🏷️ Basic Information

Make:

Arctic Cat

Model Years Covered:

2006

Vehicle Type:

All-Terrain Vehicle (ATV)

Primary Market:

Utility/Recreational

Chassis Codes:

Not specified, but covers various 4x4 configurations

Generation Details:

This manual covers specific models within the 2006 model year, representing a distinct generation of Arctic Cat utility ATVs.

👋 Introduction

Market Position:

Arctic Cat's utility ATVs of this era were positioned as robust, capable machines for a variety of tasks, including work, hunting, and trail riding. They competed with other major manufacturers in the mid-to-large displacement utility ATV segment.

Competitive Analysis:

Competed with models from Honda (e.g., Foreman, Rancher), Yamaha (e.g., Grizzly), Polaris (e.g., Sportsman), and Kawasaki (e.g., Prairie). Key competitive advantages often lay in their engine power (especially the V-Twin), suspension design (like FIS), and utility-focused features like cargo racks and towing capacity.

Key Features:

The 2006 lineup offered a range of engine options including single-cylinder H1 and V-Twin configurations, robust 4x4 drivetrains, and advanced suspension systems for their time. Models like the TRV offered 2-up seating, and TBX variants provided enhanced cargo capabilities.

Engine Variants:

The offering of both the robust single-cylinder H1 engine and the powerful V-Twin engine provided consumers with distinct performance choices within the 2006 Arctic Cat ATV lineup.

📋 Manual Details

Models Covered:

Arctic Cat 400 4x4, Arctic Cat 400 4x4 LE, Arctic Cat 400 4x4 TBX, Arctic Cat 400 4x4 TRV, Arctic Cat 400 4x4 VP, Arctic Cat 500 4x4, Arctic Cat 500 4x4 LE, Arctic Cat 500 4x4 TBX, Arctic Cat 500 4x4 TRV, Arctic Cat 650 H1 4x4, Arctic Cat 650 V-TWIN 4x4, Arctic Cat 650 V-TWIN 4x4 LE. Includes variations like automatic/manual transmissions, FIS and ACT rear suspensions.

Variations Covered:

Explicitly states coverage of all variations including automatic and manual transmissions, FIS (Fully Independent Rear Suspension), and ACT rear suspension, ensuring broad applicability across the 2006 model range.

Page Count:

531

Manual Type:

Factory Service Manual / Repair Manual

Language:

English

Format:

PDF Download

📖 Manual Coverage

Systems Covered:

Engine (including disassembly/reassembly, lubrication, cooling, fuel system, ignition, starting), Transmission (drive train components), Suspension (front and rear, including FIS and ACT), Steering, Braking System, Electrical System (including wiring diagrams, charging system, lighting), Body and Frame, Chassis components, Fuel Injection (EFI models), Carburetion, Exhaust System, Wheels and Tires.

Braking System:

Covers front and rear hydraulic disc brake systems, including brake pad replacement, caliper service, master cylinder maintenance, brake fluid bleeding procedures, and rotor inspection.

Steering System:

Covers steering components, tie rods, steering column, handle grips, and any associated linkages or components. Includes inspection for play and proper lubrication.

Drive Train:

Details on the drive shafts, CV joints, front and rear differentials, and the engagement mechanisms for the 4WD system. Covers lubrication and inspection for wear or damage.

Procedures Included:

Complete tear down and rebuild procedures, routine maintenance (oil changes, filter replacements, lubrication), troubleshooting common problems, diagnostic procedures, repair instructions, component testing, adjustments (carburetor, valves, throttle cable), fluid changes (coolant, brake fluid, transmission fluid), suspension setup, electrical diagnostics, wiring harness repair, component installation, torque specifications for all critical fasteners.

Engine Overhaul:

Detailed step-by-step instructions for complete engine disassembly, inspection of internal components (pistons, rings, valves, crankshaft, connecting rods), cylinder head service, and reassembly with correct torque specifications and clearances.

Suspension Repair Adjustment:

Covers disassembly, cleaning, lubrication, and reassembly of front A-arm suspension and rear independent suspension systems (FIS and ACT). Includes procedures for shock absorber servicing, bushings, ball joints, and wheel bearings.

Electrical Troubleshooting:

Extensive troubleshooting guides for common electrical issues such as no-spark conditions, battery charging problems, lighting failures, and starter malfunctions. Utilizes the included wiring diagrams to pinpoint faults.

