2016 Arctic Cat 400 4 Wheeler Service Manual
. SERVICE MANUAL ™ ™ ™ ™ www.arcticcat.com www.arcticcat.com. 2016 90 Service Manual Table Of Contents General Information/Foreword. 2 Fuel/Lubrication.54 Specifications. 2 Carburetor.54 Torque Specifications. 3 Throttle Cable Free-Play.58 Torque Conversions (ft-lb/N-m).4 Engine RPM (Idle).58 Gasoline-Oil-Lubricant.4 Gas Tank.58 Preparation For Storage.4 Gas Tank Valve.59 Preparation After Storage.
NOTE: Specifications subject to change without notice. This manual contains service, maintenance, and trouble- CHASSIS shooting information for the 2016 Arctic Cat 90 Utility/ Length (Overall) 146.8 cm (57.8 in.) DVX 90 ATV and is designed to aid in service-oriented Height (Overall) 96.2 cm (37.9 in.).
ENGINE Torque Specifications Piston Ring End (top) 0.15-0.30 mm Gap (Installed) (2nd) 0.30-0.45 mm (oil) 0.20-0.70 mm Piston Pin Outside Diameter (Min) 12.96 mm Piston Pin Bore (Max) 13.03 mm EXHAUST COMPONENTS Piston Skirt/Cylinder Clearance (Max) 0.10 mm Torque Part Part Bolted To Cylinder Head Distortion (Max) 0.05 mm. 35.4 69.4 103.4 tor-based oils. 36.7 70.7 104.7 The recommended oil to use is Arctic Cat ACX All 38.1 72.1 106.1 Weather synthetic engine oil, which has been specifically 39.4 73.4 107.4 formulated for use in this Arctic Cat engine. Although 40.8. Check the air filter and the air filter housing. Clean or replace as necessary.
Preparation After Storage Taking the ATV out of storage and correctly preparing it will assure many miles and hours of trouble-free riding. Arctic Cat recommends the following procedure to pre- pare the ATV. NOTE: Foam Filter Cleaner and Foam Filter Oil are available from Arctic Cat.
Compress the filter by pressing it between the palms of both hands to remove excess solvent. Do not twist or CD654 wring the filter or it will develop cracks. CD655 CD659 4. Remove the spark plug wire and the spark plug; then rotate the engine clockwise to the TDC position on the compression stroke. NOTE: The “T” mark on the rotor/flywheel is aligned with the timing pointer on the crankcase, and intake and exhaust valve adjuster screws must not have pressure on them.
WARNING Always wear safety glasses when using compressed air. Remove the spark plug; then attach the high tension lead to the plug and ground the plug on the cylinder head well away from the spark plug hole. Attach the Compression Tester Kit (p/n 0444-213). NOTE: The engine must be warm and the battery .
KM140B YT215A 4. Install the drain plug and tighten to 18 ft-lb. WARNING recommended lubricant in the fill hole while observ- Before installing the spark arrester, wait for the muffler ing the oil level hole. Stop pouring if oil is observed at the threads of the oil level hole. Shut the engine off and allow to stand for 2-3 min- utes. Remove the oil level stick and wipe with a clean cloth. Install the oil level completely into the engine.
Arctic Cat 400 4x4 Manual
Remove the oil level stick; the engine oil level should be at the appropriate level. Loosen the brake shoe return spring; then remove the brake shoes. Turn both cable adjusters in 1/4 turn increments (clockwise) until the wheels spin with a very slight amount of drag. MD2042 Removing Rear Brake Pads 4. Lower the ATV; then push it forward and compress 1.
Installing Front Brake Shoes 1. Place the brake shoes onto the backing plate over the stationary pivot pin and rotating cam.
Install the brake return spring. YT216A NOTE: Always compress the hydraulic brake lever several times to check that the brakes are firm. If the brakes are not firm, bleeding the system is necessary.
Remove the cooling duct. Remove the eight cap screws securing the drive belt cover; then remove the cover. Account for a gasket and two alignment pins. NOTE: The gasket does not need to be removed unless it is being replaced or unless additional servic- ing is being done requiring its removal.
Shift the transmission into reverse; then remove the cap screw securing the linkage to the transmission shift arm. Verify the transmission is in reverse, the ignition switch is in the ON position, the reverse indicator light is illuminated, and the shift lever is fully in the reverse position. Steering/Body/Controls The following steering components should be inspected periodically to ensure safe and proper operation.
