2005 Arctic Cat 500 4x4 ATV Service Repair Manual.pdf
- 1. TABLE OF CONTENTS Click on the RED TEXT to go! Foreword 1. General Information (Vol. I) 2. Periodic Maintenance/Tune-Up (Vol. I) 3. Engine/Transmission (Vol. I) 4. Fuel/Lubrication/Cooling (Vol. II) 5. Electrical System (Vol. II) 6. Drive System (Vol. II) 7. Suspension (Vol. II) 8. Steering/Frame (Vol. II) 9. Controls/Indicators (Vol. II) 10. Aids for Maintenance (Vol. II) 11. Troubleshooting (Vol. II) 1 2 3 4 5 6 7 8 9 10 11
- 2. FOREWORD This Arctic Cat Service Manual contains service, maintenance, and troubleshooting information for the 2005 Arctic Cat ATV models. The complete two-volume set is designed to aid service personnel in service-oriented applications. This volume 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 volume 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 two-volume set. 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 fol- low the directive because it deals with the possibility of severe personal injury or even death. The symbol ! 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 infor- mation worthy of particular attention. The symbol AT THIS POINT directs the technician to certain and spe- cific procedures to promote efficiency and to improve clarity. At the time of publication, all information, photographs, and illustrations were technically correct. Some photographs used in this volume 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. © 2004 Arctic Cat Inc. August 2004 ®™ Trademarks of Arctic Cat Inc., Thief River Falls, MN 56701 Table of Contents
- 3. 1-1 1 SECTION 1 - GENERAL INFORMATION TABLE OF CONTENTS General Specifications (250)................................... 1-2 General Specifications (300)................................... 1-3 General Specifications (400/400 TBX - Automatic Transmission)............ 1-4 General Specifications (400 - Manual Transmission) ............................... 1-5 General Specifications (500 - Manual Transmission) ............................... 1-6 General Specifications (500/500 TBX/TRV - Automatic Transmission).... 1-7 General Specifications (650 H1) .............................................................. 1-8 General Specifications (650 V-Twin) ........................................................ 1-9 Break-In Procedure ............................................... 1-10 Gasoline - Oil - Lubricant ...................................... 1-10 Genuine Parts ....................................................... 1-11 Preparation For Storage........................................ 1-11 Preparation After Storage...................................... 1-12
- 4. 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 1250-1350 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 Voltage (primary/CDI) 98.3-147.5 volts (terminal to ground) Magneto Coil Resistance (trigger) (charging) 84-126 ohms (black/yellow to green/white) 0.44-0.66 ohm (yellow to yellow) Magneto Coil Peak Voltage (trigger) (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 3.5 L (3.7 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/8W/27W Headlight 12V/27W (2) Starting System Electric w/Manual Recoil (Emergency)
