Arctic Cat 2008 400 4x4 User manual

Arctic Cat
Models 400 4x4/400 4x4 3in1/500 4x4/500 4x4 3in1/650 H1/650 H1 3in1/700 Diesel
Operator`s manual

Page 1 Have a good trip! Your Arctic Cat-Team
INTRODUCTION
Congratulations for purchasing a high quality All-Terrain-Vehicle (ATV) by ARCTIC CAT. Be sure, as the owner/operator of
the ATV to become thoroughly familiar with its basic operation, maintenance and storage procedures. Carefully read the
Operator’s Manual before starting your ATV.
Particularly important information is distinguished in this manual by the notations „Warning, Caution and Note“. !! WARNING !!
refers to the safety of ATV operators, bystanders or persons inspecting or repairing the ATV. Please follow exactly the
instructions in order not to endanger your health or even your life. !! PRECAUTION !! indicates special precautions that must
be taken to avoid damage to the ATV. nNOTE provides key information to make procedures easier or more clear.
This booklet contains instructions on how to start and operate the ATV as well as some important information on how to
store it in the season break. For bigger repairs and service please contact an authorized ARCTIC CAT ATV dealer.
At the time of publication, all information and illustrations were technically correct. Some illustrations are used for clarity
purposes only and are not designed to depict actual conditions. Because Arctic Cat constantly refines and improves its
products , no retroactive obligation is incurred.
This ARCTIC CAT operator’s manual should be considered a permanent part of the ATV and must remain with the ATV
at the time of resale. If the ATV changes ownership please contact the warranty service of the company ARCTIC CAT,
Industriestraße 43, 5600 ST. JOHANN/PG., to ensure a proper registration. This manual was prepared by the service
department of ARCTIC CAT.
When in need of replacement parts, oil or accessories for your ARCTIC CAT ATV, be sure to use only GENUINE ARCTIC
CAT PARTS, OIL AND ACCESSORIES. Only genuine ARCTIC CAT parts, oil and accessories are engineered to meet
the standards and requirements of your ARCTIC CAT ATV. For a complete list of accessories refer to the current ARCTIC
CAT ATV Accessory Catalog. Your ARCTIC CAT ATV dealer will be pleased to aid you in service and maintenance
procedures.

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OWNER/VEHICLE
SURNAME
NAME
ZIP/CITY
Street/Nr.
Vehicle model
Chassis number
Engine number
Key number
Purchase date
Dealer
Dealer
Dealer`s signature and stamp
Vehicle owner
Owner`s signature

PAGE 3
Table of contents
Issue Page
TECHNICAL DATA ARCTIC CAT ATV............................................... 4
LOCATION OF PARTS AND CONTROLS ...................................... 13
OPERATOR´S MANUAL ................................................................ 15
GENERAL INFORMATION............................................................. 22
CONTROL LOCATIONS AND FUNCTIONS.................................... 24
GASOLINE / OIL / LUBRICANT ..................................................... 32
BREAK-IN PROCEDURE............................................................... 34
GENERAL MAINTENANCE............................................................ 37
PREPARATION FOR STORAGE .................................................... 49
PREPARATION AFTER STORAGE ................................................ 50
FOR YOUR SAFETY ..................................................................... 51
ACTIVE RIDING ............................................................................ 54
TROUBLESHOOTING ................................................................... 66
WARRANTY .................................................................................. 68
NOTES.......................................................................................... 73

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Engine and Drive 400 4x4 400 4x4 3in1
Type Four-cycle/Oil cooled Four-cycle/Oil cooled
Bore x Stroke 82x72,1 mm 82x72,1 mm
Displacement 376 ccm 376 ccm
Ignition type CDI CDI
Ignition timing 10° BTDC < 1500 turns/min 10° BTDC < 1500 turns/min
Spark plug type NGK CR7EA NGK CR7EA
Spark plug gap 0,7-0,8 mm 0,7-0,8 mm
Brake type Hydraulic service brake; mechanic parking brake
Carburetor type Keihin CVK 34 Keihin CVK 34
Chassis
Length (overall) 205 cm 244,5 cm
Height (overall) 122 cm 125 cm
Width (overall) 112 cm 120,7 cm
Suspension travel (front and rear) 21 cm 21 cm
Wheelbase 127 cm 147 cm
Front Tire Size 185-65-15 or 25x8-12 185-65-15 or 25x8-12
Technical Data ARCTIC CAT ATV

