI LO HI Switch 18 Tool Kit 19 Horn 20 Turn Light Switch 21 Hazard Warning Switch 1 2 12 3 4 5 6 7 8 9 10 11 14 16 15 15 18 13 17 19 20 21 ...

Page 11: ...eye protec tion can result in an accident and increases your chances of a severe injury in the event of an accident Operating without protective clothing increases your chances of severe injury in the event of an accident HOW TO AVOID THE HAZARD Always wear an approved helmet that fits properly You should also wear 10 Warnings ATV 0004 Protective clothing Goggles Helmet Gloves Boots Eye protection...

Page 12: ...is ATV at excessive speeds WHAT CAN HAPPEN Increases your chances or losing control of the ATV which can result in an accident HOW TO AVOID THE HAZARD Always ride at a speed that is proper for the terrain visibility and operating conditions and your experience ...

Page 13: ...D Attempting wheelies jumps and other stunts WHAT CAN HAPPEN Increases the chance of an accident including a rollover HOW TO AVOID THE HAZARD Never attempt stunts such as wheelies or jumps Don t try to show off Warnings ATV 0005 ...

Page 14: ...chedules described in this Operator s Manual WARNINGS POTENTIAL HAZARD Removing hands from handlebars or feet from footrests during operation WHAT CAN HAPPEN Removing even one hand or foot can reduce your ability to control the ATV or could cause you to lose your balance and fall off the ATV If you remove a foot from a footrest your foot or leg may come into contact with the wheels which could inj...

Page 15: ...N You can come upon hidden rocks bumps or holes without enough time to react Could result in the ATV overturning or going out of control HOW TO AVOID THE HAZARD Go slowly and be extra careful when operating on unfamiliar terrain Always be alert to changing terrain conditions when operating the ATV Warnings ATV 0006 ...

Page 16: ...oss of traction or ATV control which could result in an accident including a rollover HOW TO AVOID THE HAZARD Do not operate on rough slippery or loose terrain until you have learned and practiced the skills necessary to control the ATV on such terrain Always be especially cautious on these kinds of terrain Warnings WARNINGS ATV 0007 ...

Page 17: ...Practice turning at slow speeds before attempting to turn at faster speeds Do not turn at excessive speed WARNINGS POTENTIAL HAZARD Operating on steep hills WHAT CAN HAPPEN The ATV can overturn more easily on steep hills than on level surfaces or small hills HOW TO AVOID THE HAZARD Never operate the ATV on hills too steep for the ATV or for your abilities Practice on smaller hills before attemptin...

Page 18: ...ays check the terrain carefully before you start up any hill Never climb hills with slippery or loose surfaces Shift your weight forward Never open the throttle suddenly or make sudden gear changes The ATV could flip over backwards Never go over the top of any hill at high speed An obstacle a sharp drop or another vehicle or person could be on the other side of the hill Warnings WARNINGS 739 503A ...

Page 19: ...s follow proper procedures for going down hills as described in this Operator s Manual Always check the terrain carefully before you start down any hill Shift your weight backward Never go down a hill at high speed Avoid going down a hill at an angle that would cause the ATV to lean sharply to one side Go straight down the hill where possible Warnings ATV 0009 ...

Page 20: ...ou have mastered the turning technique as described in this Operator s Manual Practice first on level ground Be very careful when turning on any hill Avoid crossing the side of a steep hill if possible When crossing the side of a hill Always follow proper procedures as described in this Operator s Manual Avoid hills with slippery or loose surfaces Shift your weight to the uphill side of the ATV AT...

Page 21: ... a hill If you lose all forward speed Keep weight uphill Apply the brakes Engage the parking brake lock after you are stopped If you begin rolling backwards Keep weight uphill Apply the brakes while rolling backwards When fully stopped engage the parking brake lock Dismount on uphill side or to a side if pointed straight uphill Turn the ATV around and mount following the procedure described in thi...

