Operator’s Manual 2010 450 H1 550 H1 700 H1 700 H1 Mud Pro 700 H1 TBX 1000 H2 Mud Pro Thundercat SHARE O UR PASSI O N.TM ! 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. UNDER 16 WARNING Operating this ATV if you are under the age of 16 increases your chance of severe injury or death. NEVER operate this ATV if you are under 16.
Your 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. FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SERIOUS INJURY OR DEATH. Training is available: U.S. owners, call For your safety, understand and follow 1-800-887-2887; Canadian owners, all the warnings contained in this Oper- call 1-613-739-1535.
Foreword Congratulations and thank you from Arctic Cat Inc. for purchasing an ARCTIC CAT® All-Terrain Vehicle (ATV). Built with American engineering and manufacturing know-how, it is designed to provide superior ride, comfort, and utility. Protect Your Sport • Know all local, state/provincial riding laws, • Respect your ATV, • Respect the environment, and • You will gain the respect of others. We also advise you to strictly follow the recommended maintenance program as outlined.
Table of Contents FOREWORD......................................... 1 DIVISION I - SAFETY ATV SAFETY ALERT ........................... 5 RIDER TRAINING COURSE ................ 6 HANGTAG ............................................ 7 WARNING LABELS & INFORMATION ................................. 8 WARNINGS ..................................... 9-17 PREVENTION................................ 18-22 Safe Riding Clothing and Gear ........... 18 Condition of the ATV ...........................
DIVISION I - SAFETY An 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.
An ATV is not a toy and can be hazardous to operate. • Always be sure there are no obstacles or people behind you when you operate in reverse. When it is safe to proceed in reverse, go slowly. Avoid turning at sharp angles in reverse. • Always use the size and type tires specified in this manual. Always maintain proper tire pressure as described in this manual. • Never improperly install or improperly use accessories on this ATV. • Never install a twist grip throttle on this ATV.
ATV Safety Alert The Consumer Product Safety Commission has concluded that ALL-TERRAIN VEHICLES (ATV’s) may present a risk of DEATH or SEVERE INJURY in certain circumstances. Accidents may occur for many reasons: • A child under 16 years old should never operate an ATV without adult supervision. Children need to be observed carefully because not all children have the strength, size, skills, or judgment to operate an ATV safely.
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. owners only, one incentive, and free rider training courses for appropriate immediate family members per ATV purchase).
Hangtag An Arctic Cat ATV comes with a hangtag containing important safety information. Anyone who rides the ATV should read and understand this information before riding. 2258-133 Pour commander des Etiquettes de Mise en Garde gratuites, voyez votre détaillant de autorisé VTT Arctic Cat pour le numéro de pièce 1436-344. ! WARNING Indicates a potential hazard that could result in a serious injury or death.
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 this page.
Warnings 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. HOW TO AVOID THE HAZARD Beginning and inexperienced operators should complete the certified training course offered. They should then regularly practice the skills learned in the course and the operating techniques described in this Operator’s Manual.
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. HOW TO AVOID THE HAZARD Never operate the ATV on any paved surfaces, including sidewalks, driveways, parking lots, and streets. ! WARNING POTENTIAL HAZARD Operating this ATV on public streets, roads, or highways.
Warnings ! WARNING WARNINGS 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 this ATV at excessive speeds.
Warnings ! WARNING POTENTIAL HAZARD Removing hands from handlebar or feet from footrests during operation. WHAT CAN HAPPEN Removing even one hand or foot can reduce your ability to control the ATV or could cause you to lose your balance and fall off the ATV. If you remove a foot from a footrest, your foot or leg may come into contact with the wheels, which could injure you or cause an accident.
Warnings ! WARNING WARNINGS 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 Manual. Practice turning at slow speeds before attempting to turn at faster speeds. Do not turn at excessive speed. ! WARNING POTENTIAL HAZARD Climbing hills improperly. WHAT CAN HAPPEN Could cause loss of control or cause the ATV to overturn.
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 Going down a hill improperly. WHAT CAN HAPPEN Could cause loss of control or cause the ATV to overturn.
