🏷️ Basic Information

Make:

Arctic Cat

Model:

400, 500, 650

Year:

2006

Product Type:

Service Manual

Document Code Identifier:

Likely internal Arctic Cat service manual numbering scheme, not explicitly provided but implied by service manual nature.

👋 Introduction

Product Segment:

Utility and Sport ATVs, popular for trail riding, hunting, and general farm use.

Key Competitors:

Polaris Sportsman series, Can-Am Outlander series, Yamaha Kodiak/Grizzly series, Suzuki KingQuad series, Kawasaki Brute Force series.

Vehicle Platform Versatility:

The manual covers a range of engine sizes and chassis configurations (e.g., standard, TBX for utility box, TRV for two-up riding), indicating a robust platform.

Manual Value Proposition:

Provides essential technical information for owners and technicians to maintain and repair their 2006 Arctic Cat ATVs, ensuring longevity and optimal performance.

📋 Manual Details

Covered Models:

Arctic Cat 400, 400 TBX, 400 TRV, 400 MANUAL, 500, 500 TBX, 500 TRV, 500 MANUAL, 650 H1, 650 V-TWIN

Estimated Page Count:

Estimated 500-800 pages (typical for comprehensive ATV service manuals).

Manual Type:

Full Service and Repair Manual

Language:

English

Format:

PDF Download

📖 Manual Coverage

Engine:

Detailed diagnostics, repair, and overhaul procedures for the 400cc, 500cc, and 650cc engine variants. Includes component identification, disassembly, inspection, assembly, and torque specifications.

Fuel System:

Carburetor and fuel injection system diagnostics, cleaning, adjustment, and repair. Fuel pump, fuel filter, and fuel tank servicing.

Ignition System:

Spark plug specifications, ignition coil testing, CDI unit diagnostics, and timing adjustments.

Cooling System:

Radiator, fan, thermostat, water pump, and coolant specifications. Pressure testing and leak detection.

Transmission Drivetrain:

Detailed procedures for CVT (Continuously Variable Transmission) servicing, clutch inspection and replacement, gear case disassembly, lubrication, and maintenance. Includes differential and axle servicing.

Suspension:

Front and rear suspension component inspection, adjustment, and replacement. Shock absorber servicing and spring specifications.

Steering:

Handlebar, steering column, tie rod, and knuckle inspection and adjustment. Wheel alignment procedures.

Brakes:

Hydraulic brake system diagnostics, caliper, master cylinder, and brake line servicing. Brake pad replacement, fluid bleeding, and parking brake adjustment.

Electrical System:

Wiring diagrams, battery testing and maintenance, starter motor, alternator/stator, lighting system troubleshooting, and fuse/relay identification.

Frame Bodywork:

Frame inspection, minor body panel repair and replacement, seat servicing, and fender/rack attachment procedures.

Maintenance:

Scheduled maintenance intervals, lubrication points, fluid changes (oil, coolant, brake fluid), filter replacement, and general inspection procedures.

Troubleshooting:

Comprehensive diagnostic flowcharts and symptom-based troubleshooting guides for common mechanical and electrical issues.

Repair:

Step-by-step disassembly, repair, and reassembly instructions for all major components and systems.

Disassembly Reassembly:

Detailed instructions for removing and reinstalling all major assemblies and sub-assemblies.

Torque Specifications:

Precise torque values for all critical fasteners and bolts.

Depth Of Coverage:

Comprehensive, covering from basic rider-level maintenance to in-depth mechanical overhauls and diagnostics. Suitable for both amateur and professional mechanics.

Diagnostic Capabilities:

Includes diagnostic procedures for engine performance, electrical faults, and drivetrain issues.

Special Tools:

Lists and descriptions of special tools required for specific repair and diagnostic procedures.

📊 Manual Specifications

File Format:

PDF

Searchability:

Typically searchable text-based PDF for quick information retrieval.

Print Quality:

High resolution, suitable for printing individual pages or the entire manual.

Binding Type:

N/A (Digital PDF download)

Paper Type:

N/A (Digital PDF download)

⚙️ Engine Specifications

Engine Type 400:

Likely a single-cylinder, liquid-cooled, four-stroke engine (specific displacement around 375-400cc).

Engine Type 500:

Likely a single-cylinder, liquid-cooled, four-stroke engine (specific displacement around 475-500cc).

Engine Type 650:

Likely a V-twin, liquid-cooled, four-stroke engine (specific displacement around 650cc).

Horsepower Range:

Estimated 20-30 HP for 400/500cc models, 40-50 HP for 650cc V-Twin models (actual figures vary by specific engine and tuning).

Torque Range:

Torque figures typically in the range of 20-35 lb-ft for 400/500cc and 35-45 lb-ft for 650cc, optimized for low-end pulling power.

Carburetion Injection:

Early models may feature Keihin carburetors (e.g., CVK), while later or higher-trim models might have electronic fuel injection (EFI) for improved throttle response and altitude compensation. The manual will cover both possibilities.

