Arctic Cat 2011 450 550 650For

700 Arctic
1000 Service Manual
Cat Parts Call 606-678-9623 or 606-561-4983
Full download: http://manualplace.com/download/arctic-cat-2011-450-550-650-700-1000-service-manual/

FOREWORD

This Arctic Cat Service Manual contains service, maintenance, and troubleshooting information for certain 2011
Arctic Cat ATV models (see cover). The complete manual is designed to aid service personnel in service-oriented
applications.
Arctic Cat offers additional publications (when they become available) to aid in servicing other ATV models. To
service models not included in this manual, please refer to the following publications:
• 2011 Y-12+ Service Manual
• 2011 T-14 Service Manual
• 2011 300 DVX/Utility Service Manual
• 2011 366 Service Manual
• 2011 700 Diesel Service Manual
This manual is divided into sections. Each section covers a specific ATV component or system and, in addition to
the standard service procedures, includes disassembling, inspecting, and assembling instructions. When using this
manual as a guide, the technician should use discretion as to how much disassembly is needed to correct any given
condition.
The service technician should become familiar with the operation and construction of each component or system
by carefully studying the complete manual. This manual will assist the service technician in becoming more aware
of and efficient with servicing procedures. Such efficiency not only helps build consumer confidence but also saves
time and labor.
All Arctic Cat ATV publications and decals display the words Warning, Caution, Note, and At This Point to
emphasize important information. The symbol ! WARNING identifies personal safety-related information.
Be sure to follow the directive because it deals with the possibility of severe personal injury or even death. A
CAUTION identifies unsafe practices which may result in ATV-related damage. Follow the directive because it
deals with the possibility of damaging part or parts of the ATV. The symbol  NOTE: identifies supplementary
information worthy of particular attention. The symbol  AT THIS POINT directs the technician to certain
and specific procedures to promote efficiency and to improve clarity.
At the time of publication, all information, photographs, and illustrations were technically correct. Some photo-
graphs used in this manual are used for clarity purposes only and are not designed to depict actual conditions.
Because Arctic Cat Inc. constantly refines and improves its products, no retroactive obligation is incurred.
All materials and specifications are subject to change without notice.
Keep this manual accessible in the shop area for reference.
Product Service and
Warranty Department
Arctic Cat Inc.

© 2010 Arctic Cat Inc. September 2010

www.mymowerparts.com
®™ Trademarks of Arctic Cat Inc., Thief River Falls, MN 56701
Manual
Table
This is the cut pages sample. Download all 275 page(s) at: of Contents
ManualPlace.com
 For Arctic Cat Parts Call 606-678-9623 or 606-561-4983 Click on the blue text to go.

Service

1
TABLE OF CONTENTS

10 Manual
Note: To navigate through this manual, use the PAGE UP/PAGE DOWN buttons on the keyboard, click on the
Table of Contents bookmarks on the left side of the screen, or click the blue text below. To return to this page,
click the Manual Table of Contents button at the bottom of each page.

2
Section

450
450
45
1. General Information/Specifications 550
55 1
0
650
6 50
700
70
7 0
2. Periodic Maintenance
1000
10 2
0 00

3. Engine/Transmission 3
4. Fuel/Lubrication/Cooling 4
5. Electrical System 5
6. Drive System 6
7. Suspension
7
8. Steering/Frame
8
9. Controls/Indicators
9

SHARE OUR PASSION.

TM

www.mymowerparts.com
 For Arctic Cat Parts Call 606-678-9623 or 606-561-4983

SECTION 1 - GENERAL INFORMATION/

SPECIFICATIONS

TABLE OF
CONTENTS

General Specifications ............................................ 1-2

Torque Specifications .............................................. 1-3
Torque Conversions (ft-lb/N-m) ............................... 1-5
Tightening Torque (General Bolts) .......................... 1-5
Break-In Procedure ................................................. 1-5
Gasoline - Oil - Lubricant ........................................ 1-5
Genuine Parts ......................................................... 1-6
Preparation For Storage.......................................... 1-6
Preparation After Storage........................................ 1-7
www.mymowerparts.com
Manual 1-1
Table of Contents
 For Arctic Cat Parts Call 606-678-9623 or 606-561-4983

General Specifications

450 1000
CHASSIS CHASSIS
Brake Type Hydraulic w/Brake Lever Lock Brake Type Hydraulic w/Brake Lever Lock and
and Auxiliary Brake Auxiliary Brake
Tire Size Front - 25 x 8-12 Tire Size Front - 26 x 9-12
Rear - 25 x 10-12 Rear - 26 x 11-12
(Mud Pro) Front - 28 x 9-14
Tire Inflation Pressure 0.35 kg/cm² (5 psi)
(Mud Pro) Rear - 28 x 11-14
MISCELLANY (Cruiser) Front - 25 x 8-12
(Cruiser) Rear - 25 x 10-12
Gas Tank Capacity 21.6 L (5.7 U.S. gal.) - FIS
20.0 L (5.3 U.S. gal.) - TRV Tire Inflation Pressure 0.35 kg/cm² (5 psi)
Coolant Capacity 2.9 L (3.0 U.S. qt) MISCELLANY
Rear Drive Capacity 250 ml (8.5 fl oz)* Gas Tank Capacity 21.6 L (5.7 U.S. gal.) - FIS
20.0 L (5.3 U.S. gal.) - Cruiser/TRV
Front Differential Capacity 275 ml (9.3 fl oz)**
Coolant Capacity 3.3 L (3.5 U.S. qt)
Engine Oil Capacity 2.85 L (3.0 U.S. qt) - Overhaul
2.50 L (2.6 U.S. qt) - Change Differential Capacity 275 ml (9.3 fl oz)*
Gasoline (recommended) 87 Octane Regular Unleaded Rear Drive Capacity 250 ml (8.5 fl oz)**
Engine Oil (recommended) Arctic Cat ACX All Weather Engine Oil 2.6 L (2.75 U.S. qt) - Overhaul
(Synthetic) Capacity 2.1 L (2.25 U.S. qt) - Change
Differential/Rear Drive Lubricant SAE Approved 80W-90 Hypoid Gasoline (recommended) 87 Octane Regular Unleaded
Drive Belt Width (minimum) 28.5 mm (1.12 in.) Engine Oil (recommended) Arctic Cat ACX All Weather (Synthetic)
Brake Fluid DOT 4 Front Differential/Rear Drive SAE Approved 80W-90 Hypoid
Lubricant
Taillight/Brakelight 12V/8W/27W
Drive Belt Width (minimum) 35.6 mm (1.40 in.)
Headlight 12V/37W (2)
Brake Fluid DOT 4
550/650/700
Taillight/Brakelight 12V/8W/27W
CHASSIS
Headlight 12V/27W (2)
Brake Type Hydraulic w/Brake Lever Lock
and Auxiliary Brake Specifications subject to change without notice.
Tire Size Front - 25 x 8-12 * One inch below plug threads.
Rear - 25 x 10-12 ** At the plug threads.
(650 Mud Pro) Front - 28 x 9-14
(650 Mud Pro) Rear - 28 x 9-14
(700 Mud Pro) Front - 28 x 9-14
(700 Mud Pro) Rear - 28 x 11-14
Tire Inflation Pressure 0.35 kg/cm² (5 psi)
MISCELLANY
Gas Tank Capacity 21.6 L (5.7 U.S. gal.) - FIS
21.9 L (5.8 U.S. gal.) - TBX
20.0 L (5.3 U.S. gal.) - TRV/
Cruiser
Coolant Capacity 2.9 L (3.0 U.S. qt)
Differential Capacity 275 ml (9.3 fl oz)*
Rear Drive Capacity 250 ml (8.5 fl oz)**
Engine Oil Capacity 2.5 L (2.6 U.S. qt) - Overhaul
1.9 L (2.0 U.S. qt) - Change
Gasoline (recommended) 87 Octane Regular Unleaded
Engine Oil (recommended) Arctic Cat ACX All Weather
(Synthetic)
Differential/Rear Drive Lubricant SAE Approved 80W-90 Hypoid
Drive Belt Width (minimum) 35.6 mm (1.40 in.)
Brake Fluid DOT 4
Taillight/Brakelight 12V/8W/27W
Headlight 12V/27W (2)

