Arctic Cat Crossfire 700 EFI (EB) 2006 User manual

FOREWORD
This Arctic Cat Service Manual contains service, maintenance, and troubleshooting information for certain 2008
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. To
service models not included in this manual, please refer to the following publications:
• 2008 Y-12 Service Manual
• 2008 DVX/Utility 250 Service Manual
• 2008 366 Service Manual
• 2008 DVX 400 Service Manual
• 2008 700 Diesel Service Manual
• 2008 Thundercat 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.
The service technician should become familiar with the operation and construction of each component or system
by carefully studying the complete manual. This manual will assist the service technician in becoming more aware
of and efficient with servicing procedures. Such efficiency not only helps build consumer confidence but also saves
time and labor.
All Arctic Cat ATV publications and decals display the words Warning, Caution, Note, and At This Point to
emphasize important information. The symbol ! WARNING identifies personal safety-related information.
Be sure to follow the directive because it deals with the possibility of severe personal injury or even death. The
symbol ! CAUTION identifies unsafe practices which may result in ATV-related damage. Follow the direc-
tive 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 tech-
nician 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.
© 2007 Arctic Cat Inc. July 2007
®™ Trademarks of Arctic Cat Inc., Thief River Falls, MN 56701
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400 Automatic
400 Manual
500 Automatic
500 Manual
650 H1
700 EFI
700 H1 EFI
400 Automatic
400 Manual
500 Automatic
500 Manual
650 H1
700 EFI
700 H1 EFI
08
08
Service Manual
TM
ATV
ATV
MORE TO GO ON.
TABLE OF CONTENTS
Foreword
Click on the red text to go.
Section
1. General Information/Specifications
2. Periodic Maintenance
3. Engine/Transmission
4. Fuel/Lubrication/Cooling
5. Electrical System
6. Drive System
7. Suspension
8. Steering/Frame
9. Controls/Indicators
1
2
3
4
5
6
7
8
9
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1-1
1
SECTION 1 - GENERAL INFORMATION/
SPECIFICATIONS
TABLE OF
CONTENTS
General Specifications ............................................ 1-2
Torque Specifications .............................................. 1-3
Torque Conversions (ft-lb/N-m) ............................... 1-5
Tightening Torque (General Bolts) .......................... 1-5
Break-In Procedure ................................................. 1-6
Gasoline - Oil - Lubricant ........................................ 1-6
Genuine Parts ......................................................... 1-7
Preparation For Storage .......................................... 1-7
Preparation After Storage........................................ 1-7
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1-2
General Specifications*
* Specifications subject to change without notice.
** One inch below plug threads.
*** At the plug threads.
400
CHASSIS
Brake Type Hydraulic w/Brake Lever Lock
and Auxiliary Brake
Tire Size Front - 25 x 8-12
Rear - 25 x 10-12
Tire Inflation Pressure 0.35 kg/cm² (5 psi)
MISCELLANY
Gas Tank Capacity (rated) 24.6 L (6.5 U.S. gal.)
Rear Drive Capacity 250 ml (8.5 fl oz)**
Front Differential Capacity 275 ml (9.3 fl oz)***
Engine Oil Capacity 3.08 L (3.25 U.S. qt)
Gasoline (recommended) 87 Octane Regular Unleaded
Engine Oil (recommended) SAE 5W-30
Differential/Rear Drive Lubricant
SAE Approved 80W-90 Hypoid
Drive Belt Width (Automatic) (mini-
mum)
28.5 mm (1.12 in.)
Brake Fluid DOT 4
Taillight/Brakelight 12V/8W/27W
Headlight 12V/37W (2)
500/650 H1
CHASSIS
Brake Type Hydraulic w/Brake Lever Lock
and Auxiliary Brake
Tire Size Front - 25 x 8-12
Rear - 25 x 10-12
Tire Inflation Pressure 0.35 kg/cm² (5 psi)
MISCELLANY
Gas Tank Capacity (rated) 24.6 L (6.5 U.S. gal.)
20.8 L (5.5 U.S. gal.) - TRV
Coolant Capacity 2.9 L (3.0 U.S. qt)
Differential Capacity 275 ml (9.3 fl oz)**
Rear Drive Capacity 250 ml (8.5 fl oz)***
Engine Oil Capacity 3.4 L (3.5 U.S. qt) - Manual
2.5 L (2.6 U.S. qt) - Automatic
Gasoline (recommended) 87 Octane Regular Unleaded
Engine Oil (recommended) SAE 5W-30
Differential/Rear Drive Lubricant
SAE Approved 80W-90 Hypoid
Drive Belt Width (Automatic) (mini-
mum)
38 mm (1.33 in.) - 500
35.5 mm (1.40 in.) - 650 H1
Brake Fluid DOT 4
Taillight/Brakelight 12V/8W/27W
Headlight 12V/27W (2)
700 EFI
CHASSIS
Brake Type Hydraulic w/Brake Lever Lock
and Auxiliary Brake
Tire Size Front - 25 x 8-12
Rear - 25 x 10-12
Tire Inflation Pressure 0.35 kg/cm² (5 psi)
MISCELLANY
Gas Tank Capacity (rated) 24.6 L (6.5 U.S. gal.)