Fuel Type:

Unleaded gasoline, typically 87 octane.

🔧 Transmission

Transmission Type:

Automatic CVT (Continuously Variable Transmission) with engine braking.

Gear Reduction Options:

Some models (especially utility variants like TBX) may have a selectable 2WD/4WD system, often with a locked front differential option, and potentially a low-range gear selector for towing or steep inclines. Manual versions are explicitly mentioned for 400 and 500, suggesting a potential for a manual transmission option, though CVT is far more common in this class.

Drive System:

Shaft drive, with selectable 2WD/4WD. Likely features an automotive-style differential for smoother steering in 4WD.

Gear Ratios:

The manual will detail specific CVT drive and driven clutch ratios, as well as final drive gear ratios for front and rear differentials.

Transmission Fluid:

Typically requires a specialized CVT fluid or a high-quality synthetic gear oil. The manual will specify the exact Arctic Cat P/N or equivalent type and viscosity.

📐 Dimensions

Length Approx:

Generally around 80-85 inches (203-216 cm) for standard models, potentially longer for TBX/TRV variants.

Width Approx:

Around 45-48 inches (114-122 cm).

Height Approx:

Around 45-48 inches (114-122 cm).

Dry Weight Approx:

500-650 lbs (227-295 kg), depending on model and configuration.

Ground Clearance Approx:

Around 10-12 inches (25-30 cm).

Towing Capacity:

Often rated around 1000-1500 lbs (454-680 kg).

Rack Capacity:

Front and rear racks typically rated for 50-100 lbs (23-45 kg) each. TBX models will feature a larger utility box with higher cargo capacity.

🛡️ Safety Features

Atv Safety Standards:

ATVs are designed for off-road use and are subject to specific safety guidelines. The manual will emphasize safe operating practices and maintenance for rider safety.

Braking System:

Hydraulic disc brakes on all wheels, providing reliable stopping power. Parking brake mechanism.

Engine Braking:

The CVT system provides significant engine braking on descents, enhancing control and reducing brake wear.

Lighting:

Headlights, taillight, and brake light for visibility and signaling.

Rollover Protection:

While not ROPS-equipped like cars, the sturdy frame and handlebar design offer some stability. Proper riding technique is paramount.

💡 Technology Features

Display Features:

Basic digital display for odometer, trip meter, fuel level, and indicator lights. Advanced infotainment systems are not typical for this era/class of ATV.

Performance Enhancements:

EFI (on some models) provides improved performance across varying altitudes and temperatures. Selectable 4WD offers enhanced traction.

Diagnostic Ports:

While not OBD-II like cars, these ATVs will have specific diagnostic connectors for dealer-level tools or advanced aftermarket diagnostic equipment, which the manual may reference.

🔧 Maintenance

Oil Change Interval:

Typically every 100 hours or annually. The manual will specify exact intervals based on usage conditions.

Air Filter Cleaning:

Check and clean every 20-30 hours of operation, or more frequently in dusty conditions.

Spark Plug Replacement:

Recommended every 100-200 hours or annually for optimal performance. The manual will specify the correct plug type and gap.

Engine Oil:

Typically SAE 10W-40 or 20W-50 synthetic or semi-synthetic motorcycle/ATV specific oil. Manual will list Arctic Cat's recommended lubricant P/N or API/JASO specifications.

Coolant:

Ethylene glycol-based antifreeze mixed with distilled water, typically a 50/50 ratio. Manual will specify type and capacity.

Brake Fluid:

DOT 3 or DOT 4 hydraulic brake fluid. Manual will specify type and capacity for bleeding.

Common Wear Items:

CVT belt wear, suspension bushings, brake pads, wheel bearings, and spark plugs are common wear items that may require periodic replacement.

Electrical Connectors:

Corrosion or loose connections in electrical connectors can sometimes cause intermittent issues, especially in wet environments. Manual's electrical diagrams are crucial for troubleshooting.

📚 Vehicle History

Arctic Cat Legacy:

Arctic Cat has a long history in powersports, initially known for snowmobiles, and expanded into ATVs with a focus on robust engineering and off-road performance.

Platform Development:

The 2006 models represent a mature generation of Arctic Cat ATVs, building on earlier designs with refinements in engine performance, suspension, and utility features. The introduction of the 650 V-Twin was a significant step up in power and capability.

Manufacturing Location:

Arctic Cat ATVs are primarily manufactured in the United States, with a significant portion of production historically occurring in Thief River Falls, Minnesota.

🏆 Awards & Recognition

Industry Awards:

Arctic Cat ATVs of this era generally received positive reviews for their utility and off-road capability. Specific awards for the 2006 models may exist within industry publications, but the manual itself is not an award but a technical resource.

Consumer Reviews:

Owner feedback from this period often highlighted the robust chassis and powerful engines, particularly the 650 V-Twin. Some noted potential for maintenance complexities common to multi-cylinder engines.