www.mymowerparts.com
1-2 Manual Section
Table of Contents Table of Contents
 For Arctic Cat Parts Call 606-678-9623 or 606-561-4983

Torque Specifications

EXHAUST COMPONENTS DRIVE TRAIN COMPONENTS

Torque (450)
Part Part Bolted To Torque
ft-lb N-m Part Part Bolted To
Exhaust Pipe Engine 20 27 ft-lb N-m
Spark Arrester Muffler 48 5.5 Engine Mounting Through-Bolt Frame 35 47
in.-lb Front Differential Frame/Differential 38 52
ELECTRICAL COMPONENTS Bracket
Engine/Harness Ground Cap Crankcase 8 11 Output Flange Rear Flange Output 20 27

1
Joint
Screw
Pinion Housing Differential Housing 23 31
Coil (650)* Frame 12 16
Differential Housing Cover*** Differential Housing 23 31
Coil (EFI) Air Filter Housing 7 10
Drive Bevel Gear Nut** Shaft 72 98
STEERING COMPONENTS
Lock Collar Differential Housing 125 169
Steering Post Bearing Frame 20 27
Housing Hub Nut Shaft/Axle (max) 200 272
Steering Post Bearing Flange Frame 20 27 Oil Drain Plug Front Differential/ Rear 45 5
Drive in.-lb
Lower Steering Bearing Steering Post 40 54
Washer Cap Screw*** Oil Fill Plug Front Differential/ Rear 16 22
Drive
Tie Rod End Knuckle/Steering Post 30 41
Oil Drain Plug Engine 16 22
BRAKE COMPONENTS
Rear Drive Input Shaft/Housing Differential Housing 23 31
Brake Disc* Hub 15 20
Wheel Hub 40 54
Brake Hose Caliper 20 27
Rear Drive Gear Case Frame 38 52
Brake Hose Master Cylinder 20 27
Engine Output Shaft** Rear Gear Case Input 20 27
Brake Hose Auxiliary Brake Cylinder 20 27 Flange
Master Cylinder (Rear) Frame 12 16 DRIVE TRAIN COMPONENTS
Hydraulic Caliper Knuckle 20 27 (550/650/700)
(w/”Patch-Lock”) Engine Mounting Through-Bolt Frame 40 54
Master Cylinder Clamp Master Cylinder 6 8 Engine (TRV) Engine Cradle 40 54
Brake Pedal Brake Pedal Axle 25 34 Engine Cradle (TRV)** Rubber Mount 25 34
CHASSIS COMPONENTS Rubber Mount (TRV) Frame Bracket 35 47
Footrest Frame (8 mm) 20 27 Front Differential* Frame/Differential 38 52
Footrest Frame (10 mm) 40 54 Bracket
SUSPENSION COMPONENTS (Front) Output Flange Rear Flange Output 20 27
Joint
A-Arm Frame 50 68
Pinion Housing Differential Housing 23 31
Knuckle Ball Joint 35 47
Differential Housing Cover*** Differential Housing 23 31
Shock Absorber Frame/Upper A-Arm 50 68
Drive Bevel Gear Nut*** Shaft 72 98
Knuckle A-Arm 50 68
Differential Gear Case*** Hub 19 26
SUSPENSION COMPONENTS (Rear)
Lock Collar Differential Housing 125 169
Shock Absorber (Upper) Frame 50 68
Hub Nut Shaft/Axle (max) 200 272
Shock Absorber (Lower) Lower A-Arm 20 27
Oil Drain Plug Front Differential/ Rear 45 5
A-Arm Frame 50 68 Drive in.-lb
Knuckle A-Arm 35 47 Oil Fill Plug Front Differential/ Rear 16 22
Knuckle (H2) A-Arm 50 68 Drive
Oil Drain Plug Engine 16 22
Rear Drive Input Shaft/Housing Differential Housing 23 31
Wheel Hub 40 54
Rear Drive Gear Case Frame 38 52
Engine Output Shaft ** Rear Gear Case Input 20 27
Flange
* w/Blue Loctite #243
** w/Red Loctite #271
*** w/Green Loctite #609

www.mymowerparts.com
Manual Section 1-3
Table of Contents Table of Contents
 For Arctic Cat Parts Call 606-678-9623 or 606-561-4983

DRIVE TRAIN COMPONENTS ENGINE/TRANSMISSION (550/650/700)

