400 TRV® 550 TRV® XT™/LIMITED 500 TRV® 700 TRV® XT™/LIMITED 1000 TRV® LIMITED 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.
Your 2-Up ATV Can Be Hazardous To Operate. A collision or rollover can occur quickly, even during routine maneuvers such as turning and driving on hills or over obstacles, if you fail to take proper precautions. For your safety and the safety of a passenger, it is important to understand and follow all the warnings contained in this Operator’s Manual and the labels on your ATV prior to riding. FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SERIOUS INJURY OR DEATH.
Foreword Congratulations and thank you from Arctic Cat Inc. for purchasing an ARCTIC CAT® TRV. Built with American engineering and manufacturing know-how, it is designed to provide superior ride, comfort, and utility. This Operator’s Manual is furnished to make sure that the operator and passenger are aware of safe operating procedures. It also includes information about the general care and maintenance of your ATV. Carefully read the following pages.
Table of Contents Foreword................................................. 1 Parts and Accessories .......................... 1 Limited Warranty ................................... 3 Warranty Procedure/Owner Responsibility .................................... 4 Arctic Cat ATV Emission Control Warranty Statement ........................... 5 Arctic Cat Emission Control System Limited Warranty.................. 6 U.S. EPA Emission Control Statement/ Warranty Coverage (U.S. Only).........
Limited Warranty Arctic Cat Inc. (hereinafter referred to as Arctic Cat) extends a limited warranty as described below on each new Arctic Cat ATV it assembles and on each genuine Arctic Cat ATV part and accessory assembled and sold by an authorized Arctic Cat ATV dealer.
Warranty Procedure/Owner Responsibility At the time of sale, a TRV 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 warranty coverage.
Arctic Cat ATV Emission Control Warranty Statement Warranty Rights and Obligations Arctic Cat Inc. (hereinafter referred to as Arctic Cat) and the California Air Resources Board are pleased to explain the emission control system warranty for each new Arctic Cat ATV sold in the state of California. In California, a new ATV must be designed, built, and equipped to meet the state’s stringent anti-smog standards.
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.
U.S. EPA Emission Control Statement/Warranty Coverage (U.S. Only) STATEMENT/WARRANTY Arctic Cat warrants to the original retail purchaser, and each subsequent purchaser, that all U.S. EPAcertified 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. Your authorized Arctic Cat ATV dealer will repair or replace any defective emission-related component at no cost to you during the warranty period.
Declaration of Conformity Application of council directives: 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: Standards to which conformity is declared: Manufacturer (if not issuing agent): 400 TRV 500 TRV 550 TRV/XT 550 Limited 700 Limited 1000 Limited 700 TRV/XT EN 61000-6-2:2005 EN 55012:2007 Arctic Cat Inc. 601 Brooks Ave S.
DIVISION I - SAFETY A 2-UP ATV Is Not A Toy And Can Be Hazardous To Operate. • Always go slowly and be extra careful when operating on unfamiliar terrain. Always be alert to changing terrain conditions when operating the ATV. • Never operate on excessively rough, slippery, or loose terrain. • 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.
A 2-Up ATV Is Not A Toy And Can Be Hazardous To Operate. • Never carry a passenger who cannot place both feet on the footrests and who cannot securely hold onto the handholds. FOR MORE INFORMATION ABOUT TRV SAFETY, contact your local Arctic Cat ATV dealer or 1613-739-1535 (Canada). TRV PASSENGER INSTRUCTIONS Operator, tell your passenger to: • Hold firmly onto the handholds. • Keep both feet on the footrests even when stopped. • Stay directly behind you leaning as you lean.
Rider Training Course FOR MORE INFORMATION ABOUT ATV SAFETY, in the U.S., call the Consumer Product Safety Commission at (800) 638-2772 or the ATV Distibutors’ Safety Hotline at (800) 852-5344 or in Canada, call the Canada Safety Council In Canada, the Canada Safety Council at 1-613-739-1535 (CSC) provides an ATV Rider’s Course to teach safe ATV operating skills. They ext. 227. Arctic Cat sponsors a free Rider Training Course to teach ATV riding skills or to reinforce current riding skills.
