2003 Arctic Cat 500 4x4 Automatic TBX ATV Service Repair Manual

2003
ATV SERVICE MANUAL
CD-ROM
Click on the Text to Go!
TABLE OF CONTENTS
Section
1. General Information
2. Periodic Maintenance/Tune-Up
3. Engine/Transmission
4. Fuel/Lubrication/Cooling
5. Electrical System
6. Drive System
7. Suspension
8. Steering/Frame
9. Controls/Indicators
10. Aids for Maintenance
11. Troubleshooting
1
2
3
4
5
6
7
8
9
10
11

1-1
1
SECTION 1 - GENERAL INFORMATION
TABLE OF
CONTENTS
General Specifications (250)................................... 1-2
General Specifications (300)................................... 1-3
General Specifications
(400 - Automatic Transmission)............................ 1-4
(400 - Manual Transmission)................................ 1-5
(500 - Manual Transmission)................................ 1-6
(500 - Automatic Transmission)............................ 1-7
General Specifications (500 TBX)........................... 1-8
Break-In Procedure ................................................. 1-9
Gasoline - Oil - Lubricant ........................................ 1-9
Genuine Parts ....................................................... 1-10
Preparation For Storage........................................ 1-11
Preparation After Storage...................................... 1-11
Back to Table of Contents

1-2
General Specifications*
(250)
* Specifications subject to change without notice.
** One inch below plug threads.
CARBURETOR
Type Keihin CVK32
Main Jet 138
Slow Jet 38
Low Speed Fuel Screw Setting
(turns)
1 3/4
Jet Needle N8TT
Needle Jet 4.0/3.4
Idle RPM 1300-1400
Starter Jet 60
Float Arm Height 17 mm (0.7 in.)
Throttle Cable Free-Play
(at lever)
3-6 mm
(1/8-1/4 in.)
ELECTRICAL
Ignition Timing 5° BTDC below 1800 RPM
35° BTDC above 3800 RPM
Spark Plug Type NGK DR7EA
Spark Plug Gap 0.6-0.7 mm (0.024-0.028 in.)
Spark Plug Cap 8000-12,000 ohms
Ignition Coil Resistance
(primary)
(secondary)
0.4-0.6 ohm
(terminal to ground)
5200-7800 ohms
(high tension - plug cap
removed - to ground)
Ignition Coil Peak (primary/CDI)
Voltage
98.3-147.5 volts
Magneto Coil Resistance (trigger)
(charging)
84-126 ohms (black/yellow to
green/white)
0.44-0.66 ohm (yellow to
yellow)
Magneto Coil Peak (trigger)
Voltage
(charging)
3.12-4.68 volts (black/yellow
to green/white)
30-45 volts (yellow to yellow)
Magneto Output (approx) 220W @ 5000 RPM
CHASSIS
Dry Weight (approx) 2x4 - 245 kg (540 lb)
4x4 - 261 kg (575 lb)
Length (overall) 202 cm (79.5 in.)
Height (overall) 114 cm (45 in.)
Width (overall) 114 cm (45 in.)
Suspension Travel 16.5 cm (6.5 in.)
Ground Clearance 20.3 cm (8.0 in.)
Brake Type Hydraulic w/Brake Lever Lock
and Auxiliary Brake
Wheelbase 127 cm (50 in.)
Tracking 89 cm (35 in.)
Tire Size Front - AT23 x 8-12
Rear - AT24 x 9-12
Tire Inflation Pressure 0.35 kg/cm² (5 psi)
Turning Radius 3.0 m (9.85 ft)
MISCELLANY
Gas Tank Capacity (rated) 17.98 L (4.75 U.S. gal.)
Reserve Capacity 2.46 L (0.65 U.S. gal.)
Engine Oil Capacity 3.4 L (3.5 U.S. qt)
Gasoline (recommended) 87 Octane Regular Unleaded
Engine Oil (recommended) SAE 10W-40
Differential Capacity (front - 4x4) 275 ml (9.3 fl oz)**
Differential Lubricant (front - 4x4) SAE Approved
80W-90 Hypoid
Brake Fluid DOT 4
Taillight/Brakelight 12V/5W/27W
Headlight 12V/27W (2)
Starting System Electric w/Manual Recoil
(Emergency)
Back to Section Table of ContentsBack to Table of Contents

1-3
1
(300)
CARBURETOR
Type Keihin CVK32
Main Jet 135
Slow Jet 38
(turns)
2 1/4
Jet Needle N8TT
Needle Jet 4.0/3.4
Idle RPM 1300-1400
Starter Jet 65
Throttle Cable Free-Play (at lever) 3-6 mm (1/8-1/4 in.)
ELECTRICAL
Ignition Timing 5° BTDC @ 1800 RPM
30° BTDC @ 3800 RPM
Spark Plug Type NGK DR7EA
Ignition Coil Resistance (primary)
(secondary)
0.4-0.6 ohm
5200-7800 ohms
Ignition Coil Peak (primary/CDI)
Voltage
98.3-147.5 volts
(charging)
84-126 ohms
(black/yellow to green/white)
0.44-0.66 ohm
(yellow to yellow)
Voltage (charging)
3.12-4.68 volts (black/yellow
to green/white)
30-45 volts (yellow to yellow)
CHASSIS
4x4 - 263 kg (580 lb)
Length (overall) 202 cm (79.5 in.)
Height (overall) 114 cm (45 in.)
Width (overall) 114 cm (45 in.)
Suspension Travel 16.5 cm (6.5 in.)
Ground Clearance 20.3 cm (8.0 in.)
and Auxiliary Brake
Tire Size (2x4) Front - AT23 x 8-12
Rear - AT25 x 10-12
Tire Size (4x4) Front - AT24 x 9-12
Rear - AT25 x 10-12
MISCELLANY
Differential Lubricant (front - 4x4) SAE Approved
80W-90 Hypoid
Brake Fluid DOT 4
(Emergency)
Back to Section Table of Contents Back to Table of Contents

1-4
(400 - Automatic Transmission)
*** At the plug threads.
CARBURETOR
Type Keihin CVK32
Main Jet 150
Slow Jet 38
(turns)
2 1/8
Jet Needle N8TV
Needle Jet 4.0/3.4
Idle RPM 1250-1350
Starter Jet 60
ELECTRICAL
Spark Plug Type NGK CR7E
(secondary)
0.4-0.6 ohm
5200-7800 ohms
IgnitionCoilPeak (primary/CDI)
Voltage
160.8-241.2 volts
(source)
(charging)
160-240 ohms
(green to blue)
0.08-0.12 ohm
(yellow to white)
0.32-0.48 ohm
(black to black)
Voltage (source)
(charging)
5.04-7.56 volts (green to
blue)
0.7-1.05 volts (yellow to
white)
12.5-18.6 volts (black to black
#1) (black to black #2)
CHASSIS
4x4 - 282 kg (622 lb) - ACT
4x4 - 286 kg (630 lb) - FIS
Length (overall) 2x4 - 202 cm (79.5 in.)
4x4 - 205 cm (81 in.)
Height (overall) 122 cm (48 in.) - ACT
125 cm (49.3 in.) - FIS
Width (overall) 112 cm (44.25 in.) - ACT
121 cm (47.5 in.) - FIS
CHASSIS (Cont)
Suspension Travel (front) 21.5 cm (8.45 in.) - ACT
25 cm (10 in.) - FIS
Suspension Travel (rear) 18.2 cm (7.2 in.) - ACT
25 cm (10 in.) - FIS
Ground Clearance 20.3 cm (8 in.)
and Auxiliary Brake
Wheel Stance 89 cm (35 in.)
Tire Size Front - KT25 x 8-12
Rear - KT25 x 10-12 - ACT
Rear - KT25 x 11-12 - FIS
MISCELLANY
Rear Drive Capacity 275 ml (9.3 fl oz) - ACT***
250 ml (8.5 fl oz) - FIS**
Differential/Rear Drive Lubricant SAE Approved
80W-90 Hypoid
Brake Fluid DOT 4
(Emergency)

