Arctic Cat 2015 XR User manual

SERVICE MANUAL
www.arcticcat.com
XR

FOREWORD
This Arctic Cat Service Manual contains service, maintenance, and troubleshooting information for certain 2015
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. For
service models not included in this manual, please refer to the following publications:
• 2015 90 Service Manual
• 2015 150 Service Manual
• 2015 300 DVX/Utility Service Manual
• 2015 400 Service Manual
• 2015 450 Service Manual
• 2015 700 Diesel Service Manual
• 2015 XC 450 Service Manual
• 2015 Core/TRV/Mud Pro 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.
This service manual is designed primarily for use by an Arctic Cat CatMaster Basic Level technician. The proce-
dures found in this manual are of varying difficulty, and certain service procedures in this manual require one or
more special tools to be completed. The technician should use sound judgement when determining which proce-
dures can be completed based on skill level and access to appropriate special tools.
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. A
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 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.
© 2015 Arctic Cat Inc. January 2015
®™ Trademarks of Arctic Cat Inc., Thief River Falls, MN 56701

1
TABLE OF CONTENTS
General Information ........................................................ 2
General Specifications.................................................. 2
Torque Specifications.................................................... 2
Torque Conversions (ft-lb/N-m)..................................... 3
Gasoline - Oil - Lubricant.............................................. 3
Genuine Parts............................................................... 4
Preparation For Storage ............................................... 4
Preparation After Storage ............................................. 5
Periodic Maintenance...................................................... 6
Lubrication Points ......................................................... 6
Air Filter ........................................................................ 6
Valve/Tappet Clearance ................................................ 7
Testing Engine Compression ........................................ 7
Spark Plug .................................................................... 8
Muffler/Spark Arrester .................................................. 8
Engine/Transmission Oil - Filter .................................... 9
Liquid Cooling System................................................ 10
Front Differential/Rear Drive Lubricant ....................... 11
Nuts/Bolts/Cap Screws ............................................... 12
Shift Lever................................................................... 12
Hydraulic Brake Systems............................................ 12
Burnishing Brake Pads ............................................... 14
Checking/Replacing V-Belt ......................................... 14
Steering/Frame/Controls............................................... 16
Front Body Panel/Side Panels/Rack ........................... 16
Rear Body Panel/Rack................................................ 17
LCD Gauge................................................................. 18
Steering Post/Tie Rods............................................... 18
Handlebar Grip ........................................................... 21
Throttle Control........................................................... 22
Steering Knuckles....................................................... 23
Measuring/Adjusting Toe-Out ..................................... 24
Shift Lever................................................................... 25
Front Bumper.............................................................. 26
Belly Panel.................................................................. 26
Muffler......................................................................... 26
Seat ............................................................................ 27
Headlights/Taillights-Brakelights ................................. 27
Troubleshooting .......................................................... 29
Engine/Transmission .................................................... 30
Specifications (500) .................................................... 31
Specifications (550/700) ............................................. 31
Troubleshooting .......................................................... 32
Removing Engine/Transmission ................................. 34
Servicing Engine (500) ............................................... 36
Servicing Engine (550/700) ........................................ 74
Installing Engine/Transmission ................................. 112
Fuel/Lubrication/Cooling ............................................ 114
Throttle Body ............................................................ 114
Throttle Cable Free-Play........................................... 115
Engine RPM (Idle) .................................................... 115
Gas Tank................................................................... 115
Testing Oil Pump Pressure........................................116
Liquid Cooling System ..............................................117
Troubleshooting .........................................................119
Electrical System .........................................................120
Battery.......................................................................120
Accessory Receptacle/Connector .............................121
Brakelight Switch.......................................................121
Engine Coolant Temperature (ECT) Sensor..............122
Fan Motor ..................................................................122
Power Distribution Module (PDM) .............................123
Ignition Coil ...............................................................123
EFI Sensors/Components .........................................124
Speed Sensor ...........................................................125
RPM Limiter ..............................................................125
Electronic Power Steering (EPS) ..............................126
Ignition Switch ...........................................................127
Handlebar Control Switches......................................128
Drive Select Switch ...................................................129
Front Differential Actuator System.............................129
Stator Coil .................................................................129
Starter Relay .............................................................130
Starter Motor .............................................................131
Electronic Control Module (ECM)..............................131
Fuel Pump/Fuel Level Sensor ...................................131
Regulator/Rectifier ....................................................133
Headlights .................................................................133
Taillights - Brakelights................................................133
Ignition Timing...........................................................134
Tilt Sensor .................................................................134
Throttle Position Sensor (TPS)..................................135
Gear Position Switch .................................................136
EFI Diagnostic System..............................................137
Troubleshooting .........................................................142
Drive System/Brake System .......................................143
Front Drive Actuator/Differential Lock........................143
Front Differential ........................................................144
Drive Axles ................................................................156
Rear Gear Case ........................................................158
Hub............................................................................159
Hand Brake Lever/Master Cylinder Assembly...........160
Hydraulic Brake Caliper.............................................162
Troubleshooting Drive System...................................165
Troubleshooting Brake System..................................165
Suspension...................................................................166
Shock Absorbers.......................................................166
Front A-Arms .............................................................167
Rear A-Arms .............................................................169
Rear Sway Bar ..........................................................171
Wheels and Tires ......................................................172
Troubleshooting .........................................................173

