Positioning:
The 2006 Arctic Cat ATVs covered by this manual represented a strong offering in the utility ATV segment, known for their robust build, versatile capabilities, and a range of engine options.
Competitors:
Competed against models from Polaris (Sportsman series), Can-Am (Outlander series), Yamaha (Grizzly series), and Honda (Foreman, Rubicon series) in the mid-to-large displacement utility ATV market.
Features:
Key features across these models included independent suspension, selectable 2WD/4WD, powerful engines (especially the 650 V-Twin), and specialized configurations like the TBX with a dump bed and TRV for two-up riding.
Engine:
Complete engine overhaul, diagnosis, and repair procedures for 400cc and 500cc class engines (likely Suzuki-based for 400/500 and H1 for 650), including cooling, lubrication, fuel delivery, and ignition systems.
Transmission:
Detailed coverage of automatic and manual transmission systems, including gearbox, clutch, and final drive components. Also covers CVT systems where applicable.
Drive System:
Covers front and rear drive systems, differentials, CV joints, driveshafts, and 4WD engagement mechanisms (including Arctic Cat's Active Descent Control - ADC, and Four-Wheel Independent Suspension - FIS where applicable).
Suspension:
Comprehensive coverage of front and rear suspension systems, including independent suspension components (struts, control arms, shocks, springs), bearings, and bushings. Specific details for ACT (Arctic Cat Traction) and FIS (Fully Independent Suspension) systems.
Steering Frame:
Detailed procedures for steering system components (tie rods, steering column, rack and pinion), frame inspection, and chassis alignment.
Electrical System:
Extensive coverage of the electrical system, including battery, starter, alternator/stator, ignition system, lighting, charging system, wiring diagrams, switches, fuses, and electronic control units (ECUs).
Controls Indicators:
Information on hand controls, foot controls, dashboard indicators, and warning lights.
Fuel System:
Carburetor or EFI system components, fuel pump, fuel lines, fuel filter, and fuel tank.
Cooling System:
Radiator, cooling fan, water pump, coolant hoses, thermostat, and overflow reservoir.
Exhaust System:
Exhaust manifold, muffler, and heat shields.
Bodywork Plastics:
Fenders, body panels, racks, seat, and associated mounting hardware.
Maintenance:
Routine maintenance, tune-ups, oil changes, filter replacements, lubrication schedules, and general upkeep procedures.
Troubleshooting:
Systematic troubleshooting guides for diagnosing and resolving common mechanical and electrical issues, including diagnostic charts and error code interpretations.
Rebuild Restore:
Step-by-step instructions for major component overhauls, rebuilds, and restorations, covering engines, transmissions, and other key assemblies.
Diagnostics:
Detailed diagnostic flowcharts and procedures for identifying and resolving issues across all major systems.
Specifications Data:
Includes essential technical specifications, torque values, clearances, and tolerances for various components and assemblies.
Depth:
Comprehensive, dealership-level technical information suitable for professional technicians and experienced DIY enthusiasts. Covers everything from basic adjustments to complete unit overhauls.
Wiring Diagrams:
Comprehensive electrical wiring diagrams with component locations and color coding.
Part Number Reference:
While not a parts catalog, it implies reference to part numbers for correct component identification during repair.
Engine Type 400:
Likely a 375cc-400cc class, liquid-cooled, 4-stroke engine (often of Suzuki origin for this era).
Engine Type 500:
Likely a 475cc-500cc class, liquid-cooled, 4-stroke engine (often of Suzuki origin for this era).
Engine Type 650:
Arctic Cat H1 or V-Twin 650cc liquid-cooled, 4-stroke engine.
Horsepower Estimate 400:
Estimated 28-32 HP range (actual figures vary by specific model and tuning).
Horsepower Estimate 500:
Estimated 32-36 HP range (actual figures vary by specific model and tuning).
Horsepower Estimate 650:
Estimated 45-50 HP range (actual figures vary by specific model and tuning).
Carburetion Ignition:
Carbureted (Mikuni or Keihin) and/or electronic fuel injection (EFI) depending on the specific model and sub-variant.
Dash Features:
Digital instrument cluster displaying speed, RPM, odometer, trip meter, fuel level (on some models), 2WD/4WD indicator, gear selection, and various warning lights.
Selectable 4Wd:
Electronic push-button or lever-actuated selectable 2WD/4WD system with differentials for enhanced traction.
Engine Braking:
Integrated engine braking provided by the CVT system, aiding in downhill descents.
Charging Port:
Optional DC power outlet for charging electronic devices on some models.
Oil Change Interval:
Typically recommended every 100 hours or annually, whichever comes first. Check manual for specific grades.
Spark Plug Replacement:
Recommended every 100-200 hours or as needed based on inspection.
Air Filter Maintenance:
Requires regular inspection and cleaning/replacement, especially in dusty conditions. Typically advised every 50 hours or as needed.
Engine Oil Spec:
API SG or higher, SAE 10W-40 or 20W-50 depending on ambient temperature. Refer to manual for specific viscosity recommendations. Synthetic blends are often recommended for performance.
Coolant Spec:
Ethylene glycol-based antifreeze (e.g., SAE 20W, 50/50 mix with distilled water). Specific Arctic Cat coolant may be recommended.
Brake Fluid Spec:
DOT 3 or DOT 4 hydraulic brake fluid.
Gearcase Oil Spec:
API GL-4 or GL-5, SAE 80W-90 hypoid gear oil for differentials and gearcases. Specific Arctic Cat gear oils may be recommended.
Common Problems:
Common issues can include starter solenoid failures, charging system issues (stator), CVT belt wear, suspension component wear (ball joints, bushings), and carburetor or EFI sensor issues depending on the specific model.
Preventative Maintenance:
Regular cleaning, lubrication of moving parts (pivot points, cables), and timely fluid changes are crucial for longevity. Vigilant inspection of suspension and steering components is recommended.
Arctic Cat Legacy:
Arctic Cat, a long-standing manufacturer of snowmobiles, expanded significantly into the ATV market in the late 1990s and early 2000s, leveraging their engineering expertise.
Evolution 2006:
The 2006 models represented a refinement of Arctic Cat's ATV platform, building on previous successes with more powerful engines, improved suspension designs (FIS and ACT), and specialized variants like the TBX and TRV.
Manufacturing Location:
Manufactured by Arctic Cat Inc., primarily in Thief River Falls, Minnesota, USA.