Carburetor Rebuild Adjustment:

Comprehensive instructions for carburetor disassembly, cleaning, reassembly, jetting specifications (main jet, pilot jet, needle settings), idle speed adjustment, and mixture screw settings for carbureted models.

Technical Depth:

Comprehensive. Covers everything from basic maintenance and troubleshooting to in-depth engine overhauls, transmission repairs, and electrical system diagnostics. Includes detailed diagrams, part identification, and specific torque values essential for accurate servicing.

Diagnostic Charts:

The manual likely includes detailed diagnostic flowcharts and symptom-based troubleshooting tables to help identify the root cause of various mechanical and electrical problems.

Component Illustrations:

The manual features numerous illustrations, diagrams, and part schematics that clearly identify components and guide technicians through disassembly, assembly, and repair processes. This visual aid is invaluable for understanding complex systems.

📊 Manual Specifications

File Format:

PDF

Print Quality:

Printable without restrictions. High resolution for clear viewing of diagrams and text.

Binding Type:

N/A (Digital Download)

Paper Type:

N/A (Digital Download)

Features:

Clickable chapters, searchable text, no printing or saving restrictions, free replacement upon loss.

⚙️ Engine Specifications

Engine Type:

Varies by model: Liquid-cooled, SOHC, 4-stroke (H1 engine); Liquid-cooled, V-Twin, 4-stroke (V-TWIN engine). Specific displacements for 400, 500, and 650 models are detailed within the manual.

Displacement Variations:

The manual covers models with approximately 375cc (400 series), 470cc (500 series), and 650cc (650 series) engine displacements, with precise figures for each specific engine variant provided within the document.

Horsepower Torque:

Specific horsepower and torque figures are provided for each engine variant within the manual, crucial for performance tuning and diagnostics. Expect mid-to-high 30s HP for 400/500 models and potentially higher for the 650 V-Twin.

Fuel Delivery:

Carbureted for some models (e.g., 400, 500 base models) and Electronic Fuel Injection (EFI) for others, particularly higher-trim or specific engine variants. The manual covers both systems, including jetting specifications for carburetors and EFI sensor diagnostics.

Oil Type Capacity:

The manual specifies the correct Arctic Cat synthetic engine oil (or equivalent) viscosity grade (e.g., SAE 0W-40 or 10W-40 depending on ambient temperature) and exact capacities for the engine, transmission, and differential based on model and component. Crucial for longevity.

Coolant Type:

Typically a 50/50 mix of ethylene glycol antifreeze and distilled water. The manual details coolant capacity, flush procedures, and thermostat specifications.

🔧 Transmission

Transmission Type:

Automatic Continuously Variable Transmission (CVT) with high/low range and reverse (Arctic Cat Speed-Drive). Some models may have offered manual transmission variants, though less common for this utility segment.

Transmission Options:

The manual notes that it covers variations including automatic and manual transmissions, suggesting certain models or sub-trims might have had manual gearbox options. The primary transmission is the Arctic Cat Speed-Drive CVT.

Cvt Features:

Features include engine braking, automatic engagement, and a drive belt system. The manual provides detailed inspection, replacement, and adjustment procedures for the CVT drive and driven clutches, as well as belt specifications.

Transmission Fluid:

Specific Arctic Cat synthetic gear oil or equivalent for the transmission and differentials is specified. The manual details fluid capacities and change intervals for the transmission, front differential, and rear differential.

📐 Dimensions

Overall Length Width Height:

Specific dimensions for each model (400, 500, 650) are detailed in the manual, including variations based on suspension type (FIS, ACT) and body style (TBX, TRV). Generally, expect lengths around 83-85 inches and widths around 48-50 inches.

Dry Weight Curb Weight:

Dry weights and curb weights for each model variant are listed in the manual, typically ranging from around 600 lbs for smaller models to over 700 lbs for larger V-Twin configurations.

Rack Capacity:

Front and rear rack capacities are specified, generally around 50 lbs for the front and 150 lbs for the rear. TBX models often feature enhanced cargo box capabilities.

Towing Rating:

Towing capacities are specified, typically rated at 1050 lbs for most models, with specific hitch and ball mount requirements outlined in the manual.