1-5
1
(400 - Manual Transmission)
CARBURETOR
Type Keihin CVK32
Main Jet 150
Slow Jet 38
(turns)
2 1/8
Jet Needle N8TV
Needle Jet 4.0/3.4
Idle RPM 1250-1350
Starter Jet 60
ELECTRICAL
(secondary)
0.4-0.6 ohm
5200-7800 ohms
Igniton Coil Peak (primary/CDI)
Voltage
160.8-241.2 volts
(source)
(charging)
160-240 ohms
(green to blue)
0.08-0.12 ohm
(yellow to white)
0.32-0.48 ohm
(black to black)
Voltage (source)
(charging)
5.04-7.56 volts (green to blue)
0.7-1.05 volts
(yellow to white)
12.5-18.6 volts
(black to black #1)
(black to black #2)
Magneto Output (approx) 220 W @ 5000 RPM
CHASSIS
4x4 - 276 kg (609 lb) - ACT
4x4 - 280 kg (617 lb) - FIS
Length (overall) 2x4 - 202 cm (79.5 in.)
4x4 - 205 cm (81 in.)
Height (overall) 122 cm (48 in.) - ACT
125 cm (49.3 in.) - FIS
Width (overall) 112 cm (44.25 in.) - ACT
121 cm (47.5 in.) - FIS
Suspension Travel (front) 21.5 cm (8.45 in.) - ACT
25 cm (10 in.) - FIS
CHASSIS (Cont)
Suspension Travel (rear) 18.2 cm (7.2 in.) - ACT
25 cm (10 in.) - FIS
and Auxiliary Brake
Wheel Stance 89 cm (35 in.)
Rear - KT25 x 10-12 - ACT
Rear - KT25 x 11-12 - FIS
MISCELLANY
Rear Drive Capacity 275 ml (9.3 fl oz) - ACT***
250 ml (8.5 fl oz) - FIS**
80W-90 Hypoid
Brake Fluid DOT 4
(Emergency)

1-6
(500 - Manual Transmission)
CARBURETOR
Type Keihin CVK36
Main Jet 148
Slow Jet 75
(turns)
1 7/8
Jet Needle N3RS
Needle Jet 6.0/4.0
Idle RPM 1250-1350
Starter Jet 90
ELECTRICAL
(secondary)
0.4-0.6 ohm
5200-7800 ohms
Voltage
142.4-213.6 volts
(source)
(charging)
160-240 ohms
(green to blue)
0.08-0.12 ohm
(yellow to white)
0.32-0.48 ohm
(black to black)
Voltage (source)
(charging)
0.40-0.62 volt
(yellow to white)
9.44-14.2 volts
(black to black #1)
(black to black #2)
CHASSIS
Dry Weight (approx) 288.5 kg (636 lb)
Length (overall) 205 cm (81 in.)
Height (overall) 125 cm (49.3 in.)
Width (overall) 120.7 cm (47.5 in.)
Suspension Travel (front) 25 cm (10 in.)
Suspension Travel (rear) 25 cm (10 in.)
CHASSIS (Cont)
and Auxiliary Brake
Rear - KT25 x 11-12
MISCELLANY
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)***
80W-90 Hypoid
Brake Fluid DOT 4
(Emergency)

1-7
1
(500 - Automatic Transmission)
CARBURETOR
Type Keihin CVK36
Main Jet 148
Slow Jet 75
(turns)
1 7/8
Jet Needle N3RS
Needle Jet 6.0/4.0
Idle RPM 1250-1350
Starter Jet 90
Throttle Cable Free-Play (at lever) 3 -6 mm (1/8-1/4 in.)
ELECTRICAL
(secondary)
0.4-0.6 ohm
5200-7800 ohms
Voltage
142.4-213.6 volts
(source)
(charging)
160-240 ohms
(green to blue)
0.08-0.12 ohm
(yellow to white)
0.32-0.48 ohm
(black to black)
Voltage (source)
(charging)
0.40-0.62 volt
(yellow to white)
9.44-14.2 volts
(black to black #1)
(black to black #2)
CHASSIS
Dry Weight (approx) 293 kg (646 lb)
Length (overall) 205 cm (81 in.)
and Auxiliary Brake
Rear - KT25 x 11-12
MISCELLANY
80W-90 Hypoid
Brake Fluid DOT 4
(Emergency)

1-8
(500 TBX)
CARBURETOR
Type Keihin CVK36
Main Jet 148
Slow Jet 75
(turns)
1 7/8
Jet Needle N3RS
Needle Jet 6.0/4.0
Idle RPM 1250-1350
Starter Jet 90
ELECTRICAL
(secondary)
0.4-0.6 ohm
5200-7800 ohms
Voltage
142.4-213.6 volts
(source)
(charging)
160-240 ohms
(green to blue)
0.08-0.12 ohm
(yellow to white)
0.32-0.48 ohm
(black to black)
Voltage (source)
(charging)
0.40-0.62 volt
(yellow to white)
9.44-14.2 volts
(black to black #1)
(black to black #2)
CHASSIS
Dry Weight (approx) 331.5 kg (731 lb)
Length (overall) 244.5 cm (96.25 in.)
and Auxiliary Brake
Rear - KT25 x 11-12
MISCELLANY
80W-90 Hypoid
Brake Fluid DOT 4
(Emergency)

1-9
1
Break-In Procedure
A new ATV and an overhauled ATV engine require a
“break-in” period. The first 10 hours (or 200 miles) are
most critical to the life of this ATV. Proper operation
during this break-in period will help assure maximum
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. Do not idle the
engine for excessively long periods of time.
During the break-in period, a maximum of 1/2 throttle
is recommended; however, brief full-throttle accelera-
tions and variations in driving speeds contribute to
good engine break-in.
During the break-in period (or whenever the brake
pads are replaced), the hydraulic brake pads must be
burnished. Slow disc-speed hydraulic brakes must be
properly burnished in order to achieve maximum stop-
ping power.
!NOTE: Do not be reluctant to heat up the brake
pads during the burnishing procedure.
After the completion of the break-in period, the engine
oil and oil filter should be changed. Other maintenance
after break-in should include checking of all pre-
scribed adjustments and tightening of all fasteners.
Gasoline - Oil - Lubricant
RECOMMENDED GASOLINE
The recommended gasoline to use is 87 minimum
octane regular unleaded. In many areas, oxygenates
(either ethanol or MTBE) are added to the gasoline.
Oxygenated gasolines containing up to 10% ethanol,
5% methane, or 5% MTBE are acceptable gasolines.
When using ethanol blended gasoline, it is not neces-
sary to add a gasoline antifreeze since ethanol will pre-
vent the accumulation of moisture in the fuel system.
RECOMMENDED ENGINE/
TRANSMISSION OIL
The recommended oil to use is Arctic Cat 4-Cycle
Engine Oil (p/n 0436-005) or an equivalent oil which
is rated SE, SF, or SG under API service classification.
These oils meet all of the lubrication requirements of
the Arctic Cat ATV engine. The recommended engine
oil viscosity is SAE 10W-40. Ambient temperature
should determine the correct weight of oil. See the
following viscosity chart for details.
VISCOSITY CHART
OILCHART
! CAUTION
BRAKE PADS MUST BE BURNISHED TO
ACHIEVE FULL BRAKING EFFECTIVENESS.
Braking distance will be extended until brake
pads are properly burnished.
TO PROPERLY BURNISH THE BRAKES, USE
FOLLOWING PROCEDURE:
" Choose an area sufficiently large to safely
accelerate ATV to 30 mph and to brake to a stop.
" Accelerate to 30 mph; then compress brake
lever to decelerate to 0-5 mph.
" Repeat procedure five times until brakes are
burnished.
" This procedure burnishes the brake pads,
stabilizes the pad material, and extends the life
of the brake pads.
! WARNING
Do not attempt sudden stops or put the ATV into
a situation where a sudden stop will be required
until the brake pads are properly burnished.
! CAUTION
Do not use white gas. Only Arctic Cat approved
gasoline additives should be used.
! 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 recommended are racing,
vegetable, non-detergent, and castor-based oils.

1-10
RECOMMENDED FRONT
DIFFERENTIAL/REAR DRIVE
LUBRICANT
The recommended lubricant is Arctic Cat Gear Lube
(p/n 0436-007) 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 and rear drives.
FILLING GAS TANK
ATV0049B
Since gasoline expands as its temperature rises, the gas
tank must be filled to its rated capacity only. Expan-
sion room must be maintained in the tank particularly
if the tank is filled with cold gasoline and then moved
to a warm area.
Tighten the gas tank cap securely after filling the tank.
Genuine Parts
When replacement of parts is necessary, use only gen-
uine Arctic Cat ATV parts. They are precision-made to
ensure high quality and correct fit. Refer to the appro-
priate Illustrated Parts Manual for the correct part
number, quantity, and description.
! CAUTION
Any lubricant used in place of the recommended
lubricant could cause serious front differential/
rear drive damage.
! WARNING
Always fill the gas tank in a well-ventilated area.
Never add fuel to the ATV gas tank near any open
flames or with the engine running. DO NOT
SMOKE while filling the gas tank.
! WARNING
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.
For Arctic Cat Discount Parts Call 606-678-9623 or 606-561-4983
www.mymowerparts.com

