2009 ARCTIC CAT OFFICIAL FACTOTY SERVICE | REPAIR | SHOP MANUAL - COVERS: ARCTIC CAT 400 TRV, 500 AUTOMATIC, 500 MANUAL, 550 H1, 550 H1 TRV, 700H1, 700 H1 CRUISER, THUNDERCAT AND 1000 H2 CRUISER ATV - INSTANT DOWNLOAD! VERY HIGH QUALITY FACTORY SERVICE MANUAL - BEST MANUAL YOU COULD GET ANYWHERE!! SERVICE MANUAL COVERS: ================ 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 General Specifications ............................................ 1-2 Torque Specifications .............................................. 1-3 Torque Conversions (ft-lb/N-m) ............................... 1-6 Tightening Torque (General Bolts) .......................... 1-6 Break-In Procedure ................................................. 1-6 Gasoline - Oil - Lubricant ........................................ 1-6 Genuine Parts ......................................................... 1-7 Preparation For Storage.......................................... 1-7 Preparation After Storage........................................ 1-8 Periodic Maintenance Chart.................................... 2-2 Periodic Maintenance.............................................. 2-3 Lubrication Points.................................................... 2-3 Air Filter................................................................... 2-3 Valve/Tappet Clearance (Feeler Gauge Procedure) ................................... 2-4 Valve/Tappet Clearance (Valve Adjuster Procedure) (400/500/H1 Models) ........................................... 2-5 Valve/Tappet Clearance (Valve Adjuster Procedure) (H2 Models).............. 2-6 Testing Engine Compression .................................. 2-6 Spark Plug(s) .......................................................... 2-7 Muffler/Spark Arrester ............................................. 2-7 Engine/Transmission Oil - Filter - Strainer .............. 2-8 Front Differential/Rear Drive Lubricant .................. 2-10 Adjusting Clutch (500 Manual Transmission) ........ 2-11 Steering Components ........................................... 2-11 Driveshaft/Coupling............................................... 2-11 Suspension/Shock Absorbers/Bushings ............... 2-11 Nuts/Bolts/Cap Screws.......................................... 2-12 Headlights/Taillight-Brakelight ............................... 2-12 Shift Lever ............................................................. 2-13 Frame/Welds/Racks .............................................. 2-14 Electrical Connections........................................... 2-14 Hydraulic Brake Systems ...................................... 2-14 Burnishing Brake Pads.......................................... 2-15 Checking/Replacing V-Belt (Automatic Transmission)................................... 2-16 Engine/Transmission ............................................... 3-2 Specifications (400)................................................. 3-2 Specifications (500)................................................. 3-3 Specifications (H1 Models)...................................... 3-4 Specifications (H2 Models)...................................... 3-4 Troubleshooting ....................................................... 3-5 400 Table of Contents ............................................. 3-9 500 (Automatic Transmission)/H1 Models Table of Contents ............................................... 3-50 500 (Manual Transmission) Table of Contents .... 3-102 H2 Models Table of Contents .............................. 3-166 Fuel/Lubrication/Cooling ......................................... 4-2 Carburetor Specifications (400/500)........................ 4-2 Carburetor Schematics (400/500) ........................... 4-2 Carburetor (400/500)............................................... 4-2 Electric Choke (400/500)......................................... 4-7 Electronic Fuel Injection (EFI Models) .................... 4-8 Throttle Cable Free-Play ....................................... 4-10 Engine RPM (Idle)................................................. 4-11 Gas Tank ............................................................... 4-11 Oil Filter/Oil Pump ................................................. 4-12 Testing Oil Pump Pressure.................................... 4-12 Oil Cooler (400/700/H2 Models)............................ 4-12 Liquid Cooling System (500/H1/H2 Models) ......... 4-13 Electric Fuel Pump/Fuel Level Sensor (EFI Models) ...................................................... 4-18 Vacuum Pulse Fuel Pump (500)............................ 4-20 Troubleshooting (400/500)..................................... 4-21 Troubleshooting (EFI Models) ............................... 4-21 Electrical System..................................................... 5-2 Specifications .......................................................... 5-2 Battery..................................................................... 5-3 RPM Limiter............................................................. 5-4 Testing Electrical Components ................................ 5-4 Accessory Receptacle/Connector ........................... 5-4 Brakelight Switch (Auxiliary).................................... 5-4 Brakelight Switch (Handlebar Control) .................... 5-5 Oil Temperature and Cooling Fan Switches (400)... 5-5 Coolant Temperature and Cooling Fan Switches (500)..................................................................... 5-6 Engine Coolant Temperature (ECT) Sensor (EFI Models) ....................................................... 5-6 Fan Motor ................................................................ 5-7 Power Distribution Module (PDM) ........................... 5-7 Ignition Coil ............................................................. 5-8 EFI Sensors/Components (EFI Models)................ 5-10 Speed Sensor ....................................................... 5-11 Ignition Switch ....................................................... 5-11 Handlebar Control Switches.................................. 5-12 Front Drive Selector Switch ................................... 