Arctic Cat ATV 2005 Operator's Manual
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Arctic Cat ATV 2005 Operator's Manual

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Do not remove this Operator's Manual from this ATV
according to the guidelines and agreement with the U.S.
Consumer Product Safety Commission.
Read this manual carefully.
It contains important safety information.
WARNING
!
Operating this ATV if you are under
the age of 16 increases your chance
UNDER
16
of severe injury or death.
NEVER operate this ATV if you are
under 16.
2005
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ATV
Operator's Manual
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  • Page 1 2005 Operator's Manual Do not remove this Operator’s Manual from this ATV according to the guidelines and agreement with the U.S. Consumer Product Safety Commission. Read this manual carefully. It contains important safety information. WARNING Operating this ATV if you are under the age of 16 increases your chance UNDER of severe injury or death.
  • Page 2 Your ATV can be hazardous to operate. A collision or rollover can occur FAILURE TO FOLLOW THE WARN- quickly, even during routine maneuvers INGS CONTAINED IN THIS MAN- such as turning and driving on hills or UAL CAN RESULT IN SERIOUS over obstacles, if you fail to take INJURY OR DEATH.

  • Page 3: Introduction

    Introduction FOREWORD Congratulations and thank you from Protect Your Sport Arctic Cat Inc. for purchasing an ARC- ® • Know all local, state/provincial rid- TIC CAT All-Terrain Vehicle (ATV). ing laws, Built with American engineering and • Respect your ATV,...

  • Page 4: Table Of Contents

    Control Locations and Functions ..93 CHANGE OF ADDRESS, OWNERSHIP, Emergency Recoil Starter ....107 OR WARRANTY TRANSFER ..155 Gas/Vent Hoses ........ 109 ARCTIC CAT ATV EMISSION CONTROL Carburetor Float Bowl Drain....109 Oil Level Inspection Window (Manual WARRANTY STATEMENT....157 Transmission Models)....110...
  • Page 5 • Always check for obstacles before oper- • Always have the ATV checked by an ating in a new area. Never attempt to authorized Arctic Cat ATV dealer if it has operate over large obstacles, such as been involved in an accident.
  • Page 6 AN ATV IS NOT A TOY AND CAN BE HAZARDOUS TO OPERATE. MORE INFORMATION • No one under the age of 16 should oper- ABOUT ATV SAFETY, call the ATV ate this ATV. Some operators at the age Safety Institute at 1-800-887-2887 of 16 may not be able to operate an ATV (U.S.) or 1-613-739-1535 (Canada).
  • Page 7 ATV SAFETY ALERT The Consumer Product Safety Com- * A child under 16 years old should mission has concluded that ALL-TER- never operate an ATV with an RAIN VEHICLES (ATV’s) engine size greater than 90 cc. present a risk of DEATH or SEVERE * A child under 16 years old should INJURY in certain circumstances.

  • Page 8: Rider Training Course

    Rider Training Course Arctic Cat sponsors a free Rider Train- ing Course to teach ATV riding skills or to reinforce current riding skills. First-time purchasers without any pre- vious ATV riding experience will receive $100.00 from Arctic Cat through the SVIA/ASI after complet- ing the training course (U.S.

  • Page 9: Hang Tags & Warning Information

    Arctic Cat ATV dealer for a replacement. Pour commander des Etiquettes de Mise en Garde gratuites, voyez votre détail- lant de autorisé VTT Arctic Cat pour le numéro de pièce 0436-601. Indicates a potential hazard that could ! WARNING...

  • Page 10: Warning Labels

    Warning Labels (250/300) Indicates a potential hazard that could ! WARNING result in a serious injury or death.
  • Page 11 Warning Labels (400/500/650/650 V-Twin) Indicates a potential hazard that could ! WARNING result in a serious injury or death.
  • Page 12 Warning Labels (400 TBX/500 TBX) Indicates a potential hazard that could ! WARNING result in a serious injury or death.