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400 4x4 400 4x4 3in1
Rear Tire Size 205-60-15 or 25x11-12 205-60-15 or 25x11-12
Tire Inflation Pressure
On Road
0,8-1,0 bar (according to load and
route)
0,8-1,0 bar (according to load and
route)
Tire Inflation Pressure
Off Road
0,8-1,0 bar (according to load and
route)
0,8-1,0 bar (according to load and
route)
Miscellany
Dry weight 288,5 kg 300 kg
Gas tank capacity 24,6 l 20,8 l
Reserve capacity 2,46 l 2 l
Differential capacity 275 ml 275 ml
Differential lubricant SAE 80W-90
Taillight / Brakelight 12V/5W/21W
Engine oil capacity 3,4 L 3,4 L
Rear drive volume 250 ml 250 ml
Gasoline (recommended) 87 Octane Regular Unleaded (EU: Regular Gasoline 91 oct.)
Engine oil (recommended) SAE 10W-40

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Headlight 12V/35W (2)
Starting System Electric with Manual Recoil*
Technical Data ARCTIC CAT ATV 500 4x4/500 4x4 3in1
Engine and Drive 500 4x4 500 4x4 3in1
Type Four-cycle/Liquid cooled Four-cycle/Liquid cooled
Bore x Stroke 87,5x82 mm 87,5x82 mm
Displacement 493 ccm 493 ccm
Igntion type CDI CDI
Ignition timing 10° BTDC < 1500 turns/min 10° BTDC < 1500 turns/min
Spark plug type NGK CR6E NGK CR6E
Spark plug gap 0,7-0,8 mm 0,7-0,8 mm
Brake type Hydraulic service brake; mechanic parking brake
Carburetor type Keihin CVK 36 Keihin CVK 36
* according to equipment

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Chassis 500 4x4 500 4x4 3in1
Length (overall) 210,8 cm 244,5 cm
Height (overall) 125 cm 125 cm
Width (overall) 120,7 cm 120,7 cm
Suspension travel (front and rear) 21 cm 21 cm
Wheelbase 127 cm 147 cm
Front Tire Size 185-65-15 or 25x8-12 185-65-15 or 25x8-12
Rear Tire Size 205-60-15 or 25x11-12 205-60-15 or 25x11-12
Tire Inflation Pressure
On Road
0,8-1,0 bar (according to load and
route)
0,8-1,0 bar (according to load and
route)
Tire Inflation Pressure
On Road
0,8-1,0 bar (according to load and
route)
0,8-1,0 bar (according to load and
route)
Miscellany
Dry weight 310 kg 310 kg
Gas tank capacity 24,6 l 20,8 l
Reserve capacity 2,46 l 2 l
Differential capacity (front) 275 ml 275 ml
Differential Lubricant SAE 80W-90 SAE 80W-90

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Rear drive volume 250 ml 250 ml
Coolant volume 2,9 l 2,9 l
Taillight / Brake light 12V/5W/21W 12V/5W/21W
Engine oil capacity 2,5 l 2,5 l
Gasoline 87 Octane Regular Unleaded (EU: Regular Gasoline 91 oct.)
Engine oil (recommended) SAE 10W-40 SAE 10W-40
Head light 12V/35W (2) 12V/35W (2)
Starting System Electric with Manual Recoil*
* according to equipment

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Technical Data ARCTIC CAT ATV 650 H1/650 H1 3in1
Engine and Drive 650 H1 650 H1 3in1
Type Four-cycle/Liquid cooled Four-cycle/Liquid cooled
Bore x Stroke 97,9x85 mm 97,9x85 mm
Displacement 641 ccm 641 ccm
Ignition type CDI CDI
Ignition timing 10° BTDC < 1500 turns/min 10° BTDC < 1500 turns/min
Spark plug type NGK CR6E NGK CR6E
Spark plug gap 0,7-0,8 mm 0,7-0,8 mm
Brake type Hydraulic service brake; mechanic parking brake
Carburetor type Keihin CVK-40 Keihin CVK-40
Chassis
Length (overall) 210,8 cm 244,5 cm
Height (overall) 125 cm 125 cm
Width (overall) 120,7 cm 120,7 cm
Suspension travel (front and rear) 21 cm 21 cm
Wheelbase 127 cm 147 cm

