Arctic Cat 400 3in1 User manual
Arctic Cat Model 400/400-3in1/500/650-V2/650-H1-3in1
Operator`s Manual
ENGLISCH 21.05.2006, 14:41 Uhr1
ENGLISCH 21.05.2006, 14:41 Uhr2
Page 1 Have a good trip!
INTRODUCTION
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. qNOTE 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 renes 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.
PARTS AND ACCESSORIES
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 engi-
neered 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.
ENGLISCH 21.05.2006, 14:41 Uhr3
Page 2
OWNER/VEHICLE
SURNAME
NAME
ZIP/CITY
Street/Nr.
Vehicle model
Chaccis number
Engine number
Key number
Purchase date
Dealer
Dealer
Dealer´s signature und stamp
Vehicle owner
Owner´s signature
ENGLISCH 21.05.2006, 14:41 Uhr4
Page 3
TABLE OF CONTENTS
Issue Page
TECHNICAL DATA ARCTIC CAT ATV..................................................4
LOCATION OF PARTS AND CONTROLS ......................................... 11
OPERATOR’S MANUAL....................................................................13
GENERAL INFORMATION ................................................................ 20
CONTROL LOCATIONS AND FUNCTIONS.......................................22
GASOLINE / OIL / LUBRICANT.........................................................30
BREAK-IN PROCEDURE.................................................................. 32
GENERAL MAINTENANCE............................................................... 35
PREPARATION FOR STORAGE....................................................... 47
PREPARATION AFTER STORAGE ................................................... 48
FOR YOUR SAFETY.........................................................................49
ACTIVE RIDING................................................................................52
TROUBLESHOOTING....................................................................... 64
WARRANTY......................................................................................66
NOTES .............................................................................................71
ENGLISCH 21.05.2006, 14:41 Uhr5
Page 4
TECHNICAL DATA ARCTIC CAT ATV
Engine and Drive 400 400 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 U/min 10° BTDC < 1500 U/min
Spark plug type NGK CR7EA NGK CR7EA
Spark plug gap 0,7-0,8 mm 0,7-0,8 mm
Brake type Hydraulic foot brake; hydraulic parking brake
Carburetor type Keihin CVK 34 Keihin CVK 34
Chassis 4x4 4x4
Length (Overall) 205 cm 244,5 cm
Height (Overall) 122 cm 125 cm
Width (Overall) 112 cm 120,7 cm
Suspension travel (front, rear) 25 cm 25 cm
Wheelbase 127 cm 147 cm
ENGLISCH 21.05.2006, 14:41 Uhr6
Page 5
Front Tire Size 185-65-15 oder 25x8-12 185-65-15 oder 25x8-12
Rear Tire Size 205-60-15 oder 25x11-12 205-60-15 oder 25x11-12
Tire Ination Pressure
On Road
0,8-1,0 bar (according to load
and route)
0,8-1,0 bar (according to load
and route)
Tire Ination Pressure
Off Road
0,8-1,0 bar (according to load
and route)
0,8-1,0 bar (according to load
and route)
Miscellany 4x4 4x4
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 (Front) 275 ml 275 ml
Differential Lubricant SAE 80W-90
Taillight/Brake light 12V/5W/21W
Engine Oil Capacity 3,4 L 3,4 L
Rear drive volume 250 ml 250 ml
Gasoline (Recommended) 87 Octan Regular Unleaded (EU: Regular Gasoline 91 oct.)
Engine oil (Recommended) SAE 10W-40
ENGLISCH 21.05.2006, 14:41 Uhr7
Page 6
Headlight 12V/35W (2)
Starting System Electric with Manual Recoil
Technical Data ARCTIC CAT ATV 500
Engine and Drive 500
Type Four-cycle/Liquid cooled
Bore x Stroke 87,5x82 mm
Displacement 493 ccm
Ignition type CDI
Ignition timing 10° BTDC < 1500 U/min
Spark plug type NGK CR6E
Spark plug gap 0,7-0,8 mm
Brake type Hydraulic foot brake; hydraulic parking brake
Carburetor type Keihin CVK 36
ENGLISCH 21.05.2006, 14:41 Uhr8
Page 7
Chassis 4x4
Length (Overall) 210,8 cm
Height (Overall) 125 cm
Width (Overall) 120,7 cm
Suspension travel (front) 25 cm
Wheelbase 127 cm
Front Tire Size 185-65-15 oder 25x8-12
Rear Tire Size 205-60-15 oder 25x11-12
Tire Ination Pressure
On Road 0,8-1,0 bar (according to load and route)
Tire Ination Pressure
Off Road 0,8-1,0 bar (according to load and route)
Miscellany 4x4
Dry weight 310 kg
Gas tank capacity 24,6 l
Reserve capacity 2,46 l
Differential capacity (Front) 275 ml
Differential Lubricant SAE 80W-90
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Page 8
Rear drive volume 250 ml
Coolant volume 2,9 l
Taillight/Brake light 12V/5W/21W
Engine Oil capacity 2,5 l
Gasoline (Recommended) 87 Octan Regular Unleaded (EU: Regular Gasoline 91 oct.)