2
General Information
NOTE: Some photographs and illustrations used in
this manual are used for clarity purposes only and
are not designed to depict actual conditions.
NOTE: Whenever a part is worn excessively, cracked,
or damaged in any way, replacement is necessary.
General Specifications
Specifications subject to change without notice.
* One inch below plug threads. ** At the plug threads.
Torque Specifications
* w/Blue Loctite #243 ** w/Red Loctite #271
*** w/Green Loctite #609 **** w/Three Bond Sealant
***** w/ “Patch-Lock”
MISCELLANY
Tire Size Front - 25 x 8-12
Rear - 25 x 10-12
Tire Inflation Pressure 0.35 kg/cm² (5 psi)
Spark Plug Type (500)
(550/700)
NGK CR7E
NGK CPR8E
Spark Plug Gap (500)
(550/700)
0.7-0.8 mm (0.028-0.031 in.)
0.5-0.6 mm (0.019-0.024 in.)
Gas Tank Capacity 21.6 L (5.7 U.S. gal.)
Coolant Capacity 2.9 L (3.0 U.S. qt)
Rear Drive Capacity 250 ml (8.5 fl oz)*
Front Differential Capacity 275 ml (9.3 fl oz)**
Engine Oil Capacity (approx) (500)
(550/700)
2.8 L (3.0 U.S. qt) - Overhaul
2.5 L (2.6 U.S. qt) - Change
2.5 L (2.6 U.S. qt) - Overhaul
1.9 L (2.0 U.S. qt) - Change
Gasoline (recommended) 87 Octane Regular Unleaded
Engine Oil (recommended) Arctic Cat ACX All Weather
(Synthetic)
Differential/Rear Drive Lubricant SAE Approved 80W-90 Hypoid
Drive Belt Width (minimum) 28.5 mm (1.12 in.)
Brake Fluid DOT 4
Taillight/Brakelight High Intensity LED
Headlight High Intensity LED
ELECTRICAL SYSTEM
Ignition Timing 10° BTDC @ 1500 RPM
Spark Plug Cap 5000 ohms
Ignition Coil Resistance (primary)
(secondary)
Less than 5.0 ohms
12k-19k ohms
Ignition Coil Primary Voltage Battery Voltage
Stator Coil (CKP sensor)
Resistance (AC generator)
104-156 ohms
Less than 1 ohm
Crankshaft Position Sensor 2.0 AC volts or more
AC Generator Output (no load) 75 AC volts @ 5000 RPM
EXHAUST COMPONENTS
Part Part Bolted To Torque
ft-lb N-m
Exhaust Pipe Engine 20 27
Spark Arrester Muffler 48
in.-lb
5.5
Heat Shield Exhaust Pipe 8 11
STEERING COMPONENTS
Steering Shaft Frame 20 27
Steering Shaft Flange Frame 11 15
Steering Post Handlebar Block 20 27
Tie Rod End** Knuckle/Steering Shaft 55 74
EPS Housing Frame 35 47
Handlebar End Cap Handlebar 8 11
BRAKE COMPONENTS
Brake Disc Hub 15 20
Brake Hose Frame 12 16
Brake Hose Caliper/Cylinder 20 27
Master Cylinder Master Cylinder Clamp 6 8
Master Cylinder Frame 12 16
Caliper Knuckle 20 27
Brake Clip A-Arm 40
in.-lb
4.5
Brake Pedal Pedal Axle 25 34
MISCELLANEOUS COMPONENTS
Radiator Frame 12 16
Coil Frame 10
in.-lb
1.1
Front Bumper Frame Mount 20 27
Front Bumper Frame 35 47
Belly Panel Frame 6 8
Rack Frame/Rack Mount 13 18
Taillight Rear Fascia 13 18
Gas Tank Mounting Bracket Frame 8 11
Rear Fascia Frame 13 18
Side Panel/Console Frame 8 11
Front Fascia Front Bumper (lower) 8 11
Front Fascia Front Bumper (upper) 5 7
Rack Mount Frame 13 18
SUSPENSION COMPONENTS
A-Arm Frame 50 68
Knuckle Ball Joint 35 47
Shock Absorber Frame/A-Arm 50 68
Knuckle A-Arm 50 68
Sway Bar Frame 35 47
Sway Bar Link Lower A-Arm 25 33
DRIVE TRAIN COMPONENTS
Front Differential* Frame/Differential
Bracket
38 52
Oil Fill Plug Front Differential/Rear
Drive
16 22
Wheel (Steel) Hub 40 54
Wheel (Aluminum w/black nuts) Hub 60 81
Wheel (Aluminum w/chrome
nuts)
Hub 80 108
Rear Gear Case* Frame 38 52
Hub Axle 200 272
Oil Drain Plug Front Differential/Rear
Drive
45
in.-lb
5
Pinion Housing Differential Housing 23 31
Differential Housing Cover*** Differential Housing 23 31
Input Shaft Assembly Differential Housing 23 31
Thrust Button** Gear Case Cover 8 11
Input Shaft/Housing Gear Case 23 31
Output Shaft Flange 20 27