20.8 L (5.5 U.S. gal.) - TRV
Coolant Capacity 2.9 L (3.0 U.S. qt)
Differential Capacity 275 ml (9.3 fl oz)**
Rear Drive Capacity 250 ml (8.5 fl oz)***
Engine Oil Capacity 2.5 L (2.6 U.S. qt)
Gasoline (recommended)
87 Octane Regular Unleaded
Engine Oil (recommended) SAE 5W-30
Differential/Rear Drive Lubricant SAE Approved
80W-90 Hypoid
Drive Belt Width (minimum) 35.6 mm (1.40 in.)
Brake Fluid DOT 4
Taillight/Brakelight 12V/8W/27W
Headlight 12V/27W (2)
700 H1 EFI
CHASSIS
Brake Type Hydraulic w/Brake Lever Lock
and Auxiliary Brake
Tire Size Front - 25 x 8-12
Rear - 25 x 10-12
Tire Inflation Pressure 0.35 kg/cm² (5 psi)
MISCELLANY
Gas Tank Capacity (rated) 24.6 L (6.5 U.S. gal.)
Coolant Capacity 2.9 L (3.0 U.S. qt)
Differential Capacity 275 ml (9.3 fl oz)**
Rear Drive Capacity 250 ml (8.5 fl oz)***
Engine Oil Capacity 2.5 L (2.6 U.S. qt)
Gasoline (recommended) 87 Octane Regular Unleaded
Engine Oil (recommended) SAE 5W-30
Differential/Rear Drive Lubricant SAE Approved 80W-90 Hypoid
Drive Belt Width (minimum) 35.6 mm (1.40 in.)
Brake Fluid DOT 4
Taillight/Brakelight 12V/8W/27W
Headlight 12V/27W (2)
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1-3
1
Torque Specifications
* w/Blue Loctite #243
** w/Red Loctite #271
*** w/Green Loctite #609
EXHAUST COMPONENTS
Part Part Bolted To Torque
ft-lb N-m
Exhaust Pipe
(400/500/H1 Models)
Engine 20 27
Exhaust Pipe (700 EFI) Cylinder Head 17 23
ELECTRICAL COMPONENTS
Coil (Carbureted Models)* Frame 12 16
Coil (EFI Models) Air Filter Housing 7 10
STEERING COMPONENTS
Steering Post Bearing Housing Frame 20 27
Steering Post Bearing Flange Frame 20 27
Lower Steering Bearing
Washer Cap Screw***
Steering Post 40 54
Tie Rod End Knuckle/
Steering Post
30 41
BRAKE COMPONENTS
Brake Disc* Hub 15 20
Brake Hose Caliper 20 27
Brake Hose Master Cylinder 20 27
Brake Hose Auxiliary Brake Cylinder 20 27
Master Cylinder (Rear) Frame 12 16
Hydraulic Caliper Knuckle 20 27
CHASSIS COMPONENTS
Footrest Frame (8 mm) 20 27
Footrest Frame (10 mm) 40 54
SUSPENSION COMPONENTS (Front)
A-Arm Frame 35 47
Knuckle Ball Joint 35 47
Shock Absorber Frame 35 47
Shock Absorber Upper A-Arm 35 47
Knuckle A-Arm 35 47
SUSPENSION COMPONENTS (Rear)
Axle Retainer Assembly
(Manual Transmission Models)
Axle Housing 40 54
Shock Absorber (Upper) Frame 35 47
Shock Absorber (Lower) Lower A-Arm 20 27
A-Arm Frame 35 47
Knuckle A-Arm 35 47
DRIVE TRAIN COMPONENTS
(400/500 - Manual Transmission)
Part Part Bolted To Torque
ft-lb N-m
Engine (Lower Rear/Front) Frame 40 54
Front Differential Frame/Differential
Bracket
38 52
Pinion Housing Differential Housing 23 31
Differential Housing Cover*** Differential Housing 23 31
Drive Bevel Gear Nut*** Shaft 72 98
Lock Collar Differential Housing 125 169
Hub Nut Shaft/Axle (max) 200 270
Oil Drain Plug Front Differential/
Rear Drive
45 in.-lb 5
Oil Fill Plug Front Differential/
Rear Drive
16 22
Oil Drain Plug Engine 16 22
Inspection Plug Front Differential/
Rear Drive
48 in.-lb 5.5
Wheel Hub 40 54
Oil Fitting (400) Engine 6 8
Input Shaft Housing Differential Housing 23 31
Rear Drive Gear Case Frame 45 61
Engine Output Flange Rear Gear Case
Input Flange
20 27
DRIVE TRAIN COMPONENTS
(400/500 - Automatic Transmission/H1 Models)
Engine Mounting Through-Bolt
(400/500)
Frame 40 54
Engine (650 H1) Engine Cradle 40 54
Engine Cradle (650 H1/TRV)** Rubber Mount 25 34
Rubber Mount (650 H1/TRV) Frame Bracket 35 47
Front Differential* Frame/Differential
Bracket
38 52
Output Flange Rear Flange
Output Joint
20 27
Input Shaft Housing Differential Housing 23 31
Differential Housing Cover*** Differential Housing 23 31
Drive Bevel Gear Nut*** Shaft 72 98
Differential Gear Case*** Hub 19 26
Lock Collar Differential Housing 125 169
Hub Nut Shaft/Axle (max) 200 270
Oil Drain Plug Front Differential/
Rear Drive
45 in.-lb 5
Oil Fill Plug Front Differential/
Rear Drive
16 22
Oil Drain Plug Engine 16 22
Wheel Hub 40 54
Rear Drive Gear Case Frame 38 52
Engine Output Flange Rear Gear Case
Input Flange
20 27
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1-4
* w/Blue Loctite #243