Handlebar grips worn, broken, or loose. Handlebar bent, cracked, and an equal and complete full-left and full-right turn capability. Steering post bearing assembly/bearing housing bro- ken, worn, or binding. YT226 YT228A 12.
Remove the Allen-head cap screws securing the han- 3. Install the remaining main body caps screws (two cap dlebar clamps to the handlebar.
Screws from under the front fenders, two cap screws from under the rear fenders). Tighten the cap screws and the cap screws from step 4 to 86 in.-lb.
Install the handlebar cover with two cap screws and push pin, and connect the one 4-pin connector and two 2-pin connectors. Connect both 2-pin headlight connectors. Install the footwells with the Phillips-head screws and cap screws. Route the CDI connector, main relay, and main fuse case through the plastic and connect the CDI unit. MD2405 YT234 7.
Remove the cotter pins; then remove the two inner CLEANING AND INSPECTING tie rod ends from the steering post. Wash the tie rod ends in parts-cleaning solvent. Dry with compressed air. Inspect the pivot area for wear. Apply a low-temperature grease to the ends. Install handlebar with marks aligned with the handle- bar mounting clamps.
Install the caps; then tighten the cap screws to 10 ft-lb. Install the inner tie rod ends. Tighten the nuts to 20 ft-lb and install new cotter pins. KM060A MD2419 4.
MD2105 MD2445 10. Install the handlebar bracket, the cover, and the seat. On the Utility, install the front and rear racks. Handlebar Grip REMOVING 1. Using a compressed air nozzle and low pressure, peel up the inner corner of the grip. Handlebar Switch REMOVING 1. Disconnect the handlebar switch assembly wiring connector.
MD2436 YT218 2. Remove the handlebar switch assembly from the handlebar. Connect the handlebar switch assembly wiring con- nector. KM544 YT218 Hand Brake Lever Assemblies!
WARNING MD2436 After removing and installing brake-related components, INSTALLING. Remove the brakeline hose bolt; then drain brake fluid into the container. Account for two copper washers. MD2440 KM208B 7. Remove the cap screws securing the hand brake lever assembly to the handlebar and remove the hand brake/master cylinder assembly.
MD2452 KM208A 2. Install the throttle cable into the throttle control 5. Install the brakeline hose on the master cylinder with housing; then install the cover and secure with the the brakeline hose bolt and two washers. Do not screws. Tighten the bolt at this time. MD2461 YT219 2. Install the new bulb; then align the connector to the housing.
Push forward; then rotate the connector Headlights clockwise until it is fully seated. NOTE: The bulb portion of the headlight is fragile. Brakelight/Taillight HANDLE WITH CARE. When replacing the head- light bulb, do not touch the glass portion of the bulb.
Troubleshooting Problem: Handling too heavy or stiff Condition Remedy 1. Front wheel alignment incorrect 1. Adjust alignment 2. Lubrication inadequate 2.
Lubricate appropriate components 3. Tire inflation pressure incorrect 3. Adjust pressure 4. Tie rod ends seizing 4. Replace tie rod ends 5. This section has been organized into sub-sections which show a progression for the complete servicing of the Arc- tic Cat Y-12+ engine/transmission. NOTE: Arctic Cat recommends the use of new gas- kets, lock nuts, and seals and lubricating all internal components when servicing the engine/transmission.
Remove the air filter housing cover and air filter ele- ment. Remove the intake boot from the carburetor; then remove the cap screws securing the air filter housing to the crankcase and remove the air filter housing and intake boot.
Removing Top-Side Components A. CAMSHAFT HOLDER/ROCKER ARMS B.
CYLINDER HEAD/CAMSHAFT NOTE: Arctic Cat recommends the use of new gas- kets, lock nuts, and seals and lubricating all internal components when servicing the engine/transmission. Remove the intake pipe/carburetor assembly.
Remove the camshaft from the cylinder head and secure the cam chain to prevent it falling into the crankcase. YT109B YT168A CAUTION Do not rotate the crankshaft without keeping tension on the cam chain or engine damage could occur. AT THIS POINT . NOTE: If valves are discolored, they must be replaced.
Arctic Cat recommends taking heads to a 3. Remove the valve springs; then invert the cylinder qualified machine shop for valve replacement or valve head and remove the valves. Servicing Valves/Valve Guides/Valve Seats If valves, valve guides, or valve seats require servicing or replacement, Arctic Cat recommends the components be taken to a qualified machine shop for servicing. CAUTION If valves are discolored or pitted or if the seating sur- face is worn, the valve must be replaced. Measuring Piston Skirt/Cylinder 2.