3
* w/Blue Loctite #243
** w/Red Loctite #271
*** w/Green Loctite #609
**** w/Three Bond Sealant
Torque Conversions
(ft-lb/N-m)
Gasoline - Oil - Lubricant
RECOMMENDED GASOLINE
The recommended gasoline to use is 87 minimum octane
regular unleaded. In many areas, oxygenates are added to
the gasoline. Oxygenated gasolines containing up to 10%
ethanol or 5% methane 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.
ENGINE/TRANSMISSION
Part Part Bolted To Torque
ft-lb N-m
Clutch Shoe** (500) Crankshaft 147 199
Clutch Shoe** (550/700) Crankshaft 221 300
Driven Pulley** (500) Driveshaft 147 199
Driven Pulley** (550/700) Driveshaft 162 220
Ground Wire Engine 8 11
Magneto Cover Crankcase 9.5 13
Speed Sensor Housing
(550/700)
Crankcase 8.5 11.5
Oil Drain Plug Engine 16 22
Clutch Cover/Housing Crankcase 9.5 13
Cam Sprocket** Camshaft 10 14
Cylinder Crankcase 8 11
V-Belt Cover Clutch Cover/Housing 45
in.-lb
5
Movable Drive Face** (500) Centrifugal Clutch
Housing
147 199
Movable Drive Face** (550/700) Centrifugal Clutch
Housing
165 224
Starter Clutch** Flywheel 26 35
Output Shaft Nut** Output Shaft 59 80
Valve Cover Cylinder Head 8.5 11.5
Stator Coil (New) Magneto Cover 13 18
Stator Coil (Existing) Magneto Cover 11.5 15
Oil Strainer Cap Crankcase 10 14
Tappet Cover Valve Cover 8.5 11.5
Rotor/Flywheel Crankshaft 107 145
Oil Pump** Crankcase 8.5 11.5
Water Pump/Housing Magneto Cover 8 11
Water Pump Cover Water Pump Housing 11.5 15
Crankcase Half (6 mm) Crankcase Half 10 14
Crankcase Half (8 mm) Crankcase Half 21 28
Starter Motor Crankcase 10 14
Shift Lever Shift Axle 8 11
Engine Mounting Through-Bolt Frame 35 47
ENGINE/TRANSMISSION (500)
Cylinder Head (Cap Screw) Crankcase 28 38
Cylinder Head (Nut) Cylinder 20 27
Oil Pump Drive Gear** Crankshaft 63 85
Cam Chain Tensioner Guide Cylinder Head 11 15
Cam Chain Tensioner Cylinder 10 14
Water Pump Drive Gear Crankshaft 28 38
ENGINE/TRANSMISSION (550/700)
Output Yoke Nut** Output Shaft 200 270
Shift Cam Plate Shift Cam Shaft 8 11
Cylinder Head (Cap Screw) Crankcase 40 54
Cylinder Head Nut (6 mm) Cylinder 8.5 11.5
Cylinder Head Nut (8 mm) Cylinder 21 28
Shift Cam Stopper Crankcase 8 11
Crankshaft Bushing Crankshaft 25 34
Oil Pump Drive Gear** Crank Balancer Shaft 63 85
Outer Magneto Cover Left-Side Cover 10 14
Secondary Shaft Bearing
Housing
Crankcase Half 28 38
ft-lb N-m ft-lb N-m ft-lb N-m ft-lb N-m
11.4 26 35.4 51 69.4 76 103.4
22.7 27 36.7 52 70.7 77 104.7
34.1 28 38.1 53 72.1 78 106.1
45.4 29 39.4 54 73.4 79 107.4
56.8 30 40.8 55 74.8 80 108.8
68.2 31 42.2 56 76.2 81 110.2
79.5 32 43.5 57 77.5 82 111.5
810.9 33 44.9 58 78.9 83 112.9
912.2 34 46.2 59 80.2 84 114.2
10 13.6 35 47.6 60 81.6 85 115.6
11 15 36 49 61 83 86 117
12 16.3 37 50.3 62 84.3 87 118.3
13 17.7 38 51.7 63 85.7 88 119.7
14 19 39 53 64 87 89 121
15 20.4 40 54.4 65 88.4 90 122.4
16 21.8 41 55.8 66 89.8 91 123.8
17 23.1 42 57.1 67 91.1 92 125.1
18 24.5 43 58.5 68 92.5 93 126.5
19 25.8 44 59.8 69 93.8 94 127.8
20 27.2 45 61.2 70 95.2 95 129.2
21 28.6 46 62.6 71 96.6 96 130.6
22 29.9 47 63.9 72 97.9 97 131.9
23 31.3 48 65.3 73 99.3 98 133.3
24 32.6 49 66.6 74 100.6 99 134.6
25 34 50 68 75 102 100 136
CAUTION
Do not use white gas. Only Arctic Cat approved gaso-
line additives should be used.

