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Summary of Contents for Arctic Cat 1000 XT 2014

FOREWORD

This Arctic Cat Service Manual contains service, maintenance, and troubleshooting information for certain 2007

Arctic Cat ATV models (see cover). The complete manual is designed to aid service personnel in service-oriented

applications.

Arctic Cat offers additional publications (when they become available) to aid in servicing other ATV models. To

service models not included in this manual, please refer to the following publications:

• 2007 Y-12 Service Manual

• 2007 DVX/Utility 250 Service Manual

• 2007 DVX 400 Service Manual

• 2007 Prowler Service Manual

• 2007 700 Diesel Service Manual

This manual is divided into sections. Each section covers a specific ATV component or system and, in addition to

the standard service procedures, includes disassembling, inspecting, and assembling instructions. When using this

manual as a guide, the technician should use discretion as to how much disassembly is needed to correct any given

condition.

The service technician should become familiar with the operation and construction of each component or system

by carefully studying the complete manual. This manual will assist the service technician in becoming more

aware of and efficient with servicing procedures. Such efficiency not only helps build consumer confidence but

also saves time and labor.

All Arctic Cat ATV publications and decals display the words Warning, Caution, Note, and At This Point to

emphasize important information. The symbol ! WARNING identifies personal safety-related information.

Be sure to follow the directive because it deals with the possibility of severe personal injury or even death. The

symbol ! CAUTION identifies unsafe practices which may result in ATV-related damage. Follow the direc-

tive because it deals with the possibility of damaging part or parts of the ATV. The symbol NOTE: identifies

supplementary information worthy of particular attention. The symbol  AT THIS POINT directs the

technician to certain and specific procedures to promote efficiency and to improve clarity.

At the time of publication, all information, photographs, and illustrations were technically correct. Some photo-

graphs used in this manual are used for clarity purposes only and are not designed to depict actual conditions.

Because Arctic Cat Inc. constantly refines and improves its products, no retroactive obligation is incurred.

All materials and specifications are subject to change without notice.

Keep this manual accessible in the shop area for reference.

Product Service and

Warranty Department

Arctic Cat Inc.

© 2006 Arctic Cat Inc. August 2006

®™ Trademarks of Arctic Cat Inc., Thief River Falls, MN 56701

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TABLE OF CONTENTS

Foreword

Click on the red text to go.

Section

1. General Information

2. Periodic Maintenance/Tune-Up

3. Engine/Transmission

4. Fuel/Lubrication/Cooling

5. Electrical System

6. Drive System

7. Suspension

8. Steering/Frame

9. Controls/Indicators

10. Aids for Maintenance

11. Troubleshooting

1

2

3

4

5

6

7

8

9

10

11

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1-1

1

SECTION 1 — GENERAL INFORMATION

TABLE OF

CONTENTS

General Specifications

(400/400 TRV — Automatic Transmission)……..….. 1-2

General Specifications

(400 — Manual Transmission)…………..………….….. 1-3

General Specifications

(500 — Manual Transmission)…………..………….….. 1-4

General Specifications

(500 — Automatic Transmission).…………….……….. 1-5

General Specifications

(650 H1/650 H1 TBX/650 H1 TRV)………..……….. 1-6

General Specifications

(700 EFI) ……………………….………….…………….….. 1-7

Break-In Procedure …..……………..…………….……….. 1-8

Gasoline — Oil — Lubricant …………….…………….…….. 1-8

Genuine Parts …………………..…………….……………... 1-9

Preparation For Storage……..…………….……………... 1-9

Preparation After Storage………………….……………. 1-10

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1-2

General Specifications*

(400/400 TRV — Automatic

Transmission)

* Specifications subject to change without notice.

** One inch below filler plug threads.

*** At the oil level plug threads.

CARBURETOR

Type Keihin CVK34

Main Jet 135

Slow Jet 38

Pilot Screw Setting (turns) 1 3/4

Jet Needle NAZG

Idle RPM

(engine warm)

1250-1350

Starter Jet 75

Float Arm Height 17 mm (0.7 in.)

Throttle Cable Free-Play (at lever) 3-6 mm (1/8-1/4 in.)

ELECTRICAL

Ignition Timing 10° BTDC @ 1500 RPM

Spark Plug Type NGK CR7E

Spark Plug Gap 0.7-0.8 mm (0.028-0.032

in.)

Spark Plug Cap 8000-12,000 ohms

Ignition Coil

Resistance

(primary)

(secondary)

Less than 1 ohm

(terminal to ground)

5200-7800 ohms

(high tension — plug cap

removed — to ground)

Ignition Coil Peak

Voltage

(primary/

CDI)

250-375 DC volts

(terminal to ground)

Magneto Coil

Resistance

(trigger)

(source)

(charging)

160-240 ohms

(green to blue)

Less than 1 ohm

(yellow to white)

Less than 1 ohm

(black to black)

Magneto Coil Peak

Voltage

(trigger)

(source)

5.04-7.56 volts

(green to blue)

0.7-1.05 volts

(yellow to white)

Stator Coil Output (no load) 60 AC volts @ 5000 RPM

(black to black #1)

(black to black #2)

Magneto Output (approx) 220W @ 5000 RPM

CHASSIS

Brake Type Hydraulic w/Brake Lever

Lock and Auxiliary Brake

Tire Size Front — 25 x 8-12

Rear — 25 x 10-12

Tire Inflation Pressure 0.35 kg/cm² (5 psi)

MISCELLANY

Gas Tank Capacity (rated) 24.6 L (6.5 U.S. gal.)

20.8 L (5.5 U.S. gal.) — TRV

Rear Drive Capacity 250 ml (8.5 fl oz)**

Differential Capacity (front — 4×4) 275 ml (9.3 fl oz)***

Engine Oil Capacity 3.08 L (3.25 U.S. qt)

Gasoline (recommended) 87 Octane Regular Unleaded

Engine Oil (recommended) SAE 5W-30

Differential/Rear Drive Lubricant SAE Approved

80W-90 Hypoid

Drive Belt Width 28.5 mm (1.12 in.)

Brake Fluid DOT 4

Taillight/Brakelight 12V/8W/27W

Headlight 12V/37W (2)

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1-3

1

General Specifications*

(400 — Manual Transmission)

* Specifications subject to change without notice.

** One inch below filler plug threads.

*** At the oil level plug threads.

CARBURETOR

Type Keihin CVK34

Main Jet 135

Slow Jet 38

Pilot Screw Setting (turns) 1 3/4

Jet Needle NAZG

Idle RPM

(engine warm)

1250-1350

Starter Jet 75

Float Arm Height 17 mm (0.7 in.)

Throttle Cable Free-Play

(at lever)

3-6 mm (1/8-1/4 in.)

ELECTRICAL

Ignition Timing 10° BTDC @ 1500 RPM

Spark Plug Type NGK CR7E

Spark Plug Gap 0.7-0.8 mm (0.028-0.032 in.)

Spark Plug Cap 8000-12,000 ohms

Ignition Coil

Resistance

(primary)

(secondary)

Less than 1 ohm

(terminal to ground)

5200-7800 ohms

(high tension — plug cap

removed — to ground)

Ignition Coil

Peak Voltage

(primary/

CDI)

250-375 DC volts

(terminal to ground)

Magneto Coil

Resistance

(trigger)

(source)

(charging)

160-240 ohms

(green to blue)

Less than 1 ohm

(yellow to white)

Less than 1 ohm

(black to black)

Magneto Coil

Peak Voltage

(trigger)

(source)

5.04-7.56 volts

(green to blue)

0.7-1.05 volts

(yellow to white)

Stator Coil Out-

put

(no load) 60 AC volts @ 5000 RPM

(black to black #1)

(black to black #2)

Magneto Output (approx) 220 W @ 5000 RPM

CHASSIS

Brake Type Hydraulic w/Brake Lever Lock

and Auxiliary Brake

Tire Size Front — 25 x 8-12

Rear — 25 x 10-12

Tire Inflation Pressure 0.35 kg/cm² (5 psi)

MISCELLANY

Gas Tank Capacity (rated) 24.6 L (6.5 U.S. gal.)

Rear Drive Capacity 250 ml (8.5 fl oz)**

Differential Capacity (front — 4×4) 275 ml (9.3 fl oz)***

Engine Oil Capacity 3.08 L (3.25 U.S. qt)

Gasoline (recommended) 87 Octane Regular

Unleaded

Engine Oil (recommended) SAE 5W-30

Differential/Rear Drive Lubricant SAE Approved

80W-90 Hypoid

Brake Fluid DOT 4

Taillight/Brakelight 12V/8W/27W

Headlight 12V/37W (2)

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1-4

General Specifications*

(500 — Manual Transmission)

* Specifications subject to change without notice.

** At the oil level plug threads.

*** At the filler plug threads.

CARBURETOR

Typ e Ke i hi n C V K3 6

Main Jet 138

Slow Jet 40

Pilot Screw Setting (turns) 1 3/4

Jet Needle NFKG

Idle RPM

(engine warm)

1250-1350

Starter Jet 85

Float Arm

Height

17 mm (0.7 in.)

Throttle Cable Free-Play (at

lever)

3-6 mm (1/8-1/4 in.)

ELECTRICAL

Ignition Timing 10° BTDC @ 1500 RPM

Spark Plug Type NGK CR6E

Spark Plug Gap 0.7-0.8 mm (0.028-0.032

in.)

Spark Plug Cap 8000-12,000 ohms

Ignition Coil

Resistance

(primary)

(secondary)

Less than 1 ohm

(terminal to ground)

5200-7800 ohms

(high tension — plug cap

removed — to ground)

Ignition Coil

Peak Voltage

(primary/

CDI)

140-215 DC volts

(terminal to ground)

Magneto Coil

Resistance

(trigger)

(source)

(charging)

160-240 ohms

(green to blue)

Less than 1 ohm

(yellow to white)

Less than 1 ohm

(black to black)

Magneto Coil

Peak Voltage

(trigger)

(source)

4.2-6.3 volts

(green to blue)

0.40-0.62 volt

(yellow to white)

Stator Coil Out-

put

(no load) 60 AC volts @ 5000 RPM

(black to black #1)

(black to black #2)

Magneto Output (approx) 325W @ 5000 RPM

CHASSIS

Brake Type Hydraulic w/Brake Lever

Lock and Auxiliary Brake

Tire Size Front — 25 x 8-12

Rear — 25 x 10-12

Tire Inflation

Pressure

0.35 kg/cm² (5 psi)

MISCELLANY

Gas Tank Capacity (rated) 24.6 L (6.5 U.S. gal.)

Coolant Capacity 2.9 L (3.0 U.S. qt)

Differential Capacity 275 ml (9.3 fl oz)**

Rear Drive Capacity 250 ml (8.5 fl oz)***

Engine Oil Capacity 3.4 L (3.5 U.S. qt)

Gasoline (recommended) 87 Octane Regular

Unleaded

Engine Oil (recommended) SAE 5W-30

Differential/Rear Drive Lubricant SAE Approved

80W-90 Hypoid

Brake Fluid DOT 4

Taillight/Brakelight 12V/8W/27W

Headlight 12V/27W (2)

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1-5

1

General Specifications*

(500 — Automatic Transmission)

* Specifications subject to change without notice.