Using a feeler gauge, measure each piston-ring end gap. Acceptable ring end gap must be within specifi- Clearance cations. Measure the cylinder front to back in six places. CC995 YT137 Measuring Piston Pin, Connecting Rod 2. MD1343C YT123 CAUTION Cleaning/Inspecting Cylinder 1. Wash the cylinder in parts-cleaning solvent.
Incorrect installation of the piston rings will result in engine damage. Inspect the cylinder for pitting, scoring, scuffing, CYLINDER/CYLINDER HEAD warping, and corrosion.
If marks are found, repair the surface using a cylinder hone. Inspecting Camshaft Bearing/ Sprocket 1. Inspect the camshaft bearings for roughness during rotation or signs of discoloration. Wash the cylinder in parts-cleaning solvent. Inspect the cylinder for pitting, scoring, scuffing, and corrosion. If marks are found, repair the surface using a #320 grit ball hone.
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YT161 YT158 C. CYLINDER HEAD/CAMSHAFT D. CAMSHAFT HOLDER/ROCKER ARMS NOTE: Steps 1-3 in the preceding sub-section must precede this procedure.
While keeping tension on the cam chain, place the front cam chain guide into the cylinder. CAUTION Care should be taken that the bottom of the chain guide is secured in the crankcase boss. Place the camshaft holder into position on the cylin- der head making sure the camshaft bearings are seated correctly; then install four flat washers (A) and four nuts (B). Tighten in a crisscross pattern to 15 ft-lb. Install two alignment pins into the top of the cylinder head as illustrated.
YT170 YT099A YT090A YT160A 13. Install the intake pipe/carburetor assembly onto the 2. Remove the flange nut (A) securing the fixed drive cylinder head using a new O-ring. Tighten the flange face to the crankshaft.
Account for the kick-start nuts to 7 ft-lb. Remove the centrifugal clutch housing; then remove the centrifugal clutch shoe/driven pulley assembly. YT104 NOTE: It may be necessary to strike the head of the bolt sharply with a hammer after tightening to free YT022 the one-way housing from the crankshaft. YT028 YT023A 2.
Secure the gear position switch wire as shown; then 5. Install the driven pulley/centrifugal clutch assembly tighten the cap screw on the hold-down clip securely.
Onto the transmission input shaft; then install the centrifugal clutch housing and secure with a flange nut (coated with red Loctite #271). YT157 YT099A Right-Side Components AT THIS POINT To service center crankcase components only, proceed to Removing Right-Side Components. NOTE: For efficiency, it is preferable to remove and disassemble only those components which need to be addressed and to service only those components. The technician should use discretion and sound judgment. Remove the five internal and three external cap screws securing the inner magneto housing to the crankcase; then remove the housing. Account for two alignment pins and a gasket. NOTE: Some engine oil will spill when the cap screws are loosened.
YT035 YT041A 2. Loosen the shift detent plug (A) approximately eight NOTE: The driveshaft thrust washer may be stuck turns; then remove the cap screws securing the trans- to the cover.
Make sure to install it on the driveshaft mission case cover. YT042A YT063 6.
Remove the countershaft (C). Account for one thrust washer. Remove the forward/reverse shift dog. Remove the shift shaft (E); then remove the shift cam/detent assembly (F). Using a plastic mallet, drive the input driveshaft (D) and bearing from the transmission case.
YT053 YT100B 3. Inspect all splined shafts for excessive spline wear, AT THIS POINT twisting, or discoloration. The main shaft is now completely disassembled for 4.
Inspect the shift fork and shift dog mating surfaces inspection. For galling, discoloration, or excessive wear. AT THIS POINT Installing Right-Side Components The main shaft is now ready for installation into the transmission.
TRANSMISSION NOTE: For steps 1-3, refer to illustration YT100C. Assembling 1. Install new oil seals in the transmission case and cover. Place the alignment pins in the correct locations; then install a new gasket on the transmission case.
Install the shift cam/detent assembly; then install the shift shaft aligning the timing index marks. Making sure the input driveshaft thrust washer is installed, carefully install the transmission case cover. Disassembling Crankcase Halves 1.
Remove one remaining cap screw from the right-side crankcase half; then tap the right-side crankcase half from the left side leaving the crankshaft in the left side. Account for a gasket and two alignment pins. YT036B YT118A YT220A 11. Using an appropriate caliper, measure crankshaft web-to-web distance. Measurement must not exceed 45.15 - 45.20 mm.