4
RECOMMENDED ENGINE/
TRANSMISSION OIL
The recommended oil to use is Arctic Cat ACX All
Weather synthetic which has been specifically formu-
lated for use in this Arctic Cat engine. Although Arctic
Cat ACX All Weather synthetic engine oil is the only oil
recommended for use in this engine, use of any API certi-
fied SM 0W-40 oil is acceptable.
OILCHARTJ
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 hyp-
oid. This lubricant meets all of the lubrication requirements
of the Arctic Cat ATV front differentials and rear drives.
FILLING GAS TANK
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.
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 Illus-
trated Parts Manual for the correct part number, quantity,
and description.
Preparation For Storage
Arctic Cat recommends the following procedure to pre-
pare 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.
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. Stop the engine.
Install the air filter and housing cover.
4. Plug the exhaust hole in the exhaust system with a
clean cloth.
5. Apply light oil to the upper steering post bushing and
plungers of the shock absorbers.
6. 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.
7. Fill the cooling system to the bottom of the stand
pipe in the radiator neck with properly mixed cool-
ant.
8. Disconnect the battery cables; then remove the bat-
tery, clean the battery posts and cables, and store in a
clean, dry area.
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.
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 gasoline 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.
CAUTION
If the interior of the air filter housing is dirty, clean the
area before starting the engine.

5
9. Store the ATV indoors in a level position.
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 pre-
pare 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. Check the coolant level and add properly mixed
coolant as necessary.
6. Charge the battery; then install. Connect the battery
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 mak-
ing sure all calibrated nuts, cap screws, and bolts are
tightened to specifications.
9. Check tire pressure. Inflate to recommended pres-
sure as necessary.
10. Make sure the steering moves freely and does not
bind.
11. Check the spark plug. Clean or replace as necessary.
CAUTION
Avoid storing outside in direct sunlight and avoid using
a plastic cover as moisture will collect on the ATV caus-
ing rusting. CAUTION
The ignition switch must be in the OFF position prior to
installing the battery or damage may occur to the igni-
tion system.
CAUTION
Connect the positive battery cable first; then the nega-
tive.

6
Periodic Maintenance
This section has been organized into sub-sections which show
common maintenance procedures for the Arctic Cat ATV.
 NOTE: Arctic Cat recommends the use of new gas-
kets, lock nuts, and seals and lubricating all internal
components when servicing the engine/transmission.
SPECIAL TOOLS
A number of special tools must be available to the techni-
cian when performing service procedures in this section.
NOTE: Special tools are available from the Arctic
Cat Service Department.
Lubrication Points
It is advisable to lubricate certain components periodi-
cally to ensure free movement. Apply light oil to the
components using the following list as reference.
A. Throttle Lever Pivot
B. Brake Lever Pivot
C. Auxiliary Brake Pedal Pivot
Air Filter
1. Remove the seat; then remove the clips securing the
air filter housing cover.
XR002A
2. Loosen the clamp securing the air filter to the inside
of the housing; then remove the filter.
XR029A
3. Carefully remove the pre-filter from the air filter. If
the air filter is dirty, it must be replaced.
XR049
4. Using an air hose, clean the pre-filter.
5. Slide the pre-filter over the closed end of the new fil-
ter and install into the housing. Tighten the clamp
securely.
6. Install the air filter housing cover and secure with the
clips.
7. Install the seat.
CHECKING AND CLEANING DRAINS
1. Inspect the drains beneath the main housing for
water/oil and for proper sealing.
XR055A
Description p/n
Compression Tester Kit 0444-213
Oil Filter Wrench 0644-389
Spanner Wrench 0444-240
Valve Clearance Adjuster 0444-255