- 5. 1-3 1 General Specifications* (300) * Specifications subject to change without notice. ** One inch below plug threads. CARBURETOR Type Keihin CVK32 Main Jet 135 Slow Jet 38 Low Speed Fuel Screw Setting (turns) 2 1/4 Jet Needle N8TT Needle Jet 4.0/3.4 Idle RPM 1250-1350 Starter Jet 65 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 @ 1800 RPM 30° BTDC @ 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 Voltage (primary/CDI) 98.3-147.5 volts (terminal to ground) Magneto Coil Resistance (trigger) (charging) 84-126 ohms (black/yellow to green/white) 0.44-0.66 ohm (yellow to yellow) Magneto Coil Peak Voltage (trigger) (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) 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.) Brake Type Hydraulic w/Brake Lever Lock and Auxiliary Brake Wheelbase 127 cm (50 in.) Tracking 89 cm (35 in.) Tire Size Front - AT24 x 9-12 Rear - AT25 x 10-12 Tire Inflation Pressure 0.35 kg/cm² (5 psi) Turning Radius 2.7 m (8.9 ft) MISCELLANY Gas Tank Capacity (rated) 17.98 L (4.75 U.S. gal.) Reserve Capacity 2.46 L (0.65 U.S. gal.) Differential Capacity (front) 275 ml (9.3 fl oz)** Engine Oil Capacity 3.5 L (3.7 U.S. qt) Gasoline (recommended) 87 Octane Regular Unleaded Engine Oil (recommended) SAE 10W-40 Differential Lubricant (front) SAE Approved 80W-90 Hypoid Brake Fluid DOT 4 Taillight/Brakelight 12V/8W/27W Headlight 12V/27W (2) Starting System Electric w/Manual Recoil (Emergency)
- 6. 1-4 General Specifications* (400/400 TBX - Automatic Transmission) * Specifications subject to change without notice. ** One inch below filler plug threads. *** At the oil level plug threads. CARBURETOR Type Keihin CVK34 Main Jet 142/140 TBX Slow Jet 38 Low Speed Fuel Screw Setting (turns) 2/1 1/8 TBX Jet Needle NA2G Needle Jet 6.0/4.0 Idle RPM 1250-1350 Starter Jet 75 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 10° BTDC @ 1500 RPM Spark Plug Type NGK CR7E Spark Plug Gap 0.7-0.8 mm (0.028-0.032 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 Voltage (primary/CDI) 160.8-241.2 volts (terminal to ground) Magneto Coil Resistance (trigger) (source) (charging) 160-240 ohms (green to blue) 0.08-0.12 ohm (yellow to white) 0.32-0.48 ohm (black to black) Magneto Coil Peak Voltage (trigger) (source) (charging) 5.04-7.56 volts (green to blue) 0.7-1.05 volts (yellow to white) 60 volts (black to black #1) (black to black #2) Magneto Output (approx) 220W @ 5000 RPM CHASSIS Dry Weight (approx) 282 kg (622 lb) - ACT 286 kg (630 lb) - FIS 323.5 kg (713 lb) - TBX Length (overall) 205 cm (81 in.) 244.5 cm (96 in.) - TBX 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.) Brake Type Hydraulic w/Brake Lever Lock and Auxiliary Brake Wheelbase 127 cm (50 in.) Wheel Stance 89 cm (35 in.) Tire Size Front - 25 x 8-12 Rear - 25 x 10-12 - ACT Rear - 25 x 10-12 - FIS Tire Inflation Pressure 0.35 kg/cm² (5 psi) Turning Radius 2.7 m (8.9 ft) MISCELLANY Gas Tank Capacity (rated) 17.98 L (4.75 U.S. gal.) - ACT/FIS 20.8 L (5.5 U.S. gal.) - TBX Reserve Capacity 2.46 L (0.65 U.S. gal.) - ACT/FIS Rear Drive Capacity 275 ml (9.3 fl oz) - ACT*** 250 ml (8.5 fl oz) - FIS** Differential Capacity (front - 4x4) 275 ml (9.3 fl oz) - ACT**/ FIS*** Engine Oil Capacity 3.08 L (3.25 U.S. qt) Gasoline (recommended) 87 Octane Regular Unleaded Engine Oil (recommended) SAE 10W-40 Differential/Rear Drive Lubricant SAE Approved 80W-90 Hypoid Drive Belt Width 30.3 mm (1.19 in.) Brake Fluid DOT 4 Taillight/Brakelight 12V/8W/27W Headlight 12V/27W (2) Starting System Electric w/Manual Recoil (Emergency)