5-13 Front Drive Selector Actuator (400/500)................ 5-14 Front Drive/Differential Lock Actuator (H1/H2 Models) .................................................. 5-14 Differential Lock Switch (500)................................ 5-15 Differential Lock Control Switch (H1/H2 Models) .................................................. 5-15 Stator Coil (400/500) ............................................. 5-15 Stator Coil/Crankshaft Position (CKP) Sensor (EFI Models) ...................................................... 5-16 Starter Relay ......................................................... 5-17 Starter Motor ......................................................... 5-18 CDI Unit (400/500) ................................................ 5-22 Electronic Control Unit (ECU) (EFI Models) .......... 5-22 Regulator/Rectifier................................................. 5-22 Headlights ............................................................. 5-22 Taillight - Brakelight ............................................... 5-23 Ignition Timing....................................................... 5-23 ECU Error Codes (EFI Models)............................. 5-23 Tilt Sensor (EFI Models)........................................ 5-24 Throttle Position Sensor (TPS) (EFI Models) ........ 5-25 Troubleshooting ..................................................... 5-28 Drive System........................................................... 6-2 Front Drive Actuator (400/500)/Electronic Differential Lock (H1/H2 Models) ......................... 6-2 Front Differential ...................................................... 6-3 Drive Axles ............................................................ 6-17 Rear Gear Case .................................................... 6-21 Hub........................................................................ 6-23 Hydraulic Brake Caliper......................................... 6-25 Troubleshooting Drive System............................... 6-26 Troubleshooting Brake System.............................. 6-27 Suspension ............................................................. 7-2 Shock Absorbers ..................................................... 7-2 Front A-Arms ........................................................... 7-3 Rear A-Arms ........................................................... 7-5 Wheels and Tires .................................................... 7-7 Troubleshooting ....................................................... 7-8 Steering/Frame........................................................ 8-2 Steering Post/Tie Rods ........................................... 8-2 Handlebar Grip ........................................................ 8-5 Steering Knuckles ................................................... 8-6 Measuring/Adjusting Toe-In..................................... 8-8 Front Rack ............................................................... 8-9 Front Bumper Assembly .......................................... 8-9 Front Body Panel/Side Panels............................... 8-10 Footrests ............................................................... 8-13 Belly Panel ............................................................ 8-14 Exhaust System .................................................... 8-14 Rear Body Panel/Rack .......................................... 8-14 Taillight Assembly.................................................. 8-15 Seat ....................................................................... 8-16 Troubleshooting ..................................................... 8-17 Hand Brake Lever/Master Cylinder Assembly ......... 9-2 Throttle Control ....................................................... 9-3 Front Differential Lock Cable (500).......................... 9-4 Shift Lever ............................................................... 9-4 Speedometer/Tachometer/LCD............................... 9-5 -------------------------------------------------------------------------------------- File Format: PDF Compatible: All Versions of Windows & Mac Downloadable: YES Language: English Requirements: Adobe PDF Reader & WinZip. DESCRIPTION: ========= COVERS ALL MODELS & ALL REPAIRS A-Z THIS IS NOT SOME GENERIC REPAIR INFORMATION. IT IS A VEHICLE SPECIFIC SERVICE MANUAL! THIS HIGHLY DETAILED SERVICE REPAIR MANUAL CONTAINS EVERYTHING YOU WILL EVER NEED TO SERVICE, REPAIR, RESTORE, MAINTAIN, REFURBISH OR EVEN REBUILD YOUR VEHICLE. COMPLETE & EASY TO USE STEP-BY-STEP INSTRUCTIONS, ILLUSTRATIONS, DIAGRAMS, SPECIFICATIONS & WIRING SCHEMATICS WILL HELP ASSIST YOU TO PERFORM RIGHT FROM VERY SIMPLE REPAIRS TO COMPLEX ONES !!. CLEAR PICTURES AND ZOOMABLE ILLUSTRATIONS HELP YOU PERFORM YOUR SERVICE REPAIR WITH UTMOST EASE! NO TECHNICAL EXPERTISE REQUIRED. YOU SEE IT AND YOU DO IT (DO-IT-YOURSELF MANUAL) THIS IS THE SAME MANUAL THAT TECHNICIANS AND MECHANICS IN DEALERSHIPS & ELSEWHERE USE TO SERVICE & REPAIR YOUR VEHICLE! YOU CAN REFER THIS MANUAL RIGHT FROM YOUR PC/LAPTOP OR ONLY PRINT OFF THE PAGES THAT YOU REQUIRE FOR THE MOMENT. -------------------------------------------------------------------------------------- RELATED TERMS: ========= Arctic Cat ATV 400 TRV 500 550 700 1000 Thundercat Service Manual 2009 2009 Arctic Cat 400 H1 TRV 4x4 pictures, prices, information, and specifications. 2009 Arctic Cat 400 H1 TRV 4x4 arctic cat 400trv service manual, 400trv service, 400trv repair, 400trv fix ARCTIC CAT 400 TRV, 500 AUTOMATIC, 500 MANUAL, 2009 ARCTIC CAT 550 H1, 2009 ARCTIC CAT 550 H1 TRV, 2009 ARCTIC CAT 700H1, 2009 ARCTIC CAT 700 H1 CRUISER, 2009 ARCTIC CAT THUNDERCAT AND 1000 H2 CRUISER ATV 2009 ARCTIC CAT SERVICE MANUAL / REPAIR MANUAL / SHOP MANUAL 2009 Arctic Cat 400TRV, 500, 550 700 ATV service manual -------------------------------------------------------------------------------------- PLEASE NOTE: ========= 1) Looking for some other Service manual, please check: (for massive collection of service manuals.) USE THIS DIY FACTORY SERVICE MANUAL = GET YOUR REPAIRS DONE BY TODAY! = FULL VALUE FOR MONEY :) !! THANK YOU FOR VISITING THIS PAGE. HAVE A NICE DAY THERE!!