Page 1

TABLE OF CONTENTS Click on the RED TEXT to go!

Foreword 1.

General Information (Vol. I)

1

2.

Periodic Maintenance/Tune-Up (Vol. I)

2

3.

Engine/Transmission (Vol. I)

3

4.

Fuel/Lubrication/Cooling (Vol. II)

4

5.

Electrical System (Vol. II)

5

6.

Drive System (Vol. II)

6

7.

Suspension (Vol. II)

7

8.

Steering/Frame (Vol. II)

8

9.

Controls/Indicators (Vol. II)

9

10. Aids for Maintenance (Vol. II)

10

11. Troubleshooting (Vol. II)

11


Table of Contents

FOREWORD This Arctic Cat Service Manual contains service, maintenance, and troubleshooting information for the 2005 Arctic Cat ATV models. The complete two-volume set is designed to aid service personnel in service-oriented applications. This volume 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 volume 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 two-volume set. 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 directive 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 photographs used in this volume 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.

Š 2004 Arctic Cat Inc. Ž™ Trademarks of Arctic Cat Inc., Thief River Falls, MN 56701

August 2004


SECTION 1 - GENERAL INFORMATION TABLE OF CONTENTS General Specifications (250) ................................... 1-2 General Specifications (300) ................................... 1-3 General Specifications (400/400 TBX - Automatic Transmission) ............ 1-4 General Specifications (400 - Manual Transmission) ............................... 1-5 General Specifications (500 - Manual Transmission) ............................... 1-6 General Specifications (500/500 TBX/TRV - Automatic Transmission) .... 1-7 General Specifications (650 H1) .............................................................. 1-8 General Specifications (650 V-Twin) ........................................................ 1-9 Break-In Procedure ............................................... 1-10 Gasoline - Oil - Lubricant ...................................... 1-10 Genuine Parts ....................................................... 1-11 Preparation For Storage........................................ 1-11 Preparation After Storage...................................... 1-12

1

1-1


General Specifications* (250)

CHASSIS

CARBURETOR Type

Keihin CVK32

Main Jet

138

Slow Jet

38

Dry Weight (approx)

2x4 - 245 kg (540 lb) 4x4 - 261 kg (575 lb)

Length (overall)

202 cm (79.5 in.)

Height (overall)

114 cm (45 in.)

Low Speed Fuel Screw Setting (turns)

1 3/4

Width (overall)

114 cm (45 in.)

Jet Needle

N8TT

Suspension Travel

16.5 cm (6.5 in.)

Needle Jet

4.0/3.4

Ground Clearance

20.3 cm (8.0 in.)

Idle RPM

1250-1350

Brake Type

Starter Jet

60

Hydraulic w/Brake Lever Lock and Auxiliary Brake

Float Arm Height

17 mm (0.7 in.)

Wheelbase

127 cm (50 in.)

Tracking

89 cm (35 in.)

Tire Size

Front - AT23 x 8-12 Rear - AT24 x 9-12

Tire Inflation Pressure

0.35 kg/cm² (5 psi)

Turning Radius

3.0 m (9.85 ft)

Throttle Cable Free-Play (at lever)

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

ELECTRICAL Ignition Timing

5° BTDC below 1800 RPM 35° BTDC above 3800 RPM

MISCELLANY

Spark Plug Type

NGK DR7EA

Spark Plug Gap

0.6-0.7 mm (0.024-0.028 in.)

Gas Tank Capacity (rated)

Spark Plug Cap

8000-12,000 ohms

Reserve Capacity

2.46 L (0.65 U.S. gal.)

Engine Oil Capacity

3.5 L (3.7 U.S. qt)

Gasoline (recommended)

87 Octane Regular Unleaded

Ignition Coil Resistance

Ignition Coil Peak Voltage

(primary) 0.4-0.6 ohm (terminal to ground) (secondary) 5200-7800 ohms (high tension - plug cap removed - to ground) (primary/CDI) 98.3-147.5 volts (terminal to ground)

Magneto Coil Resistance

Magneto Coil Peak Voltage

Magneto Output (approx)

1-2

(trigger) 84-126 ohms (black/yellow to green/white) (charging) 0.44-0.66 ohm (yellow to yellow) (trigger) 3.12-4.68 volts (black/yellow to green/white) (charging) 30-45 volts (yellow to yellow) 220W @ 5000 RPM

17.98 L (4.75 U.S. gal.)

Engine Oil (recommended)

SAE 10W-40

Differential Capacity (front - 4x4)

275 ml (9.3 fl oz)**

Differential Lubricant (front - 4x4)

SAE Approved 80W-90 Hypoid

Brake Fluid

DOT 4

Taillight/Brakelight

12V/8W/27W

Headlight

12V/27W (2)

Starting System

Electric w/Manual Recoil (Emergency)

* Specifications subject to change without notice. ** One inch below plug threads.


General Specifications* (300)

CARBURETOR

CHASSIS

Type

Keihin CVK32

Dry Weight (approx)

Main Jet

135

Length (overall)

202 cm (79.5 in.)

Slow Jet

38

Height (overall)

114 cm (45 in.)

Low Speed Fuel Screw Setting (turns)

2 1/4

Width (overall)

114 cm (45 in.)

Jet Needle

N8TT

Suspension Travel

16.5 cm (6.5 in.)

Needle Jet

4.0/3.4

263 kg (580 lb)

Ground Clearance

20.3 cm (8.0 in.)

Brake Type

Hydraulic w/Brake Lever Lock and Auxiliary Brake

Idle RPM

1250-1350

Starter Jet

65

Wheelbase

127 cm (50 in.)

Float Arm Height

17 mm (0.7 in.)

Tracking

89 cm (35 in.)

Throttle Cable Free-Play (at lever)

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

Tire Size

Front - AT24 x 9-12 Rear - AT25 x 10-12

Tire Inflation Pressure

0.35 kg/cm² (5 psi)

Turning Radius

2.7 m (8.9 ft)

ELECTRICAL Ignition Timing

5° BTDC @ 1800 RPM 30° BTDC @ 3800 RPM

MISCELLANY

Spark Plug Type

NGK DR7EA

Spark Plug Gap

0.6-0.7 mm (0.024-0.028 in.)

Gas Tank Capacity (rated)

17.98 L (4.75 U.S. gal.)

Spark Plug Cap

8000-12,000 ohms

Reserve Capacity

2.46 L (0.65 U.S. gal.)

Ignition Coil Resistance

Ignition Coil Peak Voltage

(primary) 0.4-0.6 ohm (terminal to ground) (secondary) 5200-7800 ohms (high tension - plug cap removed - to ground) (primary/CDI) 98.3-147.5 volts (terminal to ground)

Magneto Coil Resistance

Magneto Coil Peak Voltage

Magneto Output (approx)

(trigger) 84-126 ohms (black/yellow to green/white) (charging) 0.44-0.66 ohm (yellow to yellow) (trigger) 3.12-4.68 volts (black/yellow to green/white) (charging) 30-45 volts (yellow to yellow) 220W @ 5000 RPM

1

Differential Capacity (front)

275 ml (9.3 fl oz)**

Engine Oil Capacity

3.5 L (3.7 U.S. qt)

Gasoline (recommended)

87 Octane Regular Unleaded

Engine Oil (recommended)

SAE 10W-40

Differential Lubricant (front)

SAE Approved 80W-90 Hypoid

Brake Fluid

DOT 4

Taillight/Brakelight

12V/8W/27W

Headlight

12V/27W (2)

Starting System

Electric w/Manual Recoil (Emergency)

* Specifications subject to change without notice. ** One inch below plug threads.