Hangtags This Arctic Cat TRV comes with hangtags containing important safety information. Anyone who rides the ATV should read and understand this information before riding. (400) 2257-220 2258-417 Pour commander des Etiquettes de Mise en Garde gratuites, voyez votre détaillant de autorisé VTT Arctic Cat pour le numéro de pièce 1436-799. 12 ! WARNING Indicates a hazardous situation which, if not avoided, could result in death or serious injury.
Warning Labels & Information An Arctic Cat ATV comes with several labels containing important safety 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. NOTE: The location and content of labels on the ATV you have purchased may differ from those shown on these two pages.
Warning Labels & Information (cont) CR040A 14 ! WARNING Indicates a hazardous situation which, if not avoided, could result in death or serious injury.
Warnings NOTE: The illustrations in this Warnings sub-section apply to an operator and a passenger even though some may show only the operator. ! WARNING POTENTIAL HAZARD Operating this ATV without proper instruction. WHAT CAN HAPPEN The risk of an accident is greatly increased if the operator does not know how to operate the ATV properly in different situations and on different types of terrain.
Warnings ! WARNING POTENTIAL HAZARD Carrying a passenger under the age of 12 on this ATV. WHAT CAN HAPPEN Could cause an accident, resulting in injury or death to you and/or your passenger. HOW TO AVOID THE HAZARD Never carry a passenger under the age of 12. The passenger must allow the operator to shift positions as needed during operation, must always keep feet on the footrests, and must always keep hands on handholds. NEVER CARRY MORE THAN ONE PASSENGER.
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. ! WARNING POTENTIAL HAZARD Operating or riding as a passenger on this ATV without wearing an approved helmet, eye protection, and protective clothing.
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. Always follow the inspection and maintenance procedures and schedules described in this Operator’s Manual.
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. HOW TO AVOID THE HAZARD Go slowly and be extra careful when operating on unfamiliar terrain. Always be alert to changing terrain conditions when operating the ATV.
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. Practice on smaller hills before attempting larger hills. ! WARNING POTENTIAL HAZARD Climbing hills improperly. WHAT CAN HAPPEN Could cause loss of control or cause the ATV to overturn.
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. When you go over obstacles, always follow proper procedures as described in this Operator’s Manual. ! WARNING POTENTIAL HAZARD Skidding or sliding.
Warnings ! WARNING POTENTIAL HAZARD Stalling, rolling backwards, or improperly dismounting while climbing a hill. WHAT CAN HAPPEN Could result in the ATV overturning. HOW TO AVOID THE HAZARD Use proper gear and maintain steady speed when climbing a hill. If you lose all forward speed: Keep weight uphill. Apply the brakes. Engage the brake lever lock after you are stopped. If you begin rolling backwards: Keep weight uphill. Apply the brakes while rolling backwards.
Warnings ! WARNING POTENTIAL HAZARD Operating the ATV through deep or fast flowing water. WHAT CAN HAPPEN Tires may float, causing loss of traction and loss of control, which could lead to an accident. HOW TO AVOID THE HAZARD Never operate the ATV in fast flowing water or in water deeper than the footrests. Remember that wet brakes may have reduced stopping capability. Test your brakes after leaving water. If necessary, apply them several times to dry out the pads.
Warnings ! WARNING POTENTIAL HAZARD Operating the ATV with improper modifications. WHAT CAN HAPPEN Improper installation of accessories or modification of the ATV may cause changes in handling which, in some situations, could lead to an accident. HOW TO AVOID THE HAZARD Never modify the ATV through improper installation or improper use of accessories.
