2005-2006 Arctic Cat 400 ATV Service & Repair Manual

FOREWORD This Arctic Cat Service Manual contains service, maintenance, and troubleshooting information for the 2006 Arc- tic Cat ATV models. The complete manual is designed to aid service personnel in service-oriented applications. This manual is divided into sections. Each section covers a specific ATV component or system and, in addition to the standard service procedures, includes disassembling, inspecting, and assembling instructions. When using this manual as a guide, the technician should use discretion as to how much disassembly is needed to correct any given condition. The service technician should become familiar with the operation and construction of each component or system by carefully studying the complete manual. This manual will assist the service technician in becoming more aware of and efficient with servicing procedures. Such efficiency not only helps build consumer confidence but also saves time and labor. All Arctic Cat ATV publications and decals display the words Warning, Caution, Note, and At This Point to emphasize important information. The symbol ! WARNING identifies personal safety-related information. Be sure to follow the directive because it deals with the possibility of severe personal injury or even death. The symbol ! CAUTION identifies unsafe practices which may result in ATV-related damage. Follow the directive because it deals with the possibility of damaging part or parts of the ATV. The symbol NOTE: identifies supplementary information worthy of particular attention. The symbol AT THIS POINT directs the technician to certain and specific procedures to promote efficiency and to improve clarity. At the time of publication, all information, photographs, and illustrations were technically correct. Some photographs used in this manual are used for clarity purposes only and are not designed to depict actual conditions. Because Arctic Cat Inc. constantly refines and improves its products, no retroactive obligation is incurred. All materials and specifications are subject to change without notice. Keep this manual accessible in the shop area for reference. Product Service and Warranty Department Arctic Cat Inc. © 2005 Arctic Cat Inc. October 2005 ®™ Trademarks of Arctic Cat Inc., Thief River Falls, MN 56701 Back to TOC

MORE TO GO ON. TM TABLE OF CONTENTS Click on the Red text to go. Foreword Section 1. General Information 2. Periodic Maintenance/Tune-Up 3. Engine/Transmission 4. Fuel/Lubrication/Cooling 5. Electrical System 6. Drive System 7. Suspension 8. Steering/Frame 9. Controls/Indicators 10. Aids for Maintenance 11. Troubleshooting 1 2 3 4 5 6 7 8 9 10 11

1-1 1 SECTION 1 - GENERAL INFORMATION TABLE OF CONTENTS General Specifications (400/400 TBX/400 TRV - Automatic Transmission) ...................................... 1-2 General Specifications (400 - Manual Transmission) ................................ 1-3 General Specifications (500 - Manual Transmission) ................................ 1-4 General Specifications (500/500 TBX/500 TRV - Automatic Transmission) ..................................... 1-5 General Specifications (650 H1) ............................................................... 1-6 General Specifications (650 V-Twin) ......................................................... 1-7 Break-In Procedure ................................................. 1-8 Gasoline - Oil - Lubricant ........................................ 1-8 Genuine Parts ......................................................... 1-9 Preparation For Storage .......................................... 1-9 Preparation After Storage...................................... 1-10 Back to TOC

