Arctic Cat ATVs 450cc. 550cc. 650cc. 700cc. 1000cc. (2011) Service Manual
450, 550, 650, 700, 1000cc.
WORKSHOP, REPAIR, SERVICE MANUAL
ARCTIC CAT ATVs 450cc. 550cc. 650cc. 700cc. 1000cc. (2011) - WORKSHOP, REPAIR, SERVICE MANUAL - Service Manual, to Arctic Cat ATVs 450cc. 550cc. 650cc. 700cc. 1000cc. (2011). CONTENTS: 1. GENERAL INFORMATION/SPECIFICATIONS - General specifications - Torque specifications - Torque conversions (ft-lb/n-m) - Tightening torque (general bolts) - Break-in procedure - Gasoline - oil - lubricant - Recommended gasoline - Recommended engine/ transmission oil - Recommended front differential/rear drive lubricant - Filling gas tank - Genuine parts - Preparation for storage - Preparation after storage 2. PERIODIC MAINTENANCE - Periodic maintenance chart - Periodic maintenance - Special tools - Lubrication points - Air filter - Checking and cleaning drains - Valve/tappet clearance - Feeler gauge procedure - Valve adjuster procedure - Testing engine compression - Spark plug(s) - Muffler/spark arrester - Engine/transmission oil - filter - strainer - Oil - filter - Strainer - Liquid cooling system - Checking/filling - Front differential/rear drive lubricant - Nuts/bolts/cap screws - Headlights/taillight- brakelight - Checking/adjusting headlight aim - Shift lever - Checking adjustment - Adjusting shift lever - Frame/welds/racks - Hydraulic brake systems - Checking/bleeding - Inspecting hoses - Checking/replacing pads - Burnishing brake pads - Checking/replacing v-belt - Removing - Installing 3. ENGINE/TRANSMISSION - Engine/transmission - Special tools - Specifications (450) - Specifications (550/650/700) - Specifications (1000) - Troubleshooting - Table of contents (450) - Removing engine/ transmission - Top-side components - Removing top-side components - A. Cylinder head cover/ rocker arms b. Cylinder head/camshaft - C. Cylinder d. Piston - Servicing top-side components - Valve assembly - Cleaning/inspecting cylinder head cover - Removing valves - Measuring valve stem runout - Measuring valve stem outside diameter - Measuring valve face/seat width - Measuring valve face radial runout - Measuring valve guide (inside diameter) - Servicing valves/valve guides/valve seats - Measuring rocker arm (inside diameter) - Measuring rocker arm shaft (outside diameter) - Installing valves - Piston assembly - Cleaning/inspecting piston - Removing piston rings - Cleaning/inspecting piston ring grooves - Measuring piston-ring end gap (installed) - Measuring piston pin, connecting rod small end, and piston-pin bore - Measuring piston skirt/ cylinder clearance - Installing piston rings - Cylinder/cylinder head assembly - Cleaning/inspecting cylinder head - Measuring cylinder head distortion - Cleaning/inspecting cylinder - Inspecting cam chain guide - Honing cylinder - Measuring camshaft runout - Measuring camshaft lobe height - Inspecting camshaft bearing journal - Measuring camshaft to cylinder head clearance - Inspecting camshaft spring/drive pin - Installing top-side components - A. Piston b. Cylinder - C. Cylinder head/camshaft d. Cylinder head cover/ rocker arms - Left-side components - Removing left-side components - A. Water pump b. Speed sensor c. Magneto cover/ stator assembly - D. Rotor/flywheel e. Starter clutch/gear f. Starter motor - G. Shift shaft h. Drive gear - Servicing left-side components - Inspecting starter clutch/gear - Replacing starter clutch assembly - Replacing starter gear bearing - Inspecting stator/magneto cover assembly - Replacing stator/ crankshaft position sensor - Replacing magneto cover bearings - Installing left-side components - A. Starter clutch/gear b. Rotor/flywheel - C. Magneto cover d. Water pump - Right-side components - Removing right-side components - A. V-belt cover b. Driven pulley c. Clutch cover - D. Centrifugal clutch assembly e. Oil pump drive gear f. Oil pump driven gear - G. Oil pump/oil strainer - Servicing right-side components - Inspecting centrifugal clutch shoe - Inspecting centrifugal clutch housing - Inspecting primary one-way drive - Inspecting oil pump - Driven pulley assembly - Installing right-side components - A. Oil strainer/oil pump - B. Clutch cover c. Fixed drive face d. Movable drive face - Center crankcase components - Separating crankcase halves - Disassembling crankcase half - Servicing center crankcase components - Secondary gears - Checking backlash - Correcting backlash - Checking tooth contact - Correcting tooth contact - Crankshaft assembly - Measuring connecting rod (small end inside diameter) - Measuring connecting rod (small end deflection) - Measuring connecting rod (big end side-to-side) - Measuring crankshaft (runout) - Measuring crankshaft (web-to-web) - Countershaft - Disassembling - Assembling - Assembling crankcase half - Joining crankcase halves - Installing engine/transmission - Table of contents (550/650/700) - Removing engine/ transmission - Top-side components - Removing top-side components - A. Valve cover/rocker arms b. Cylinder head/camshaft - C. Cylinder d. Piston - Servicing top-side