(1000) Torque
Torque Part Part Bolted To
Part Part Bolted To ft-lb N-m
ft-lb N-m Crankshaft Spacer Crankshaft 25 34
Engine Mount (Rear) Frame 45 61 Speed Sensor Housing Crankcase 8 11
Front Differential Frame/Differential 38 52 Clutch Shoe** Crankshaft 221 300
Bracket
Clutch Cover/Housing Assembly Crankcase 8 11
Rear Gear Case Frame 38 52
Crankcase Half (6 mm) Crankcase Half 8 11
Pinion Housing Differential Housing 23 31
Crankcase Half (8 mm) Crankcase Half 20 27
Differential Housing Cover*** Differential Housing 23 31
Cylinder Head (Cap Screw) Crankcase 40 54
Lock Collar Differential Housing 125 169
Cylinder Head Nut (6 mm) Cylinder 8 11
Hub Nut Shaft/Axle (max) 200 272
Cylinder Head Nut (8 mm) Cylinder 18 24
Oil Drain Plug Front Differential/ 45 5
Rear Drive in.-lb Valve Cover**** Cylinder Head 8.5 11.5
Oil Fill Plug Front Differential/ 16 22 Driven Pulley Nut Driveshaft 80 108
Rear Drive Ground Wire Engine 8 11
Oil Drain Plug Engine 16 22 Magneto Cover Crankcase 8 11
Wheel Hub 40 54 Oil Pump Drive Gear** Crank Balancer Shaft 63 85
Rear Drive Input Shaft/Housing Differential Housing 23 31 Output Shaft Nut Output Shaft 59 80
Rear Output Drive Flange Rear Yoke Flange 20 27 Outer Magneto Cover Left-Side Cover 6 8
Shift Cam Stopper Shift Stopper 8 11 Magneto Rotor Nut Crankshaft 107 145
Shift Cam Plate Shift Cam Shaft 8 11 Cam Sprocket** Camshaft 10 13.5
Shifter Housing Crankcase 8 11 Starter Motor Crankcase 8 11
Engine Output Shaft** Rear Gear Case 20 27 V-Belt Cover Clutch Cover 8 11
Input Flange Drive Pulley Nut** Clutch Shaft 165 224
ENGINE/TRANSMISSION Movable Drive Face Nut** Clutch Shaft 165 224
(450)
Output Yoke Nut Driven Output Shaft 74 100
Clutch Shoe** Crankshaft 147 199
Secondary Shaft Bearing Crankcase Half 28 38
Clutch Cover/Housing Assembly Crankcase 8 11 Housing
Left-Side Cover Crankcase 8 11 ENGINE/TRANSMISSION (1000)
Crankcase Half (6 mm) Crankcase Half 10 13.5 Clutch Shoe** Crankshaft 221 300
Crankcase Half (8 mm) Crankcase Half 21 28 Clutch Cover/Housing Assembly Crankcase 8 11
Cylinder Nut Crankcase Half 8 11 Crankcase Half Crankcase Half 8 11
Cylinder Head (Cap Screw) Crankcase 28 38 Crankcase Lower Cover (6 mm) Crankcase 8 11
Cylinder Head Nut Cylinder 20 27 Crankcase Lower Cover (8 mm) Crankcase 20 27
Valve Cover**** Cylinder Head 8 11 Cylinder Head (Cap Screw) Crankcase 37 50
Oil Pump Drive Gear** Crankshaft 63 86 Cylinder Head (6 mm) Cylinder 8 11
Driven Pulley Nut** Driveshaft 147 199 Cylinder Head (8 mm) Cylinder 18 24
Ground Cable Engine 8 11 Cylinder Head Cover Cylinder Head 8.5 11.5
Output Shaft Flange Nut Output Shaft 59 80 Driven Pulley Nut** Driveshaft 80 108
Magneto Rotor Nut Crankshaft 107 146 Ground Wire Engine 8 11
Cam Sprocket** Camshaft 11 15 Magneto Cover Crankcase 8 11
Cam Chain Tensioner Guide Cylinder 11 15 Oil Filler Cover Crankcase 8 11
Starter Motor Crankcase 8 11 Speed Sensor Housing Crankcase 8 11
V-Belt Cover Crankcase 8 11 Starter Motor Crankcase 8 11
Valve Adjuster Jam Nut Valve Adjuster 7 9.5 V-Belt Housing Crankcase 8 11
Oil Fitting Engine 8 11 Intake Manifold Cylinder 8 11
Oil Pump** Crankcase 8 11 Output Shaft Yoke Nut Output Shaft 59 80
Rotor/Flywheel Nut Crankshaft 107 145
Tappet Cover Valve Cover 8 11
Cam Sprocket** Camshaft 10 13.5
Cam Chain Tensioner Cylinder 10 13.5
V-Belt Cover Clutch Cover 8 11
Magneto Cover Crankcase 8 11
Movable Drive Face Nut** Clutch Shaft 165 224
Rear Driveline Output Drive Flange 20 27
Oil Pump Cover* Crankcase 8 11
Movable Drive Face Nut** Clutch Shaft 147 199
Oil Strainer Cap Crankcase 8 11
Water Pump Cover/Housing Magneto Cover 8 11
Shift Cam Stopper Crankcase 8 11
Water Pump Drive Gear Crankshaft 28 38
Shift Cam Stopper Spring Shift Cam Stopper 8 11
* w/Blue Loctite #243 Shift Cam Plate Shift Cam Shaft 8 11
** w/Red Loctite #271 Shifter Housing Crankcase 8 11
*** w/Green Loctite #609
Secondary Drive Gear Nut Gear 74 100
**** w/Three Bond Sealant
Output Yoke Nut Output Shaft 74 100
* w/Blue Loctite #243 ** w/Red Loctite #271
*** w/Green Loctite #609
www.mymowerparts.com ****w/Bond Sealant

1-4 Manual Section

Table of Contents Table of Contents
 For Arctic Cat Parts Call 606-678-9623 or 606-561-4983