Page 22: ...es always follow proper procedures as described in this Operator s Manual WARNINGS POTENTIAL HAZARD Skidding or sliding WHAT CAN HAPPEN You may lose control of the ATV You may also regain traction unexpectedly which may cause the ATV to overturn HOW TO AVOID THE HAZARD Learn to safely control skidding or sliding by practicing at slow speeds and on level smooth terrain On extremely slippery surface...

Page 23: ...than the footrests Remember that wet brakes may have reduced stopping capability Test your brakes after leaving water If necessary apply them several times to dry out the pads WARNINGS POTENTIAL HAZARD Improperly operating in reverse WHAT CAN HAPPEN You could hit an obstacle or person behind you resulting in serious injury HOW TO AVOID THE HAZARD Before you engage reverse gear make sure there are ...

Page 24: ...tor s Manual WARNINGS POTENTIAL HAZARD Operating the ATV with improper modifications WHAT CAN HAPPEN Improper installation of accessories or modification of the ATV may cause changes in handling which in some situations could lead to an accident HOW TO AVOID THE HAZARD Never modify theATV through improper installation or improper use of accessories All parts and accessories added to this ATV shoul...

Page 25: ...y for ATV riding in order to prevent scraped skin and serious head injuries It s easy and could save you time in the long run not having to contend with an injury Of course it also makes sense to remember the seasons Wear a hat under your helmet and a snowmobile suit in the winter and lighter protective clothing in the summer ATV Following is the minimum protection you need to wear during every ri...

Page 26: ...ad from injury if it has cracks fissures or other damage to its outside or core padding Remember your helmet won t do you any good if the chin strap isn t fastened Eye Protection Wear eye protection such as goggles to completely surround your eyes to prevent getting dirt or other items in your eyes Do not depend on sunglasses for proper eye protection Sunglasses are not recommended they don t prev...

Page 27: ...some rough terrain and there s no way you want your brakes to go out when riding downhill You need to check the following parts on your ATV before every ride 1 Tires and Wheels 2 Controls and Cables Brake Throttle 3 Lights and Electric 4 Oil Gasoline and Fluids 5 Chassis and Suspension Prevention Condition of the ATV 26 ...

Page 28: ...o be replaced CONTROLS AND CABLE With the engine running and brake applied check all transmission positions low high neutral and reverse A Brakes Depress the brake pedal If either it feels soft or squishy it could be low on fluid or have a leak refer to the General Maintenance section of this Operator s Manual for instructions Don t use the ATV until the brakes are operating normally Test the brak...

Page 29: ...he ATV Don t drive the ATV unless all systems are working Check the ignition switch OIL AND FUEL Start with a full tank of gas before every ride and while you re at it top off the oil Don t forget to check for fluid leaks around the ATV CHASSIS AND SUSPENSION Grass and leaves can gum up your suspension and shocks Clear and clean the suspension arms shock absorbers springs and fenders Check smoothn...

Page 30: ...n board Tools Water Identification First Aid Kit requested by law in some countries Safety Jacket Warning Triangle For rides that are longer in duration and distance the following additional items are recommended Money Maps Emergency Kit with Flashlight and First Aid Kit Tools Routine maintenance will generally eliminate the need for emergency repairs Riding on rough terrain could cause loosening ...

Page 31: ...out it you re anonymous Money It may be necessary to make an urgent phone call Maps Maps may be unnecessary when you re familiar with the area But when you re riding on unfamiliar trails it s good to know where you are what s coming up and how to get back Emergency Kit with Flashlight and First Aid Kit You ll need several items in your Emergency Kit including a flashlight The matches will come in ...

Page 32: ...ATV Basic Operating Maneuvers Active riding and basic maneuvers are the foundation of your ATV ride Without basic skills it s impossible to move to this level active riding These are your basic maneuvers Mounting the ATV Braking Stopping Starting the Engine Shifting Starting a Cold Engine Parking Varying Temperature Adjustments Dismounting the ATV Mounting the ATV To get seated 1 From the left sid...