Prevention Overview Gloves When using this 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 surroundings before riding your ATV, you give up control over the situation. Using ATV prevention techniques helps you forecast potential hazards before they injure you or damage your ATV. Your hands are targets for flying objects and branches.
Prevention If you drop or damage your helmet, get a new one immediately. Your helmet may not protect your head from injury if it has cracks, fissures, or other damage to its outside or core padding. Long Pants and Long Sleeved Shirt The goal is to protect your body from branches, long grass, airborne objects, or anything else that could scrape your skin. Remember, your helmet won’t do you The more thick and durable the material, any good if the chin strap isn’t fastened.
Prevention A. Brakes 4. OIL AND FUEL Squeeze your hand brake lever. If it feels soft or “squishy,” it could be low on fluid or have a leak — refer to the General Maintenance section of this Operator’s Manual for instructions. Don’t use the ATV until the brakes are operating normally. Start with a full tank of gas before every ride, and while you’re at it, top off the oil. Don’t forget to check for fluid leaks around the ATV. Watch the overheat lamp to ensure the engine coolant level is adequate.
Prevention Identification First Aid and Survival You need to prepare for the unexpected. Emergencies and accidents are traumatic enough, but they’re even worse when you’re not prepared for them. At the minimum during every ATV ride, you should have the following items on board: • • • • Tools Water Identification First Aid Kit If something does happen to you, the emergency personnel will want to know who you are and whom to contact. It’s possible you may be in no condition to give them that information.
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 turn by centrifugal force. Although a car is relatively stable, enough centrifugal force can cause the ATV to overturn.
Sound Judgment Overview You are not invincible. Knowing the first “S” in “P.A.S.S.” stands for “Sound Judgment” means you need to use yours. Do you consider yourself to be pretty conservative, or are you a heavy risktaker? Before continuing with this section on sound judgment, check your Risk Factor by doing this short survey: 1. Do you drive over the speed limit? 1 2 3 Never Sometimes Often 2. Are you more daring around your friends than you are when alone? 1 2 3 Never Sometimes Often 9.
Sound Judgment Terrain Trail Signs Always pay close attention to the terrain you’re on, even if it is familiar to you. You can’t assume the landscape you’re used to doesn’t change. Changes to landscape can happen at nearly any time. Fences can be constructed and excavations dug in a short period of time. Weather, climate, and development take their toll. Night Riding Riding at night can be very hazardous.
Sound Judgment Cargo Limitations Riding Companions Limit the ATV to the load capacity ratings identified in the Load Capacity Ratings chart. So if you and your passenger combined weigh in at over 500 lb (226 kg), leave some of that extra cargo at home. Riding with companions on several vehi- The combined weight limit, including you, cles is not the same as riding one ATV your passenger, your rack cargo, and your with a passenger.
Sound Judgment Speedrack Alcohol and Drug Consumption (Operator When installing Speedrack accessoand/or Passenger) ries, make sure to read and carefully follow the instructions provided in Alcohol is related to a high percentage of each kit including all weight restric- all hospital admissions due to accidents tions as noted on placards and decals. in the U.S. It’s extremely dangerous to drink alcoholic beverages and ride... it’s NOTE: Use extra caution when also very foolish.
Sound Judgment Your Physical Condition Group Behavior Being physically exhausted is like being drunk. Try to do something that’s detailoriented when you’re really tired, and you’ll feel totally uncoordinated. People occasionally do crazier and riskier things in a group than they would consider doing by themselves. When you’re riding with others and things start to get out of hand, decide whether you’re willing to be injured or see your friends injured. Don’t ride: 1.
Supervision Overview You’re responsible for supervising those who ride your ATV. Your wisdom is valuable... it’ll bring them all back safely— your friends, your family, your relatives, and your ATV. It’s crucial you consider yourself a supervisor for all riders of your ATV. Whether you accept responsibility or not, the truth is you are responsible for others riding your ATV. TRV’s are a little different from the handling to the stability to the controls.