Warnings ! WARNING WARNINGS 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 Skidding or sliding. WHAT CAN HAPPEN You may lose control of the ATV. You may also regain traction unexpectedly, which may cause the ATV to overturn. HOW TO AVOID THE HAZARD Learn to safely control skidding or sliding by practicing at slow speeds and on level, smooth terrain. On extremely slippery surfaces, such as ice, go slowly and be very cautious in order to reduce the chance of skidding or sliding out of control.
Warnings Operating the ATV with improper tires or with improper or uneven tire pressure. WHAT CAN HAPPEN Use of improper tires on the ATV or operation of the ATV with improper or uneven tire pressure may cause loss of control increasing your risk of accident. HOW TO AVOID THE HAZARD Always use the size and type tires specified in this Operator’s Manual for this ATV. Always maintain proper tire pressure as described in this Operator’s Manual.
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 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. Following the safety instructions and warnings in this manual will help you “P.A.S.S.” the safety test. P.A.S.S.
Prevention If you drop or damage your helmet, get a new one immediately. Your helmet Your helmet is the most important piece may not protect your head from injury of protective gear for safe riding. A hel- if it has cracks, fissures, or other dammet can prevent a severe head injury. age to its outside or core padding. There are several types of helmets on the market, but make sure you wear a Remember, your helmet won’t do you helmet that complies with the current any good if the chin strap isn’t fastened.
Prevention Condition of the ATV The second step in Prevention is checking the condition of your ATV. Chances are good that you’ll be using your ATV in some rough terrain, and there’s no way you want your brakes to go out when riding downhill. You need to check the following parts on your ATV before every ride. 1. Tires and Wheels 2. Controls and Cables 3. Lights and Electric 4. Oil and Fuel 5. Chassis 6.
Prevention 5. CHASSIS B. Throttle The throttle should have a free, smooth range of motion. If it seems to “stick” at any point, refer to the General Maintenance section of this Operator’s Manual for instructions. Driving your ATV with a sticking throttle can turn your leisurely ride into an unwelcome accident. Don’t drive your ATV if the throttle sticks. Check: 1. Free, smooth range of motion Hi-beam Lo-beam Taillight/brakelight Status/warning indicators Check: 1. Ignition switch 2. Stop switch 4.
Prevention Tools Cellular Phone Routine maintenance will generally eliminate the need for emergency repairs. Riding on rough terrain could cause loosening of nuts, bolts, and fasteners. Especially on long rides, carrying the right tools can prevent an inconvenience from becoming a crisis. It may be necessary to make an urgent phone call. Carry these items on your ATV: 1. 2. 3. 4. 5. 6.
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. Although a car is relatively stable, enough centrifugal force can cause an ATV to overturn.
Sound Judgment Overview You are not invincible. Knowing that 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 7.
Sound Judgment The thing about terrain is that sometimes you don’t know it’s changed until The environment you operate an ATV you get there. Whether it’s familiar or in is often harsh and sometimes dan- not, check out your surroundings gerous if you don’t take proper precau- before and during your ride. tions. Environment Night Riding Weather You need to consider the weather. It is dangerous to ride your ATV when the weather is bad or potentially bad. Keep abreast with weather forecasts.
Sound Judgment Trail Riding Outsloped trails (trails that slant to allow rain to run off) make trail riding a bit more challenging. Accepting that challenge means keeping your weight shifted into the slope. Denying the challenge means sliding off the trail. Use sound judgment when trail riding; that means riding on a trail that fits your ability level. If the trail is pretty rugged, standing up on your footrests will make it easier for you to endure the rough terrain.
Sound Judgment Those Around You People do all kinds of things that you can’t predict or control. Riding Companions Leave a lot of space between you and other riders, especially in dusty and dirty conditions, because it’ll be difficult to see the riders in front of you stopping. .
Sound Judgment Cargo Limitations One reason why passengers are prohibited on ATV’s is because their presence throws off the weight and balance of the ATV. Cargo can do the same if it weighs too much. Limit the ATV to the load capacity ratings identified in the following chart for the particular model being operated. So if you’re weighing in at over 215 lb (97 kg) when you ride, leave some of that extra cargo at home.