7
2. Replace any 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 drains.
Valve/Tappet Clearance
To check and adjust valve/tappet clearance, use the fol-
lowing procedure.
1. Remove the timing inspection plug; then remove the
tappet covers and spark plug (for more detailed
information, see Engine/Transmission - Servicing
Top-Side Components).
2. Rotate the crankshaft to the TDC position on the
compression stroke.
GZ063
NOTE: At this point, the rocker arms and adjuster
screws must not have pressure on them.
Feeler Gauge Procedure
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 clear-
ance is within specifications. Tighten each jam nut
securely after completing the adjustment.
CC007DC
Valve Adjuster Procedure
NOTE: 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.
A. Place Valve Clearance 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.
B. 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.
C. Align the valve adjuster handle with one of the
marks on the valve adjuster dial.
D. 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 counter-
clockwise will open the valve/tappet clearance by
0.05 mm (0.002 in.) per mark.
E. While holding the adjuster dial at the proper
clearance setting, tighten the jam nut securely
with the valve adjuster handle.
3. Install the timing inspection plug.
4. Place the tappet covers into position making sure the
proper cap screws are with the proper cover. Tighten
the cap screws securely.
5. Install the spark plug.
Testing Engine
Compression
1. Remove the high tension lead from the spark plug.
CAUTION
The drain to the right is the clean air section of the filter
housing. Any leak of this 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 measure-
ment of clearance. Failure to measure the valve clear-
ance accurately could cause valve component damage.
VALVE/TAPPET CLEARANCE
500 0.08-0.12 mm (0.003-0.005 in.) - Intake
0.15-0.20 mm (0.006-0.008 in.) - Exhaust
550/700 0.08-0.12 mm (0.003-0.005 in.) - Intake
0.13-0.17 mm (0.005-0.007 in.) - Exhaust

8
2. Using compressed air, blow any debris from around
the spark plug.
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.
4. Attach the Compression Tester Kit.
NOTE: The engine should be warm (operating tem-
perature) and the battery fully charged for an accu-
rate compression test. Throttle must be in the
wide-open throttle (WOT) position. In the event the
engine cannot be run, cold values are included.
5. While holding the throttle lever in the full-open posi-
tion, crank the engine over with the electric starter
until the gauge shows a peak reading (five to 10
compression strokes).
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. Engine warmed up.
F. Intake not restricted.
NOTE: To service valves, see Engine/Transmission.
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 Engine/Transmission).
Spark Plug
A light brown insulator indicates that a plug is correct. A
white or dark insulator indicates that the engine may need
to be serviced. To maintain a hot, strong spark, keep the
plug free of carbon.
ATV-0051
Adjust the gap to correct specification (see General Infor-
mation for proper type and gap). Use a feeler gauge to
check the gap.
ATV0052
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
At the intervals shown in the Periodic Maintenance
Chart, clean the spark arrester using the following proce-
dure.
1. Remove the three cap screws securing the spark
arrester assembly to the muffler; then loosen and
remove the arrester.
! WARNING
Always wear safety glasses when using compressed
air.
COMPRESSION
Model PSI Hot (WOT) PSI Cold (WOT)
500 95-115 N/A
550 120-140 80-120
700 125-145 100-140
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.

9
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 48 in.-lb.
CF104
Engine/Transmission
Oil - Filter
OIL - FILTER
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.
CF109M
KC372A
3. Remove the drain plug from the bottom of the engine
and drain the oil into a drain pan.
733-441A
4. Using the adjustable Oil Filter Wrench and a suitable
wrench, remove the old oil filter.
NOTE: Clean up any excess oil after removing the
filter.
5. 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.
550/700
500