Torque Conversions Break-In Procedure

(ft-lb/N-m)
A new ATV and an overhauled ATV engine require a
“break-in” period. The first 10 hours (or 200 miles) are
ft-lb N-m ft-lb N-m ft-lb N-m ft-lb N-m
most critical to the life of this ATV. Proper operation dur-
1 1.4 26 35.4 51 69.4 76 103.4 ing this break-in period will help assure maximum life
2 2.7 27 36.7 52 70.7 77 104.7 and performance from the ATV.
3 4.1 28 38.1 53 72.1 78 106.1
During the first 10 hours (or 200 miles) of operation,
4 5.4 29 39.4 54 73.4 79 107.4 always use less than 1/2 throttle. Varying the engine
5 6.8 30 40.8 55 74.8 80 108.8 RPM during the break-in period allows the components
to “load” (aiding the mating process) and then “unload”
1
6 8.2 31 42.2 56 76.2 81 110.2
(allowing components to cool). Although it is essential to
7 9.5 32 43.5 57 77.5 82 111.5
place some stress on the engine components during
8 10.9 33 44.9 58 78.9 83 112.9 break-in, care should be taken not to overload the engine
9 12.2 34 46.2 59 80.2 84 114.2 too often. Do not pull a trailer or carry heavy loads dur-
10 13.6 35 47.6 60 81.6 85 115.6 ing the 10-hour break-in period.
11 15 36 49 61 83 86 117 When the engine starts, allow it to warm up properly. Idle
12 16.3 37 50.3 62 84.3 87 118.3 the engine several minutes until the engine has reached
13 17.7 38 51.7 63 85.7 88 119.7 normal operating temperature. Do not idle the engine for
14 19 39 53 64 87 89 121
excessively long periods of time.
15 20.4 40 54.4 65 88.4 90 122.4 During the break-in period, a maximum of 1/2 throttle is
16 21.8 41 55.8 66 89.8 91 123.8 recommended; however, brief full-throttle accelerations
17 23.1 42 57.1 67 91.1 92 125.1 and variations in driving speeds contribute to good
engine break-in.
18 24.5 43 58.5 68 92.5 93 126.5
19 25.8 44 59.8 69 93.8 94 127.8 After the completion of the break-in period, the engine
20 27.2 45 61.2 70 95.2 95 129.2 oil and oil filter should be changed. Other maintenance
after break-in should include checking of all prescribed
21 28.6 46 62.6 71 96.6 96 130.6
adjustments and tightening of all fasteners (see Periodic
22 29.9 47 63.9 72 97.9 97 131.9 Maintenance Chart in Section 1).
23 31.3 48 65.3 73 99.3 98 133.3
24 32.6 49 66.6 74 100.6 99 134.6
25 34 50 68 75 102 100 136 Gasoline - Oil - Lubricant

Tightening Torque RECOMMENDED GASOLINE

(General Bolts) The recommended gasoline to use is 87 minimum octane
regular unleaded. In many areas, oxygenates (either etha-
nol or MTBE) are added to the gasoline. Oxygenated
Thread Diameter Tightening gasolines containing up to 10% ethanol, 5% methane, or
Type of Bolt 5% MTBE are acceptable gasolines.
A (mm) Torque
(Conventional or 4 Marked Bolt) 5 12-36 in.-lb
When using ethanol blended gasoline, it is not necessary
6 36-60 in.-lb
to add a gasoline antifreeze since ethanol will prevent the
8 7-11 ft-lb accumulation of moisture in the fuel system.
10 16-25 ft-lb
(7 Marked Bolt) 5 24-48 in.-lb CAUTION
6 6-8 ft-lb Do not use white gas. Only Arctic Cat approved gaso-
8 13-20 ft-lb line additives should be used.
10 29-43 ft-lb

www.mymowerparts.com
Manual Section 1-5
Table of Contents Table of Contents
 For Arctic Cat Parts Call 606-678-9623 or 606-561-4983
RECOMMENDED ENGINE/
TRANSMISSION OIL

CAUTION
Any oil used in place of the recommended oil could
cause serious engine damage. Do not use oils which
contain graphite or molybdenum additives. These oils
can adversely affect clutch operation. Also, not recom-
mended are racing, vegetable, non-detergent, and cas-
tor-based oils.

The recommended oil to use is Arctic Cat ACX All

Weather synthetic engine oil, which has been specifically
formulated for use in this Arctic Cat engine. Although ATV0049B
Arctic Cat ACX All Weather synthetic engine oil is the ! WARNING
only oil recommended for use in this engine, use of any
API certified SM 5W-50 oil is acceptable. Do not overflow gasoline when filling the gas tank. A
fire hazard could materialize. Always allow the engine to
cool before filling the gas tank.

! WARNING
Do not over-fill the gas tank.

Tighten the gas tank cap securely after filling the tank.

Genuine Parts

When replacement of parts is necessary, use only genuine

Arctic Cat ATV parts. They are precision-made to ensure
OILCHARTI high quality and correct fit. Refer to the appropriate Illus-
trated Parts Manual for the correct part number, quantity,
RECOMMENDED FRONT and description.
DIFFERENTIAL/REAR DRIVE
LUBRICANT
Preparation For Storage
The recommended lubricant is Arctic Cat Gear Lube or
an equivalent gear lube which is SAE approved 80W-90
hypoid. This lubricant meets all of the lubrication
requirements of the Arctic Cat ATV front differentials CAUTION
and rear drives. Prior to storing the ATV, it must be properly serviced to
prevent rusting and component deterioration.
CAUTION
Any lubricant used in place of the recommended lubri- Arctic Cat recommends the following procedure to pre-
cant could cause serious front differential/rear drive pare the ATV for storage.
damage.
1. Clean the seat cushion (cover and base) with a
FILLING GAS TANK damp cloth and allow it to dry.
2. Clean the ATV thoroughly by washing dirt, oil,
! WARNING grass, and other foreign matter from the entire
Always fill the gas tank in a well-ventilated area. Never ATV. Allow the ATV to dry thoroughly. DO NOT
add fuel to the ATV gas tank near any open flames or get water into any part of the engine or air intake.
with the engine running. DO NOT SMOKE while filling
the gas tank. 3. Either drain the gas tank or add Fuel Stabilizer to
the gas in the gas tank. Remove the air filter hous-
Since gasoline expands as its temperature rises, the gas ing cover and air filter. Start the engine and allow
tank must be filled to its rated capacity only. Expansion it to idle; then using Arctic Cat Engine Storage
room must be maintained in the tank particularly if the Preserver, rapidly inject the preserver into the air
tank is filled with cold gasoline and then moved to a filter opening for a period of 10 to 20 seconds;
warm area. then stop the engine. Install the air filter and hous-
ing cover.