NOTE: Use extra caution when operating an ATV with additional loads such as accessories and/or cargo. Handling of the ATV may be adversely affected. Reduce speed when adding additional loads. ! WARNING POTENTIAL HAZARD Overloading the ATV or carrying or towing cargo improperly. WHAT CAN HAPPEN Could cause changes in ATV handling, which could lead to an accident. HOW TO AVOID THE HAZARD Never exceed the stated load capacity for the ATV. Cargo should be properly distributed and securely attached.
Sound Judgment THE EFFECTS OF ALCOHOL* The Number of Drinks that Impair Mental and Physical Abilities 1-2 DRINKS Mental processes such as restraint, awareness, concentration, and judgment affected; reaction time slowed; inability to perform complicated tasks. 3-4 DRINKS Depth perception, glare recovery, eye movement, and focus affected; decreased judgment and control. 5+ DRINKS Coordination deteriorates, loss of critical judgment, and impaired memory and comprehension.
Supervision 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 that you consider yourself a supervisor for all riders of your ATV. Whether you accept responsibility or not, the truth is that you are responsible for others riding your ATV.
Supervision Arctic Cat and the ATV Safety Institute recommend that all ATV operators ride the appropriate-sized ATV according to age. Category Age (Years) Speed Limitations (MPH) NOTES Y-12+ 12 or Older 15 - Limited 30 - Maximum Operate Under Adult Supervision T-14 14 or Older 20 - Limited 30 - Limited 38 - Maximum Operate Under Adult Supervision G&S 16 or Older According to Local Regulations — 32 ! WARNING Indicates a potential hazard that could result in a serious injury or death.
DIVISION II - OPERATION/ MAINTENANCE Preface This Arctic Cat ATV Operator’s Manual should be considered a permanent part of the ATV and must remain with the ATV at the time of resale. If the ATV changes ownership more than once, contact Arctic Cat Inc., Service Department, P.O. Box 810, Thief River Falls, MN 56701, for proper registration information. You have chosen a quality Arctic Cat ATV designed and manufactured to give dependable service.
ATV Specifications* ENGINE 450 H1 550 H1 Four-Cycle/Fan Cooled 4-Valve OHC Four-Cycle/Liquid Cooled OHC Bore x Stroke 89 mm x 71.12 mm (3.5 x 2.8 in.) 92 mm x 82 mm (3.62 x 3.22 in.) Displacement Type 442.45 cc (27 cu in.) 545 cc (33.6 cu in.) Spark Plug Type NGK CR8E NGK CPR8E Spark Plug Gap 0.5-0.6 mm (0.020-0.024 in.) 0.7-0.8 mm (0.028-0.032 in.) Brake Type Hydraulic w/Brake Lever Lock and Auxiliary Brake CHASSIS Length (Overall) 215 cm (84.75 in.) Height (Overall) 125 cm (49.3 in.
ATV Specifications* ENGINE Type 700 H1/TBX 700 H1 Mud Pro Four-Cycle/Liquid Cooled OHC Bore x Stroke 102 mm x 85 mm (4.01 x 3.35 in.) Displacement 695 cc (42.4 cu in.) Spark Plug Type NGK CR6E Spark Plug Gap 0.7 - 0.8 mm (0.028 - 0.032 in.) Brake Type Hydraulic w/Brake Lever Lock and Auxiliary Brake CHASSIS Length (Overall) 215 cm (84.75 in.) 249 cm (98.00 in.) - TBX 219.71 cm (86.5 in.) Height (Overall) 122.0 cm (48.0 in.) 125.0 cm (49.3 in.) - TBX 131.45 cm (51.75 in.
ATV Specifications* ENGINE Thundercat Type 1000 H2 Mud Pro Four-Cycle/Liquid-Cooled V-Twin Bore x Stroke 92 mm x 71.6 mm (3.66 x 2.81 in.) Displacement 950 cc (58 cu in.) Spark Plug Type NGK CPR8E (2) Spark Plug Gap 0.7 - 0.8 mm (0.028 - 0.032 in.) Brake Type Hydraulic w/Brake Lever Lock and Auxiliary Brake Fuel System EFI CHASSIS Length (Overall) 215 cm (84.75 in.) 240 cm (94.50 in.) Height (Overall) 121.9 cm (48.0 in.) 131.6 cm (51.8 in.) Width (Overall) 120.7 cm (47.5 in.