10
6. Install the engine drain plug and tighten to 16 ft-lb.
Pour the specified amount of the recommended oil in
the filler hole. Install the oil level stick/filler plug.
7. Start the engine (while the ATV is outside on level
ground) and allow it to idle for a few minutes.
8. Turn the engine off and wait approximately one min-
ute.
9. Remove the oil level stick and wipe it with a clean
cloth.
10. Install the oil level stick and thread into the engine
case.
11. Remove the oil level stick; the oil level must be
within the operating range but not exceeding the
upper mark.
XR075A
12. Inspect the area around the drain plug and oil filter
for leaks.
Liquid Cooling System
NOTE: Debris in front of the engine or packed
between the cooling fins of the radiator can reduce
cooling capability. Using a garden hose, wash the
radiator to remove any debris preventing air flow.
The cooling system capacity can be found in General
Information. The cooling system should be inspected
daily for leakage and damage. If leakage or damage is
detected, take the ATV to an authorized Arctic Cat ATV
dealer for service. Also, the coolant level should be
checked periodically.
NOTE: High engine RPM, low vehicle speed, or
heavy load can raise engine temperature. Decreasing
engine RPM, reducing load, and selecting an appro-
priate transmission gear can lower the temperature.
When filling the cooling system, use a coolant/water
mixture which will satisfy the coldest anticipated weather
conditions of the area in accordance with the coolant
manufacturer’s recommendations. While the cooling sys-
tem 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 bot-
tom of the stand pipe in the radiator neck.
Checking/Filling
1. Remove the rubber access plug from the front fender.
XR061
2. Carefully rotate the radiator cap counterclockwise to
release pressure; then remove the cap.
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 recom-
mended are racing, vegetable, non-detergent, and cas-
tor-based oils.
CAUTION
Do not over-fill the engine with oil. Always make sure
that the oil level is not above the upper mark.
CAUTION
Arctic Cat does not recommend using a pressure
washer to clean the radiator core. The pressure may
bend or flatten the fins causing restricted air flow, and
electrical components on the radiator could be dam-
aged. Use only a garden hose with spray nozzle at nor-
mal tap pressure.
CAUTION
Continued operation of the ATV with high engine tem-
perature may result in engine damage or premature
wear.

11
XR060
3. Add coolant as necessary; then install the radiator
cap and access plug.
NOTE: Use a good quality, biodegradable gly-
col-based, automotive-type antifreeze.
Front Differential/Rear
Drive Lubricant
When changing the lubricant, use approved SAE 80W-90
hypoid gear lube.
To check lubricant, remove the fill plug; the lubricant
level should be 1 in. below the threads of the plug. If low,
add SAE approved 80W-90 hypoid gear lubricant as nec-
essary.
To change the lubricant, use the following procedure.
1. Place the ATV on level ground.
2. Remove each oil filler plug.
3. Drain the oil into a drain pan by removing in turn the
drain plug from each.
XR019A
XR017A
4. After all the oil has been drained, install the drain
plugs and tighten securely.
5. Pour recommended oil into each filler hole.
XR022A
NOTE: Arctic Cat recommends the use of genuine
Arctic Cat lubricants.
6. Install the filler plugs.
! WARNING
Never check the coolant level when the engine is hot or
the cooling system is under pressure.
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.
CAUTION
Any lubricant used in place of the recommended gear
lube could result in premature failure of the shock lim-
iter. Do not use any lubricant containing graphite or
molybdenum additives or other friction-modified lubri-
cants as these may cause severe damage to shock lim-
iter components.
CAUTION
Inspect the oil for any signs of metal filings or water. If
found, take the ATV to an authorized Arctic Cat ATV
dealer for servicing.
Front

12
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 Gen-
eral Information).
Shift Lever
CHECKING ADJUSTMENT
XR004A
ADJUSTING SHIFT LEVER
1. Remove the seat and left side panel.
2. With the ignition switch in the ON position, loosen
jam nut (A) (left-hand threads); then loosen jam nut
(C) and with the shift lever in the reverse position,
adjust the coupler (B) until the transmission is in
reverse and the (R) icon appears on the LCD.
XR080A
3. Tighten the jam nuts securely; then shift the trans-
mission to each position and verify correct adjust-
ment.
4. Install the left-side engine cover and seat making
sure the seat locks securely in place.
NOTE: An E (Error) in the gear position icon indi-
cates no signal or a poor ground wire connection in
the circuit. Troubleshoot the harness connectors,
gear position switch connector, gear position switch,
and LCD connector.
Hydraulic Brake Systems
CHECKING/BLEEDING
The hydraulic brake systems have been filled and bled at
the factory. To check and/or bleed a hydraulic brake sys-
tem, use the following procedure.
1. With the master cylinder in a level position, check the
fluid level in the reservoir. On the hand brake if the
level in the reservoir is adequate, the sight glass will
appear dark. If the level is low, the sight glass will
appear clear. On the auxiliary brake, the level must be
between the MIN and MAX lines on the reservoir.
CF295A
XR021A
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 main brake system, use the following
procedure.
A. Remove the cover and fill the reservoir with DOT
4 Brake Fluid; then install and secure the cover.
B. Slowly compress the brake lever several times.
! WARNING
Never shift the ATV into reverse gear when the ATV is
moving as it could cause the ATV to stop suddenly
throwing the operator from the ATV.