** w/Red Loctite #271
*** w/Green Loctite #609
DRIVE TRAIN COMPONENTS
(700 EFI)
Part Part Bolted To Torque
ft-lb N-m
Engine Mount (Rear) Frame 40 54
Front Differential**** Frame/Differential
Bracket
45 61
Rear Drive Gear Case Frame 45 61
Input Shaft Housing Differential Housing 23 31
Differential Housing Cover*** Differential Housing 23 31
Lock Collar Differential Housing 125 169
Hub Nut Shaft/Axle (max) 200 270
Oil Drain Plug Front Differential/
Rear Drive
45 in.-lb 5
Oil Fill Plug Front Differential/
Rear Drive
16 22
Oil Drain Plug Engine 16 22
Wheel Hub 40 54
Engine Output Flange Rear Gear Case
Input Flange
20 27
Rear Drive Gear Case Frame 45 61
Engine Damper Mount Frame 20 27
ENGINE/TRANSMISSION
(400/500 - Manual Transmission)
Clutch Shoe Crankshaft 94 127
Clutch Sleeve Hub Countershaft 72 98
Crankcase Half (6 mm) Crankcase Half 8 11
Crankcase Half (8 mm) Crankcase Half 16 22
Cylinder Head (Cap Screw) Cylinder 28 38
Cylinder Head (6 mm Nut) Cylinder 8 11
Cylinder Head (8 mm Nut) Cylinder 18 24
Cylinder Head Cover Cylinder Head 7 9.5
Left-Side Cover (6 mm) Crankcase Half 8 11
Left-Side Cover (8 mm) Crankcase Half 16 22
Oil Pump Drive Gear Crank Balancer
Shaft
58 79
Oil Pump* Crankcase 7 9.5
Output Shaft Gear Output Shaft 72 98
Rear Output Shaft Output Joint 20 27
Recoil Starter Left-Side Cover 6 8
Reverse Cam Stopper Housing Crankcase 16 22
Right-Side Cover Crankcase 8 11
Magneto Rotor Nut Crankshaft 116 157
Shift Stop Housing Crankcase 16 22
Cam Sprocket** Camshaft 11 15
Starter Cup Crankshaft 25 34
Spark Plug Engine 12 16
Movable Drive Face** Driveshaft 72 98
Engine Damper Thermostat Hous-
ing
79.5
ENGINE/TRANSMISSION
(400/500 - Automatic Transmission)
Part Part Bolted To Torque
ft-lb N-m
Clutch Shoe Crankshaft 94 127
Clutch Cover/Housing Assembly Crankcase 8 11
Crankcase Half (6 mm) Crankcase Half 8 11
Crankcase Half (8 mm) Crankcase Half 16 22
Cylinder Head (Cap Screw) Crankcase 28 38
Cylinder Head (6 mm) Cylinder 8 11
Cylinder Head (8 mm) Cylinder 18 24
Cylinder Head Cover Cylinder Head 7 9.5
Driven Pulley Nut** Driveshaft 80 110
Ground Wire Engine 8 11
Magneto Cover (500) Crankcase 8 11
Movable Drive Face** Fixed Drive Face 74 100
Oil Pump Drive Gear Crank Balancer 36 49
Output Shaft Flange Nut Output Shaft 72 98
Recoil Starter Left-Side Cover 6 8
Magneto Rotor Nut Crankshaft 116 157
Cam Sprocket** Camshaft 11 15
Starter Cup Crankshaft 25 34
V-Belt Cover Crankcase 8 11
Spark Plug Engine 12 16
Valve Adjuster Jam Nut Valve Adjuster 7 9.5
Oil Pump Crankcase 7 9.5
Drive Pulley Nut** Clutch Shaft 80 110
ENGINE/TRANSMISSION
(H1 Models)
Clutch Shoe Crankshaft 221 300
Clutch Cover/Housing Assembly Crankcase 8 11
Crankcase Half (6 mm) Crankcase Half 8 11
Crankcase Half (8 mm) Crankcase Half 20 27
Cylinder Head (Cap Screw) Crankcase 40 54
Cylinder Head (6 mm) Cylinder 8 11
Cylinder Head (8 mm) Cylinder 18 24
Cylinder Head Cover Cylinder Head 9 12
Driven Pulley Nut Driveshaft 221 300
Ground Wire Engine 8 11
Magneto Cover Crankcase 8 11
Movable Drive Face Nut** Fixed Drive Face 221 300
Oil Pump Drive Gear Crank Balancer
Shaft
63 85
Output Shaft Flange Nut Output Shaft 59 80
Outer Magneto Cover Left-Side Cover 8 11
Magneto Rotor Nut Crankshaft 107 145
Cam Sprocket** Camshaft 10 13.5
V-Belt Cover Clutch Cover 8 11
Spark Plug Engine 8 11
Drive Pulley Nut** Clutch Shaft 221 300
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1-5
1
* w/Blue Loctite #243
** w/Red Loctite #271
*** w/Green Loctite #609
Torque Conversions
(ft-lb/N-m)
Tightening Torque
(General Bolts)
ENGINE/TRANSMISSION (700 EFI)
Part Part Bolted To Torque
ft-lb N-m
Clutch Shoe Crankshaft 111 150.5
Clutch Cover/Housing Assembly Crankcase 7 9.5
Crankcase Half (6 mm) Crankcase Half 7 9.5
Crankcase Half (8 mm) Crankcase Half 19 26
Cylinder Head (Cap Screw) Crankcase
(2 Steps)
18
27
24
37
Cylinder Head (6 mm) Cylinder 7 9.5
Cylinder Head Cover Cylinder Head
(2 Steps)
7
10
9.5
13.5
Driven Pulley Cap Screw Fixed Face 81 110
Cam Chain Tensioner Pivot Bolt Cylinder 17 23
Crankshaft Balancer Nut Crankshaft 111 150.5
Thermostat Housing Engine 7 9.5