** At the oil level plug threads.

*** At the filler plug threads.

CARBURETOR

Type Keihin CVK36

Main Jet 138

Slow Jet 40

Pilot Screw Setting (turns) 1 3/4

Jet Needle NFKG

Idle RPM (engine warm) 1250-1350

Starter Jet 85

Float Arm Height 17 mm (0.7 in.)

Throttle Cable Free-Play

(at lever)

3-6 mm (1/8-1/4 in.)

ELECTRICAL

Ignition Timing 10° BTDC @ 1500 RPM

Spark Plug Type NGK CR6E

Spark Plug Gap 0.7-0.8 mm (0.028-0.032 in.)

Spark Plug Cap 8000-12,000 ohms

Ignition Coil

Resistance

(primary)

(secondary)

Less than 1 ohm

(terminal to ground)

5200-7800 ohms

(high tension — plug cap

removed — to ground)

Ignition Coil Peak

Voltage

(primary/

CDI)

140-215 DC volts

(terminal to ground)

Magneto Coil

Resistance

(trigger)

(source)

(charging)

160-240 ohms

(green to blue)

Less than 1 ohm

(yellow to white)

Less than 1 ohm

(black to black)

Magneto Coil

Peak Voltage

(trigger)

(source)

4.2-6.3 volts

(green to blue)

0.40-0.62 volt

(yellow to white)

Stator Coil Output (no load) 60 AC volts @ 5000 RPM

(black to black #1)

(black to black #2)

Magneto Output (approx) 325W @ 5000 RPM

CHASSIS

Brake Type Hydraulic w/Brake Lever

Lock and Auxiliary Brake

Tire Size Front — 25 x 8-12

Rear — 25 x 10-12

Tire Inflation Pressure 0.35 kg/cm² (5 psi)

MISCELLANY

Gas Tank Capacity (rated) 24.6 L (6.5 U.S. gal.)

Coolant Capacity 2.9 L (3.0 U.S. qt)

Differential Capacity 275 ml (9.3 fl oz)**

Rear Drive Capacity 250 ml (8.5 fl oz)***

Engine Oil Capacity 2.5 L (2.6 U.S. qt)

Gasoline (recommended) 87 Octane Regular

Unleaded

Engine Oil (recommended) SAE 5W-30

Differential/Rear Drive Lubricant SAE Approved

80W-90 Hypoid

Drive Belt Width (minimum) 38 mm (1.33 in.)

Brake Fluid DOT 4

Taillight/Brakelight 12V/8W/27W

Headlight 12V/27W (2)

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1-6

General Specifications*

(650 H1/650 H1 TBX/650 H1 TRV)

* Specifications subject to change without notice.

** At the oil level plug threads.

*** At the filler plug threads.

CARBURETOR

Type Keihin CVK36

Main Jet 132

Slow Jet 40

Pilot Screw Setting (turns) 1 1/4

Jet Needle NFKS

Idle RPM (engine warm) 1250-1350

Starter Jet 85

Float Arm Height 17 mm (0.7 in.)

Throttle Cable Free-Play

(at lever)

3-6 mm (1/8-1/4 in.)

ELECTRICAL

Ignition Timing 10° BTDC @ 1500 RPM

Spark Plug Type NGK CR6E

Spark Plug Gap 0.7-0.8 mm (0.028-0.032

in.)

Spark Plug Cap 4000 ohms

Ignition Coil

Resistance

(primary)

(secondary)

Less than 1 ohm

(terminal to ground)

5200-7800 ohms

(high tension — plug cap

removed — to ground)

Ignition Coil Peak

Voltage

(primary/

CDI)

142.4-213.6 DC volts

(terminal to ground)

Magneto Coil

Resistance

(trigger)

(source)

(charging)

160-240 ohms

(green to blue)

Less than 1 ohm

(yellow to white)

Less than 1 ohm

(black to black)

Magneto Coil

Peak Voltage

(trigger)

(source)

4.2-6.3 volts

(green to blue)

0.40-0.62 volt

(yellow to white)

Stator Coil Output (no load) 60 AC volts @ 5000 RPM

(black to black #1)

(black to black #2)

Magneto Output (approx) 325W @ 5000 RPM

CHASSIS

Brake Type Hydraulic w/Brake Lever

Lock and Auxiliary Brake

Tire Size Front — 25 x 8-12

Rear — 25 x 10-12

Tire Inflation Pressure 0.35 kg/cm² (5 psi)

MISCELLANY

Gas Tank Capacity (rated) 24.6 L (6.5 U.S. gal.)

20.8 L (5.5 U.S. gal.) — TBX/

TRV

Coolant Capacity 2.9 L (3.0 U.S. qt)

Differential Capacity 275 ml (9.3 fl oz)**

Rear Drive Capacity 250 ml (8.5 fl oz)***

Engine Oil Capacity 3.4 L (3.5 U.S. qt)

Gasoline (recommended) 87 Octane Regular

Unleaded

Engine Oil (recommended) SAE 5W-30

Differential/Rear Drive Lubricant SAE Approved

80W-90 Hypoid

Belt Width 35.5 mm (1.40 in.)

Brake Fluid DOT 4

Taillight/Brakelight 12V/8W/27W

Headlight 12V/27W (2)

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1-7

1

General Specifications*

(700 EFI)

* Specifications subject to change without notice.

** One inch below plug threads.

*** At the plug threads.

FUEL INJECTION

Type Electronic Throttle Body

Idle RPM (engine warm) 1200-1400

Throttle Cable Free-Play

(at lever)

3-6 mm (1/8-1/4 in.)

ELECTRICAL

Spark Plug Type NGK CR6E

Spark Plug Gap 0.7-0.8 mm (0.028-0.032 in.)

Spark Plug Cap 8000-12,000 ohms

Ignition Coil

Resistance

(primary)

(secondary)

Less than 1 ohm

(terminal (+) to terminal (-))

12k-19k ohms

(plug cap to terminal (+))

Ignition Coil Peak

Voltage

(ECU) 80 volts or more

(wire (+) to wire (-))

Stator Coil (crankshaft position

Resistance sensor)

(charging)

150-250 ohms

(blue to white)

Less than 1 ohm

(yellow to yellow)

Crankshaft Position Sensor

Peak Voltage

5.0 volts or more

(blue to white)

Stator Coil Output (no load) 75 AC volts @ 5000 RPM

(yellow to yellow)

CHASSIS

Brake Type Hydraulic w/Brake Lever

Lock and Auxiliary Brake

Tire Size Front — 25 x 8-12

Rear — 25 x 10-12

Tire Inflation Pressure 0.35 kg/cm² (5 psi)

MISCELLANY

Gas Tank Capacity (rated) 24.6 L (6.5 U.S. gal.)

Coolant Capacity 2.9 L (3.0 U.S. qt)

Differential Capacity 275 ml (9.3 fl oz)**

Rear Drive Capacity 250 ml (8.5 fl oz)***

Engine Oil Capacity 2.45 L (2.6 U.S. qt)

Gasoline (recommended) 87 Octane Regular

Unleaded

Engine Oil (recommended) SAE 5W-30

Differential/Rear Drive Lubricant SAE Approved

80W-90 Hypoid

Drive Belt Width (minimum) 35.6 mm (1.40 in.)

Brake Fluid DOT 4

Taillight/Brakelight 12V/8W/27W

Headlight 12V/27W (2)

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1-8

Break-In Procedure

A new ATV and an overhauled ATV engine require

a “break-in” period. The first 10 hours (or 200

miles) are most critical to the life of this ATV.

Proper operation during this break-in period will

help assure maximum life and performance from the

ATV.

During the first 10 hours (or 200 miles) of operation,

always use less than 1/2 throttle. Varying the engine

RPM during the break-in period allows the compo-

nents to “load” (aiding the mating process) and then

“unload” (allowing components to cool). Although

it is essential to place some stress on the engine

components during break-in, care should be taken

not to overload the engine too often. Do not pull a

trailer or carry heavy loads during the 10-hour

break-in period.

When the engine starts, allow it to warm up prop-

erly. Idle the engine several minutes until the engine

has reached normal operating temperature. Do not

idle the engine for excessively long periods of time.

During the break-in period, a maximum of 1/2 throt-

tle is recommended; however, brief full-throttle

accelerations and variations in driving speeds con-

tribute to good engine break-in.

During the break-in period (or whenever the brake

pads are replaced), the hydraulic brake pads must be

burnished. Slow disc-speed hydraulic brakes must

be properly burnished in order to achieve maximum

stopping power.

NOTE: Do not be reluctant to heat up the brake

pads during the burnishing procedure.

After the completion of the break-in period, the

engine oil and oil filter should be changed. Other

maintenance after break-in should include checking

of all prescribed adjustments and tightening of all

fasteners.

Gasoline — Oil —

Lubricant

RECOMMENDED GASOLINE

The recommended gasoline to use is 87 minimum

octane regular unleaded. In many areas, oxygenates

(either ethanol or MTBE) are added to the gasoline.

Oxygenated gasolines containing up to 10% ethanol,

5% methane, or 5% MTBE are acceptable gasolines.

When using ethanol blended gasoline, it is not nec-

essary to add a gasoline antifreeze since ethanol will

prevent the accumulation of moisture in the fuel sys-

tem.

RECOMMENDED ENGINE/

TRANSMISSION OIL

The recommended oil to use is Arctic Cat 4-Cycle

Engine Oil or an equivalent oil which is rated SE,

SF, or SG under API service classification. These

oils meet all of the lubrication requirements of the

Arctic Cat ATV engine. The recommended engine

oil viscosity is SAE 5W-30. Ambient temperature

should determine the correct weight of oil. See the

following viscosity chart for details.

! CAUTION

BRAKE PADS MUST BE BURNISHED TO ACHIEVE

FULL BRAKING EFFECTIVENESS. Braking distance

will be extended until brake pads are properly bur-

nished.

TO PROPERLY BURNISH THE BRAKES, USE FOL-

LOWING PROCEDURE:

• Choose an area sufficiently large to safely accel-

erate ATV to 30 mph and to brake to a stop.

• Accelerate to 30 mph; then compress brake lever

to decelerate to 0-5 mph.

• Repeat procedure five times until brakes are bur-

nished.

• This procedure burnishes the brake pads, stabi-

lizes the pad material, and extends the life of the

brake pads.

! WARNING

Do not attempt sudden stops or put the ATV into a

situation where a sudden stop will be required until

the brake pads are properly burnished.

! CAUTION

Do not use white gas. Only Arctic Cat approved gas-

oline additives should be used.

! CAUTION

Any oil used in place of the recommended oil could

cause serious engine damage. Do not use oils which

contain graphite or molybdenum additives. These

oils can adversely affect clutch operation. Also, not

recommended are racing, vegetable, non-detergent,

and castor-based oils.

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1-9

1

OILCHARTC

RECOMMENDED FRONT

DIFFERENTIAL/REAR DRIVE

LUBRICANT

The recommended lubricant is Arctic Cat Gear Lube

or an equivalent gear lube which is SAE approved

80W-90 hypoid. This lubricant meets all of the

lubrication requirements of the Arctic Cat ATV

front differentials and rear drives.