  • Page 13: Location Of Parts And Controls

    Location of Parts and Controls (250/300) 1. Battery 2. Headlights 3. Hand Brake Lever 4. Fuel Valve 5. Choke Lever 6. Seat Lock Lever AF965 7. Tool Storage 8. Gearshift Pedal 9. Auxiliary Brake Pedal 10. Brake Lever Lock 11. Key Switch 12.
  • Page 14 Location of Parts and Controls (400 FIS/ACT) 1. Battery 2. Headlights 3. Hand Brake Lever 4. Fuel Valve 5. Power Distribution Module 6. Seat Lock Lever AL659C 7. Storage Compartment 8. Gearshift Pedal* 9. Auxiliary Brake Pedal 10. Brake Lever Lock 11.
  • Page 15 Location of Parts and Controls (500/650/650 V-Twin) 7. Storage Compartment 8. Gearshift Pedal* 9. Auxiliary Brake Pedal 10. Brake Lever Lock 11. Key Switch 12. Reverse Lever (Manual Transmission) AL672A 12. Low Range-High Range- Neutral-Reverse Lever 13. Throttle Limiter 14. Throttle Lever 15.
  • Page 16 Location of Parts and Controls (400 TBX/500 TBX) 1. Battery 2. Headlights 3. Hand Brake Lever 4. Tailgate Latch 5. Reverse Override Switch 6. Seat Lock Lever CD043 7. Left-Side Storage Compartment 8. Rigth-Side Storage Compartment 9. Auxiliary Brake Pedal 10.

  • Page 17: Warnings

    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).
  • Page 18 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 seri- ously affect handling and control of the ATV and may cause the ATV to go out of control.
  • Page 19 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.
  • Page 20 Warnings ! WARNING POTENTIAL HAZARD Failure to inspect the ATV before operating. Failure to properly maintain the ATV. WHAT CAN HAPPEN Increases the possibility of an accident or equipment damage. HOW TO AVOID THE HAZARD Always inspect your ATV each time you use it to make sure the ATV is in safe operating condition.
  • Page 21 Warnings ! WARNING POTENTIAL HAZARD Failure to use extra care when operating on rough, slippery, or loose terrain. WHAT CAN HAPPEN Could cause loss of traction or ATV control, which could result in an accident including a rollover. HOW TO AVOID THE HAZARD Do not operate on rough, slippery, or loose terrain until you have learned and practiced the skills necessary to control the ATV on such terrain.
  • Page 22 Warnings ! WARNING POTENTIAL HAZARD Climbing hills improperly. WHAT CAN HAPPEN Could cause loss of control or cause the ATV to over- turn. HOW TO AVOID THE HAZARD Always follow proper procedures for climbing hills as described in this Operator’s Manual.
  • Page 23 Warnings ! WARNING POTENTIAL HAZARD Improperly crossing hills or turning on hills. WHAT CAN HAPPEN Could cause loss of control or cause the ATV to overturn. HOW TO AVOID THE HAZARD Never attempt to turn the ATV around n any hill until you have mastered the turn- ing technique as described in this Operator’s Manual.
  • Page 24 Warnings ! WARNING POTENTIAL HAZARD Improperly operating over obstacles. WHAT CAN HAPPEN Could cause loss of control or a collision. Could cause the ATV to overturn. HOW TO AVOID THE HAZARD Before operating in a new area, check for obstacles. Never attempt to ride over large obstacles, such as large rocks or fallen trees.
  • Page 25 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.

  • Page 26: Prevention

    Prevention Overview When using an ATV, prevention is the name of the game. “Had you only known” something could go wrong, you would have prevented it. If you don’t notice your conditions and sur- roundings before riding your ATV, you give up control over the situation.

  • Page 27: Condition Of The Atv

    Prevention Helmet Long Pants and Long Sleeved Shirt Your helmet is the most important piece of protective gear for safe riding. A hel- The goal is to protect your body from met can prevent a severe head injury. branches, long grass, airborne objects, There are several types of helmets on or anything else that could scrape your the market, but make sure you wear a...
  • Page 28 Prevention One easy way to remember what parts you need to check is by using the acronym “T-CLOC.” It stands for: TIRES CONTROLS LIGHTS AND OIL AND FUEL CHASSIS AND WHEELS AND CABLES ELECTRIC TIRES AND WHEELS Test the brake lever lock and see if it locks the hand brake lever into posi- Correct tire pressure is crucial.

  • Page 29: First Aid And Survival

    Prevention First Aid and Survival Check: 1. Ignition switch You need to prepare for the unex- 2. Stop switch pected. Emergencies and accidents are traumatic enough, but they’re even OIL AND FUEL worse when you’re not prepared for Start with a full tank of gas before them.
  • Page 30 Prevention Identification Emergency Kit with Flashlight and First Aid If something does happen to you, the emergency personnel will want to know who you are and whom to con- You’ll need several items in your tact. It’s possible you may be in no Emergency Kit including a flashlight.