- 7. 1-5 1 General Specifications* (400 - Manual Transmission) * Specifications subject to change without notice. ** One inch below filler plug threads. *** At the oil level plug threads. CARBURETOR Type Keihin CVK34 Main Jet 142 Slow Jet 38 Low Speed Fuel Screw Setting (turns) 2 Jet Needle NA2G Needle Jet 6.0/4.0 Idle RPM 1250-1350 Starter Jet 75 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 10° BTDC @ 1500 RPM Spark Plug Type NGK CR7E Spark Plug Gap 0.7-0.8 mm (0.028-0.032 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 Voltage (primary/CDI) 160.8-241.2 volts (terminal to ground) Magneto Coil Resistance (trigger) (source) (charging) 160-240 ohms (green to blue) 0.08-0.12 ohm (yellow to white) 0.32-0.48 ohm (black to black) Magneto Coil Peak Voltage (trigger) (source) (charging) 5.04-7.56 volts (green to blue) 0.7-1.05 volts (yellow to white) 60 volts (black to black #1) (black to black #2) Magneto Output (approx) 220 W @ 5000 RPM CHASSIS Dry Weight (approx) 276 kg (609 lb) - ACT 280 kg (617 lb) - FIS Length (overall) 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 Ground Clearance 20.3 cm (8 in.) Brake Type Hydraulic w/Brake Lever Lock and Auxiliary Brake Wheelbase 127 cm (50 in.) Wheel Stance 89 cm (35 in.) Tire Size Front - 25 x 8-12 Rear - 25 x 10-12 - ACT Rear - 25 x 10-12 - FIS Tire Inflation Pressure 0.35 kg/cm² (5 psi) Turning Radius 2.7 m (8.9 ft) MISCELLANY Gas Tank Capacity (rated) 17.98 L (4.75 U.S. gal.) Reserve Capacity 2.46 L (0.65 U.S. gal.) Rear Drive Capacity 275 ml (9.3 fl oz) - ACT*** 250 ml (8.5 fl oz) - FIS** Differential Capacity (front - 4x4) 275 ml (9.3 fl oz) - ACT**/ FIS*** Engine Oil Capacity 3.08 L (3.25 U.S. qt) Gasoline (recommended) 87 Octane Regular Unleaded Engine Oil (recommended) SAE 10W-40 Differential/Rear Drive Lubricant SAE Approved 80W-90 Hypoid Brake Fluid DOT 4 Taillight/Brakelight 12V/8W/27W Headlight 12V/27W (2) Starting System Electric w/Manual Recoil (Emergency)
- 8. 1-6 General Specifications* (500 - Manual Transmission) * Specifications subject to change without notice. ** At the oil level plug threads. *** At the filler plug threads. CARBURETOR Type Keihin CVK36 Main Jet 148/138 w/Fuel Pump Slow Jet 40 Low Speed Fuel Screw Setting (turns) 1 7/8/1 3/4 w/Fuel Pump Jet Needle NFKG/NFCS w/Fuel Pump Needle Jet 6.0/4.0 Idle RPM 1250-1350 Starter Jet 102 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 10° BTDC @ 1500 RPM Spark Plug Type NGK CR6E Spark Plug Gap 0.7-0.8 mm (0.028-0.032 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 Voltage (primary/CDI) 142.4-213.6 volts (terminal to ground) Magneto Coil Resistance (trigger) (source) (charging) 160-240 ohms (green to blue) 0.08-0.12 ohm (yellow to white) 0.32-0.48 ohm (black to black) Magneto Coil Peak Voltage (trigger) (source) (charging) 4.2-6.3 volts (green to blue) 0.40-0.62 volt (yellow to white) 60 volts (black to black #1) (black to black #2) Magneto Output (approx) 325W @ 5000 RPM CHASSIS Dry Weight (approx) 288.5 kg (636 lb) Length (overall) 210.8 cm (83 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.) Ground Clear- ance 20.3 cm (8 in.) CHASSIS (Cont) Brake Type Hydraulic w/Brake Lever Lock and Auxiliary Brake Wheelbase 127 cm (50 in.) Tracking 89 cm (35 in.) Tire Size Front - 25 x 8-12 Rear - 25 x 11-12 Tire Inflation Pressure 0.35 kg/cm² (5 psi) Turning Radius 2.7 m (8.9 ft) MISCELLANY Gas Tank Capacity (rated) 24.6 L (6.5 U.S. gal.) 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 3.4 L (3.5 U.S. qt) Gasoline (recommended) 87 Octane Regular Unleaded Engine Oil (recommended) SAE 10W-40 Differential/Rear Drive Lubricant SAE Approved 80W-90 Hypoid Brake Fluid DOT 4 Taillight/Brakelight 12V/8W/27W Headlight 12V/27W (2) Starting System Electric w/Manual Recoil (Emergency)