DIVISION II - OPERATION/MAINTENANCE TRV Specifications ENGINE/DRIVE Type Bore x Stroke Displacement Spark Plug Type Spark Plug Gap Brake Types CHASSIS Length (Overall) Height (Overall) Width (Overall) Suspension Travel Tire Size (Front) Tire Size (Rear) Tire Inflation Pressure MISCELLANY Dry Weight (Approx) Gas Tank Capacity Coolant Capacity 400/500 550/700/1000 Four-Cycle/Oil Cooled - 400 Four-Cycle/Liquid Cooled - 500/550/700 Four-Cycle/Liquid-Cooled V-Twin - 1000 81.0 mm x 71.2 mm 92 mm x 82 mm (3.
Location of Parts and Controls 1. Battery 2. Headlights 3. Hand Brake Lever 4. Passenger Seat Latch Handles 5. Reverse Override Switch 6. Seat Lock Lever CR037A 7. Storage Compartment 8. Rear Foot Brake 9. Taillight/Brakelight 10. Brake Lever Lock 11. Key Switch 12. Shift Lever 13. Throttle Limiter 14. Throttle Lever CR036A 15. Operator’s Manual Location 16. Drive Select Switch 17. Handwarmer/Thumbwarmer Switch (Limited) 18. Headlight HI/LO Switch 19. Starter Button 20. Engine Stop Switch 21.
ATV Operation 2. Get seated in a comfortable position and keep hands firmly on the handholds. Basic Operating Maneuvers Active riding and basic maneuvers are 3. Always keep your feet planted on the foundation of your ride. Without the footrests. basic skills, it’s impossible to move to this level — active riding. These are your Starting the Engine basic maneuvers: Always start with the ATV on a flat, level surface.
ATV Operation Starting a Cold Engine NOTE: Do not touch the throttle lever until the engine has run for at NOTE: It is very important not to least 3 minutes. touch or compress the throttle lever during the starting procedures. 3. If the engine does not start, press the starter button again for eight sec1. Turn off all electrical accessories onds. (hand warmer, lights, etc.
ATV Operation 3. To engage reverse gear from neutral, move the shift lever outward and rearward into the R position. CAUTION Always come to a complete stop before attempting to shift from one range to the other or into reverse. Always shift on level ground, or engage the brake lever lock before shifting into another range or into reverse. Shifting (700/1000) 1. To engage any gear position from park, move the shift lever upward to the desired position.
ATV Operation Leaning, Weight Shift, and Balance Handling the TRV (Active Riding Techniques) When you turn, the trick is to move forward and slide over to the side of the seat that’s on the inside of the turn. Support Active riding involves moving your your body weight on the outside footrest. body. You and your passenger must learn At the same time, lean your body and the to lean and shift body weight into turns to passenger body to the inside of the turn. maintain control.
ATV Operation Sharp Turns Wide Turns Many accidents happen during turns. If After mastering wide turns, practice the you don’t understand turning techniques, advanced skill of sharp turns. it’s easy for the ATV to get away from you by losing traction, plowing, or tipping. Use this method for wide turns: ATV-0046 ATV-202 ATV-0045 1. Ease off the throttle as you approach the turn to slow down. 2.
ATV Operation K-Turns Quick Turns Quick turns are the most difficult turns Use K-turns if you accidentally stall while and should only be done after you are riding uphill; you need to take action before the ATV rolls backward down the hill. experienced with your ATV. ATV-203 1. Ease off the throttle as you approach the turn to slow down. 2.
ATV Operation 4. Ask the passenger to dismount. 5. Get off the ATV on the uphill side. 6. If you’re to the left of the ATV, turn the handlebar all the way left. 7. Partially release the brake, but lightly hold the brake lever. 3. If you lose speed, release the throttle (so your front tires don’t lift), OR 4. If that doesn’t work and you still have forward motion and the terrain permits, do a U-turn, go back down, and try climbing again, OR 5.