  • Page 31: Active Riding

    Active Riding Overview 2. Grab the right-side handlebar. “Active Riding” is the second part of 3. Swing your leg over the seat and “P.A.S.S.” It involves an understanding set your right foot down on the of how your body weight, balance, right-side footrest.
  • Page 32 Active Riding Starting A Cold Engine (250/300/650 V-Twin)  NOTE: It is very important not to touch or compress the throttle lever during the starting proce- dures. 1. Turn off all electrical accessories (hand warmer, lights, etc.); then rotate the ignition switch key to 738-436A the first position (ON) leaving the ...
  • Page 33 Active Riding • 0° C (32° F) - Use 5W-30 Arctic Cat 4-Cycle Engine Oil (p/n 0436-003). • -18° C (0° F) - Install 20 amp/hr Battery Kit (p/n 0436-183). • Below -18° C (0° F) - Install in-hose Engine Heater Kit (p/n 0436-035).
  • Page 34 Shifting always be prepared. Whether you’re (Manual Transmission) stopping slowly or stopping quickly, do The Arctic Cat ATV with a manual this: transmission has five forward gears. 1. Squeeze the brake lever on the left The neutral position is where you start.
  • Page 35 Also, on Transmission) the 300/400 FIS/500/650/650 V-Twin 4x4 models, determine whether or The Arctic Cat ATV with an automatic not you will be operating in 2- transmission has a dual-range transmis- wheel drive or 4-wheel drive. Make sion with reverse.

  • Page 36: How To Handle The Atv (Active Riding Techniques)

    Active Riding How to Handle the ! CAUTION ATV (Active Riding Always come to a complete stop Techniques) before attempting to shift from one Active riding involves moving your range to the other or into reverse. body. You must learn to lean and shift Always shift on level ground, or engage the brake lever lock before your weight into your turns to maintain...
  • Page 37 Active Riding Wide Turns 3. Shift into first gear. About 20% of ATV accidents happen 4. Release the brake slowly and during turns. If you don’t understand apply the throttle. turning techniques, it’s easy for the Leaning, Weight Shift, ATV to get away from you by losing and Balance traction, plowing, or tipping.
  • Page 38 Active Riding Sharp Turns Quick Turns After mastering wide turns, practice Quick turns are the most difficult turns the advanced skill of sharp turns. and should only be done after you are experienced with your ATV. ATV-0038 ATV-0021 ATV-0039 ATV-0022 ATV-0040 1.
  • Page 39 Active Riding K-Turns 2. Shut off the engine. Use K-turns if you accidentally stall 3. Keep your body weight shifted while riding uphill; you need to take forward. action before the ATV rolls backward 4. Get off the ATV on the uphill side. down the hill.
  • Page 40 Active Riding ATV-0033 1. Shift down and accelerate before you start climbing; then maintain a steady pace. 2. Lean as far forward as possible. For steeper hills, come off your seat to stand and lean forward. 3. If you lose speed, quickly shift to a lower gear.
  • Page 41 Active Riding Swerving Swerving is usually an emergency reaction to avoid an obstacle but is sim- ilar to quick turns. The difference is that quick turns involve slight accelera- tion in the turn; don’t accelerate if you swerve. ATV-211 1. Keep your speed low and consis- tent.

  • Page 42: Tips

    Active Riding Crossing Obstacles 5. Apply a little throttle when the front tires make contact with the Crossing obstacles is risky; avoid it if obstacle. possible. Riding over logs, rocks, and ruts means combining all the active rid- 6. Lean forward and release the throt- ing skills into one big motion.
  • Page 43 Active Riding 3. Backing down hills is a bad idea; 3. Nice and easy, apply the hand do a U-turn or K-turn instead to brake lever. turn around. 4. When you come to a stop, follow Skidding or Sliding the procedure for the K-turn. If you lose control after hitting sand, 5.
  • Page 44 Active Riding 5. Take into account that your ATV ! WARNING could stall while crossing; give yourself enough time to get off the Do not attempt to free frozen brakes road. by pouring warm water on the brake pads and housings. 6.

  • Page 45: Sound Judgment

    Sound Judgment Overview 8. Do you hurt yourself because you do things that are out of your You are not invincible. Knowing that ability range? the first “S” in “P.A.S.S.” stands for “Sound Judgment” means you need to Never Sometimes Often use yours.