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650 H1 650 H1 3in1
Front Tire Size 185-65-15 or 25x8-12 185-65-15 or 25x8-12
Rear Tire Size 205-60-15 or 25x11-12 205-60-15 or 25x11-12
Tire Inflation Pressure On Road 0,8-1,0 bar (according to load and route)
Tire Inflation Pressure Off Road 0,8-1,0 bar (according to load and route)
Miscellany 650 H1 650 H1 3in1
Dry weight 348 kg 348 kg
Gas tank capacity 24,6 l 20,8 l
Reserve capacity 2,46 l 2 l
Differential capacity (front) 275 ml 275 ml
Differential Lubricant SAE 80W-90
Taillight / Brakelight 12V/5W/21W
Engine oil capacity 3,4 l 3,4 l
Rear drive volume 250 ml 250 ml
Gasoline (recommended) 87 Octane Regular Unleaded (EU: Regular Gasoline 91 oct.)
Engine oil (recommended) SAE 10W-40
Headlight 12V/35W (2)
Starting System Electric with Manual Recoil*
* according to equipment

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Engine and Drive 700 Diesel
Type Four-cycle Diesel/Liquid cooling
Bore x Stroke 75x77,6 mm
Displacement 686 ccm
Brake type Hydraulic service brake; mechanic parking brake
Chassis
Length (overall) 237 cm
Height (overall) 124,5 cm
Width (overall) 120 cm
Suspension travel (front and rear) 20 cm
Wheelbase 147 cm
Front Tire Size 25x8-12
Rear Tire Size 25x10-12
Tire Inflation Pressure On Road 0,8-1,0 bar (according to load and route)
Tire Inflation Pressure Off Road 0,8-1,0 bar (according to load and route)
Technical Data ARCTIC CAT ATV 700 Diesel

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Miscellany 700 Diesel
Dry weight 374 kg
Gas tank capacity 20,8l
Reserve capacity 2 l
Differential capacity (front) 275 ml
Differential Lubricant SAE 80W-90
Taillight/Brake light 12V/5W/21W / 12V/8W/27W
Engine oil capacity 2 l
Rear drive capacity 250 ml
Gasoline (recommended) 42-50 Cetan
Engine oil (recommended) SAE 10W-40
Transmission oil SAE80W-90/600ml
Head light 12V/27W (2)
Starting System Electric

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Location of Parts and Controls Models 400 4x4/400 4x4 3in1/500 4x4/500 4x4 3in1/650 H1/
650 H1 3in1
01.Battery (under the seat)
02.Headlight
04.Seat lock
05.Tool storage (under the seat
09.Gearshift lever
11.Recoil starter
12.Taillight/Brake light/Registration number
13.Operator´s Manual Location
21.Storage box
1
2
4
5
21
9
11
12
13
Symbolic pictures

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Location of Parts and Controls Models 400 4x4/400 4x4 3in1/500 4x4/500 4x4 3in1/650 H1/
650 H1 3in1/700 Diesel
6.Hand brake lever and parking brake
8.Ignition switch
010.Hazard warning lights
014.E-Starter
015.Drive selector (Model 4x4)
016.Low beam / full beam
017.Horn
018.Blinker left side and right side
019.Mirror
020.Differential lock
19 19
q NOTE
The ATV you have purchased may differ slightly
from those shown in the figures of this manual.
q NOTE
The engine is turned off with the ignition key.
15
17
18
14 10
16
8
6
20

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Operator`s Manual
Precautionary measures
The more you familiarize with the
operation of your vehicle, the better
you can handle it.
Always wear protective clothing:
Helmet, goggles, long-sleeved
shirt, long pants and boots with low
heels and a good tread which pre-
vents you from slipping.
!! WARNING !!
Beginning and inexperienced ATV
riders should take a rider training
course in occasion of which they
obtain or reinforce riding skills and
get to know some operating tech-
niques. For further information ple-
ase contact an authorized ARCTIC
CAT dealer.
Check before starting
!! WARNING !!
Always inspect this ATV each
time you use it to make sure it is
in safe operating conditions. Use
the checklist you’ll find at the next
page.
Brake burnishing procedure:
The service brake is activated by
the foot pedal (according to direc-
tive 93/14A EC homologation) or
via the left hand brake lever (both
hydraulic). The right hand lever
only activates the parking/auxiliary
brake which must not be used as
service brake.
!! IMPORTANT !!
For perfect brake efficiency you
have to burnish the brake pads.
To do so, please follow the instruc-
tions below:
Choose an area sufficiently large
to safely accelerate your ATV to 30
km/h.
Accelerate to 30 km/h, then com-
press brake lever to decelerate to
0 – 5 km/h.
Repeat this procedure approx. 20
times until brakes are heated up.
When mounting the mirrors, please
do not screw them in completely to
the stop, but fix them first with the
counter-nut. (Otherwise you risk to
seriously damage the support!)