Location of Parts and Controls FI025C 1. Battery 2. Headlights FI016H 3. Hand Brake Lever 13. Throttle Limiter 4. Power Distribution Module 14. Throttle Lever 5. Radiator Access Panel 15. DC Power Outlet 6. Seat Latch 16. Taillight/Brakelight 7. Storage Compartment 17. Operator’s Manual Location 8. Reverse Override Switch 18. Headlight HI/LO Switch 9. Auxiliary Brake Pedal 19. Engine Starter Button 10. Brake Lever Lock 20. Emergency Stop Switch 11. Key Switch 21.
ATV Operation 5. Always keep your feet planted on the footrests. Basic Operating Maneuvers Active riding and basic maneuvers are the foundation of your ATV ride. Without basic skills, it’s impossible to move to this level— active riding. These are your basic maneuvers: • • • • • • • • Starting the Engine Always start with the ATV on a flat, level surface. Carbon monoxide poisoning can kill you, so keep your ATV outside while it’s running.
NOTE: It is very important not to touch or compress the throttle lever during the starting procedures. 1. Turn off all electrical accessories (hand warmer, lights, etc.); then rotate the ignition switch key to the first position (ON) leaving the headlights OFF. Note that the N is indicated on the LCD. 2. Press on the starter button. CAUTION Do not run the starter motor for more than eight seconds per starting attempt. The starter motor may overheat causing severe starter motor damage.
NOTE: The high range is for nor- Dismounting the ATV mal riding with light loads. The low range is for carrying heavy loads After you’ve followed the procedure or trailer towing. Compared to for parking, it’s time to dismount: HIGH range, the LOW range posi1. Double check that the brake lever tion provides slower speed and lock is engaged. greater torque to the wheels. 2. Swing your right leg over to the CAUTION left side of the seat.
ATV-0024 ATV-0012 1. Keep your feet on the footrests and both hands on the handlebar. 2. Hold the brake lever, and release the brake lever lock. 3. Shift into gear. 4. Release the brake slowly and apply the throttle. 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 your body weight on the outside footrest. At the same time, lean your body to the inside of the turn.
ATV-0044 ATV-0040 1. Ease off the throttle as you approach the turn to slow down. 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. 2. Use the principles of leaning, weight shifting, and balancing— shift your body weight to the inside of the turn. 3. Gradually increase your speed as you come out of the turn. 3.
ATV-0022 ATV-0020 ATV-0023 ATV-0034 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 balancing—shift your body weight to the inside of the turn). ATV OPERATION 1. Ease off the throttle as you approach the turn to slow down. ATV-0035 3. Follow this with slight acceleration. 4. For multiple turns, repeat this movement as needed. 5.
2. Shut off the engine. 3. Keep your body weight shifted forward. 4. Get off the ATV on the uphill side. 5. If you’re to the left of the ATV, turn the handlebar all the way left. 6. Partially release the brake, but lightly hold the brake lever. 7. Let the ATV roll to your right side until it faces slightly downhill. 8. Reapply the brakes. 9. Get back on the ATV from the uphill side, and keep your weight shifted uphill when you sit down. 10. Start the engine and follow the method for riding downhill.
ATV-0017 ATV-0030 ATV-0028 ATV OPERATION ATV-0018 ATV-0031 ATV-0029 1. Shift your body weight as far back on the seat as possible. 1. Keep your speed low and consistent. 2. Keep it in a low gear; stay out of neutral. 2. Shift all your body weight to the uphill side of the seat; also, support your weight on the uphill footrest. 3. Lightly apply the brake and ease up on the throttle. Sidehilling/Traversing Sidehilling is considered an advanced skill; it’s really tricky and unpredictable.
Swerving Crossing Obstacles 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. 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.
6. Lean forward and release the throttle when the front tires clear the obstacle. 2. Keep your hand off the brakes until you’re out of the skid. 3. Shift your weight forward. 7. Keep your body loose to absorb Sometimes your ATV may not respond any shock. and goes straight ahead instead of let8. If the ATV starts tipping, shift ting you turn. Here’s how to handle it: your weight to keep it in balance. 1. Slow down. To clear a single-track (only one tire contacts) obstacle, follow the same 2.