www.mymowerparts.com
1-6 Manual Section
Table of Contents Table of Contents
 For Arctic Cat Parts Call 606-678-9623 or 606-561-4983
1. Clean the ATV thoroughly.
CAUTION
If the interior of the air filter housing is dirty, clean the 2. Clean the engine. Remove the cloth from the
area before starting the engine. exhaust system.
4. On the 650 drain the carburetor float chamber. 3. Check all control wires and cables for signs of
wear or fraying. Replace if necessary.
5. Plug the exhaust hole in the exhaust system with a
clean cloth. 4. Change the engine/transmission oil and filter.
6. Apply light oil to the upper steering post bushing 5. Check the coolant level and add properly mixed
and plungers of the shock absorbers. coolant as necessary.
7. Tighten all nuts, bolts, cap screws, and screws. 6. Charge the battery; then install. Connect the bat-
Make sure rivets holding components together are tery cables.
1
tight. Replace all loose rivets. Care must be taken
that all calibrated nuts, cap screws, and bolts are
tightened to specifications. CAUTION
The ignition switch must be in the OFF position prior to
8. Fill the cooling system to the bottom of the stand installing the battery or damage may occur to the igni-
pipe in the radiator neck with properly mixed tion system.
coolant.
CAUTION
9. Disconnect the battery cables; then remove the Connect the positive battery cable first; then the nega-
battery, clean the battery posts and cables, and tive.
store in a clean, dry area.
7. Check the entire brake systems (fluid level, pads,
10. Store the ATV indoors in a level position. etc.), all controls, headlights, taillight, brakelight,
and headlight aim; adjust or replace as necessary.
CAUTION
8. Tighten all nuts, bolts, cap screws, and screws
Avoid storing outside in direct sunlight and avoid using
making sure all calibrated nuts, cap screws, and
a plastic cover as moisture will collect on the ATV caus-
bolts are tightened to specifications.
ing rusting.
9. Check tire pressure. Inflate to recommended pres-
sure as necessary.
Preparation After 10. Make sure the steering moves freely and does not
Storage bind.
11. Check the spark plug(s). Clean or replace as nec-
Taking the ATV out of storage and correctly preparing it essary.
will assure many miles and hours of trouble-free riding.
Arctic Cat recommends the following procedure to pre-
pare the ATV.

www.mymowerparts.com
Manual Section 1-7
Table of Contents Table of Contents
For Arctic Cat Parts Call 606-678-9623 or 606-561-4983

SECTION 2 -
PERIODIC MAINTENANCE

TABLE OF
CONTENTS

Periodic Maintenance Chart.................................... 2-2

Periodic Maintenance.............................................. 2-3
Lubrication Points.................................................... 2-3
Air Filter................................................................... 2-3
Valve/Tappet Clearance .......................................... 2-4
Testing Engine Compression .................................. 2-5
Spark Plug(s) .......................................................... 2-6
Muffler/Spark Arrester ............................................. 2-6
Engine/Transmission Oil - Filter - Strainer .............. 2-6
Liquid Cooling System ............................................ 2-8
Front Differential/Rear Drive Lubricant .................... 2-9
Nuts/Bolts/Cap Screws.......................................... 2-10
Headlights/Taillight-Brakelight ............................... 2-10
Shift Lever ............................................................. 2-12
Frame/Welds/Racks .............................................. 2-12
Hydraulic Brake Systems ...................................... 2-12
Burnishing Brake Pads.......................................... 2-14
Checking/Replacing V-Belt.................................... 2-14
www.mymowerparts.com
Manual 2-1
Table of Contents
 For Arctic Cat Parts Call 606-678-9623 or 606-561-4983
A = Adjust I = Inspect
C = Clean L = Lubricate
Periodic Maintenance D = Drain R = Replace
Chart T = Tighten

Initial Service Every Every 3 Every 6

Every Year
After Break-In Every Month or Months or Months or
Item (First Month or Day Every 100 Every 300 Every 500 or Every As Needed
1500 Miles
100 Miles) Miles Miles Miles
Battery I I C
Fuses I R
Air Filter/Drain Tube I I C* R
Valve/Tappet Clearance I I A
Engine Compression I
Spark Plug(s) I I R
(4000 Mi or 18 Mo)
Muffler/Spark Arrester C R
Gas/Vent Hoses I I R (2 Yrs)
Throttle Cable I I C-L A-R
Carburetor Float Chamber D*
(650)
Engine Idle RPM (650) I I A
Engine-Transmission Oil Level I A
Engine-Transmission Oil/Filter R R*/R**/R*** R
Oil Strainer I I C
Front Differential/Rear Drive Lubricant I I R (4 Yrs)
Tires/Air Pressure I I R
Steering Components I I I R
V-Belt I l R
Suspension (Ball joint boots, drive axle I I R
boots front and rear, tie rods,
differential and rear drive bellows)
Nuts/Cap Screws/Screws I I T
Ignition Timing I
Headlight/Taillight-Brakelight I I R
Switches I I R
Shift Lever I A-L
Handlebar Grips I R
Handlebar I I R
Gauges/Indicators I I R
Frame/Welds/Racks I l
Electrical Connections I l C
Complete Brake System (Hydraulic & I I C L-R
Auxiliary)
Brake Pads I I* R
Brake Fluid I I R (2 Yrs)
Brake Hoses I I R (4 Yrs)
Coolant/Cooling System I I R (2 Yrs)
* Service/Inspect more frequently when operating in adverse conditions.
** When using an API certified SM 5W-50 oil.
*** When using Arctic Cat ACX All Weather synthetic oil, oil change interval and strainer inspection can be increased to every
1,000 miles or every year.

www.mymowerparts.com
2-2 Manual Section
Table of Contents Table of Contents
 For Arctic Cat Parts Call 606-678-9623 or 606-561-4983
3. Remove the foam element from the frame making sure not
to tear the element.
Periodic Maintenance
450

This section has been organized into sub-sections which

show common maintenance procedures for the Arctic Cat
ATV.
NOTE: Arctic Cat recommends the use of new gas-
kets, lock nuts, and seals and lubricating all internal
components when servicing the engine/transmission.