1-11
1
Preparation
For Storage
Arctic Cat recommends the following procedure to
prepare the ATV for storage.
1. Clean the seat cushion (cover and base) with a
damp cloth and allow it to dry.
2. Clean the ATV thoroughly by washing dirt, oil,
grass, and other foreign matter from the entire
ATV. Allow the ATV to dry thoroughly. DO NOT
get water into any part of the engine or air intake.
3. Either drain the gas tank or add Fuel Stabilizer
(p/n 0638-165) to the gas in the gas tank. Remove
the air filter housing cover and air filter. Start the
engine and allow it to idle; then using Arctic Cat
Engine Storage Preserver (p/n 0636-177), rapidly
inject the preserver into the air filter opening for a
period of 10 to 20 seconds; then stop the engine.
Install the air filter and housing cover.
4. Drain the carburetor float chamber.
5. Plug the exhaust hole in the exhaust system with a
clean cloth.
6. Apply light oil to the upper steering post bushing
and plungers of the shock absorbers.
7. Tighten all nuts, bolts, cap screws, and screws.
Make sure rivets holding components together are
tight. Replace all loose rivets. Care must be taken
that all calibrated nuts, cap screws, and bolts are
tightened to specifications.
8. On liquid cooled models, fill the cooling system to
the bottom of the stand pipe in the radiator neck
with properly mixed coolant.
9. Disconnect the battery cables; then remove the
battery, clean the battery posts and cables, and
store in a clean, dry area.
10. Store the ATV indoors in a level position.
Preparation After
Storage
Taking the ATV out of storage and correctly preparing
it will assure many miles and hours of trouble-free
riding. Arctic Cat recommends the following proce-
dure to prepare the ATV.
1. Clean the ATV thoroughly.
2. Clean the engine. Remove the cloth from the
exhaust system.
3. Check all control wires and cables for signs of
wear or fraying. Replace if necessary.
4. Change the engine/transmission oil and filter.
5. On liquid cooled models, check the coolant level
and add properly mixed coolant as necessary.
6. Charge the battery; then install. Connect the
battery cables.
7. Check the entire brake systems (fluid level, pads,
etc.), all controls, headlights, taillight, brakelight,
and headlight aim; adjust or replace as necessary.
8. Tighten all nuts, bolts, cap screws, and screws
making sure all calibrated nuts, cap screws, and
bolts are tightened to specifications.
9. Check tire pressure. Inflate to recommended
pressure as necessary.
10. Make sure the steering moves freely and does not
bind.
11. Check the spark plug. Clean or replace as
necessary.
12. Inspect the air filter and air cleaner housing for
obstructions.
.
! CAUTION
Prior to storing the ATV, it must be properly
serviced to prevent rusting and component
deterioration.
! CAUTION
Avoid storing outside in direct sunlight and avoid
using a plastic cover as moisture will collect on
the ATV causing rusting.

1-12
NOTES

2-1
2
SECTION 2 -
PERIODIC MAINTENANCE/TUNE-UP
TABLE OF
CONTENTS
Periodic Maintenance Chart.................................... 2-2
Lubrication Points.................................................... 2-3
Battery..................................................................... 2-3
Fuses ...................................................................... 2-4
Air Cleaner (250/300).............................................. 2-4
Air Cleaner/Filter (400/500)..................................... 2-8
Valve/Tappet Clearance
(Feeler Gauge Procedure) ................................ 2-10
(Valve Adjuster Procedure) ............................... 2-11
Testing Engine Compression ................................ 2-12
Spark Plug............................................................. 2-12
Muffler/Spark Arrester........................................... 2-13
Gas/Vent Hoses .................................................... 2-14
Adjusting Throttle Cable........................................ 2-14
Adjusting Engine RPM (Idle) ................................. 2-14
Engine/Transmission Oil - Filter - Strainer
(250/300)........................................................... 2-15
Engine/Transmission Oil - Filter - Strainer
(400/500)........................................................... 2-17
Front Differential/Rear Drive Lubricant.................. 2-19
Adjusting Clutch (250/300).................................... 2-20
Adjusting Clutch
(400/500 Manual Transmission) ......................... 2-21
Tires ...................................................................... 2-21
Steering Components ........................................... 2-21
Driveshaft/Coupling............................................... 2-22
Suspension/Shock Absorbers/Bushings ............... 2-22
Nuts/Bolts/Cap Screws.......................................... 2-22
Ignition Timing....................................................... 2-22
Headlight/Taillight-Brakelight................................. 2-22
Switches................................................................ 2-23
Reverse Shift Lever ............................................... 2-23
Indicator Lights...................................................... 2-25
Frame/Welds/Racks .............................................. 2-26
Electrical Connections........................................... 2-26
Hydraulic Hand Brake System .............................. 2-26
Auxiliary Brake. ..................................................... 2-28
Burnishing Brake Pads.......................................... 2-29
Coolant (500) ........................................................ 2-30
Checking/Replacing V-Belt
(Automatic Transmission) ................................... 2-30
Back to Table of Contents

2-2
Periodic Maintenance
Chart
* Service/Inspect more frequently when operating in adverse conditions.
Item
Initial Service
After Break-In
(First Mo or
200 Mi)
Every
Day
Every Month
or
Every 100
Miles
Every 3
Months or
Every 300
Miles
Every 6
Months or
Every 500
Miles
Every Year or
Every 1500
Miles
As Needed
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 I R (4000 Mi or
18 Mo)
Muffler/Spark Arrester C R
Gas/Vent Hoses I C
Gas Tank Valve I C
Throttle Cable I I C-L A-R
Carb Float Chamber D*
Engine RPM (Idle) I I A
Engine-Transmission Oil
Level
I A
Engine-Transmission
Oil/Filter
R I R* R
Oil Strainer I I C
Front Differential/Rear Drive
Lubricant
I I l l R
Clutch I l A
Tires I R
Steering Components I I I R
V-Belt I l R
Suspension (Ball joint boots,
drive axle boots front and
rear, tie rods, differential
and rear drive bellows)
l* R
Nuts/Cap Screws/Screws I I I A
Ignition Timing I
Headlight/Taillight-
Brakelight
I I R
Switches I R
Reverse Shift Lever I A-L
Choke Cable I C-L R
Recoil Starter I C-R
Handlebar Grips I R
Handlebars I R
Gauges/Indicators I R
Frame/Welds/Racks I l
Electrical Connections l C
Complete Brake System
(Hydraulic & Auxiliary)
I I C L-R
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)
A = Adjust I = Inspect
C = Clean L = Lubricate
D = Drain R = Replace

2-3
2
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
B. Brake Lever Pivot/Cable Ends
C. Auxiliary Brake Cable Ends
D. Choke Cable Upper End
E. Reverse Lever Cable End
F. Idle RPM Screw (Carburetor)
Battery
AF879D
The level of the battery fluid must be kept between the
upper and lower level lines at all times. If the level
drops below the lower level line, add only distilled
water until it reaches upper level line.
If the battery is discharged, remove the battery from
the ATV and charge the battery at the standard charg-
ing rate of 1.4A x 10 hr.
ChargTim
Charge
To remove and charge the battery, use the following
procedure.
1. Remove the battery hold-down bracket.
2. Remove the negative battery cable; then remove
the positive cable and the battery vent tube.
Remove the battery from the ATV. Care should be
taken not to damage the vent tube.
! WARNING
Battery acid is harmful if it contacts eyes, skin, or
clothing. Care must be taken whenever handling a
battery.
! WARNING
Anytime service is performed on a battery, the fol-
lowing must be observed: keep sparks, open flame,
cigarettes, or any other flame away. Always wear
safety glasses. Protect skin and clothing when han-
dling a battery. When servicing battery in enclosed
space, keep the area well-ventilated. Make sure bat-
tery venting is not obstructed.
! WARNING
Avoid spillage and contact with skin, eyes, and
clothing.
! CAUTION
Do not charge the battery while it is in the ATV
with the battery terminals connected.