Page 33: ...the fuel valve is in the ON position 2 Climb up onto the ATV and sit down 3 Compress the hand brake then engage the brake lever lock 4 Shift the transmission into neutral 5 Turn on the ignition 6 Press the starter button 7 Let the engine warm up Another way to remember the starting procedure is by using the acro nym BONE C It stands for B O N E C BRAKES ON NEUTRAL ENGINE CHOKE Automatic Active Rid...

Page 34: ...it is thoroughly warmed up If the engine is run for a shorter period of time the spark plug may not have reached a high enough temperature to burn off the excess fuel in the combustion chamber Active Riding 33 ACTIVE RIDING Engaging the starter motor for longer than eight seconds at a time can damage the ATV The starter motor and wiring harness may overheat If the engine does not start after sever...

Page 35: ...throttle lever com pletely 4 Never ride the brake Even maintaining minimal pressure on the brake lever or brake pedal will cause the brake pads to drag on Active Riding 34 Excessive repetitive use of the hydraulic brake for high speed stops will cause overheating of the brake fluid and premature brake pad wear which will result in an unexpected loss of brakes WARNING Use only Arctic Cat approved b...

Page 36: ...ould result WARNING ACTIVE RIDING Always shift into low range when operating on wet or uneven ter rain when towing or pushing heavy loads and when using a plow Failure to follow this caution may result in premature V belt failure or in damage to related drive system components CAUTION nNote The high range is for normal riding with light loads The low range is for carrying heavy loads or trailer to...

Page 37: ...on a hill shift the ATV into low range and block the rear wheels 5 otherwise try to park only on level surfaces 6 Engage the brake lever lock Dismounting the ATV After you ve followed the procedure for parking it s time to dismount 1 Double check that the brake lever lock is engaged 2 Swing your right leg over to the left side of the seat 3 Step to the ground on the left side of the ATV Active Rid...

Page 38: ... experience Safe riding techniques include Riding Riding Downhill Leaning Weight Shift and Balance Riding Uphill Wide Turns Sidehilling Traversing Sharp Turns Swerving Quick Turns Crossing Obstacles K Turns Riding Once the engine is warm the ATV is ready to go 1 Keep your feet on the footrests and both hands on the handlebar 2 Apply the brakes releasing the brake lever lock 3 Move the shift lever ...

Page 39: ... the side that s lifting and make the turn wider if possible Active Riding 38 ATV 004 ATV 0045 ATV 0044 Wide Turns About 20 of ATV accidents happen during turns If you don t under stand turning techniques it s easy for the ATV to get away from you by losing traction plowing or tipping Use this method for wide turns 1 Ease off the throttle as you approach the turn to slow down 2 Use the principles ...

Page 40: ...ed as you come out of the turn Active Riding 39 ACTIVE RIDING ATV 0038 ATV 0039 ATV 0040 Quick Turns Quick turns are the most difficult turns and should only be done after you are experienced with your ATV 1 Ease off the throttle as you approach the turn to slow down 2 Turn the handlebars and shift your weight and balance at the 3 same time as you enter the turn use the principles of leaning 4 wei...

Page 41: ... ATV on the uphill side 5 If you re to the left of the ATV turn the handlebar all the way left 6 Partially release the brake but lightly hold the brake lever 7 Let the ATV roll to your right side until it faces slightly downhill 8 Reapply the brakes 9 Get back on the ATV from the uphill side and keep your weight shifted uphill when you sit down 10 Start the engine and follow the method for riding ...

Page 42: ...ills come off your seat to stand and lean forward 3 If you lose speed quickly shift to a lower gear in case of gear box At the same time release the throttle so your front tires don t lift OR 4 If that doesn t work and you still have forward motion and the ter rain permits do a U turn go back down and try climbing again OR 5 If you have lost all forward motion follow the K turn procedure Active Ri...