1-3


General Specifications* (400/400 TBX - Automatic Transmission)

CARBURETOR Type

Keihin CVK34

Main Jet

142/140 TBX

Slow Jet

38

Low Speed Fuel Screw Setting (turns)

2/1 1/8 TBX

CHASSIS (Cont) Suspension Travel (front)

21.5 cm (8.45 in.) - ACT 25 cm (10 in.) - FIS

Suspension Travel (rear)

18.2 cm (7.2 in.) - ACT 25 cm (10 in.) - FIS

Ground Clearance

20.3 cm (8 in.)

Brake Type

Hydraulic w/Brake Lever Lock and Auxiliary Brake

Jet Needle

NA2G

Needle Jet

6.0/4.0

Wheelbase

127 cm (50 in.)

Idle RPM

1250-1350

Wheel Stance

89 cm (35 in.)

Starter Jet

75

Tire Size

Front - 25 x 8-12 Rear - 25 x 10-12 - ACT Rear - 25 x 10-12 - FIS

Tire Inflation Pressure

0.35 kg/cm² (5 psi)

Turning Radius

2.7 m (8.9 ft)

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)

Ignition Coil Peak Voltage

(primary/CDI)

Magneto Coil Resistance

(trigger) (source) (charging)

Magneto Coil Peak Voltage

(trigger) (source) (charging)

Magneto Output (approx)

0.4-0.6 ohm (terminal to ground) 5200-7800 ohms (high tension - plug cap removed - to ground) 160.8-241.2 volts (terminal to ground)

Gas Tank Capacity (rated)

17.98 L (4.75 U.S. gal.) ACT/FIS 20.8 L (5.5 U.S. gal.) - TBX

Reserve Capacity

2.46 L (0.65 U.S. gal.) ACT/FIS

Rear Drive Capacity

275 ml (9.3 fl oz) - ACT*** 250 ml (8.5 fl oz) - FIS**

Differential Capacity (front - 4x4)

275 ml (9.3 fl oz) - ACT**/ FIS***

Engine Oil Capacity

3.08 L (3.25 U.S. qt)

160-240 ohms (green to blue) 0.08-0.12 ohm (yellow to white) 0.32-0.48 ohm (black to black)

Gasoline (recommended)

87 Octane Regular Unleaded

Engine Oil (recommended)

SAE 10W-40

Differential/Rear Drive Lubricant

SAE Approved 80W-90 Hypoid

5.04-7.56 volts (green to blue) 0.7-1.05 volts (yellow to white) 60 volts (black to black #1) (black to black #2)

Drive Belt Width

30.3 mm (1.19 in.)

Brake Fluid

DOT 4

Taillight/Brakelight

12V/8W/27W

220W @ 5000 RPM

CHASSIS Dry Weight (approx)

282 kg (622 lb) - ACT 286 kg (630 lb) - FIS 323.5 kg (713 lb) - TBX

Length (overall)

205 cm (81 in.) 244.5 cm (96 in.) - TBX

Height (overall)

122 cm (48 in.) - ACT 125 cm (49.3 in.) - FIS

Width (overall)

112 cm (44.25 in.) - ACT 121 cm (47.5 in.) - FIS

1-4

MISCELLANY

Headlight

12V/27W (2)

Starting System

Electric w/Manual Recoil (Emergency)

* Specifications subject to change without notice. ** One inch below filler plug threads. *** At the oil level plug threads.


General Specifications* (400 - Manual Transmission)

CHASSIS (Cont)

CARBURETOR Type

Keihin CVK34

Main Jet

142

Slow Jet

38

Low Speed Fuel Screw Setting (turns)

2

Jet Needle

NA2G

Needle Jet

6.0/4.0

Suspension Travel (rear)

18.2 cm (7.2 in.) - ACT 25 cm (10 in.) - FIS

Ground Clearance

20.3 cm (8 in.)

Brake Type

Hydraulic w/Brake Lever Lock and Auxiliary Brake

Wheelbase

127 cm (50 in.)

Wheel Stance

89 cm (35 in.)

Tire Size

Front - 25 x 8-12 Rear - 25 x 10-12 - ACT Rear - 25 x 10-12 - FIS

Idle RPM

1250-1350

Starter Jet

75

Float Arm Height

17 mm (0.7 in.)

Tire Inflation Pressure

0.35 kg/cm² (5 psi)

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

Turning Radius

2.7 m (8.9 ft)

Throttle Cable Free-Play (at lever)

1

MISCELLANY

ELECTRICAL Ignition Timing

10° BTDC @ 1500 RPM

Gas Tank Capacity (rated)

17.98 L (4.75 U.S. gal.)

Spark Plug Type

NGK CR7E

Reserve Capacity

2.46 L (0.65 U.S. gal.)

Spark Plug Gap

0.7-0.8 mm (0.028-0.032 in.)

Rear Drive Capacity

Spark Plug Cap

8000-12,000 ohms

275 ml (9.3 fl oz) - ACT*** 250 ml (8.5 fl oz) - FIS**

Differential Capacity (front - 4x4)

275 ml (9.3 fl oz) - ACT**/ FIS***

Ignition Coil Resistance

(primary) (secondary)

Ignition Coil Peak Voltage

(primary/CDI)

Magneto Coil Resistance

(trigger)

Magneto Coil Peak Voltage

0.4-0.6 ohm (terminal to ground) 5200-7800 ohms (high tension - plug cap removed - to ground) 160.8-241.2 volts (terminal to ground)

160-240 ohms (green to blue) (source) 0.08-0.12 ohm (yellow to white) (charging) 0.32-0.48 ohm (black to black) (trigger)

5.04-7.56 volts (green to blue) (source) 0.7-1.05 volts (yellow to white) (charging) 60 volts (black to black #1) (black to black #2)

Magneto Output (approx)

Engine Oil Capacity

3.08 L (3.25 U.S. qt)

Gasoline (recommended)

87 Octane Regular Unleaded

Engine Oil (recommended)

SAE 10W-40

Differential/Rear Drive Lubricant

SAE Approved 80W-90 Hypoid

Brake Fluid

DOT 4

Taillight/Brakelight

12V/8W/27W

Headlight

12V/27W (2)

Starting System

Electric w/Manual Recoil (Emergency)

* Specifications subject to change without notice. ** One inch below filler plug threads. *** At the oil level plug threads.

220 W @ 5000 RPM

CHASSIS Dry Weight (approx)

276 kg (609 lb) - ACT 280 kg (617 lb) - FIS

Length (overall)

205 cm (81 in.)

