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post #1 of 19 Old 05-28-2019, 07:48 PM Thread Starter
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06 FIS 400 Manual Shift

Long time lurker, first post. I have a 2006 AC 400 4X4 that is giving me the fits.

Background, I had a misfire a couple of years ago and wouldn't rev up. A new Flywheel and stator, carb cleanings, voltage regulator, new plug and ignition coil, finally found that the exhaust lobe on the cam turned into a circle.

I replaced the cam and rockers this past weekend and it revs great now and power is back. I still have oil starvation at the top of the head though and don't want to ruin what I just replaced. I removed the right side cover and inspected the oil pump which is good. New oil filter. Disconnected the oil cooler line next to the oil filter and have good steady flow.

My question is how does oil make its way to the head? The only thing I cannot get a definitive answer is where is the oil pressure relief valve? It's the only thing I can think of that would be restricting lubrication to the top but I have no idea how oil flows or where the valve is.

I have a service manual for it and there's no mention how oil flows or valve location. Any help is appreciated greatly. Thanks.

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post #2 of 19 Old 05-28-2019, 09:22 PM
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Sled: 16 Bearcat XT, 06 T660 TT, 05 S/Cat 600
ATV: 03 400 4x4 auto FIS, 05 300 4x4
I have an 03 manual and oil flow chart is in section 4 fuel lubrication cooling.

Current Sled rides
2005 Sabercat 600 EFI LX
2006 T660 Turbo Touring
2016 Bearcat 2000XT

Past Sled rides
1993 Pantera 550 EFI
1980 El Tigre 6000

Current ATV rides
2005 A/C 300 manual 4x4
RTR Bushings & shock bushings
Motobatt Battery


2003 A/C 400 auto 4x4 FIS
RTR Steerlites & Shock Bushings
Motobatt Battery
26" Kenda Bearclaw HTR's


Past ATV rides
2003 A/C 400 manual ACT 4x4
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post #3 of 19 Old 05-29-2019, 07:41 AM Thread Starter
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So ultimately this relief valve could be my issue. Is this internal? I didn't see it in the right side.
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post #4 of 19 Old 05-29-2019, 08:25 AM
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Garage
Sled: 16 Bearcat XT, 06 T660 TT, 05 S/Cat 600
ATV: 03 400 4x4 auto FIS, 05 300 4x4
Itís doesnít show in manual but Iím wondering if this is it under that nut by oil filter. I took a picture of my 03 400 auto.
06 FIS 400 Manual Shift-img_2097.jpg

Current Sled rides
2005 Sabercat 600 EFI LX
2006 T660 Turbo Touring
2016 Bearcat 2000XT

Past Sled rides
1993 Pantera 550 EFI
1980 El Tigre 6000

Current ATV rides
2005 A/C 300 manual 4x4
RTR Bushings & shock bushings
Motobatt Battery


2003 A/C 400 auto 4x4 FIS
RTR Steerlites & Shock Bushings
Motobatt Battery
26" Kenda Bearclaw HTR's


Past ATV rides
2003 A/C 400 manual ACT 4x4
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post #5 of 19 Old 05-29-2019, 08:26 AM Thread Starter
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I looked at that and wasn't sure if that was it but there's a lot of reason to believe that may be it.

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post #6 of 19 Old 05-29-2019, 09:16 AM Thread Starter
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So in the book it states Oil Gallery Plug for that item. But shows a listing in the parts fiche for a Oil Pressure Relief Valve.

The search continues...
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post #7 of 19 Old 05-29-2019, 09:21 AM Thread Starter
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With the orientation of the picture, it would appear that it threads into the case near the oil filter but it doesn't seem to be the location.
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post #8 of 19 Old 05-29-2019, 12:28 PM
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Garage
Sled: 16 Bearcat XT, 06 T660 TT, 05 S/Cat 600
ATV: 03 400 4x4 auto FIS, 05 300 4x4
Yea I got confused with the diagrams too. Not sure now.

Current Sled rides
2005 Sabercat 600 EFI LX
2006 T660 Turbo Touring
2016 Bearcat 2000XT

Past Sled rides
1993 Pantera 550 EFI
1980 El Tigre 6000

Current ATV rides
2005 A/C 300 manual 4x4
RTR Bushings & shock bushings
Motobatt Battery


2003 A/C 400 auto 4x4 FIS
RTR Steerlites & Shock Bushings
Motobatt Battery
26" Kenda Bearclaw HTR's


Past ATV rides
2003 A/C 400 manual ACT 4x4
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post #9 of 19 Old 05-29-2019, 12:44 PM Thread Starter
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Looks like the engine needs to be split. F***. Looks to be the inside of the left crankcase just above the highlighted E you can see where the oil filter spins on.
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Last edited by Badvnm85; 05-29-2019 at 12:46 PM. Reason: Added notes
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post #10 of 19 Old 05-29-2019, 06:25 PM Thread Starter
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Can I get another opinion on this? I am really tempted to tear this down and replace the valve as well as standard bore rebuild kit.

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