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WARNING A NING Operating this ATV if you are under Operating this ATV if you are under the age of 16 increases your chance UNDER of severe injury or death. NEVER operate this ATV if you are under 16. Do not remove this Operator’s Manual from this ATV according to the guidelines and agreement with the U.S.
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Operator’s 613-739-1535. Manual and the labels on your ATV. Un cours d’instruction est disponible: This Arctic Cat ATV Operator’s Manual pour les propriétaires canadiens, compo- should be considered a permanent part of sez le 613-739-1535.
Arctic Cat able service. Be sure, as the owner/opera- ATV, be sure to use only GENUINE tor of an Arctic Cat ATV, to become ARCTIC CAT PARTS, OIL, AND thoroughly familiar with its basic opera- ACCESSORIES.
Arctic Cat ATV dealer. No transportation charges, rental charges, or inconvenience costs will be paid by Arctic Cat. The warranty is validated upon examination of said parts by Arctic Cat or an authorized Arctic Cat ATV dealer. Arctic Cat reserves the right to inspect such parts at its factory for final determination if warranty should apply.
At the time of sale, an ATV Rider Training Certificate and Owner Registration form is to be completed by the selling dealer and consumer. The receipt of the form by Arctic Cat is a condition precedent to warranty coverage. It is the selling dealer’s responsibility to retain and/or submit appropriate copies of the form to the appropriate place(s) to initiate war- ranty coverage.
Manual. Arctic Cat recommends the retention of all receipts covering maintenance performed on the ATV, but Arctic Cat cannot deny warranty solely for the lack of receipts or for failure to ensure the performance of all scheduled maintenance on the emission control system.
Arctic Cat Emission Control System Limited Warranty Arctic Cat Inc., P.O. Box 810, Thief River Falls, MN 56701 (hereinafter referred to as Arctic Cat) warrants that this new Arctic Cat ATV manufactured on or after January 1st, 1997: A. Is designed, built, and equipped so as to conform at the time of initial purchase with all applicable regulations of the California Air Resources Board and B.
Arctic Cat warrants to the original retail purchaser, and each subsequent purchaser, that all U.S. EPA- certified Arctic Cat ATV’s are designed, built, and equipped to conform to all U.S. EPA Emission Control Regulations. Please read the following information completely.
Date of Issue: June, 1997 EC Machinery Directive 2006/42/EC Date of Issue: May, 2006 Issued by European Commission. Type of Equipment: All-Terrain Vehicles Brand Name: Arctic Cat Model: 500 4x4 550 4x4 700 4x4 700 Mud Pro 700 TBX 4x4...
• Always follow proper procedures for turning as described in this manual. Practice turning at slow speeds before attempting to turn at faster speeds. Do not turn at excessive speed. • Always have the ATV checked by an authorized Arctic Cat ATV dealer if it has been involved in an accident.
ATV Safety Alert The Consumer Product Safety Commis- * Never carry a passenger on an ATV. Carrying a passenger may upset the sion has concluded that ALL-TERRAIN balance of the ATV and may cause it VEHICLES (ATV’s) may present a risk to go out of control.
Rider Training Course Arctic Cat sponsors a free Rider Training Course to teach ATV riding skills or to reinforce current riding skills. First-time purchasers without any previous ATV riding experience will receive a $100.00 coupon from Arctic Cat through the SVIA/ASI after completing the training course (U.S.
Hangtag An Arctic Cat ATV comes with a hangtag containing important safety information. Anyone who rides the ATV should read and understand this information before rid- ing. 2258-133 Pour commander des Etiquettes de Mise en Garde gratuites, voyez votre détaillant de autorisé...
The labels should be considered as permanent parts of the ATV. If a label comes off or becomes hard to read, contact your Arctic Cat ATV dealer for a replacement. NOTE: The location and content of labels on the ATV you have purchased may differ from those shown on this page.
They should then regularly practice the skills learned in the course and the operating techniques described in this Operator’s Manual. For more information about the training course, contact an authorized Arctic Cat ATV dealer or call 1-800-887-2887 (U.S.) or 1-613-739-1535 (Canada).
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Warnings ! WARNING POTENTIAL HAZARD Operating this ATV on paved surfaces. WHAT CAN HAPPEN The ATV’s tires are designed for off-road use only, not for use on pavement. Paved surfaces may seriously affect handling and control of the ATV and may cause the ATV to go out of control.