YT122 AT THIS POINT The center components are now disassembled for inspection. Examine crankcase halves for discoloration in bear- ing bosses, cracks, or signs of warping. Servicing Crankcase Components 1. Assembling Crankcase Half 1. Place the timing chain into the crankcase; then install the crankshaft assembly into the crankcase half. Install the oil pump drive chain and driven gear and secure the gear to the pump shaft with the nut tight- ened to 7 ft-lb.
Install the stator/trigger coil assembly and secure with four cap screws. Tighten securely. Install the rear engine mounting through-bolt and nut; then tighten the front and rear nuts to 32.5 ft-lb.
Install the rotor flywheel making sure the crankshaft 4. Connect the gasline hose (A) to the carburetor; then connect the crankcase breather hose (B) to the air fil- ter housing. Connect the shift linkage; then install the air filter housing and air filter. Tighten all hardware securely. Troubleshooting Problem: Engine will not start or is hard to start (Compression too low) Condition Remedy 1.
Piston rings worn excessively 1. Replace rings 2. Cylinder bore worn 2. Replace - rebore cylinder 3. Spark plug seating poorly 3. Tighten plug 4.
Problem: Exhaust smoke dirty or heavy Condition Remedy 1. Piston rings - cylinder worn 1. Replace - service rings - cylinder 2. Cylinder wall scored - scuffed 2. Replace - service cylinder 3. Crankcase over-full of oil 3. Drain excess oil from crankcase - recheck oil level 4.
Fuel/Lubrication This section has been organized for servicing the fuel system. The technician should use discretion and sound judgment when removing/disassembling and assembling/ installing components.! WARNING Whenever any maintenance or inspection is made on a fuel system when there may be fuel leakage, there CD592 should be no welding, smoking, open flames, etc., in the 5. Remove the jet holder; then remove the main jet from the jet holder. Remove the float pin; then lift the float with needle valve from the carburetor body. CD604 CD603 CD605 4. Remove the pilot screw assembly.
Account for a 7. Dry all components with compressed air only mak- ing sure all holes, orifices, and channels are unob- structed. Inspect the carburetor body for cracks, nicks, stripped threads, and any other imperfections in the casting. Inspect float for damage. CD601 CD594 7. Place the float chamber into position making sure the 3. Connect the choke assembly connector.
Seal is properly seated; then secure with the Phillips- head screws and washers. Install the carburetor onto the intake manifold; then tighten the cap screws securely. Install the gas hose onto the carburetor. Turn the idle adjustment screw in or out until the engine idles at 1700 RPM. CD588 YT015B!
WARNING Throttle Cable Free-Play Adjust the idle to the correct RPM. Make sure the engine is at normal operating temperature before adjusting the To adjust the throttle cable free-play, use the following idle RPM. Remove the two cap screws securing the gas tank; 3. Install the main body panel (see Steering/Body/Con- then remove gas tank from vehicle. Trols - Body). Gas Tank Valve This ATV has a valve mounted on the side of the frame separate from the gas tank. Troubleshooting Problem: Starting impaired Condition Remedy 1.
Arctic Cat 400 Service Manual
Carburetor leaking air 1. Tighten - adjust carburetor - replace gasket 2. Choke not operating properly 2. Check choke assembly Problem: Idling or low speed impaired Condition Remedy 1. Slow jet obstructed - loose 1. (approximately 68° F).
NOTE: Optional battery charging adapters are available from your authorized Arctic Cat dealer to Battery connect directly to your vehicle from the recom- mended chargers to simplify the maintenance charging process. NOTE: Perform this test on the switch side of the Charging connector. NOTE: Arctic Cat recommends the use of the 1. Turn the ignition switch to the ON position.
CTEK Multi US 800 or the CTEK Multi US 3300 for battery maintenance charging. Connect the red tester lead to the high tension lead NOTE: If the meter does not read as specified, (plug cap removed); then connect the black tester replace the switch/component, connector, or switch lead to either primary lead. NOTE: If the meter reads more than 1 ohm of resis- 2. Connect the red tester lead to the red wire and the black tester lead to the green wire (with the regula- tance, troubleshoot or replace the switch/component, tor/rectifier plugged in).
CAUTION Fuse Always disconnect the battery when performing resis- tance tests to avoid damaging the multimeter. Set the meter selector to the OHMS position. The main (7 amp) fuse is located on the frame near the battery under the seat. Problem: Starter button not effective Condition Remedy 1. Battery charge low 1.