Engine Damper Stopper Frame 20 27
Movable Driven Face Ring Nut Fixed Driven Face 74 100
Ground Wire Engine 8 11
Magneto Cover Crankcase 8 11
Movable Drive Face** Driveshaft 81 110
Oil Pump Drive Gear Crank Balancer
Shaft
37 50
Drive Bevel Gear Nut Output Shaft 74 100
Outer Magneto Cover Left-Side Cover 6 8
Magneto Rotor Nut Crankshaft 118 160
Cam Idler Shaft Cylinder Head 30 41
Starter Cup Crankshaft 19 26
V-Belt Cover Crankcase 7 9.5
Spark Plug Engine 8 11
Cam Chain Tensioner Cylinder 7 9.5
Tensioner Plug Cam Chain Ten-
sioner
60 in.-lb 7
Camshaft Holder Cylinder Head 7 9.5
Timing Inspection Plug Magneto Cover 17 23
Crankshaft Balancer Drive Gear
Cap Screw
Crankshaft
Balancer
37 50
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
Type of Bolt Thread Diameter
A (mm)
Tightening
Torque
(Conventional or 4 Marked Bolt) 5 12-36 in.-lb
6 36-60 in.-lb
8 7-11 ft-lb
10 16-25 ft-lb
(7 Marked Bolt) 5 24-48 in.-lb
6 6-8 ft-lb
8 13-20 ft-lb
10 29-43 ft-lb
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1-6
Break-In Procedure
A new ATV and an overhauled ATV engine require a
“break-in” period. The first 10 hours (or 200 miles) are
most critical to the life of this ATV. Proper operation
during this break-in period will help assure maximum
life and performance from the ATV.
During the first 10 hours (or 200 miles) of operation,
always use less than 1/2 throttle. Varying the engine
RPM during the break-in period allows the compo-
nents to “load” (aiding the mating process) and then
“unload” (allowing components to cool). Although it
is essential to place some stress on the engine compo-
nents during break-in, care should be taken not to
overload the engine too often. Do not pull a trailer or
carry heavy loads during the 10-hour break-in period.
When the engine starts, allow it to warm up properly.
Idle the engine several minutes until the engine has
reached normal operating temperature. Do not idle the
engine for excessively long periods of time.
During the break-in period, a maximum of 1/2 throttle
is recommended; however, brief full-throttle accelera-
tions and variations in driving speeds contribute to
good engine break-in.
After the completion of the break-in period, the engine
oil and oil filter should be changed. Other maintenance
after break-in should include checking of all pre-
scribed adjustments and tightening of all fasteners.
Gasoline - Oil -
Lubricant
RECOMMENDED GASOLINE
The recommended gasoline to use is 87 minimum
octane regular unleaded. In many areas, oxygenates
(either ethanol or MTBE) are added to the gasoline.
Oxygenated gasolines containing up to 10% ethanol,
5% methane, or 5% MTBE are acceptable gasolines.
When using ethanol blended gasoline, it is not neces-
sary to add a gasoline antifreeze since ethanol will pre-
vent the accumulation of moisture in the fuel system.
RECOMMENDED ENGINE/
TRANSMISSION OIL
The recommended oil to use is Arctic Cat 4-Cycle
Engine Oil or an equivalent oil which is rated SE, SF,
or SG under API service classification. These oils
meet all of the lubrication requirements of the Arctic
Cat ATV engine. The recommended engine oil viscos-
ity is SAE 5W-30. Ambient temperature should deter-
mine the correct weight of oil. See the following
viscosity chart for details.
OILCHARTC
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 hypoid. This lubricant meets all of the lubrica-
tion requirements of the Arctic Cat ATV front differen-
tials and rear drives.
! CAUTION
Do not use white gas. Only Arctic Cat approved gas-
oline additives should be used.
! 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.
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1-7
1
FILLING GAS TANK
ATV0049B
Since gasoline expands as its temperature rises, the gas
tank must be filled to its rated capacity only. Expan-
sion 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 gen-
uine Arctic Cat ATV parts. They are precision-made to
ensure high quality and correct fit. Refer to the appro-
priate Illustrated Parts Manual for the correct part
number, quantity, and description.