Crossing Water Your ATV can only handle water up to its footrests. Any more than that and you risk engine damage and/or personal injury. Stay away from fast moving rivers. ATV tires can be buoyant, so if the water is too deep, you might find the ATV suddenly afloat. 7. It’s illegal to cross public roads in some places. Know your local laws. Driving In Cold Weather NOTE: Check that all control levers move freely. Make sure that the footrest, shift lever, and auxiliary brake pedal are free of ice and 1.
Go slowly and be extra careful when riding on snow-covered or ice-covered terrain. Always be alert to changing terrain conditions when operating the ATV. 4. Practice driving in an open snowcovered or ice-covered area at slow speeds before driving on snow-covered or ice-covered trails. 5. Learn how the ATV responds to steering and braking on the type of terrain to be encountered on the ride. Stopping The ATV To stop the ATV, first release the throttle lever. Next, apply the brake.
General Information ATV IDENTIFICATION NUMBERS The Arctic Cat ATV has two identification numbers: Vehicle Identification Number (VIN) and Engine Serial Number (ESN). The VIN is located on the frame support rail. Always provide the ATV name, Vehicle Identification Number, and Engine Serial Number when contacting an authorized Arctic Cat ATV dealer for parts, service, accessories, or warranty. If a complete engine must be replaced, ask the dealer to notify Arctic Cat for correct registration information.
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 the headlights and taillight are on. The key cannot be removed in this position. CAUTION Leaving the ignition switch in the ON or LIGHTS position for a long period of time when the engine is not running may cause the battery to discharge. Always leave the ignition switch in the OFF position when engine is not running.
CAUTION 1. Squeeze the hand brake two or three times and release it. Do not attempt to either engage or disengage the 4WD lock while the ATV is moving. 2. Depress and hold the brake lever lock. The 4WD lock allows the operator to 3. While holding in on the brake lever lock, squeeze the brake lever. mechanically lock the front differential to apply equal power to both front NOTE: It will click as it engages wheels.
Reverse Override Switch These ATV’s are equipped with a reverse speed limiter system. When additional RPM is needed in reverse, depress and hold the override switch. NOTE: The reverse override switch is active in 4WD only. ! WARNING CF245A Never activate the override switch while the throttle is open as a loss of control may result. Use the headlight HI/LO switch to select the high or low headlight beam when the ignition switch is in the Throttle Lever LIGHTS position.
1. Loosen the jam nut. 2. Turn the throttle limiter screw clockwise to decrease engine RPM maximum or counterclockwise to increase engine RPM maximum. 3. Tighten the jam nut securely. NOTE: The ATV is equipped with an RPM limiter that retards ignition timing when maximum RPM is approached. When the RPM limiter is activated, it could be misinterpreted as a high-speed misfire. Auxiliary Brake Pedal 1.
Continued operation with high engine temperature may result in engine damage or premature wear. 5. Fuel Level Indicator - Indicates approximate amount of gasoline in the gas tank. NOTE: When the bottom segment flashes, approximately 3.5 L NOTE: High engine RPM, low (0.92 U.S. gal.) of gasoline remains vehicle speed, or heavy load can in the tank. raise engine temperature. 6.
12. Speedometer - Indicates the approximate vehicle speed in miles per hour (MPH) or kilometers per hour (km/h). NOTE: To change mph/km/h display, press and release Mode Button (3) until the icon (MPH/km/h) appears; then press the Set Button (4) to change the display. Condition Warning Display - Uses odometer/trip meter display of the LCD to warn of a system error condition requiring attention. A.
8. Needle Indicator Display - Dis NOTE: The Mode Button must be plays which speedometer function pressed and released to shift (MPH or km/h) or tachometer modes. Approximately two secfunction (RPM) is selected. onds after the Mode Button is released, the digital gauge will NOTE: The speedometer and return to full display. tachometer functions may be 4. Set/Reset Button - In conjunction switched by pressing the Set/ with the Mode Button, sets and Reset Button. resets various displays on the digi9.