1-2 General Specifications* (400/400 TBX/400 TRV - Automatic Transmission) * Specifications subject to change without notice. ** One inch below filler plug threads. *** At the oil level plug threads. CARBURETOR Type Keihin CVK34 Main Jet 142 - VP 140 - FIS Slow Jet 38 Pilot Screw Setting (turns) 1 3/8 - VP 1 1/8 - FIS Jet Needle NAZG Idle RPM (engine warm) 1250-1350 Starter Jet 75 Float Arm Height 17 mm (0.7 in.) Throttle Cable Free-Play (at lever) 3-6 mm (1/8-1/4 in.) ELECTRICAL Ignition Timing 10° BTDC @ 1500 RPM Spark Plug Type NGK CR7E Spark Plug Gap 0.7-0.8 mm (0.028-0.032 in.) Spark Plug Cap 8000-12,000 ohms Ignition Coil Resistance (primary) (secondary) Less than 1 ohm (terminal to ground) 5200-7800 ohms (high tension - plug cap removed - to ground) Ignition Coil Peak Voltage (primary/ CDI) 250-375 volts (terminal to ground) Magneto Coil Resistance (trigger) (source) (charging) 160-240 ohms (green to blue) Less than 1 ohm (yellow to white) Less than 1 ohm (black to black) Magneto Coil Peak Voltage (trigger) (source) 5.04-7.56 volts (green to blue) 0.7-1.05 volts (yellow to white) Stator Coil Output (no load) 60 AC volts @ 5000 RPM (black to black #1) (black to black #2) Magneto Output (approx) 220W @ 5000 RPM CHASSIS Brake Type Hydraulic w/Brake Lever Lock and Auxiliary Brake Tire Size Front - 25 x 8-12 Rear - 25 x 10-12 - VP Rear - 25 x 10-12 - FIS Tire Inflation Pressure 0.35 kg/cm² (5 psi) MISCELLANY Gas Tank Capacity (rated) 17.98 L (4.75 U.S. gal.) - VP 24.6 L (6.5 U.S. gal.) - FIS 20.8 L (5.5 U.S. gal.) - TBX/ TRV Reserve Capacity 2.46 L (0.65 U.S. gal.) - VP Rear Drive Capacity 275 ml (9.3 fl oz) - VP*** 250 ml (8.5 fl oz) - FIS** Differential Capacity (front - 4x4) 275 ml (9.3 fl oz) - VP**/ FIS*** Engine Oil Capacity 3.08 L (3.25 U.S. qt) Gasoline (recommended) 87 Octane Regular Unleaded Engine Oil (recommended) SAE 10W-40 Differential/Rear Drive Lubri- cant SAE Approved 80W-90 Hypoid Drive Belt Width 28.5 mm (1.12 in.) Brake Fluid DOT 4 Taillight/Brakelight 12V/8W/27W Headlight 12V/37W (2) - 400/400 TRV 12V/27W (2) - 400 TBX Back to TOC Back to Section TOC Next

1-3 1 General Specifications* (400 - Manual Transmission) * Specifications subject to change without notice. ** One inch below filler plug threads. *** At the oil level plug threads. CARBURETOR Type Keihin CVK34 Main Jet 142 - VP 140 - FIS Slow Jet 38 Pilot Screw Setting (turns) 1 3/8 - VP 1 1/8 - FIS Jet Needle NAZG Idle RPM (engine warm) 1250-1350 Starter Jet 75 Float Arm Height 17 mm (0.7 in.) Throttle Cable Free-Play (at lever) 3-6 mm (1/8-1/4 in.) ELECTRICAL Ignition Timing 10° BTDC @ 1500 RPM Spark Plug Type NGK CR7E Spark Plug Gap 0.7-0.8 mm (0.028-0.032 in.) Spark Plug Cap 8000-12,000 ohms Ignition Coil Resistance (primary) (secondary) Less than 1 ohm (terminal to ground) 5200-7800 ohms (high tension - plug cap removed - to ground) Ignition Coil Peak Voltage (primary/ CDI) 250-375 volts (terminal to ground) Magneto Coil Resistance (trigger) (source) (charging) 160-240 ohms (green to blue) Less than 1 ohm (yellow to white) Less than 1 ohm (black to black) Magneto Coil Peak Voltage (trigger) (source) 5.04-7.56 volts (green to blue) 0.7-1.05 volts (yellow to white) Stator Coil Out- put (no load) 60 AC volts @ 5000 RPM (black to black #1) (black to black #2) Magneto Output (approx) 220 W @ 5000 RPM CHASSIS Brake Type Hydraulic w/Brake Lever Lock and Auxiliary Brake Tire Size Front - 25 x 8-12 Rear - 25 x 10-12 - VP Rear - 25 x 10-12 - FIS Tire Inflation Pressure 0.35 kg/cm² (5 psi) MISCELLANY Gas Tank Capacity (rated) 17.98 L (4.75 U.S. gal.) - VP 24.6 L (6.5 U.S. gal.) - FIS Reserve Capacity 2.46 L (0.65 U.S. gal.) - VP Rear Drive Capacity 275 ml (9.3 fl oz) - VP*** 250 ml (8.5 fl oz) - FIS** Differential Capacity (front - 4x4) 275 ml (9.3 fl oz) - VP**/ FIS*** Engine Oil Capacity 3.08 L (3.25 U.S. qt) Gasoline (recommended) 87 Octane Regular Unleaded Engine Oil (recommended) SAE 10W-40 Differential/Rear Drive Lubricant SAE Approved 80W-90 Hypoid Brake Fluid DOT 4 Taillight/Brakelight 12V/8W/27W Headlight 12V/37W (2) Back to TOC Back to Section TOC Next Back