NOTE: Some photographs and illustrations used in

this section are used for clarity purposes only and
are not designed to depict actual conditions.
FI515

NOTE: Critical torque specifications are located in

550/650/700

2
Section 1.

SPECIAL TOOLS
A number of special tools must be available to the techni-
cian when performing service procedures in this section.
Description p/n
Compression Tester Kit 0444-213
Oil Filter Wrench 0644-389
Tachometer 0644-275
Timing Light 0644-296
Valve Clearance Adjuster 0444-255 CD747

NOTE: Special tools are available from the Arctic 1000

Cat Service Parts Department.

Lubrication Points

It is advisable to lubricate certain components periodi-

cally to ensure free movement. Apply light oil to the
components using the following list as reference.
A. Throttle Lever Pivot/Cable Ends
GZ019
B. Brake Lever Pivot/Cable Ends
4. Fill a wash pan larger than the element with a
C. Auxiliary Brake Cable Ends non-flammable solvent; then dip the element in the
solvent and wash it.
D. Shift Lever Cable End
NOTE: Foam Air Filter Cleaner and Foam Air Filter
E. Idle RPM Screw (650) Oil are available from Arctic Cat.

5. Squeeze the element by pressing it between the

Air Filter palms of both hands to remove excess solvent. Do
not twist or ring the element or it will develop
cracks.
Use the following procedure to remove the filter and 6. Dry the element.
inspect and/or clean it.
7. Put the element in a plastic bag; then pour in air filter
1. Remove the fasteners securing the storage compart- oil and work the oil into the element.
ment and remove the storage compartment.
8. Squeeze the element to remove excess oil.
2. Remove the air filter housing cover and the air fil-
ter/frame assembly.
www.mymowerparts.com
Manual Section 2-3
Table of Contents Table of Contents
 For Arctic Cat Parts Call 606-678-9623 or 606-561-4983

CAUTION
A torn air filter can cause damage to the ATV engine.
Dirt and dust may get inside the engine if the element is
torn. Carefully examine the element for tears before and
after cleaning it. Replace the element with a new one if it
is torn.
9. Clean any dirt or debris from inside the air cleaner.
10. Install the air filter/frame assembly and cover.
11. Install the storage compartment and cover.
CHECKING AND CLEANING DRAINS
GZ063
1. Inspect the drains beneath the main housing for NOTE: At this point, the rocker arms and adjuster
debris and for proper sealing.
screws must not have pressure on them.

Feeler Gauge Procedure

A. Using a feeler gauge, check each valve/tappet
clearance. If clearance is not within specifica-
tions, loosen the jam nut and rotate the tappet
adjuster screw until the clearance is within speci-
fications. Tighten each jam nut securely after
completing the adjustment.

CAUTION
The feeler gauge must be positioned at the same angle
as the valve and valve adjuster for an accurate measure-
ment of clearance. Failure to measure the valve clear-
KX045A ance accurately could cause valve component damage.
2. Replace any drain that is cracked or shows any signs
of hardening or deterioration.
VALVE/TAPPET CLEARANCE
CAUTION Intake 0.101 mm (0.004 in.)

The drain to the right is the clean air section of the filter Exhaust 0.152 mm (0.006 in.)
housing. Any leak of this drain will allow dirt into the
engine intake causing severe engine damage.

3. Wipe any accumulation of oil or gas from the filter

housing and drains.

Valve/Tappet Clearance

To check and adjust valve/tappet clearance, use the fol-

lowing procedure.
1. Remove the timing inspection plug; then remove the CC007DC
tappet covers and spark plug(s) (for more detailed B. On the H2 models, rotate the engine 270° to the
information, see Section 3 - Servicing Top-Side TDC position of the rear cylinder; then repeat step
Components). A.
NOTE: On the H2 models, remove the crankshaft
end cap and install the special cap screw (left-hand
threads) to rotate the engine.

2. Rotate the crankshaft to the TDC position on the

compression stroke (front cylinder on the H2 mod-
els).

www.mymowerparts.com
2-4 Manual Section
Table of Contents Table of Contents
 For Arctic Cat Parts Call 606-678-9623 or 606-561-4983

Testing Engine
Compression

To test engine compression, use the following procedure.

1. Remove the high tension lead(s) from the spark
plug(s).
2. Using compressed air, blow any debris from around
the spark plug(s).
GZ059
! WARNING
Valve Adjuster Procedure Always wear safety glasses when using compressed
air.
NOTE: The seat, storage compartment cover

2
assembly, compartment box, air filter/filter housing, 3. Remove the spark plug(s); then attach the high ten-
and left-side/right-side splash panels must be sion lead(s) to the plug(s) and ground the plug(s) on
removed for this procedure. the cylinder head(s) well away from the spark plug
hole(s).
A. Place Valve Clearance Adjuster onto the jam nut
securing the tappet adjuster screw; then rotate the 4. Attach the Compression Tester Kit.
valve adjuster dial clockwise until the end is
NOTE: The engine should be warm (operating tem-
seated in the tappet adjuster screw.
perature) and the battery full charged for an accurate
B. While holding the valve adjuster dial in place, use compression test. Throttle must be in the wide-open
the valve adjuster handle and loosen the jam nut; throttle (WOT) position. In the event the engine can
then rotate the tappet adjuster screw clockwise not be run, cold values are included.
until friction is felt.
5. While holding the throttle lever in the full-open posi-
C. Align the valve adjuster handle with one of the tion, crank the engine over with the electric starter
marks on the valve adjuster dial. until the gauge shows a peak reading (five to 10
D. While holding the valve adjuster handle in place, compression strokes).
rotate the valve adjuster dial counterclockwise
until proper valve/tappet clearance is attained. COMPRESSION
Model PSI Hot (WOT) PSI Cold (WOT)
NOTE: Refer to the appropriate specifications in 450 95-115 N/A
Feeler Gauge Procedure sub-section for the proper 550 120-140 80-120
valve/tappet clearance. 650/700 125-145 100-140
1000 (Front) 125-145 80-120
NOTE: Rotating the valve adjuster dial counter-
1000 (Rear) 165-185 150-190
clockwise will open the valve/tappet clearance by
0.05 mm (0.002 in.) per mark. 6. If compression is abnormally low, inspect the
following items.
E. While holding the adjuster dial at the proper
clearance setting, tighten the jam nut securely A. Verify starter cranks engine over at normal
with the valve adjuster handle. speed (approximately 400 RPM).
F. Rotate the engine 270° to the TDC position of the
rear cylinder; then repeat steps A-E for the rear B. Gauge functioning properly.
cylinder.
C. Throttle lever in the full-open position.
3. Install the timing inspection plug; then on the H2
models, remove the cap screw and install the crank- D. Valve/tappet clearance correct.
case end cap.
E. Valve not bent or burned.
4. Place the tappet covers into position making sure the
proper cap screws are with the proper cover. Tighten F. Valve seat not burned.
the cap screws securely.
NOTE: To service valves, see Section 3.
5. Install the spark plug(s).
7. Pour 29.5 ml (1 fl oz) of oil into the spark plug hole,
reattach the gauge, and retest compression.
8. If compression is now evident, service the piston
rings (see Section 3).
www.mymowerparts.com
Manual Section 2-5
Table of Contents Table of Contents
 For Arctic Cat Parts Call 606-678-9623 or 606-561-4983
1. Remove the three cap screws securing the spark
arrester assembly to the muffler; then loosen and
Spark Plug(s) remove the arrester.

