Target Audience:
Professional technicians and experienced ATV owners performing their own service
Intended Use:
Work and utility ATV with towing and hauling capability
Competitive Position:
Competed with Polaris Sportsman 500 and Honda Foreman Rubicon in the utility class
Engine:
500cc liquid-cooled four-stroke single
Drivetrain:
Automatic CVT transmission with selectable 2WD/4WD
Suspension:
Independent front suspension with rear swingarm
Load Capability:
Front and rear racks for cargo
Engine Service:
Complete removal, disassembly, inspection and rebuild procedures
Fuel System:
Carburetor service, fuel pump and tank procedures
Cooling System:
Radiator, coolant and thermostat service
Transmission / CVT:
Automatic drive belt, clutch and transmission service
Electrical System:
Wiring diagrams, charging, starting and ignition
Suspension:
Front A-arm and rear swingarm service
Steering:
Steering component inspection and replacement
Brakes:
Hydraulic brake service, pads, discs and bleeding
Final Drive:
Front differential, hubs and rear axle service
Wheels and Tires:
Removal, installation and specifications
Frame and Body:
Rack, fender and frame repair procedures
Lubrication:
Fluid capacities and lubrication points
Wiring Diagrams:
Included
Torque Specifications:
Included throughout procedures
Exploded Views:
Component diagrams and exploded illustrations
Troubleshooting:
Diagnostic charts and fault-finding procedures
Special Tools:
Special tool requirements identified where needed
Part Numbers:
Factory part numbers referenced in procedures
Specifications Tables:
Wear limits and factory service specifications
Fluid Capacities:
Engine oil, coolant and gear case capacities
Parts Sourcing:
N/A - service manual only, not a parts catalog
File Format:
PDF (searchable, bookmarked, zoomable)
Compatibility:
Windows, macOS, Linux, iOS, and Android — any device with a PDF reader
Requirements:
A PDF reader application (e.g. Adobe Acrobat Reader, free)
Searchability:
Fully text searchable for fast lookup of any topic
Print Quality:
High-resolution digital pages, printable at full clarity
Binding Type:
N/A — digital download, no physical binding
Paper Type:
N/A — digital download, no physical paper
Type:
Four-stroke, liquid-cooled single cylinder
Displacement:
500cc class
Valvetrain:
SOHC, 4-valve
Starting System:
Electric start with recoil backup
Cooling:
Liquid-cooled with radiator
Rated Output:
N/A - exact figure not verified, consult manual
Drive:
CVT automatic with selectable 2WD/4WD
Crash Test Rating:
N/A - ATVs are not crash tested like road vehicles
Brakes:
Hydraulic disc brakes
Active Features:
4WD engagement for improved traction
Passive Features:
Footwell design and operator presence requirements per ATV standards
Manual Guidance:
Service safety warnings and precautions included throughout
Audio System:
N/A - utility ATV, no factory audio
Driver Assistance:
N/A - not applicable to this vehicle class
Instrumentation:
Speedometer and indicator lamps covered in electrical section
Electrical:
Electric start and 12V charging system
Service Intervals:
Scheduled maintenance tables included in manual
Engine Oil:
Recommended oil specification and capacities provided
Coolant:
Coolant type and capacity specified
CVT Belt:
Drive belt inspection interval and replacement procedure
Common Wear Items:
Brake pads, CVT belt, bushings and spark plug
Air Filter:
Service interval and cleaning/replacement procedure
Manufacturer:
Arctic Cat, Minnesota-based powersports manufacturer founded in 1960
Model Evolution:
The 500 4x4 Automatic joined Arctic Cat's utility ATV line in the late 1990s, evolving with annual updates through the early 2000s
Production Location:
United States (Arctic Cat production facilities)
2002 Model Year:
Continued as a flagship utility ATV in Arctic Cat's lineup