FILLING GAS TANK

ATV0049B

Since gasoline expands as its temperature rises, the

gas tank must be filled to its rated capacity only.

Expansion room must be maintained in the tank par-

ticularly if the tank is filled with cold gasoline and

then moved to a warm area.

Tighten the gas tank cap securely after filling the

tank.

Genuine Parts

When replacement of parts is necessary, use only

genuine Arctic Cat ATV parts. They are precision-

made to ensure high quality and correct fit. Refer to

the appropriate Illustrated Parts Manual for the cor-

rect part number, quantity, and description.

Preparation

For Storage

Arctic Cat recommends the following procedure to

prepare the ATV for storage.

1. Clean the seat cushion (cover and base) with a

damp cloth and allow it to dry.

2. Clean the ATV thoroughly by washing dirt, oil,

grass, and other foreign matter from the entire

ATV. Allow the ATV to dry thoroughly. DO

NOT get water into any part of the engine or air

intake.

! CAUTION

Any lubricant used in place of the recommended

lubricant could cause serious front differential/rear

drive damage.

! WARNING

Always fill the gas tank in a well-ventilated area.

Never add fuel to the ATV gas tank near any open

flames or with the engine running. DO NOT SMOKE

while filling the gas tank.

! WARNING

Do not overflow gasoline when filling the gas tank. A

fire hazard could materialize. Always allow the

engine to cool before filling the gas tank.

! WARNING

Do not over-fill the gas tank.

! CAUTION

Prior to storing the ATV, it must be properly serviced

to prevent rusting and component deterioration.

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1-10

3. Either drain the gas tank or add Fuel Stabilizer

to the gas in the gas tank. Remove the air filter

housing cover and air filter. Start the engine and

allow it to idle; then using Arctic Cat Engine

Storage Preserver, rapidly inject the preserver

into the air filter opening for a period of 10 to 20

seconds; then stop the engine. Install the air fil-

ter and housing cover.

4. On carbureted models, drain the carburetor float

chamber.

5. Plug the exhaust hole in the exhaust system with

a clean cloth.

6. Apply light oil to the upper steering post bush-

ing and plungers of the shock absorbers.

7. Tighten all nuts, bolts, cap screws, and screws.

Make sure rivets holding components together

are tight. Replace all loose rivets. Care must be

taken that all calibrated nuts, cap screws, and

bolts are tightened to specifications (see Section

10).

8. On liquid cooled models, fill the cooling system

to the bottom of the stand pipe in the radiator

neck with properly mixed coolant.

9. Disconnect the battery cables; then remove the

battery, clean the battery posts and cables, and

store in a clean, dry area.

10. Store the ATV indoors in a level position.

Preparation After

Storage

Taking the ATV out of storage and correctly prepar-

ing it will assure many miles and hours of trouble-

free riding. Arctic Cat recommends the following

procedure to prepare the ATV.

1. Clean the ATV thoroughly.

2. Clean the engine. Remove the cloth from the

exhaust system.

3. Check all control wires and cables for signs of

wear or fraying. Replace if necessary.

4. Change the engine/transmission oil and filter.

5. On liquid cooled models, check the coolant level

and add properly mixed coolant as necessary.

6. Charge the battery; then install. Connect the bat-

tery cables.

7. Check the entire brake systems (fluid level,

pads, etc.), all controls, headlights, taillight,

brakelight, and headlight aim; adjust or replace

as necessary.

8. Tighten all nuts, bolts, cap screws, and screws

making sure all calibrated nuts, cap screws, and

bolts are tightened to specifications (see Section

10).

9. Check tire pressure. Inflate to recommended

pressure as necessary.

10. Make sure the steering moves freely and does

not bind.

11. Check the spark plug. Clean or replace as neces-

sary.

! CAUTION

If the interior of the air filter housing is dirty, clean

the area before starting the engine.

! CAUTION

Avoid storing outside in direct sunlight and avoid

using a plastic cover as moisture will collect on the

ATV causing rusting.

! CAUTION

The ignition switch must be in the OFF position prior

to installing the battery or damage may occur to the

ignition system.

! CAUTION

Connect the positive battery cable first; then the

negative.

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2-1

2

SECTION 2 —

PERIODIC MAINTENANCE/TUNE-UP

TABLE OF

CONTENTS

Periodic Maintenance Chart………………………….….. 2-2

Lubrication Points…………………………….………….….. 2-3

Battery…………………….……………..…………….……….. 2-3

Fuses …………..………………………..…………….……….. 2-4

Air Cleaner/Filter ………………………..…………….…….. 2-4

Valve/Tappet Clearance

(Feeler Gauge Procedure) …………..…………….….. 2-6

Valve/Tappet Clearance

(Valve Adjuster Procedure) ……………….…………… 2-6

Valve/Tappet Clearance (700 EFI)…………….……….. 2-7

Testing Engine Compression………..…………….…….. 2-9

Spark Plug…….…………….………….…………….……… 2-10

Muffler/Spark Arrester …………..…………….…………. 2-10

Gas/Vent Hoses …………………..…………….…………. 2-11

Adjusting Throttle Cable ……..…………….………….… 2-11

Adjusting Engine RPM (Idle) ….…………….…………. 2-11

Engine/Transmission Oil — Filter — Strainer ………… 2-12

Front Differential/Rear Drive Lubricant ……………… 2-14

Adjusting Clutch

(400/500 Manual Transmission) ……………….…… 2-14

Tires …………….………………………..…………….……… 2-15

Steering Components ……………………………….…… 2-15

Driveshaft/Coupling …………………….…………….…… 2-15

Suspension/Shock Absorbers/Bushings …………… 2-16

Nuts/Bolts/Cap Screws……………..…………….……… 2-16

Ignition Timing………….……………..…………….……… 2-16

Headlight/Taillight-Brakelight ………………..…………. 2-16

Switches ………….………….…………….…………….…… 2-17

Shift Lever ……….………….…………….…………….…… 2-18

Frame/Welds/Racks ……………………………….……… 2-19

Electrical Connections…..…………….…………….…… 2-19

Hydraulic Brake Systems ……………….…………….… 2-20

Burnishing Brake Pads….…………….…………….…… 2-21

Coolant (500/650 H1/700 EFI) …………..……………. 2-22

Checking/Replacing V-Belt ………….…………….…… 2-22

Adjusting Differential Lock Cable……..………….…… 2-24

Exhaust Chart .…………….…………….………….……… 2-25

Intake Chart…..…………….…………….………….……… 2-26

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Periodic Maintenance

Chart

A = Adjust I = Inspect

C = Clean L = Lubricate

D = Drain R = Replace

* Service/Inspect more frequently when operating in adverse conditions.

Item

Initial Service

After Break-In

(First Mo or

100 Mi)

Every

Day

Every

Month or

Every

100 Miles

Every 3

Months

or Every

300 Miles

Every 6

Months

or Every

500 Miles

Every

Year or

Every

1500 Miles

As

Needed

Battery I I C

Fuses IR

Air Filter/Drain Tube I I C* R

Valve/Tappet Clearance I I A

Engine Compression I

Spark Plug I I R (4000 Mi

or 18 Mo)

Muffler/Spark Arrester CR

Gas/Vent Hoses I I R (2 Yrs)

Throttle Cable I I C-L A-R

Carburetor Float Chamber

(Carbureted Models)

D*

Engine Idle RPM

(Carbureted Models)

IIA

Engine-Transmission Oil Level I A

Engine-Transmission Oil/Filter R R* R

Oil Strainer I I C

Front Differential/Rear Drive Lubri-

cant

IR (4 Yrs)

Clutch (Manual) I l A

Tires/Air Pressure I I R

Steering Components I I I R

V-Belt (Automatic) I l R

Suspension (Ball joint boots, drive

axle boots front and rear, tie rods,

differential and rear drive bellows)

Il* R

Nuts/Cap Screws/Screws I I I A

Ignition Timing I

Headlight/Taillight-Brakelight I I R

Switches I I R

Shift Lever IA—L

Recoil Starter

(Except certain 650 H1 models)

IC—R

Handlebar Grips I R

Handlebars I I R

Gauges/Indicators I I R

Frame/Welds/Racks I I l

Electrical Connections lC

Complete Brake System (Hydraulic

& Auxiliary)

II C L—R

Brake Pads I I* R

Brake Fluid I I R (2 Yrs)

Brake Hoses I I R (4 Yrs)

Coolant/Cooling System I I R (2 Yrs)

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2

Lubrication Points

It is advisable to lubricate certain components peri-

odically to ensure free movement. Apply light oil to

the components using the following list as reference.

A. Throttle Lever Pivot/Cable Ends

B. Brake Lever Pivot/Cable Ends

C. Auxiliary Brake Cable Ends

D. Shift Lever Cable End

E. Idle RPM Screw (Carburetor) (If Applicable)

Battery

The level of the battery fluid must be kept between

the upper and lower level lines at all times. If the

level drops below the lower level line, add only dis-

tilled water until it reaches upper level line.

If the battery is discharged, remove the battery from

the ATV and charge the battery at 1.5 amps for 10

hours.

To remove and charge the battery, use the following

procedure.

1. Remove the battery hold-down bracket.

2. Remove the negative battery cable; then remove

the positive cable and the battery vent tube.

Remove the battery from the ATV. Care should

be taken not to damage the vent tube.

3. Remove the vent plugs; then (if necessary) fill

the battery with distilled water to the upper

level indicated on the battery.

4. Trickle charge the battery at 1.5 amps for 10

hours.

5. After charging, check fluid level and fill with

distilled water as necessary; then install vent

plugs.

6. Place the battery into position in the ATV and

secure with the hold-down bracket.

7. Attach the vent tube and check the vent tube to

make sure it is not crimped or obstructed in any

way and that it is properly routed through and

secured to the frame.

8. Connect cables to the proper terminals: positive

cable to the positive terminal (+) and negative

cable to the negative terminal (-). Connect the

negative cable last.

! WARNING

Battery acid is harmful if it contacts eyes, skin, or

clothing. Care must be taken whenever handling a

battery.

! WARNING

Anytime service is performed on a battery, the fol-

lowing must be observed: keep sparks, open flame,

cigarettes, or any other flame away. Always wear

safety glasses. Protect skin and clothing when han-

dling a battery. When servicing battery in enclosed

space, keep the area well-ventilated. Make sure bat-

tery venting is not obstructed.

! WARNING

Avoid spillage and contact with skin, eyes, and

clothing.

! CAUTION

Do not charge the battery while it is in the ATV with

the battery terminals connected.

! CAUTION

Never exceed the standard charging rate.

! CAUTION

Before installing the battery, make sure the ignition

switch is in the OFF position.

! CAUTION

Connecting cables in reverse (positive to negative

and negative to positive) can cause serious damage

to the electrical system.

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Fuses

The fuses are located in a power distribution module

under the seat.

If there is any type of electrical system failure,

always check the fuses first.

NOTE: To remove a fuse, compress the locking

tabs on either side of the fuse case and lift out.

0411-828

0411-837

1411-502

1411-311

Air Cleaner/Filter

The air filter inside the air filter housing must be

kept clean to provide good engine power and gas

mileage. If the ATV is used under normal condi-

tions, service the filter at the intervals specified. If

operated in dusty, wet, or muddy conditions, inspect

and service the filter more frequently. Use the fol-

lowing procedure to remove the filter and inspect

and/or clean it.