Height (overall)

122 cm (48 in.) - ACT 125 cm (49.3 in.) - FIS

Width (overall)

112 cm (44.25 in.) - ACT 121 cm (47.5 in.) - FIS

Suspension Travel (front)

21.5 cm (8.45 in.) - ACT 25 cm (10 in.) - FIS

1-5


General Specifications* (500 - Manual Transmission)

CHASSIS (Cont)

CARBURETOR Type

Keihin CVK36

Main Jet

148/138 w/Fuel Pump

Slow Jet

40

Low Speed Fuel Screw Setting (turns)

1 7/8/1 3/4 w/Fuel Pump

Jet Needle

NFKG/NFCS w/Fuel Pump

Needle Jet

6.0/4.0

Idle RPM

1250-1350

Starter Jet

102

Brake Type

Hydraulic w/Brake Lever Lock and Auxiliary Brake

Wheelbase

127 cm (50 in.)

Tracking

89 cm (35 in.)

Tire Size

Front - 25 x 8-12 Rear - 25 x 11-12

Tire Inflation Pressure

0.35 kg/cm² (5 psi)

Turning Radius

2.7 m (8.9 ft)

MISCELLANY

Float Arm Height

17 mm (0.7 in.)

Gas Tank Capacity (rated)

24.6 L (6.5 U.S. gal.)

Throttle Cable Free-Play (at lever)

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

Coolant Capacity

2.9 L (3.0 U.S. qt)

ELECTRICAL

Differential Capacity

275 ml (9.3 fl oz)** 250 ml (8.5 fl oz)***

Ignition Timing

10° BTDC @ 1500 RPM

Rear Drive Capacity

Spark Plug Type

NGK CR6E

Engine Oil Capacity

3.4 L (3.5 U.S. qt)

0.7-0.8 mm (0.028-0.032 in.)

Gasoline (recommended)

87 Octane Regular Unleaded

Engine Oil (recommended)

SAE 10W-40

Differential/Rear Drive Lubricant

SAE Approved 80W-90 Hypoid

Brake Fluid

DOT 4

Taillight/Brakelight

12V/8W/27W

Spark Plug Gap Spark Plug Cap

8000-12,000 ohms

Ignition Coil Resistance

(primary) (secondary)

Ignition Coil Peak Voltage Magneto Coil Resistance

Magneto Coil Peak Voltage

(primary/CDI)

0.4-0.6 ohm (terminal to ground) 5200-7800 ohms (high tension - plug cap removed - to ground) 142.4-213.6 volts (terminal to ground)

(trigger)

160-240 ohms (green to blue) (source) 0.08-0.12 ohm (yellow to white) (charging) 0.32-0.48 ohm (black to black) (trigger) 4.2-6.3 volts (green to blue) (source) 0.40-0.62 volt (yellow to white) (charging) 60 volts (black to black #1) (black to black #2)

Magneto Output (approx)

325W @ 5000 RPM

CHASSIS Dry Weight (approx)

288.5 kg (636 lb)

Length (overall)

210.8 cm (83 in.)

Height (overall)

125 cm (49.3 in.)

Width (overall)

120.7 cm (47.5 in.)

Suspension Travel (front)

25 cm (10 in.)

Suspension Travel (rear)

25 cm (10 in.)

Ground Clearance

20.3 cm (8 in.)

1-6

Headlight

12V/27W (2)

Starting System

Electric w/Manual Recoil (Emergency)

* Specifications subject to change without notice. ** At the oil level plug threads. *** At the filler plug threads.


General Specifications* (500/500 TBX/TRV - Automatic Transmission)

CHASSIS

CARBURETOR Dry Weight (approx)

293 kg (646 lb) 331.5 kg (731 lb) - TBX 339 kg (748 lb) - TRV

40

Length (overall)

1 7/8 TRV/1 3/4 w/Fuel Pump

210.8 cm (83 in.) 244.5 cm (96 in.) - TBX/TRV

Height (overall)

NFKG TRV/NFCS w/Fuel Pump

125 cm (49.3 in.) 128 cm (50.5 in.) - TRV

Width (overall)

120.7 cm (47.5 in.)

Needle Jet

6.0/4.0

Suspension Travel (front)

25 cm (10 in.)

Idle RPM

1250-1350

Suspension Travel (rear)

25 cm (10 in.)

Starter Jet

102

Ground Clearance

20.3 cm (8 in.)

Float Arm Height

17 mm (0.7 in.)

Brake Type

Throttle Cable Free-Play (at lever)

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

Hydraulic w/Brake Lever Lock and Auxiliary Brake

Wheelbase

127 cm (50 in.) 147 cm (58 in.) - TRV

Type

Keihin CVK36

Main Jet

148 TRV/138 w/Fuel Pump

Slow Jet Low Speed Fuel Screw Setting (turns) Jet Needle

ELECTRICAL Ignition Timing

10° BTDC @ 1500 RPM

Tracking

89 cm (35 in.)

Spark Plug Type

NGK CR6E

Tire Size

Spark Plug Gap

0.7-0.8 mm (0.028-0.032 in.)

Front - 25 x 8-12 Rear - 25 x 11-12

Tire Inflation Pressure

0.35 kg/cm² (5 psi)

Spark Plug Cap

8000-12,000 ohms

Turning Radius

2.7 m (8.9 ft)

Ignition Coil Resistance

(primary) (secondary)

Ignition Coil Peak Voltage

(primary/CDI)

Magneto Coil Resistance

(trigger) (source) (charging)

Magneto Coil Peak Voltage

(trigger) (source) (charging)

Magneto Output (approx)

0.4-0.6 ohm (terminal to ground) 5200-7800 ohms (high tension - plug cap removed - to ground) 142.4-213.6 volts (terminal to ground)

1

MISCELLANY Gas Tank Capacity (rated)

24.6 L (6.5 U.S. gal.)/ 17.98 L (4.75 U.S. gal.) TRV/20.8 L (5.5 U.S. gal.) TBX

Reserve Capacity

2.46 L (0.65 U.S. gal.) - TRV

160-240 ohms (green to blue) 0.08-0.12 ohm (yellow to white) 0.32-0.48 ohm (black to black)

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)

4.2-6.3 volts (green to blue) 0.40-0.62 volt (yellow to white) 60 volts (black to black #1) (black to black #2)

Gasoline (recommended)

87 Octane Regular Unleaded

Engine Oil (recommended)

SAE 10W-40

Differential/Rear Drive Lubricant

SAE Approved 80W-90 Hypoid

325W @ 5000 RPM

Drive Belt Width

36.7 mm (1.44 in.)

Brake Fluid

DOT 4

Taillight/Brakelight

12V/8W/27W

Headlight

12V/27W (2)

Starting System

Electric w/Manual Recoil (Emergency)

* Specifications subject to change without notice. ** At the oil level plug threads. *** At the filler plug threads.

