Arctic Cat XR 500 Operator's Manual
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Arctic Cat XR 500 Operator's Manual

2015
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O P E R A T O R ' S M A N U A L
!
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.
WARNING
XR 500/550/700
www.arcticcat.com
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.

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Summary of Contents for Arctic Cat XR 500

  • Page 1 Operating this ATV if you are under Read this manual carefully. the age of 16 increases your chance UNDER It contains important safety of severe injury or death. information. NEVER operate this ATV if you are under 16. XR 500/550/700 www.arcticcat.com...
  • Page 2 Arctic Cat dealer for a replacement. tions. FAILURE TO FOLLOW THE WARN- For your safety, it is important to under-...

  • Page 3: Foreword

    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.

  • Page 4: Table Of Contents

    Control Locations and Functions..47 Warranty Procedure/Owner Power Steering ........50 Responsibility........4 Speedometer/LCD Gauge....51 Arctic Cat ATV Emission Control Electric Fuel Pump ....... 54 Warranty Statement......5 Gas Hoses ........... 54 Arctic Cat Emission Control System Oil Level Stick........54 Limited Warranty .........

  • Page 5: Limited Warranty

    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.

  • Page 6: Warranty Procedure/Owner Responsibility

    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.

  • Page 7: Arctic Cat Atv Emission Control Warranty Statement

    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.

  • Page 8: 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 9: Epa Emission Control Statement/Warranty Coverage (U.s. Only)

    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.

  • Page 10: Declaration Of Conformity

    EMC Directive 97/24/EC 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: XR 500 4x4 XR 700 4x4 XR 550 4x4 Standards...

  • Page 11: Division I - Safety

    • 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.

  • Page 12: Atv Safety Alert

    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.

  • Page 13: Rider Training Course

    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.

  • Page 14: Warning Labels, Hangtag, And Information

    Anyone who rides the ATV should read and understand this information before riding. 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. ...
  • Page 15 WL2015XR_1 Indicates a hazardous situation which, if not ! WARNING avoided, could result in death or serious injury.

  • Page 16: 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 17 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.
  • Page 18 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 19 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.
  • Page 20 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.
  • Page 21 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.
  • Page 22 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 23 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.

  • Page 24: Warnings

    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.

  • Page 25: Prevention

    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.

  • Page 26: Atv Condition

    Prevention 1. Tires and Wheels Helmets should have one of these: 2. Controls and Cables 1. DOT label 2. Snell label 3. Lights and Electric 3. ANSI Z90.1 label 4. Oil and Fuel 5. Chassis 6. Miscellaneous Items 1. Tires and Wheels Correct tire pressure is crucial.

  • Page 27: First Aid And Survival

    Prevention B. Throttle 5. Chassis The throttle should have a free, smooth Grass and leaves can gum-up your suspen- range of motion. If it seems to “stick” at sion and shocks. Clear and clean the sus- any point, refer to the General Mainte- pension arms, shock springs, and fenders.
  • Page 28 Prevention Tools Cellular Phone Routine maintenance will generally elim- It may be necessary to make an urgent inate the need for emergency repairs. phone call. Riding on rough terrain could cause loos- Maps/GPS (Global ening of nuts, bolts, and fasteners. Espe- Positioning System) cially on long rides, carrying the right Maps may be unnecessary when you’re...

  • Page 29: Active Riding

    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.

  • Page 30: Sound Judgment

    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.

  • Page 31: Those Around You

    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.

  • Page 32: Equipment

    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.

  • Page 33: Load Capacity Ratings

    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 Front Rack (Max) Could cause changes in ATV handling, Rear Rack (Max) which could lead to an accident.
  • Page 34 Sound Judgment Your Physical Condition TESTIMONIAL Your physical condition is critical to safe operation. Don’t ride when DOCUMENT#: X46481A1 CITY/STATE: LAUREL, MS extremely tired and consider your health SEX: M when planning longer rides. AGE: 25 BODY PART: ALL PARTS BODY Don’t ride: DATE ACCIDENT: 6-25-93 DISPOSITION: DOA...

  • Page 35: Sipde

    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.

  • Page 36: Supervision

    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...

  • Page 37: Division Ii - Operation/Maintenance

    2.4 L (2.5 U.S. qt) - 500 1.9 L (2.0 U.S. qt) - 550/700 Gasoline (Recommended) 87 Octane Regular Unleaded Engine Oil (Recommended) Arctic Cat ACX All Weather (Synthetic) Front Differential/Rear Drive Lubricant SAE Approved 80W-90 Hypoid Brake Fluid DOT 4...

  • Page 38: Location Of Parts And Controls

    Location of Parts and Controls XR026A XR054A 1. Battery 13. Throttle Limiter 2. Headlights 14. Throttle Lever 3. Hand Brake Lever 15. DC Power Outlet 4. Power Distribution Module 16. Taillight/Brakelight 5. Radiator Access Panel 17. Operator’s Manual Location 6. Seat Latch 18.

