Arctic Cat 400 TBX Manuals

Manuals and User Guides for Arctic Cat 400 TBX. We have 1 Arctic Cat 400 TBX manual available for free PDF download: Service Manual

Arctic Cat 400 TBX Service Manual

Arctic Cat 400 TBX Service Manual (520 pages)

Brand: Arctic Cat | Category: Offroad Vehicle | Size: 189 MB

Table of Contents

Section 1 - General Information

3
Section 2 - Periodic Maintenance/Tune-Up

13
- Periodic Maintenance Chart
  14
- Battery
  15
- Lubrication Points
  15
- Fuses
  16
- Air Cleaner/Filter
  17
- Valve/Tappet Clearance (Feeler Gauge Procedure)
  21
- Valve/Tappet Clearance (650 V-Twin - Feeler Gauge Procedure)
  22
- Valve/Tappet Clearance (Valve Adjuster Procedure)
  22
- Valve/Tappet Clearance (650 V-Twin - Valve Adjuster Procedure)
  23
- Testing Engine Compression
  24
- Muffler/Spark Arrester
  25
- Spark Plug
  25
- Adjusting Choke Cable (650 V-Twin)
  26
- Adjusting Engine RPM (Idle)
  26
- Adjusting Throttle Cable
  26
- Gas/Vent Hoses
  26
- Engine/Transmission Oil - Filter - Strainer
  27
- Front Differential/Rear Drive Lubricant
  29
- Adjusting Clutch (400/500 Manual Transmission)
  30
- Driveshaft/Coupling
  31
- Steering Components
  31
- Tires
  31
- Headlight/Taillight-Brakelight
  32
- Ignition Timing
  32
- Nuts/Bolts/Cap Screws
  32
- Suspension/Shock Absorbers/Bushings
  32
- Switches
  33
- Reverse Shift Lever
  34
- Electrical Connections
  36
- Frame/Welds/Racks
  36
- Hydraulic Brake Systems
  36
- Burnishing Brake Pads
  39
- Coolant (500/650 H1/650 V-Twin)
  39
- Checking/Replacing V-Belt (400/500/650 H1)
  40
- Checking/Replacing V-Belt (650 V-Twin)
  41
- Adjusting Differential Lock Cable
  44
Section 3 - Engine/Transmission

45
Table of Contents

55
- Top-Side Components
  58
- Removing Top-Side Components
  59
- Left-Side Components
  62
- Removing Left-Side Components
  62
- Removing Right-Side Components
  67
- Right-Side Components
  67
- Center Crankcase Components
  71
- Separating Crankcase Halves
  71
- Disassembling Crankcase Half
  72
Servicing Components

74
- Cylinder/Cylinder Head Assembly
  81
- Recoil Starter
  84
- Servicing Left-Side Components
  84
- Measuring Shift Fork (Thickness)
  87
- Measuring Shift Fork Groove (Width)
  88
- Measuring Shift Fork to Groove (Side Clearance)
  88
- Primary Clutch Assembly
  88
- Servicing Right-Side Components
  88
- Inspecting Oil Pump
  91
- Secondary Gears
  91
- Servicing Center Crankcase Components
  91
- Crankshaft Assembly
  93
- Driveshaft
  94
- Countershaft
  100
- Assembling Crankcase Half
  103
- Joining Crankcase Halves
  105
- Installing Right-Side Components
  106
- Installing Left-Side Components
  109
- Installing Top-Side Components
  113
- Installing Engine/Transmission
  119
Table of Contents

123
- Removing Top-Side Components
  126
- Top-Side Components
  126
- Left-Side Components
  130
- Removing Left-Side Components
  130
- Removing Right-Side Components
  133
- Right-Side Components
  133
- Center Crankcase Components
  137
- Separating Crankcase Halves
  137
- Disassembling Crankcase Half
  138
- Servicing Components
  140
- Assembling Crankcase Half
  161
- Joining Crankcase Halves
  163
- Installing Right-Side Components
  164
- Installing Left-Side Components
  168
- Installing Top-Side Components
  169
- Installing Engine/Transmission
  175
Table of Contents

178
- Removing Top-Side Components
  183
- Top-Side Components
  183
- Left-Side Components
  187
- Removing Left-Side Components
  187
- Right-Side Components
  189
- Removing Right-Side Components
  190
- Center Crankcase Components
  193
- Separating Crankcase Halves
  193
- Disassembling Crankcase Half
  194
- Servicing Components
  196
- Assembling Crankcase Half
  217
- Joining Crankcase Halves
  219
- Installing Right-Side Components
  221
- Installing Left-Side Components
  224
- Installing Top-Side Components
  226
- Installing Engine/Transmission
  232
Table of Contents

236
- Removing Top-Side Components
  240
- Top-Side Components
  240
- Left-Side Components
  244
- Removing Left-Side Components
  244
- Removing Right-Side Components
  249
- Right-Side Components
  249
- Center Crankcase Components
  254
- Separating Crankcase Halves
  254
- Disassembling Crankcase Half
  255
- Assembling Crankcase Half
  285
- Joining Crankcase Halves
  288
- Installing Right-Side Components
  289
- Installing Left-Side Components
  293
- Installing Top-Side Components
  298
- Installing Engine/Transmission
  305
Section 4 - Fuel/Lubrication/Cooling