Page 43: ... your skills are advanced or not try to avoid this kind of riding If you re in a situation where you absolutely have to sidehill follow this method 1 Keep your speed low and consistent 2 Shift all your body weight to the uphill side of the seat also sup port your weight on the uphill footrest 3 Steer like you re driving into the hill 4 If the ATV feels like it s tipping turn the handlebar downhill...

Page 44: ...f you swerve 1 Ease off the throttle as you approach the obstacle 2 Turn the handlebar At the same time shift your weight and ba lance as you swerve Use the principles of leaning weight shift ing and balancing shift your body weight to the inside of the turn 3 Keep your hand off the brake until the emergency is over and reback in control Active Riding 43 ACTIVE RIDING ATV 0043 ATV 0042 ATV 0041 ...

Page 45: ...ph 2 Approach the obstacle head on 3 Come up off the seat 4 Keep your weight on the footrests 5 Apply a little throttle when the front tires make contact with the obstacle 6 Lean forward and release the throttle when the front tires clear the obstacle 7 Keep your body loose to absorb any shock 8 If the ATV starts tipping shift your weight to keep it in balance To clear a single track only one tire...

Page 46: ... Backing down hills is a bad idea do a U turn or K turn instead to turn around Skidding or Sliding If you lose control after hitting sand ice oil or water Turn your handlebar into the direction of the slide 1 Keep your hand off the brakes until you re out of the skid 2 Shift your weight forward Sometimes your ATV may not respond and goes straight ahead instead of letting you turn Here s how to han...

Page 47: ...ay away from fast moving rivers ATV tires can be buoyant so if the water is too deep you might find the ATV suddenly afloat 1 Physically check the depth and current of the water especially if you can t see the bottom You re also checking for boulders logs or any other hidden obstacles 2 Keep your speed slow 3 Make sure you have a way out on the other side of the water 4 If you get stuck in the slu...

Page 48: ...s 5 Learn how the ATV responds to steering and braking on the type of terrain to be encountered on the ride Active Riding 47 ACTIVE RIDING Before riding manually move the ATV forward and backward to make certain that all wheels roll freely CAUTION Do not attempt to free frozen brakes by pouring warm water on the brake pads and housings WARNING nNote After the brakes thaw dry them by applying them ...

Page 49: ...Stopping The ATV To stop the ATV first release the throttle lever Next apply the bra kes Stopping The Engine To Stop the engine turn the ignition switch key to the OFF position Active Riding 48 ...

Page 50: ...ep abreast with wea ther forecasts Terrain Just because you re on familiar terrain doesn t mean you can start daydreaming You can t assume that the landscape you re used to doesn t change Changes to landscape can happen at nearly any time Fences can be constructed and excavations dug in a short peri od of time Weather climate and development take their toll The thing about terrain is that sometime...

Page 51: ...or you to endure the rough terrain Make yourself visible by using headlights and taillights and pull com pletely off the trail if you need to stop Outsloped trails trails that slant to allow rain to run off make trail riding a bit more challenging Accepting that challenge means kee ping your weight shifted into the slope Denying the challenge means sliding off the trail Sound Judgment 50 ...

Page 52: ... riders in front of you stopping Riding with companions on several ATV s is not the same as riding one ATV with a passenger Passengers are prohibited The extra weight on the seat makes the ATV difficult to control Other Vehicles Depending on where you re riding you might encounter other ATV s bikes or motor vehicles on public lands Respect the presence of others and make yourself be seen If you ca...

Page 53: ...section of this Operator s Manual tells you about taking care of your ATV If at any time abnormal noises vibrations or improper functioning of any component of this ATV is detected DO NOT OPERATE THE ATV Take the ATV to an authorized Arctic Cat ATV dealer for inspection and adjustment or repair Cargo Limitations Limit the ATV to the specified load capacity rating The combined weight limit includin...

Page 54: ... may cause changes in handling which could lead to an accident Never modify the ATV with improper installation or use of improper ac cessories All parts and accessories installed on this ATV must be genuine Arctic Cat parts and accessories designed for use on this ATV Install and use them according to instructions If you have any questions contact an authorized Arctic Cat ATV dealer WARNING nNote ...

