Arctic Cat 400 Clutch Replacement: A Step-by-Step Guide

Nov 17, 2025 by Alex Braham 56 views

So, you're looking to tackle an Arctic Cat 400 clutch replacement? Awesome! Doing it yourself can save you some serious cash and give you a great sense of accomplishment. This guide will walk you through the process, step by step, making it as straightforward as possible. Let's dive in!

Why Replace Your Arctic Cat 400 Clutch?

Before we get our hands dirty, let's understand why you might need to replace your clutch in the first place. There are several telltale signs that indicate your clutch is on its way out, and recognizing these early can prevent further damage to your ATV.

Slipping Clutch: This is one of the most common symptoms. You'll notice that when you give your Arctic Cat 400 throttle, the engine revs up, but the ATV doesn't accelerate as it should. It feels like you're losing power, especially when climbing hills or hauling loads. A slipping clutch is a sign that the friction plates are worn down and can no longer grip the clutch basket effectively. Ignoring this can lead to a complete loss of power transmission, leaving you stranded. Regular inspection and timely replacement of worn clutch components are essential to maintain optimal performance and prevent costly repairs.
Jerky Engagement: Instead of a smooth takeoff, your Arctic Cat might lurch or jerk when you engage the clutch. This can be caused by worn or damaged clutch plates, a sticky clutch cable, or issues with the clutch basket. A jerky engagement not only makes for an uncomfortable ride but can also put stress on other components of your drivetrain, potentially leading to more significant problems down the road. Addressing this issue promptly will ensure a smoother, more controlled riding experience.
Difficulty Shifting: If you find it hard to shift gears, especially into first or reverse, your clutch could be the culprit. A worn or damaged clutch can prevent the gears from meshing properly, making shifting difficult and potentially damaging the transmission. Forcing the gears can cause further wear and tear, so it's crucial to investigate the clutch if you're experiencing shifting problems. Proper clutch maintenance and timely repairs will help maintain smooth and reliable gear changes.
Unusual Noises: Strange noises, such as grinding or squealing, when you engage or disengage the clutch, are often a sign of trouble. These noises can indicate worn bearings, damaged clutch plates, or other internal issues. Ignoring these sounds can lead to more severe damage and potentially a complete clutch failure. Identifying and addressing the source of the noise early on can prevent further complications and ensure your Arctic Cat 400 continues to run smoothly.
Worn Clutch Cable: Sometimes the issue isn't the clutch itself but the cable that actuates it. A frayed, stretched, or sticky clutch cable can prevent the clutch from engaging or disengaging properly. This can lead to slipping, jerky engagement, or difficulty shifting. Inspecting the clutch cable regularly and lubricating or replacing it as needed can help maintain proper clutch function and prevent these issues. A well-maintained clutch cable ensures smooth and reliable clutch operation.

Tools and Parts You'll Need

Alright, so you've determined that your Arctic Cat 400 needs a new clutch. Here’s what you'll need to gather before you start:

New Clutch Kit: Make sure you get the right one for your specific year and model of Arctic Cat 400. A complete kit usually includes the clutch plates, friction plates, and springs.
Clutch Holding Tool: This tool is essential for holding the clutch basket in place while you remove the center nut. Trying to do it without this tool can be a real pain.
Socket Set: You'll need a variety of sockets to remove the clutch cover and other components.
Torque Wrench: This is crucial for tightening the clutch nut and cover bolts to the correct specifications. Overtightening can damage the clutch, while undertightening can lead to slippage.
Pliers: For removing and installing cotter pins and other small parts.
Screwdrivers: Both Phillips and flathead screwdrivers will come in handy.
Oil Drain Pan: To catch the oil when you remove the clutch cover.
New Gasket: The clutch cover gasket will likely need to be replaced to prevent leaks.
Shop Rags: For wiping up spills and keeping your workspace clean.
Penetrating Oil: To loosen any stubborn bolts or nuts.
Service Manual: A service manual specific to your Arctic Cat 400 model is invaluable. It will provide detailed instructions, diagrams, and torque specifications.

Having all these tools and parts ready before you start will make the job much smoother and prevent frustrating delays.

Step-by-Step Arctic Cat 400 Clutch Replacement

Okay, let's get down to the nitty-gritty. Follow these steps carefully, and you'll have your Arctic Cat 400 back up and running in no time.

Step 1: Preparation

Gather Your Tools and Parts: Make sure you have everything you need within easy reach.
Drain the Engine Oil: Place the oil drain pan under the engine and remove the drain plug to drain the oil. Replace the drain plug and tighten it to the correct torque specification.
Clean the Area: Clean the area around the clutch cover to prevent dirt and debris from entering the engine.

Step 2: Remove the Clutch Cover

Remove the Footrest: You may need to remove the footrest on the right side of the ATV to access the clutch cover bolts.
Remove the Clutch Cable: Disconnect the clutch cable from the clutch lever on the engine case.
Remove the Clutch Cover Bolts: Use the appropriate socket to remove the bolts holding the clutch cover in place. Keep track of the location of each bolt, as they may be different lengths.
Carefully Remove the Clutch Cover: Gently tap the clutch cover with a rubber mallet to loosen it. Be careful not to damage the gasket surface. Once the cover is loose, carefully remove it, being mindful of any oil that may still be inside.