1-7


General Specifications* (650 H1)

CHASSIS (Cont)

CARBURETOR Type

Keihin CVK40

Main Jet

TBA

Slow Jet

TBA

Low Speed Fuel Screw Setting (turns)

TBA

Jet Needle

TBA

Needle Jet

TBA

Idle RPM

1250-1350

Starter Jet

TBA

Brake Type

Hydraulic w/Brake Lever Lock and Auxiliary Brake

Wheelbase

127 cm (50 in.)

Tracking

89 cm (35 in.)

Tire Size

Front - 25 x 8-12 Rear - 25 x 11-12

Tire Inflation Pressure

0.35 kg/cm² (5 psi)

Turning Radius

2.7 m (8.9 ft)

MISCELLANY

Float Arm Height

17 mm (0.7 in.)

Gas Tank Capacity (rated)

24.6 L (6.5 U.S. gal.)

Throttle Cable Free-Play (at lever)

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

Coolant Capacity

2.9 L (3.0 U.S. qt)

ELECTRICAL

Differential Capacity

275 ml (9.3 fl oz)** 250 ml (8.5 fl oz)***

Ignition Timing

10° BTDC @ 1500 RPM

Rear Drive Capacity

Spark Plug Type

NGK CR6E

Engine Oil Capacity

3.4 L (3.5 U.S. qt)

0.7-0.8 mm (0.028-0.032 in.)

Gasoline (recommended)

87 Octane Regular Unleaded

Engine Oil (recommended)

SAE 10W-40

Differential/Rear Drive Lubricant

SAE Approved 80W-90 Hypoid

Spark Plug Gap Spark Plug Cap

8000-12,000 ohms

Ignition Coil Resistance

(primary) (secondary)

Ignition Coil Peak Voltage Magneto Coil Resistance

Magneto Coil Peak Voltage

(primary/CDI)

0.4-0.6 ohm (terminal to ground) 5200-7800 ohms (high tension - plug cap removed - to ground) 142.4-213.6 volts (terminal to ground)

(trigger)

160-240 ohms (green to blue) (source) 0.08-0.12 ohm (yellow to white) (charging) 0.32-0.48 ohm (black to black) (trigger) 4.2-6.3 volts (green to blue) (source) 0.40-0.62 volt (yellow to white) (charging) 60 volts (black to black #1) (black to black #2)

Magneto Output (approx)

325W @ 5000 RPM

CHASSIS Dry Weight (approx)

288.5 kg (636 lb)

Length (overall)

210.8 cm (83 in.)

Height (overall)

125 cm (49.3 in.)

Width (overall)

120.7 cm (47.5 in.)

Suspension Travel (front)

25 cm (10 in.)

Suspension Travel (rear)

25 cm (10 in.)

Ground Clearance

20.3 cm (8 in.)

1-8

Belt Width

33.3 mm (1.47 in.)

Brake Fluid

DOT 4

Taillight/Brakelight

12V/8W/27W

Headlight

12V/27W (2)

Starting System

Electric w/Manual Recoil (Emergency)

* Specifications subject to change without notice. ** At the oil level plug threads. *** At the filler plug threads.


General Specifications* (650 V-Twin)

CHASSIS

CARBURETOR

Dry Weight (approx)

293 kg (646 lb)

Length (overall)

210.8 cm (83 in.)

Height (overall)

125 cm (49.3 in.)

40

Width (overall)

120.7 cm (47.5 in.)

2 1/2

Suspension Travel (front)

25 cm (10 in.)

Jet Needle

BZL-2.470

Suspension Travel (rear)

25 cm (10 in.)

Needle Jet

3.6 #3

Ground Clearance

20.3 cm (8 in.)

Idle RPM

1050-1150

Brake Type

Float Arm Height

3-5 mm (0.12-0.20 in.)

Hydraulic w/Brake Lever Lock and Auxiliary Brake

Throttle Cable Free-Play (at lever)

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

Wheelbase

127 cm (50 in.)

Tracking

89 cm (35 in.)

Tire Size

Front - 26 x 8-12 Rear - 26 x 11-12

Type

Keihin CVKR-D32 (2)

Main Jet

120 - Front 115 - Rear

Slow Jet Pilot Screw Setting (turns)

ELECTRICAL Spark Plug Type

NGK CR7E

Spark Plug Gap

0.7-0.8 mm (0.028-0.032 in.)

Tire Inflation Pressure

0.35 kg/cm² (5 psi)

Turning Radius

2.7 m (8.9 ft)

4750-6250 ohms

MISCELLANY

Spark Plug Cap Ignition Coil Resistance

(primary) (secondary)

Ignition Coil Peak Voltage Magneto Coil Resistance

(primary/CDI) (trigger) (charging)

Magneto Coil Peak Voltage

(trigger) (charging)

0.09-0.13 ohm (terminal (+) to terminal (-)) 3800-5800 ohms (high tension - plug cap removed - to ground)

Gas Tank Capacity (rated)

24.6 L (6.5 U.S. gal.)

Coolant Capacity

2.7 L (2.8 U.S. qt)

Differential Capacity

275 ml (9.3 fl oz)**

100 volts or more (wire (+) to ground)

Rear Drive Capacity

250 ml (8.5 fl oz)***

Engine Oil Capacity

1.75 L (1.85 U.S. qt)

110-140 ohms (blue to black/white) 0.33-0.49 ohm (black to black)

Gasoline (recommended)

87 Octane Regular Unleaded

Engine Oil (recommended)

SAE 10W-40

3.6 volts or more (blue to black/white) 39-59 volts @ 3000 RPM (black to black #1) (black to black #2)

Differential/Rear Drive Lubricant

SAE Approved 80W-90 Hypoid

Drive Belt Width (minimum)

30.3 mm (1.19 in.)

Brake Fluid

DOT 4

Taillight/Brakelight

12V/8W/27W

Headlight

12V/27W (2)

Starting System

Electric w/Manual Recoil (Emergency)

1

* Specifications subject to change without notice. ** One inch below plug threads. *** At the plug threads.

1-9


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 components 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 properly. 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 throttle is recommended; however, brief full-throttle accelerations and variations in driving speeds contribute 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.

! CAUTION BRAKE PADS MUST BE BURNISHED TO ACHIEVE FULL BRAKING EFFECTIVENESS. Braking distance will be extended until brake pads are properly burnished. TO PROPERLY BURNISH THE BRAKES, USE FOLLOWING PROCEDURE: z Choose an area sufficiently large to safely accelerate ATV to 30 mph and to brake to a stop.

z

Accelerate to 30 mph; then compress brake lever to decelerate to 0-5 mph.

z

Repeat procedure five times until brakes are burnished.

z

This procedure burnishes the brake pads, stabilizes the pad material, and extends the life of the brake pads.

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 necessary to add a gasoline antifreeze since ethanol will prevent the accumulation of moisture in the fuel system.

! CAUTION Do not use white gas. Only Arctic Cat approved gasoline additives should be used.

RECOMMENDED ENGINE/ TRANSMISSION OIL

! 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.