CLEANING AND INSPECTING

FILTER

1. Remove the seat; then remove the appropriate

reinstallable rivets securing the storage compart-

ment.

CF145C

CD710C

400/400 TRV/500 Auto

400/500 Manual

650 H1/650 H1 TBX/650 H1 TRV

700 EFI

! CAUTION

Always replace a blown fuse with a fuse of the same

type and rating.

! CAUTION

Failure to inspect the air filter frequently if the vehi-

cle is used in dusty, wet, or muddy conditions can

damage the engine.

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2

2. On the 400, remove the storage compartment

assembly by elevating the rear of the compart-

ment, moving it rearward, and lifting it off.

CF143A

3. On the 500/650 H1/700 EFI, raise the storage

compartment cover; then slide the cover forward

and off the compartment. Remove the storage

compartment.

CD669

4. Unsnap the four spring-clip fasteners

(400/500/650 H1) or remove two wing-nuts

(700 EFI); then remove the air filter cover.

CD675A

FI033

5. Remove the air filter/filter screen assembly and

separate the foam filter from the screen.

6. Fill a wash pan larger than the filter with a

non-flammable cleaning solvent; then dip the

filter in the solvent and wash it.

NOTE: Foam Air Filter Cleaner and Foam Air Fil-

ter Oil are available from Arctic Cat.

7. Dry the filter.

8. Put the filter in a plastic bag; then pour in air fil-

ter oil and work the filter. Reattach the filter to

the filter screen.

9. Clean any dirt or debris from inside the air

cleaner. Be sure no dirt enters the carburetor (if

equipped).

10. Place the filter assembly in the air filter housing

making sure it is properly positioned and prop-

erly seated with the filter screen down.

CD674

! CAUTION

A torn air filter can cause damage to the ATV engine.

Dirt and dust may get inside the engine if the ele-

ment is torn. Carefully examine the element for tears

before and after cleaning it. Replace the element

with a new one if it is torn.

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11. Install the air filter housing cover and secure

with the retaining clips (400/500/650 H1) or

wing-nuts (700 EFI).

12. Install the storage compartment; then secure

with the reinstallable rivets.

CHECKING AND CLEANING

DRAINS

1. Inspect one-way drains beneath the main hous-

ing for debris and for proper sealing.

KX045A

2. Replace any one-way drain that is cracked or

shows any signs of hardening or deterioration.

3. Wipe any accumulation of oil or gas from the

filter housing and one-way drains.

Valve/Tappet

Clearance

(Feeler Gauge Procedure)

NOTE: For the 700 EFI, see Valve/Tappet Clear-

ance (700 EFI) in this section.

To check and adjust valve/tappet clearance, use the

following procedure.

1. Remove the timing inspection plug; then

remove the tappet covers (for more detailed

information, see Section 3 — Servicing Top-Side

Components).

2. Rotate the crankshaft to the TDC position on the

compression stroke.

NOTE: At this point, the rocker arms and

adjuster screws must not have pressure on them.

3. Using a feeler gauge, check each valve/tappet

clearance. If clearance is not within specifica-

tions, loosen the jam nut and rotate the tappet

adjuster screw until the clearance is within spec-

ifications. Tighten each jam nut securely after

completing the adjustment.

CC007DB

4. Install the timing inspection plug.

5. Place the two tappet covers into position making

sure the proper cap screws are with the proper

cover. Tighten the cap screws securely.

Valve/Tappet Clearance

(Valve Adjuster Procedure)

NOTE: For the 700 EFI, see Valve/Tappet Clear-

ance (700 EFI) in this section.

To check and adjust valve/tappet clearance, use the

following procedure.

! CAUTION

The one-way drain to the right is the clean air sec-

tion of the filter housing. Any leak of this one-way

drain will allow dirt into the engine intake causing

severe engine damage.

! CAUTION

The feeler gauge must be positioned at the same

angle as the valve and valve adjuster for an accurate

measurement of clearance. Failure to measure the

valve clearance accurately could cause valve com-

ponent damage.

VALVE/TAPPET CLEARANCE (400/500)

Intake 0.05-0.10 mm (0.002-0.004 in.)

Exhaust (400) 0.22-0.27 mm (0.009-0.011 in.)

Exhaust (500) 0.17-0.22 mm (0.007-0.009 in.)

VALVE/TAPPET CLEARANCE (650 H1)

Intake 0.1016 mm (0.004 in.)

Exhaust 0.1524 mm (0.006 in.)

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2

NOTE: On the TBX/500/650 H1, the seat, storage

compartment cover assembly, compartment box,

air filter/filter housing, and left-side/right-side

splash panels must be removed for this procedure.

1. Remove the timing inspection plug; then

remove the tappet covers (for more detailed

information, see Section 3 — Servicing Top-Side

Components).

CF005

2. Rotate the crankshaft to the TDC position on the

compression stroke.

NOTE: At this point, the rocker arms and

adjuster screws must not have pressure on them.

NOTE: Use Valve Clearance Adjuster (p/n

0444-078) for this procedure.

3. Place the valve adjuster onto the jam nut secur-

ing the tappet adjuster screw; then rotate the

valve adjuster dial clockwise until the end is

seated in the tappet adjuster screw.

4. While holding the valve adjuster dial in place,

use the valve adjuster handle and loosen the jam

nut; then rotate the tappet adjuster screw clock-

wise until friction is felt.

5. Align the valve adjuster handle with one of the

marks on the valve adjuster dial.

6. While holding the valve adjuster handle in

place, rotate the valve adjuster dial counter-

clockwise until proper valve/tappet clearance is

attained.

NOTE: Refer to the appropriate specifications in

Feeler Gauge Procedure sub-section for the proper

valve/tappet clearance.

NOTE: Rotating the valve adjuster dial counter-

clockwise will open the valve/tappet clearance by

0.05 mm (0.002 in.) per mark.

7. While holding the adjuster dial at the proper

clearance setting, tighten the jam nut securely

with the valve adjuster handle.

8. Place the two tappet covers with O-rings into

position; then tighten the covers securely.

9. Install the spark plug; then install the timing

inspection plug.

Valve/Tappet

Clearance

(700 EFI)

To check and adjust valve/tappet clearance, use the

following procedure.

NOTE: The seat, heat shields, splash panels,

front rack, and front fenders must be removed for

this procedure (see Section 8).

1. Remove the spark plug cap/high tension lead;

then using compressed air, blow any debris from

around the spark plug.

2. Remove the recoil starter assembly; then

remove the valve timing inspection plug and the

cylinder head cover.

FI039A

3. Using an appropriate bar, rotate the engine

through two full revolutions; then while on the

compression stroke, align the TDC line on the

starter clutch with the index mark on the crank-

case.

! WARNING

Always wear safety glasses when using compressed

air.

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FI041A

NOTE: Rotating the engine ensures that any

trapped oil is squeezed from the tappets and tap-

pet shims. Oil trapped in these areas could result

in a false valve clearance reading.

4. Using an appropriate thickness gauge, measure

and record the clearance of both intake valves;

then measure and record the clearance of both

exhaust valves. Valve clearance must be within

specifications.

FI046

5. Identify the valves that are not within specifica-

tions; then remove the corresponding camshaft

(see Section 3 — Removing Top-Side Compo-

nents).

6. Mark the valve tappets in order to return them to

the proper position during assembly.

FI054

7. Fold a suitable towel and use it to plug the cam-

shaft drive passageway; then using a magnet,

remove the tappet and shim from the appropriate

valve.

FI055

FI056

8. Note the three digit number on the surface of the

tappet shim; then refer to the appropriate tappet

shim selection table at the end of this section for

the correct replacement.

VALVE/TAPPET CLEARANCE (700 EFI)

Intake 0.10-0.20 mm (0.004-0.008 in.)

Exhaust 0.20-0.30 mm (0.008-0.012 in.)

 AT THIS POINT

If valve clearance is within specifications, proceed

to step 12.

! CAUTION

When removing camshaft holders, use extreme care

not to drop alignment pins into the engine.

! CAUTION

If the camshaft passageway is not plugged, tappet

shims could fall into the engine crankcase.

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2

FI051

A. Measured tappet clearance from step 4 in ver-

tical column on left.

B. Present shim size horizontal row at the top.

C. Match measured clearance in vertical column

with current shim size in horizontal row to

find recommended replacement size.

9. Apply engine oil to both surfaces of the tappet

shim; then place the shim on the valve with the

numbers toward the tappet.

FI053

10. Install the tappet on the appropriate valve; then

install the camshaft.

11. Using an appropriate bar, rotate the engine

through two full revolutions; then rotate to TDC

on the compression stroke and check the valve

tappet clearance.

NOTE: Rotating the engine ensures that any

excess oil is squeezed from the tappets and tappet

shims. Oil trapped in these areas could result in a

false valve clearance reading.

12. Using a new gasket, apply Three Bond Sealant

to the camshaft end caps of the cylinder head

cover gasket; then install the cylinder head

cover and tighten the four cap screws to specifi-

cations (see Section 10).

13. Install the valve timing inspection plug and

tighten securely; then install the recoil starter

assembly and secure with the four cap screws

coated with blue Loctite #242. Tighten to speci-

fications (see Section 10).

14. Install the spark plug cap/high tension lead,

front fenders, front rack, and splash panels; then

install the heat shields and seat making sure the

seat locks securely.

Testing Engine

Compression

To test engine compression, use the following pro—

cedure.

1. Remove the high tension lead from the spark

plug.

2. Using compressed air, blow any debris from

around the spark plug.

3. Remove the spark plug; then attach the high ten-

sion lead to the plug and ground the plug on the

cylinder head well away from the spark plug

hole.

4. Attach the Compression Tester Kit (p/n

0444-213).

NOTE: The engine must be warm and the bat-

tery must be fully charged for this test.

5. While holding the throttle lever in the full-open

position, crank the engine over with the electric

starter until the gauge shows a peak reading

(five to 10 compression strokes).

NOTE: For the 400, the compression should be

within a range of 95-115 psi in the full-open throttle

position. For the 500/650 H1, the compression

should be within a range of 70-85 psi in the

full-open throttle position. For the 700 EFI, the

compression should be within a range of 130-155

psi in the full-open throttle position.

! WARNING

Always wear safety glasses when using compressed

air.

! CAUTION

On the 700 EFI, do not ground the spark plug on the

cylinder head cover. The cover is made of magne-

sium and any contact with spark or electrical arc will

severely pit the surface.

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6. If compression is abnormally low, inspect the

following items.

A. Verify starter cranks engine over at normal

speed (approximately 400 RPM).

B. Gauge functioning properly.

C. Throttle lever in the full-open position.

D. Valve/tappet clearance correct.

E. Valve not bent or burned.

F. Valve seat not burned.

NOTE: To service valves, see Section 3.

7. Pour 29.5 ml (1 fl oz) of oil into the spark plug

hole, reattach the gauge, and retest compression.

8. If compression is now evident, service the piston

rings (see Section 3).

Spark Plug

A light brown insulator indicates that a plug is cor-

rect. A white or dark insulator indicates that the

engine may need to be serviced or the carburetor (if

equipped) may need to be adjusted. To maintain a

hot, strong spark, keep the plug free of carbon.

