2011 Arctic Cat 400 TRV ATV Service Manual
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- 2011 arctic cat 400TRV service manual
Factory Service Manual for Arctic Cat 400 TRV ATV.
Manual is indexed and searchable for easy access to information. It has hundreds of high quality images and diagrams, a must have manual to perform maintenance and repairs.
Manual Chapters:
- GENERAL INFORMATION/ SPECIFICATIONS
- PERIODIC MAINTENANCE
- ENGINE / TRANSMISSION
- FUEL / LUBRICATION / COOLING
- ELECTRICAL SYSTEM
- DRIVE SYSTEM
- SUSPENSION
- STEERING / FRAME
- CONTROLS / INDICATORS
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Full list of manual chapters:
TABLE OF CONTENTS
SECTION 1 - GENERAL INFORMATION/ SPECIFICATIONS
General Specifications
Torque Specifications
Torque Conversions (ft-lb/N-m)
Break-In Procedure
Gasoline - Oil - Lubricant
RECOMMENDED GASOLINE
RECOMMENDED ENGINE/ TRANSMISSION OIL
RECOMMENDED FRONT DIFFERENTIAL/REAR DRIVE LUBRICANT
FILLING GAS TANK
Genuine Parts
Preparation For Storage
Preparation After Storage
SECTION 2 - PERIODIC MAINTENANCE
Periodic Maintenance Chart
Periodic Maintenance
SPECIAL TOOLS
Lubrication Points
Air Filter
CHECKING AND CLEANING DRAINS
Valve/Tappet Clearance
Feeler Gauge Procedure
Valve Adjuster Procedure
Testing Engine Compression
Spark Plug
Muffler/Spark Arrester
Engine/Transmission Oil - Filter - Strainer
OIL - FILTER
STRAINER
Front Differential/Rear Drive Lubricant
Nuts/Bolts/Cap Screws
Headlights/Taillight - Brakelight
CHECKING/ADJUSTING HEADLIGHT AIM
Shift Lever
CHECKING ADJUSTMENT
ADJUSTING SHIFT LEVER
Frame/Welds/Racks
Hydraulic Brake Systems
CHECKING/BLEEDING
INSPECTING HOSES
CHECKING/REPLACING PADS
Burnishing Brake Pads
Checking/Replacing V-Belt
REMOVING
INSTALLING
SECTION 3 - ENGINE/TRANSMISSION
Engine/Transmission
SPECIAL TOOLS
Specifications
Troubleshooting
Table of Contents (400 TRV)
Removing Engine/ Transmission
Top-Side Components
Removing Top-Side Components
A. Valve Cover/Rocker Arms B. Cylinder Head/Camshaft
C. Cylinder D. Piston
Servicing Top-Side Components
VALVE ASSEMBLY
Cleaning/Inspecting Cylinder Head Cover
Removing Valves
Measuring Valve Stem Runout
Measuring Valve Stem Outside Diameter
Measuring Valve Face/Seat Width
Measuring Valve Face Radial Runout
Measuring Valve Guide/Valve Stem Deflection (Wobble Method)
Measuring Valve Guide (Inside Diameter)
Servicing Valves/Valve Guides/Valve Seats
Measuring Rocker Arm (Inside Diameter)
Measuring Rocker Arm Shaft (Outside Diameter)
Installing Valves
PISTON ASSEMBLY
Cleaning/Inspecting Piston
Removing Piston Rings
Cleaning/Inspecting Piston Rings
Measuring Piston-Ring End Gap (Installed)
Measuring Piston Pin, Connecting Rod Small End, and Piston-Pin Bore
Measuring Piston Skirt/ Cylinder Clearance
Installing Piston Rings
CYLINDER/CYLINDER HEAD ASSEMBLY
Cleaning/Inspecting Cylinder Head
