This workshop service repair manual provides comprehensive coverage for a range of All-Terrain Vehicles (ATVs), including the 400, 400TBX, 400TRV, 500, 500TRV, 500TBX, 550FIS, 650/700 FIS/TBX/TRV, 650 H1, 650 V-TWIN, and 1000 Series ATVs. These models are known for their robust build and off-road capability, designed for utility and recreational use. The manual delves into various engine configurations, from single-cylinder to V-Twin, and covers both carbureted and fuel-injected systems, along with automatic CVT transmissions and selectable 2WD/4WD drive modes.
This manual serves as an in-depth resource for maintenance, repair, and troubleshooting, mirroring the detail found in factory-authorized service manuals. It covers all major systems, including engine assembly and overhaul, drivetrain, suspension, steering, brakes, and electrical components. Users will find detailed step-by-step repair instructions, routine maintenance schedules, fluid specifications, torque values, and troubleshooting guides, all supported by detailed diagrams and exploded views. This extensive documentation is invaluable for DIY enthusiasts, owners, and professional mechanics alike to ensure the optimal performance and longevity of their ATVs.
Model:
400, 400TBX, 400TRV, 500, 500TRV, 500TBX, 550FIS, 650/700 FIS/TBX/TRV, 650 H1, 650 V-TWIN, 1000 Series ATVs
Product Type:
ATV Repair Manual
Target User:
DIY enthusiasts, ATV owners, and professional mechanics performing repairs, maintenance, and servicing on Arctic Cat ATVs.
Manual Type Comparison:
This manual serves as the equivalent of a factory-authorized service manual, offering a higher level of detail than a basic owner's manual.
Comprehensiveness:
Extremely comprehensive, covering a wide range of models and encompassing all aspects of maintenance and repair.
Visual Content:
Includes crucial visual aids such as exploded views, detailed diagrams, and photographic illustrations.
Utility:
Ideal for diagnostics, routine servicing, major component overhauls, and troubleshooting.
Comprehensive Coverage:
Covers all major systems and components of the specified Arctic Cat ATV series.
Estimated Page Count:
Variable (typical for comprehensive workshop manuals, often 500+ pages depending on specific models and years covered)
Type:
Workshop Service Repair Manual
Engine Systems:
Engine assembly, disassembly, overhaul, cooling system, lubrication system, carburetor system, fuel system, ignition system, starting system, battery system, exhaust system.
Drivetrain Transmission:
Transmission, clutch, drive system, differentials (front and rear), differential lock system.
Suspension Steering Brakes:
Suspension components, axles, hydraulic brakes, auxiliary brake, hand brake, steering system/handlebars.
Electrical Lighting:
Lighting system, starter motor, magneto coil, speed sensor, controls and indicators.
Body Chassis:
Body panels, bumper, rack, seat, cargo box.
Maintenance Tuneup:
Routine maintenance, tune-up procedures, service intervals, break-in procedure.
Repair Overhaul:
Detailed step-by-step repair and overhaul instructions for all covered systems and components.
Troubleshooting:
Comprehensive troubleshooting guides for diagnosing common problems and malfunctions.
Technical Data Specs:
Torque specifications, fluid specifications, maintenance data, specifications section.
Depth:
In-depth, professional-level repair and diagnostic information equivalent to factory service manuals.
Visual Aid Quality:
Detailed exploded views, pictures, and diagrams to illustrate procedures.
Searchability:
Likely searchable text within the PDF for efficient information retrieval.
Printability:
Fully printable, allowing users to print selected pages or the entire manual.
Binding:
N/A (Digital format)
Paper Quality:
N/A (Digital format)
Engine Family:
V-Twin (for 650, 1000 models), Single-cylinder (for 400, 500, 550 models)
Engine Cooling:
Liquid-cooled (typical for these series)
Engine Ignition:
CDI (Capacitor Discharge Ignition) or similar electronic ignition system (specifics vary by model and year).
Displacement Range:
Approximately 375cc to 950cc, depending on the specific model (e.g., 400, 500, 550, 650, 700, 1000).
Fuel Delivery:
Carburetor or Electronic Fuel Injection (EFI) depending on the model and year. Manual covers both types.
Transmission Type:
Automatic (CVT - Continuously Variable Transmission)
Gear Selection:
High, Low, Neutral, Reverse, Park (typical for Arctic Cat ATVs).
Drive Modes:
2WD/4WD selectable, often with locking front differential. Details on engaging and maintaining these systems are included.
Vehicle Type:
All-Terrain Vehicle (ATV)
Dry Weight:
Varies significantly by model, typically ranging from 600 lbs to over 800 lbs. The manual will contain specific weights for each model.
Braking System:
Hydraulic disc brakes (front and rear), potentially engine braking system. Manual provides details on brake component service and adjustment.
Controls:
Throttle, brake levers, gear selector, handlebar steering. Manual details on control system maintenance and adjustment.
Instrument Cluster:
Manual will cover the function and troubleshooting of the digital instrument cluster, including speed indicators, warning lights, and fuel gauges.
Differential Lock:
Detailed explanation of the front differential lock system, its operation, and maintenance procedures.
Lighting System Operation:
Covers the operation and maintenance of headlights, taillights, and brake lights.
Troubleshooting Approach:
The manual employs a systematic troubleshooting approach, often referencing diagnostic codes or symptom-based issue resolution.
Recommended Intervals:
The manual will detail specific service intervals for oil changes, filter replacements, spark plugs, valve adjustments, brake service, and drive belt inspection, typically based on mileage or operating hours.
Engine Oil Type:
Will specify recommended engine oil viscosity grades (e.g., SAE 10W-40, SAE 20W-50) and API service classifications. Likely JASO MA certified for wet clutches.
Coolant Type:
Will specify the type of antifreeze/coolant required, typically a mixture of ethylene glycol and distilled water.
Brake Fluid Type:
Will specify the required DOT brake fluid type (e.g., DOT 3, DOT 4).
Gear Lube Type:
Will specify recommended gear oil for differentials and transmission components.
Common Wear Items:
While not explicitly listed as 'known issues', the manual's comprehensive coverage of wear items like drive belts, suspension bushings, brake pads, and CV joint boots implies common maintenance areas for these ATVs.
Engine Bolt Torques:
Detailed torque specifications for critical engine components (e.g., cylinder head bolts, crankshaft bolts, clutch bolts) are provided.
Chassis Bolt Torques:
Torque specifications for chassis, suspension, and brake components are also included.
Manufacturer:
Arctic Cat Inc. (now Textron Off Road/Arctic Cat)
Series Overview:
This manual covers a range of popular Arctic Cat ATV models known for their utility and off-road performance, spanning several engine displacements and specialized variants (e.g., TBX for 'Tough-Terrain Big-Capacity X', TRV for 'Traction, Ride, Versatility').
Industry Standing:
Arctic Cat ATVs in these series are generally recognized for their robust build, off-road capability, and versatility for both work and recreation. While the manual itself doesn't receive awards, its quality reflects industry standards for technical documentation.
