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Arctic Cat 700 EFI Service Manual

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See also: Operator's Manual
FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983
FOREWORD
This Arctic Cat Service Manual contains service, maintenance, and troubleshooting information for certain 2008
Arctic Cat ATV models (see cover). The complete manual is designed to aid service personnel in service-oriented
applications.
Arctic Cat offers additional publications (when they become available) to aid in servicing other ATV models. To
service models not included in this manual, please refer to the following publications:
•
2008 Y-12 Service Manual
•
2008 DVX/Utility 250 Service Manual
•
2008 366 Service Manual
•
2008 DVX 400 Service Manual
•
2008 700 Diesel Service Manual
•
2008 Thundercat Service Manual
This manual is divided into sections. Each section covers a specific ATV component or system and, in addition to
the standard service procedures, includes disassembling, inspecting, and assembling instructions. When using this
manual as a guide, the technician should use discretion as to how much disassembly is needed to correct any given
condition.
The service technician should become familiar with the operation and construction of each component or system
by carefully studying the complete manual. This manual will assist the service technician in becoming more aware
of and efficient with servicing procedures. Such efficiency not only helps build consumer confidence but also saves
time and labor.
All Arctic Cat ATV publications and decals display the words Warning, Caution, Note, and At This Point to
emphasize important information. The symbol ! WARNING identifies personal safety-related information.
Be sure to follow the directive because it deals with the possibility of severe personal injury or even death. The
symbol ! CAUTION identifies unsafe practices which may result in ATV-related damage. Follow the direc-
tive because it deals with the possibility of damaging part or parts of the ATV. The symbol
supplementary information worthy of particular attention. The symbol
nician to certain and specific procedures to promote efficiency and to improve clarity.
At the time of publication, all information, photographs, and illustrations were technically correct. Some photo-
graphs used in this manual are used for clarity purposes only and are not designed to depict actual conditions.
Because Arctic Cat Inc. constantly refines and improves its products, no retroactive obligation is incurred.
All materials and specifications are subject to change without notice.
Keep this manual accessible in the shop area for reference.
Product Service and
Warranty Department
Arctic Cat Inc.
© 2007 Arctic Cat Inc.
www.mymowerparts.com
®™ Trademarks of Arctic Cat Inc., Thief River Falls, MN 56701
AT THIS POINT directs the tech-
Back to TOC
NOTE: identifies
July 2007

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Summary of Contents for Arctic Cat 700 EFI

  • Page 1 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.
  • Page 2 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 TABLE OF CONTENTS Foreword Click on the red text to go. Section MORE TO GO ON. 400 Automatic 400 Automatic General Information/Specifications 400 Manual 400 Manual Periodic Maintenance 500 Automatic...

  • Page 3: Table Of Contents

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SECTION 1 - GENERAL INFORMATION/ SPECIFICATIONS TABLE OF CONTENTS General Specifications ..........1-2 Torque Specifications ..........1-3 Torque Conversions (ft-lb/N-m) ....... 1-5 Tightening Torque (General Bolts) ......1-5 Break-In Procedure ..........1-6 Gasoline - Oil - Lubricant ........

  • Page 4: General Specifications

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 General Specifications* 700 EFI CHASSIS CHASSIS Brake Type Hydraulic w/Brake Lever Lock Brake Type Hydraulic w/Brake Lever Lock and Auxiliary Brake and Auxiliary Brake Tire Size Front - 25 x 8-12...

  • Page 5: Torque Specifications

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Torque Specifications EXHAUST COMPONENTS DRIVE TRAIN COMPONENTS (400/500 - Manual Transmission) Torque Part Part Bolted To Torque ft-lb N-m Part Part Bolted To ft-lb Exhaust Pipe Engine (400/500/H1 Models) Engine (Lower Rear/Front)
  • Page 6 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 DRIVE TRAIN COMPONENTS ENGINE/TRANSMISSION (700 EFI) (400/500 - Automatic Transmission) Torque Torque Part Part Bolted To Part Part Bolted To ft-lb ft-lb Engine Mount (Rear) Frame Clutch Shoe Crankshaft Front Differential****...