  • Page 39: Atv Operation

    ATV Operation 6. Press the starter button. Basic Operating Maneuvers CAUTION Do not run the starter motor for more Active riding and basic maneuvers are than eight seconds per starting the foundation of your ATV ride. Without attempt. The starter motor may over- basic skills, it’s impossible to move to heat causing severe starter motor this level—...

  • Page 40: Handling The Atv (Active Riding Techniques)

    ! WARNING  NOTE: The high range is for nor- Use only Arctic Cat approved brake mal riding with light loads. The low fluid. Never substitute or mix differ- range is for carrying heavy loads or ent types or grades of brake fluid.

  • Page 41: Wide Turns

    Leaning, Weight Shift, Your safety depends on using safe riding and Balance techniques. Statistics from the U.S. Con- sumer Product Safety Commission When you turn, the trick is to move for- (CPSC) say that inexperienced riders ward and slide over to the side of the seat who don’t use safe riding techniques are that’s on the inside of the turn.

  • Page 42: Quick Turns

    ATV-0046 ATV-0039 ATV-0045 ATV-0040 1. Ease off the throttle as you approach the turn to slow down. 2. Use the principles of leaning, weight shifting, and balancing—shift your body weight to the inside of the turn. 3. You might have to lean into the turn more than you do in a wide turn.
  • Page 43 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- ing—shift your body weight to the inside of the turn).

  • Page 44: Riding Uphill

    7. Let the ATV roll to your right side 3. If you lose speed, quickly shift to a until it faces slightly downhill. lower gear. At the same time, release the throttle (so your front tires don’t 8. Reapply the brakes. lift), OR 9.
  • Page 45 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.

  • Page 46: Tips

    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.

  • Page 47: Crossing Roads

    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.

  • Page 48: Stopping The Engine

     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...

  • Page 49: General Information

    The key to complete warranty claims properly. No cannot be removed in this position. warranty will be allowed by Arctic Cat if LIGHTS position — The ignition circuit is the VIN or ESN is removed or mutilated complete and headlights and taillight are on.

  • Page 50: Shift Lever

    Shift Lever ! WARNING The 4WD lock is intended for use where minimum traction is available. NEVER EXCEED 10 MPH (16 kph) with the lock engaged. Maneuverabil- ity and handling characteristics will differ with the lock engaged. Hand Brake Lever/Brake Lever Lock XR004A This ATV has a dual-range automatic...

  • Page 51: Engine Stop Switch

     NOTE: The brake lever lock must lock the wheels. If it doesn’t, take the ATV to an authorized Arctic Cat ATV dealer for service. ! WARNING Always check to be sure that the brake lever lock has been disengaged before operating the ATV.

  • Page 52: Power Steering

    Throttle Lever Power Steering This ATV was produced with an Elec- tronic Power Steering (EPS) system to reduce steering effort and driver fatigue over a broad range of operating condi- tions. The EPS system engages when the igni- tion switch is turned to the ON position and disengages after approximately five minutes (to conserve battery power) if the engine is not running.

  • Page 53: Speedometer/Lcd Gauge

    If the code continues to be dis- to shift between standard (MPH/miles/ played, take your ATV to an autho- Fahrenheit) and metric (km/h/kilome- rized Arctic Cat Dealer for EPS ters/Celsius). system servicing before resuming operation. To set the clock, use the following pro- CAUTION cedure.
  • Page 54 NOTE: Take the vehicle to an radiator core. The pressure may bend authorized Arctic Cat dealer to have or flatten the fins causing restricted the error corrected and the system air flow, and electrical components error reset as soon as possible.
  • Page 55 Diagnostic Trouble Codes Display Fault Description P0266 Cylinder #2 Fuel injector Balance/ Display Fault Description Open C0063 Tilt Sensor Circuit High P0336 Crankshaft Angle Sensor Synchroni- C0064 Tilt Sensor Circuit Low/SG/Open zation C1263 Backup/Reverse-Light Circuit Open P0337 Crankshaft Angle Sensor Circuit/SG C1264 Backup/Reverse-Light Circuit High P0339 Crankshaft Angle Sensor Intermittent/ C1265 Backup/Reverse-Light Circuit Low/...

  • Page 56: Electric Fuel Pump

    Electric Fuel Pump Seat Latch An electric fuel pump is incorporated in the gas tank to deliver gasoline to the fuel injector. The fuel pump is activated when the ignition switch is in the ON position.  NOTE: Both the ignition and fuel pump functions will be interrupted by the Tilt Sensor if the ATV tips over past 60°-70°.

  • Page 57: Trailering And Towing

    Arctic Cat ATV’s are equipped with a than when not towing a trailer. frame-mounted receiver for a standard 5.1 cm (2 in.) receiver hitch. The stan-...

  • Page 58: Gasoline-Oil-Lubricant

    CAUTION tilated area. Never add gasoline to the ATV gas tank near any open flames or Do not use white gas. Only Arctic Cat with the engine running or hot. DO approved gasoline additives should NOT SMOKE while filling the gas be used.