13
C. Remove the protective cap, install one end of a clear
hose onto the REAR 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.
XR167A
NOTE: During the bleeding procedure, watch the
sight glass very closely to make sure there is always
a sufficient amount of brake fluid. If low, refill the res-
ervoir before the bleeding procedure is continued.
Failure to maintain a sufficient amount of fluid in the
reservoir will result in air in the system.
D. At this point, perform step B and C on the
FRONT LEFT bleeder screw; then move to the
FRONT RIGHT bleeder screw and follow the
same procedure.
E. Repeat step D until the brake lever is firm.
4. To bleed the auxiliary brake system, use the follow-
ing procedure.
A. Remove the cover and fill the reservoir with DOT
4 Brake Fluid; then install and secure the cover.
B. Slowly compress the brake pedal several times.
C. Remove the protective cap, install one end of a clear
hose onto the rear bleeder screw, and direct the
other end into a container; then while holding slight
pressure on the brake pedal, open the bleeder screw
and watch for air bubbles. Close the bleeder screw
before releasing the brake pedal. Repeat this proce-
dure until no air bubbles are present.
XR023A
NOTE: During the bleeding procedure, watch the
reservoir very closely to make sure there is always a
sufficient amount of brake fluid. If low, refill the reser-
voir before the bleeding procedure is continued. Fail-
ure to maintain a sufficient amount of fluid in the
reservoir will result in air in the system.
D. Repeat step B and C until the brake pedal is firm.
5. 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.
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 thick-
ness of each of the brake pads as follows.
NOTE: As brake pads wear, it may be necessary to
“top-off” the brake fluid in the reservoir.
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 proce-
dure.
A. Remove the wheel.
B. Remove the cap screws securing the caliper
holder to the knuckle; then remove the pads.
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 sur-
faces.

14
PR237
C. Install the new brake pads.
D. Secure the caliper to the knuckle and/or axle
housing with new “patch-lock” cap screws.
Tighten to 20 ft-lb.
XR012A
E. Install the wheel; then using a crisscross pattern,
tighten the wheel nuts in 20 ft-lb increments to a
final torque of 40 ft-lb (steel wheel), 60 ft-lb (alu-
minium wheel w/black nuts), or 80 ft-lb (aluminum
wheel w/chrome nuts).
5. Burnish the brake pads (see Burnishing Brake Pads
in this section).
Burnishing Brake Pads
Brake pads (both main and auxiliary) must be burnished to
achieve full braking effectiveness. Braking distance will be
extended until brake pads are properly burnished. To prop-
erly 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 release the accelerator
pedal and compress brake lever or apply the auxil-
iary brake to decelerate to 0-5 mph.
3. Repeat procedure on each brake system twenty times.
4. Verify that the brakelight illuminates when the hand
lever is compressed or the brake pedal is depressed.
Checking/Replacing
V-Belt
REMOVING
1. Remove the right-side footrest and brake pedal (see
Steering/Frame/Controls).
XR087A
2. Remove the cap screws securing the CVT cover;
then using a rubber mallet, gently tap on the cover
tabs to loosen the cover. Remove the cover.
XR089
3. Remove the nut securing the movable drive face;
then remove the face. Account for the flat washer
and spacer.
NOTE: Keep the drive face plate in contact with the
drive face when removing or installing the drive face
to prevent the rollers from falling out.
! 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.

15
CF364A
CD966A
4. Install the cap screw from the tool kit into the driven
pulley fixed face; then turn the cap screw clockwise
to spread the pulley faces. Remove the V-belt.
GZ076
GZ085
INSTALLING
1. Place the V-belt into position on the driven pulley
and over the front shaft.
GZ085
NOTE: The arrows on the V-belt should point in
direction of engine rotation (forward).
2. Pinch the V-belt together near its center and slide the
spacer and movable drive face onto the front shaft.
Secure the drive face with a washer and nut (coated with
red Loctite #271). Using an appropriate spanner wrench,
tighten the nut to 147 ft-lb (500) or 165 ft-lb (550/700).
CF379A
NOTE: At this point, the cap screw can be removed
from the driven pulley.
3. With the vehicle in neutral, rotate the V-belt and
clutches counterclockwise until the V-belt is flush
with the top of the driven pulley.
4. Place the CVT cover gasket into position; then install
the cover and secure with the cap screws. Tighten the
cap screws to 45 in.-lb.
5. Install the right-side footrest and brake pedal (see
Steering/Frame/Controls). Tighten the pedal cap
screw to 25 ft-lb.
6. Secure the front fender to the footrest with the three
cap screws. Tighten securely.
CAUTION
Make sure the movable drive face plate is fully engaged
onto the splines of the clutch shaft before tightening the
nut or false torque readings may occur. This will cause
the assembly to loosen damaging the shaft and clutch
face plate.