A light brown insulator indicates that a plug is correct. A

white or dark insulator indicates that the engine may need
to be serviced or the carburetor (if equipped) may need to
be adjusted. To maintain a hot, strong spark, keep the
plug free of carbon.

CF105A
2. Using a suitable brush, clean the carbon deposits
from the screen taking care not to damage the screen.
NOTE: If the screen or gasket is damaged in any
way, it must be replaced.

ATV-0051
3. Install the spark arrester assembly with gasket; then
secure with the three cap screws. Tighten to 48 in.-lb.
CAUTION
Before removing a spark plug, be sure to clean the area
around the spark plug. Dirt could enter engine when
removing or installing the spark plug.
Adjust the gap to 0.7-0.8 mm (0.028-0.032 in.) for proper
ignition. Use a feeler gauge to check the gap.

CF104

Engine/Transmission
Oil - Filter - Strainer
ATV0052C
When installing the spark plug, be sure to tighten it OIL - FILTER
securely. A new spark plug should be tightened 1/2 turn
once the washer contacts the cylinder head. A used spark The engine should always be warm when the oil is
plug should be tightened 1/8 - 1/4 turn once the washer changed so the oil will drain easily and completely.
contacts the cylinder head. 1. Park the ATV on level ground.
2. Remove the oil level stick/filler plug.
Muffler/Spark Arrester

At the intervals shown in the Periodic Maintenance

Chart, clean the spark arrester using the following proce-
dure.

! WARNING
Wait until the muffler cools to avoid burns.
www.mymowerparts.com
2-6 Manual Section
Table of Contents Table of Contents
 For Arctic Cat Parts Call 606-678-9623 or 606-561-4983
7. Install the engine drain plug and tighten to 16 ft-lb.
H1 Pour the specified amount of the recommended oil in
the filler hole. Install the oil level stick/filler plug.

CAUTION
Any oil used in place of the recommended oil could
cause serious engine damage. Do not use oils which
contain graphite or molybdenum additives. These oils
can adversely affect clutch operation. Also, not recom-
mended are racing, vegetable, non-detergent, and cas-
tor-based oils.

8. Start the engine (while the ATV is outside on level

CF109M
ground) and allow it to idle for a few minutes.

1000 9. Turn the engine off and wait approximately one min-
ute.
10. Remove the oil level stick and wipe it with a clean
cloth.
11. Install the oil level stick and thread into the engine
2
case.
12. Remove the oil level stick; the oil level must be
within the operating range but not exceeding the
upper mark.

GZ415A
3. Remove the drain plug from the bottom of the engine
and drain the oil into a drain pan.

GZ461A

CAUTION
Do not over-fill the engine with oil. Always make sure
that the oil level is not above the upper mark.
733-441A
13. Inspect the area around the drain plug and oil filter
4. Remove the oil filter plug from the filter mounting for leaks.
boss (located on the front side of the transmission
case) and allow the filter to drain completely. Install STRAINER
the plug and tighten securely.
1. Remove the belly panel.
5. Using the adjustable Oil Filter Wrench and a suitable
wrench, remove the old oil filter. 2. Remove the cap screws securing the oil strainer cap;
then remove the cap.
NOTE: Clean up any excess oil after removing the
filter.

6. Apply oil to a new filter O-ring and check to make

sure it is positioned correctly; then install the new oil
filter. Tighten securely.
NOTE: Install a new O-ring each time the filter is
replaced.

www.mymowerparts.com
Manual Section 2-7
Table of Contents Table of Contents
 For Arctic Cat Parts Call 606-678-9623 or 606-561-4983

Liquid Cooling System

NOTE: Debris in front of the engine or packed

between the cooling fins of the radiator can reduce
cooling capability. Using a garden hose, wash the
radiator to remove any debris preventing air flow.

CAUTION
Arctic Cat does not recommend using a pressure
CC091D
washer to clean the radiator core. The pressure may
bend or flatten the fins causing restricted air flow, and
3. Remove the two cap screws securing the strainer; electrical components on the radiator could be dam-
then remove the strainer. aged. Use only a garden hose with spray nozzle at nor-
NOTE: Thoroughly clean any sealant from the oil mal tap pressure.
strainer cap.
The cooling system capacity can be found in Section 1.
The cooling system should be inspected daily for leakage
and damage. If leakage or damage is detected, take the
ATV to an authorized Arctic Cat ATV dealer for service.
Also, the coolant level should be checked periodically.

CAUTION
Continued operation of the ATV with high engine tem-
perature may result in engine damage or premature
wear.

NOTE: High engine RPM, low vehicle speed, or

heavy load can raise engine temperature. Decreasing
engine RPM, reducing load, and selecting an appro-
priate transmission gear can lower the temperature.
CC163D

AT THIS POINT When filling the cooling system, use a coolant/water
To check/service oil strainer, see Section 3.
mixture which will satisfy the coldest anticipated weather
conditions of the area in accordance with the coolant
4. Place the oil strainer into position beneath the crank- manufacturer’s recommendations. While the cooling sys-
case and secure with the cap screws. Tighten tem is being filled, air pockets may develop; therefore,
securely. run the engine for five minutes after the initial fill, shut
the engine off, and then fill the cooling system to the bot-
5. Place the strainer cap into position on the strainer tom of the stand pipe in the radiator neck.
making sure silicone sealant is applied; then secure
with the cap screws. Tighten securely. Checking/Filling
1. On the 700/1000, remove the two screws from the
front of the radiator access panel. On the
450/550/650, remove the four screws securing the
radiator access panel.