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- 10. 1-7 1 General Specifications* (500/500 TBX/TRV - Automatic Transmission) * Specifications subject to change without notice. ** At the oil level plug threads. *** At the filler plug threads. CARBURETOR Type Keihin CVK36 Main Jet 148 TRV/138 w/Fuel Pump Slow Jet 40 Low Speed Fuel Screw Setting (turns) 1 7/8 TRV/1 3/4 w/Fuel Pump Jet Needle NFKG TRV/NFCS w/Fuel Pump Needle Jet 6.0/4.0 Idle RPM 1250-1350 Starter Jet 102 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 10° BTDC @ 1500 RPM Spark Plug Type NGK CR6E Spark Plug Gap 0.7-0.8 mm (0.028-0.032 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 Voltage (primary/CDI) 142.4-213.6 volts (terminal to ground) Magneto Coil Resistance (trigger) (source) (charging) 160-240 ohms (green to blue) 0.08-0.12 ohm (yellow to white) 0.32-0.48 ohm (black to black) Magneto Coil Peak Voltage (trigger) (source) (charging) 4.2-6.3 volts (green to blue) 0.40-0.62 volt (yellow to white) 60 volts (black to black #1) (black to black #2) Magneto Output (approx) 325W @ 5000 RPM CHASSIS Dry Weight (approx) 293 kg (646 lb) 331.5 kg (731 lb) - TBX 339 kg (748 lb) - TRV Length (overall) 210.8 cm (83 in.) 244.5 cm (96 in.) - TBX/TRV Height (overall) 125 cm (49.3 in.) 128 cm (50.5 in.) - TRV Width (overall) 120.7 cm (47.5 in.) Suspension Travel (front) 25 cm (10 in.) Suspension Travel (rear) 25 cm (10 in.) Ground Clearance 20.3 cm (8 in.) Brake Type Hydraulic w/Brake Lever Lock and Auxiliary Brake Wheelbase 127 cm (50 in.) 147 cm (58 in.) - TRV Tracking 89 cm (35 in.) Tire Size Front - 25 x 8-12 Rear - 25 x 11-12 Tire Inflation Pressure 0.35 kg/cm² (5 psi) Turning Radius 2.7 m (8.9 ft) MISCELLANY Gas Tank Capacity (rated) 24.6 L (6.5 U.S. gal.)/ 17.98 L (4.75 U.S. gal.) - TRV/20.8 L (5.5 U.S. gal.) - TBX Reserve Capacity 2.46 L (0.65 U.S. gal.) - TRV 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) Gasoline (recommended) 87 Octane Regular Unleaded Engine Oil (recommended) SAE 10W-40 Differential/Rear Drive Lubricant SAE Approved 80W-90 Hypoid Drive Belt Width 36.7 mm (1.44 in.) Brake Fluid DOT 4 Taillight/Brakelight 12V/8W/27W Headlight 12V/27W (2) Starting System Electric w/Manual Recoil (Emergency)
- 11. 1-8 General Specifications* (650 H1) * Specifications subject to change without notice. ** At the oil level plug threads. *** At the filler plug threads. CARBURETOR Type Keihin CVK40 Main Jet TBA Slow Jet TBA Low Speed Fuel Screw Setting (turns) TBA Jet Needle TBA Needle Jet TBA Idle RPM 1250-1350 Starter Jet TBA 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 10° BTDC @ 1500 RPM Spark Plug Type NGK CR6E Spark Plug Gap 0.7-0.8 mm (0.028-0.032 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 Voltage (primary/CDI) 142.4-213.6 volts (terminal to ground) Magneto Coil Resistance (trigger) (source) (charging) 160-240 ohms (green to blue) 0.08-0.12 ohm (yellow to white) 0.32-0.48 ohm (black to black) Magneto Coil Peak Voltage (trigger) (source) (charging) 4.2-6.3 volts (green to blue) 0.40-0.62 volt (yellow to white) 60 volts (black to black #1) (black to black #2) Magneto Output (approx) 325W @ 5000 RPM CHASSIS Dry Weight (approx) 288.5 kg (636 lb) Length (overall) 210.8 cm (83 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.) Ground Clearance 20.3 cm (8 in.) CHASSIS (Cont) Brake Type Hydraulic w/Brake Lever Lock and Auxiliary Brake Wheelbase 127 cm (50 in.) Tracking 89 cm (35 in.) Tire Size Front - 25 x 8-12 Rear - 25 x 11-12 Tire Inflation Pressure 0.35 kg/cm² (5 psi) Turning Radius 2.7 m (8.9 ft) MISCELLANY Gas Tank Capacity (rated) 24.6 L (6.5 U.S. gal.) 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 3.4 L (3.5 U.S. qt) Gasoline (recommended) 87 Octane Regular Unleaded Engine Oil (recommended) SAE 10W-40 Differential/Rear Drive Lubricant SAE Approved 80W-90 Hypoid Belt Width 33.3 mm (1.47 in.) Brake Fluid DOT 4 Taillight/Brakelight 12V/8W/27W Headlight 12V/27W (2) Starting System Electric w/Manual Recoil (Emergency)