Preparation For Storage
Arctic Cat recommends the following procedure to
prepare the ATV for storage.
1. Clean the seat cushion (cover and base) with a
damp cloth and allow it to dry.
2. Clean the ATV thoroughly by washing dirt, oil,
grass, and other foreign matter from the entire
ATV. Allow the ATV to dry thoroughly. DO NOT
get water into any part of the engine or air intake.
3. Either drain the gas tank or add Fuel Stabilizer to
the gas in the gas tank. Remove the air filter hous-
ing 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;
then stop the engine. Install the air filter and hous-
ing cover.
4. On carbureted models, drain the carburetor float
chamber.
5. Plug the exhaust hole in the exhaust system with a
clean cloth.
6. Apply light oil to the upper steering post bushing
and plungers of the shock absorbers.
7. Tighten all nuts, bolts, cap screws, and screws.
Make sure rivets holding components together are
tight. Replace all loose rivets. Care must be taken
that all calibrated nuts, cap screws, and bolts are
tightened to specifications.
8. On liquid cooled models, fill the cooling system to
the bottom of the stand pipe in the radiator neck
with properly mixed coolant.
9. Disconnect the battery cables; then remove the
battery, clean the battery posts and cables, and
store in a clean, dry area.
10. Store the ATV indoors in a level position.
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 proce-
dure to prepare the ATV.
1. Clean the ATV thoroughly.
! WARNING
Always fill the gas tank in a well-ventilated area.
Never add fuel to the ATV gas tank near any open
flames or with the engine running. DO NOT SMOKE
while filling the gas tank.
! 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.
! CAUTION
Avoid storing outside in direct sunlight and avoid
using a plastic cover as moisture will collect on the
ATV causing rusting.
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1-8
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. On liquid cooled models, check the coolant level
and add properly mixed coolant as necessary.
6. Charge the battery; then install. Connect the bat-
tery 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
making 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 neces-
sary.
! CAUTION
The ignition switch must be in the OFF position prior
to installing the battery or damage may occur to the
ignition system.
! CAUTION
Connect the positive battery cable first; then the
negative.
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2-1
2
SECTION 2 -
PERIODIC MAINTENANCE
TABLE OF
CONTENTS
Periodic Maintenance Chart .................................... 2-2
Periodic Maintenance.............................................. 2-3
Lubrication Points.................................................... 2-3
Battery..................................................................... 2-3
Fuses ...................................................................... 2-4
Air Filter................................................................... 2-5
Valve/Tappet Clearance
(Feeler Gauge Procedure) ................................... 2-7
Valve/Tappet Clearance
(Valve Adjuster Procedure) .................................. 2-7
Valve/Tappet Clearance (700 EFI)........................... 2-8
Testing Engine Compression................................. 2-10
Spark Plug............................................................. 2-10
Muffler/Spark Arrester ........................................... 2-11
Adjusting Throttle Cable ........................................ 2-11
Adjusting Engine RPM (Idle) ................................. 2-12
Engine/Transmission Oil - Filter - Strainer ............ 2-12
Front Differential/Rear Drive Lubricant .................. 2-14
Adjusting Clutch
(400/500 Manual Transmission) ......................... 2-15
Tires ...................................................................... 2-15
Steering Components ........................................... 2-15
Driveshaft/Coupling ............................................... 2-16
Suspension/Shock Absorbers/Bushings ............... 2-16
Nuts/Bolts/Cap Screws.......................................... 2-16
Ignition Timing ....................................................... 2-16
Headlights/Taillight-Brakelight ............................... 2-16
Shift Lever ............................................................. 2-17
Frame/Welds/Racks .............................................. 2-19
Electrical Connections........................................... 2-19
Hydraulic Brake Systems ...................................... 2-19
Burnishing Brake Pads.......................................... 2-21
Coolant (Liquid Cooled Models) ............................ 2-21
Checking/Replacing V-Belt ................................... 2-21
Adjusting Differential Lock Cable........................... 2-22
Exhaust Chart ....................................................... 2-24
Intake Chart........................................................... 2-25
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2-2
Periodic Maintenance
Chart
A = Adjust I = Inspect
C = Clean L = Lubricate
D = Drain R = Replace
T = Tighten
* Service/Inspect more frequently when operating in adverse conditions.