ATV Operation Sidehilling/Traversing Swerving Sidehilling is considered an advanced skill; it’s really tricky and unpredictable. So, whether your skills are advanced or not, try to avoid this kind of riding. If you’re in a situation where you absolutely have to sidehill, follow this method: Swerving is usually an emergency reaction to avoid an obstacle but is similar to quick turns. The difference is that quick turns involve slight acceleration in the turn; don’t accelerate if you swerve.
ATV Operation Crossing Obstacles Crossing obstacles is risky; avoid it if possible. Riding over logs, rocks, and ruts means combining all the active riding skills into one big motion. Your ATV will respond differently for different obstacles (logs, ruts, etc.), but these are general guidelines for overcoming twotrack (both tires contacting the obstacle at the same time) obstacles: 7. Apply a little throttle when the front tires make contact with the obstacle. 8.
ATV Operation Skidding or Sliding Crossing Water If you lose control after hitting sand, ice, This ATV can only handle water up to its footrests. Any more than that and you mud, or water: risk engine damage and/or personal 1. Turn your handlebar into the direc- injury. Stay away from fast moving rivtion of the slide. ers. Tires can be buoyant, so if the water 2. Keep your hand off the brakes until is too deep, you might find the ATV suddenly afloat. you’re out of the skid. 3. Shift your weight forward.
ATV Operation Cold Weather Driving NOTE: After the brakes thaw, dry them by applying them several NOTE: Check that all control times while riding slowly. levers move freely. Make sure that the footrest, shift lever, and rear foot NOTE: After riding through brake are free of ice and snow. water, mud, snow, or slush, it is important to dry both brake sys! WARNING tems before parking the ATV.
General Information TRV Identification Numbers This ATV has two identification numbers: Vehicle Identification Number (VIN) and Engine Serial Number (ESN). These numbers are required by the dealer to complete warranty claims properly. No warranty will be allowed by Arctic Cat if the VIN or ESN is removed or mutilated in any way. GZ001D Always provide the ATV name, VIN, and The VIN is located on the frame support ESN when contacting an authorized Arctic rail.
OFF position — All electrical circuits except the accessory plug are off. The engine will not start. The key can be removed in this position. NOTE: The accessory plug is powered by the battery at all times. ON position — The ignition circuit is complete and the engine can run. The key cannot be removed in this position. LIGHTS position — The ignition circuit is complete and headlights and taillight are on. The key cannot be removed in this position.
CR027C 738-420B The passenger’s handwarmers are controlled by a rocker-type switch located beneath the right-side handgrip. There are three positions on the switch (Low/ Off/High). 1. Squeeze the hand brake two or three times and release it. 2. Depress and hold the brake lever lock. 3. While holding in on the brake lever lock, squeeze the brake lever. NOTE: It will click as it engages and the brake lever will not return to its released position. 4.
Rear Foot Brake NOTE: This ATV has safety interlock switches which prevent the starter motor from activating when the transmission is not in neutral. To start the ATV while in gear, depress the rear foot brake or compress the brake lever; then depress the starter button. Reverse Override Switch This ATV is equipped with a reverse speed limiter system. When additional Pressing the rear foot brake downward RPM is needed in reverse, depress and hold the override switch.
NOTE: Turn the key switch to the OFF position then back to the ON position to reset the code. If the code continues to be displayed, take your ATV to an authorized Arctic Cat Dealer for EPS system servicing before resuming operation. CAUTION ATV-0053 2. Turn the throttle limiter screw clockwise to decrease engine RPM maximum or counterclockwise to increase engine RPM maximum. Never operate this ATV with a code indicated on the LCD gauge/speedometer.
The LCD will go blank except the word VOLT will flash on the LCD whenever a low voltage (<9 DC volts) or a high voltage (>16 DC volts) is detected. When voltage returns to normal, the gauge must be reset by turning the ignition key to the OFF position and then to the ON position. B. Press and hold the Set/Reset Button (4) until the minutes stop scrolling and the hour display starts to scroll.