  • Page 46: Environment

    Sound Judgment Environment Paved Surfaces The environment controls you, not the other way around. And there’s nothing Don’t do it! The ATV isn’t designed you can do about it except respect it. for pavement. Its handling becomes more difficult on paved surfaces. Weather Trail Riding You need to consider the weather.

  • Page 47: Those Around You

    ATV is detected, DO NOT you’re invisible, too. OPERATE THE ATV. Take the ATV to an authorized Arctic Cat ATV dealer TESTIMONIAL for inspection and adjustment or repair. DOCUMENT#: N490117A1 Cargo Limitations CITY/STATE: N.

  • Page 48: Personal Choices

    Chart: throw you off balance if it’s not distrib- uted evenly, side-to-side and front-to- rear. If you have 160 lb (73 kg) on the Arctic Cat ATV Load Capacity Ratings rear rack only and you’re heading up ITEM Specifications an incline, shifting your own weight...
  • Page 49 Sound Judgment Multi-Rack Platform (MRP) Rack: Substances to avoid when riding: 1. Alcohol When installing MRP accessories, 2. Over-the-counter or prescription drugs make sure to read and carefully fol- 3. Illegal/mood altering drugs low the instructions provided in each Be aware of prescription and over-the- kit.
  • Page 50 Sound Judgment Your Physical Group Behavior Condition People always do crazier and riskier things in a group than they would con- Being physically exhausted is like sider doing by themselves. When being drunk. Try to do something that’s you’re ATV riding with others and detail-oriented when you’re really things start to get out of hand, decide tired, and you’ll feel totally uncoordi-...

  • Page 51: Supervision

    Supervision Overview TESTIMONIAL You’re responsible for supervising DOCUMENT#: N37023A1 those who ride your ATV. Your wisdom CITY/STATE: MOOERSFORKS, NY is valuable . . . it’ll bring them all back SEX: F AGE: 5 safely—your friends, your family, your BODY PART: UPPER TRUNK relatives, and your ATV.
  • Page 52 Supervision Arctic Cat and the ATV Safety Institute TESTIMONIAL recommend that all ATV operators ride the appropriate-sized ATV according to DOCUMENT#: X46418A1 CITY/STATE: LAUREL, MS age. SEX: M AGE: 25 BODY PART: ALL PARTS BODY Speed Engine Size DATE ACCIDENT: 6-25-93...

  • Page 53: Division Ii - Operation/ Maintenance

    PARTS AND ACCESSORIES When in need of replacement parts, oil, or accessories for your Arctic Cat ATV, be sure to use only GENUINE ARCTIC CAT PARTS, OIL, AND ACCESSORIES. Only genuine Arctic Cat parts, oil, and accessories are engineered to meet the standards and requirements of your Arctic Cat ATV.

  • Page 54: Declaration Of Conformity

    EMC Directive 89/336/EEC Date of Issue: October, 1993 EC Machinery Directive 89/392/EEC Date of Issue: June, 1993 Issued by European Commission. Type of Equipment: All Terrain Vehicles Brand Name: Arctic Cat Model: 250 2x4 500 4x4 250 4x4 650 4x4...