Page 55: ...an continue to ride in your favourite areas The quickest way to have a land area closed is by riding over the regulations Group Behaviour People always do crazier and riskier things in a group than they would consider doing by themselves When you re ATV riding with others and things start to get out of hand decide whether you re willing to be injured or see your friends injured SIPDE By themselves...

Page 56: ...r of experience with ATV riding or taken an ATV training course it s your responsibility to keep them off your ATV It can be dangerous especially for underaged children all the more reason for you to be firm Experienced Trained Riders If anyone is going to borrow your ATV you are responsible for their supervision Before they ride have them take the training course have them watch the safety video ...

Page 57: ...56 NOTES ...

Page 58: ...operate the ATV within your level of skill and current terrain conditions Division II of this manual covers operator related maintenance operating instructions and storage instructions If major repair or service is ever required contact an authorized Arctic Cat ATV dealer for professional service At the time of publication all information and illustrations in Division II were technically correct S...

Page 59: ...heelbase 121 9 cm 48 in Tire Size Front 24x8 12 Tire Size Rear 24x10 12 Tire Inflation Pressure 0 28 kg cm 2 4 0 psi MISCELLANY Dry Weight Approx 263 kg 580 lb Gas Tank Capacity Rated 15 1 L 4 0 U S gal Reserve Capacity 2 5 L 0 65 U S gal Rear Drive Capacity 250 ml 8 5 fl oz Engine Oil Capacity 3 3 L 3 5 U S qt Overhaul Gasoline Recommended EU unleaded 91 Octane Engine Oil Rec SAE5W 30 Rear Drive ...

Page 60: ...48 in Tire Size Front 24x8 12 Tire Size Rear 24x10 12 Tire Inflation Pressure 0 28 kg cm 2 4 0 psi MISCELLANY Dry Weight Approx 279 kg 615 lb Gas Tank Capacity Rated 15 1 L 4 0 U S gal Reserve Capacity 2 5 L 0 65 U S gal Differential Capacity 275 ml 9 3 fl oz Rear Drive Capacity 250 ml 8 5 fl oz Engine Oil Capacity 3 3 L 3 5 U S qt Overhaul Gasoline Recommended EU unleaded 91 Octane Engine Oil Rec...

Page 61: ...n the front of the frame The Engine Serial Number is located on the rear of the engine and is visible from the left side IGNITION SWITCH KEY Two keys come with the ATV Keep the spare key in a safe place An identifying number is stamped on each key Use this number when ordering a replacement key The same applies for the keys of the anti theft device ATV 0055 GENERAL INFORMATIION 60 ü VIN ...

Page 62: ...am position 3 Temperature Indicator A red light will illuminate if the engine overheats The light should be off during normal operation Liquid Crystal Display LCD 1 Adjust Button Used to toggle between Clock Hour Meter Odometer and Trip Meter in the display 5 In conjunction with the Mode Button 2 sets the clock and resets the trip meter to zero Also used to toggle between MPH and km h 61 CONTROL L...

Page 63: ... Press and hold the Adjust Set Button 1 and Mode Button 2 until the hour display starts to flash ap proximately three seconds then release the buttons and press the Adjust Button 1 to set the hour C After the correct hour is attained momentarily press the Mode Button 2 to toggle the clock to the minute display minutes flashing then press the Adjust Button 1 to set the minutes After approxima tely ...

Page 64: ... R position Foot Brake Pedal or Left Hand Brake Lever Pressing the foot brake pedal downwards or compressing the hand brake lever will apply the bra ke to the front and rear wheels 63 GENERAL INFORMATION nNote Clock memory power is supplied through the 15 amp accessory fuse and verified during gauge power up and reset In the event of clock memory power failure blown fuse etc the gauge will power u...