Measuring Cylinder Head Distortion
Cleaning/Inspecting Cylinder
Inspecting Cam Chain Guide
Honing Cylinder
Measuring Camshaft Runout
Measuring Camshaft Lobe Height
Inspecting Camshaft Bearing Journal
Measuring Camshaft to Cylinder Head Clearance
Inspecting Camshaft Spring/Drive Pin
Installing Top-Side Components
A. Piston B. Cylinder
C. Cylinder Head/Camshaft D. Valve Cover/Rocker Arms
Left-Side Components
Removing Left-Side Components
A. Cover/Stator Assembly
B. Rotor/Flywheel C. Starter Motor
Installing Left-Side Components
A. Starter Idler Gears B. Rotor/Flywheel
C. Cover
Right-Side Components
Removing Right-Side Components
A. V-Belt Cover B. Driven Pulley C. Clutch Cover
D. Gear Position Switch E. Centrifugal Clutch Assembly F. Oil Pump Drive Gear G. Oil Pump Driven Gear
H. Oil Pump/Oil Strainer
Servicing Right-Side Components
INSPECTING CENTRIFUGAL CLUTCH SHOE
INSPECTING CENTRIFUGAL CLUTCH HOUSING
INSPECTING PRIMARY ONE-WAY DRIVE
INSPECTING OIL PUMP
DRIVEN PULLEY ASSEMBLY
Installing Right-Side Components
A. Oil Strainer/Oil Pump
B. Clutch Cover C. Fixed Drive Face D. Movable Drive Face
Center Crankcase Components
Separating Crankcase Halves
Disassembling Crankcase Half
Servicing Center Crankcase Components
SECONDARY GEARS
Checking Backlash
Correcting Backlash
Checking Tooth Contact
Correcting Tooth Contact
CRANKSHAFT ASSEMBLY
Measuring Connecting Rod (Small End Inside Diameter)
Measuring Connecting Rod (Small End Deflection)
Measuring Connecting Rod (Big End Side-to-Side)
Measuring Crankshaft (Runout)
Measuring Crankshaft (Web-to-Web)
COUNTERSHAFT
Disassembling
ASSEMBLING
Assembling Crankcase Half
Joining Crankcase Halves
Installing Engine/Transmission
SECTION 4 - FUEL/LUBRICATION/COOLING
Fuel/Lubrication/Cooling
SPECIAL TOOLS
Carburetor Specifications
Carburetor
REMOVING
DISASSEMBLING
CLEANING AND INSPECTING
ASSEMBLING
INSTALLING
Electric Choke
REMOVING
INSPECTING/TESTING
INSTALLING
Throttle Cable Free-Play
Engine RPM (Idle)
Gas Tank
REMOVING
CLEANING AND INSPECTING
INSTALLING
Oil Filter/Oil Pump
Testing Oil Pump Pressure
Oil Cooler
REMOVING
INSTALLING
Vacuum Pulse Fuel Pump
TESTING
REMOVING
INSTALLING
Troubleshooting
SECTION 5 - ELECTRICAL SYSTEM
Electrical System
SPECIAL TOOLS
Electrical Connections
Specifications
Battery
RPM Limiter
Testing Electrical Components
Accessory Receptacle/Connector
VOLTAGE
Brakelight Switch (Auxiliary)
VOLTAGE (Wiring Harness Side)
RESISTANCE (Switch Connector)
Brakelight Switch (Handlebar Control)
VOLTAGE (Wiring Harness Connector)
RESISTANCE (Switch Connector)
Oil Temperature and Cooling Fan Switches
Fan Motor
RESISTANCE (Fan Motor Connector)
Power Distribution Module (PDM)
FUSES
RELAYS
Ignition Coil
RESISTANCE
Primary Winding
Secondary Winding
Spark Plug Cap
PEAK VOLTAGE
Primary/CDI
Speed Sensor
Ignition Switch
VOLTAGE
RESISTANCE
Handlebar Control Switches