  • Page 7: Torque Conversions (Ft-Lb/N-M)

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 ENGINE/TRANSMISSION (700 EFI) Torque Conversions Torque (ft-lb/N-m) Part Part Bolted To ft-lb Clutch Shoe Crankshaft 150.5 Clutch Cover/Housing Assembly Crankcase ft-lb ft-lb ft-lb ft-lb Crankcase Half (6 mm) Crankcase Half 35.4...

  • Page 8: Break-In Procedure

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 RECOMMENDED ENGINE/ TRANSMISSION OIL Break-In Procedure ! CAUTION Any oil used in place of the recommended oil could A new ATV and an overhauled ATV engine require a “break-in” period. The first 10 hours (or 200 miles) are cause serious engine damage.

  • Page 9: Genuine Parts

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 FILLING GAS TANK 1. Clean the seat cushion (cover and base) with a damp cloth and allow it to dry. ! WARNING 2. Clean the ATV thoroughly by washing dirt, oil, grass, and other foreign matter from the entire Always fill the gas tank in a well-ventilated area.

  • Page 10: Www.mymowerparts.com

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 2. Clean the engine. Remove the cloth from the ! CAUTION exhaust system. Connect the positive battery cable first; then the 3. Check all control wires and cables for signs of negative.
  • Page 11 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SECTION 2 - PERIODIC MAINTENANCE TABLE OF CONTENTS Periodic Maintenance Chart ........2-2 Periodic Maintenance..........2-3 Lubrication Points............ 2-3 Battery..............2-3 Fuses ..............2-4 Air Filter ..............2-5 Valve/Tappet Clearance (Feeler Gauge Procedure) ........

  • Page 12: Periodic Maintenance Chart

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 A = Adjust I = Inspect Periodic Maintenance C = Clean L = Lubricate Chart D = Drain R = Replace T = Tighten Initial Service Every Every 3 Every 6...

  • Page 13: Periodic Maintenance

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Periodic Maintenance Battery This section has been organized into sub-sections After being in service, batteries require regular cleaning which show common maintenance procedures for the and recharging in order to deliver peak performance and Arctic Cat ATV.

  • Page 14: Fuses

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 A. When using an automatic battery charger, ! CAUTION always follow the charger manufacturer’s instructions. Before installing the battery, make sure the ignition B. When using a constant-current battery charger, switch is in the OFF position.

  • Page 15: Air Filter

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 ! CAUTION 650 H1 Always replace a blown fuse with a fuse of the same type and rating. Air Filter Use the following procedure to remove the filter and inspect and/or clean it.
  • Page 16 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CF143A FI033 3. On all models except the 400, raise the storage 5. Remove the air filter element/screen assembly and compartment cover; then slide the cover forward separate the element from the screen.

  • Page 17: Valve/Tappet Clearance (Feeler Gauge Procedure)

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CHECKING AND CLEANING ! CAUTION DRAINS The feeler gauge must be positioned at the same 1. Inspect the drains beneath the main housing for angle as the valve and valve adjuster for an accurate debris and for proper sealing.

  • Page 18: Valve/Tappet Clearance (700 Efi)

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Valve/Tappet Clearance (700 EFI) To check and adjust valve/tappet clearance, use the following procedure. NOTE: The seat, heat shields, splash panels, front rack, and front fenders must be removed for this procedure (see Section 8).
  • Page 19 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 4. Using an appropriate thickness gauge, measure and record the clearance of both intake valves; then measure and record the clearance of both exhaust valves. Valve clearance must be within specifications.

  • Page 20: Testing Engine Compression

    ! CAUTION On the 700 EFI, do not ground the spark plug on the cylinder head cover. The cover is made of magne- sium and any contact with spark or electrical arc will severely pit the surface.