Page 65: ...ar wheels 1 Engage the brake lever lock 2 Attempt to push the ATV 64 nNote It will click as it engages and the brake lever will not return to its re leased position nNote The brake lever lock must lock the wheels If it doesn t take the ATV to an authorized Arctic Cat ATV dealer for service Always check to be sure that the brake lever lock has been disen gaged before operating the ATV An accident c...

Page 66: ...engaged Throttle Lever Control engine RPM with the po sition of the throttle lever Operate this lever with the thumb Pushing it forward increases engine RPM and allowing it to retract decreases engine RPM Throttle lever travel may be li mited by adjusting the throttle limiter screw The throttle limiter should be adjusted according to the operator s skill and experience To adjust the throttle limit...

Page 67: ...WL DRAIN Periodically the float bowl should be drained to remove condensati on To drain the float bowl use the following procedure 1 Place a suitable container beneath the drain hose 2 Loosen the drain screw and allow the gasoline and conden sation to flow into the container 3 Tighten the drain screw securely 66 Leaving the fuel valve in the ON or RES position when the engine is off can be hazardo...

Page 68: ... lift up on the latch release located at the rear of the seat then raise the rear of the seat and slide it rear ward 2 To lock the seat into position slide the front of the seat into the seat retainer and push down firmly on rear of seat The seat should automatically lock into position nNote The ATV sould be on level ground when checking the engine oil level Do not overfill the engine with oil Alw...

Page 69: ...areas oxygenates either ethanol or MTBE are added to the gasoline Oxygenated gasolines containing up to 10 ethanol 5 methane or MTBE are acceptable gasolines When using ethanol blended gasoline it is not necessary to add a gasoline antifreeze since ethanol will prevent the accumulation of moisture in the fuel system nNote Suitable hold down straps are available from your Arctic Cat ATV dealer Ordi...

Page 70: ...r details Recommended Transmission Rear Drive Lubricant 69 GENERAL INFORMATION nNote Arctic Cat recommends the use of genuine Arctic Cat lubricants Any oil used in place of the recommended oil could cause serious engine damage CAUTION OILCHARTB nNote Arctic Cat recommends the use of genuine Arctic Cat lubricants The recommended lubricant transmission and rear drive is SAE approved 80W 90 hypoid Th...

Page 71: ...r filling the tank then install the vent tube making sure it is properly routed BREAK IN PROCEDURE New ATV s and renewed ATV engines require a break in period The first month is most critical to the life of this ATV Proper operation during this break in period will help assure maximum life and perfor mance from the ATV During the first 10 hours of operation always use less than throttle Varying th...

Page 72: ...aintenance after break in should include checking of all prescribed adjustments and tightening of all fasteners At the discretion and expense of the owner operator the ATV may be taken to an authorized Arctic Cat ATV dealer for this initial service 71 BRAKE PADS MUST BE BURNISHED TO ACHIEVE FULL BRA KING EFFECTIVENESS TO PROPERLY BURNISH THE BRAKES USE FOLLOWING PROCEDURE Choose an area sufficient...

Page 73: ...of this ATV is detected DO NOT OPERATE THE ATV Take the ATV to an authorized Arctic Cat ATV dealer for inspection and adjustment or repair GENERAL MAINTENANCE nNote Proper maintenance of the ATV is important for optimum performance Follow the Maintenance Schedule in your Service Booklet ...

Page 74: ...ment positions to allow the spring to be adjusted for different riding and loading conditions If the spring action is too soft or too stiff adjust it according to the chart MAINTENANCE IN DETAIL nNote Arctic Cat recommends the use of genuine Arctic Cat lubricants Continued operation of the ATV with high engine temperature may result in engine damage or premature wear CAUTION nNote High engine RPM ...

Page 75: ... scheduled intervals The engine should always be warm when the oil is changed so the oil will drain easily and completely 1 Park the ATV on level ground 2 Loosen the oil level stick Be careful not to allow conta minates to enter the opening 3 Remove the drain plug from the bottom of the engine and drain the oil into a drain pan 4 Remove the oil filter plug from the filter mounting boss loca ted on...

