Arctic Cat 2010 700 Diesel Service Manual
Arctic Cat 2010 700 Diesel Service Manual
Arctic Cat 2010 700 Diesel Service Manual
2010 ARCTIC
700 Diesel Service
CAT ATV Manual
DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983
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FOREWORD
This Arctic Cat Service Manual contains service, maintenance, and troubleshooting information for the 2010
Arctic Cat 700 Diesel SD ATV. The complete manual is designed to aid service personnel in service-oriented
applications.
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 specific symbols 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 atten-
tion. 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.
TABLE OF CONTENTS
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Foreword
1. General Information/Specifications
1
2. Periodic Maintenance/Tune-Up
2
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
700 Diesel SD
V
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TABLE OF
CONTENTS
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ENGINE/TRANSMISSION
1
Drive Clutch Flywheel/PTO Shaft 40 54
6 6-8 ft-lb
Movable Drive Face* Fixed Drive Hub 85 116 8 13-20 ft-lb
Oil Pump Engine Block 22 30 10 29-43 ft-lb
Output Shaft* Output Shaft Coupler 20 27
Output Shaft Nut* Output Shaft 80 108
Starter V-Belt Housing 35 48
Flywheel/PTO Shaft Crankshaft 40 54
Crankshaft Pulley Timing Belt Drive Pulley 9 12 Torque Conversions
Chamber Ring Nut Chamber (Step 1) 72 98 (ft-lb/N-m)
(Step 2) 130 177
Glow Plug Cylinder Head 18 24
Crankshaft Pulley*** Crankshaft 260 354
ft-lb N-m ft-lb N-m ft-lb N-m ft-lb N-m
Timing Belt Idler Nut Engine Block 29 39
1 1.4 26 35.4 51 69.4 76 103.4
V-Belt Cover V-Belt Housing 9 12
2 2.7 27 36.7 52 70.7 77 104.7
V-Belt Housing Crankcase/Transmission 25 34
3 4.1 28 38.1 53 72.1 78 106.1
Fuel Rail Unit Injectors 36 in.-lb 4
4 5.4 29 39.4 54 73.4 79 107.4
Gear Case (Left) Gear Case (Right) 8 11
5 6.8 30 40.8 55 74.8 80 108.8
Oil Pan Crankcase 7 10
6 8.2 31 42.2 56 76.2 81 110.2
Oil Pan Cover Oil Pan 7 10
7 9.5 32 43.5 57 77.5 82 111.5
Crankshaft Seal/Flange Engine Block 9 12 8 10.9 33 44.9 58 78.9 83 112.9
Camshaft Support Cylinder Head 7 10 9 12.2 34 46.2 59 80.2 84 114.2
Housing
10 13.6 35 47.6 60 81.6 85 115.6
Fuel Injector Control Unit Injector 11 in.-lb 1.2
Rack 11 15 36 49 61 83 86 117
Unit Injector Retainer Cylinder Head (5 Steps) 15 20 12 16.3 37 50.3 62 84.3 87 118.3
Nut 13 17.7 38 51.7 63 85.7 88 119.7
Camshaft Drive Pulley Camshaft 59 80 14 19 39 53 64 87 89 121
Lift Pump Eccentric Camshaft 59 80 15 20.4 40 54.4 65 88.4 90 122.4
Water Pump Engine Block 22 30 16 21.8 41 55.8 66 89.8 91 123.8
CHASSIS COMPONENTS 17 23.1 42 57.1 67 91.1 92 125.1
Shift Lever*** Shift Axle 8 11 18 24.5 43 58.5 68 92.5 93 126.5
SUSPENSION COMPONENTS (Front) 19 25.8 44 59.8 69 93.8 94 127.8
A-Arm Frame 50 68 20 27.2 45 61.2 70 95.2 95 129.2
Ball Joint Cap Screw Knuckle 35 48 21 28.6 46 62.6 71 96.6 96 130.6
22 29.9 47 63.9 72 97.9 97 131.9
Shock Absorber Frame 50 68
23 31.3 48 65.3 73 99.3 98 133.3
Shock Absorber Upper A-Arm 50 68
24 32.6 49 66.6 74 100.6 99 134.6
SUSPENSION COMPONENTS (Rear)
25 34 50 68 75 102 100 136
A-Arm Frame 50 68
Shock Absorber (Upper) Frame 50 68
Shock Absorber (Lower) Lower A-Arm 20 27
Knuckle A-Arm 50 68
* w/Red Loctite #271
*** w/Blue Loctite #243
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RECOMMENDED ENGINE OIL
Break-In Procedure The recommended oil to use is an oil which is rated SJ/
CF under API service classification. These oils meet
all of the lubrication requirements of the Arctic Cat
A new ATV and an overhauled ATV engine require a engine. The recommended engine oil viscosity is SAE
“break-in” period. The first 10 hours (or 200 miles) are 10W-40. Ambient temperature should determine the
most critical to the life of this ATV. Proper operation correct weight of oil. See the viscosity chart or an
during this break-in period will help assure maximum authorized Arctic Cat ATV dealer for details.
life and performance from the ATV.
During the first 10 hours (or 200 miles) of operation,
always use less than 1/2 throttle. Varying the engine
RPM during the break-in period allows the compo-
nents to “load” (aiding the mating process) and then
“unload” (allowing components to cool). Although it
is essential to place some stress on the engine compo-
nents during break-in, care should be taken not to
overload the engine too often. Do not pull a trailer or
carry heavy loads during the 10-hour break-in period.
When the engine starts, allow it to warm up properly.
Idle the engine several minutes until the engine has
reached normal operating temperature. OILCHARTE
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FILLING FUEL TANK 1. Clean the seat cushion (cover and base) with a
damp cloth and allow it to dry.
! WARNING 2. Clean the ATV thoroughly by washing dirt, oil,
Always fill the fuel tank in a well-ventilated area. grass, and other foreign matter from the entire
Never add fuel to the ATV fuel tank near any open ATV. Allow the ATV to dry thoroughly. DO NOT
flames or with the engine running. DO NOT SMOKE get water into any part of the engine or air intake.
while filling the fuel tank.
3. Fill the fuel tank with fresh #1 or #2 diesel fuel
(according to ambient temperatures); then add a
quality anti-microbial additive. Run the engine in
a well-ventilated area for several minutes to make
sure fresh, treated fuel is circulated throughout the
entire injection system.
CAUTION 1
DO NOT store the ATV with biodiesel (B20) in the
fuel system. Severe damage to the fuel system may
occur.
Arctic Cat recommends the following procedure to 3. Check all control wires and cables for signs of
prepare the ATV for storage. wear or fraying. Replace if necessary.
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4. Change the engine oil and filter. 7. Check the entire brake systems (fluid level, pads,
etc.), all controls, headlights, taillight, brakelight,
5. Check the coolant level and add properly mixed and headlight aim; adjust or replace as necessary.
coolant as necessary.
8. Tighten all nuts, bolts, cap screws, and screws
6. Charge the battery; then install. Connect the bat- making sure all calibrated nuts, cap screws, and
tery cables. bolts are tightened to specifications.
CAUTION 9. Check tire pressure. Inflate to recommended pres-
sure as necessary.
The ignition switch must be in the OFF position prior
to installing the battery or damage may occur to the 10. Make sure the steering moves freely and does not
electrical system. bind.
CAUTION
Connect the positive battery cable first; then the
negative.
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SECTION 2 -
PERIODIC MAINTENANCE/TUNE-UP
TABLE OF
CONTENTS
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