Arctic Cat DVX 400 2004, Service Manual

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3
Table of Contents
(Removing/
Disassembling/
Assembling/Installing)
Removing Engine/Transmission.............................. 3-3
Left-Side Components ............................................ 3-6
Removing Left-Side Components ........................... 3-6
Right-Side Components .......................................... 3-8
Removing Right-Side Components......................... 3-8
Top-Side Components........................................... 3-11
Removing Top-Side Components ......................... 3-11
Center Crankcase Components............................ 3-13
Separating Crankcase Halves............................... 3-13
Disassembling Crankcase Half ............................. 3-14
Servicing Components.......................................... 3-15
Assembling Crankcase Half .................................. 3-33
Joining Crankcase Halves..................................... 3-34
Installing Right-Side Components......................... 3-35
Installing Left-Side Components ........................... 3-39
Installing Top-Side Components ........................... 3-39
Installing Engine/Transmission.............................. 3-43
Removing Engine/
Transmission
Many service procedures can be performed without
removing the engine/transmission from the frame.
Closely observe the note introducing each sub-section for
this important information.
Secure the ATV on a support stand to elevate the wheels.
1. Remove the seat.
2. Remove the negative cable from the battery; then
remove the positive cable. Remove the battery hold-
down; then remove the battery.
3. Remove the radiator cap; then drain the engine coolant.
4. Remove the lower engine protective cover (1); then
drain the oil from the crankcase.
SP137
5. Drain the oil from the oil tank.
6. Remove the gearshift lever (2) and account for the
two spacers.
7. Remove the engine oil outlet pipe (3) and the inlet
pipe (4); then remove the spacer and O-ring from
behind the outlet pipe.
SP138
SP139
CLUTCH (cont)
Engine Coolant Fan (off

on)
Thermo-Switch (on

off)
Operating Temperature
88
°C (190°F)
82
°C (180°F)
Drive Chain 96 Links, 20-Pitch Length 319.4
mm (12.57 in.)
Drive Chain Slack 30-40 mm (1.2-1.6 in.)

AT THIS POINT
If the technician’s objective is to service/replace
the starter clutch, starter torque limiter, starter, or
water pump, the engine/transmission does not
have to be removed from the frame.
! WARNING
Make sure the ATV is solidly supported on the
support stand to avoid injury.
! CAUTION
Battery acid is harmful if it contacts eyes, skin, or
clothing. Care must be taken whenever handling a
battery.