11. High Beam Indicator - The High Beam icon will appear only when the headlights are on high beam. 12. Odometer/Trip Meter Indicator Display - Displays which function (ODO, Trip, or Trip 2) is selected. The letters EFI (digital/analog gauge) or a diagnostic trouble code (DTC) (digital gauge) will flash on the LCD whenever an EFI system error is detected. After 30 seconds, the gauge will return to normal, but the letters or code will continue to flash until the malfunction is corrected.
B. Press and hold Set/Reset Button (4) until minutes stop scrolling and the hour display starts to scroll. Momentarily release when correct hour is displayed; then repeatedly press and release Set/Reset Button until correct minutes are displayed. NOTE: Approximately two seconds after releasing either Button, the LCD will return to normal operation. NOTE: Clock memory power is supplied through the 15-amp accessory fuse and verified during gauge “power-up” and reset.
Electric Fuel Pump 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°. Righting the ATV will reactivate the ignition and fuel pump. Vacuum Fuel Pump (400) A vacuum fuel pump is mounted under the seat to deliver gasoline to the carburetor.
1. Direct the float bowl drain hose into a Windshied (Limited) container. CAUTION ! WARNING Do not drain float bowl contents directly onto the engine. Gasoline is highly flammable and could ignite. Use a hose. Remove the windshield before trailering the ATV or damage to the windshield may occur. To remove the windshield, loosen the left and right plastic knobs and remove the wind2. Loosen the drain screw and allow the shield assembly. Tighten the knobs securely gasoline and condensation to flow out.
2. Lift the rear of the seat up; then pull slightly to the rear and lift the seat off the mountings. 3. To lock the seat into position, engage the two front mounting lugs into the mounting rack; then, holding down firmly on the front of the seat, push the seat forward until the rear tabs engage the rear mounting latches. 2. To lock the seat into position, slide the front of the seat into the seat retainers and push down firmly on rear of seat. The seat should automatically lock into position.
Rack Loading When loading a trailer properly, two The racks are designed to carry specified items are critical: Gross Trailer Weight load capacity. Always refer to the Load (the weight of the trailer plus cargo) and Capacity Ratings chart for proper capacity. Trailer Tongue Weight. ! WARNING ! WARNING Make sure the load on the rack will not interfere with the controls or obstruct the view of the operator.
NOTE: Suitable hold-down straps are available from your Arctic Cat ATV dealer. Ordinary rope is not recommended because it can stretch under load. CAUTION When using hold-down straps, care must be taken not to damage the ATV. OILCHARTJ Gasoline-Oil-Lubricant Recommended Gasoline Recommended Front Differential/Rear Drive Lubricant The recommended gasoline to use is 87 minimum octane regular unleaded. In many areas, oxygenates are added to the gasoline.
ATV-049D During the first 10 hours of operation, always use less than ½ throttle. Varying the engine RPM during the break-in period allows the components to “load” (aiding the engine/transmission component mating process) and then “unload” (allowing components to cool). Although it is essential to place some stress on the engine components during break-in, care should be taken not to overload the engine too often. Do not pull a trailer during the break-in period.
General Maintenance NOTE: Proper maintenance of the ATV is important for optimum performance. Follow the Maintenance Schedule and all ensuing maintenance and care instructions/information. NOTE: Proper maintenance procedures for each item can be found on the corresponding page indicated. If, at any time, abnormal noises, vibrations, or improper functioning of any component of this ATV is detected, DO NOT OPERATE THE ATV.
Liquid Cooling System (500/550/700/1000) 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 service. Also, the coolant level should be checked periodically. When filling the cooling system, use a coolant/water mixture which will satisfy the coldest anticipated weather conditions of the area in accordance with the coolant manufacturer’s recommendations.