2-4
3. Remove the vent plugs; then (if necessary) fill the
battery with distilled water to the upper level
indicated on the battery.
4. Trickle charge the battery at 1.4 amps for 10
hours.
5. After charging, check fluid level and fill with dis-
tilled water as necessary; then install vent plugs.
6. Place the battery into position in the ATV and
secure with the hold-down bracket.
7. Attach the vent tube and check the vent tube to
make sure it is not crimped or obstructed in any
way and that it is properly routed through and
secured to the frame.
8. Connect cables to the proper terminals: positive
cable to the positive terminal (+) and negative
cable to the negative terminal (-). Connect the neg-
ative cable last.
AF733D
FUSES
The main (30 Amp) fuse is located in a fuse block on
the frame near the right rear tire and protected by a
snap-on cover.
!NOTE: To remove the fuse, compress the locking
tabs on either side of the fuse case and lift out.
The remaining fuses are located in a fuse block under
the center cover in the front fender assembly (on the
250/300) or under the seat (on the 400/500).
If there is any type of electrical system failure, always
check the fuses first.
Air Cleaner
(250/300)
The air filter inside the air cleaner must be kept clean
to provide good engine power and gas mileage. If the
ATV is used under normal conditions, service the filter
at the intervals specified. If operated in dusty, wet, or
muddy conditions, inspect and service the filter more
frequently.
CLEANING AND INSPECTING FILTER
1. Remove the seat.
2. Remove the two machine screws securing the air
cleaner housing cover.
! CAUTION
Never exceed the standard charging rate.
! CAUTION
Before installing the battery, make sure the
ignition switch is in the OFF position.
! CAUTION
Connecting cables in reverse (positive to
negative and negative to positive) can cause
serious damage to the electrical system.
250/300 400/500
10 A
IGN
10 A
LIGHTS
15 A
LIGHTS
10 A
HIGH
10 A
ACC
10 A
LO
10 A
SPARE
10 A
IGN
15 A
FAN
15 A
ACC
! CAUTION
Always replace a blown fuse with a fuse of the
same type and rating.
! CAUTION
Failure to inspect the air filter frequently if the
ATV is used in dusty, wet, or muddy conditions
can damage the ATV engine.

2-5
2
CH044D
3. Pull the retainer out and remove the filter with
foam wrap.
CH045D
4. Remove the foam wrap from the filter.
AL642D
5. Wash the polyester filter and the foam wrap with
warm soapy water and rinse.
6. Allow the foam wrap to air dry thoroughly.
!NOTE: Either allow the polyester filter to air dry
or blow dry using low-pressure compressed air.
Direct the compressed air through the filter from
the opposite direction as normal operation air
flow.
7. Place the foam wrap around the air filter; then
install the filter with wrap into the air cleaner mak-
ing sure it is properly in position and properly
seated and secure with the retainer.
CH046D
CH045D
8. Install the air cleaner housing cover and secure
with the machine screws; then install the seat mak-
ing sure the seat is properly secured.
CH044D
9. Check the drain tube for gasoline or oil accumula-
tion. If noticed, remove the drain tube cap from
beneath the cleaner, drain the gasoline or oil into a
suitable container, and install and secure the tube
cap.
10. Inspect one-way drain beneath the air cleaner for
debris and sealing.! CAUTION
Do not put oil on either the filter or the foam
wrap.

2-6
733-715B
REMOVING AIR CLEANER
1. Remove the seat; then remove the air-intake snor-
kel.
CH040D
CH041D
2. Remove the two machine screws securing the air
cleaner housing cover.
CH044D
3. Pull the retainer out and remove the filter with
foam wrap.
CH045D
4. Remove the machine screws securing the air
cleaner to the frame.
CH047D
CH048D
One-Way

2-7
2
5. Loosen the clamp securing the air cleaner to the
carburetor boot.
CH049D
6. Remove the crankcase breather hose from the air
cleaner.
CH050D
7. Remove the air cleaner from the frame.
INSTALLING AIR CLEANER
CH050D
2. Secure the carburetor boot to the air cleaner.
CH049D
3. Install the machine screws securing the air cleaner
to the frame.
CH048D
CH047D
KEY
1. Air Cleaner Assy
2. Retainer Slider
3. Filter
4. Cap
5. Cap Screw
6. Joint
7. Clamp
8. Clip
9. Drain Plug
10. Valve
11. Clamp
12. Breather Hose
13. Clamp
14. Boot
15. Clamp
16. Snorkel
17. Clip
18. Strap
19. Plug
20. Tool Kit
21. Cap Screw
22. Spring
23. Plug
24. Check Valve
25. Clip
26. Clamp
27. Lock Washer
1. Place the air cleaner into the frame; then connect
the crankcase breather hose.
0736-899

2-8
4. Install the filter with foam wrap into the air
cleaner; then secure with the retainer.
CH045D
5. Install the air cleaner housing cover and secure
with the machine screws.
CH044D
6. Install the air-intake snorkel.
CH041D
CH040D
7. Install the seat making sure it is properly secured.
Air Cleaner/Filter
(400/500)
The air filter inside the air filter housing must be kept
clean to provide good engine power and gas mileage.
If the ATV is used under normal conditions, service
the filter at the intervals specified. If operated in dusty,
wet, or muddy conditions, inspect and service the filter
more frequently. Use the following procedure to
remove the filter and inspect and/or clean it.
CLEANING AND INSPECTING FILTER
1. Remove the seat.
2. Remove the air filter housing cover from the
retaining clips.
733-444A
3. Loosen the clamp; then remove the filter.
! CAUTION
Failure to inspect the air filter frequently if the
vehicle is used in dusty, wet, or muddy
conditions can damage the engine.

2-9
2
AF640DA
CH046D
4. Fill a wash pan larger than the filter with a
non-flammable cleaning solvent; then dip the filter
in the solvent and wash it.
!NOTE: Foam Filter Cleaner (p/n 0436-194) and
Foam Filter Oil (p/n 0436-195) are available from
Arctic Cat.
5. Dry the filter.
6. Put the filter in a plastic bag; then pour in air filter
oil and work the filter.
7. Clean any dirt or debris from inside the air cleaner.
Be sure no dirt enters the carburetor.
8. Place the filter in the air filter housing making sure
it is properly in position and properly seated and
secure with the clamp.
9. Install the air filter housing cover and secure with
the retaining clips; then install the seat making
sure the seat is properly secured.
CHECKING/DRAINING DRAIN TUBE
1. Periodically check the drain tube for gasoline or
oil accumulation. If noticed, remove the drain tube
cap from beneath the front housing, drain the gas-
oline or oil into a suitable container, and install
and secure the tube cap.
2. Inspect one-way drain beneath the main housing
for debris and for proper sealing.
ATV-0087
REMOVING AIR CLEANER
1. Remove the seat.
2. Remove the air cleaner cover from the retaining
clips.
AL645D
3. Loosen the clamp and remove the filter.
AF640DA
! 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.
One-Way

2-10
4. Loosen the clamp securing the air cleaner to the
front boot; then loosen the clamp securing the air
cleaner to the rear filter sleeve.
5. Remove the machine screws securing the air
cleaner to the flange support and frame.
6. Remove the air cleaner from the frame.
INSTALLING
0736-950
1. Place the air cleaner into the frame.
2. Install the machine screws securing the air cleaner
to the flange support and frame.
3. Install the rear filter sleeve onto the air cleaner;
then tighten the clamp securely.
4. Install the front boot onto the air cleaner; then
tighten the clamp securely.
5. Install the filter with foam wrap into the air
cleaner; then tighten the clamp securely.
AF640DA
6. Place the air cleaner cover into position and secure
with the retaining clips.
AL645D
7. Install the seat making sure the seat is properly
secured.
Valve/Tappet
Clearance
(Feeler Gauge Procedure)
To check and adjust valve/tappet clearance, use the
following procedure.
!NOTE: On the 250/300, the seat and air-intake
snorkel must be removed for this procedure.
!NOTE: On the 400/500, the seat assembly, side
panels, and gas tank must be removed for this pro-
cedure.
1. Remove the timing inspection plug; then remove
the tappet covers (for more detailed information,
see Section 3 - Servicing Top-Side Components).
2. Rotate the crankshaft to the TDC position on the
compression stroke.
!NOTE: At this point, the rocker arms and
adjuster screws must not have pressure on them.
3. Using a feeler gauge, check each valve/tappet
clearance. If clearance is not within specifications,
loosen the jam nut and rotate the tappet adjuster
screw until the clearance is within specifications.
Tighten each jam nut securely after completing the
adjustment.
KEY
1. Clamp
2. Boot
3. Clamp
4. Housing
5. Clip
6. Gasket
7. Snorkel
8. Clamp
9. Spring
10. Machine Screw
11. Expansion Nut
12. Vent Hose
13. Filter
14. Heat Shield
15. Valve
16. Drain Cap
17. Clamp
18. Clamp
19. Support
! CAUTION
The feeler gauge must be positioned at the same
angle as the valve and valve adjuster for an
accurate measurement of clearance. Failure to
measure the valve clearance accurately could
cause valve component damage.