Engine Oil (Recommended) SAE 10W-40
H 12V/35W (2)
Headlight 12V/35W (2)
Starting System Electric with Manual Recoil
ENGLISCH 21.05.2006, 14:42 Uhr10
Page 9
Technical Data ARCTIC CAT ATV 650 V2 /650H1 3in1
Engine and Drive 650 V2 650 H1 3in1
Type Four-cycle/Liquid cooled Four-cycle/Liquid cooled
Bore x Stroke 80x63 mm 97,9x85 mm
Displacment 633 ccm 641 ccm
Ignition type CDI CDI
Ignition timing 10° BTDC < 1500 U/min 10° BTDC < 1500 U/min
Spark plug type NGK CR7E NGK CR6E
Spark plug gap 0,7-0,8 mm 0,7-0,8 mm
Brake type Hydraulic foot brake; hydraulic parking brake
Carburetor type Keihin CVKR-D32 (2) Keihin CVK-40
Chassis 4x4 4x4
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/rear) 25 cm 21 cm
Wheelbase 127 cm 147 cm
ENGLISCH 21.05.2006, 14:42 Uhr11
Page 10
Front Tire Size 185-65-15 oder 25x8-12 185-65-15 oder 25x8-12
Rear Tire Size 205-60-15 oder 25x11-12 205-60-15 oder 25x11-12
Tire Ination Pressure On Road 0,8-1,0 bar (according to load and route)
Tire Ination Pressure Off Road 0,8-1,0 bar (according to load and route)
Miscellany 4x4 Automatik
Dry weight 341 kg 348 kg
Gas tank capacity 24,6 l 20,8 l
Coolant volume 2,7 l 2,7 l
Differential capacity (Front) 275 ml 275 ml
Differential Lubricant SAE 80W-90
Taillight/Brake light 12V/5W/21W
Engine Oil capacity 1,75 l 3,4 l
Rear drive volume 250 ml 250 ml
Gasoline (Recommended) 87 Octan Regular Unleaded (EU: Regular Gasoline 91 oct.)
Engine Oil (Recommended) SAE 10W-40
Headlight 12V/35W (2)
Starting System Electric with Manual Recoil
ENGLISCH 21.05.2006, 14:42 Uhr12
Page 11
LOCATION OF PARTS AND CONTROLS
MODELS 400/400-3in1/500/650-V2/650-H1-3in1
12.Taillight/Brake Light/Registration number
13.Operator´s Manual Location (under the sat)
21.Storage box
1
23
4
5
21
911
12
13
Symbolic pictures
01.Battery (under the seat)
02.Headlight
03.Fuel Valve
04.Seat Lock
05.Tool storage (under the seat)
9.Gearshift lever
11.Recoil starter
ENGLISCH 21.05.2006, 14:42 Uhr13
Page 12
6.Hand Brake Lever and Parking Brake
0 8.Ignition switch
010.Hazard Warning Light
014.E-Starter
015.Drive Selector (Model 4x4)
016.Low beam/full beam
017.Horn
018.Blinker left side and right side
019.Choke Lever (Model 650-V2)
020.Mirrors
022.Blinker indicator
22
24
20 20
q NOTE
The ATV you have purchased may differ
slightly from those shown in the gures of this
manual.
q NOTE
The engine is turned off with the ignition key.
15
17
18
14 10
16
8
6
19
ENGLISCH 21.05.2006, 14:43 Uhr14
Page 13
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
techniques. For further information
please contact an authorized
ARCTIC CAT ATV-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 nd at the next
page.
Brake burnishing procedure:
The main brake is activated by
the foot pedal (according to direc-
tive 93/14A EC homologation).
The hand lever activates only the
parking/auxiliary brake which must
not be used as service brake.
For off road use, there is the pos-
sibility to exchange the brake cir-
cuits - thus, the service brake is
activated by the hand lever.
For this purpose an appropriate
conversion kit is available. For more
details, please ask your dealer.
!! IMPORTANT !!
For perfect brake efciency you
have to burnish the brake pads.
To do so, please follow the instruc-
tions below:
Choose an area sufciently 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.
The mirrors are to be found on the
vehicle. When mounting the mir-
rors, please do not crew them in
completely to the stop, but x them
rst with the counter-nut. (Other-
wise you risk to seriously damage
the support!
ENGLISCH 21.05.2006, 14:44 Uhr15
ATV-CHECKLIST
Steering system
Turn the handlebars completely to
the right/left – there must be no
resistance. All parts of the steering
system must be properly xed. No
play is allowed and steering has to
move freely.
Brakes
Check the brake uid level. Push
the hydraulic brake lever several
times. Check the lever for tightness
and maneuverability. Test the park-
ing brake:
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
ller cap is closed.
Lights
Inspect all lights (full beam and low
beam light).
Engine Oil
Check the oil level at the inspection
window (250/300) or with the oil
level stick (400/500) and, if neces-
sary, ll some engine oil into the
crankcase.
Transmission Oil
Check the oil level in the front differ-
ential (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).
