Arctic Cat 500 4x4 User manual
Arctic Cat
Models 500 4x4/500 4x4 TRV/650 H1/650 H1 TRV/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. n NOTE 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
GmbH, 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.
Page 2
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 .......................................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
Page 4
Chassis 500 4x4 500 4x4 TRV
Length (overall) 218 cm 239 cm
Height (overall) 129 cm 129 cm
Width (overall) 124 cm 124 cm
Suspension travel (front and rear) 21 cm 21 cm
Wheelbase 128 cm 148 cm
Technical Data ARCTIC CAT ATV 500 4x4/500 4x4 TRV
Engine and Drive 500 4x4 500 4x4 TRV
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; mechanical parking brake
Carburetor type Keihin CVK 36 Keihin CVK 36
Rear drive volume 250 ml
Coolant volume 2.9 l
Engine oil capacity 2.5 l
Gasoline EU Unleaded 91 Octane
Engine oil (recommended) SAE 10W-40
Page 5
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 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
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 340 kg
Gas tank capacity 24.6 l 20.8 l
Reserve capacity 2.46 l 2 l
Differential capacity (front) 275 ml
Differential Lubricant SAE 80W-90 Hypoid
Page 6
Headlight 12V/35W (2)
Taillight / Brake light 12V/5W/21W
Starting System Electric with Manual Recoil*
* according to equipment
Page 7
Technical Data ARCTIC CAT ATV 650 H1/650 H1 TRV
Engine and Drive 650 H1 650 H1 TRV
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; mechanical parking brake
Carburetor type Keihin CVK-40 Keihin CVK-40
Chassis
Length (overall) 218 cm 239 cm
Height (overall) 129 cm 129 cm
Width (overall) 124 cm 124 cm
Suspension travel (front and rear) 21 cm 21 cm
Wheelbase 128 cm 148 cm
Page 8
650 H1 650 H1 TRV
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 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 650 H1 650 H1 TRV
Dry weight 318 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 Hypoid
Engine oil capacity 3.4 l
Rear drive volume 250 ml
Gasoline (recommended) EU Unleaded 91 Octane
Engine oil (recommended) SAE 10W-40
Headlight 12V/35W (2)
Taillight / Brakelight 12V/5W/21W
Starting System Electric with Manual Recoil*
* according to equipment
Page 9
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; mechanical parking brake
Chassis
Length (overall) 237 cm
Height (overall) 124.5 cm
Width (overall) 120 cm
Suspension travel (front and rear) 21 cm
Wheelbase 147 cm
Front Tire Size 25x8-12
Rear Tire Size 25x10-12
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)
Technical Data ARCTIC CAT ATV 700 Diesel
Page 10
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 Hypoid
Engine oil capacity 2 l
Rear drive capacity 250 ml
Gasoline (recommended) 42-50 Cetan
Engine oil (recommended) SAE 10W-40
Transmission oil SAE 80W-90 Hypoid
Headlight 12V/35W (2)
Taillight/Brake light 12V/5W/21W
Starting System Electric
Page 11
Location of Parts and Controls Models 500 4x4/500 4x4 TRV/650 H1/650 H1 TRV
01.Battery (under the seat)
02.Headlight
04.Seat lock
05.Tool storage (under the seat)
7.Towing device
09.Gearshift lever
11.Recoil starter
12.Registration number light
13.Operator´s Manual Location
21.Storage box
22.Taillight/Brake light
1
2
4
5
21
9
11
12
13
Symbolic pictures
7
22
22
Page 12
Location of Parts and Controls Models 500 4x4/500 4x4 TRV/650 H1/650 H1 TRV/700 Diesel
6. Hand brake lever
8. Ignition switch
010. Hazard warning switch
014. E-Starter
015. Drive selector
016. Position light/Low beam/High beam
017. Horn switch
018. Turn signal switch
19. Mirror
020. Differential lock
21. Winch Switch
23. Emergency/Parking brake
19 19
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
20
21
23
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 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 nd 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 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.
When mounting the mirrors, please
do not screw them in completely to
the stop, but x them rst 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 xed. No
play is allowed and steering has to
move freely.
Brakes
Check the brake uid 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 rear.
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 (positon lights,
high beam,low beam light, turn and
stop lights).
Engine oil
Check the oil level with the oil level
stick and, if necessary, ll some en-
gine oil into the crankcase.
Transmission oil
Check the oil level in the front diffe-
rential as well as in the rear drive.
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
Page 14
Page 15
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
(500, 650 H1)
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
Some ATV models have an emer-
gency recoil starter to use if the
electric starter becomes inoperati-
ve. 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.
Picture: 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.
Page 16
Page 17
!! 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
neutral, move the shift lever out-
ward and rearward into the R po-
sition.
!! 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.
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 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.
!! WARNING !!
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 follo-
wing points:
Braking
1 = R
2 = N
3 = H
4 = L
Page 18
q NOTE
Further information on how to
maintain the hydraulic brake system
can be found in the Service booklet.
The brake uid is the most important
part of the system. Keep an eye on
the right level. If there’s some kind of
dirt in the brake system or the brake
uid, the uid has to be changed.
(Impurities in the brake uid lower
the boiling point).
1. Never „ride“ the brake. Even
maintaining minimal pressure on
the brake will cause the brake pads
to drag on the disc.
2. The service brake is the main
brake for the ATV.
3. In order to stop the vehicle,
release the throttle control and push
the brake pedal.
4. The left hand brake lever
disposes of a detent used to block
the whole hydraulic system. When
using the detent, the wheels are
blocked additionally.
!! WARNING !!
Excessive repetitive use of the
hydraulic 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.
Parking
Please observe the following points:
• After the ATV stops, shift into
neutral.
• Turn off the engine.
• Try to park only on level surfaces.
If you have to park on a hill, shift the
ATV into low gear.
• Engage the mechanical parking
brake. (right hand lever)
This manual suits for next models
2
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