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arctic cat 2009 400 TRV 500 550 700 1000 thundercat Service Repair Manual

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This manual covers the 2009 400 TRV, 500 TRV, 550 TRV, 700 TRV, and 1000 Thundercat All-Terrain Vehicles. The 2009 ATV lineup offered a range of powerful and versatile machines...
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Taper: Atv
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UGS: 70384
arctic cat 2009 400 TRV 500 550 700 1000 thundercat Service Repair Manualarctic cat 2009 400 TRV 500 550 700 1000 thundercat Service Repair Manualarctic cat 2009 400 TRV 500 550 700 1000 thundercat Service Repair Manualarctic cat 2009 400 TRV 500 550 700 1000 thundercat Service Repair Manual
This manual covers the 2009 400 TRV, 500 TRV, 550 TRV, 700 TRV, and 1000 Thundercat All-Terrain Vehicles. The 2009 ATV lineup offered a range of powerful and versatile machines designed for both utility and recreational use. The TRV models provided the convenience of two-up seating, enhancing their versatility for passengers, while the Thundercat series represented the pinnacle of performance within the ATV range for that era, emphasizing robust engineering and capability. These ATVs are equipped with liquid-cooled, four-stroke engines across various displacements, featuring automatic CVT transmissions and selectable 2WD/4WD drivetrains with front differential lock on many configurations. This comprehensive service and repair manual provides detailed instructions for the maintenance, diagnosis, and repair of your 2009 ATV. It covers all major systems, including the engine, fuel, lubrication, cooling, ignition, starting, charging, transmission, drivetrain, suspension, steering, braking, and electrical systems. The manual includes scheduled maintenance procedures, general repair guidelines, troubleshooting guides, component removal and installation steps, overhaul procedures, wiring diagrams, torque specifications, and diagnostic procedures. Whether you are performing routine maintenance or tackling complex repairs, this guide offers the essential technical information needed to keep your ATV operating at its best.
🏷️ Basic Information
Identification
Make:
Arctic Cat
Model:
TRV 400, 500, 550, 700, 1000 Thundercat
Year:
2009
Atv Type:
Utility/Recreational All-Terrain Vehicle
Codes
Manual Product Code:
Likely internal sales/product code, not directly extractable from provided info.
👋 Introduction
Market Position
Vehicle Segment:
All-Terrain Vehicle (ATV), Utility/Recreational
Competitive Analysis
Key Competitors 2009:
Polaris Sportsman series, Can-Am Outlander series, Yamaha Grizzly series, Kawasaki Brute Force series, Suzuki KingQuad series.
Key Features
Model Lineup Highlights:
The 2009 Arctic Cat TRV and Thundercat lineup offered a range of powerful engines in versatile ATV platforms, emphasizing durability and capability for work and recreation. TRV models typically featured 2-up seating for passenger comfort.
Trv 2 Up Seating:
The TRV designation signifies the 'Two-Rider Vehicle' configuration, typically featuring a comfortable passenger seat with backrest and handholds.
📋 Manual Details
Coverage Areas
Vehicles Covered:
Arctic Cat 2009 400 TRV, 500 TRV, 550 TRV, 700 TRV, 1000 Thundercat
Variant Coverage:
Covers multiple engine sizes and TRV/Thundercat configurations within the 2009 model year. May address minor differences between models.
Page Count
Estimated Page Count:
Highly variable based on specific model/engine, typically 500-1500+ pages for a comprehensive service manual.
Manual Type
Type:
Service and Repair Manual
Manual Purpose:
Comprehensive guide for diagnosing, repairing, maintaining, and overhauling the specified Arctic Cat ATV models.
Language
Language:
English (presumed, standard for Arctic Cat documentation)
Format
Format:
Digital Download (PDF)
📖 Manual Coverage
Systems Covered
Major Systems:
Engine Mechanical, Engine Fuel System, Engine Lubrication, Cooling System, Ignition System, Starting System, Charging System, Transmission (CVT), Drivetrain (2WD/4WD), Suspension (Front & Rear), Steering System, Braking System, Electrical System, Chassis & Frame, Body Panels, Accessories
Electrical System Details:
Complete wiring diagrams, component testing, troubleshooting for lighting, ignition, charging, starting, EFI, instrumentation, and accessories.
Chassis And Frame Integrity:
Information on frame inspection, welding procedures (if applicable), and component mounting points.
Procedures Included
Repair And Maintenance:
Scheduled Maintenance, General Repair Procedures, Troubleshooting Guides, Component Removal & Installation, Overhaul Procedures, Wiring Diagrams, Torque Specifications, Diagnostic Procedures
Engine Overhaul Procedures:
Detailed steps for engine disassembly, inspection, repair, and reassembly, including piston, rings, cylinder, crankshaft, camshaft, valve train.
Drivetrain And Axle Repair:
Procedures for front and rear driveshafts, CV joints, differential service, and axle replacement.
Bodywork And Plastics Repair:
Guidance on removing and reinstalling body panels, fenders, and headlights; may include minor plastic repair techniques.
Technical Depth
Scope Of Detail:
Comprehensive, covering routine maintenance to complete engine and transmission rebuilds, electrical system diagnostics, and chassis repair.
Suspension And Steering Repair:
Comprehensive instructions for front and rear suspension component replacement (shocks, springs, A-arms, bushings), steering column, tie rods, and wheel alignment.
Electrical Component Testing:
Detailed test procedures for starter motor, alternator/stator, ignition coil, CDI unit (if applicable), fuel pump, sensors, and switches using multimeters and oscilloscopes.
Troubleshooting Flowcharts:
Likely includes diagnostic flowcharts and symptom-based troubleshooting guides to efficiently identify problems.