  • Page 21: Muffler/Spark Arrester

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 ATV-0051 CF105A 2. Using a suitable brush, clean the carbon deposits ! CAUTION from the screen taking care not to damage the screen. Before removing a spark plug, be sure to clean the area around the spark plug.

  • Page 22: Adjusting Engine Rpm (Idle)

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 AL611D AF920D 2. Turn the adjuster until the throttle cable has proper ! WARNING free-play of 3-6 mm (1/8-1/4 in.) at the lever. Adjust the idle to the correct RPM. Make sure the engine is at normal operating temperature before adjusting the idle RPM.
  • Page 23 Install the plug and tighten securely. 5. On the 700 EFI, remove the left-side engine cover and the left-front inner fender panel. 6. Using the adjustable Oil Filter Wrench and a suit- able wrench, remove the old oil filter.

  • Page 24: Front Differential/Rear Drive Lubricant

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CC163D AL677C 3. Drain the oil into a drain pan by removing in turn AT THIS POINT the drain plug from each. To check/service oil strainer, see Section 3. 4. Place the oil strainer into position beneath the crankcase and secure with the cap screws.

  • Page 25: Adjusting Clutch (400/500 Manual Transmission)

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 4. Rotate adjustment screw #2 alternately clockwise and counterclockwise to ensure free movement Adjusting Clutch without binding; then lock the jam nut securing adjustment screw #2. (400/500 Manual Transmission) 5. Rotate adjustment screw #1 clockwise 1/8 turn;...

  • Page 26: Driveshaft/Coupling

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 2. Using the Tachometer, start the engine and run at 1500 RPM; ignition timing should be 10° BTDC. Driveshaft/Coupling 3. Install the timing inspection plug. If ignition timing cannot be verified, the rotor may be...

  • Page 27: Shift Lever

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 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.
  • Page 28 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CF238A CF258A 3. Tighten the jam nuts securely; then shift the trans- mission to each position and verify correct adjust- ment. 4. Install the left-side engine cover and seat making sure the seat locks securely in place.

  • Page 29: Frame/Welds/Racks

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 9. Shift the transmission into each of the remaining positions and verify that the appropriate icon is displayed for the selected gear shift position (H - High, L - Low, and R - Reverse).
  • Page 30 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 NOTE: During the bleeding procedure, watch the NOTE: The brake pads should be replaced as a reservoir sight glass very closely to make sure set. there is always a sufficient amount of brake fluid.

  • Page 31: Burnishing Brake Pads

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 2. Remove the cap screws securing the V-belt cover noting the location of the different-lengthed cap Burnishing Brake Pads screws for installing purposes; then using a rubber mallet, gently tap on the cover tabs to loosen the cover.

  • Page 32: Adjusting Differential Lock Cable

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 NOTE: At this point, the push-bolt can be removed. 4. Rotate the V-belt and clutches until the V-belt is flush with the top of the driven clutch. 5. Place the V-belt cover gasket into position; then...
  • Page 33 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 2. Select the 2WD position on the front drive selector switch; then turn the ignition switch to the ON position and select the LOCK position on the dif- ferential lock selector. The front drive actuator should operate engaging four-wheel drive.

  • Page 34: Exhaust Chart

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Exhaust Chart NOTE: Use this chart in conjunction with the pro- cedure found in Valve/Tappet Clearance (700 EFI) in this section. www.mymowerparts.com ATV2152A Next Back 2-24 Back to TOC Back to Section TOC...

  • Page 35: Intake Chart

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Intake Chart NOTE: Use this chart in conjunction with the pro- cedure found in Valve/Tappet Clearance (700 EFI) in this section. www.mymowerparts.com Back 2-25 Back to TOC Back to Section TOC...

This manual is also suitable for:

400500h1700 h1 efi650 h1

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