CAUTION Position Continued operation of the ATV with high engine temperature may result in engine damage or premature wear. 1 Spring Force Setting Load Soft Light 2 3 NOTE: High engine RPM, low vehicle speed, or heavy load can raise 4 engine temperature. Decreasing 5 Stronger Stiff Heavy engine RPM, reducing load, and selecting an appropriate transmis- NOTE: Before attempting to sion gear can lower the temperature.
Front Differential And Rear Drive Gear Lubricant (Inspecting/Changing) Check and change the gear lubricant in each according to the Maintenance Schedule. When changing the lubricant, use approved SAE 80W-90 hypoid oil and use the following procedure. NOTE: To check each, remove each filler plug. The oil level 3. Remove the drain plug from the bot- should be at the threads of each tom of the engine and drain the oil plug. into a drain pan. 1. Place the ATV on level ground. GZ007C 2.
Brake Lever Lock CF113A 6. Install the filler plugs. Hydraulic Hand Brake ! WARNING Be sure to inspect the hydraulic brake system before each use. Always maintain brakes according to the Maintenance Schedule. 738-420B Check to make sure the brake lever lock engages properly and that the brake (when engaged) locks the wheels. 1. Pump the brake lever 2 or 3 times. 2. Engage the brake lever lock. 3. Attempt to push the ATV.
Protective Rubber Boots The protective boots should be inspected periodically according to the Maintenance Schedule. Ball Joint Boots (Upper and Lower/Right and Left) PR376B 4. Install the wheel and tighten using a crisscross pattern in 20 ft-lb increments to 40 ft-lb (steel wheels) or 80 ft-lb (aluminum wheels). Rear Foot Brake The rear foot brake must be properly maintained to be fully functional. ! WARNING Be sure to inspect the rear foot brake system before each use.
3. Inspect the four tie rod boots for Loss of battery charge may be caused by cracks, tears, or perforations. ambient temperature, ignition OFF current draw, corroded terminals, self discharge, 4. Check the tie rod end free-play by frequent start/stops, and short engine run grasping the tie rod near the end and times. Frequent winch usage, snow plowattempting to move it up and down. ing, extended low RPM operation, short 5.
5. Plug the battery charger into a 110- Charging volt electrical outlet. NOTE: Arctic Cat recommends 6. If using the CTEK Multi US 800, the use of the CTEK Multi US 800 there are no further buttons to push. or the CTEK Multi US 3300 for batIf using the CTEK Multi US 3300, tery maintenance charging. press the Mode button (A) at the left of the charger until the Maintenance 1. Be sure the battery and terminals Charge Icon (B) at the bottom illuhave been cleaned with a baking minates.
Jump-Starting NOTE: Arctic Cat does not recommend jump-starting a vehicle with a dead battery but rather to remove the battery, service it, and correctly charge it; however, in an emergency, it may be necessary to jump-start a vehicle. If so, use the following procedure to carefully and safely complete this procedure. ! WARNING CAUTION Always make sure the electrical systems are of the same voltage and ground polarity prior to connecting jumper cables. If not, severe electrical damage may occur. 4.
7. Attach one clamp of the negative (black) jumper cable to the negative (-) terminal (3) of the good battery (B); then attach the other clamp of the negative (black) jumper cable (4) to an unpainted metal surface (A) on the engine or frame well away from dead battery and fuel system components. ! WARNING Never make the final connection to a battery as a spark could ignite hydrogen gases causing an explosion of the battery resulting in acid burns or blindness.
3. Tighten the knurled nut against the throttle cable adjuster securely; then slide the rubber boot over the adjuster. Engine Idle RPM Adjustment (400) NOTE: Idle RPM is not adjustable on the EFI models. To properly adjust the idle, a tachometer is necessary. CAUTION Failure to inspect the air filter frequently if the ATV is used in dusty, wet, or muddy conditions can damage the engine. 1. Remove the reinstallable rivets at the rear of the steering post cover; then unlatch the storage compartment lid.