RESISTANCE (HI Beam)
RESISTANCE (LO Beam)
DIODE (Starter Button)
RESISTANCE (Emergency Stop)
RESISTANCE (Reverse Override)
Drive Select Switch
RESISTANCE
VOLTAGE
Front Drive/Differential Lock Actuator
VOLTAGE
Stator Coil
VOLTAGE (AC Generator - Regulated Output)
VOLTAGE (Charging Coil - No Load)
RESISTANCE (Charging Coil)
RESISTANCE (Trigger Coil)
PEAK VOLTAGE
Trigger Coil
Starter Relay
Starter Motor
TESTING VOLTAGE
REMOVING
INSTALLING
CDI Unit
Regulator/Rectifier
TESTING
Headlights
VOLTAGE
Taillight - Brakelight
VOLTAGE (Taillight)
VOLTAGE (Brakelight)
Ignition Timing
Troubleshooting
SECTION 6 - DRIVE SYSTEM
Drive System
GENERAL INFORMATION
SPECIAL TOOLS
Front Drive Actuator/Differential Lock
REMOVING
INSTALLING
Front Differential
REMOVING DIFFERENTIAL
Disassembling Input Shaft
Assembling Input Shaft
Disassembling Differential Assembly
Disassembling Pinion Gear
Assembling Pinion Gear
Shimming Procedure/Shim Selection
Backlash
Ring Gear End-Play
Assembling Differential Assembly
Removing/Installing Axle Seal
INSTALLING DIFFERENTIAL
Drive Axles
REMOVING REAR DRIVE AXLE
REMOVING FRONT DRIVE AXLE
CLEANING AND INSPECTING
DISASSEMBLING/ASSEMBLING AXLES
INSTALLING REAR DRIVE AXLE
INSTALLING FRONT DRIVE AXLE
Rear Gear Case
REMOVING
RING GEAR/THRUST BUTTON
Removing
Inspecting
Installing/Shimming
INSTALLING
Hub
REMOVING
CLEANING AND INSPECTING
INSTALLING
Hydraulic Brake Caliper
REMOVING/DISASSEMBLING
CLEANING AND INSPECTING
ASSEMBLING/INSTALLING
Troubleshooting Drive System
Troubleshooting Brake System
SECTION 7 - SUSPENSION
Suspension
Troubleshooting
Shock Absorbers
REMOVING
CLEANING AND INSPECTING
INSTALLING
Front A-Arms
REMOVING
CLEANING AND INSPECTING
INSTALLING
Rear A-Arms
REMOVING
CLEANING AND INSPECTING
INSTALLING
Wheels and Tires
TIRE SIZE
TIRE INFLATION PRESSURE
REMOVING
CLEANING AND INSPECTING
INSTALLING
CHECKING/INFLATING
SECTION 8 - STEERING/FRAME
Steering/Frame
Steering Post/Tie Rods
REMOVING
CLEANING AND INSPECTING
INSTALLING
Handlebar Grip
REMOVING
INSPECTING
INSTALLING
Steering Knuckles
REMOVING AND DISASSEMBLING
CLEANING AND INSPECTING
ASSEMBLING AND INSTALLING
Measuring/Adjusting Toe-Out
Front Rack
REMOVING
CLEANING AND INSPECTING
INSTALLING
Front Bumper Assembly
REMOVING
CLEANING AND INSPECTING
INSTALLING
Front Body Panel/Side Panels
REMOVING
CLEANING AND INSPECTING
INSTALLING
Footrests
REMOVING
CLEANING AND INSPECTING
INSTALLING
Belly Panel
REMOVING/INSTALLING
Exhaust System
REMOVING MUFFLER
INSPECTING MUFFLER
INSTALLING MUFFLER
Rear Body Panel/Rack
REMOVING
CLEANING AND INSPECTING
INSTALLING
Taillight Assembly
REMOVING
INSPECTING
INSTALLING
Seat
REMOVING/INSTALLING
Troubleshooting
SECTION 9 - CONTROLS/INDICATORS
Hand Brake Lever/Master Cylinder Assembly
REMOVING
INSPECTING
INSTALLING
Throttle Control
REMOVING
INSTALLING
ADJUSTING
Shift Lever
REMOVING
INSTALLING
LCD Gauge
REPLACING