ATV-0051

Adjust the gap to 0.7-0.8 mm (0.028-0.032 in.) for

proper ignition. Use a feeler gauge to check the gap.

ATV0052B

When installing the spark plug, be sure to tighten it

securely. A new spark plug should be tightened 1/2

turn once the washer contacts the cylinder head. A

used spark plug should be tightened 1/8 — 1/4 turn

once the washer contacts the cylinder head.

Muffler/Spark Arrester

The muffler has a spark arrester which must be peri-

odically cleaned. At the intervals shown in the Peri-

odic Maintenance Chart, clean the spark arrester

using the following procedure.

1. Remove the three cap screws securing the spark

arrester assembly to the muffler; then loosen and

remove the arrester.

CF105A

2. Using a suitable brush, clean the carbon deposits

from the screen taking care not to damage the

screen.

NOTE: If the screen or gasket is damaged in any

way, it must be replaced.

3. Install the spark arrester assembly with gasket;

then secure with the three cap screws. Tighten to

0.6 kg-m (4.0 ft-lb).

! CAUTION

Before removing a spark plug, be sure to clean the

area around the spark plug. Dirt could enter engine

when removing or installing the spark plug.

! WARNING

Wait until the muffler cools to avoid burns.

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2-11

2

CF104

Gas/Vent Hoses

Replace the gas hose every two years. Damage from

aging may not always be visible. Do not bend or

obstruct the routing of the carburetor/throttle body

vent hose. Make certain that the vent hose is

securely connected to the carburetor/throttle body

and the opposite end is always open.

Adjusting Throttle

Cable

To adjust the throttle cable free-play, follow this

procedure.

1. Slide the rubber boot away; then loosen the jam

nut from the throttle cable adjuster.

AL611D

2. Turn the adjuster until the throttle cable has

proper free-play of 3-6 mm (1/8-1/4 in.) at the

lever.

ATV-0047

3. Tighten the jam nut against the throttle cable

adjuster securely; then slide the rubber boot over

the adjuster.

Adjusting Engine RPM

(Idle)

NOTE: The idle RPM is not adjustable on the

700 EFI.

To properly adjust the idle RPM, a tachometer is

necessary. To adjust idle RPM, use the following

procedure.

NOTE: The idle adjustment screw is located on

the right-hand side of the carburetor.

1. With the transmission in neutral, start the engine

and warm it up to normal operating temperature.

2. Turn the idle adjustment screw clockwise one

turn past the recommended RPM setting; then

turn it counterclockwise to 1250-1350 RPM.

AF920D

! WARNING

Adjust the idle to the correct RPM. Make sure the

engine is at normal operating temperature before

adjusting the idle RPM.

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2-12

Engine/Transmission

Oil — Filter — Strainer

OIL — FILTER

Change the engine oil and oil filter at the scheduled

intervals. The engine should always be warm when

the oil is changed so the oil will drain easily and

completely.

1. Park the ATV on level ground.

2. Remove the oil level stick/filler plug.

ATV-0075

0735-505

3. Remove the drain plug from the bottom of the

engine and drain the oil into a drain pan.

733-441A

4. On the 400/500, remove the oil filter plug from

the filter mounting boss (located on the front

side of the transmission case) and allow the fil-

ter to drain completely. Install the plug and

tighten securely.

5. On the 700 EFI, remove the left-side engine

cover and the left-front inner fender panel.

6. Using the adjustable Oil Filter Wrench (p/n

0644-389) and a suitable wrench, remove the

old oil filter.

NOTE: Clean up any excess oil after removing

the filter.

7. Apply oil to a new filter O-ring and check to

make sure it is positioned correctly; then install

the new oil filter. Tighten securely.

NOTE: Install a new O-ring each time the filter is

replaced.

8. Install the engine drain plug and tighten to spec-

ifications. Pour the specified amount of the rec-

ommended oil in the filler hole. Install the oil

level stick/filler plug.

9. Start the engine (while the ATV is outside on

level ground) and allow it to idle for a few min-

utes.

10. Turn the engine off and wait approximately one

minute.

11. Unscrew the oil level stick and wipe it with a

clean cloth.

12. Install the oil level stick until the threads touch

engine case.

NOTE: The oil level stick should not be threaded

into the case for checking the oil level.

13. Remove the oil level stick; the engine oil level

should be above the illustrated “L” mark but not

higher than the illustrated “F” mark.

! CAUTION

Any oil used in place of the recommended oil could

cause serious engine damage. Do not use oils which

contain graphite or molybdenum additives. These

oils can adversely affect clutch operation. Also, not

recommended are racing, vegetable, non-detergent,

and castor-based oils.

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2-13

2

ATV-0100

14. Inspect the area around the drain plug and oil fil-

ter for leaks.

15. On the 700 EFI, install the left-side engine cover

and the left-front inner fender panel.

STRAINER

To check the oil strainer, use the following proce-

dure.

1. Remove the belly panel.

2. Remove the cap screws securing the oil strainer

cap; then remove the cap. Account for the

O-ring.

CC091D

3. Remove the two Phillips-head cap screws secur-

ing the strainer.

CC163D

4. Place the oil strainer into position beneath the

crankcase and secure with the Phillips-head cap

screws. Tighten securely.

CC163D

5. Place the strainer cap into position on the

strainer making sure the O-ring is properly

installed; then secure with the cap screws.

Tighten securely.

CC091D

6. Install the belly panel.

! CAUTION

Do not over-fill the engine with oil. Always make

sure that the oil level is above the “L” mark but not

higher than the “F” mark.

 AT THIS POINT

To service oil strainer, see Section 3.

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2-14

Front Differential/Rear

Drive Lubricant

Check and change the lubricant according to the

Periodic Maintenance Chart. When changing the

lubricant, use approved SAE 80W-90 hypoid gear

lube.

To check lubricant, remove the rear drive filler plug;

the lubricant level should be 1 in. below the threads

of the plug. If low, add SAE approved 80W-90

hypoid gear lube as necessary.

To change the lubricant, use the following proce-

dure.

1. Place the ATV on level ground.

2. Remove each oil fill plug.

AL677C

3. Drain the oil into a drain pan by removing in

turn the drain plug from each.

ATV0082A

737-651B

4. After all the oil has been drained, install the

drain plugs and tighten to specifications (see

Section 10).

5. Pour the appropriate amount of recommended

oil into the filler hole.

6. Install the fill plugs.

NOTE: If the differential/rear drive oil is contam-

inated with water, inspect the drain plug, filler

plug, and/or bladder.

Adjusting Clutch

(400/500 Manual Transmission)

To adjust the clutch, use the following procedure.

1. Using an impact driver, remove the screws

securing the cover and remove the cover.

Account for the O-ring.

AM600D

2. Loosen the jam nuts securing adjustment screw

#1 (forward) and adjustment screw #2 (rear-

ward).

! CAUTION

Water entering the outer end of the axle will not be

able to enter the rear drive unless the seals are dam-

aged.

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2-15

2

CC037D

3. Rotate adjustment screw #1 counterclockwise

until it stops.

CC038D

4. Rotate adjustment screw #2 alternately clock-

wise and counterclockwise to ensure free move-

ment without binding; then lock the jam nut

securing adjustment screw #2.

5. Rotate adjustment screw #1 clockwise 1/8 turn;

then lock the jam nut securing adjustment screw

#1.



NOTE: At this point the clutch should be adjusted

correctly. Test to ensure accurate adjustment.

6. Install the cover making sure the O-ring is prop-

erly positioned; then secure with the screws.

Tires

TIRE SIZES

The ATV is equipped with low-pressure tubeless

tires of the size and type listed (see Section 1). Do

not under any circumstances substitute tires of a dif-

ferent type or size.

TIRE INFLATION PRESSURE

Front and rear tire inflation pressure should be 0.35

kg-cm² (5.0 psi).

A low-pressure gauge is provided in the tool kit to

measure the air pressure in the tires. Check the air

pressure in all tires before each use of the ATV.

Steering Components

The following steering components should be

inspected periodically to ensure safe and proper

operation.

A. Handlebar grips not worn, broken, or loose.

B. Handlebar not bent, cracked, and has equal

and complete full-left and full-right capabil-

ity.

C. Steering post bearing assembly/bearing hous-

ing not broken, worn, or binding.

D. Ball joints not worn, cracked, or damaged.

E. Tie rods not bent or cracked.

F. Knuckles not worn, cracked, or damaged.

G. Cotter pins not damaged or missing.

Driveshaft/Coupling

The following drive system components should be

inspected periodically to ensure proper operation.

A. Spline lateral movement (slop).

B. Coupling cracked, damaged, or worn.

! WARNING

Always use the size and type of tires specified.

Always maintain proper tire inflation pressure.

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2-16

Suspension/Shock

Absorbers/Bushings

The following suspension system components

should be inspected periodically to ensure proper

operation.

A. Shock absorber rods not bent, pitted, or dam-

aged.

B. Rubber damper not cracked, broken, or miss-

ing.

C. Shock absorber body not damaged, punc-

tured, or leaking.

D. Shock absorber eyelets not broken, bent, or

cracked.

E. Shock absorber eyelet bushings not worn,

deteriorated, cracked, or missing.

F. Shock absorber spring not broken or sagging.

Nuts/Bolts/Cap Screws

Tighten all nuts, bolts, and cap screws. Make sure

rivets holding components together are tight.

Replace all loose rivets. Care must be taken that all

calibrated nuts, bolts, and cap screws are tightened

to specifications (see Section 10).

Ignition Timing

NOTE: The 700 EFI rotor/flywheel does not have

timing marks; therefore, timing cannot be verified.

The ignition timing cannot be adjusted; however,

verifying ignition timing can aid in troubleshooting

other components. To verify ignition timing, use the

following procedure.

1. Attach the Timing Light (p/n 0644-296) to the

spark plug high tension lead; then remove the

timing inspection plug from the left-side crank-

case cover.

2. Using the Tachometer (p/n 0644-275), start the

engine and run at 1500 RPM; ignition timing

should be 10° BTDC.

3. Install the timing inspection plug.

If ignition timing cannot be verified, the rotor may

be damaged, the key may be sheared, the trigger

coil/CKP sensor bracket may be bent or damaged, or

the CDI unit/ECU may be faulty.

Headlight/Taillight-

Brakelight

Each time the ATV is used, lights should be checked

for proper function. Rotate the ignition switch to the

lights position; the headlights and taillight should

illuminate. Test the brakelight by compressing the

brake lever. The brakelight should illuminate.

HEADLIGHT

NOTE: The bulb portion of the headlight is frag-

ile. HANDLE WITH CARE. When replacing the

headlight bulb, do not touch the glass portion of

the bulb. If the glass is touched, it must be cleaned

with a dry cloth before installing. Skin oil residue

on the bulb will shorten the life of the bulb.

To replace the headlight bulb, use the following pro-

cedure.

1. Remove the wiring harness connector from the

back of the headlight.

2. Grasp the bulb housing, turn it counterclock-

wise, and remove the bulb.

3. Install the new bulb into the housing and rotate

it completely clockwise.

4. Install the wiring harness connector.

TAILLIGHT-BRAKELIGHT

To replace the taillight-brakelight bulb, use the fol-

lowing procedure.

