Arctic Cat DVX 400 2004 Service Manual page 147

Problem: Engine noisy (Noise seems to come from crankshaft)
Condition
1. Bearing worn - burned
2. Lower rod-end bearing worn - burned
3. Connecting rod side clearance too large
Problem: Engine noisy (Noise seems to come from transmission)
Condition
1. Gears worn - rubbing
2. Splines worn
3. Primary gears worn - rubbing
4. Bearings worn
5. Bushing worn
Problem: Engine noisy (Noise seems to come from secondary-transmission/left-side cover)
Condition
1. Gears - shaft(s) worn
2. Bearing(s)/bushing(s) damaged
Problem: Clutch slipping
Condition
1. Clutch cable out of adjustment - loss of freeplay
2. Clutch springs weak
3. Pressure disc worn - distorted
4. Clutch plates (driven - drive) distorted
Problem: Clutch dragging
Condition
1. Clutch cable out of adjustment - too much free-play
2. Clutch springs weak
3. Pressure disc - clutch plates distorted
4. Clutch release mechanism worn - damaged
Problem: Transmission will not shift
Condition
1. Gearshift cam broken
2. Gearshift forks distorted
3. Gearshift shaft worn
4. Clutch cable out of adjustment
5. Reverse selector cable adjusted improperly
Problem: Transmission will not shift back
Condition
1. Reverse shift cam broken
2. Shift shafts rubbing - sticking
3. Gearshift forks distorted - worn
4. Gearshift lever return spring broken - damaged
5. Clutch cable out of adjustment
Problem: Transmission jumps out of gear
Condition
1. Shifting gears (driveshaft - countershaft) worn
2. Gearshift forks distorted - worn
3. Cam stopper spring (gearshift cam) weak
4. Gearshift lever stopper pin worn
Problem: Engine idles poorly
Condition
1. Valve clearance out of adjustment
2. Valve seating poor
3. Valve guides defective
4. Tappet(s) worn
5. Magneto defective
6. CDI unit defective
7. Spark plug fouled - gap too wide
8. Ignition coil defective
9. Float out of adjustment
10. Jets obstructed
11. Pilot screw setting improper
Remedy
1. Replace bearing
2. Replace bearing
3. Replace thrust washer(s)
Remedy
1. Replace gears
2. Replace shaft(s)
3. Replace gears
4. Replace bearings
5. Replace bushing
Remedy
1. Replace gears - shafts
2. Replace bearing(s)/bushing(s)
Remedy
1. Adjust clutch cable
2. Replace springs
3. Replace disc
4. Replace plates
Remedy
1. Adjust cable
2. Replace springs
3. Replace disc - plates
4. Adjust - replace mechanism
Remedy
1. Replace cam
2. Replace forks
3. Replace shaft
4. Adjust cable
5. Adjust cable
Remedy
1. Replace cam
2. Repair shafts
3. Replace forks
4. Replace spring
5. Adjust cable
Remedy
1. Replace gears
2. Replace forks
3. Replace spring
4. Replace pin
Remedy
1. Adjust clearance
2. Replace - service seats - valves
3. Replace guides
4. Replace tappet(s) and camshaft(s)
5. Replace magneto
6. Replace CDI unit
7. Adjust gap - replace plug
8. Replace ignition coil
9. Adjust float height
10. Clean jets
11. Adjust pilot screw
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