The recommended oil to use is Arctic Cat 4-Cycle Engine Oil (p/n 0436-005) 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 10W-40. Ambient temperature should determine the correct weight of oil. See the following viscosity chart for details. Viscosity Chart

! 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.

„ NOTE: Do not be reluctant to heat up the brake pads during the burnishing procedure. 1-10

OILCHARTA


RECOMMENDED FRONT DIFFERENTIAL/REAR DRIVE LUBRICANT

Genuine Parts

The recommended lubricant is Arctic Cat Gear Lube (p/n 0436-007) 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.

! CAUTION Any lubricant used in place of the recommended lubricant could cause serious front differential/ rear drive damage.

FILLING GAS TANK

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 correct part number, quantity, and description.

Preparation For Storage

1

! 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.

! CAUTION Prior to storing the ATV, it must be properly serviced to prevent rusting and component deterioration.

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.

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 particularly if the tank is filled with cold gasoline and then moved to a warm area.

3. Either drain the gas tank or add Fuel Stabilizer (p/n 0638-165) 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 (p/n 0636-177), rapidly inject the preserver into the air filter opening for a period of 10 to 20 seconds; then stop the engine. Install the air filter and housing cover.

! WARNING

! CAUTION

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.

If the interior of the air filter housing is dirty, clean the area before starting the engine.

Tighten the gas tank cap securely after filling the tank.

5. Plug the exhaust hole in the exhaust system with a clean cloth.

! WARNING

6. Apply light oil to the upper steering post bushing and plungers of the shock absorbers.

ATV0049B

Do not over-fill the gas tank.

4. Drain the carburetor float chamber.

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.

1-11


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.

! CAUTION Avoid storing outside in direct sunlight and avoid using a plastic cover as moisture will collect on the ATV causing rusting.

Preparation After Storage Taking the ATV out of storage and correctly preparing it will assure many miles and hours of trouble-free riding. Arctic Cat recommends the following procedure to prepare the ATV.

5. On liquid cooled models, check the coolant level and add properly mixed coolant as necessary. 6. Charge the battery; then install. Connect the battery cables.

! 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.

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. 9. Check tire pressure. Inflate to recommended pressure as necessary.

1. Clean the ATV thoroughly.

10. Make sure the steering moves freely and does not bind.

2. Clean the engine. Remove the cloth from the exhaust system.

11. Check the spark plug. Clean or replace as necessary.

3. Check all control wires and cables for signs of wear or fraying. Replace if necessary.

12. Follow the recommendations found in the pre-start inspection.

4. Change the engine/transmission oil and filter.

1-12


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 (250/300) .............................................. 2-5 Air Cleaner/Filter (400 FIS/ACT) ............................. 2-9 Air Cleaner/Filter (TBX/500/650 H1/650 V-Twin)... 2-11 Valve/Tappet Clearance (Feeler Gauge Procedure) ................................ 2-13 Valve/Tappet Clearance (Valve Adjuster Procedure)................................ 2-14 Valve/Tappet Clearance (650 V-Twin Feeler Gauge Procedure).................................. 2-15 Valve/Tappet Clearance (650 V-Twin Valve Adjuster Procedure)................................. 2-16 Testing Engine Compression ................................ 2-17 Spark Plug............................................................. 2-17 Muffler/Spark Arrester ........................................... 2-18 Gas/Vent Hoses .................................................... 2-18 Adjusting Throttle Cable ........................................ 2-18 Adjusting Choke Cable (650 V-Twin) ..................... 2-19 Adjusting Engine RPM (Idle) ................................. 2-19 Engine/Transmission Oil - Filter - Strainer (250/300) ........................................................... 2-20 Engine/Transmission Oil - Filter - Strainer (400/500/650 H1/650 V-Twin) ............................ 2-22 Front Differential/Rear Drive Lubricant .................. 2-24 Adjusting Clutch (250/300).................................... 2-25 Adjusting Clutch (400/500 Manual Transmission) ........................ 2-26 Tires ...................................................................... 2-26 Steering Components ........................................... 2-27 Driveshaft/Coupling ............................................... 2-27 Suspension/Shock Absorbers/Bushings ............... 2-27 Nuts/Bolts/Cap Screws.......................................... 2-27 Ignition Timing ....................................................... 2-27 Headlight/Taillight-Brakelight ................................. 2-28 Switches................................................................ 2-29 Reverse Shift Lever ............................................... 2-29 Frame/Welds/Racks .............................................. 2-33 Electrical Connections........................................... 2-33 Hydraulic Brake Systems ...................................... 2-34 Auxiliary Brake (250/300/400 ACT). ...................... 2-36 Burnishing Brake Pads.......................................... 2-38 Coolant (500/650 H1/650 V-Twin) ......................... 2-38 Checking/Replacing V-Belt (400/500/650 H1) .............................................. 2-38 Checking/Replacing V-Belt (650 V-Twin) ...................................................... 2-40

2

2-1


A = Adjust C = Clean D = Drain

Periodic Maintenance Chart

Item Battery

Initial Service After Break-In (First Mo or 100 Mi)

Every Day

I

Every Month or Every 100 Miles

Every 3 Months or Every 300 Miles

I = Inspect L = Lubricate R = Replace

Every 6 Months or Every 500 Miles

I

Fuses I

Valve/Tappet Clearance

I

I

R

C*

R I

Engine Compression I

I

R (4000 Mi or 18 Mo) C

I

R (2 Yrs) I

I

I

C-L

Carb Float Chamber Engine RPM (Idle)

C A-R

D* I

Engine-Transmission Oil Level

I

A

I

Engine-Transmission Oil/Filter

R

Oil Strainer

I

Front Differential/Rear Drive Lubricant

I

Clutch (Manual)

I

Tires/Air Pressure

I

A R*

R I

C R (4 Yrs)

l

A

I

Steering Components

I

V-Belt (Automatic)

I

Suspension (Ball joint boots, drive axle boots front and rear, tie rods, differential and rear drive bellows)

I

l*

Nuts/Cap Screws/Screws

I

I

I

R

I

R l

R R

I

Ignition Timing

A I

Headlight/TaillightBrakelight

I

I

Switches

I

I

R R

Reverse Shift Lever Choke Cable (250/300/650 V-Twin)

R

I

Gas Tank Valve (250/300/400 ACT/FIS) Throttle Cable

A I

Muffler/Spark Arrester Gas/Vent Hoses

As Needed C

I

Air Filter/Drain Tube

Spark Plug

Every Year or Every 1500 Miles

I

I

I

A-L

C-L

R

Recoil Starter

I

C-R

Handlebar Grips

I

R R

Handlebars

I

I

Gauges/Indicators

I

I

Frame/Welds/Racks

I

R I

l

Electrical Connections

l I

C

C

Complete Brake System (Hydraulic & Auxiliary)

I

Brake Pads

I

I*

R

Brake Fluid

I

I

R (2 Yrs)

Brake Hoses

I

I

R (4 Yrs)

Coolant/Cooling System

I

I

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

2-2

L-R

R (2 Yrs)


Lubrication Points It is advisable to lubricate certain components periodically 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

CHARGTIM

D. Choke Cable Upper End (250/300/400) E. Reverse Lever Cable End (If applicable)

2

F. Idle RPM Screw (Carburetor)

Battery

CHARGE

To remove and charge the battery, use the following procedure.