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Warnings ! WARNING POTENTIAL HAZARD Operating this ATV after or while consuming alcohol or drugs. WHAT CAN HAPPEN Could seriously affect your judgment. Could cause you to react more slowly. Could affect your balance and perception. Could result in an accident. HOW TO AVOID THE HAZARD Never consume alcohol or drugs before or while driving this ATV.
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Warnings ! WARNING POTENTIAL HAZARD Failure to use extra care when operating the ATV on unfamiliar terrain. WHAT CAN HAPPEN You can come upon hidden rocks, bumps, or holes without enough time to react. Could result in the ATV overturning or going out of control.
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Warnings ! WARNING POTENTIAL HAZARD Turning improperly. WHAT CAN HAPPEN ATV could go out of control, causing a collision or rollover. HOW TO AVOID THE HAZARD Always follow proper procedures for turning as described in this Operator’s Man- ual. Practice turning at slow speeds before attempting to turn at faster speeds. Do not turn at excessive speed.
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Warnings ! WARNING POTENTIAL HAZARD Operating on steep hills. WHAT CAN HAPPEN The ATV can overturn more easily on steep hills than on level surfaces or small hills. HOW TO AVOID THE HAZARD Never operate the ATV on hills too steep for the ATV or for your abilities.
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Never modify the ATV through improper installation or improper use of accesso- ries. All parts and accessories added to this ATV should be genuine Arctic Cat ATV components designed for use on the ATV and should be installed and used according to instructions.
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Warnings ! WARNING POTENTIAL HAZARD Operating this ATV on public streets, roads, or highways. WHAT CAN HAPPEN You can collide with another vehicle. HOW TO AVOID THE HAZARD Never operate this ATV on any public street, road, or highway, even a dirt or gravel one. In many states it is illegal to operate an ATV on public streets, roads, or highways.
Warnings ! WARNING POTENTIAL HAZARD Operating the ATV with differential lock engaged. WHAT CAN HAPPEN The increased steering effort and reduced maneuverability caused by the locked differential could result in loss of control and an accident. HOW TO AVOID THE HAZARD Never exceed 10 MPH (16 KPH) with the differential lock engaged.
Prevention Overview Gloves Your hands are targets for flying objects When using an ATV, prevention is the and branches. Along with providing skin name of the game. “Had you only protection, gloves will shield your hands known” something could go wrong, you from harsh weather.
Prevention Long Pants and Long Sleeved Shirt Helmets should have one of these: 1. DOT label The goal is to protect your body from 2. Snell label branches, long grass, airborne objects, or 3. ANSI Z90.1 label anything else that could scrape your skin. The more thick and durable the material, the better protection it’ll provide.
Prevention A. Brakes 4. Oil and Fuel Squeeze the hand brake lever. If it feels soft Start with a full tank of gas before every or “squishy,” it could be low on fluid or ride, and while you’re at it, top off the oil. have a leak —...
Prevention Cellular Phone • Cellular Phone • Maps/GPS It may be necessary to make an urgent • Emergency Kit with Flashlight and phone call. First Aid Kit Maps/GPS (Global Tools Positioning System) Routine maintenance will generally elim- Maps may be unnecessary when you’re inate the need for emergency repairs.
Active Riding Overview “Active Riding” is the second part of “P.A.S.S.” It involves an understanding of how your body weight, balance, gravity, and physical forces affect the handling of the ATV. For example, when you drive a car quickly into a sharp turn, your body is pulled to the outside of the vehicle by centrifugal force.
Sound Judgment Overview 9. Do you tailgate other drivers when you think they’re driving too slow? You are not invincible. Knowing that the first “S” in “P.A.S.S.” stands for “Sound Never Sometimes Often Judgment” means you need to use yours. Do you consider yourself to be pretty 10.
Sound Judgment The thing about terrain is that sometimes Trail Signs you don’t know it’s changed until you get there. Whether it’s familiar or not, check out your surroundings before and during your ride. Night Riding Riding at night can be very hazardous. Obstacles and other hazards (that are eas- ily identified during daytime) are much more difficult to see and avoid.
Sound Judgment Other Vehicles ATV Maintenance Depending on where you’re riding, you You have to maintain your ATV. The might encounter other ATV’s, bikes, or General Maintenance section of this motor vehicles on public lands. Respect Operator’s Manual tells you about taking the presence of cars if you’re crossing care of your ATV.