🛡️ Safety Features

Safety Certifications:

ATVs are not typically rated by agencies like NHTSA or IIHS in the same way cars are. However, the manual will cover safety features and operational guidelines crucial for safe use.

Active Safety Features:

4WD system (selectable 2WD/4WD), engine braking provided by the CVT, responsive braking systems (disc brakes front and rear), and appropriate lighting for visibility. The manual covers operation and maintenance of these systems.

Passive Safety Features:

Handlebar guards, padded seating (on TRV models), and robust chassis design. The manual emphasizes the importance of wearing appropriate safety gear (helmet, goggles, protective clothing).

💡 Technology Features

Infotainment Features:

Basic for its time. Typically included a simple digital instrument cluster displaying speed, odometer, trip meter, gear indicator (if applicable), and warning lights. No advanced infotainment systems like touchscreens or audio were standard.

Driver Assistance Features:

Limited to the selectable 2WD/4WD system and engine braking from the CVT. The manual focuses on the mechanical and electrical operation of these core functionalities.

Electrical System Components:

Includes details on the battery, starter motor, alternator/stator, ignition system (CDI), lighting (headlights, taillights), and switches. The inclusion of full wiring diagrams is a significant technological aspect covered in this manual.

🔧 Maintenance

Recommended Intervals:

The manual provides a detailed maintenance schedule covering intervals for oil changes (e.g., every 50-100 hours or annually), filter replacements, spark plug inspection/replacement, drive belt inspection, brake service, suspension lubrication, and cooling system checks. Specific intervals are provided for various components.

Throttle Cable Adjustment:

Details on checking and adjusting throttle cable free play to ensure proper throttle response and prevent unintended acceleration.

Ignition Timing Inspection:

While most ignition systems are electronically controlled, the manual covers inspection and testing of the ignition coil, spark plug, and associated wiring for proper spark generation.

Fluid Recommendations:

Crucial details on: Engine Oil (Arctic Cat Synthetic SAE 0W-40 or 10W-40), Coolant (50/50 Ethylene Glycol Antifreeze & Distilled Water), Brake Fluid (DOT 4), Front/Rear Differential Fluid (Arctic Cat synthetic gear oil or equivalent), and CVT Belt Lube/Cleaner. Capacities and specifications are all within the manual.

Common Wear Items Diagnostics:

While not explicitly listing 'known issues' as recalls, the manual's troubleshooting section addresses common problems such as hard starting, poor performance, electrical faults, CVT belt wear, suspension noise, and brake system issues. It guides users on diagnosing and repairing these. Common wear items include brake pads, tires, and the CVT drive belt.

Tire Pressure Specs:

Recommended tire pressures for front and rear tires are provided, typically in the range of 4-6 PSI, depending on the tire model and intended use. Correct pressure is vital for handling and tire life.

Critical Torque Values:

Extensive torque specifications are provided for nearly every fastener, including critical components like cylinder head bolts, wheel lug nuts, suspension mounting bolts, engine mounts, and clutch components. Essential for safe and correct assembly.

📚 Vehicle History

Brand Heritage:

Arctic Cat has a long history in powersports, particularly with snowmobiles. Their foray into ATVs in the late 1990s and early 2000s built upon their engineering expertise, aiming to produce powerful and capable off-road machines.

Model Evolution 2006:

The 2006 models represented a significant step for Arctic Cat ATVs, featuring updated styling, improved engine performance (especially the introduction/refinement of the H1 and V-Twin engines), and advanced suspension technologies like Fully Independent Suspension (FIS) and Arctic Cat Traction (ACT). This year saw a wide range of variants to cater to different user needs.

Suspension Technology:

The 2006 Arctic Cat ATVs were notable for their adoption of Fully Independent Suspension (FIS) on many models, offering a significant improvement in ride comfort and handling over older solid axle designs. The ACT (Arctic Cat Traction) suspension system was also a feature on some variants.

Manufacturing Location:

Arctic Cat ATVs were primarily manufactured in the United States, with assembly typically occurring at their facilities in Thief River Falls, Minnesota.

🏆 Awards & Recognition

Industry Awards:

Specific awards for the 2006 models are not universally documented, but Arctic Cat ATVs of this period were generally well-regarded for their power and handling, particularly the V-Twin models, often earning positive reviews in powersports publications for their utility and performance capabilities.