! WARNING AF879D

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 distilled water until it reaches upper level line.

! WARNING Battery acid is harmful if it contacts eyes, skin, or clothing. Care must be taken whenever handling a battery.

If the battery is discharged, remove the battery from the ATV and charge the battery at the standard charging rate of 1.4A x 10 hr.

Anytime service is performed on a battery, the following must be observed: keep sparks, open flame, cigarettes, or any other flame away. Always wear safety glasses. Protect skin and clothing when handling a battery. When servicing battery in enclosed space, keep the area well-ventilated. Make sure battery venting is not obstructed.

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.

! 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.

2-3


3. Remove the vent plugs; then (if necessary) fill the battery with distilled water to the upper level indicated on the battery.

FUSES

4. Trickle charge the battery at 1.4 amps for 10 hours.

! CAUTION Never exceed the standard charging rate.

5. After charging, check fluid level and fill with distilled water as necessary; then install vent plugs.

The main fuse (on the 400 ACT) is located in a fuse block on the frame near the right rear tire and protected by a snap-on cover. The main fuses are located in a fuse block under the center cover in the front fender assembly (on the 250/300), under the seat (on the 400 TBX/500/650 H1/650 V-Twin), or under a cover above the right rear tire (on the 400 FIS). If there is any type of electrical system failure, always check the fuses first.

! CAUTION Before installing the battery, make sure the ignition switch is in the OFF position.

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.

„ NOTE: To remove the fuse, compress the locking tabs on either side of the fuse case and lift out. 250/300

400 ACT

10 A IGN 15 A LIGHTS 10 A ACC 10 A SPARE

10 A LIGHTS 10 A HIGH 10 A LO 10 A IGN 15 A FAN 15 A ACC

400/500/FIS Auto/650 H1

AF733D

! CAUTION Connecting cables in reverse (positive to negative and negative to positive) can cause serious damage to the electrical system.

411-585A

400 FIS Manual/500 Manual

0411-837

2-4


650 V-Twin

0411-903 CH044D

TRV

3. Pull the retainer out and remove the filter with foam wrap.

2 0411-838

! CAUTION Always replace a blown fuse with a fuse of the same type and rating. CH045D

4. Remove the foam wrap from the filter.

Air Cleaner (250/300)

The air filter inside the air cleaner must be kept clean to provide good engine power and gas mileage. If the ATV is used under normal conditions, service the filter at the intervals specified. If operated in dusty, wet, or muddy conditions, inspect and service the filter more frequently. CLEANING AND INSPECTING FILTER

! CAUTION Failure to inspect the air filter frequently if the ATV is used in dusty, wet, or muddy conditions can damage the ATV engine.

AL642D

5. Wash the polyester filter and the foam wrap with warm soapy water and rinse. 6. Allow the foam wrap to air dry thoroughly.

1. Remove the seat. 2. Remove the two machine screws securing the air cleaner housing cover.

„ NOTE: Either allow the polyester filter to air dry or blow dry using low-pressure compressed air. Direct the compressed air through the filter from the opposite direction as normal operation air flow.

! CAUTION Do not put oil on either the filter or the foam wrap.

2-5


7. Place the foam wrap around the air filter; then install the filter with wrap into the air cleaner making sure it is properly in position and properly seated and secure with the retainer.

10. Inspect one-way drain beneath the air cleaner for debris and sealing.

733-715C CH046D

REMOVING AIR CLEANER

1. Remove the seat; then remove the air-intake snorkel.

CH045D

8. Install the air cleaner housing cover and secure with the machine screws; then install the seat making sure the seat is properly secured.

CH040D

CH041D CH044D

9. Check the drain tube for gasoline or oil accumulation. If noticed, remove the drain tube cap from beneath the cleaner, drain the gasoline or oil into a suitable container, and install and secure the tube cap.

2-6

2. Remove the two machine screws securing the air cleaner housing cover.


5. Loosen the clamp securing the air cleaner to the carburetor boot.

CH044D

3. Pull the retainer out and remove the filter with foam wrap.

CH049D

6. Remove the crankcase breather hose from the air cleaner.

CH045D

4. Remove the machine screws securing the air cleaner to the frame.

CH050D

7. Remove the air cleaner from the frame. INSTALLING AIR CLEANER

CH047D

KEY 1. Air Cleaner Assy 2. Retainer Slider 3. Filter 4. Cap 5. Cap Screw 6. Joint 7. Clamp 8. Clip 9. Drain Plug CH048D

10. 11. 12. 13. 14. 15. 16. 17. 18.

Valve Clamp Breather Hose Clamp Boot Clamp Snorkel Clip Strap

19. 20. 21. 22. 23. 24. 25. 26. 27.

Plug Tool Kit Cap Screw Spring Plug Check Valve Clip Clamp Lock Washer 0738-682

2-7

2


1. Place the air cleaner into the frame; then connect the crankcase breather hose.

CH047D

CH050D

4. Install the filter with foam wrap into the air cleaner; then secure with the retainer.

2. Secure the carburetor boot to the air cleaner.

CH045D CH049D

3. Install the machine screws securing the air cleaner to the frame.

5. Install the air cleaner housing cover and secure with the machine screws.

CH044D CH048D

2-8

6. Install the air-intake snorkel.


2. Remove the air filter housing cover from the retaining clips.

CH041D

733-444A

3. Loosen the clamp; then remove the filter.

2

CH040D

7. Install the seat making sure it is properly secured. AF640DA

Air Cleaner/Filter (400 FIS/ACT)

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 conditions, service the filter at the intervals specified. If operated in dusty, wet, or muddy conditions, inspect and service the filter more frequently. Use the following procedure to remove the filter and inspect and/or clean it. CLEANING AND INSPECTING FILTER

! CAUTION Failure to inspect the air filter frequently if the vehicle is used in dusty, wet, or muddy conditions can damage the engine.

1. Remove the seat.

CD087

4. 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 Filter Cleaner (p/n 0436-194) and Foam Filter Oil (p/n 0436-195) are available from Arctic Cat. 5. Dry the filter.

2-9


6. Put the filter in a plastic bag; then pour in air filter oil and work the filter.

! CAUTION A torn air filter can cause damage to the ATV engine. Dirt and dust may get inside the engine if the element is torn. Carefully examine the element for tears before and after cleaning it. Replace the element with a new one if it is torn.

7. Clean any dirt or debris from inside the air cleaner. Be sure no dirt enters the carburetor. 8. Place the filter in the air filter housing making sure it is properly in position and properly seated and secure with the clamp.

AL645D

3. Loosen the clamp and remove the filter.

9. Install the air filter housing cover and secure with the retaining clips; then install the seat making sure the seat is properly secured. CHECKING/DRAINING DRAIN TUBE

1. Periodically check the drain tube for gasoline or oil accumulation. If noticed, remove the drain tube cap from beneath the front housing, drain the gasoline or oil into a suitable container, and install and secure the tube cap. 2. Inspect one-way drain beneath the main housing for debris and for proper sealing.