700/1000

CC091D
6. Install the belly panel.

FI465A

www.mymowerparts.com
2-8 Manual Section
Table of Contents Table of Contents
 For Arctic Cat Parts Call 606-678-9623 or 606-561-4983

450/550/650

MP003

FI476
6. Remove two reinstallable rivets and remove the
splash guard. The radiator cap can now be accessed
2. On the 700/1000, lift the front of the access panel; in front of the snorkels.
then slide the panel forward to disengage the two
rear tabs.
2
7. Carefully rotate the radiator cap counterclockwise to
release pressure; then remove the cap.
3. On the 700/1000, move the panel rearward until free
of the rack. On the 450/550/650, move the panel for-
ward until free of the ATV.
4. On Mud Pro models, remove four cap screws secur-
ing the snorkel housing to the front inspection panel;
then remove two cap screws from the rear of the
snorkel housing.

CF142A
8. Add coolant as necessary; then install the radiator
cap and access panel or snorkel housing.
NOTE: Use a good quality, biodegradable gly-
col-based, automotive-type antifreeze.

MP006A ! WARNING
Never check the coolant level when the engine is hot or
the cooling system is under pressure.

CAUTION
After operating the ATV for the initial 5-10 minutes, stop
the engine, allow the engine to cool down, and check
the coolant level. Add coolant as necessary.

Front Differential/Rear
Drive Lubricant
MP007A
5. Separate the front of the snorkel housing from the NOTE: On the 700 Mud Pro and 1000 models, the
rear; then remove the snorkel housing. rear drive incorporates a shock-limiting clutch pack
in the gear case input assembly that is designed to
cushion driveline shock.

www.mymowerparts.com
Manual Section 2-9
Table of Contents Table of Contents
 For Arctic Cat Parts Call 606-678-9623 or 606-561-4983

CAUTION
Any lubricant used in place of the recommended gear
case lubricant could result in premature failure of the
shock limiter. Do not use any lubricant containing
graphite or molybdenum additives or other fric-
tion-modified lubricants as these may cause severe
damage to shock limiter components.
When changing the lubricant, use approved SAE 80W-90
hypoid gear lube.
To check lubricant, remove the fill plug; the lubricant
level should be 1 in. below the threads of the plug. If low,
add SAE approved 80W-90 hypoid gear lubricant as nec- 737-651B
essary.
4. After all the lubricant has been drained, install the
To change the lubricant, use the following procedure. drain plugs and tighten to 45 in.-lb.
1. Place the ATV on level ground. 5. Pour the appropriate amount of approved SAE
80W-90 hypoid gear lubricant into the filler hole.
2. Remove each fill plug.
6. Install the fill plugs.
NOTE: If the differential/rear drive lubricant is con-
taminated with water, inspect the drain plug, fill plug,
and/or bladder.

CAUTION
Water entering the outer end of the axle will not be able
to enter the rear drive unless the seals are damaged.

Nuts/Bolts/Cap Screws
AL677C
3. Drain the lubricant into a drain pan by removing in Tighten all nuts, bolts, and cap screws. Make sure rivets
turn the drain plug from each. holding components together are tight. Replace all loose
rivets. Care must be taken that all calibrated nuts, bolts,
and cap screws are tightened to specifications (see Sec-
tion 1).

Headlights/Taillight-
Brakelight

NOTE: The bulb portion of a headlight is fragile.

HANDLE WITH CARE. When replacing a headlight
bulb, do not touch the glass portion of the bulb. If the
glass is touched, it must be cleaned with a dry cloth
ATV0082A
before installing. Skin oil residue on the bulb will
shorten the life of the bulb.

! WARNING
Do not attempt to remove a bulb when it is hot. Severe
burns may result.

To replace a headlight bulb, use the following procedure.

1. Rotate the bulb assembly counterclockwise and
remove from the headlight housing; then disconnect
from the wiring harness.

www.mymowerparts.com
2-10 Manual Section
Table of Contents Table of Contents
Arctic Cat 2011 450 550 650For
700 Arctic
1000 Service Manual
Cat Parts Call 606-678-9623 or 606-561-4983
Full download: http://manualplace.com/download/arctic-cat-2011-450-550-650-700-1000-service-manual/
2. Connect the new bulb assembly to the wiring harness
connector; then insert into the headlight housing and
rotate fully clockwise.
To replace the taillight-brakelight bulb, use the following
procedure.
1. Turn the bulb socket assembly counterclockwise and
remove from the housing.

ATV-0070C

NOTE: There should be an average operating load

on the ATV when adjusting the headlight aim.

2. Measure the distance from the floor to the mid-point

of each headlight. 2
3. Using the measurements obtained in step 2, make
horizontal marks on the aiming surface.
CF135A
2. Pull the bulb straight out of the socket; then insert a 4. Make vertical marks which intersect the horizontal
new bulb. marks on the aiming surface directly in front of the
headlights.
5. Switch on the lights. Make sure the HIGH beam is
on. DO NOT USE LOW BEAM.
6. Observe each headlight beam aim. Proper aim is
when the most intense beam is centered on the verti-
cal mark 5 cm (2 in.) below the horizontal mark on
the aiming surface.
7. Adjust each headlight by turning the adjuster knob
clockwise to raise the beam or counterclockwise to
lower the beam.

CF132A
3. Insert the bulb socket assembly into the housing and
turn it clockwise to secure.
CHECKING/ADJUSTING HEADLIGHT
AIM
The headlights can be adjusted vertically and horizon-
tally. The geometric center of the HIGH beam light zone
is to be used for vertical and horizontal aiming.
1. Position the ATV on a level floor so the headlights
are approximately 6.1 m (20 ft) from an aiming sur- CD714A
face (wall or similar aiming surface).

www.mymowerparts.com
Manual Section 2-11
Table
This is the cut pages sample. Download all of
275Contents Table of Contents
page(s) at: ManualPlace.com