1-4 General Specifications* (500 - Manual Transmission) * Specifications subject to change without notice. ** At the oil level plug threads. *** At the filler plug threads. CARBURETOR Type Keihin CVK36 Main Jet 138 Slow Jet 40 Pilot Screw Setting (turns) 1 3/4 Jet Needle NFKG Idle RPM (engine warm) 1250-1350 Starter Jet 85 Float Arm Height 17 mm (0.7 in.) Throttle Cable Free-Play (at lever) 3-6 mm (1/8-1/4 in.) ELECTRICAL Ignition Timing 10° BTDC @ 1500 RPM Spark Plug Type NGK CR6E Spark Plug Gap 0.7-0.8 mm (0.028-0.032 in.) Spark Plug Cap 8000-12,000 ohms Ignition Coil Resistance (primary) (secondary) Less than 1 ohm (terminal to ground) 5200-7800 ohms (high tension - plug cap removed - to ground) Ignition Coil Peak Voltage (primary/ CDI) 140-215 volts (terminal to ground) Magneto Coil Resistance (trigger) (source) (charging) 160-240 ohms (green to blue) Less than 1 ohm (yellow to white) Less than 1 ohm (black to black) Magneto Coil Peak Voltage (trigger) (source) 4.2-6.3 volts (green to blue) 0.40-0.62 volt (yellow to white) Stator Coil Out- put (no load) 60 AC volts @ 5000 RPM (black to black #1) (black to black #2) Magneto Output (approx) 325W @ 5000 RPM CHASSIS Brake Type Hydraulic w/Brake Lever Lock and Auxiliary Brake Tire Size Front - 25 x 8-12 Rear - 25 x 11-12 Tire Inflation Pressure 0.35 kg/cm² (5 psi) MISCELLANY Gas Tank Capacity (rated) 24.6 L (6.5 U.S. gal.) Coolant Capacity 2.9 L (3.0 U.S. qt) Differential Capacity 275 ml (9.3 fl oz)** Rear Drive Capacity 250 ml (8.5 fl oz)*** Engine Oil Capacity 3.4 L (3.5 U.S. qt) Gasoline (recommended) 87 Octane Regular Unleaded Engine Oil (recommended) SAE 10W-40 Differential/Rear Drive Lubricant SAE Approved 80W-90 Hypoid Brake Fluid DOT 4 Taillight/Brakelight 12V/8W/27W Headlight 12V/27W (2) Back to TOC Back to Section TOC Next Back

1-5 1 General Specifications* (500/500 TBX/500 TRV - Automatic Transmission) * Specifications subject to change without notice. ** At the oil level plug threads. *** At the filler plug threads. CARBURETOR Type Keihin CVK36 Main Jet 138 Slow Jet 40 Pilot Screw Setting (turns) 1 3/4 Jet Needle NFKG Idle RPM (engine warm) 1250-1350 Starter Jet 85 Float Arm Height 17 mm (0.7 in.) Throttle Cable Free-Play (at lever) 3 -6 mm (1/8-1/4 in.) ELECTRICAL Ignition Timing 10° BTDC @ 1500 RPM Spark Plug Type NGK CR6E Spark Plug Gap 0.7-0.8 mm (0.028-0.032 in.) Spark Plug Cap 8000-12,000 ohms Ignition Coil Resistance (primary) (secondary) Less than 1 ohm (terminal to ground) 5200-7800 ohms (high tension - plug cap removed - to ground) Ignition Coil Peak Voltage (primary/ CDI) 140-215 volts (terminal to ground) Magneto Coil Resistance (trigger) (source) (charging) 160-240 ohms (green to blue) Less than 1 ohm (yellow to white) Less than 1 ohm (black to black) Magneto Coil Peak Voltage (trigger) (source) 4.2-6.3 volts (green to blue) 0.40-0.62 volt (yellow to white) Stator Coil Out- put (no load) 60 AC volts @ 5000 RPM (black to black #1) (black to black #2) Magneto Output (approx) 325W @ 5000 RPM CHASSIS Brake Type Hydraulic w/Brake Lever Lock and Auxiliary Brake Tire Size Front - 25 x 8-12 Rear - 25 x 11-12 Tire Inflation Pressure 0.35 kg/cm² (5 psi) MISCELLANY Gas Tank Capacity (rated) 24.6 L (6.5 U.S. gal.)/ 20.8 L (5.5 U.S. gal.) - TBX Coolant Capacity 2.9 L (3.0 U.S. qt) Differential Capacity 275 ml (9.3 fl oz)** Rear Drive Capacity 250 ml (8.5 fl oz)*** Engine Oil Capacity 2.5 L (2.6 U.S. qt) Gasoline (recommended) 87 Octane Regular Unleaded Engine Oil (recommended) SAE 10W-40 Differential/Rear Drive Lubricant SAE Approved 80W-90 Hypoid Drive Belt Width (minimum) 38 mm (1.33 in.) Brake Fluid DOT 4 Taillight/Brakelight 12V/8W/27W Headlight 12V/27W (2) Back to TOC Back to Section TOC Next Back