AF640DA

4. Loosen the clamp securing the air cleaner to the front boot; then loosen the clamp securing the air cleaner to the rear filter sleeve. 5. Remove the machine screws securing the air cleaner to the flange support and frame. 6. Remove the air cleaner from the frame. INSTALLING

ATV0087A

REMOVING AIR CLEANER

1. Remove the seat. 2. Remove the air cleaner cover from the retaining clips.

KEY 1. 2. 3. 4. 5. 6. 7.

Clamp Boot Clamp Housing Filter Gasket Snorkel

8. 9. 10. 11. 12. 13. 14.

Clamp Spring Machine Screw Expansion Nut Support Heat Shield Valve

15. 16. 17. 18. 19.

Clip Drain Cap Clamp Clamp Vent Hose

0738-385

2-10


1. Place the air cleaner into the frame. 2. Install the machine screws securing the air cleaner to the flange support and frame. 3. Install the rear filter sleeve onto the air cleaner; then tighten the clamp securely. 4. Install the front boot onto the air cleaner; then tighten the clamp securely. 5. Install the filter with foam wrap into the air cleaner; then tighten the clamp securely.

Air Cleaner/Filter (TBX/500/650 H1/650 V-Twin)

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 conditions, service the filter at the intervals specified. If operated in dusty, wet, or muddy conditions, inspect and service the filter more frequently. Use the following procedure to remove the filter and inspect and/or clean it. CLEANING AND INSPECTING FILTER

! CAUTION Failure to inspect the air filter frequently if the vehicle is used in dusty, wet, or muddy conditions can damage the engine.

1. Remove the two reinstallable rivets at the rear of the steering post cover; then unlock the storage compartment lid. AF640DA

6. Place the air cleaner cover into position and secure with the retaining clips.

CD710A

AL645D

7. Install the seat making sure the seat is properly secured.

CD668

2. Lift the rear of the steering post cover and slide the storage compartment assembly forward; then lift and remove the cover assembly from the storage compartment.

2-11

2


CD669

CD674

3. Lift out the storage compartment box; then unsnap the four spring-clip fasteners and remove the air filter cover.

CD747

CD671

5. 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 Filter Cleaner (p/n 0436-194) and Foam Filter Oil (p/n 0436-195) are available from Arctic Cat. 6. Dry the filter. 7. Put the filter in a plastic bag; then pour in air filter oil and work the filter. Reattach the filter to the filter screen.

! CAUTION

CD675A

4. Remove the air filter/filter screen assembly and separate the foam filter from the screen.

2-12

A torn air filter can cause damage to the ATV engine. Dirt and dust may get inside the engine if the element is torn. Carefully examine the element for tears before and after cleaning it. Replace the element with a new one if it is torn.

8. Clean any dirt or debris from inside the air cleaner. Be sure no dirt enters the carburetors.


CD710A

CD746

9. Place the filter assembly in the air filter housing making sure it is properly positioned and properly seated with the filter screen down.

CHECKING AND CLEANING DRAINS

1. Inspect one-way drains beneath the main housing for debris and for proper sealing.

CD674 KX045A

10. Install the air filter housing cover and secure with the retaining clips; then install the storage compartment box. 11. Install the storage compartment cover assembly making sure the two lugs engage the slots; then secure the steering post cover with the reinstallable rivets.

2. Replace any one-way drain that is cracked or shows any signs of hardening or deterioration.

! CAUTION The one-way drain to the right is the clean air section of the filter housing. Any leak of this one-way drain will allow dirt into the engine intake causing severe engine damage.

3. Wipe any accumulation of oil or gas from the filter housing and one-way drains.

Valve/Tappet Clearance (Feeler Gauge Procedure) CD670

„ NOTE: For the 650 V-Twin, see Valve/Tappet Clearance (650 V-Twin) in this section. To check and adjust valve/tappet clearance, use the following procedure. „ NOTE: On the 250/300, the seat and air-intake snorkel must be removed for this procedure. 2-13

2


„ NOTE: On the 400 FIS/ACT, the seat assembly, side panels, and gas tank must be removed for this procedure.

400/500/650 H1

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 specifications, loosen the jam nut and rotate the tappet adjuster screw until the clearance is within specifications. Tighten each jam nut securely after completing the adjustment.

CC007DA

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.

! 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 component damage. VALVE/TAPPET CLEARANCE (250) Intake Exhaust

0.03-0.08 mm (0.001-0.003 in.) 0.08-0.13 mm (0.003-0.005 in.)

VALVE/TAPPET CLEARANCE (300) Intake Exhaust

0.03-0.08 mm (0.001-0.003 in.) 0.17-0.22 mm (0.007-0.009 in.)

VALVE/TAPPET CLEARANCE (400/500) Intake Exhaust (400) Exhaust (500)

0.05-0.10 mm (0.002-0.004 in.) 0.22-0.27 mm (0.009-0.011 in.) 0.17-0.22 mm (0.007-0.009 in.)

VALVE/TAPPET CLEARANCE (650 H1) Intake Exhaust

0.1016 mm (0.004 in.) 0.1524 mm (0.006 in.)

Valve/Tappet Clearance (Valve Adjuster Procedure)

„ NOTE: For the 650 V-Twin, see Valve/Tappet Clearance (650 V-Twin) in this section. To check and adjust valve/tappet clearance, use the following procedure. „ NOTE: On the 250/300, the seat and air-intake snorkel must be removed for this procedure. „ NOTE: On the 400 FIS/ACT, the seat assembly, side panels, and gas tank must be removed for this procedure. „ 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). 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 Gap Adjuster (p/n 0444-092) for the 250/300 or Valve Clearance Adjuster (p/n 0444-078) for the 400/500/650 H1 for this procedure.

CC409DA

2-14

3. Place the valve adjuster onto the jam nut securing 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 clockwise until friction is felt.

Valve/Tappet Clearance

5. Align the valve adjuster handle with one of the marks on the valve adjuster dial.

(650 V-Twin - Feeler Gauge Procedure)

6. While holding the valve adjuster handle in place, rotate the valve adjuster dial counterclockwise until proper valve/tappet clearance is attained.

To check and adjust valve/tappet clearance, use the following procedure.

„ NOTE: Refer to the appropriate specifications in Feeler Gauge Procedure sub-section for the proper valve/tappet clearance.

„ NOTE: Rotating the valve adjuster dial counterclockwise 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.

„ NOTE: The seat, air filter housing, front fenders, front inner covers, and side panels must be removed for this procedure. 1. Remove the cap screws securing the recoil starter; then remove the recoil starter assembly. 2. Remove the timing inspection plug; then remove the four tappet covers (for more detailed information, see Section 3 - Servicing Top-Side Components). 3. Rotate the crankshaft counterclockwise to the TDC position on the compression stroke indicated by the TF mark (A) on the flywheel. TF is top dead center front. „ NOTE: At this point, the rocker arms and adjuster screws on the front cylinder must not have pressure on them.