  • Page 55: 250 Atv Specifications

    250 ATV SPECIFICATIONS* ENGINE AND DRIVE Type Four-Cycle/Oil Cooled Bore x Stroke 66 mm x 72 mm (2.60 x 2.83 in.) Displacement 246 cc ( 15 cu in.) Ignition Type Ignition Timing 5° BTDC below 1800 RPM 35° BTDC above 3800 RPM Spark Plug Type NGK DR7EA Spark Plug Gap...
  • Page 56 300 ATV SPECIFICATIONS* ENGINE AND DRIVE Type Four-Cycle/Oil Cooled Bore x Stroke 68.5 x 76 mm (2.69 x 2.99 in.) Displacement 280 cc (16.7 cu in.) Ignition Type Ignition Timing 5° BTDC @ 1800 RPM 30° BTDC @ 3800 RPM Spark Plug Type NGK DR7EA Spark Plug Gap...
  • Page 57 400 AUTO ATV SPECIFICATIONS* ENGINE AND DRIVE Type Four-Cycle/Oil Cooled Bore x Stroke 82 mm x 71.2 mm (3.29 x 2.80 in.) Displacement 376 cc (22.94 cu in.) Ignition Type Ignition Timing 10° BTDC @ 1500 RPM Spark Plug Type NGK CR7E Spark Plug Gap 0.7 - 0.8 mm (0.028 - 0.032 in.)
  • Page 58 400 TBX ATV SPECIFICATIONS* ENGINE AND DRIVE Type Four-Cycle/Oil Cooled Bore x Stroke 82 mm x 71.2 mm (3.29 x 2.80 in.) Displacement 376 cc (22.94 cu in.) Ignition Type Ignition Timing 10° BTDC @ 1500 RPM Spark Plug Type NGK CR7E Spark Plug Gap 0.7 - 0.8 mm (0.028 - 0.032 in.)
  • Page 59 400 MANUAL ATV SPECIFICATIONS* ENGINE AND DRIVE Type Four-Cycle/Oil Cooled Bore x Stroke 82 mm x 71.2 mm (3.29 x 2.80 in.) Displacement 376 cc (22.94 cu in.) Ignition Type Ignition Timing 10° BTDC @ 1500 RPM Spark Plug Type NGK CR7E Spark Plug Gap 0.7 - 0.8 mm (0.028 - 0.032 in.)
  • Page 60 500/500 TBX ATV SPECIFICATIONS* ENGINE AND DRIVE Type Four-Cycle/ Liquid Cooled Bore x Stroke 87.5 mm x 82 mm (3.40 x 3.22 in.) Displacement 493 cc (30.1 cu in.) Ignition Type Ignition Timing 10° BTDC @ 1500 RPM Spark Plug Type NGK CR6E Spark Plug Gap 0.7 - 0.8 mm (0.028 - 0.032 in.)
  • Page 61 650 ATV SPECIFICATIONS* ENGINE AND DRIVE Type Four-Cycle/ Liquid Cooled Bore x Stroke 98 mm x 85 mm (3.86 x 3.35 in.) Displacement 641 cc (39.1 cu in.) Ignition Type Spark Plug Type Champion R6YCA Spark Plug Gap 0.7 - 0.8 mm (0.028 - 0.032 in.) Brake Type Hydraulic w/Brake Lever Lock and Auxiliary Brake Carburetor Type...
  • Page 62 650 V-Twin ATV SPECIFICATIONS* ENGINE AND DRIVE Type SOHC/V-Twin/Four-Cycle/ Liquid Cooled Bore x Stroke 80 mm x 63 mm (3.15 x 2.48 in.) Displacement 633 cc (38.6 cu in.) Ignition Type Digital DC - CDI Ignition Timing 5° BTDC @ 1500 RPM/28° BTDC @ 5000 RPM Spark Plug Type NGK CR7E Spark Plug Gap...

  • Page 63: General Information

    On the 250/300, the Engine Serial NUMBERS Number is located on the right-side rear of the engine crankcase. The Arctic Cat ATV has two identifica- tion numbers: Vehicle Identification Number (VIN) and Engine Serial Number (ESN). On the 250/300, the Vehicle Identifica-...