ATV - Checkliste
Steering system
Turn the handlebars completely to
the right/left – there must be no
resistance. All parts of the steering
system must be properly fixed. No
play is allowed and steering has to
move freely.
Brakes
Check the brake fluid level. Activa-
te the service brake several times.
Check levers for tightness and ma-
noeuvrability. Test the parking bra-
ke: The wheels must lock when the
parking brake is engaged. Check
the brake linings for signs of wear.
Tire pressure
Make sure that each tire has the
right pressure. Check the state of
the tires: tread (at least 1,6 mm for
road tires/ at least 3mm for off-road
tires).
Fuel
Check the fuel level in the tank and
the fuel pipes. Make sure that the
filler cap is closed.
Lights
Inspect all lights (full beam and low
beam light).
Engine oil
Check the oil level with the oil level
stick (400/500) and, if necessary,
fill some engine oil into the crank-
case.
Transmission oil
Check the oil level in the front diffe-
rential (model 4x4) as well as in the
rear differential (model 400/500).
Throttle
Push the throttle control several
times and check if it returns easily
and rapidly into its original position
(there should be some play).
Gear linkage
Make sure that you can shift into
all gears without problems.
Follow these steps to start up the
engine:
1. Inspect the vehicle following
the check list
2. Test the hydraulic brake sys-
tem by pushing the pedal several
times.
3. Engage the parking brake.
!! WARNING !!
Never start the vehicle if the brake
systems don’t work properly (if the
brake lever is loose, if there’s not
enough brake liquid or the parking
brake does not lock the wheels).
Your personal safety depends on
the functionality of the brake sys-
tems. The parking brake may get
loose, if it is activated for a longer
period of time. Thus, block the
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Page 17
Start up the engine
wheels with appropriate objects
(stone, wedge).
1. Test the throttle control by
pushing it several times. It must
return immediately and completely
into its original position.
!! WARNING !!
If the throttle control doesn’t work
properly the vehicle should not be
started.
1. Shift the transmission into neu-
tral.
2. Rotate the ignition key to the
O-position.
Starting a cold engine
(400, 500, 650)
If the outdoor temperature is below
+ 5 ºC
!! WARNING !!
It is very important not to touch or
compress the throttle lever during
the starting procedures.
1. Only Diesel: Preheating
!! CAUTION !!
Don’t push the E-starter button
longer than 30 seconds.
1. Push the E-starter button.
!! CAUTION !!
If the temperature is –18°C or be-
low, you should activate the carbu-
retor pump three times.
!! CAUTION !!
It is extremely important to warm
up the engine before raising the
RPM. The engine should be left
in the idle position for at least 3
– 4 minutes before you accelerate
more than half way. In case of ex-
tremely low temperatures, the
time needed for warming up incre-
ases. If you don’t warm up the en-
gine sufficiently, there could occur
damages which are excluded of
warranty.
Starting a warm engine
Accelerate slightly and press the
E-starter button.
Emergency starting
All ATV models have an emergen-
cy recoil starter to use if the elec-
tric starter becomes inoperative.
To use the recoil starter follow this
procedure:
!! WARNING !!
Be sure the transmission is in the
neutral position, there is no gear
inserted and the parking brake is
engaged when using the emergen-
cy recoil starter.

1. Pull the recoil starter handle
slowly until resistance is felt; then
give a short, quick pull.
2. Repeat until the engine starts.
!! WARNING !!
When using the recoil starter, ple-
ase keep exactly to the procedure
mentioned above.
!! CAUTION !!
To avoid damaging the recoil star-
ter, DO NOT pull the recoil rope to
its limit or release the recoil handle
from an extended position. Allow
the rope to rewind slowly.
Turning off the engine
To turn off the engine, rotate the
ignition key to the OFF-position.
Bild: 400/500/ Shifting
(Automatic transmission)
The ARCTIC CAT ATV with an
automatic transmission has a dual-
range transmission with reverse:
1. R (Reverse)
2. N (Neutral)
3. H (High Range)
4. L (Low Range)
To shift the ATV follow these steps:
1. To engage the high range from
neutral, move the shift lever for-
ward.
2. To engage the low range from
high range, move the shift lever
outward and forward.
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