Item
Initial Service
After Break-In
(First Mo or
100 Mi)
Every
Day
Every
Month or
Every 100
Miles
Every 3
Months or
Every 300
Miles
Every 6
Months or
Every 500
Miles
Every Year
or Every
1500 Miles
As Needed
Battery I I C
Fuses IR
Air Filter/Drain Tube I I C* R
Valve/Tappet Clearance I I A
Engine Compression I
Spark Plug I I R (4000 Mi
or 18 Mo)
Muffler/Spark Arrester CR
Gas/Vent Hoses I I R (2 Yrs)
Throttle Cable I I C-L A-R
Carburetor Float Chamber
(Carbureted Models)
D*
Engine Idle RPM (Carbureted Models) I I A
Engine-Transmission Oil Level I A
Engine-Transmission Oil/Filter R R* R
Oil Strainer I I C
Front Differential/Rear Drive Lubricant I I R (4 Yrs)
Clutch (Manual) I l A
Tires/Air Pressure I I R
Steering Components I I I R
V-Belt (Automatic) I l R
Suspension (Ball joint boots, drive
axle boots front and rear, tie rods,
differential and rear drive bellows)
II R
Nuts/Cap Screws/Screws I T A
Ignition Timing I
Headlight/Taillight-Brakelight I I R
Switches I I R
Shift Lever IA-L
Recoil Starter (400/500) I C-R
Handlebar Grips I R
Handlebars I I R
Gauges/Indicators I I R
Frame/Welds/Racks I l
Electrical Connections I l C
Complete Brake System
(Hydraulic & Auxiliary)
II C L-R
Brake Pads I I* R
Brake Fluid I I R (2 Yrs)
Brake Hoses I I R (4 Yrs)
Coolant (Liquid Cooled Models)/
Cooling System
II R(2Yrs)
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2-3
2
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
gaskets, lock nuts, and seals and lubricating all
internal components when servicing the
engine/transmission.
NOTE: Some photographs and illustrations used
in this section are used for clarity purposes only
and are not designed to depict actual conditions.
NOTE: Critical torque specifications are located
in Section 1.
SPECIAL TOOLS
A number of special tools must be available to the
technician when performing service procedures in this
section.
NOTE: Special tools are available from the Arctic
Cat Service Parts 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/Cable Ends
B. Brake Lever Pivot/Cable Ends
C. Auxiliary Brake Cable Ends
D. Shift Lever Cable End
E. Idle RPM Screw (Carburetor) (If Applicable)
Battery
After being in service, batteries require regular cleaning
and recharging in order to deliver peak performance and
maximum service life. The following procedure is rec-
ommended for cleaning and maintaining lead-acid bat-
teries. Always read and follow instructions provided
with battery chargers and battery products.
1. Remove the battery hold-down; then disconnect
the battery cables (negative cable first).
2. Disconnect the vent hose.
3. Remove the battery from the battery compartment;
then thoroughly wash the battery and battery com-
partment with soap and water.
NOTE: If battery posts, cable ends, or the battery
case has a build-up of white/green powder residue,
apply water and baking soda to neutralize acid;
then flush off with warm soapy water.
4. Using a wire brush, clean the battery posts and
cable ends removing all corrosive buildup.
Replace damaged cables or cable ends.
5. Add clean distilled water to bring fluid level to the
UPPER level line.
6. Using a multimeter, test the battery voltage. The
meter must read 12.5 or more DC Volts for a fully
charged battery.
NOTE: At this point, if the meter reads as speci-
fied, the battery may be returned to service (see
step 10).
7. If the meter reads less than specified voltage,
charge the battery using the following guidelines.
Description p/n
Compression Tester Kit 0444-213
Oil Filter Wrench 0644-389
Tachometer 0644-275
Timing Light 0644-296
Valve Clearance Adjuster 0444-078
! WARNING
Anytime service is performed on a battery, the fol-
lowing must be observed: keep sparks, open flame,
cigarettes, or any other flame away. Always wear
safety glasses. Protect skin and clothing when
handing a battery. When servicing battery in
enclosed space, keep the area well-ventilated. Make
sure battery venting is not obstructed.
! WARNING
Battery acid is harmful if it contacts eyes, skin, or
clothing. Care must be taken whenever handling a
battery.
! CAUTION
Never use electrolyte (sulfuric acid) to “top off” the
battery. Use only distilled water or severe battery
damage may occur.
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2-4
A. When using an automatic battery charger,
always follow the charger manufacturer’s
instructions.
B. When using a constant-current battery charger,
use the following Battery Charging Chart.
 NOTE: If the battery voltage is 11.5 DC Volts or
less, some chargers may “cut off” and fail to
charge. If this occurs, connect a fully charged
booster battery in parallel (positive to positive and
negative to negative) for a short period of time with
the charger connected. After 10-15 minutes, discon-
nect the booster battery leaving the charger con-
nected and the charger should continue to charge.
If the charger “cuts off,” replace the battery.
8. After charging the battery for the specified time,
remove the battery charger and allow the battery to
sit for 1-2 hours.
9. Connect the multimeter and test the battery volt-
age. The meter should read 12.5 or more DC Volts.
If the voltage is as specified, the battery is ready
for service.
NOTE: If voltage in step 9 is below specifications,
charge the battery an additional 1-5 hours; then
retest. Recheck electrolyte level (standard battery)
and the battery is ready for service.
10. Place the battery in the battery compartment; then
coat the battery posts and cable ends with a light
coat of multi-purpose grease.
11. Connect the battery cables (positive cable first);
then install the battery hold-down.
Fuses
The fuses are located in a power distribution module
under the seat.
If there is any type of electrical system failure, always
check the fuses first.
NOTE: To remove a fuse, compress the locking
tabs on either side of the fuse case and lift out.
0411-828
0411-837
! CAUTION
Never exceed the standard charging rate.
! WARNING
An overheated battery could explode causing severe
injury or death. Always monitor charging times and
charge rates carefully. Stop charging if the battery
becomes very warm to the touch. Allow it to cool
before resuming charging.