Sound Judgment Load Capacity Ratings ! WARNING Arctic Cat ATV Load Capacity Ratings POTENTIAL HAZARD ITEM Specifications Overloading the ATV or carrying or tow- (lb) (kg) ing cargo improperly. Max Load Capacity WHAT CAN HAPPEN Max Load Capacity - TBX...
Sound Judgment Your Physical Condition Your physical condition is critical to safe TESTIMONIAL operation. Don’t ride when DOCUMENT#: X46481A1 extremely tired and consider your health CITY/STATE: LAUREL, MS SEX: M when planning longer rides. AGE: 25 BODY PART: ALL PARTS BODY Don’t ride: DATE ACCIDENT: 6-25-93 1.
Sound Judgment SIPDE By themselves, none of these safe behav- iors and sound judgments will go very far. But when you put them all together... when you’re paying attention to how you feel, when you’re monitoring the move- ments of your ATV, and when you’re constantly evaluating your environment, then you’re practicing SIPDE.
16 operate your ATV. don’t know what they’re doing. Unless they’ve had over a year of experience with Arctic Cat and the ATV Safety Institute ATV riding or taken an ATV training recommend that all ATV operators ride the course, it’s your responsibility to keep...
Four-Cycle/Liquid-Cooled V-Twin - 1000 Bore x Stroke 89 mm x 71.12 mm (3.5 x 2.8 in.) - 500 92 mm x 82 mm (3.62 x 3.22 in.) - 550 102 mm x 85 mm (4.01 x 3.35 in.) - 700 92 mm x 71.6 mm (3.66 x 2.81 in.) - 1000...
Location of Parts and Controls FI016H FI025C 739-569D 1. Battery 14. Throttle Lever 2. Headlights 15. DC Power Outlet 3. Hand Brake Lever 16. Taillight/Brakelight 4. Power Distribution Module 17. Operator’s Manual Location 5. Radiator Access Panel 18. Headlight HI/LO Switch 6.
ATV Operation Starting the Engine Basic Operating Always start with the ATV on a flat, level Maneuvers surface. Carbon monoxide poisoning can kill you, so keep your ATV outside while it’s Active riding and basic maneuvers are running. Follow these steps to start it up: the foundation of your ATV ride.
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! WARNING attempting to shift from one range to the other or into reverse. Always shift Use only Arctic Cat approved brake on level ground, or engage the brake fluid. Never substitute or mix differ- lever lock before shifting into another ent types or grades of brake fluid.
2. Stop the engine using the engine stop switch. 3. Turn off the ignition. 4. If you have to park on a hill, shift the ATV into low gear or park (if applica- ble). 5. Engage the brake lever lock. Dismounting the ATV ATV-0012 After you’ve followed the procedure for...
3. Gradually increase your speed as you come out of the turn. Sharp Turns After mastering wide turns, practice the advanced skill of sharp turns. ATV-0025 Wide Turns About 20% of ATV accidents happen dur- ing turns. If you don’t understand turning techniques, it’s easy for the ATV to get away from you by losing traction, plowing, ATV-0038...
Quick Turns Quick turns are the most difficult turns and should only be done after you are experienced with your ATV. ATV-203 1. Ease off the throttle as you approach the turn to slow down. 2. Turn the handlebar, shift your weight, and balance at the same time as you enter the turn (use the principles of leaning, weight shifting, and balanc-...
5. If you’re to the left of the ATV, turn 2. Lean as far forward as possible. For the handlebar all the way left. steeper hills, come off your seat to stand and lean forward. 6. Partially release the brake, but lightly hold the brake lever.
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1. Keep your speed low and consistent. 2. Shift all your body weight to the uphill side of the seat; also, support your weight on the uphill footrest. 3. Steer like you’re driving into the hill. 4. If the ATV feels like it’s tipping, turn the handlebar downhill.
3. Keep your hand off the brake until the 6. Lean forward and release the throttle emergency is over and you’re back in when the front tires clear the obstacle. control. 7. Keep your body loose to absorb any Crossing Obstacles shock.
Sometimes your ATV may not respond 3. Make sure you have a way out on the and goes straight ahead instead of letting other side of the water. you turn. Here’s how to handle it: 4. If you get stuck in the sludge or mud, 1.
2. If the tires are frozen to the ground, NOTE: After riding through water, pour warm water around them to melt mud, snow, or slush, it is important the ice. to dry both brake systems before parking the ATV. CAUTION ! WARNING Before riding, manually move the ATV...