Step 3: Remove the Old Clutch

Use the Clutch Holding Tool: Install the clutch holding tool to prevent the clutch basket from rotating.
Remove the Clutch Nut: Use a socket and breaker bar to loosen and remove the clutch nut. This nut can be very tight, so you may need to use some penetrating oil and a cheater bar for extra leverage.
Remove the Clutch Basket: Carefully remove the clutch basket from the engine case. Inspect the basket for any signs of wear or damage, such as grooves or notches. If the basket is damaged, it should be replaced.
Remove the Clutch Plates and Friction Plates: Remove the clutch plates and friction plates one at a time, noting their order and orientation. Inspect the plates for wear, damage, or discoloration. Replace any plates that are worn or damaged.
Remove the Clutch Springs: Remove the clutch springs and inspect them for wear or damage. Replace the springs if they are weak or broken.

Step 4: Install the New Clutch

Install the New Clutch Springs: Install the new clutch springs into the clutch basket.
Install the New Clutch Plates and Friction Plates: Install the new clutch plates and friction plates in the same order and orientation as the old ones. Be sure to soak the new friction plates in fresh engine oil for at least 30 minutes before installation.
Install the Clutch Basket: Carefully install the clutch basket back into the engine case.
Install the Clutch Nut: Install the clutch nut and tighten it to the correct torque specification using a torque wrench. Be sure to use the clutch holding tool to prevent the basket from rotating.

Step 5: Reinstall the Clutch Cover

Install a New Gasket: Install a new clutch cover gasket to ensure a proper seal.
Reinstall the Clutch Cover: Carefully reinstall the clutch cover, making sure it is properly aligned.
Reinstall the Clutch Cover Bolts: Reinstall the clutch cover bolts and tighten them to the correct torque specification. Follow the correct tightening sequence to ensure even pressure on the gasket.
Reconnect the Clutch Cable: Reconnect the clutch cable to the clutch lever on the engine case.
Reinstall the Footrest: Reinstall the footrest if you removed it.

Step 6: Final Steps

Refill the Engine Oil: Refill the engine with the correct amount of oil, as specified in your owner's manual.
Adjust the Clutch Cable: Adjust the clutch cable to ensure proper clutch engagement and disengagement. There should be a small amount of free play in the clutch lever.
Test the Clutch: Start the engine and test the clutch to make sure it is working properly. Check for any signs of slipping, jerky engagement, or difficulty shifting.

Tips and Tricks for a Smooth Arctic Cat 400 Clutch Replacement

Take Pictures: Before you disassemble anything, take pictures of the clutch assembly. This will help you remember how everything goes back together.
Keep Everything Clean: Keep your workspace clean and organized. This will prevent dirt and debris from entering the engine and make the job easier.
Use a Torque Wrench: Always use a torque wrench to tighten the clutch nut and cover bolts to the correct specifications. This will prevent damage to the clutch and ensure proper sealing.
Soak the Friction Plates: Soak the new friction plates in fresh engine oil for at least 30 minutes before installation. This will help them absorb oil and prevent slipping.
Refer to the Service Manual: The service manual is your best friend. It will provide detailed instructions, diagrams, and torque specifications specific to your Arctic Cat 400 model.

Troubleshooting Common Issues

Even with the best instructions, you might run into a snag or two. Here are some common issues and how to troubleshoot them:

Clutch Slipping After Replacement:
- Incorrect Clutch Adjustment: Double-check your clutch cable adjustment. Too much slack can cause slipping.
- Incorrect Oil Type: Make sure you're using the correct oil type for your Arctic Cat 400. Some oils contain friction modifiers that can cause clutch slippage. Consult your service manual for the recommended oil type.
- Worn or Damaged Clutch Plates: Even new clutch plates can be defective. Inspect the plates for any signs of damage or manufacturing defects.
Difficulty Shifting After Replacement:
- Clutch Not Fully Disengaging: This could be due to improper clutch cable adjustment or a sticky clutch cable. Adjust the cable and lubricate it if necessary.
- Bent or Damaged Shift Forks: If the shifting problem persists, the issue may be with the shift forks inside the transmission. This requires a more in-depth repair.
Leaking Clutch Cover:
- Damaged Gasket: Ensure the gasket is properly seated and not damaged. Replace it if necessary.
- Overtightened Bolts: Overtightening the cover bolts can warp the cover and cause leaks. Use a torque wrench to tighten the bolts to the correct specification.

When to Seek Professional Help

While replacing your Arctic Cat 400 clutch is a manageable task for many DIYers, there are situations where seeking professional help is the best course of action.

Lack of Experience: If you're not comfortable working on engines or lack the necessary mechanical experience, it's best to leave the job to a qualified mechanic. Incorrectly installing the clutch can cause serious damage to your ATV.
Specialized Tools Required: Some clutch replacements may require specialized tools that you don't have. A professional mechanic will have the necessary tools and expertise to complete the job correctly.
Complex Issues: If you encounter complex issues during the replacement process, such as damaged gears or a malfunctioning transmission, it's best to seek professional help. These issues may require specialized knowledge and equipment to diagnose and repair.
Warranty Concerns: If your Arctic Cat 400 is still under warranty, performing the clutch replacement yourself may void the warranty. Check your warranty terms and conditions before proceeding.

Replacing your Arctic Cat 400 clutch can seem daunting, but with the right preparation, tools, and instructions, it's a task you can definitely tackle. Remember to take your time, follow the steps carefully, and don't hesitate to seek professional help if you're unsure about anything. Happy wrenching, guys! Good luck and have fun!