2-11
2
CC409DA
CC007DA
4. Install the timing inspection plug.
5. Place the two tappet covers into position making
sure the proper cap screws are with the proper
cover. Tighten the cap screws securely.
(Valve Adjuster Procedure)
To check and adjust valve/tappet clearance, use the
!NOTE: On the 250/300, the seat and air-intake
snorkel must be removed for this procedure.
!NOTE: On the 400/500, the seat assembly, side
panels, and gas tank must be removed for this pro-
cedure.
1. Remove the timing inspection plug; then remove
the tappet covers (for more detailed information,
see Section 3 - Servicing Top-Side Components).
2. Rotate the crankshaft to the TDC position on the
compression stroke.
!NOTE: At this point, the rocker arms and
adjuster screws must not have pressure on them.
!NOTE: Use Valve Gap Adjuster (p/n 0444-092) for
the 250/300 or Valve Clearance Adjuster (p/n
0444-078) for the 400/500 for this procedure.
3. Place the valve adjuster onto the jam nut securing
the tappet adjuster screw; then rotate the valve
adjuster dial clockwise until the end is seated in
the tappet adjuster screw.
4. While holding the valve adjuster dial in place, use
the valve adjuster handle and loosen the jam nut;
then rotate the tappet adjuster screw clockwise
until friction is felt.
5. Align the valve adjuster handle with one of the
marks on the valve adjuster dial.
6. While holding the valve adjuster handle in place,
rotate the valve adjuster dial counterclockwise
until proper valve/tappet clearance is attained.
!NOTE: Refer to the appropriate specifications in
Feeler Gauge Procedure sub-section for the
proper valve/tappet clearance.
!NOTE: Rotating the valve adjuster dial counter-
clockwise will open the valve/tappet clearance by
0.05 mm (0.002 in.) per mark.
7. While holding the adjuster dial at the proper clear-
ance setting, tighten the jam nut securely with the
valve adjuster handle.
8. Place the two tappet covers with O-rings into posi-
tion; then tighten the covers securely.
VALVE/TAPPET CLEARANCE (250)
Intake 0.03-0.08 mm (0.001-0.003 in.)
Exhaust 0.08-0.13 mm (0.003-0.005 in.)
VALVE/TAPPET CLEARANCE (300)
Intake 0.03-0.08 mm (0.001-0.003 in.)
Exhaust 0.17-0.22 mm (0.007-0.009 in.)
VALVE/TAPPET CLEARANCE (400/500)
Intake 0.05-0.10 mm (0.002-0.004 in.)
Exhaust (400) 0.22-0.27 mm (0.009-0.011 in.)
Exhaust (500) 0.17-0.22 (0.007-0.009 in.)
400/500

2-12
CC366D
9. Install the spark plug; then install the timing
inspection plug.
CC411D
Testing Engine
Compression
To test engine compression, use the following proce-
dure.
1. Remove the high tension lead from the spark plug.
2. Using compressed air, blow any debris from
around the spark plug.
3. Remove the spark plug; then attach the high ten-
sion lead to the plug and ground the plug on the
cylinder head well away from the spark plug hole.
4. Attach the Compression Gauge (p/n 0444-096).
!NOTE: The engine must be warm and the battery
must be fully charged for this test.
5. While holding the throttle lever in the full-open
position, crank the engine over with the electric
starter until the gauge shows a peak reading (five
to 10 compression strokes).
!NOTE: For the 250/300, the compression should
be within a range of 157.5-192.5 psi in the full-open
throttle position. For the 400/500, the compression
should be within a range of 63-77 psi in the
full-open throttle position.
6. If compression is abnormally low, inspect the
following items.
A. Verify starter cranks engine over.
B. Gauge is functioning properly.
C. Throttle lever in the full-open position.
D. Valve/tappet clearance correct.
E. Valve bent or burned.
F. Valve seat burned.
!NOTE: To service valves, see Section 3.
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).
Spark Plug
A light brown insulator indicates that the plug is cor-
rect. A white or dark insulator indicates that the engine
may need to be serviced or the carburetor may need to
be adjusted. To maintain a hot, strong spark, keep the
plug free of carbon.
! WARNING
Always wear safety glasses when using com-
pressed air.

2-13
2
ATV-0051
Adjust the gap to 0.6 - 0.7 mm (0.024 - 0.028 in.) on
the 250/300 or to 0.7 - 0.8 mm (0.028 - 0.032 in.) on
the 400/500 for proper ignition. Use a feeler gauge to
check the gap.
ATV0052B
When installing the spark plug, be sure to tighten it
securely. A new spark plug should be tightened 1/2
turn once the washer contacts the cylinder head. A
used spark plug should be tightened 1/8 - 1/4 turn once
the washer contacts the cylinder head.
Muffler/Spark Arrester
The muffler has a spark arrester which must be period-
ically cleaned. At the intervals shown in the Periodic
Maintenance Chart, clean the spark arrester using the
!NOTE: Determine which style muffler/spark
arrester is being serviced and refer to the appro-
priate procedure.
STYLE A
1. Shift the transmission into neutral and set the
brake lever lock.
2. Elevate the front of the ATV on a safety stand
until the muffler is horizontal.
3. Remove the plug from the bottom of the muffler.
AN600A
4. Start the engine and increase RPM to “blow out”
the accumulated carbon particles.
5. Stop the engine. Wait until the muffler cools; then
install the plug and tighten securely.
STYLE B
1. Remove the nuts securing the spark arrester; then
remove the arrester.
AN616A
2. Using a wire brush, remove carbon deposits from
the arrester taking care not to damage the screen.
AN617
! CAUTION
Before removing the spark plug, be sure to clean
the area around the spark plug. Dirt could enter
engine when removing or installing the spark
plug.
! WARNING
Wait until the muffler cools to avoid burns.
Style B

2-14
3. Check the arrester screen for holes or tears, and
check the condition of the gasket. Replace compo-
nents as necessary.
4. Install the spark arrester and nuts; tighten nuts to
1.1 kg-m (8 ft-lb).
Gas/Vent Hoses
Replace the gas hose every two years. Damage from
aging may not always be visible. Do not bend or
obstruct the routing of the carburetor vent hose. Make
certain that the vent hose is securely connected to the
carburetor and the opposite end is always open.
Adjusting Throttle
Cable
To adjust the throttle cable free-play, follow this pro-
cedure.
1. Slide the rubber boot away; then loosen the jam
nut from the throttle cable adjuster.
AL611D
2. Slide the rubber boot away and turn the adjuster
until the throttle cable has proper free-play of 3-6
mm (1/8 - 1/4 in.) at the lever.
ATV-0047
3. Tighten the jam nut against the throttle cable
adjuster securely; then slide the rubber boot over
the adjuster.
Adjusting Engine RPM
(Idle)
To properly adjust the idle RPM, a tachometer is nec-
essary. To adjust idle RPM, use the following proce-
dure.
!NOTE: To access the idle adjustment screw, it
will be necessary to remove the seat on the
250/300 models. The idle adjustment screw is
located on the right-hand side of the carburetor on
the 400/500 models.
1. With the transmission in neutral, start the engine
and warm it up to normal operating temperature.
2. Turn the idle adjustment screw clockwise one turn
past the recommended RPM setting; then turn it
counterclockwise to the correct RPM setting.
CC795B

2-15
2
AF920C
Engine/Transmission
Oil - Filter - Strainer
(250/300)
OIL - FILTER
Change the engine oil and oil filter at the scheduled
intervals. The engine should always be warm when the
oil is changed so the oil will drain easily and com-
pletely.
1. Park the ATV on level ground.
2. Remove the oil filler plug.
733-714A
3. Remove both drain plugs from the bottom of the
engine and drain the oil into a drain pan.
733-441C
4. Remove the nuts securing the filter cover.
5. Remove the filter cover; then pull out the oil filter
element and properly discard. Remove and prop-
erly discard the O-ring from the filter cover.
CH080DA
!NOTE: Clean up any excess oil after removing
the filter.
6. Apply oil to a new cover O-ring and check to
make sure it is positioned correctly in the cover.
With the open end of the filter element directed
toward the center of the engine, slide the element
into position.
IDLE RPM
MODEL RPM
250/300 1300-1400
400/500 1250-1350
! WARNING
Adjust the idle to the correct RPM. Make sure the
engine is at normal operating temperature before
adjusting the idle RPM.
Adjustment Screw
(400/500)