- 12. 1-9 1 General Specifications* (650 V-Twin) * Specifications subject to change without notice. ** One inch below plug threads. *** At the plug threads. CARBURETOR Type Keihin CVKR-D32 (2) Main Jet 120 - Front 115 - Rear Slow Jet 40 Pilot Screw Setting (turns) 2 1/2 Jet Needle BZL-2.470 Needle Jet 3.6 #3 Idle RPM 1050-1150 Float Arm Height 3-5 mm (0.12-0.20 in.) Throttle Cable Free-Play (at lever) 3-6 mm (1/8-1/4 in.) ELECTRICAL Spark Plug Type NGK CR7E Spark Plug Gap 0.7-0.8 mm (0.028-0.032 in.) Spark Plug Cap 4750-6250 ohms Ignition Coil Resistance (primary) (secondary) 0.09-0.13 ohm (terminal (+) to terminal (-)) 3800-5800 ohms (high tension - plug cap removed - to ground) Ignition Coil Peak Voltage (primary/CDI) 100 volts or more (wire (+) to ground) Magneto Coil Resistance (trigger) (charging) 110-140 ohms (blue to black/white) 0.33-0.49 ohm (black to black) Magneto Coil Peak Voltage (trigger) (charging) 3.6 volts or more (blue to black/white) 39-59 volts @ 3000 RPM (black to black #1) (black to black #2) CHASSIS Dry Weight (approx) 293 kg (646 lb) Length (overall) 210.8 cm (83 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.) Ground Clearance 20.3 cm (8 in.) Brake Type Hydraulic w/Brake Lever Lock and Auxiliary Brake Wheelbase 127 cm (50 in.) Tracking 89 cm (35 in.) Tire Size Front - 26 x 8-12 Rear - 26 x 11-12 Tire Inflation Pressure 0.35 kg/cm² (5 psi) Turning Radius 2.7 m (8.9 ft) MISCELLANY Gas Tank Capacity (rated) 24.6 L (6.5 U.S. gal.) Coolant Capacity 2.7 L (2.8 U.S. qt) Differential Capacity 275 ml (9.3 fl oz)** Rear Drive Capacity 250 ml (8.5 fl oz)*** Engine Oil Capacity 1.75 L (1.85 U.S. qt) Gasoline (recommended) 87 Octane Regular Unleaded Engine Oil (recommended) SAE 10W-40 Differential/Rear Drive Lubricant SAE Approved 80W-90 Hypoid Drive Belt Width (minimum) 30.3 mm (1.19 in.) Brake Fluid DOT 4 Taillight/Brakelight 12V/8W/27W Headlight 12V/27W (2) Starting System Electric w/Manual Recoil (Emergency)
- 13. 1-10 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 over- load 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 bur- nished. 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 prescribed 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 fol- lowing viscosity chart for details. OILCHARTA ! 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: z Choose an area sufficiently large to safely accelerate ATV to 30 mph and to brake to a stop. z Accelerate to 30 mph; then compress brake lever to decelerate to 0-5 mph. z Repeat procedure five times until brakes are burnished. z 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. Viscosity Chart
- 14. 1-11 1 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. Expansion 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 genu- ine 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 num- ber, quantity, and description. 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. ! 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. ! CAUTION Prior to storing the ATV, it must be properly serviced to prevent rusting and component deterioration. ! CAUTION If the interior of the air filter housing is dirty, clean the area before starting the engine.