1. Turn the bulb socket assembly counterclockwise

and remove from the housing.

! WARNING

Do not attempt to remove the bulb when it is hot.

Severe burns may result.

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2-17

2

CF135A

2. Pull the bulb straight out of the socket; then

insert a new bulb.

CF132A

3. Insert the bulb socket assembly into the housing

and turn it clockwise to secure.

CHECKING/ADJUSTING

HEADLIGHT AIM

The headlights can be adjusted vertically and hori-

zontally. The geometric center of the HIGH beam

light zone is to be used for vertical and horizontal

aiming.

1. Position the ATV on a level floor so the head-

lights are approximately 6.1 m (20 ft) from an

aiming surface (wall or similar aiming surface).

NOTE: There should be an average operating

load on the ATV when adjusting the headlight aim.

2. Measure the distance from the floor to the

mid-point of each headlight.

3. Using the measurements obtained in step 2,

make horizontal marks on the aiming surface.

4. Make vertical marks which intersect the hori-

zontal marks on the aiming surface directly in

front of the headlights.

5. Switch on the lights. Make sure the HIGH beam

is on. DO NOT USE LOW BEAM.

6. Observe each headlight beam aim. Proper aim is

when the most intense beam is centered on the

vertical mark 5 cm (2 in.) below the horizontal

mark on the aiming surface.

ATV-0070C

7. Adjust each headlight by turning the adjuster

knob clockwise to raise the beam or counter-

clockwise to lower the beam.

CD714A

Switches

Each time the ATV is used, switches should be

checked for proper operation. Use the following list

for reference.

A. Ignition switch — engine will start.

B. Emergency stop switch — engine will stop.

C. Reverse switch — reverse indicator light will

illuminate.

D. Hi/Lo switch — headlight beam bright and

dim.

E. Brake switches — rear brakelight will illumi-

nate.

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2-18

Shift Lever

CHECKING ADJUSTMENT

CF150B

CF238A

CF130A

Stop the ATV completely and shift the transmission

into the R position. The reverse gear indicator light

should be illuminated.

If the reverse light does not illuminate when shifted

to the reverse position, the switch may be faulty, the

fuse may be blown, the bulb may be faulty, a con-

nection may be loose or corroded, or the lever may

need adjusting. To adjust, proceed to Adjusting Shift

Lever.

ADJUSTING SHIFT LEVER

0739-739

0739-701

1. Place the shift lever in the R position; then

remove the seat.

NOTE: Steps 2-8 are for all models except the

700 EFI. For the 700 EFI, proceed to step 9.

! WARNING

Never shift the ATV into reverse gear when the ATV

is moving as it could cause the ATV to stop sud-

denly throwing the operator from the ATV.

KEY

1. Handle

2. Push Clip

3. Shift Plate

4. Stamped Nut

5. Lever

6. Spring

7. Axle

8. Nut

9. O-Ring

10. Axle

11. O-Ring

12. Cap Screw

13. Washer

14. Nut

15. Rod End

16. Linkage

17. Bushing

18. Washer

19. E-Ring

400/500 Manual Transmission

KEY

1. Handle

2. Push Clip

3. Shift Plate

4. Stamped Nut

5. Lever

6. Spring

7. Axle

8. Nut

9. O-Ring

10. Axle

11. O-Ring

12. Cap Screw

13. Washer

14. Nut

15. Rod End

16. Linkage

17. Bushing

18. Washer

19. E-Ring

400/500 Automatic Transmission/

650 H1/700 EFI

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2-19

2

2. Remove the left-side splash panel.

3. Loosen shift rod end jam nut (A).

AF941A

4. Using two open-end wrenches, remove lock nut

(B) securing the shift rod to the upper shift axle.

Discard the lock nut.

NOTE: Never reuse a lock nut. Once a lock nut

has been removed, it must be replaced with a new

lock nut.

5. Push the upper shift axle down completely.

6. Rotate the shift rod end as necessary to align its

threaded shaft with the hole in the upper shift

axle. Secure with a new lock nut (B). Tighten

securely.

7. Tighten jam nut (A) to secure the adjustment.

8. Install the left-side splash panel; then install the

seat.

9. Loosen the front shift rod jam nut (1) (left-hand

threads); then loosen the rear shift rod jam nut

(2) (right-hand threads).

FI059A

FI010A

10. Turn the ignition switch to the ON position; then

move the shift arm (3) until the Neutral icon (N)

appears on the LCD.

11. Rotate the shift rod (4) until the shifter is

directly aligned with the Neutral position on the

shift gate.

12. While holding the shift rod with an open-end

wrench, tighten the shift rod jam nuts securely.

13. Shift the transmission into each of the remaining

positions and verify that the appropriate icon is

displayed for the selected gear shift position (H —

High, L — Low, and R — Reverse).

NOTE: An E (Error) in the gear position icon

indicates no signal or a poor ground wire connec-

tion in the circuit. Troubleshoot the harness con-

nectors, gear shift position connector, gear shift

position switch, and LCD connector.

Frame/Welds/Racks

The frame, welds, and racks should be checked peri-

odically for damage, bends, cracks, deterioration,

broken components, and missing components. If

replacement or repair constitutes removal, see Sec-

tion 8.

Electrical Connections

The electrical connections should be checked peri-

odically for proper function. In case of an electrical

failure, check fuses, connections (for tightness, cor-

rosion, damage), and/or bulbs. If an electrical com-

ponent needs to be tested for proper function, see

Section 5.

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2-20

Hydraulic

Brake Systems

CHECKING/BLEEDING

The hydraulic brake systems have been filled and

bled at the factory. To check and/or bleed a hydrau-

lic brake system, use the following procedure.

1. With the master cylinder in a level position,

check the fluid level in the reservoir. If the level

in the reservoir is not visible in the sight glass,

add DOT 4 brake fluid.

738-420A

AL681

2. Compress the brake lever/pedal several times to

check for a firm brake. If the brake is not firm,

the system must be bled.

3. To bleed the brake system, use the following

procedure.

A. Remove the cover and fill the reservoir with

DOT 4 Brake Fluid.

B. Install and secure the cover; then slowly

compress the brake lever several times.

C. Remove the protective cap, install one end of

a clear hose onto one FRONT bleeder screw,

and direct the other end into a container; then

while holding slight pressure on the brake

lever, open the bleeder screw and watch for

air bubbles. Close the bleeder screw before

releasing the brake lever. Repeat this proce-

dure until no air bubbles are present.

AF637D

PR377A

NOTE: During the bleeding procedure, watch the

reservoir sight glass very closely to make sure

there is always a sufficient amount of brake fluid.

When the sight glass changes from dark to light,

refill the reservoir before the bleeding procedure is

continued. Failure to maintain a sufficient amount

of fluid in the reservoir will result in air in the sys-

tem.

D. Repeat step C until the brake lever is firm.

E. At this point, perform step B, C, and D on the

other FRONT bleeder screw; then move to

the REAR bleeder screw and follow the same

procedure.

4. Carefully check the entire hydraulic brake system

that all hose connections are tight, the bleed

screws are tight, the protective caps are installed,

and no leakage is present.

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2-21

2

INSPECTING HOSES

Carefully inspect the hydraulic brake hoses for

cracks or other damage. If found, the brake hoses

must be replaced.

CHECKING/REPLACING PADS

The clearance between the brake pads and brake

discs is adjusted automatically as the brake pads

wear. The only maintenance that is required is

replacement of the brake pads when they show

excessive wear. Check the thickness of each of the

brake pads as follows.

1. Remove a front wheel.

2. Measure the thickness of each brake pad.

3. If thickness of either brake pad is less than 1.0

mm (0.039 in.), the brake pads must be replaced.

PR376B

NOTE: The brake pads should be replaced as a

set.

4. To replace the brake pads, use the following pro-

cedure.

A. Remove the wheel.

B. Remove the cap screws securing the caliper

holder to the knuckle; then remove the pads.

PR237

C. Install the new brake pads.

D. Secure the caliper to the knuckle and/or axle

housing with the cap screws. Tighten to spec-

ifications.

PR377B

E. Install the wheel. Tighten to specifications.

5. Burnish the brake pads (see Burnishing Brake

Pads in this section).

Burnishing Brake Pads

Brake pads (both hydraulic and auxiliary) must be

burnished to achieve full braking effectiveness.

Braking distance will be extended until brake pads

are properly burnished. To properly burnish the

brake pads, use the following procedure.

1. Choose an area large enough to safely accelerate

the ATV to 30 mph and to brake to a stop.

2. Accelerate to 30 mph; then compress brake

lever or apply the auxiliary brake to decelerate

to 0-5 mph.

! CAUTION

This hydraulic brake system is designed to use DOT

4 brake fluid only. If brake fluid must be added, care

must be taken as brake fluid is very corrosive to

painted surfaces.

! WARNING

Failure to properly burnish the brake pads could

lead to premature brake pad wear or brake loss.

Brake loss can result in severe injury.

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2-22

3. Repeat procedure on each brake system five

times until brake pads are burnished.

4. Adjust the auxiliary brake (if necessary).

5. Verify that the brakelight illuminates when the

hand lever is compressed or the brake pedal is

depressed.

Coolant

(500/650 H1/700 EFI)

The cooling system should be inspected daily for

leakage and damage. Also, the coolant level should

be checked periodically.

When filling the cooling system, use premixed Arc-

tic Cat Antifreeze. While the cooling system is

being filled, air pockets may develop; therefore, run

the engine for five minutes after the initial fill, shut

the engine off, and then fill the cooling system to the

bottom of the stand pipe in the radiator neck.

Checking/Replacing

V-Belt

REMOVING

1. Remove the right-side footrest (see Section 8).

2. Remove the cap screws securing the V-belt

cover noting the location of the differ-

ent-lengthed cap screws for installing purposes;

then using a rubber mallet, gently tap on the

cover tabs to loosen the cover. Remove the

cover.

CD078

NOTE: Note the location of the main engine

ground wire for installing purposes.

3. Remove the nut securing the movable drive

face; then remove the face. Account for the

spacer.

CC546

CC547

4. Remove the V-belt.

! CAUTION

After operating the ATV for the initial 5-10 minutes,

stop the engine, allow the engine to cool down, and

check the coolant level. Add coolant as necessary.

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2-23

2

CC550

INSTALLING

1. Spread the faces of the driven clutch by pushing

the inner face toward the engine while turning it

counterclockwise; then when the faces are sepa-

rated, insert a wedge (approximately 3/8 in.

thick) between the faces. Release the inner face.

CC549

2. Place the V-belt into position on the driven

clutch and over the front shaft.

CC550

NOTE: The arrow on the V-belt should point for-

ward.

3. Pinch the V—belt together near its center and

slide the spacer and movable drive face onto the

driveshaft. Secure the drive face with a nut.

Tighten the nut to specifications (see Section

10).

CC552

NOTE: At this point, the wedge can be removed

from between the driven clutch faces.

4. Rotate the V-belt and clutches until the V-belt is

flush with the top of the driven clutch.

5. Place the V-belt cover gasket into position; then

install the cover and secure with the cap screws

making sure the different-lengthed cap screws

are in their proper location. Tighten the cap

screws to specifications (see Section 10).