Gearshift Pedal and Reverse
Lever
Inspect the gearshift pedal and
make sure that you can shift into all
gears without problems. Examine
the reverse lever and see if it moves
freely and engages properly.
Follow these steps to start it up:
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
Page 14
ENGLISCH 21.05.2006, 14:44 Uhr16
Page 15
Starting the engine
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: DON’T PARK THE VEHI-
CLE LONGER THAN AN HOUR
IN A STEEP TERRAIN WITH THE
PARKING BRAKE ENGAGED.
4.Test the throttle control by push-
ing 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.
5. Shift the transmission into neu-
tral.
6. Rotate the ignition key to the ON-
position.
Starting a cold engine
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. Move the choke lever (650 V-
2) until it is engaged (you’ll feel a
light pressure). Push the E-starter
button with the index nger of your
left hand
!! CAUTION !!
Don’t push the E-starter button
longer than 30 seconds.
2. When the engine starts, return
the choke lever half way. Once the
engine is warmed up, return the
choke lever completely.
!! CAUTION !!
ATV 500: If the temperature is –
18°C or below, you should activate
the carburetor pump three times.
If the outdoor temperature is + 5 º
C or more:
Move the choke lever half way and
press the E-starter button.
Once the engine is warmed up, re-
turn the choke lever.
!! 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 extremely low
temperatures, the time needed for
warming up increases. If you don’t
warm up the engine sufciently,
there could occur damages which
ENGLISCH 21.05.2006, 14:44 Uhr17
are excluded of warranty.
Starting a warm engine
If the engine is already warm, it is
not necessary to use the choke.
Accelerate slightly and press the
E-starter button.
q NOTE
If it is already warm, the engine is
started without using the choke.
If you use it still, starting is made
more difcult by the gas/air mixture
in high quantity.
Emergency starting
All ATV models have an emergency
recoil starter
to use if the electric starter be-
comes inoperative.
To use the recoil starter follow this
procedure:
!! WARNING !!
Be sure the transmission is in the
neutral position, there is no gear in-
serted and the parking brake is en-
gaged when using the emergency
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.
400/500/650
!! WARNING !!
When using the recoil starter,
please keep exactly to the proce-
dure mentioned above.
!! CAUTION !!
To avoid damaging the recoil start-
er, 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.
Shifting
(Automatic Transmission)
The ARCTIC CAT ATV with an
automatic transmission has a dual-
range transmission with reverse:
Page 16
ENGLISCH 21.05.2006, 14:44 Uhr18
Page 17
1. R (Reverse Gear)
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.
!! WARNING !!
The high range is for normal riding
with light loads. The low range is
for carrying heavy loads or trailer
towing. Compared to HIGH range,
the LOW range position provides
slower speed and greater torque to
the wheels.
3. To engage reverse gear from N,
move the shift lever outward and
rearward into the R position.
!! CAUTION !!
Always come to a complete stop
before attempting to shift from one
range to the other or into reverse.
Always shift on level ground, or
engage the parking brake before
shifting into another range or into
reverse.
1 = R
2 = N
3 = H
4 = L
ENGLISCH 21.05.2006, 14:44 Uhr19
Page 18
Braking
Brake burnishing procedure:
The main brake is activated by
the foot pedal (according to direc-
tive 93/14A EC homologation).
The hand lever activates only the
parking/auxiliary brake which must
not be used as service brake.
For off road use, there is the pos-
sibility to exchange the brake cir-
cuits - thus, the service brake is
activated by the hand lever.
For this purpose an appropriate
conversion kit is available. For more
details, please ask your dealer.
To do so, please follow the instruc-
tions below:
1. Choose an area sufciently large
to safely accelerate your ATV to 30
km/h.
2. Accelerate to 30 km/h, then com-
press brake lever to decelerate to 0
– 5 km/h.
3.Repeat this procedure approx 20
times until brakes are heated up.
!! IMPORTANT !!
Please note that new brake pads
have to be prepared. Don’t put
yourself into situations that require
an immediate braking unless the
brake pads are working properly
(this may result in serious acci-
dents!)
When using the hydraulic brakes,
you must be familiar with the fol-
lowing points:
q NOTE
Further information on how to
maintain the hydraulic brake sys-
tem can be found in the „General
Maintenance“ booklet.
1.The brake uid is the most im-
portant part of the system. Keep
an eye on the right level. If there’s
some kind of dirt in the brake sys-
tem or the brake uid, the uid has
to be changed. (Impurities in
the brake uid lower the boiling
point).
2.Never „ride“ the brake. Even
maintaining minimal pressure on
the brake lever will cause the brake
pads to drag on the disc.
3. The footbrake is the main brake
for the ATV
!! WARNING !!
Excessive repetitive use of the hy-
draulic brake for high speed stops
will cause overheating of the brake
uid and premature brake pad
wear.
!! WARNING !!
Use only DOT 4 brake liquid. Don’t
use several types of brake liquids
which may result in an unexpected
loss of brakes. Before starting your
ATV check the brake liquid level
and the state of the brake pads.
4. In order to stop the vehicle, re-
ENGLISCH 21.05.2006, 14:44 Uhr20
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4
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