These numbers are required by the dealer to complete warranty claims properly. No ON position — The ignition circuit is warranty will be allowed by Arctic Cat if complete and the engine can run. The key the VIN or ESN is removed or mutilated cannot be removed in this position.
OFF position when engine is not running. Shift Lever KC342C (500/550/1000 Limited) This switch allows the operator to oper- ate the ATV in either two-wheel drive (rear wheels) or four-wheel drive (all wheels). For normal riding on flat, dry, hard surfaces, two-wheel drive should be sufficient.
Before starting the engine, lock the wheels. If it doesn’t, take the make sure the ignition switch is in the ATV to an authorized Arctic Cat ATV ON position, the transmission is in neu- dealer for service. tral, and the brake lever lock is engaged.
1. Loosen the jam nut. NOTE: This ATV has safety interlock switches which prevent the starter 2. Turn the throttle limiter screw clock- motor from activating when the trans- wise to decrease engine RPM maxi- mission is not in neutral. To start the mum or counterclockwise to increase ATV while in gear, depress the rear foot engine RPM maximum.
If the code con- NOTE: Approximately two seconds tinues to be displayed, take your ATV to after releasing either Button, the an authorized Arctic Cat Dealer for EPS LCD will return to normal operation. system servicing before resuming ...
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NOTE: Take the ATV to an autho- eter (ODO) or trip meter (TRIP), press rized Arctic Cat ATV dealer to have the Mode Button (3) to select the dis- the EFI error corrected and to have tance mode; then press the Set But- the ECU reset as soon as possible.
7. Speedometer/Tachometer - A needle indicates approximate vehicle speed NOTE: The engine hour meter will in mph or km/h when speedometer not activate until engine speed function is selected or rpm when exceeds 500 RPM. tachometer function is selected.
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CAUTION must be reset by turning the ignition key to OFF; then back to ON. Arctic Cat does not recommend using a pressure washer to clean the radiator core. The pressure may bend or flatten the fins causing restricted air flow, and electrical components on the radiator could be damaged.
(blown fuse, etc.), the gauge will “power- NOTE: Take the ATV to an autho- up,” reset, and shut down repeatedly rized Arctic Cat ATV dealer to have until clock memory power the error corrected and the system restored.
NOTE: Take the ATV to an autho- operation as oil pressure is not moni- rized Arctic Cat ATV dealer to have tored on these models. the EFI error corrected and to have the ECM reset as soon as possible.
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11. Drive Select Indicator - Displays CAUTION 4WD when selected by the drive select switch or when the 4WD lock Arctic Cat does not recommend is engaged. The display is blank when using a pressure washer to clean the in 2WD.
NOTE: Take the ATV to an autho- oil level should be above the “L” mark rized Arctic Cat ATV dealer to have but not higher than the “F” mark. the EFI error corrected and to have the ECM reset as soon as possible.
Never use the racks as a towing or 1. To raise the cargo box, rotate either trailering point. handle upward; then raise the cargo Arctic Cat ATV’s are equipped with a box. frame-mounted receiver for a standard 2. To lower the cargo box, push down 5.1 cm (2 in.) receiver hitch.
Transporting When transporting the ATV, Arctic Cat recommends that the ATV be in its normal operating position (on all four wheels) and the following procedure be used. 1. Engage the brake lever lock and place the transmission in gear. CAUTION...
Never add gasoline to the CAUTION ATV gas tank near any open flames or with the engine running or hot. DO Do not use white gas. Only Arctic Cat NOT SMOKE while filling the gas approved gasoline additives should tank.
Burnishing Brake Pads New ATV’s and renewed ATV engines require a “break-in” period. The first Brake pads must be burnished to achieve month is most critical to the life of this full braking effectiveness. Braking distance ATV. Proper operation during this break-in will be extended until brake pads are prop- period will help assure maximum life and erly burnished.
I=Inspect and clean, adjust, lubricate, replace as necessary T=Tighten R = Replace C = Clean * Dealer maintenance ** When using Arctic Cat ACX All Weather synthetic oil, oil change interval can be increased to every 1,000 miles or every year.
FI476 damage is detected, take the ATV to an 2. On the 700/1000, lift the front of the authorized Arctic Cat ATV dealer for ser- access panel; then slide the panel for- vice. Also, the coolant level should be ward to disengage the two rear tabs.
Maintenance (Mud Pro) the snorkel housing. When operating in muddy conditions, it is extremely important to clean the radiator core frequently. Arctic Cat requires inspecting and/or flushing the radiator core before each use to prevent overheat- ing resulting in severe engine damage.
