Arctic Cat DVX 400 2004, Service Manual

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11

NOTE: If no resistance is indicated, check the
ground connection for tightness and for cleanli-
ness. If there is still no meter indication, replace
the brush assembly.
ASSEMBLING/INSTALLING
1. Align the tab on the brush holder with the notch in
the right-side cover; then install the holder.
2. On the positive post, install an O-ring washer, a fiber
washer, a flat washer, and a lock washer. Secure with
the nut.
3. Install the armature into the starter housing; then
while holding the brushes out, slide the commutator
into the brush holder.
4. Apply a small amount of grease to the right-side
cover bushing; then install the cover on the starter
housing making sure the O-ring is in place and the
reference marks align.
5. Install the washer set on the armature shaft; then
install the housing O-ring on the starter housing.
6. Apply a small amount of grease to the left-side cover
bushing.
7. Place the left-side cover onto the starter housing
making sure the housing O-ring is in place and it
seats properly.
8. Apply red Loctite #271 to the threads of the two
through-bolts and install. Tighten to specification.
9. Apply a small amount of grease to the O-ring seal on
the starter; then install the starter into the crankcase.
Secure with cap screws and wiring forms. Tighten
cap screws securely.
10. Secure the positive cable to the starter with the nut
and tighten to specification.
11. Connect the battery making sure to connect the posi-
tive cable first.
TESTING VOLTAGE
Perform this test on the starter motor positive terminal.

NOTE: The ignition switch must be in the ON
position, the emergency stop switch in the RUN
position, the reverse lever (on manual transmis-
sion models) in the FORWARD position, and the
shift lever (on automatic transmission models) in
the NEUTRAL position.
1. Set the meter selector to the D.C. Voltage position.
2. Connect the red tester lead to the starter terminal;
then connect the black tester lead to ground.
3. With the starter button depressed, the meter must
show battery voltage and the starter motor should
operate.
AR607D

NOTE: If the meter showed battery voltage but
the starter did not operate or operated slowly,
inspect battery voltage (at the battery), starter
motor condition, and/or ground connections.

NOTE: If the meter showed no battery voltage,
inspect the main fuse, ground connections, starter
motor lead, battery voltage (at the battery), or the
switches.
Starter Relay
VOLTAGE
1. Remove the seat.
2. Set the meter selector to D.C. Voltage position; then
connect the red tester lead to the battery side of the
starter relay and the black tester lead to the starter
cable side of the starter relay.
3. The meter must show battery voltage.

NOTE: If the meter showed no battery voltage,
check the battery for charge or battery to solenoid
connections.
4. Turn the ignition switch to the ON position, com-
press the clutch lever, and depress the starter button.
5. The meter must show 0 D.C. volts and the starter
motor should run.

NOTE: If the meter shows voltage, replace the
starter relay. If the meter shows battery voltage,
continue with step 6.
6. Connect the red tester lead to the yellow/black wire
on the starter relay; then connect the black tester lead
to ground.
7. Compress the clutch lever; then depress the starter
button.
8. The meter should show battery voltage.