Arctic Cat 400 TRV Manuals

Manuals and User Guides for Arctic Cat 400 TRV. We have 3 Arctic Cat 400 TRV manuals available for free PDF download: Service Manual, Operator's Manual

Arctic Cat 400 TRV Service Manual (520 pages)

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

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

Arctic Cat 400 TRV Service Manual (274 pages)

Brand: Arctic Cat | Category: Offroad Vehicle | Size: 45 MB

Service Manual

2
- Drive System
  2
- Front Differential
  5
Section 6 - Drive System

216
- Drive Axles
  231
- Rear Gear Case
  236
- Hub
  238
- Hydraulic Brake Caliper
  240
- Troubleshooting Brake System
  243
- Troubleshooting Drive System
  243
Suspension

245
- Shock Absorbers
  245
- Front A-Arms
  246
- Rear A-Arms
  248
- Wheels and Tires
  250
- Troubleshooting
  251
Section 8 - Steering/Frame

252
- Steering Post/Tie Rods
  253
- Steering/Frame
  253
- Handlebar Grip
  256
- Steering Knuckles
  257
- Measuring/Adjusting Toe-In
  259
- Front Bumper Assembly
  260
- Front Rack
  260
- Front Body Panel/Side Panels
  261
- Footrests
  264
- Belly Panel
  265
- Exhaust System
  265
- Rear Body Panel/Rack
  265
- Taillight Assembly
  266
- Seat
  267
- Troubleshooting
  270
Hand Brake Lever/

272
- Hand Brake Lever/Master Cylinder Assembly
  272
- Throttle Control
  273
- Shift Lever
  274
- Speedometer/Tachometer/Lcd
  274

Arctic Cat 400 TRV Operator's Manual (84 pages)

Brand: Arctic Cat | Category: Offroad Vehicle | Size: 3 MB

Foreword

3
Parts and Accessories

3
- Protect Your Sport
  3
- Table of Contents
  4
Limited Warranty

5
Warranty Procedure/Owner Responsibility

6
Arctic Cat ATV Emission Control Warranty Statement

7
Arctic Cat Emission Control System Limited Warranty

8
EPA Emission Control Statement/Warranty Coverage (U.S. Only)

9
Declaration of Conformity

10
- Division I - Safety
  11
2-Up ATV Safety Alert

12
Rider Training Course

13
Hangtags

14
Warning Labels & Information

15
- Warning Labels & Information
  16
Warnings

17
Prevention

27
- Safe Riding Clothing and Gear (Operator and Passenger)
  27
- TRV Condition
  28
  - T-Cloc
    28
- First Aid and Survival
  30
- Prevention
  30
Active Riding

31
Sound Judgment

32
- Environment
  32
- Those Around You
  33
- Equipment
  34
- Load Capacity Ratings
  34
- Speedrack
  35
- Personal Choices
  35
  - Sipde
    36
  - Sound Judgment
    36
Supervision

37
- Taking Responsibility
  37
  - Inexperienced Riders
    37
  - Experienced Riders
    37
- Division II - Operation/Maintenance
  38
TRV Specifications

38
Location of Parts and Controls

39
ATV Operation

40
- Basic Operating Maneuvers
  40
  - Starting the Engine
    40
  - Bone-C
    40
  - Starting a Cold Engine
    41
  - Dismounting the Trv
    42
- Handling the TRV (Active Riding Techniques)
  43
  - Wide Turns
    44
  - Sharp Turns
    44
  - Quick Turns
    45
  - Riding Downhill
    46
  - Riding Uphill
    46
- Tips
  48
  - Skidding or Sliding
    49
  - Stopping the Engine
    50
General Information

51
- TRV Identification Numbers
  51
- Ignition Switch Key
  51
- Control Locations and Functions
  51
  - Shift Lever
    52
  - Drive Select Switch
    52
  - Rear Foot Brake
    54
  - Throttle Lever
    54
  - Engine Stop Switch
    54
  - Electric Starter Button
    54
- Power Steering (Xt/Limited)
  55
- Speedometer/Lcd
  56
- Oil Level Stick
  57
- Windshied (Limited)
  58
- Mirrors (Limited)
  58
- Rear Seat Lock
  58
- Front Seat Lock
  59
- Storage Box (Limited)
  59
- Safety Flag Bracket
  59
- Rack Loading
  59
- Trailering and Towing
  60
- Transporting
  60
- Gasoline-Oil-Lubricant
  61
- Engine Break-In
  62
- Burnishing Brake Pads
  62
General Maintenance

63
- Maintenance Schedule
  63
- Liquid Cooling System
  64
- Oil Cooler (1000)
  64
- Shock Absorbers
  65
- General Lubrication
  65
- Hydraulic Hand Brake
  67
  - Brake Fluid
    67
  - Brake Lever Lock
    67
  - Brake Hoses
    67
  - Brake Pads
    67
- Rear Foot Brake
  68
- Protective Rubber Boots
  68
- Battery
  69
- Spark Plug(S)
  72
- Throttle Cable Adjustment
  72
- Air Filter
  73
- Air Filter Housing Drains
  74
- Draining V-Belt Cover
  74
- Tires
  74
- Wheels
  75
- Muffler/Spark Arrester
  75
- Light Bulb Replacement
  76
- Checking/Adjusting Headlight Aim
  76
- Fuses
  77
- Electrical Output Terminals
  77
- Tool Storage Tray/Battery Hold-Down
  77
Preparation for Storage

78
Preparation after Storage

79
Maintenance Record

80
Change of Address, Ownership, or Warranty Transfer

81
Identification Numbers Record

83

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More Arctic Cat Manuals

Arctic Cat 400 TRV Manuals

Arctic Cat 400 TRV Service Manual (520 pages)

Table of Contents

Section 1 - General Information

Section 2 - Periodic Maintenance/Tune-Up

Section 3 - Engine/Transmission

Table of Contents

Servicing Components

Table of Contents

Table of Contents

Table of Contents

Section 4 - Fuel/Lubrication/Cooling

Section 5 - Electrical System

Section 6 - Drive System

Section 7 - Suspension

Section 8 - Steering/Frame

Arctic Cat 400 TRV Service Manual (274 pages)

Table of Contents

Service Manual

Section 6 - Drive System

Suspension

Section 8 - Steering/Frame

Hand Brake Lever/

Arctic Cat 400 TRV Operator's Manual (84 pages)

Table of Contents

Foreword

Parts and Accessories

Limited Warranty

Warranty Procedure/Owner Responsibility

Arctic Cat ATV Emission Control Warranty Statement

Arctic Cat Emission Control System Limited Warranty

EPA Emission Control Statement/Warranty Coverage (U.S. Only)

Declaration of Conformity

2-Up ATV Safety Alert

Rider Training Course

Hangtags

Warning Labels & Information

Warnings

Prevention

Active Riding

Sound Judgment

Supervision

TRV Specifications

Location of Parts and Controls

ATV Operation

General Information

General Maintenance

Preparation for Storage

Preparation after Storage

Maintenance Record

Change of Address, Ownership, or Warranty Transfer

Identification Numbers Record

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