CD083

NOTE: Make sure the main engine ground wire

is installed and secured in the proper location.

6. Secure the front fender to the footrest with the

two cap screws. Tighten securely.

7. Install the right-side footrest (see Section 8).

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2-24

Adjusting Differential

Lock Cable

NOTE: The following procedure does not

include the 400 TRV model.

If the differential or differential lock system has

been serviced, the differential lock cable should be

checked and/or adjusted for proper free-play.

To adjust the cable, use the following procedure.

1. With the differential lock selector in the

UNLOCK position, slide the rubber boot (A) off

the adjuster; then loosen the jam nut (B). Turn

the adjuster (C) to achieve 6.35 mm (0.250 in.)

of free-play measured at the end of the differen-

tial lock lever.

CD560A

2. Select the 2WD position on the front drive

selector switch; then turn the ignition switch to

the ON position and select the LOCK position

on the differential lock selector. The front drive

actuator should operate engaging four-wheel

drive.

NOTE: It may be necessary to turn the handle-

bar or rock the ATV forward and backward to align

the differential lock splines and allow engagement.

3. Return the differential lock selector to the

UNLOCK position and listen for the front drive

actuator to operate.

4. Turn the ignition switch to the OFF position.

Tighten the jam nut securely; then install the

boot on the adjuster.

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2-25

2

Exhaust Chart

NOTE: Use this chart in conjunction with the

procedure found in Valve/Tappet Clearance (700

EFI) in this section.

ATV2152A

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2-26

Intake Chart NOTE: Use this chart in conjunction with the

procedure found in Valve/Tappet Clearance (700

EFI) in this section.

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3-1

3

SECTION 3 — ENGINE/TRANSMISSION

TABLE OF

CONTENTS

Engine/Transmission ……….…………….…………….….. 3-2

Specifications (400 — Automatic Transmission)…….. 3-3

Specifications (400 — Manual Transmission).……….. 3-4

Specifications (500 — Automatic Transmission)…….. 3-6

Specifications (500 — Manual Transmission).……….. 3-7

Specifications (650 H1) ……………………….…………… 3-9

Specifications (700 EFI) ………..…………….…………. 3-10

400 (Manual Transmission)

Table of Contents ……………..………….…………….… 3-11

400 (Automatic Transmission)

Table of Contents ……………..………….…………….… 3-76

500 (Automatic Transmission)/650 H1

Table of Contents ……………..………….…………….. 3-130

500 (Manual Transmission)

Table of Contents ……………..………….…………….. 3-185

700 EFI Table of Contents……………………….……. 3-256

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3-2

Engine/Transmission

This section has been organized into sub-sections

which show a progression for the complete servic-

ing of the Arctic Cat ATV engine/transmission.

To service the center crankcase halves, the

engine/transmission must be removed from the

frame.

To service top-side, left-side, and right-side compo-

nents, the engine/transmission does not have to be

removed from the frame.

NOTE: Arctic Cat recommends the use of new

gaskets, lock nuts, and seals and lubricating all

internal components when servicing the

engine/transmission.

NOTE: Some photographs and illustrations used

in this section are used for clarity purposes only

and are not designed to depict actual conditions.

NOTE: Critical torque specifications are located

in Section 10.

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3-3

3

Specifications*

(400 — Automatic Transmission)

* Specifications subject to change without notice.

VALVES AND GUIDES

Valve Face Diameter (intake)

(exhaust)

30.6 mm (1.20 in.)

27.0 mm (1.06 in.)

Valve/Tappet Clearance

(cold engine)

(intake)

(exhaust)

0.05-0.10 mm

(0.002-0.004 in.)

0.22-0.27 mm

(0.009-0.011 in.)

Valve Guide/Stem

Clearance

(intake)

(exhaust)

0.010-0.037 mm

(0.0004-0.0015 in.)

0.030-0.057 mm

(0.0012-0.0022 in.)

Valve Guide/Valve Stem

Deflection

(wobble deflection)

(max) 0.35 mm (0.014 in.)

Valve Guide Inside Diameter 5.000-5.012 mm

(0.1969-0.1973 in.)

Valve Stem Outside

Diameter

(intake)

(exhaust)

4.975-4.990 mm

(0.1959-0.1965 in.)

4.955-4.970 mm

(0.1951-0.1957 in.)

Valve Stem Runout (max) 0.05 mm (0.002 in.)

Valve Head Thickness (min) 0.5 mm (0.02 in.)

Valve Stem End Length (min) 2.3 mm (0.09 in.)

Valve Face/Seat Width 0.9-1.1 mm

(0.035-0.043 in.)

Valve Seat Angle (intake)

(exhaust)

45°

45°

Valve Face Radial Runout (max) 0.03 mm (0.001 in.)

Valve Spring Free Length (min) 38.8 mm (1.53 in.)

Valve Spring Tension

@ 32.5 mm (1.28 in.)

(outer) 18.6-21.4 kg

(41-47 lb)

CAMSHAFT AND CYLINDER HEAD

Cam Lobe Height (min) (intake)

(exhaust)

32.830 mm

(1.293 in.)

32.830 mm

(1.293 in.)

Camshaft Journal Oil

Clearance

(max) 0.15 mm (0.0059 in.)

Camshaft Journal Holder

Inside

(right & center)

(left)

22.012-22.025 mm

(0.8666-0.8671 in.)

17.512-17.525 mm

(0.6894-0.6900 in.)

Camshaft Journal

Outside Diameter

(right & center)

(left)

21.959-21.980 mm

(0.8645-0.8654 in.)

17.466-17.484 mm

(0.6876-0.6883 in.)

Camshaft Runout (max) 0.10 mm (0.004 in.)

Rocker Arm Inside Diameter 12.000-12.018 mm

(0.472-0.473 in.)

Rocker Arm Shaft Outside Diameter 11.973-11.984 mm

(0.4714-0.4718 in.)

Cylinder Head Distortion (max) 0.05 mm (0.002 in.)

Cylinder Head Cover

Distortion

(max) 0.05 mm (0.002 in.)

CYLINDER, PISTON, AND RINGS

Piston Skirt/Cylinder Clearance 0.060-0.073 mm

(0.0024-0.0029 in.)

Cylinder Bore 82.000-82.015 mm

(3.2283-3.2289 in.)

Piston Diameter 15 mm (0.6 in.)

from Skirt End

81.930-81.945 mm

(3.2256-3.2262 in.)

Piston Ring Free End Gap

(min)

(1st Ring)

(2nd Ring)

8.9 mm

(0.3504 in.)

8.3 mm

(0.3268 in.)

Bore x Stroke 82 x 71.2 mm

(3.29 x 2.80 in.)

Cylinder Trueness (max) 0.05 mm (0.002 in.)

Piston Ring End Gap — Installed 0.33-0.61 mm

(0.013-0.024 in.)

Piston Ring to Groove

Clearance (max)

(1st)

(2nd)

0.180 mm

(0.0071 in.)

0.150 mm

(0.0059 in.)

Piston Ring Groove Width (1st)

(2nd)

(oil)

1.01-1.03 mm

(0.0398-0.0406 in.)

1.01-1.03 mm

(0.0398-0.0406 in.)

2.01-2.03 mm

(0.0791-0.0799 in.)

Piston Ring Thickness (1st)

(2nd)

0.97-0.99 mm

(0.0381-0.0389 in.)

0.97-0.99 mm

(0.0381-0.0389 in.)

Piston Pin Bore (max) 20.03 mm (0.789 in.)

Piston Pin Outside Diameter (min) 19.98 mm (0.787 in.)

CRANKSHAFT

Connecting Rod

(small end inside diameter)

(max) 20.04 mm

(0.7889 in.)

Connecting Rod

(big end side-to-side)

0.10-0.55 mm

(0.004-0.022 in.)

Connecting Rod (big end width) 21.95-22.00 mm

(0.8642-0.8661 in.)

Connecting Rod

(small end deflection)

(max) 3 mm (0.12 in.)

Crankshaft (web-to-web) 59.9-60.1 mm

(2.358-2.366 in.)

Crankshaft Runout (max) 0.08 mm (0.003 in.)

Oil Pressure at 60°C

(140°F) @ 3000 RPM

(above)

(below)

1.1 kg/cm² (16 psi)

1.5 kg/cm² (21 psi)

Cooling Fan Thermo-Switch

Operating Temperature

(off J on)

(on J off)

120°C (248°F)

110°C (230°F)

Engine Oil Thermo-Switch

Operating Temperature

(off J on)

(on J off)

160°C (320°F)

140°C (284°F)

FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983

www.mymowerparts.com

3-4

Specifications*

(400 — Manual Transmission)

VALVES AND GUIDES

Valve Face Diameter (intake)

(exhaust)

30.6 mm (1.20 in.)

27.0 mm (1.06 in.)

Valve/Tappet Clearance

(cold engine)

(intake)

(exhaust)

0.05-0.10 mm

(0.002-0.004 in.)

0.22-0.27 mm

(0.009-0.011 in.)

Valve Guide/Stem

Clearance

(intake)

(exhaust)

0.010-0.037 mm

(0.0004-0.0015 in.)

0.030-0.057 mm

(0.0012-0.0022 in.)

Valve Guide/Valve Stem

Deflection

(wobble deflection)

(max) 0.35 mm (0.014 in.)

Valve Guide Inside Diameter 5.000-5.012 mm

(0.1969-0.1973 in.)

Valve Stem Outside

Diameter

(intake)

(exhaust)

4.975-4.990 mm

(0.1959-0.1965 in.)

4.955-4.970 mm

(0.1951-0.1957 in.)

Valve Stem Runout (max) 0.05 mm (0.002 in.)

Valve Head Thickness (min) 0.5 mm (0.02 in.)

Valve Stem End Length (min) 2.3 mm (0.09 in.)

Valve Face/Seat Width 0.9-1.1 mm

(0.035-0.043 in.)

Valve Seat Angle (intake)

(exhaust)

45°

45°

Valve Face Radial

Runout

(max) 0.03 mm (0.001 in.)

Valve Spring Free Length (min) 38.8 mm (1.53 in.)

Valve Spring Tension

@ 32.5 mm (1.28 in.)

(outer) 18.6-21.4 kg

(41-47 lb)

CAMSHAFT AND CYLINDER HEAD

Cam Lobe Height (min) (intake)

(exhaust)

32.830 mm (1.293 in.)

32.830 mm (1.293 in.)

Camshaft Journal Oil

Clearance

(max) 0.15 mm (0.0059 in.)

Camshaft Journal Holder

Inside

(right & center)

(left)

22.012-22.025 mm

(0.8666-0.8671 in.)

17.512-17.525 mm

(0.6894-0.6900 in.)

Camshaft Journal

Outside Diameter

(right & center)

(left)

21.959-21.980 mm

(0.8645-0.8654 in.)

17.466-17.484 mm

(0.6876-0.6883 in.)

Camshaft Runout (max) 0.10 mm (0.004 in.)

Rocker Arm Inside Diameter 12.000-12.018 mm

(0.472-0.473 in.)

Rocker Arm Shaft Outside Diameter 11.973-11.984 mm

(0.4714-0.4718 in.)

Cylinder Head Distortion (max) 0.05 mm (0.002 in.)