2-16
0733-752
7. Place the filter cover in position and secure with
the nuts. Tighten securely.
8. Install the engine drain plugs and tighten to 2.2
kg-m (16 ft-lb). Pour 3.4 L (3.5 U.S. qt) of the rec-
ommended oil in the filler hole; then install the
filler plug.
9. Start the engine (while the ATV is outside on level
ground) and allow it to idle for a few minutes.
10. Turn the engine off and wait approximately one
minute. Recheck the oil level in the engine oil
inspection window. The oil level should be visible
through the window. If oil is not visible, add rec-
ommended oil until the oil level is visible between
the lines of the window.
ATV-0074
11. Inspect the area around the drain plug and oil filter
for leaks.
STRAINER
To check the oil strainer, use the following procedure.
1. Remove the skid plate.
2. Remove the Phillips-head cap screws securing the
oil strainer cap; then remove the cap. Note the
directional arrow on the cap for assembly pur-
poses.
CC442DA
3. Remove the Phillips-head screws securing the
strainer; then remove the strainer.
CC443D
!NOTE: To service the oil strainer, see Section 3.
4. Place the oil strainer into position and secure with
the Phillips-head screws.
! CAUTION
If the oil filter element is inserted backwards,
engine damage will occur due to lack of oil flow.
! CAUTION
KEY
1. Engine Oil Pump
2. Driven Gear
3. Pin
4. Circlip
5. Cap Screw
6. Strainer
7. Cap Screw
8. Cap
9. O-Ring
10. Cap Screw
11. Drain Plug
12. Gasket
13. Filter
14. Filter O-Ring
15. Cap
16. Check Plug
17. Gasket
18. Cap O-Ring
19. Spring
20. Stud Bolt
21. Stud Bolt
22. Nut

2-17
2
CC443D
5. Place the strainer cap into position on the crank-
case; then secure with the Phillips-head cap screws
(coated with red Loctite #271). Tighten securely.
CC442DA
6. Install the skid plate.
Engine/Transmission
Oil - Filter - Strainer
(400/500)
OIL - FILTER
Change the engine oil and oil filter at the scheduled
intervals. The engine should always be warm when the
oil is changed so the oil will drain easily and com-
pletely.
1. Park the ATV on level ground.
2. Remove the oil level stick/filler plug.
3. Remove the drain plug from the bottom of the
engine and drain the oil into a drain pan.
733-441A
4. Remove the oil filter plug from the filter mounting
boss (located on the front-right side of the trans-
mission case) and allow the filter to drain com-
pletely.
5. Using the Oil Filter Wrench (p/n 0444-042) and a
ratchet handle (or a socket or box-end wrench),
remove the old oil filter.
!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.
Manual
Transmission
Level Stick/
Filler Plug
Automatic Transmission
Level Stick/Filler Plug
ATV-0075
0735-505

2-18
7. Install the oil filter drain plug and tighten securely.
8. Install the engine drain plug and tighten to 2.2
kg-m (16 ft-lb). Pour 3.08 L (3.25 U.S. qt) - 400,
3.4 L (3.5 U.S. qt) - 500 manual, or 2.5 L (2.6 U.S.
qt) - 500 automatic of the recommended oil in the
filler hole. Install the oil level stick/filler plug.
9. Start the engine (while the ATV is outside on level
ground) and allow it to idle for a few minutes.
10. Turn the engine off and wait approximately one
minute.
11. Unscrew the oil level stick and wipe it with a clean
cloth.
12. Install the oil level stick until the threads touch
engine case.
!NOTE: The oil level stick should not be threaded
into the case for checking the oil level.
13. Remove the oil level stick; the engine oil level
should be above the illustrated “L” mark but not
higher than the illustrated “F” mark.
ATV-0100
14. Inspect the area around the drain plug and oil filter
for leaks.
STRAINER
To check the oil strainer, use the following procedure.
1. Remove the skid plate.
2. Remove the cap screws securing the oil strainer
cap; then remove the cap. Account for the O-ring.
CC091D
3. Remove the two Phillips-head cap screws securing
the strainer.
CC163D
!NOTE: To service oil strainer, see Section 3.
4. Place the oil strainer into position beneath the
crankcase and secure with the Phillips-head cap
screws. Tighten securely.
CC163D
5. Place the strainer cap into position on the strainer
making sure the O-ring is properly installed; then
secure with the cap screws. Tighten securely.
! CAUTION
!CAUTION
Do not over-fill the engine with oil. Always make
sure that the oil level is above the “L” mark but
not higher than the “F” mark.

2-19
2
CC091D
6. Install the skid plate.
Front Differential/Rear
Drive Lubricant
Check and change the lubricant according to the Peri-
odic Maintenance Chart. When changing the lubricant,
use approved SAE 80W-90 hypoid gear lube. To
check lubricant, use the following procedure.
1. On FIS models, remove the rear drive filler plug;
the lubricant level should be 1 in. below the
threads of the plug. If low, add SAE approved
80W-90 hypoid gear lube as necessary.
2. On ACT models, remove the rear drive inspection
plug; the lubricant level should be at the threads of
the plug. If low, add SAE approved 80W-90
hypoid gear lube as necessary.
AF923A
To change the lubricant, use the following procedure.
1. Place the ATV on level ground.
2. Remove each oil filler plug.
0736-568
ATV-0077
737-686A
3. Drain the oil into a drain pan by removing in turn
the drain plug from each.
ATV0082A
ACT
375/400/500
400 ACT Models
400/500

2-20
ATV-1096
737-651A
4. After all the oil has been drained, install the drain
plugs and tighten to 0.5 kg-m (3.5 ft-lb).
5. Pour the appropriate amount of recommended oil
into the filler hole.
6. Install the filler plugs.
!NOTE: If the differential/rear drive oil is contami-
nated with water, inspect the drain plug, filler plug,
and/or bladder.
Adjusting Clutch
(250/300)
To adjust the clutch, use the following procedure.
1. Using an impact driver, remove the cover.
Account for the O-ring.
CH081D
2. Loosen the jam nut securing the adjustment screw.
CH086D
3. Rotate the adjustment screw clockwise until it
stops.
4. Rotate the adjustment screw counterclockwise 1/8
turn; then lock the jam nut securing the adjustment
screw.
!NOTE: At this point the clutch should be
adjusted correctly. Test ride the ATV to ensure
accurate adjustment.
5. Secure the cover making sure the O-ring is prop-
erly positioned.
CH081D
! CAUTION
Water entering the outer end of the axle will not
be able to enter the rear drive unless the seals
are damaged.
400 ACT
400/500

2-21
2
Adjusting Clutch
(400/500 Manual Transmission)
To adjust the clutch, use the following procedure.
1. Using an impact driver, remove the screws secur-
ing the cover and remove the cover. Account for
the O-ring.
AM600D
2. Loosen the jam nuts securing adjustment screw #1
(forward) and adjustment screw #2 (rearward).
CC037D
3. Rotate adjustment screw #1 counterclockwise
until it stops.
CC038D
4. Rotate adjustment screw #2 alternately clockwise
and counterclockwise to ensure free movement
without binding; then lock the jam nut securing
adjustment screw #2.
5. Rotate adjustment screw #1 clockwise 1/8 turn;
then lock the jam nut securing adjustment screw
#1.
!NOTE: At this point the clutch should be
adjusted correctly. Test to ensure accurate adjust-
ment.
6. Install the cover making sure the O-ring is prop-
erly positioned; then secure with the screws.
Tires
TIRE SIZES
The ATV is equipped with low-pressure tubeless tires
of the size and type listed. Do not under any circum-
stances substitute tires of a different type or size.
TIRE INFLATION PRESSURE
Front and rear tire inflation pressure should be 0.35
kg-cm² (5.0 psi).
A low-pressure gauge is provided in the tool kit to
measure the air pressure in the tires. Check the air
pressure in all tires before each use of the ATV.
Steering Components
The following steering components should be
inspected periodically to ensure safe and proper opera-
tion.
A. Handlebar grips not worn, broken, or loose.
B. Handlebar not bent, cracked, and has equal and
complete full-left and full-right capability.
C. Steering post bearing assembly/bearing hous-
ing not broken, worn, or binding.
D. Ball joints not worn, cracked, or damaged.
E. Tie rods not bent or cracked.
F. Knuckles not worn, cracked, or damaged.
G. Cotter pins not damaged or missing.
! WARNING
Always use the size and type of tires specified.
Always maintain proper tire inflation pressure.