12. Battery Condition Indicator - The speedometer/tachometer needle will not function and the LCD will go blank except the word VOLT will flash on the LCD whenever a low voltage (< 9 DC volts) or high voltage (>16 DC volts) is detected. When voltage returns to normal, the gauge must be reset by turning the ignition key to OFF; then back to ON. NOTE: High engine RPM, low vehicle speed, or heavy load can raise engine temperature.
2. Install the oil level stick and thread into the engine case. NOTE: The oil level stick should be threaded in for checking purposes. FI001A 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. 3. Remove the oil level stick; the engine oil level should be above the “L” mark but not higher than the “F” mark. CAUTION Do not overfill the engine with oil.
TAILGATE LATCH (TBX) 1. To open a compartment, lift the straps off the hatch lugs. 2. To close a compartment, pull the straps over the hatch lugs. SAFETY FLAG BRACKET A bracket is provided for mounting a flag at the rear of the ATV. RACK LOADING 1. To open the tailgate, pull the latch (Front and Rear) 739-569A (located at the center of the tailgate). The front rack and rear rack are designed to carry specified load capaci2. To close the tailgate, press forward ties. Always refer to the ATV Load firmly.
Make sure that the load in the trailer is properly secured and will not shift while moving. Also, do not overload the trailer. ! WARNING 1. Engage the brake lever lock and place the transmission in gear. 2. Secure the ATV with load rated hold-down straps. Never exceed any of the ATV weight restrictions. NOTE: Suitable hold-down straps are available from your ArcTrailer Tongue Weight is the down- tic Cat ATV dealer.
GASOLINE-OILLUBRICANT Recommended Gasoline The recommended gasoline to use in this ATV is 87 minimum octane regular unleaded. In many areas, oxygenates (either ethanol or MTBE) are added to the gasoline. Oxygenated gasolines OILCHARTI containing up to 10% ethanol, 5% methane, or MTBE are acceptable gas- Recommended Front Differential/Rear Drive olines.
ing the gas tank. A fire hazard could materialize. Always allow the engine to cool before filling the gas tank. Brakes Brake pads must be burnished to achieve full braking effectiveness. Braking distance will be extended until Do not overfill the gas tank. brake pads are properly burnished. To properly burnish the brake pads, use Tighten the gas tank cap securely after the following procedure. filling the tank.
General Maintenance NOTE: Proper maintenance of the ATV is important for optimum performance. Follow the Maintenance Schedule and all ensuing Maintenance Instructions/Information. If the owner/operator does not feel qualified to perform any of these maintenance procedures or checks, take the ATV to an authorized Arctic Cat ATV dealer for professional service.
MAINTENANCE SCHEDULE Battery Initial 100 Every 100 Every 300 Every 500 Page miles after miles or 1 miles or 3 miles or 6 break-in month months months 72 I I * Engine nuts and bolts - I I * Valve clearance - I I Spark plug 76 76 I I I Replace every 4000 miles or 18 months Liquid cooling system 66 I Oil cooler (700/1000) 67 I I I Throttle cable 76 I Inspect every time before riding Gas hoses 59 I Inspect every time before riding Engine/transmission oil and filter 68 R Air
LIQUID COOLING SYSTEM 700/1000 NOTE: Debris in front of the engine or packed between the cooling fins of the radiator can reduce cooling capability. Using a garden hose, wash the radiator to remove any debris preventing air flow. CAUTION Arctic Cat does not recommend using a pressure washer to clean the radiator core. The pressure may bend or flatten the fins causing restricted air flow, and electrical components on the radiator could be damaged.
NOTE: Use a good quality, biodegradable glycol-based, automotive-type antifreeze. ! WARNING Never check the coolant level when the engine is hot or the cooling system is under pressure. CAUTION Failure to remove dirt and debris from the radiator prior to operating the ATV may cause overheating resulting in severe engine damage. CAUTION Arctic Cat does not recommend using a pressure washer to clean the radiator core.