366
- Carburetor (400/500/650 H1)
  367
- Carburetor Schematics
  367
- Carburetor Specifications
  367
- Carburetor (650 V-Twin)
  369
  - Troubleshooting
    373
- Cleaning and Inspecting Carburetor
  378
- Choke Cable Free-Play (650 V-Twin)
  379
- Engine RPM (Idle)
  379
- Throttle Cable Free-Play
  379
- Gas Tank (400 VP)
  380
- Gas Tank (FIS Models)
  381
- Gas Tank Valve (400 VP)
  381
- Electric Fuel Pump (650 V-Twin)
  382
- Gas/Vent Hoses
  382
- Vacuum Pulse Fuel Pump (400 FIS/500/650 H1)
  382
- Oil Flow Charts
  383
- Oil Filter/Oil Pump
  384
- Testing Oil Pump Pressure
  386
- Oil Cooler (400)
  387
- Oil Cooler (650 H1)
  387
- Liquid Cooling System (500/650 H1/650 V-Twin)
  388
- Radiator
  388
- Hoses/Thermostat (500/650 H1)
  389
- Hoses/Thermostat (650 V-Twin)
  390
- Fan
  391
- Servicing Water Pump (500 - Manual Transmission)
  391
- Servicing Water Pump (500/650 H1 - Automatic Transmission)
  392
- Water Pump/Alternator Cover (650 V-Twin)
  394
- Testing Electric Fuel Pump (650 V-Twin)
  396
- Testing Vacuum Pulse Fuel Pump (400 FIS/500/650 H1)
  398
Section 5 - Electrical System

400
- Electrical System
  400
- Battery
  401
- Specifications
  401
- Accessory Receptacle/Connector (400/500/650 H1/650 V-Twin)
  402
- Brakelight Switch (Auxiliary)
  402
- RPM Limiter
  402
- Testing Electrical Components
  402
- Brakelight Switch (Handlebar Control)
  403
- Coolant Temperature and Cooling Fan Switches (500/650 H1/650 V-Twin)
  404
- Oil Temperature and Cooling Fan Switches (400)
  404
- Fan Motor
  405
- Fuses
  407
- Ignition Coil
  407
- Indicator Lights (400 VP)
  408
- Electronic Speedometer Speed Sensor
  409
- Ignition Switch
  410
- Handlebar Control Switches
  411
- Front Drive Selector Switch (400 FIS/500/650 H1/650 V-Twin)
  412
- Differential Lock Switch (400FIS/500/650 H1/650 V-Twin)
  413
- Front Drive Selector Actuator (400 FIS/500/ 650 H1/650 V-Twin)
  413
- Magneto Coils (400/500/650 H1)
  414
- Magneto Coils (650 V-Twin)
  415
- Starter Motor
  416
- Starter Relay
  421
- CDI Unit (400 FIS/TBX/500/650 H1/650 V-Twin)
  422
- Headlights
  422
- Neutral Start/Front Drive Actuator/Start-In-Gear/Differential Lock/2Wd Relays (FIS Models)
  422
- Regulator/Rectifier
  422
- Ignition Timing (400/500/650 H1)
  423
- Taillight - Brakelight
  423
- Ignition Timing (650 V-Twin)
  424
- V-Belt Failure Mode Clearing (650 V-Twin)
  424
- 100-Hour Belt Inspection Mode Clearing (650 V-Twin)
  425
- Engine Brake Actuator Resistance (650 V-Twin)
  425
- Engine Brake Controller Power Supply Voltage (650 V-Twin)
  425
- (650 V-Twin)
  426
- Controller-To-Engine Brake Actuator Voltage (650 V-Twin)
  426
- Output-To-Actuator Voltage (650 V-Twin)
  427
- Output-To-Speed Sensor Voltage (650 V-Twin)
  427
- Speed Sensor Signal Voltage (650 V-Twin)
  427
- Tilt Sensor Voltage (650 V-Twin)
  428
Section 6 - Drive System

430
- Drive System
  431
- General Information
  431
- Front Drive Actuator (400 FIS/500/650 H1/ 650 V-Twin)
  432
  - Suspension 7
    432
- Front Differential (FIS Models)
  433
- Drive Axles
  448
- VP - Rear Suspension
  453
- Hub
  457
- Rear Gear Case (FIS Models)
  457
- Hydraulic Brake Caliper
  459
Section 7 - Suspension

460
- Front and Rear Suspension Assembly Schematics
  461
- Shock Absorbers
  462
- Front A-Arms
  463
- Swing Arms (VP - Rear Suspension)
  463
- Rear A-Arms (FIS - Rear Suspension)
  466
- Wheels and Tires
  468
Section 8 - Steering/Frame

470
- Steering Post/Tie Rods
  471
- Handlebar Grip
  476
- Steering Knuckles
  477
- Measuring/Adjusting Toe-In
  479
- Front Rack
  480
- Front Bumper Assembly
  481
- Front/Rear Body Panel
  481
- Front Body Panel/Side Panels (TBX/TRV/500/ 650 H1/650 V-Twin)
  484
- Footrests
  488
- Belly Panel
  489
- Exhaust System
  489
- Rear Body Panel/Rack (500/650 H1/650 V-Twin)
  490
- Cargo Box (TBX Models)
  492
- Side Storage Box (TBX Models)
  492
- Adjusting Headlight
  493
- Seat
  494
- Taillight Assembly
  494
- Hand Brake Lever/Master Cylinder Assembly
  497
- Auxiliary Brake Assembly Schematic
  499
- Throttle Control
  499
- Drive Selector (FIS Models)
  501
- Front Differential Lock (TBX/400 FIS/500/ 650 H1/650 V-Twin)
  501
- Gearshift Pedal (Manual Transmission)
  501
- Reverse Shift Lever
  502
- Speedometer/Tachometer/Lcd (400 FIS/500/ 500 TBX/TRV/650 H1/650 V-Twin)
  503
  - Tightening Torque
    509
  - Troubleshooting
    511
- Engine
  512
- Drive
  515
- Fuel System
  516
- Electrical
  517
- Steering/Suspension
  519
- Brakes
  520

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