2-22
Driveshaft/Coupling
The following drive system components should be
inspected periodically to ensure proper operation.
A. Spline lateral movement (slop).
B. Rubber coupling cracked, damaged, or worn.
Suspension/Shock
Absorbers/Bushings
The following suspension system components should
be inspected periodically to ensure proper operation.
A. Shock absorber rods bent, pitted, or damaged.
B. Rubber damper cracked, broken, or missing.
C. Shock absorber body damaged, punctured, or
leaking.
D. Shock absorber eyelets broken, bent, or
cracked.
E. Shock absorber eyelet bushings worn, deter-
iorated, cracked, or missing.
F. Shock absorber spring broken or sagging.
Nuts/Bolts/Cap Screws
Tighten all nuts, bolts, and cap screws. Make sure riv-
ets holding components together are tight. Replace all
loose rivets. Care must be taken that all calibrated
nuts, bolts, and cap screws are tightened to specifica-
tions. For proper torque values, see Section 10.
Ignition Timing
The ignition timing cannot be adjusted; however, veri-
fying ignition timing can aid in troubleshooting other
components. To verify engine timing, use the follow-
ing procedure.
1. Attach the engine Timing Light (p/n 0644-197) to
the spark plug high tension lead; then remove the
timing inspection plug from the left-side crankcase
cover.
2. Using the Arctic Cat Engine Tachometer (p/n
0644-275), start the engine and run at the recom-
mended RPM; ignition timing should be the rec-
ommended degrees BTDC.
3. Install the timing inspection plug.
If ignition timing cannot be verified, the rotor may be
damaged, the key may be sheared, the trigger coil
bracket may be bent or damaged, or the CDI unit may
be faulty.
Headlight/Taillight-
Brakelight
Each time the ATV is used, lights should be checked
for proper function. Rotate the ignition switch to the
lights position; the headlights and taillight should illu-
minate. Test the brakelight by compressing the brake
lever. The brakelight should illuminate.
HEADLIGHT
!NOTE: The bulb portion of the headlight is frag-
ile. HANDLE WITH CARE. When replacing the
headlight bulb, do not touch the glass portion of
the bulb. If the glass is touched, it must be cleaned
with a dry cloth before installing. Skin oil residue
on the bulb will shorten the life of the bulb.
To replace the headlight bulb, use the following proce-
dure.
1. Remove the wiring harness connector from the
back of the headlight.
2. Grasp the bulb housing, turn it counterclockwise,
and remove the bulb.
3. Install the new bulb into the housing and rotate it
completely clockwise.
4. Install the wiring harness connector.
IGNITION TIMING
MODEL TIMING/RPM
250
5° BTDC below 1800
35° BTDC above 3800
300
5° BTDC @ 1800
30° BTDC @ 3800
400 10° BTDC @ 3000
500 10° BTDC @ 1500
! WARNING
Do not attempt to remove the bulb when it is hot.
Severe burns may result.

2-23
2
TAILLIGHT-BRAKELIGHT
To replace the taillight-brakelight bulb, use the follow-
ing procedure.
1. Remove the two screws and remove the lens
cover.
2. Push the bulb in and turn it counterclockwise.
3. Install the new bulb by turning it clockwise while
pushing in.
4. Install the lens cover.
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
surface (wall or similar aiming surface).
!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.
3. Using the measurements obtained in step 2, make
horizontal marks on the aiming surface.
4. Make vertical marks which intersect the horizontal
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 ver-
tical mark 5 cm (2 in.) below the horizontal mark
on the aiming surface.
ATV-0070BA
AF926A
7. Adjust each headlight until correct aim is
obtained.
A. Horizontal — Loosen nut (A) and adjust for
proper aiming. Tighten the nut securely.
B. Vertical— Loosen nut (B) and adjust for proper
aiming. Tighten the nut securely.
Switches
Each time the ATV is used, switches should be
checked for proper operation. Use the following list
for reference.
A. Ignition switch — engine will start.
B. Emergency stop switch — engine will stop.
C. Reverse switch — reverse indicator light
illuminates.
D. Hi/Lo switch — headlight beam bright and
dim.
E. Brake switches — rear brakelight illuminates.
Reverse Shift Lever
CHECKING ADJUSTMENT
0736-566
! CAUTION
Tighten the lens cover screws only until they are
snug.
Manual Transmission

2-24
0736-565
Stop the ATV completely and shift the transmission
into the R position. The reverse gear indicator light
should be illuminated.
If the reverse lever light does not illuminate when
shifted to the reverse position, the switch may be
faulty, the fuse may be blown, the bulb may be faulty,
a connection may be loose or corroded, or the lever
may need adjusting. To adjust, proceed to Adjusting
Shift Lever.
ADJUSTING SHIFT LEVER
0737-593
! WARNING
Never shift the ATV into reverse gear when the ATV
is moving as it could cause the ATV to stop sud-
denly throwing the operator from the ATV.
KEY
1. Nut
2. Cap Screw
3. Axle
4. Shift Lever
5. O-Ring
6. O-Ring
7. Washer
8. Spring
9. Axle
10. Handle
11. Push Clip
12. Linkage
13. Rod End
14. Nut
15. Bushing
16. Washer
17. E-Ring
18. Reverse Switch
19. Retainer
20. Bracket
21. Cap Screw
22. Shift Plate
23. Shield
24. Machine Screw
25. Self-Tapping Screw
Manual Transmission

2-25
2
1. Place the shift lever in the R position.
2. Remove the seat.
3. Remove the gas tank (see Section 4).
4. Loosen shift rod end jam nut (A).
AF941A
5. Using two open-end wrenches, remove lock nut
(B) securing the shift rod to the upper shift axle.
Discard the lock nut.
!NOTE: Never reuse a lock nut. Once a lock nut
has been removed, it must be replaced with a new
lock nut.
6. Push the upper shift axle down completely.
AF942
7. Rotate the shift rod end as necessary to align its
threaded shaft with the hole in the upper shift axle.
Secure with a new lock nut (B). Tighten securely.
8. Tighten jam nut (A) to secure the adjustment.
9. Install the gas tank (see Section 4); then install the
seat.
Indicator Lights
Each time the ATV is used, the lights should be
checked for proper function. Use the following for ref-
erence.
!NOTE: The number and functions of the indica-
tor lights will vary from model to model.
KEY
1. Nut
2. Cap Screw
3. Axle
4. Lever
5. O-Ring
6. O-Ring
7. Washer
8. Spring
9. Axle
10. Handle
11. Push Clip
12. Linkage
13. Rod End
14. Nut
15. Bushing
16. Washer
17. E-Ring
18. Plate
19. Shield
20. Machine Screw
21. Self-Tapping Screw
0737-699

2-26
733-707B
1. High Beam Indicator — A blue light will illumi-
nate when the lights are on high beam. The light
will not be illuminated when the lights are
switched to low beam.
2. Temperature Indicator — A red light will illu-
minate if the engine overheats. The light should be
off during normal operation.
!NOTE: High engine RPM, low vehicle speed, or
heavy load can raise engine temperature. Decreas-
ing engine RPM, reducing load, and selecting an
appropriate transmission gear can lower the tem-
perature.
!NOTE: Debris in front of the engine (or packed
between the cooling fins of the radiator on the 500
or packed between the oil cooler cooling fins on
the 250/300/400) can reduce cooling capability.
Using a hose, pressure-wash the radiator (on the
500) or engine and oil cooler (on the 250/300/400)
to remove any debris preventing air flow.
3. Neutral Indicator — A green light will illuminate
when the transmission is in neutral and the ignition
switch is on. The light will go out when shifted
into any gear other than neutral.
4. Reverse Indicator — An orange light will illumi-
nate when the transmission is shifted into reverse
gear. The light will go off when shifted out of
reverse.
Frame/Welds/Racks
The frame, welds, and racks should be checked period-
ically for damage, bends, cracks, deterioration, broken
components, and missing components. If replacement
or repair constitutes removal, see Section 8.
Electrical Connections
The electrical connections should be checked periodi-
cally for proper function. In case of an electrical fail-
ure, check fuses, connections (for tightness, corrosion,
damage), and/or bulbs. If an electrical component
needs to be tested for proper function, see Section 5.
Hydraulic Hand
Brake System
CHECKING/BLEEDING
The hydraulic brake system has been filled and bled at
the factory. To check and/or bleed the hydraulic brake
system, use the following procedure.
1. With the master cylinder in a level position, check
the fluid level. It must be above the lower mark
and below the upper mark.
733-443C
2. Compress the brake lever several times to check
for a firm lever. If the lever is not firm, the brake
system must be bled.
3. To bleed the brake system, use the following pro-
cedure.
! CAUTION
Continued operation of the ATV with high engine
temperature may result in engine damage or
premature wear.
Coolant Temperature Switch
OFF to ON 115° C (239° F) - Approx
ON to OFF 108° C (226° F) - Approx