16
Steering/Frame/Controls
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 capability.
C. Steering post bearing assembly/bearing housing
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.
The frame, welds, and racks should be checked periodi-
cally for damage, bends, cracks, deterioration, broken
components, and missing components.
Front Body Panel/Side
Panels/Rack
NOTE: The technician should use sound judgment
and discretion when determining which components
require removing to service a particular component.
NOTE: To remove the front rack, the front body
panel must be removed.
REMOVING
1. Remove the seat; then remove the shift lever knob.
2. Remove the left-side engine cover; then remove the
fasteners securing the side panels to the frame.
Remove the side panels.
XR135A
3. Remove the torx-head screws securing the center
access cover to the console.
XR134A
4. Pry the gauge from the console; then disconnect the
gauge and set aside.
5. Slide the console rearward to disengage the tabs;
then tilt the console up and disconnect the ignition
switch and accessory plug connectors.
6. Remove the torx-head screws (three on each side)
securing the front body panel to the footwell.
7. Disconnect the headlight and running light connec-
tors; then remove the snap clips securing the harness
to the front body panel.
XR139A
8. Remove the two bolts securing the lower fascia to
the front bumper. Discard the bolts.
9. Remove the three shoulder bolts securing the rack
mount to the frame. Discard the bolts.
XR138A
10. Remove the four torx-head screws securing the fas-
cia to the front bumper.

17
XR133A
CLEANING AND INSPECTING
1. Clean all components with warm soap and water.
2. Inspect for cracks and/or loose rivets.
3. Inspect for any missing decals.
INSTALLING
1. Place the front body panel/rack assembly into posi-
tion on the frame.
2. Connect the headlights and running lights; then
secure the harnesses to the frame using the existing
push clips.
3. Secure the front fascia to the front bumper using the
existing four torx-head screws.
4. Secure the lower fascia to the front bumper using
two new “patch-lock” bolts. Tighten to 8 ft-lb.
5. Secure the rack mount to the frame using new
“patch-lock” shoulder bolts. Tighten to 13 ft-lb.
6. Secure the front body panel to the footwells using the
existing cap screws.
7. With the console tilted up, connect the accessory
plug and ignition switch harnesses; then tilt the con-
sole into position and slide forward until correctly
positioned.
8. Install the center access panel and secure to the con-
sole with the two torx-head screws. Tighten to 8
ft-lb.
9. Connect the gauge; then press the gauge into posi-
tion.
10. Install the side panels making sure the tabs are all
correctly in the slots and the shift lever is correctly
oriented; then secure with the fasteners.
11. Install the left-side engine cover; then install the shift
lever knob.
12. Install the seat making sure it locks securely in place.
Rear Body Panel/Rack
REMOVING
NOTE: If the technician’s objective is to remove the
rear rack, proceed to step 6.
1. Remove the seat; then remove the shift lever knob
and side panels.
2. Remove the torx-head screws (three on each side)
securing the rear body panel to the footwell.
XR127
3. Remove the hose clamp securing the gas tank to the
gas tank hose. Account for the hose clamp.
XR130
4. Disconnect the taillight connectors.
5. Remove the two torx-head screws securing the rear
fascia to the frame.
CAUTION
Seal off the opening to prevent contaminants from fall-
ing into the gas tank.

18
XR131A
6. Remove the four lock nuts securing the rear body
panel to the mounting tabs on the frame. Discard the
lock nuts.
CLEANING AND INSPECTING
1. Clean all body panel components with warm soap
and water.
2. Inspect for cracks and loose rivets.
3. Inspect for missing decals.
INSTALLING
1. Position the rear body panel onto the frame.
2. Secure the gas tank hose to the gas tank using the
existing hose clamp.
3. Secure the rear body panel to the footwell using the
existing torx-head screws.
4. Install the rack and secure with four new lock nuts.
Tighten to 13 ft-lb.
5. Secure the rear fascia to the frame using the two
existing torx-head screws. Tighten to 13 ft-lb.
6. Connect the taillight connectors.
7. Install the side panels, shift lever knob, and seat.
LCD Gauge
REMOVING/INSTALLING
To remove the gauge, pull out on one side of it; then dis-
connect the multi-pin connector and remove the gauge.
XR106
To install the gauge, connect the multi-pin connector and
press the gauge into the dash.
NOTE: Ensure the rubber mounting ring is oriented
correctly on the tab and seats fully through the pod.
WT601A
Steering Post/Tie Rods
REMOVING
1. Remove the seat and side and side panels; then
remove the center access cover.
2. Remove the gauge; then tilt the console up out of the
way.
3. Remove the handlebar cover.
XR142
! WARNING
When removing the right rear lock nut, ensure the muf-
fler is properly cooled to avoid severe burns.