1-6 General Specifications* (650 H1) * Specifications subject to change without notice. ** At the oil level plug threads. *** At the filler plug threads. CARBURETOR Type Keihin CVK40 Main Jet 138 Slow Jet 40 Pilot Screw Setting (turns) 2 Jet Needle NFKN Idle RPM (engine warm) 1250-1350 Starter Jet 85 Float Arm Height 17 mm (0.7 in.) Throttle Cable Free-Play (at lever) 3-6 mm (1/8-1/4 in.) ELECTRICAL Ignition Timing 10° BTDC @ 1500 RPM Spark Plug Type NGK CR6E Spark Plug Gap 0.7-0.8 mm (0.028-0.032 in.) Spark Plug Cap 8000-12,000 ohms Ignition Coil Resistance (primary) (secondary) Less than 1 ohm (terminal to ground) 5200-7800 ohms (high tension - plug cap removed - to ground) Ignition Coil Peak Voltage (primary/ CDI) 142.4-213.6 volts (terminal to ground) Magneto Coil Resistance (trigger) (source) (charging) 160-240 ohms (green to blue) Less than 1 ohm (yellow to white) Less than 1 ohm (black to black) Magneto Coil Peak Voltage (trigger) (source) 4.2-6.3 volts (green to blue) 0.40-0.62 volt (yellow to white) Stator Coil Out- put (no load) 60 AC volts @ 5000 RPM (black to black #1) (black to black #2) Magneto Output (approx) 325W @ 5000 RPM CHASSIS Brake Type Hydraulic w/Brake Lever Lock and Auxiliary Brake Tire Size Front - 25 x 8-12 Rear - 25 x 11-12 Tire Inflation Pressure 0.35 kg/cm² (5 psi) MISCELLANY Gas Tank Capacity (rated) 24.6 L (6.5 U.S. gal.) Coolant Capacity 2.9 L (3.0 U.S. qt) Differential Capacity 275 ml (9.3 fl oz)** Rear Drive Capacity 250 ml (8.5 fl oz)*** Engine Oil Capacity 3.4 L (3.5 U.S. qt) Gasoline (recommended) 87 Octane Regular Unleaded Engine Oil (recommended) SAE 10W-40 Differential/Rear Drive Lubricant SAE Approved 80W-90 Hypoid Belt Width 35.5 mm (1.40 in.) Brake Fluid DOT 4 Taillight/Brakelight 12V/8W/27W Headlight 12V/27W (2) Back to TOC Back to Section TOC Next Back

1-7 1 General Specifications* (650 V-Twin) * Specifications subject to change without notice. ** One inch below plug threads. *** At the plug threads. CARBURETOR Type Keihin CVKR-D32 (2) Main Jet 122 - Standard 118 - California Slow Jet 40 Pilot Screw Setting (turns) 2 1/4 (front) 2 1/2 (rear) Jet Needle NBZP Idle RPM (enigne warm) 1050-1150 Starter Jet 100 Float Arm Height 4 mm (0.16 in.) Throttle Cable Free-Play (at lever) 3-6 mm (1/8-1/4 in.) ELECTRICAL Spark Plug Type NGK CR7E Spark Plug Gap 0.7-0.8 mm (0.028-0.032 in.) Spark Plug Cap 4750-6250 ohms Ignition Coil Resistance (primary) (secondary) Less than 1 ohm (terminal (+) to terminal (-)) 3800-5800 ohms (high tension - plug cap removed - to ground) Ignition Coil Peak Voltage (primary/ CDI) 100 volts or more (wire (+) to ground) Magneto Coil Resistance (trigger) (charging) 110-140 ohms (blue to black/white) Less than 1 ohm (black to black) Magneto Coil Peak Voltage (trigger) 3.6 volts or more (blue to black/white) Stator Coil Out- put (no load) 39-59 AC volts @ 3000 RPM (black to black #1) (black to black #2) CHASSIS Brake Type Hydraulic w/Brake Lever Lock and Auxiliary Brake Tire Size Front - 26 x 8-12 Rear - 26 x 11-12 Tire Inflation Pressure 0.35 kg/cm² (5 psi) MISCELLANY Gas Tank Capacity (rated) 24.6 L (6.5 U.S. gal.) Coolant Capacity 2.7 L (2.8 U.S. qt) Differential Capacity 275 ml (9.3 fl oz)** Rear Drive Capacity 250 ml (8.5 fl oz)*** Engine Oil Capacity 1.75 L (1.85 U.S. qt) Gasoline (recommended) 87 Octane Regular Unleaded Engine Oil (recommended) SAE 10W-40 Differential/Rear Drive Lubricant SAE Approved 80W-90 Hypoid Drive Belt Width (minimum) 30.3 mm (1.19 in.) Brake Fluid DOT 4 Taillight/Brakelight 12V/8W/27W Headlight 12V/27W (2) Back to TOC Back to Section TOC Next Back