SHOCK ABSORBERS Each shock absorber should be visibly checked weekly for excessive fluid leakage (some seal leakage may be observed but it does not indicate the shock is in need of replacement), cracks or breaks in the lower case, or a bent shock rod. If any one of these conditions is detected, replacement is necessary. NOTE: When the ATV is operated in extremely cold weather (-23°C/-10°F or colder), a small amount of leakage may be present. Unless the leakage is excessive, replacement is not necessary.
4. Using the oil filter wrench and a ratchet handle (or a socket or boxend 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. 5. Apply oil to the new filter O-ring and check to make sure it is positioned correctly; then install the new oil filter. Tighten securely. CF107B 6. Install the engine drain plug and tighten it securely. Pour the recommended oil in the filler hole. Install the level stick. 7.
Brake Lever Lock CF116A NOTE: Arctic Cat recommends 738-420B the use of genuine Arctic Cat lubri- Check to make sure the brake lever cants. lock engages properly and that the brake (when engaged) locks the 6. Install the filler plugs. wheels. HYDRAULIC HAND BRAKE 1. Pump the brake lever 2 or 3 times. 2. Engage the brake lever lock. ! WARNING Be sure to inspect the hydraulic brake system before each use. Always maintain brakes according to the Maintenance Schedule. Brake Fluid 3.
3. If thickness of either brake pad is less than 1.0 mm (0.039 in.), take the ATV to an authorized Arctic Cat ATV dealer to have brake pads replaced. 2. Press the auxiliary brake pedal several times to check for firmness. 3. If the pedal is not firm, the system must be bled. NOTE: Take the ATV to an authorized Arctic Cat ATV dealer for this service. PROTECTIVE RUBBER BOOTS PR376B The protective boots should be inspected periodically according to the Maintenance Schedule. 4.
Tie Rod Boots (Inner and Outer/Right and Left) 1. Inspect all drive axle boots for cracks, tears, or perforations. 2. If boot damage is present, contact an authorized Arctic Cat ATV dealer for service. BATTERY The battery is located under the seat. 1. 2. 3. 4. 5. After being in service, batteries require regular cleaning and recharging in order to deliver peak performance and CC792 maximum service life.
3. Using a wire brush, clean the battery posts and cable ends removing all corrosive buildup. Replace damaged cables or cable ends. CAUTION Do not remove seal strip. ! WARNING Battery acid is harmful if it contacts eyes, skin, or clothing. Care must be taken whenever handling a battery. 4. Using a multimeter, test the battery voltage. The meter must read at least 12.5 DC Volts for a fully charged battery. ! WARNING An overheated battery could explode causing severe injury or death.
8. Place the battery in the battery compartment; then coat the battery posts and cable ends with a light coat of multi-purpose grease. 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 CAUTION correctly charge it; however, in an Before installing the battery, make emergency, it may be necessary to sure the ignition switch is in the OFF jump-start a vehicle. If so, use the position.
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. Move the vehicle to be used for the jump-start close enough to ensure the jumper cables easily reach; then shift into neutral, set and lock the brakes, shut off all electrical accessories, and turn the ignition switch OFF. NOTE: Make sure all switches on the vehicle to be jump-started are turned OFF. 5.
SPARK PLUG(S) When installing the spark plug, be sure to tighten it securely. A new spark plug should be tightened 1/2 turn once the washer contacts the cylinder head. A used spark plug should be tightened 1/8 - 1/4 turn once the washer contacts the cylinder head. The ATV comes equipped with a specified spark plug. See the appropriate specifications chart for the correct spark plug. A light brown insulator indicates that the plug is correct.
CAUTION Failure to inspect the air filter frequently if the ATV is used in dusty, wet, or muddy conditions can damage the engine. 4. Fill a wash pan larger than the element with a non-flammable solvent; then dip the element in the solvent and wash it. NOTE: Foam Air Filter Cleaner and Foam Air Filter Oil are avail1. Raise the storage compartment able from Arctic Cat. cover; then slide the cover forward 5. Squeeze the element by pressing it and off the compartment.
TIRES ! WARNING Always use the size and type of tires as specified. Refer to the specifications chart for proper tire inflation pressure, and always maintain proper tire inflation pressure. GZ018A DRAINING V-BELT COVER Tire Tread Condition The use of worn-out tires on an ATV is very dangerous. A tire is considered to be worn out when the depth of the tread is less than 3 mm (1/8 in.). Be sure to replace the tires before reaching this minimum specification.