  • Page 64: Ignition Switch Key

    ATV-0056 properly. No warranty will be allowed OFF position — All electrical circuits by Arctic Cat if the VIN or ESN is except the accessory plug are off. The removed or mutilated in any way. engine will not start. The key can be removed in this position.
  • Page 65 Speedometer (300/400 1. Odometer/Trip Meter Display ACT Auto/400 TBX) Button — Press the display button to display the Odometer (10), the A & B Trip Meters (10), and in conjunction with the Clock/Hour Display Button (6), the speedome- ter km/h and mph displays. 2.
  • Page 66 6. Clock/Hour Meter Display But- 10. Odometer/Trip Meters (A & B) ton — Press the display button to — Odometer registers the total dis- switch to either the clock or hour tance the ATV has traveled. Trip meter and in conjunction with the meters can register two different Odometer/Trip Meter Display But- types of distances (for instance, A...
  • Page 67 3. Neutral Indicator — The Neutral  NOTE: Debris in front of the light will illuminate when the engine (or packed between the transmission is in neutral and the cooling fins of the radiator) can ignition switch is on. The light will reduce cooling capability.
  • Page 68 14. Mode Button — Used (in con- junction with the Odometer/Trip Meters/Hour Meter) to shift the odometer/trip meters/hour meter display through the four modes: odometer, trip meter (A), trip meter (B), and hour meter. Reverse Shift Lever (Manual Transmission) 736-567A To shift into reverse gear, stop the ATV Select HIGH, LOW, or SUPER-LOW completely and shift the transmission...
  • Page 69 4. Allow the range lever to lock into To shift to a different range, use the fol- the desired position. lowing procedure: 1. Stop the ATV completely. If on an ! CAUTION inclined surface, engage the brake Make sure the range lever locks into lever lock.
  • Page 70 ! CAUTION 400/500 Always shift into low range when operating on wet or uneven terrain, when towing or pushing heavy loads, and when using a plow. Fail- ure to follow this caution may result in premature V-belt failure or in damage to related drive system components.
  • Page 71 To either engage or disengage the front wheels, come to a complete stop; then either push (to engage) or pull (to dis- engage) the front wheel differential. Apply slight throttle until positive engagement of the differential has been observed. ! CAUTION Do not attempt to either engage or KX016A disengage...
  • Page 72 The engine cannot be started or lock the wheels. If it doesn’t, take will not run. If the emergency stop the ATV to an authorized Arctic Cat switch is used to stop engine without ATV dealer for service. turning off ignition switch, the battery may discharge.
  • Page 73 Reverse Override Switch - Automatic Transmission These ATV’s are equipped with a reverse speed limiter system. When additional RPM is needed in reverse, depress and hold the override switch. ! WARNING ATV-0053 Never activate the override switch 1. Loosen the jam nut. while the throttle is open as a loss of control may result.
  • Page 74 Decompression Lever (250/300)  NOTE: The engine on some mod- els can be started in any gear if the hand brake lever is applied. How- ever, it is recommended to shift into neutral before starting the engine. ATV-1098 In the OFF position, the valve will not allow gasoline to flow to the carbure- tor.

  • Page 75: Emergency Recoil Starter

    If the emergency recoil starter is to be STARTER used on automatic transmission mod- els, make sure the range/reverse shift All Arctic Cat ATV models have an selector is in the neutral position. emergency recoil starter if the electric starter becomes inoperative. This recoil...

  • Page 76: Oil Level Inspection Window (Manual Transmission Models)

    OIL LEVEL STICK ! WARNING (Automatic Transmission Models) Do not drain float bowl contents directly onto the engine. Gasoline is There is an oil level stick for checking highly flammable and could ignite. the engine oil level. To check the oil Use a hose.

  • Page 77: Seat Latch (250/300)

    ! CAUTION ! WARNING Do not overfill the engine with oil. Make sure the seat is secure before Always make sure the oil level is mounting the ATV. Severe personal above the “L” mark but not higher injury may result if the seat is not than the “F”...

  • Page 78: Cargo Box Latch Handles (400 Tbx/500 Tbx)

    CARGO BOX LATCH RACK LOADING HANDLES (Front and Rear) (400 TBX/500 TBX) The front rack and rear rack are designed to carry specified load capaci- ties. Always refer to the appropriate ATV Load Capacity Ratings Chart for proper capacities. ! WARNING Make sure the loads on the front and rear racks will not interfere with the ATV controls or obstruct the...

  • Page 79: Transporting Atv

    TRANSPORTING ATV 738-424 ! WARNING When transporting the ATV, Arctic Cat recommends that the ATV be in its nor- Make sure that the load in the trailer mal operating position (on all four is properly secured and will not wheels) and the following procedure be shift while moving.

  • Page 80: Gasoline-Oil-Lubricant

    10% ethanol, 5% Lubricant methane, or MTBE are acceptable gas- olines.  NOTE: Arctic Cat recommends the use of genuine Arctic Cat lubri- When using ethanol blended gasoline, cants. it is not necessary to add a gasoline antifreeze since ethanol will prevent...

  • Page 81: Break-In Procedure

    RPM during the break-in ATV may be taken to an authorized period allows the components to “load” Arctic Cat ATV dealer for this initial (aiding the engine/transmission com- service. ponent mating process) and then “unload”...

  • Page 82: General Maintenance

    ATV is important for optimum tenance procedures or checks, take the performance. Follow the Mainte- ATV to an authorized Arctic Cat ATV nance Schedule and all ensuing Maintenance Instructions/Informa- dealer for professional service.