📊 Manual Specifications
File Format
Digital Specifications:
Likely a searchable PDF, allowing for easy navigation and keyword searches. High resolution for clear diagrams.
Searchability:
Likely OCR-processed PDF for effective keyword searching, greatly enhancing diagnostic and repair efficiency.
Print Quality
Printability:
Designed for digital viewing but likely printable for workshop use.
Diagram Clarity:
Expect high-resolution, clear line drawings and schematics for easy interpretation of assembly and disassembly steps.
Binding Type
Binding:
N/A (Digital Format)
Paper Type
Paper Quality:
N/A (Digital Format)
⚙️ Engine Specifications
Primary Engine
Engine Types Covered:
Single-cylinder, 4-stroke, SOHC, liquid-cooled engines across various displacements (approx. 375cc for 400, 471cc for 500, 546cc for 550, 695cc for 700, and 951cc V-Twin for 1000 Thundercat).
Engine Cooling System:
Liquid-cooled with radiator, fan, thermostat, and coolant reservoir. Manual covers system inspection, flushing, and component replacement.
Bore And Stroke:
Specific bore and stroke dimensions for each engine variant will be provided, essential for engine rebuilding and specification verification.
Performance
Horsepower Range:
Varies significantly by engine: estimated 20-35 HP for smaller engines, up to 60+ HP for the 1000cc Thundercat.
Torque Figures:
Specific torque output figures will vary by engine displacement and tune, detailed within the manual for reference during assembly.
Fuel System
Fuel Delivery:
Fuel Injection (EFI) for most models, particularly 550, 700, and 1000. Carbureted models may exist for the 400/500 depending on specific sub-variants or regional markets.
Carburetor Specifications:
For carbureted models, the manual will list specific carburetor models, jetting, float bowl adjustment, and synchronization procedures.
🔧 Transmission
Standard
Transmission Type:
Automatic CVT (Continuously Variable Transmission) with High/Low range and Reverse.
Optional
Gear Ratios:
Specific ratios for High and Low range will be detailed in the manual, crucial for performance tuning and troubleshooting.
Features
Drivetrain Modes:
Selectable 2WD/4WD with front differential lock (on many models).
📐 Dimensions
Exterior
Length Width Height:
Varies by model; typically around 80-90 inches (L) x 45-50 inches (W) x 48-55 inches (H).
Weights
Dry Weight:
Ranges from approximately 600 lbs (400 TRV) to over 750 lbs (1000 Thundercat).
Towing Capacity:
Typically rated around 1,050 lbs (476 kg), with specific hitch and safety chain requirements detailed in the manual.
Cargo
Rack Capacity:
Front and rear racks typically rated for 50-100 lbs each. Towing capacity often around 1,050 lbs.
🛡️ Safety Features
Ratings
Atv Safety Standards:
Manufactured to meet relevant ATV safety standards; manual will detail safe operating practices.
Active Features
Braking System Type:
Hydraulic disc brakes on all wheels, often with sealed brake components.
Passive Features
Lighting And Visibility:
Halogen headlights, taillight, brake light. Manual will cover electrical system for diagnostics.
💡 Technology Features
Infotainment
Gauge Cluster:
Digital/Analog combination gauge cluster displaying speed, RPM, odometer, trip meter, fuel level, 4WD indicator, 2WD/4WD selector, engine temperature warning, oil pressure warning, and gear selection (P/R/N/H/L).
Driver Assistance
Efi System:
Electronic Fuel Injection systems manage fuel delivery and ignition timing for optimal performance and emissions.
Connectivity
Accessory Ports:
May include accessory power outlets for charging devices or powering aftermarket accessories.
🔧 Maintenance
Service Intervals
Routine Maintenance Schedule:
Includes intervals for: Oil & Filter Change (e.g., every 50-100 hours or annually), Air Filter Cleaning/Replacement (e.g., every 25-50 hours), Spark Plug Check/Replacement, Belt Inspection/Replacement (CVT Belt), Valve Clearance Adjustment, Gearbox/Differential Fluid Changes, Brake Inspection, Coolant Flush.
Brake Fluid Change Interval:
Recommended interval for brake fluid flush and replacement (e.g., every 1-2 years) to maintain braking performance.
Fluid Specifications
Recommended Fluids:
Engine Oil (e.g., SAE 10W-40 Synthetic or Mineral, API SG or higher), Gearcase Oil (specific Arctic Cat or equivalent gear oil), Brake Fluid (DOT 3 or DOT 4), Coolant (Antifreeze/Water mixture, typically 50/50).
Cv T Fluid Type:
Specific CVT fluid or high-quality ATF (Automatic Transmission Fluid) type as specified by Arctic Cat. Critical for CVT longevity and performance.
Known Issues
Common Wear Items And Trouble Points:
CVT belt wear/failure, suspension component wear (ball joints, tie rods), electrical connections (corrosion), starter issues, fuel pump reliability (on some EFI models), potential cooling system leaks.
Engine Timing Chain Wear:
Potential for timing chain stretch or tensioner wear on higher mileage engines, with manual outlining inspection and replacement.
📚 Vehicle History
Brand Heritage
Arctic Cat Atv Legacy:
Arctic Cat has a long history in powersports, transitioning from snowmobiles to ATVs, building a reputation for robust and powerful machines.
Model Evolution
Trv Thundercat Development:
The TRV line evolved to offer 2-up capability, while the Thundercat series represented the pinnacle of performance within the Arctic Cat ATV range for that era.
Thundercat Performance Emphasis:
The Thundercat line historically focused on delivering high horsepower and aggressive performance for enthusiasts seeking maximum power.
Production
Manufacturing Origin:
Arctic Cat ATVs are typically manufactured in the United States (e.g., Thief River Falls, Minnesota).
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