Charge - replace battery 2. Switch contacts defective 2. Replace switch 3.
Starter motor brushes not seating 3. Repair - replace brushes 4. Starter relay defective 4. Replace relay 5. Drive System Drive Chain/Sprockets CHECKING DRIVE CHAIN AND SPROCKETS The following drive system components should be inspected periodically to ensure proper operation. Remove the link plate and link noting the position of A.
2001 Arctic Cat 400 Manual
Chain (excessive stretch or slack). MD1854 YT175A 3. Remove the left and right rear wheels.
REMOVING FRONT DRIVE SPROCKET 4. Remove the two axle nuts securing the brake hub to 1. With the chain installed and with the rear brake the axle; then remove three cap screws securing the applied, remove the two cap screws securing the rear sprocket to the sprocket retainer. NOTE: When using a beam-style torque wrench, it is necessary to calculate the torque value using the fol- lowing formula due to the offset of the special tool used to tighten the axle nuts. If using a clicker or elec- tronic torque wrench, install the torque wrench at a 90°.
REMOVING AXLE HOUSING 1. Secure the ATV on a support stand to elevate the rear wheels.! WARNING Make sure the ATV is solidly supported on the support stand to avoid injury. Remove two cap screws securing the brake caliper to the axle housing.
CLEANING AND INSPECTING NOTE: Always clean and inspect the drive axle components to determine if any service or replace- ment is necessary. Replace all components showing signs of wear or damage. Using a clean towel, wipe away any oil or grease. KM234 MD2133 4.
Remove the hub assembly. Account for outer hub 3. Secure the rear sprocket to the sprocket retainer. Tighten the three cap screws (threads coated with blue Loctite #242) to 20 ft-lb. Repeat procedure for other hub.
CLEANING AND INSPECTING 1. MD2384A MD2380 3. Repeat procedure for the other hub.
Repeat procedure for the other hub. INSTALLING HUB BEARINGS AND INSTALLING HUB SEALS 1. Lightly lubricate the seals with bearing grease; then install the hub assembly. Lightly lubricate the bearings with bearing grease; then using a plastic mallet and a bearing driver or appropriate 2. Troubleshooting Drive System Problem: Power not transmitted from engine to wheels Condition Remedy 1.
Drive chain worn - broken 1. Replace chain 2. Countershaft sprocket worn - broken 2. Replace countershaft sprocket 3. Rear sprocket worn - broken 3.
Replace rear sprocket 4. Remove the front shock absorbers.
Suspension REMOVING REAR SHOCK ABSORBER 1. Secure the ATV on a support stand to elevate the wheels and to release the load on the suspension. The following suspension system components should be! WARNING inspected periodically to ensure proper operation. INSTALLING FRONT SHOCK ABSORBERS 1. Place a shock absorber into position on the frame and A-arm and install the two cap screws and self-lock- ing nuts.
Tighten the nuts to 29 ft-lb. MD2315 CAUTION Do not tighten the cap screws beyond the 29 ft-lb speci- fication or the shock eyelet or mount WILL be damaged. MD2428 MD2121 5. Remove the tie rod end from the steering knuckle. Remove the A-arm.
Remove the rubber spindle pin boot; then remove the cotter pin and flanged castle nut from the spindle pin. Lower the steering knuckle assembly from the A- arm. Secure the shock absorber to the A-arm with the cap screw and self-locking nut. Tighten the nut to 29 ft-lb. CAUTION Do not tighten the nut beyond the 29 ft-lb specification or the shock eyelet or mount WILL be damaged. Remove the long cap screw and self-locking nut securing the front of the swing arm to the frame brackets; then remove the swing arm from the frame. Account for two seals, a spacer, a rubber swing arm guard, and a washer.
KM217B MD2007 KM212A. Wheels and Tires TIRE SIZE! WARNING Use only Arctic Cat approved tires when replacing tires.
Failure to do so could result in unstable ATV operation. The ATV is equipped with low-pressure tubeless tires of the size and type listed (see General Information/Fore- word - Specifications).
CLEANING AND INSPECTING NOTE: If repair is needed, follow the instructions found on the tire repair kit or remove the wheel and 1. Clean the wheels and hubs with parts-cleaning solvent. Have it repaired professionally by an authorized Arc- 2. Effective: September 2015 ©2015 Arctic Cat Inc. Printed in U.S.A. ®™Trademarks of Arctic Cat Inc., Thief River Falls, MN 56701 p/n 2260-585.