9. Squeeze the element to remove excess oil; then install in the frame. CAUTION A torn air filter can cause damage to the engine. Dirt and dust may get inside the engine if the element is torn. Carefully examine the element for tears before and after cleaning it. Replace the element with a new one if it is torn. CD675A 4. Remove the air filter assembly and separate the foam filter from the frame. 400/500/550/700 10. Clean any dirt or debris from inside the air filter housing.
! WARNING The use of worn-out tires can be dangerous and can increase the risk of an accident. Tire Replacement This ATV has low-pressure tubeless tires. Air is sealed by the contact surfaces of CF110A the inner wheel rim and the tire bead. If either the inner wheel rim or tire bead is 3. Shift the range lever to the neutral damaged, air may leak. Be extremely position; then start the engine. careful not to damage these areas when 4. Increase and decrease engine RPM replacing tires.
5. Remove the wheel. 6. Install the wheel and install the lug nuts. 3. Install the spark arrester assembly and secure with the three cap screws. Tighten cap screws to 48 in.-lb. Light Bulb 7. Tighten the nuts in a crisscross pattern in 20 ft-lb increments to 40 ft-lb Replacement (steel wheels) or 80 ft-lb (aluminum The wattage rating of each bulb is shown wheels). in the chart. When replacing a burned bulb, always use the same wattage rating. 8. Remove the jack.
2. Push the bulb in and turn it counterclockwise. 3. Install the new bulb by turning it clockwise while pushing in. 4. Install the lens cover. CAUTION Tighten the lens cover screws only until they are snug. 6. Observe each headlight beam aim. Proper aim is when the most intense beam is centered on the vertical mark 5 cm (2 in.) below the horizontal mark on the aiming surface. 7.
CAUTION 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. Tool Storage Tray/ Battery Hold-Down A basic tool kit is provided with the ATV. Electrical Output Terminals Two output terminals for electrical accessories are located on the front wiring harness and one output terminal for electrical accessories is located on the rear wiring harness.
Preparation For Storage CAUTION Prior to storing the ATV, it must be properly serviced to prevent rusting and component deterioration. Arctic Cat recommends the following procedure to prepare this ATV for storage. An authorized Arctic Cat ATV dealer should perform this service; however, the owner/operator may perform this service if desired. 1. Clean the seat cushion (cover and base) with a damp cloth and allow to dry. 2.
Preparation After Storage Taking the ATV out of storage and correctly preparing it will assure many miles and hours of trouble-free riding. Arctic Cat recommends the following procedure to prepare the ATV. 1. Clean the ATV thoroughly. 2. Clean the engine. Remove the cloth from the exhaust system. 3. Check all control wires and cables for signs of wear or fraying. Replace if necessary. 4. Change the engine/transmission oil and filter. 5. Check the coolant level and add properly mixed coolant as necessary. 6.
Change of Address, Ownership, or Warranty Transfer Arctic Cat Inc. keeps on file the current name and address of the owner of this vehicle. This allows Arctic Cat to reach the current owner with any important safety information which may be necessary to protect customers from personal injury or property damage. 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.
Fold Back Place Stamp Here CHANGE OF ADDRESS/OWNERSHIP ARCTIC CAT INC. PRODUCT SERVICE AND WARRANTY DEPT. P.O.
Maintenance Record DATE MILEAGE SERVICE PERFORMED/NOTES 83
NOTES 84
Identification Numbers Record 1. KEY IDENTIFICATION NUMBER: The key identification number is stamped on the key as shown in the illustration. Record this number in the space provided for reference if you ever need a new key. 2. VEHICLE IDENTIFICATION NUMBER: 3. ENGINE SERIAL NUMBER: 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.
©2013 Arctic Cat Inc. ™ ®Trademarks of Arctic Cat Inc., Thief River Falls, MN 56701 (218) 681-9851 - U.S.