Battery Charging Chart (Constant-Current Charger)
Battery Voltage
(DC)
Charge
State
Charge Time Required
(at 1.5-2.0 Amps)
12.5 or more 100% None
12.2-12.4 75%-99% 3-6 hours
12.0-12.2 50%-74% 5-11 hours
11.0-11.9 25%-49% 13 hours (minimum)
11.5 or less 0-24% 20 hours (minimum)
! CAUTION
Before installing the battery, make sure the ignition
switch is in the OFF position.
! CAUTION
Connecting cables in reverse (positive to negative
and negative to positive) can cause serious damage
to the electrical system.
400/500/500 TRV Auto
400/500 Manual
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2-5
2
1411-502
1411-672
1411-311
1411-673
1411-526
Air Filter
Use the following procedure to remove the filter and
inspect and/or clean it.
CLEANING AND INSPECTING
FILTER
1. Remove the seat; then remove the appropriate
reinstallable rivets securing the storage compart-
ment.
CF145C
CF260B
2. On the 400, remove the storage compartment
assembly by elevating the rear of the compart-
ment, moving it rearward, and lifting it off.
650 H1
650 H1 TRV
700 EFI
700 EFI TRV
700 H1 EFI
! CAUTION
Always replace a blown fuse with a fuse of the same
type and rating.
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2-6
CF143A
3. On all models except the 400, raise the storage
compartment cover; then slide the cover forward
and off the compartment. Remove the storage
compartment.
CD669
4. Unsnap the four spring-clip fasteners (400/500/H1
Models) or remove two wing-nuts (700 EFI); then
remove the air filter cover.
CD675A
FI033
5. Remove the air filter element/screen assembly and
separate the element from the screen.
6. Fill a wash pan larger than the element with a
non-flammable cleaning solvent; then dip the ele-
ment in the solvent and wash it.
NOTE: Foam Air Filter Cleaner and Foam Air Fil-
ter Oil are available from Arctic Cat.
7. Dry the element.
8. Put the element in a plastic bag; then pour in air
filter oil and work the oil into the element. Attach
the element to the filter screen.
9. Clean any dirt or debris from inside the air cleaner.
Be sure no dirt enters the carburetor (if equipped).
10. Place the filter assembly in the air filter housing
making sure it is properly positioned and properly
seated with the filter screen down.
CD674
11. Install the air filter housing cover and secure with
the retaining clips (400/500/H1 Models) or
wing-nuts (700 EFI).
12. Install the storage compartment; then secure with
the reinstallable rivets.
! CAUTION
A torn air filter element can cause damage to the
ATV engine. Dirt and dust may get inside the engine
if the element is torn. Carefully examine the element
for tears before and after cleaning it. Replace the ele-
ment with a new one if it is torn.
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2-7
2
CHECKING AND CLEANING
DRAINS
1. Inspect the drains beneath the main housing for
debris and for proper sealing.
KX045A
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
(Feeler Gauge Procedure)
NOTE: For the 700 EFI, see Valve/Tappet Clear-
ance (700 EFI) in this section.
To check and adjust valve/tappet clearance, use the
following procedure.
1. Remove the timing inspection plug; then remove
the tappet covers (for more detailed information,
see Section 3 - Servicing Top-Side Components).
2. Rotate the crankshaft to the TDC position on the
compression stroke.
NOTE: At this point, the rocker arms and adjuster
screws must not have pressure on them.
3. Using a feeler gauge, check each valve/tappet
clearance. If clearance is not within specifications,
loosen the jam nut and rotate the tappet adjuster
screw until the clearance is within specifications.
Tighten each jam nut securely after completing the
adjustment.
CC007DC
4. Install the timing inspection plug.
5. Place the two tappet covers into position making
sure the proper cap screws are with the proper
cover. Tighten the cap screws securely.
Valve/Tappet Clearance
(Valve Adjuster Procedure)
NOTE: For the 700 EFI, see Valve/Tappet Clear-
ance (700 EFI) in this section.
To check and adjust valve/tappet clearance, use the
following procedure.
NOTE: On the 500/H1 models, the seat, storage
compartment cover assembly, compartment box,
air filter/filter housing, and left-side/right-side
splash panels must be removed for this procedure.
1. Remove the timing inspection plug; then remove
the tappet covers (for more detailed information,
see Section 3 - Servicing Top-Side Components).
! 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 dam-
age.
! CAUTION
The feeler gauge must be positioned at the same
angle as the valve and valve adjuster for an accurate
measurement of clearance. Failure to measure the
valve clearance accurately could cause valve com-
ponent damage.
VALVE/TAPPET CLEARANCE (400/500)
Intake 0.05-0.10 mm (0.002-0.004 in.)
Exhaust (400) 0.22-0.27 mm (0.009-0.011 in.)
Exhaust (500) 0.17-0.22 mm (0.007-0.009 in.)
VALVE/TAPPET CLEARANCE (H1 Models)
Intake 0.1016 mm (0.004 in.)
Exhaust 0.1524 mm (0.006 in.)
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2-8
CF005
2. Rotate the crankshaft to the TDC position on the
compression stroke.
NOTE: At this point, the rocker arms and adjuster
screws must not have pressure on them.
NOTE: Use Valve Clearance Adjuster for this pro-
cedure.
3. Place the valve adjuster onto the jam nut securing
the tappet adjuster screw; then rotate the valve
adjuster dial clockwise until the end is seated in
the tappet adjuster screw.