  • Page 59: Engine Break-In

    ATV pad wear or brake loss. Brake loss can result in severe injury. may be taken to an authorized Arctic Cat ATV dealer for this initial service. To properly burnish the brakes, use fol- New ATV’s and renewed ATV engines lowing procedure: require a “break-in”...

  • Page 60: General Maintenance

    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.

  • Page 61: Liquid Cooling System

    The cooling system should be inspected daily for leakage and damage. If leakage or damage is detected, take the ATV to an authorized Arctic Cat ATV dealer for ser- vice. Also, the coolant level should be checked periodically. XR060 CAUTION 3.

  • Page 62: Shock Absorbers

    CAUTION from the sleeve and remove load from the suspension; then use the Arctic Cat does not recommend spanner wrench to adjust the sleeve using a pressure washer to clean the to the desired position.
  • Page 63 Inspect the oil for any signs of metal hole. Install the level stick. filings or water. If found, take the ATV to an authorized Arctic Cat ATV 7. Start the engine (while the ATV is dealer for servicing. outside on level ground) and allow it to idle for a few minutes.

  • Page 64: Hydraulic Hand Brake

    Carefully inspect the hydraulic brake DOT 4 brake fluid. hoses for cracks or other damage. If found, take the ATV to an authorized Arctic Cat ATV dealer to have the brake hoses replaced. Brake Pads The clearance between the brake pads and brake discs is adjusted automatically as the brake pads wear.

  • Page 65: Rear Foot Brake

     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.

  • Page 66: Battery

    Maintenance end free-play seems excessive, con- charging is required on all batteries tact an authorized Arctic Cat ATV not used for more than two weeks or dealer for service. as required by battery drain. Drive Axle Boots 1. When charging a battery in the vehi- cle, be sure the ignition switch is in the OFF position.

  • Page 67: Jump-Starting

     expectations, bring the battery to NOTE: Not using a battery char- an authorized Arctic Cat dealer for ger with the proper float mainte- further troubleshooting. nance will damage the battery if connected over extended periods.
  • Page 68 1. On the vehicle to be jump-started, remove the battery cover and any ter- CAUTION minal boots. Failure disconnect electronic ! WARNING accessories during jump-starting may cause system damage due to Any time service is performed on a power spikes. battery, following must...

  • Page 69: Spark Plug

    Consult Throttle Cable an authorized Arctic Cat ATV dealer if the Adjustment plug insulator is not a light brown color. To adjust the throttle cable free-play:...

  • Page 70: Air Filter Housing Drain

    5. Slide the pre-filter over the closed end of the new filter and install into the CAUTION housing. Tighten the clamp securely. Failure to inspect the air filter fre- 6. Install the air filter housing cover and quently if the ATV is used in dusty, secure with the clips.

  • Page 71: Tires

    If proper tools and related items are not available, have this maintenance per- Wait until the muffler cools to avoid formed by an authorized Arctic Cat ATV burns. dealer or a qualified tire repair station. 1. Remove the cap screws securing the CAUTION spark arrester assembly to the muffler.

  • Page 72: Light Bulb Replacement

    2. Connect the new headlight bulb to the wiring harness and insert into head- light assembly. Turn clockwise to secure the bulb.  NOTE: On the Limited models, the headlight is a non-serviceable com- ponent; it must be replaced as an assembly.

  • Page 73: Checking/Adjusting Headlight Aim

    2, make horizontal marks on the period of use, consult an authorized aiming surface. Arctic Cat ATV dealer immediately. 4. Make vertical marks which intersect  NOTE: To remove the fuse, com-...

  • Page 74: Electrical Output Terminals

    Electrical Output Terminals Two output terminals for electrical acces- sories are located on the front and rear wiring harnesses. The accessory plug is located on the instrument pod. CAUTION Always use electrical accessories less than 180W. XR002B Storage Compartment/ The storage compartment is above the Tools engine in front of the seat.

  • Page 75: Preparation For Storage

    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.

  • Page 76: Preparation After Storage

    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.

  • Page 77: 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 vehicle is sold to another party.
  • Page 78 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Place Stamp CHANGE OF ADDRESS/OWNERSHIP Here ARCTIC CAT INC. PRODUCT SERVICE AND WARRANTY DEPT. P.O. BOX 810 THIEF RIVER FALLS, MN 56701...

  • Page 79: Maintenance Record

    Maintenance Record DATE MILEAGE SERVICE PERFORMED/NOTES...
  • Page 80 NOTES...

  • Page 81: Identification Numbers Record

    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.
  • Page 82 • avoid paved surfaces - pavement may seriously affect handling and control LOCATE AND READ OPERATOR’S MANUAL FOLLOW ALL INSTRUCTIONS AND WARNINGS © 2014 Arctic Cat Inc. Trademarks of Arctic Cat Inc. Thief River Falls, MN 56701 p/n 2260-349 ®TM...

This manual is also suitable for:

Xr 700Xr 550

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