Page 76: ... ATV is outside on level ground and allow it to idle for a few minutes 10 Turn the engine off and wait approximately one minute Recheck oil level 11 Inspect the area around the drain plug and oil filter for leaks Front Differential And Rear Drive Lubricant Inspecting Changing Inspect and change the gear lubricant at the scheduled intervals When changing the lubricant use approved SAE 80W 90 hypoid...

Page 77: ...the reservoir is low add DOT4 brake fluid Inspect the oil for any signs of metal filings or water If found take the ATV to an authorized Arctic Cat ATV dealer for servicing CAUTION nNote If the gear case has a level plug fill to the threads of the level plug If the gear case has only a fill plug fill to within 1 in of the threads of the fill plug nNote Arctic Cat recommends the use of genuine Arct...

Page 78: ...rake pads as follows 1 Remove a front wheel 2 Measure the thickness of each brake pad 3 If thickness of either brake pad is less than 1 0 mm 0 039 in take the ATV to an authorized Arctic Cat ATV dea ler to have brake pads replaced Brake Lever Lock Check to make sure the brake lever lock engages properly and that the brake when engaged locks the wheels 1 Engage the brake lever lock 2 Attempt to pus...

Page 79: ...xcessive contact an authorized Arctic Cat ATV dealer for service Tie Rod Boots Inner and Outer Right and Left 1 Secure the ATV on a support stand to elevate the front wheels 2 Remove both front wheels 3 Inspect the four tie rod boots for cracks tears or perforations 4 Check the tie rod end free play by grasping the tie rod near the end and attempting to move it up and down 5 If boot damage is pres...

Page 80: ...ket 2 Remove the negative battery cable then remove the positive cable Remove the battery from the ATV 3 Trickle charge the battery at 1 4 amps for 5 10 hours 4 Place the battery into position in the ATV and secure with the hold down bracket Anytime service is performed on a battery the following must be observed Keep sparks open flame cigarettes or any other flame away Always wear safety glasses ...

Page 81: ...er if the plug insulator is not a light brown color To help prevent cold weather fouling make sure to thoroughly warm up the engine before operating To maintain a hot strong spark keep the plug free of carbon Before removing the spark plug be sure to clean the area around the spark plug If you do not dirt could enter engine when removing or in stalling the spark plug Adjust the gap to 0 7 0 8 mm f...

Page 82: ...play of 3 6 mm 1 8 1 4 in 3 Tighten the jam nut 1 against the throttle housing securely then slide the rubber boot over the adjuster AIR FILTER Engine The air filter inside the air filter housing must be kept clean to provide good engine power and gas mileage If the ATV is used under normal conditions service the filter at the intervals specified If operated in dusty wet or muddy conditions inspec...

Page 83: ...ent in a plastic bag then pour in air filter oil and work the oil into the element 7 Squeeze the element to remove excess oil 8 Clean any dirt or debris from inside the air cleaner Be sure no dirt enters the carburetor 9 Install the air filter and cover 10 Connect the inlet boot and tighten the clamp securely AIR FILTER HOUSING DRAIN TUBE Inspect the duck bill drain in front of the main housing fo...

Page 84: ...t The ATV has low pressure tubeless tires Air is sealed by the contact surfaces of the inner wheel rim and the tire bead If either the inner wheel rim or tire bead is damaged air may leak Be extremely careful not to damage these areas when replacing tires It is very important to use the proper tools when repairing or repla cing tires to prevent damage to the tire bead or wheel rims If proper tools...

Page 85: ... to be removed 3 Elevate the ATV by placing a jack under the axle 4 Remove the lug nuts 5 Remove the wheel 6 Install the wheel and install the lug nuts 7 Tighten the nuts in a crisscross pattern to 4 4 kg m 32 ft lb 8 Remove the jack LIGHT BULB REPLACEMENT The wattage rating of each bulb is shown in the chart When replacing a burned bulb always use the same wattage rating When breaking the tire be...