  • Page 83: Maintenance Schedule

    MAINTENANCE SCHEDULE Initial 100 Every 300 Every 500 Every 100 miles miles miles miles Item Page (160 km) (482 km) (804 km) (160 km) after break- or 3 or 6 or 1 month months months Battery * Engine nuts and bolts —...

  • Page 84: Liquid Cooling System (500/650/650 V-Twin)

    If leak- check the coolant level. Add coolant age or damage is detected, take the as necessary. ATV to an authorized Arctic Cat ATV SHOCK ABSORBERS dealer for service. Also, the coolant level should be checked periodically.

  • Page 85: General Lubrication

     NOTE: Use a spanner wrench to adjust the sleeve to the desired position. Spring Position Setting Load Force Soft Light 733-441C 4. Remove the three nuts securing the filter cover. Stronger Stiff Heavy GENERAL LUBRICATION Cables None of the cables require lubrication; however, it is advisable to lubricate the ends of the cables periodically with a good cable lubricant.
  • Page 86 9. Install the engine drain plugs and tighten securely. Pour the recom- mended oil in the filler hole. Install filler plug. 10. Start the engine (while the ATV is outside on level ground) and allow it to idle for a few minutes. 11.
  • Page 87 5. Using the oil filter wrench and a ratchet handle (or a socket or box- end wrench), remove the old oil filter and dispose of properly. Do not re-use oil filter.  NOTE: Clean up any excess oil after removing the filter. 6.
  • Page 88 2. Remove each oil filler plug. ! CAUTION Inspect the oil for any signs of metal filings or water. If found, take the ATV to an authorized Arctic Cat ATV dealer for servicing. 5. Pour recommended oil into each filler hole.

  • Page 89: Hydraulic Hand Brake

    If the level in the reser- lock the wheels. If it doesn’t, take voir is not visible in the sight glass, add the ATV to an authorized Arctic Cat DOT 4 brake fluid. ATV dealer for service. Brake Hoses Carefully inspect the hydraulic brake hoses for cracks or other damage.

  • Page 90: Auxiliary Brake (250/300/400 Act)

    3. If thickness of either brake pad is To adjust (set up) the brake, use the fol- less than 3.2 mm (0.125 in.), take lowing procedure. the ATV to an authorized Arctic 1. Loosen the right-hand jam nut Cat ATV dealer to have brake pads (wheel-side when viewing from replaced.

  • Page 91: Auxiliary Brake (Fis Models)

    When the right-hand jam nut cannot CD472 be loosened (bottoms against the rubber adjuster arm stop), both brake pads must be replaced. Take the ATV to an authorized Arctic Cat ATV dealer for this service. AUXILIARY BRAKE (FIS Models) The auxiliary brake must be main- tained to be fully functional.

  • Page 92: Protective Rubber Boots

    2. Making sure the brake pedal is fully released and against the stop,  NOTE: Take the ATV to an autho- check that the holes in the push- rized Arctic Cat ATV dealer for this rod actuator align with the hole in service. the pedal lever.

  • Page 93: Gearshift Pedal Adjustment (250/300)135

    5. If boot damage is present or ball joint free-play seems excessive, contact an authorized Arctic Cat ATV dealer for service. Tie Rod Boots (Inner and Outer/Right and Left) CC793 2. If boot damage is present, contact an authorized Arctic Cat ATV dealer for service.

  • Page 94: Battery

    1. Loosen the jam nut on the shift If the battery is discharged, remove the rod. battery from the ATV and charge the battery at the standard charging rate of 1.4 amps for 10 hours. To remove and charge the battery, use the following procedure.

  • Page 95: Spark Plug

    400/500/ need to be adjusted. Consult an 650 V-Twin authorized Arctic Cat ATV dealer if the plug insulator is not a light brown color. To help prevent cold weather fouling, make sure to thor- oughly warm up the engine before operating.

  • Page 96: Engine Idle Rpm Adjustment

    ENGINE IDLE RPM ! WARNING ADJUSTMENT Adjust the idle to the correct RPM. To properly adjust the idle, a tachome- Make sure the engine is at normal ter is necessary. If one is not available, operating temperature before take the ATV to an authorized Arctic adjusting the idle RPM.
  • Page 97 1. Remove the seat. C. On the 400 TBX/500/650/650 V-Twin, remove the two fasten- 2. Remove the air filter housing ers securing the storage com- cover. partment remove storage compartment. Remove the air cleaner housing cover 400 TBX/500/650/650 V-Twin from the four retaining clips; then remove the air filter.