CC366D

9. Install the spark plug; then install the timing inspection plug. ATV2057B

4. Using a feeler gauge, check each valve/tappet clearance. If clearance is not within specifications, loosen jam nut (B) and rotate the tappet adjuster screw (A) until the clearance is within specifications. Tighten each jam nut to specifications after completing the adjustment.

CC411D

2-15

2


Valve/Tappet Clearance (650 V-Twin - Valve Adjuster Procedure)

To check and adjust valve/tappet clearance, use the following procedure. „ NOTE: The seat, air filter housing, front fenders, front inner covers, and side panels must be removed for this procedure. KX227

! 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 component damage. VALVE/TAPPET CLEARANCE (650 V-Twin) Intake Exhaust

0.10-0.15 mm (0.0039-0.0059 in.) 0.20-0.25 mm (0.0079-0.0098 in.)

5. Rotate the crankshaft counterclockwise until the TR mark (A) aligns in the timing hole. Repeat steps 3-4 for the rear cylinder.

1. Remove the cap screws securing the recoil starter; then remove the recoil starter assembly. 2. Remove the timing inspection plug; then remove the four tappet covers (for more detailed information, see Section 3 - Servicing Top-Side Components). 3. Rotate the crankshaft counterclockwise to the TDC position on the compression stroke indicated by the TF mark on the flywheel. TF is top dead center front. „ NOTE: At this point, the rocker arms and adjuster screws must not have pressure on them. „ NOTE: Use Valve Gap Adjuster (p/n 0444-092) for this procedure. 4. Place the valve adjuster onto the jam nut securing the tappet adjuster screw; then rotate the valve adjuster dial clockwise until the end is seated in the tappet adjuster screw. 5. While holding the valve adjuster dial in place, use the valve adjuster handle and loosen the jam nut; then rotate the tappet adjuster screw clockwise until friction is felt. 6. Align the valve adjuster handle with one of the marks on the valve adjuster dial.

ATV2058B

6. Install the timing inspection plug. 7. Place the four tappet covers into position. Tighten the cap screws securely. 8. Install the recoil starter assembly and tighten the cap screws securely. 9. Install the air filter housing, front inner covers, front fenders, and side panels; then install the seat and make sure it locks securely.

7. While holding the valve adjuster handle in place, rotate the valve adjuster dial counterclockwise 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 counterclockwise will open the valve/tappet clearance by 0.07 mm (0.003 in.) per mark. 8. While holding the adjuster dial at the proper clearance setting, tighten the jam nut securely with the valve adjuster handle; then tighten the jam nuts to specifications. 9. Rotate the crankshaft counterclockwise until the TR mark aligns in the timing hole; then repeat steps 4-8 for the rear cylinder.

2-16


10. Install the timing inspection plug; then install the four tappet covers and tighten securely. 11. Install the recoil starter assembly and tighten the cap screws securely.

6. If compression is abnormally low, inspect the following items. A. Verify starter cranks engine over. B. Gauge is functioning properly.

12. Install the air filter housing, front inner covers, front fenders, and side panels; then install the seat and make sure it locks securely.

C. Throttle lever in the full-open position. D. Valve/tappet clearance correct. E. Valve bent or burned.

Testing Engine Compression To test engine compression, use the following procedure. 1. Remove the high tension lead from the spark plug.

F. Valve seat 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).

2. Using compressed air, blow any debris from around the spark plug.

! WARNING Always wear safety glasses when using compressed air.

3. Remove the spark plug; then attach the high tension lead to the plug and ground the plug on the cylinder head well away from the spark plug hole.

Spark Plug A light brown insulator indicates that the plug is correct. A white or dark insulator indicates that the engine may need to be serviced or the carburetor may need to be adjusted. To maintain a hot, strong spark, keep the plug free of carbon.

4. Attach the Compression Gauge (p/n 0444-096). „ NOTE: The engine must be warm and the battery 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 250/300, the compression should be within a range of 157.5-192.5 psi in the full-open throttle position. For the 400/500/650 H1, the compression should be within a range of 63-77 psi in the full-open throttle position. For the 650 V-Twin, the compression should be within a range of 47-81 psi in the full-open throttle position.

ATV-0051

! CAUTION Before removing the spark plug, be sure to clean the area around the spark plug. Dirt could enter engine when removing or installing the spark plug.

Adjust the gap to 0.6 - 0.7 mm (0.024 - 0.028 in.) on the 250/300 or to 0.7 - 0.8 mm (0.028 - 0.032 in.) on the 400/500/650 H1/650 V-Twin for proper ignition. Use a feeler gauge to check the gap.

2-17

2


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 vent hose. Make certain that the vent hose is securely connected to the carburetor and the opposite end is always open.

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

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.

The muffler has a spark arrester which must be periodically cleaned. At the intervals shown in the Periodic Maintenance Chart, clean the spark arrester using the following procedure.

! WARNING Wait until the muffler cools to avoid burns.

1. Shift the transmission into neutral and set the brake lever lock. AL611D

2. Elevate the front of the ATV on a safety stand until the muffler is horizontal.

2. Turn the adjuster until the throttle cable has proper free-play of 3-6 mm (1/8 - 1/4 in.) at the lever.

3. Remove the plug from the bottom of the muffler.

ATV-0047 CD451A

4. Start the engine and increase RPM to “blow out� the accumulated carbon particles. 5. Stop the engine. Wait until the muffler cools; then install the plug and tighten securely. 2-18

3. Tighten the jam nut against the throttle cable adjuster securely; then slide the rubber boot over the adjuster.


Adjusting Choke Cable (650 V-Twin)

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 the correct RPM setting.

To adjust the choke cable for proper free-play, follow this procedure. 1. Slide the rubber boot (A) off the choke cable; then loosen jam nut (B).

2 CC795B

Adjustment Screw (400/500/650 H1) CD560A

2. Turn the adjuster (C) until proper free-play of 3-4 mm (0.12-0.16 in.) is attained at the end of the adjuster.

AF920C

650 V-Twin

CD560B

3. Tighten the jam nut securely against the end of the adjuster; then slide the rubber boot over the adjuster. KX029A

Adjusting Engine RPM (Idle)

To properly adjust the idle RPM, a tachometer is necessary. To adjust idle RPM, use the following procedure. „ NOTE: To access the idle adjustment screw, it will be necessary to remove the seat on the 250/300 models. The idle adjustment screw is located on the right-hand side of the carburetor on the 400/500/650 H1/650 V-Twin models.

IDLE RPM MODEL

RPM

250/300/400/500/650 H1 650 V-Twin

1250-1350 1050-1150

! WARNING Adjust the idle to the correct RPM. Make sure the engine is at normal operating temperature before adjusting the idle RPM.

2-19


Thank you very much for your reading. Please Click Here Then Get More Information.

2005 arctic cat 500 4x4 atv service repair manual  
2005 arctic cat 500 4x4 atv service repair manual  
Advertisement