2006 Arctic Cat DVX 400 ATV Complete Service Manual

The document is a comprehensive service manual for the 2006 Arctic Cat DVX 400 ATV. It includes detailed sections on maintenance, troubleshooting, engine specifications, storage preparation, and repair procedures. It also provides safety warnings, recommended tools, and guidelines for proper operation and servicing of the ATV.

General Information and Safety

•    Manual includes service, maintenance, and troubleshooting details for the 2006 Arctic Cat DVX 400 ATV.

•    Warnings and cautions highlight personal safety and equipment protection.

•    Specifications and illustrations may differ due to product improvements.
Break-In Procedures

•    First 10 hours or 200 miles require less than 1/2 throttle operation.

•    Avoid heavy loads and allow proper engine warm-up during break-in.

•    Brake pads must be burnished for maximum effectiveness.
Maintenance and Storage

•    Use only recommended gasoline and engine oil to avoid damage.

•    Proper storage includes cleaning, draining fuel, and lubricating components.

•    Post-storage preparation involves cleaning, oil changes, and inspecting brake systems.
Troubleshooting

•    Engine issues include low compression, no spark, or fuel delivery problems.

•    Transmission problems include shifting failures and gear jumping.

•    Steering and suspension issues cover alignment, tire pressure, and worn components.
Specifications

•    Carburetor type: Mikuni BSR37; spark plug: NGK CR7E.

•    Brake type: Hydraulic disc and mechanical parking brake.

•    Recommended engine oil: SAE 10W-40; cooling system capacity: 1.2 L.
Key Adjustments and Repairs

•    Valve clearance, tappet adjustments, and clutch cable free play are critical.

•    Crankshaft and driveshaft measurements ensure proper assembly and operation.

•    Brake fluid leakage and air in the hydraulic system can impair braking performance.

•    The manual provides service, maintenance, and troubleshooting information for the 2006 Arctic Cat DVX 400 ATV. It includes disassembly, inspection, and assembly instructions for various components.

•    Safety warnings and symbols are emphasized. Symbols like WARNING and CAUTION highlight critical safety and operational details.

•    Break-in procedures are specified for new or overhauled engines. These include limiting throttle use, warming the engine properly, and burnishing brake pads.

•    Recommended fuel and oil types are detailed. Use 87 octane gasoline and SAE 10W-40 engine oil, avoiding certain additives and non-recommended oils.

•    Storage and post-storage preparation steps are outlined. Includes cleaning, draining fuel, lubricating parts, and inspecting components.

•    Periodic maintenance charts and schedules are provided. Tasks like lubrication, adjustments, and inspections are listed by frequency.

•    Troubleshooting guidance covers engine, fuel system, electrical, and steering issues. Includes symptoms, conditions, and remedies for common problems.

•    Component-specific servicing and specifications are included. Covers engine, transmission, suspension, and drive systems with detailed steps and measurements.

Chapters in the 2006 Arctic Cat DVX 400 Service Manual:

1.    General Information
    
•    Specifications, safety, and general guidelines.

2.    Periodic Maintenance/Tune-Up
   
•    Maintenance schedules, lubrication points, and adjustments.

3.    Engine/Transmission
    
•    Disassembly, inspection, assembly, and specifications for engine and transmission components.

4.    Fuel/Lubrication/Cooling
    
•    Details on the fuel system, lubrication system, cooling system, and related maintenance.

5.    Electrical System
    
•    Wiring diagrams, ignition system, and troubleshooting electrical components.

6.    Drive System
    
•    Rear drive assembly, drive chain adjustments, and axle maintenance.

7.    Suspension
    
•    Front and rear suspension assembly, shock absorbers, and swing arm details.

8.    Steering/Frame
    
•    Steering components, alignment, and frame inspection.

9.    Controls/Indicators
    
•    Handlebar controls, indicator lights, and cable adjustments.

10.    Aids for Maintenance
    
•    Tools, torque specifications, and maintenance aids.

11.    Troubleshooting
    
•    Diagnosis and remedies for common mechanical and electrical issues.
Each chapter is designed to cover specific components or systems of the ATV, providing detailed instructions for service and repair.

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