2-27
2
A. Remove the cover and fill the master cylinder
with DOT 4 Hi-Temp Brake Fluid (p/n
1639-799).
B. Install and secure the cover; then slowly
compress the brake lever several times.
C. Remove the protective cap, install one end of a
clear hose onto one FRONT bleeder screw, and
direct the other end into a container; then while
holding slight pressure on the brake lever, open
the bleeder screw and watch for air bubbles.
Close the bleeder screw before releasing the
brake lever. Repeat this procedure until no air
bubbles are present.
AF637D
730-434B
!NOTE: During the bleeding procedure, watch the
master cylinder reservoir very closely to make
sure there is always a sufficient amount of brake
fluid. If the fluid level gets below the bottom line on
the reservoir, refill the reservoir before the bleed-
ing procedure is continued.
D. Repeat step C until the brake lever is firm.
E. At this point, perform step B, C, and D on the
other FRONT bleeder screw; then move to the
REAR bleeder screw and follow the same
procedure.
4. Carefully check the entire hydraulic brake system
that all hose connections are tight, the bleed
screws are tight, the protective caps are installed,
and no leakage is present.
INSPECTING HOSES
Carefully inspect the hydraulic brake hoses for cracks
or other damage. If found, the brake hoses must be
replaced.
CHECKING/REPLACING PADS
The clearance between the brake pads and brake discs
is adjusted automatically as the brake pads wear. The
only maintenance that is required is replacement of the
brake pads when they show excessive wear. Check the
thickness of each of the brake pads as follows.
1. Remove a front wheel.
2. Measure the thickness of each brake pad.
AF739DB
3. If thickness of either brake pad is less than 3.2 mm
(0.125 in.), the brake pads must be replaced.
!NOTE: The brake pads should be replaced as a
set.
4. To replace the brake pads, use the following pro-
cedure.
A. Remove the wheel.
B. Remove the cap screws securing the caliper to
the bracket; then remove the cotter pin securing
the pads and remove the pads.
! CAUTION
This hydraulic brake system is designed to use
high-temperature DOT 4 brake fluid only. If brake
fluid must be added, care must be taken as brake
fluid is very corrosive to painted surfaces.
! WARNING
Using the Operator’s Manual as a guide, instruct
the customer on the proper use, care, burnishing
procedure, and maintenance of the hydraulic brake
system.

2-28
AF615D
C. Install the new brake pads; then secure with the
pin and cotter pin. Spread the cotter pin.
D. Secure the caliper to the knuckle and/or axle
housing with the cap screws. Tighten to 2.8
kg-m (20 ft-lb).
AF615D
E. Install the wheel. Tighten to 5.5 kg-m (40 ft-lb).
5. Burnish the brake pads (see Burnishing Brake
Pads in this section).
Auxiliary Brake
CHECKING
Although the auxiliary brake has been adjusted at the
factory, the brake should be checked for proper opera-
tion. The brake must be maintained to be fully func-
tional.
1. With the engine off, transmission in neutral, and
the reverse lever in the forward position, press the
brake pedal and attempt to move the ATV.
ATV0088D
2. If the rear wheels are locked, it is adjusted prop-
erly.
3. If the rear wheels are not locked, it must be
adjusted (set up).
ADJUSTING
To adjust (set up) the auxiliary brake, use the follow-
ing procedure.
!NOTE: Removal of the right, rear wheel
enhances access to the brake components.
1. Loosen the right-hand jam nut (wheel-side when
viewing from behind) of the adjuster arm.
733-730B
2. Pull the brake cable to the left and push the
adjuster arm to the right.
3. While holding the cable and adjuster arm in this
position, finger-tighten the left-hand jam nut until
it contacts the adjuster arm; then loosen it one
turn.
4. Tighten the right-hand jam nut securely against the
adjuster arm.
!NOTE: On the 250/300, there should be 3.2 mm
(1/8 in.) free-play gap between the brake pedal arm
and the brake pedal bracket.

2-29
2
ATV0088E
!NOTE: On the 400/500, there should be 12.7 mm
(1/2 in.) free-play gap between the pedal and the
footrest.
736-569A
5. If the free-play gap is not within tolerance, read-
just the jam nuts of the adjuster arm in 1/4 turn
increments until the correct free-play gap is
attained.
!NOTE: Apply the brake a number of times to
ensure the wheels lock and the brakelight illumi-
nates properly.
6. If the rear cable adjustment is inadequate to attain
the proper brake pedal arm free-play gap, make
adjustment at the front cable adjuster jam nuts.
MEASURING/REPLACING BRAKE PADS
Removing
1. Support the ATV on a suitable stand.
2. Remove the right rear wheel and account for the
cap screws.
3. Loosen the rear cable adjuster jam nuts; then
remove the cap screws securing the auxiliary
brake to the axle housing.
4. Remove the brake pads from the caliper.
Inspecting and Measuring
1. Inspect the pads for gouges, chips, or wear.
2. Inspect the disc for gouges, grooves, cracks, and
warpage.
3. Using a calipers, measure the thickness of each
brake pad.
4. If the thickness of either brake pad is less than 3.2
mm (0.125 in.), the brake pads must be replaced.
!NOTE: The brake pads should be replaced as a
set.
Installing
1. Place the brake pads into the caliper.
!NOTE: The metal backing of the pad will be fac-
ing the adjuster arms when installed properly.
2. Slide brake caliper assembly over the brake disc
and into position on the knuckle; then secure the
caliper with the cap screws tightened to 2.1 kg-m
(15 ft-lb).
3. Install the wheel and secure. Tighten to 5.5 kg-m
(40 ft-lb).
4. Adjust the brake (see Adjusting in this sub-sec-
tion).
5. Remove the ATV from the support stand.
!NOTE: Whenever installing new pads, the new
pads must be burnished (see Burnishing Brake
Pads in this section).
Burnishing Brake Pads
Brake pads (both hydraulic and auxiliary) must be bur-
nished to achieve full braking effectiveness. Braking
distance will be extended until brake pads are properly
burnished. To properly burnish the brake pads, use the
1. Choose an area large enough to safely accelerate
the ATV to 30 mph and to brake to a stop.
2. Accelerate to 30 mph; then compress brake lever
or apply the auxiliary brake to decelerate to 0-5
mph.
! CAUTION
If adjusting the rear cable at both ends does not
attain proper brake pedal arm free-play, the brake
pads must be replaced.
12.7 mm
(0.50 in.)
Free-Play Gap
! WARNING
Failure to properly burnish the brake pads could
lead to premature brake pad wear or brake loss.
Brake loss can result in severe injury.

2-30
3. Repeat procedure on each brake system five times
until brake pads are burnished.
4. Adjust the auxiliary brake (if necessary).
5. Verify that the brakelight illuminates when the
hand lever is compressed or the brake pedal is
depressed.
Coolant
(500)
The cooling system capacity is approximately 2.9 L (3
U.S. qt). The cooling system should be inspected daily
for leakage and damage. Also, the coolant level should
be checked periodically.
When filling the cooling system, use premixed Arctic
Cat Antifreeze (p/n 0638-395). While the cooling sys-
tem is being filled, air pockets may develop; therefore,
run the engine for five minutes after the initial fill, shut
the engine off, and then fill the cooling system to the
bottom of the stand pipe in the radiator neck.
AN604D
Checking/Replacing
V-Belt
(Automatic Transmission)
REMOVING
1. Remove the right-side footrest (see Section 8).
2. Loosen the clamp securing the cooling shroud to
the cooling duct.
AF931
3. Remove the cap screws securing the cooling
shroud to the V-belt cover; then remove the cool-
ing shroud.
AF932
4. Remove the cap screws securing the V-belt cover
noting the location of the different-lengthed cap
screws for installing purposes; then using a rubber
mallet, gently tap on the cover tabs to loosen the
cover. Remove the cover.
!NOTE: Note the location of the main engine
ground wire for installing purposes.
AF933
5. Remove the nut securing the movable drive face;
then remove the face. Account for the spacer.
! 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.

2-31
2
CC546
CC547
6. Remove the V-belt.
CC550
INSTALLING
1. Spread the faces of the driven clutch by pushing
the inner face toward the engine while turning it
counterclockwise; then when the faces are sepa-
rated, insert a wedge (approximately 3/8 in. thick)
between the faces. Release the inner face.
CC549
2. Place the V-belt into position on the driven clutch
and over the front shaft.
CC550
!NOTE: The arrow on the V-belt should point for-
ward.
3. Pinch the V-belt together near its center and slide
the spacer and movable drive face onto the drive-
shaft. Secure the drive face with a nut. Tighten the
nut to 10.4-11.8 kg-m (75-85 ft-lb).
CC552
!NOTE: At this point, the wedge can be removed
from between the driven clutch faces.
4. Rotate the V-belt and clutches until the V-belt is
flush with the top of the driven clutch.

2-32
5. Place the V-belt cover gasket into position; then
install the cover and secure with the cap screws
making sure the different-lengthed cap screws are
in their proper location. Tighten the cap screws to
1.1 kg-m (8 ft-lb).
CC736
!NOTE: Make sure the main engine ground wire is
installed and secured in the proper location.
6. Place the cooling shroud into position on the
V-belt cover; then secure with cap screws. Tighten
securely.
7. Tighten the clamp securing the cooling shroud to
the cooling duct.
AF931
8. Secure the front fender to the footrest with the two
cap screws. Tighten securely.
9. Install the right-side footrest (see Section 8).

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2003 Arctic Cat 500 4x4 Automatic TBX ATV Service Repair Manual

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2003 Arctic Cat 500 4x4 Automatic TBX ATV Service Repair Manual