  • Page 98: Air Filter Housing Drain Tube

    B. On the 400 FIS/ACT, place the 400 TBX/500/650/650 V-Twin filter in the air filter housing making sure it is properly in position and seated and secure with the clamp; then install the cover and secure with the retaining clips. C.

  • Page 99: Tires

    If proper tools and related sary). items are not available, have this main- TIRES tenance performed by an authorized Arctic Cat ATV dealer or a qualified ! WARNING tire repair station. Always use the size and type of ! CAUTION tires as specified.

  • Page 100: Wheel Removal

    1. Shift the transmission into neutral ! WARNING and engage the brake lever lock. Use only Arctic Cat approved tires 2. Elevate the front of the ATV on a when replacing tires. Failure to do safety stand until the muffler is so could result in unstable ATV horizontal.

  • Page 101: Checking/Adjusting Headlight Aim

    Headlight 4. Install the lens cover.  NOTE: The bulb portion of the ! CAUTION headlight is fragile. HANDLE WITH Tighten the lens cover screws only CARE. When replacing the head- until they are snug. light bulb, do not touch the glass portion of the bulb.

  • Page 102: Fuses

    ATV-0070 AL670A 7. Adjust each headlight until correct FUSES aim is obtained. The fuses are located in a fuse block  NOTE: On the 250/300/400 FIS/ under the center cover in the front ACT models, it will be necessary to fender assembly (on the 250/300 mod- remove the two machine screws els), under the seat (on the 400 ACT...

  • Page 103: Electrical Output Terminals

    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. ELECTRICAL OUTPUT TERMINALS 738-503A One output terminal for electrical accessories is located on the front wir- ing harness.

  • Page 104: Preparation For Storage

    Arctic Cat recommends the following the shock absorbers. procedure to prepare the ATV for stor- age. An authorized Arctic Cat ATV 7. Tighten all nuts, bolts, cap screws, dealer should perform this service; and screws. Make sure rivets hold- however, the owner/operator may per- ing components together are tight.

  • Page 105: Preparation After Storage

    (fluid level, pads, etc.), all con- miles and hours of trouble-free riding. trols, headlights, taillight, brake- Arctic Cat recommends the following light, and headlight aim; adjust or procedure to prepare the ATV. replace if necessary.
  • Page 106 NOTES...

  • Page 107: Limited Warranty

    The warranty periods are as follows: 1. Six months from the date of sale — for an Arctic Cat ATV used for recreational pur- poses. 2. Six months from date of sale — for batteries on full exchange basis.

  • Page 108: Warranty Procedure/Owner Responsibility

    (included with each new ATV) 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 warranty coverage.

  • Page 109: Change Of Address, Ownership, Or Warranty Transfer

    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.
  • Page 110 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Place Stamp Here CHANGE OF ADDRESS/OWNERSHIP ARCTIC CAT INC. PRODUCT SERVICE AND WARRANTY DEPT. P.O. BOX 810 THIEF RIVER FALLS, MN 56701...

  • Page 111: Arctic Cat Atv Emission Control Warranty Statement

    Manual. Arctic Cat recommends the retention of all receipts covering maintenance per- formed 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.

  • Page 112: Arctic Cat Emission Control System Limited Warranty

    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.

  • Page 113: Index

    INDEX Maintenance Record .......... 160 Maintenance Schedule........121 Mounting the ATV ..........45 Accessories............81 Muffler/Spark Arrester ........144 Active Riding ............45 Multi-Rack Platform (MRP)........75 Air Filter.............. 139 Oil ............... 116 Air Filter Housing Drain Tube ......141 Oil and Filter ..........

  • Page 114: Maintenance Record

    MAINTENANCE RECORD DATE MILEAGE SERVICE PERFORMED/NOTES...

  • Page 115: Identification Numbers Record

    Indicates a potential hazard that could result in serious injury or death. 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.
  • Page 116 ï avoid paved surfaces - pavement may seriously affect handling and control LOCATE AND READ OPERATORíS MANUAL FOLLOW ALL INSTRUCTIONS AND WARNINGS Dealer Imprint ©2004 Arctic Cat Inc. ôÆTrademarks of Arctic Cat Inc., Thief River Falls, MN 56701, (218) 681-4999 Printed in the U.S.A. p/n 2257-034...

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