Cylinder Head Cover

Distortion

(max) 0.05 mm (0.002 in.)

CYLINDER, PISTON, AND RINGS

Piston Skirt/Cylinder

Clearance

0.060-0.073 mm

(0.0024-0.0029 in.)

Cylinder Bore 82.000-82.015 mm

(3.2283-3.2289 in.)

Piston Diameter 15 mm (0.6 in.) from

Skirt End

81.930-81.945 mm

(3.2256-3.2262 in.)

Piston Ring Free End Gap

(min)

(1st Ring)

(2nd Ring)

8.9 mm

(0.3504 in.)

8.3 mm

(0.3268 in.)

Bore x Stroke 82 x 71.2 mm

(3.29 x 2.80 in.)

Cylinder Trueness (max) 0.05 mm (0.002 in.)

Piston Ring End Gap — Installed 0.33-0.61 mm

(0.013-0.024 in.)

Piston Ring to Groove

Clearance (max)

(1st)

(2nd)

0.180 mm

(0.0071 in.)

0.150 mm

(0.0059 in.)

Piston Ring Groove Width (1st)

(2nd)

(oil)

1.01-1.03 mm

(0.0398-0.0406 in.)

1.01-1.03 mm

(0.0398-0.0406 in.)

2.01-2.03 mm

(0.0791-0.0799 in.)

Piston Ring Thickness (1st)

(2nd)

0.97-0.99 mm

(0.0381-0.0389 in.)

0.97-0.99 mm

(0.0381-0.0389 in.)

Piston Pin Bore (max) 20.03 mm (0.789 in.)

Piston Pin Outside Diameter (min) 19.98 mm (0.787 in.)

CRANKSHAFT

Connecting Rod

(small end inside diameter)

(max) 20.04 mm

(0.7889 in.)

Connecting Rod

(big end side-to-side)

0.10-0.55 mm

(0.004-0.022 in.)

Connecting Rod (big end width) 21.95-22.00 mm

(0.8642-0.8661 in.)

Connecting Rod

(small end deflection)

(max) 3 mm (0.12 in.)

Crankshaft (web-to-web) 59.9-60.1 mm

(2.358-2.366 in.)

Crankshaft Runout (max) 0.08 mm (0.003 in.)

Oil Pressure at 60°C

(140°F) @ 3000 RPM

(above)

(below)

0.6 kg/cm² (9 psi)

1.0 kg/cm² (14 psi)

Cooling Fan Thermo-Switch

Operating Temperature

(off J on)

(on J off)

120°C (248°F)

110°C (230°F)

Engine Oil Thermo-Switch

Operating Temperature

(off J on)

(on J off)

160°C (320°F)

140°C (284°F)

FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983

www.mymowerparts.com

3-5

3

* Specifications subject to change without notice.

CLUTCH

Clutch Release Screw 1/8 turn back

Drive Plate (fiber) Thickness (min) 2.62 mm (0.103 in.)

Drive Plate (fiber) Tab 13.25-13.95 mm

(0.52-0.55 in.)

Driven Plate (warpage) (max) 0.1 mm (0.004 in.)

Clutch Spring Length (min) 33.7 mm (1.33 in.)

Clutch Wheel Inside Diameter 140.0-140.2 mm

(5.511-5.520 in.)

Starter Clutch Shoe No groove at any part

Clutch Engagement RPM 1700 ± 200

Clutch Lock-Up RPM 3400 — 4000

Primary Reduction Ratio 2.392 (67/28)

Secondary Reduction Ratio 1.133 (17/15)

Final Reduction Ratio (front)

(rear)

3.6 (36/10)

3.6 (36/10)

Secondary Transmission

Reduction Ratio

(low)

(high)

2.435 (35/13 x 19/21)

1.296 (35/27)

Gear Ratios (1st)

(2nd)

(3rd)

(4th)

(5th)

(reverse)

3.083 (37/12)

1.933 (29/15)

1.388 (25/18)

1.095 (23/21)

0.913 (21/23)

2.833 (34/12)

Engine Fork to Groove

(side clearance)

0.1-0.3 mm

(0.004-0.012 in.)

Secondary Transmission Fork to Groove

(side clearance)

0.1-0.3 mm

(0.004-0.012 in.)

Reverse Fork to Groove

(side clearance)

0.1-0.3 mm

(0.004-0.012 in.)

Shift Fork Groove Width (#1 and #2) 4.5-4.6 mm

(0.177-0.181 in.)

(secondary transmission)

(reverse)

5.45-5.55 mm

(0.215-0.219 in.)

4.0-4.1 mm

(0.157-0.161 in.)

Shift Fork Thickness (#1 and #2)

(secondary transmission)

(reverse)

4.3-4.4 mm

(0.169-0.173 in.)

5.3-5.4 mm

(0.209-0.213 in.)

3.8-3.9 mm

(0.150-0.154 in.)

FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983

www.mymowerparts.com

3-6

Specifications*

(500 — Automatic Transmission)

* Specifications subject to change without notice.

VALVES AND GUIDES

Valve Face Diameter (intake)

(exhaust)

30.6 mm (1.20 in.)

27.0 mm (1.06 in.)

Valve/Tappet Clearance

(cold engine)

(intake)

(exhaust)

0.05-0.10 mm

(0.002-0.004 in.)

0.17-0.22 mm

(0.007-0.009 in.)

Valve Guide/Stem

Clearance

(intake)

(exhaust)

0.010-0.037 mm

(0.0004-0.0015 in.)

0.030-0.057 mm

(0.0012-0.0022 in.)

Valve Guide/Valve Stem

Deflection

(wobble deflection)

(max) 0.35 mm (0.014 in.)

Valve Guide Inside Diameter 5.000-5.012 mm

(0.1969-0.1973 in.)

Valve Stem Outside

Diameter

(intake)

(exhaust)

4.975-4.990 mm

(0.1959-0.1965 in.)

4.955-4.970 mm

(0.1951-0.1957 in.)

Valve Stem Runout (max) 0.05 mm (0.002 in.)

Valve Head Thickness (min) 0.5 mm (0.02 in.)

Valve Stem End Length (min) 2.3 mm (0.09 in.)

Valve Face/Seat Width 0.9-1.1 mm

(0.035-0.043 in.)

Valve Seat Angle (intake)

(exhaust)

45°

45°

Valve Face Radial Runout (max) 0.03 mm (0.001 in.)

Valve Spring Free Length (min) 38.8 mm (1.53 in.)

Valve Spring Tension

@ 31.5 mm (1.24 in.)

(outer) 18.6-21.4 kg

(41-47 lb)

CAMSHAFT AND CYLINDER HEAD

Cam Lobe Height (min) (intake)

(exhaust)

33.13 mm (1.304 in.)

33.20 mm (1.307 in.)

Camshaft Journal Oil

Clearance

(max) 0.15 mm (0.0059 in.)

Camshaft Journal Holder

Inside

(right & center)

(left)

22.012-22.025 mm

(0.8666-0.8671 in.)

17.512-17.525 mm

(0.6894-0.6900 in.)

Camshaft Journal

Outside Diameter

(right & center)

(left)

21.959-21.980 mm

(0.8645-0.8654 in.)

17.466-17.484 mm

(0.6876-0.6883 in.)

Camshaft Runout (max) 0.10 mm (0.004 in.)

Rocker Arm Inside Diameter 12.000-12.018 mm

(0.472-0.473 in.)

Rocker Arm Shaft Outside Diameter 11.973-11.984 mm

(0.4714-0.4718 in.)

Cylinder Head Distortion (max) 0.05 mm (0.002 in.)

Cylinder Head Cover

Distortion

(max) 0.05 mm (0.002 in.)

CYLINDER, PISTON, AND RINGS

Piston Skirt/Cylinder

Clearance

0.030-0.040 mm

(0.0011-0.0015 in.)

Cylinder Bore 87.500-87.515 mm

(3.4448-3.4454 in.)

Piston Diameter 15 mm (0.6 in.) from Skirt

End

87.465-87.480 mm

(3.4435-3.4440 in.)

Piston Ring Free End Gap

(min)

(1st Ring)

(2nd Ring)

9.0 mm

(0.35 in.)

9.5 mm

(0.37 in.)

Bore x Stroke 87.5 x 82 mm

(3.40 x 3.22 in.)

Cylinder Trueness (max) 0.05 mm (0.002 in.)

Piston Ring End Gap — Installed 0.35-0.63 mm

(0.014-0.025 in.)

Piston Ring to Groove

Clearance (max)

(1st)

(2nd)

0.180 mm

(0.0071 in.)

0.150 mm

(0.0059 in.)

Piston Ring Groove Width (1st)

(2nd)

(oil)

1.01-1.03 mm

(0.0398-0.0406 in.)

1.21-1.23 mm

(0.0476-0.0484 in.)

2.51-2.53 mm

(0.0988-0.0996 in.)

Piston Ring Thickness (1st)

(2nd)

0.97-0.99 mm

(0.0382-0.0389 in.)

1.17-1.19 mm

(0.046-0.047 in.)

Piston Pin Bore (max) 23.03 mm (0.907 in.)

Piston Pin Outside Diameter (min) 22.98 mm (0.905 in.)

CRANKSHAFT

Connecting Rod

(small end inside diameter)

(max) 23.04 mm

(0.9070 in.)

Connecting Rod

(big end side-to-side)

0.10-0.65 mm

(0.0039-0.0256 in.)

Connecting Rod (big end width) 24.95-25.00 mm

(0.9822-0.9842 in.)

Connecting Rod

(small end deflection)

(max) 3 mm (0.12 in.)

Crankshaft (web-to-web) 70.9-70.1 mm

(2.796-2.804in.)

Crankshaft Runout (max) 0.08 mm (0.003 in.)

Oil Pressure at 60°C

(140°F) @ 3000 RPM

(above)

(below)

1.3 kg/cm² (18 psi)

1.7 kg/cm² (24 psi)

Cooling Fan Thermo-Switch

Operating Temperature

(off J on)

(on J off)

88°C (190°F)

82°C (180°F) (min)

Engine Coolant Thermo-Switch

Operating Temperature

(off J on)

(on J off)

(approx)

115°C (239°F)

108°C (226°F)

FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983

www.mymowerparts.com

3-7

3

Specifications*

(500 — Manual Transmission)

VALVES AND GUIDES

Valve Face Diameter (intake)

(exhaust)

30.6 mm (1.20 in.)

27.0 mm (1.06 in.)

Valve/Tappet Clearance

(cold engine)

(intake)

(exhaust)

0.05-0.10 mm

(0.002-0.004 in.)

0.17-0.22 mm

(0.007-0.009 in.)

Valve Guide/

Stem Clearance

(intake)

(exhaust)

0.010-0.037 mm

(0.0004-0.0015 in.)

0.030-0.057 mm

(0.0012-0.0022 in.)

Valve Guide/Valve

Stem Deflection

(wobble deflection)

(max) 0.35 mm (0.014 in.)

Valve Guide Inside Diameter 5.000-5.012 mm

(0.1969-0.1973 in.)

Valve Stem Outside Diame-

ter

(intake)

(exhaust)

4.975-4.990 mm

(0.1959-0.1965 in.)

4.955-4.970 mm