1-8 Break-In Procedure A new ATV and an overhauled ATV engine require a “break-in” period. The first 10 hours (or 200 miles) are most critical to the life of this ATV. Proper operation during this break-in period will help assure maximum life and performance from the ATV. During the first 10 hours (or 200 miles) of operation, always use less than 1/2 throttle. Varying the engine RPM during the break-in period allows the components to “load” (aiding the mating process) and then “unload” (allowing components to cool). Although it is essential to place some stress on the engine components during break-in, care should be taken not to overload the engine too often. Do not pull a trailer or carry heavy loads during the 10-hour break-in period. When the engine starts, allow it to warm up properly. Idle the engine several minutes until the engine has reached normal operating temperature. Do not idle the engine for excessively long periods of time. During the break-in period, a maximum of 1/2 throttle is recommended; however, brief full-throttle accelerations and variations in driving speeds con- tribute to good engine break-in. During the break-in period (or whenever the brake pads are replaced), the hydraulic brake pads must be burnished. Slow disc-speed hydraulic brakes must be properly burnished in order to achieve maximum stopping power. NOTE: Do not be reluctant to heat up the brake pads during the burnishing procedure. After the completion of the break-in period, the engine oil and oil filter should be changed. Other maintenance after break-in should include checking of all prescribed adjustments and tightening of all fasteners. Gasoline - Oil - Lubricant RECOMMENDED GASOLINE The recommended gasoline to use is 87 minimum octane regular unleaded. In many areas, oxygenates (either ethanol or MTBE) are added to the gasoline. Oxygenated gasolines containing up to 10% ethanol, 5% methane, or 5% MTBE are acceptable gasolines. When using ethanol blended gasoline, it is not nec- essary to add a gasoline antifreeze since ethanol will prevent the accumulation of moisture in the fuel system. RECOMMENDED ENGINE/ TRANSMISSION OIL The recommended oil to use is Arctic Cat 4-Cycle Engine Oil (p/n 0436-005) or an equivalent oil which is rated SE, SF, or SG under API service clas- sification. These oils meet all of the lubrication requirements of the Arctic Cat ATV engine. The recommended engine oil viscosity is SAE 10W-40. Ambient temperature should determine the correct weight of oil. See the following viscosity chart for details. ! CAUTION BRAKE PADS MUST BE BURNISHED TO ACHIEVE FULL BRAKING EFFECTIVENESS. Braking dis- tance will be extended until brake pads are properly burnished. TO PROPERLY BURNISH THE BRAKES, USE FOL- LOWING PROCEDURE: • Choose an area sufficiently large to safely accelerate ATV to 30 mph and to brake to a stop. • Accelerate to 30 mph; then compress brake lever to decelerate to 0-5 mph. • Repeat procedure five times until brakes are burnished. • This procedure burnishes the brake pads, stabi- lizes the pad material, and extends the life of the brake pads. ! WARNING Do not attempt sudden stops or put the ATV into a situation where a sudden stop will be required until the brake pads are properly burnished. ! CAUTION Do not use white gas. Only Arctic Cat approved gasoline additives should be used. ! CAUTION Any oil used in place of the recommended oil could cause serious engine damage. Do not use oils which contain graphite or molybdenum additives. These oils can adversely affect clutch operation. Also, not recommended are racing, vegetable, non- detergent, and castor-based oils. Back to TOC Back to Section TOC Next Back

2005-2006 Arctic Cat 400 ATV Service & Repair Manual

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