Page 86: ...ecure with the spring clip 4 Connect the three wire connec tor to the bulb then install the rubber boot nNote The bulb portion of the headlight is fragile HANDLE WITH CARE When replacing the headlight bulb do not touch the glass portion of the bulb If the glass is touched it must be cleaned with a dry cloth before installing Skin oil residue on the bulb will shorten the life of the bulb Do not att...

Page 87: ...ush in and rotate counterclockwise 3 To install the bulb push in and turn clockwise 4 Insert the socket into the housing and rotate it clockwise FUSES The main fuse is located under the seat near the battery The fuses are located in a power distribution module in front of the steering post under the electrical access panel If there is any type of electrical system failure always check the fuses fi...

Page 88: ...rovided with the ATV Maintain the toll kit with the ATV at all times Always replace a blown fuse with a fuse of the same type and ra ting If the new fuse blows after a short period of use consult an authorized Arctic Cat ATV dealer immediately CAUTION ...

Page 89: ... opening for a period of 10 to 20 seconds Install the air filter and housing cover 4 Drain the carburetor float bowl 5 Plug the hole in the exhaust system with a clean cloth 6 Apply light oil to the upper steering post bushing plungers of the shock absorbers and drive chain 7 Tighten all nuts bolts cap screws and screws Make sure rivets holding components together are tight Replace all loose rivet...

Page 90: ...adlights taillight brakelight and headlight aim adjust or replace if necessary 8 Check the tire pressure Inflate to recommended pressure as necessary 9 Tighten all nuts bolts cap screws and screws making sure all calibrated nuts cap screws and bolts are tightened to specifi cations 10 Make sure the steering moves freely and does not bind 11 Check the spark plug Clean or replace as necessary 12 Fol...

Page 91: ... ATV dealer No transportation or rental charges for rented vehicles will be paid by Arctic Cat The warranty is validated upon examination of said parts by Arctic Cat or an authorized Arctic Cat ATV dealer Arctic Cat reserves the right to inspect such parts at its factory The warranty periods are as follows 1 24 months form date of sale for ATVs 2 6 months from date of sale for batteries 3 30 days ...

Page 92: ...t etc unless instructed to do so by Arctic Cat Use of the ATV in any way for racing purposes Removal of the engine for use in another vehicle Removal or mutilation of the Chassis or Engine Number Use of parts not sold by Arctic Cat Damage due to improper transportation Failure to perform the prescribed service 1 Service after 500 km 2 Service after 1500 km 3 Service after 5000 km afterwards every ...

Page 93: ...ervice the ATV in accordance with Arctic Cat s recommendations in the Operator s Manual Arctic Cat will not warrant repairs required as a result of not performing standard operator maintenance storage procedures and service as outlined in the Operator s Manual Should you have any questions concerning the warranty contact an authorized Arctic Cat ATV dealer Change of address ownership or warranty t...

Page 94: ...ADDRESS CHANGE OWNERSHIP CHANGE WARRANTY TRANSFER CHANGE OF ADDRESS OWNERSHIP WARRANTY TRANSFER TO Name Address Construction year Model Chassis Nr 93 ...

Page 95: ...for reference if you ever need a new key 2 VEHICLE IDENTIFICATION NUMBER 3 ENGINE SERIAL NUMBER Record the Vehicle Identification Number and Engine Serial Number in the spaces provided to assist you in ordering parts from your authorized Arctic Cat ATV dealer or for reference in case the ATV is stolen WARNING Indicates a potential hazard that could result in serious injury or death ...

Page 96: ...ation in this booklet may not be up to date due to changes performed since printing The models shown in the pictures contain in part special equipment Please ask your ATV dealer for the newest information before placing an order The producer reserves the right to make price color material specification and model changes without notice Version 1 Printed February 2008 nNote nNote ...

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Arctic Cat 2008 400 2x4, Owner'S Manual

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