Spring CAUTION Position Setting Load Force Continued operation of the ATV with Soft Light high engine temperature may result in engine damage or premature wear. NOTE: High engine RPM, low vehi- cle speed, or heavy load can raise engine temperature.
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Inspect the oil for any signs of metal filings or water. If found, take the ATV 7. Start the engine (while the ATV is to an authorized Arctic Cat ATV outside on level ground) and allow it dealer for servicing.
If Brake Fluid found, take the ATV to an authorized Arctic Cat ATV dealer to have the brake Check the brake fluid level in the brake hoses replaced. fluid reservoir. If the level in the reser-...
NOTE: Take the ATV to an autho- 2. Remove both front wheels. rized Arctic Cat ATV dealer for this 3. Inspect the four tie rod boots for service. cracks, tears, or perforations. Protective Rubber 4.
NOTE: Optional battery charging 2. If boot damage is present, contact an adapters are available from your authorized Arctic Cat ATV dealer for authorized Arctic Cat dealer to con- service. nect directly to your vehicle from the Battery recommended chargers to simplify the maintenance charging process.
Arctic Cat dealer for further troubleshooting. Charging Jump-Starting NOTE: Arctic Cat recommends the use of the CTEK Multi US 800 or ...
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! WARNING If any of these conditions exist, DO NOT attempt a jump-start, boost, or charge the battery. An explosion could occur causing serious injury. 3. Inspect the vehicle to be used for jump-starting to determine if voltage and ground polarity are compatible. 0744-527 The vehicle must have a 12-volt DC, ...
2. Slide the rubber boot away and turn the serviced or the carburetor may need to be adjuster until the throttle lever has adjusted. Consult an authorized Arctic Cat proper free-play of 3-6 mm (1/8-1/4 in.). ATV dealer if the plug insulator is not a light brown color.
Air Filter Housing Drain(s) Inspect the drain(s) beneath the main FI515 housing for debris and for proper sealing. 500/550/700 FI705 4. Fill a wash pan larger than the ele- FI704A ment with a non-flammable solvent; Draining V-Belt Cover then dip the element in the solvent ...
If proper tools and related items are several times to “blow out” any not available, have this maintenance per- water; then stop the engine. formed by an authorized Arctic Cat ATV dealer or a qualified tire repair station. 5. Install the drain bolt and tighten securely.
Muffler/Spark Arrester CAUTION The muffler has a spark arrester which Use only specified bulbs indicated in must be periodically cleaned. At the the chart as replacement bulbs. intervals shown in the Maintenance Headlight Schedule, clean the spark arrester using the following procedure. ...
Always replace a blown fuse with a fuse of the same type and rating. If the new fuse blows after a short period of use, consult an authorized Arctic Cat ATV dealer immediately. NOTE: To remove the fuse, com- ATV-0070 press the locking tabs on either side ...
Storage Compartment/ 500/500 XT/700/700 XT/700 Tools Limited/700 Mud Pro/1000 Mud Pro A basic tool kit is provided with the ATV. Maintain the tool kit with the ATV at all times. 2411-886 550 XT/550 Limited/1000 XT ATV-1097 The storage compartment is above the engine in front of the seat.
Start the engine and is fully charged (see Battery section allow it to idle; then using Arctic Cat in this manual). Engine Preserver, rapidly inject the 9. Store the ATV indoors in a level posi- preserver into the air filter opening tion.
Preparation after Storage Taking the ATV out of storage and cor- CAUTION rectly preparing it will assure many miles and hours of trouble-free riding. Arctic Before installing the battery, make Cat recommends the following procedure sure the ignition switch is in the OFF to prepare the ATV.
Please make sure a copy of this form is completed and returned to Arctic Cat Inc. if you move or if the ATV is sold to another party. This form may also be used to transfer the unused portion of the original war- ranty to a second party.
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- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Place Stamp CHANGE OF ADDRESS/OWNERSHIP Here ARCTIC CAT INC. PRODUCT SERVICE AND WARRANTY DEPT. P.O. BOX 810 THIEF RIVER FALLS, MN 56701...
Record this number in the space provided for reference if you ever need a new key. Record the Vehicle Identification Number and Engine Serial Number in the spaces provided to assist you in ordering parts from your authorized Arctic Cat ATV dealer or for reference in case the ATV is stolen.