4. While holding the valve adjuster dial in place, use
the valve adjuster handle and loosen the jam nut;
then rotate the tappet adjuster screw clockwise
until friction is felt.
5. Align the valve adjuster handle with one of the
marks on the valve adjuster dial.
6. 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.
7. While holding the adjuster dial at the proper clear-
ance setting, tighten the jam nut securely with the
valve adjuster handle.
8. Place the two tappet covers with O-rings into posi-
tion; then tighten the covers securely.
9. Install the spark plug; then install the timing
inspection plug.
Valve/Tappet Clearance
(700 EFI)
To check and adjust valve/tappet clearance, use the
following procedure.
NOTE: The seat, heat shields, splash panels,
front rack, and front fenders must be removed for
this procedure (see Section 8).
1. Remove the spark plug cap/high tension lead; then
using compressed air, blow any debris from
around the spark plug.
2. Remove the recoil starter assembly; then remove
the valve timing inspection plug and the cylinder
head cover.
FI039A
3. Using an appropriate bar, rotate the engine through
two full revolutions; then while on the compres-
sion stroke, align the TDC line on the starter
clutch with the index mark on the crankcase.
FI041A
NOTE: Rotating the engine ensures that any
trapped oil is squeezed from the tappets and tap-
pet shims. Oil trapped in these areas could result
in a false valve clearance reading.
! WARNING
Always wear safety glasses when using compressed
air.
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2-9
2
4. Using an appropriate thickness gauge, measure
and record the clearance of both intake valves;
then measure and record the clearance of both
exhaust valves. Valve clearance must be within
specifications.
FI046
5. Identify the valves that are not within specifica-
tions; then remove the corresponding camshaft
(see Section 3 - Removing Top-Side Components).
6. Mark the valve tappets in order to return them to
the proper position during assembly.
FI054
7. Fold a suitable towel and use it to plug the cam-
shaft drive passageway; then using a magnet,
remove the tappet and shim from the appropriate
valve.
FI055
FI056
8. Note the three digit number on the surface of the
tappet shim; then refer to the appropriate tappet
shim selection table at the end of this section for
the correct replacement.
FI051
A. Measured tappet clearance from step 4 in verti-
cal column on left.
B. Present shim size horizontal row at the top.
C. Match measured clearance in vertical column
with current shim size in horizontal row to find
recommended replacement size.
9. Apply engine oil to both surfaces of the tappet
shim; then place the shim on the valve with the
numbers toward the tappet.
VALVE/TAPPET CLEARANCE (700 EFI)
Intake 0.10-0.20 mm (0.004-0.008 in.)
Exhaust 0.20-0.30 mm (0.008-0.012 in.)
 AT THIS POINT
If valve clearance is within specifications, proceed
to step 12.
! CAUTION
When removing camshaft holders, use extreme care
not to drop alignment pins into the engine.
! CAUTION
If the camshaft passageway is not plugged, tappet
shims could fall into the engine crankcase.
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2-10
FI053
10. Install the tappet on the appropriate valve; then
install the camshaft.
11. Using an appropriate bar, rotate the engine through
two full revolutions; then rotate to TDC on the
compression stroke and check the valve tappet
clearance.
NOTE: Rotating the engine ensures that any
excess oil is squeezed from the tappets and tappet
shims. Oil trapped in these areas could result in a
false valve clearance reading.
12. Using a new gasket, apply Three Bond Sealant to
the camshaft end caps of the cylinder head cover
gasket; then install the cylinder head cover and
the four cap screws.
13. Tighten the cap screws to 7 ft-lb; then tighten to 10
ft-lb.
14. Install the valve timing inspection plug and tighten
securely; then install the recoil starter assem-
bly/outer magneto cover and secure with the four
cap screws coated with blue Loctite #242. Tighten
to 6 ft-lb.
15. Install the spark plug cap/high tension lead, front
fenders, front rack, and splash panels; then install
the heat shields and seat making sure the seat locks
securely.
Testing Engine
Compression
To test engine compression, use the following proce-
dure.
1. Remove the high tension lead from the spark plug.
2. Using compressed air, blow any debris from
around the spark plug.
3. Remove the spark plug; then attach the high ten-
sion 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 must be warm and the battery
must be fully charged for this test.
5. While holding the throttle lever in the full-open
position, crank the engine over with the electric
starter until the gauge shows a peak reading (five
to 10 compression strokes).
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. Valve not bent or burned.
F. Valve seat not burned.
NOTE: To service valves, see Section 3.
7. Pour 29.5 ml (1 fl oz) of oil into the spark plug
hole, reattach the gauge, and retest compression.
8. If compression is now evident, service the piston
rings (see Section 3).
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 or the carburetor (if equipped) may
need to be adjusted. To maintain a hot, strong spark,
keep the plug free of carbon.
! WARNING
Always wear safety glasses when using compressed
air.
! CAUTION
On the 700 EFI, do not ground the spark plug on the
cylinder head cover. The cover is made of magne-
sium and any contact with spark or electrical arc will
severely pit the surface.
PEAK COMPRESSION
MODEL PSI
400 95-115
500 70-85
700 EFI 130-155
H1 Models 155-175
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