CAUTION ! WARNING When breaking the tire bead loose from the wheel, be extremely careful not to damage the inner wheel surface or the tire bead. Wait until the muffler cools to avoid burns. ! WARNING 1. Remove the three cap screws securing the spark arrester assembly to the muffler. Use only Arctic Cat approved tires when replacing tires. Failure to do so could result in unstable ATV operation.
CAUTION 2. To remove the bulb from the socket, pull it straight out of the socket. Use only specified bulbs indicated in the chart as replacement bulbs. 3. To install the bulb, push it straight into the socket. Headlight NOTE: The bulb portion of the headlight is fragile. HANDLE WITH CARE. When replacing the headlight bulb, do not touch the glass portion of the bulb. If the glass is touched, it must be cleaned with a dry cloth before installing.
550/700/700 TBX/Thundercat 5. Switch on the lights. Make sure the HIGH beam is on. DO NOT USE LOW BEAM. 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. Adjust each headlight until correct aim is obtained by turning the knob clockwise to raise or counterclockwise to lower the beam.
STORAGE COMPARTMENT/ TOOLS The storage compartment is above the engine in front of the seat. A basic tool kit is provided with the ATV. Maintain the tool kit with the ATV at all times.
Preparation for Storage CAUTION 4. Plug the hole in the exhaust system with a clean cloth. Prior to storing the ATV, it must be properly serviced to prevent rusting and component deterioration. 5. Apply light oil to the upper steering post bushing and plungers of the shock absorbers. Arctic Cat recommends the following procedure to prepare the ATV for storage. An authorized Arctic Cat ATV dealer should perform this service; however, the owner/operator may perform this service if desired. 1.
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.
LIMITED WARRANTY Arctic Cat Inc. (hereinafter referred to as Arctic Cat) extends a limited warranty on each new Arctic Cat ATV it manufactures and on each genuine Arctic Cat ATV part and accessory manufactured or sold by an authorized Arctic Cat ATV dealer. Warranty on an Arctic Cat ATV is extended to the original retail purchaser; however, the balance of the unused warranty may be transferred to a second party.
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 warranty coverage.
CHANGE OF ADDRESS, OWNERSHIP, OR WARRANTY TRANSFER Arctic Cat Inc. keeps on file the current name and address of the owner of this ATV. This will allow 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 ATV is sold to another party.
Fold Back - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - CHANGE OF ADDRESS/OWNERSHIP Place Stamp Here ARCTIC CAT INC. PRODUCT SERVICE AND WARRANTY DEPT. P.O.
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. 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. Your authorized Arctic Cat ATV dealer will repair or replace any defective emission-related component at no cost to you during the warranty period.
INDEX Accessories.....................................................33 Active Riding ...................................................23 Air Filter...........................................................76 Air Filter Housing Drain(s)...............................77 Alcohol (Effects) ..............................................30 Battery.............................................................72 Boots (Protective)............................................71 BONE-C ............................
MAINTENANCE RECORD DATE MILEAGE SERVICE PERFORMED/NOTES 93
MAINTENANCE RECORD DATE 94 MILEAGE SERVICE PERFORMED/NOTES
NOTES 95
Declaration of Conformity Application of council directives: EMC Directive 2004/108/EC Date of Issue: December, 2004 EC Machinery Directive 98/37/EC Date of Issue: June, 1993 Issued by European Commission.
Identification Numbers Record ! WARNING Indicates a potential hazard that could result in serious injury or death. 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. 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. 1.
! WARNING Improper ATV use can result in SEVERE INJURY or DEATH ALWAYS USE NEVER USE AN APPROVED ON PUBLIC HELMET AND ROADS PROTECTIVE GEAR NEVER CARRY NEVER USE PASSENGERS WITH DRUGS OR ALCOHOL NEVER operate: •without proper training or instruction •at speeds too fast for your skills or the conditions •on public roads - a collision can occur with another vehicle •with a passenger - passengers affect balance and steering and increase risk of losing control ALWAYS: •use proper riding techniques to avoid v
