General Information/Foreword; Specifications; Torque Specifications - Arctic Cat 2016 Alterra 500 Service Manual

General
Information/Foreword
This Arctic Cat Service Manual contains service, mainte-
nance, and troubleshooting information for certain 2016
Arctic Cat Alterra ATV models (see cover). The com-
plete manual is designed to aid service personnel in ser-
vice-oriented applications.
This manual is divided into sections. Each section covers
a specific ATV component or system and, in addition to
the standard service procedures, includes disassembling,
inspecting, and assembling instructions. When using this
manual as a guide, the technician should use discretion as
to how much disassembly is needed to correct any given
condition.
This service manual is designed primarily for use by an
Arctic Cat CatMaster Basic Level technician. The proce-
dures found in this manual are of varying difficulty, and
certain service procedures in this manual require one or
more special tools to be completed. The technician
should use sound judgement when determining which
procedures can be completed based on skill level and
access to appropriate special tools.

NOTE: Whenever a part is worn excessively,
cracked, or damaged in any way, replacement is nec-
essary.
When replacement of parts is necessary, use only genuine
Arctic Cat ATV parts. They are precision-made to ensure
high quality and correct fit. Refer to the appropriate Illus-
trated Parts Manual for the correct part number, quantity,
and description.
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 infor-
mation. Be sure to follow the directive because it deals
with the possibility of severe personal injury or even
death. A CAUTION identifies unsafe practices which
may result in ATV-related damage. Follow the directive
because it deals with the possibility of damaging part or
parts of the ATV. The symbol  NOTE: identifies sup-
plementary information worthy of particular attention.

AT THIS POINT directs the tech-
The symbol
nician to certain and specific procedures to promote effi-
ciency and to improve clarity.
At the time of publication, all information, photographs,
and illustrations were technically correct. Some photo-
graphs used in this manual are used for clarity purposes
only and are not designed to depict actual conditions.
Because Arctic Cat Inc. constantly refines and improves
its products, no retroactive obligation is incurred.
All materials and specifications are subject to change
without notice.
Product Service and
Warranty Department
Arctic Cat Inc.
2

Specifications


NOTE: Specifications subject to change without notice.
MISCELLANY
Tire Size
Tire Inflation Pressure
Spark Plug Type
(550/700)
Spark Plug Gap
(550/700)
Gas Tank Capacity
Coolant Capacity
Rear Drive Capacity
Front Differential Capacity
Engine Oil Capacity (approx)
(550/700)
Gasoline (recommended)
Engine Oil (recommended)
Differential/Rear Drive Lubricant
Drive Belt Width
Brake Fluid
Taillight/Brakelight
Headlight
ELECTRICAL SYSTEM
Ignition Timing
Spark Plug Cap
Ignition Coil Resistance (primary)
(secondary)
Ignition Coil Primary Voltage
Stator Coil (CKP sensor)
Resistance (AC generator)
Crankshaft Position Sensor
AC Generator Output (no load)
* One inch below plug threads. ** At the plug threads.

Torque Specifications

EXHAUST COMPONENTS
Part
Exhaust Pipe Engine
Spark Arrester Muffler
Heat Shield Exhaust Pipe
Heat Shield Frame
STEERING COMPONENTS
Steering Shaft Frame
Steering Shaft Flange Frame
Steering Post Handlebar Block
Tie Rod End** Knuckle/Steering Shaft
EPS Housing Frame
Handlebar End Cap Handlebar
Front - 25 x 8-12
Rear - 25 x 10-12
0.35 kg/cm² (5 psi)
(500) NGK CR7E
NGK CPR8E
(500) 0.7-0.8 mm (0.028-0.031 in.)
0.5-0.6 mm (0.019-0.024 in.)
21.6 L (5.7 U.S. gal.)
2.9 L (3.0 U.S. qt)
250 ml (8.5 fl oz)*
275 ml (9.3 fl oz)**
(500) 2.8 L (3.0 U.S. qt) - Overhaul
2.5 L (2.6 U.S. qt) - Change
2.5 L (2.6 U.S. qt) - Overhaul
1.9 L (2.0 U.S. qt) - Change
87 Octane Regular Unleaded
Arctic Cat ACX All Weather
(Synthetic)
SAE Approved 80W-90 Hypoid
28.5 mm (1.12 in.) - 500
35.0 mm (1.28 in.) - 550/700
DOT 4
High Intensity LED
High Intensity LED
10° BTDC @ 1500 RPM
5000 ohms
Less than 5.0 ohms
N.A.
Battery Voltage
104-156 ohms
Less than 1 ohm
2.0 AC volts or more
75 AC volts @ 5000 RPM
Torque
Part Bolted To
ft-lb N-m
20
48
in.-lb
8
54
in.-lb
20
11
20
55
35
8
27
5.5
11
6
27
15
27
74
47
11