components - Valve assembly - Cleaning/inspecting valve cover - Removing valves - Measuring valve stem runout - Measuring valve stem outside diameter - Measuring valve face/seat width - Measuring valve face radial runout - Measuring valve guide/valve stem deflection (wobble method) - Measuring valve guide (inside diameter) - Servicing valves/valve guides/valve seats - Measuring rocker arm (inside diameter) - Measuring rocker arm shaft (outside diameter) - Installing valves - Piston assembly - Cleaning/inspecting piston - Removing piston rings - Cleaning/inspecting piston rings - Measuring piston-ring end gap (installed) - Measuring piston pin (outside diameter) and piston-pin bore - Measuring piston skirt/cylinder clearance - Installing piston rings - Cylinder/cylinder head assembly - Cleaning/inspecting cylinder head - Measuring cylinder head distortion - Cleaning/inspecting cylinder - Inspecting cam chain guide - Inspecting cylinder - Measuring camshaft runout - Measuring camshaft lobe height - Inspecting camshaft bearing journal - Measuring camshaft to cylinder head clearance - Inspecting camshaft spring/drive pin - Installing top-side components - A. Piston b. Cylinder - C. Cylinder head d. Valve cover - Left-side components - Removing left-side components - A. Outer magneto cover b. Water pump c. Cover d. Rotor/flywheel - Installing left-side components - Right-side components - Removing right-side components - A. V-belt cover b. Driven pulley c. Clutch cover - Servicing right-side components - Inspecting centrifugal clutch shoe - Inspecting clutch housing - Inspecting primary one-way drive - Inspecting oil pump - Driven pulley assembly - Installing right-side components - Center crankcase components - Separating crankcase halves - Disassembling crankcase half - Servicing center crankcase components - Secondary output drive gears - Initial set-up - Checking backlash - Correcting backlash - Crankshaft assembly - Measuring connecting rod (small end inside diameter) - Measuring connecting rod (small end deflection) - Measuring connecting rod (big end side-to-side) - Measuring crankshaft (runout) - Measuring crankshaft (web-to-web) - Countershaft - Disassembling - Assembling - Assembling crankcase half - Joining crankcase halves - Installing engine/transmission - Table of contents (1000) - Removing engine/ transmission - Top-side components - Removing top-side components - A. Valve cover/rocker arms b. Cylinder head/camshaft - C. Cylinders d. Pistons - Servicing top-side components - Valve assembly - Cleaning/inspecting valve cover - Removing valves - Measuring valve stem runout - Measuring valve stem outside diameter - Measuring valve face/seat width - Measuring valve face radial runout - Measuring valve guide/valve stem deflection (wobble method) - Measuring valve guide (inside diameter) - Servicing valves/valve guides/valve seats - Measuring rocker arm (inside diameter) - Measuring rocker arm shaft (outside diameter) - Installing valves - Piston assembly - Cleaning/inspecting piston - Removing piston rings - Cleaning/inspecting piston rings - Measuring piston-ring end gap (installed) - Measuring piston pin (outside diameter) and piston-pin bore - Measuring piston skirt/cylinder clearance - Installing piston rings - Cylinder/cylinder head assembly - Cleaning/inspecting cylinder head - Measuring cylinder head distortion - Cleaning/inspecting cylinder - Inspecting cam chain guide - Inspecting cylinder - Measuring camshaft runout - Measuring camshaft lobe height - Inspecting camshaft bearing journal - Measuring camshaft to cylinder head clearance - Inspecting camshaft spring/drive pin (front camshaft only) - Installing top-side components - A. Pistons b. Cylinders - C. Cylinder head d. Valve cover - Left-side components - Removing left-side components - A. Magneto cover/stator coils b. Water pump c. Shifter assembly d. Rotor/flywheel/starter clutch e. Speed sensor/ trigger assembly - Installing left-side components - Right-side components - Removing right-side components - A. V-belt cover b. Driven pulley c. Clutch cover d. Centrifugal clutch - Servicing right-side components - Inspecting centrifugal clutch shoe - Inspecting clutch housing - Inspecting primary one-way drive - Driven pulley assembly - Installing right-side components - Center crankcase components - Separating crankcase halves - Disassembling crankcase half - Servicing center crankcase components - Secondary output drive gears - Initial set-up - Checking backlash - Correcting backlash - Oil pump assembly - Disassembling and inspecting - Assembling - Crankshaft assembly - Measuring connecting rod (small end inside diameter) - Measuring connecting rod (small end deflection) - Measuring connecting rod (big end side-to-side) - Measuring crankshaft (runout) - Measuring crankshaft (web-to-web) - Countershaft - Disassembling - Assembling - Assembling crankcase half - Joining crankcase halves - Installing engine/transmission 4. FUEL/LUBRICATION/COOLING - Fuel/lubrication/cooling - Special tools - Carburetor specifications (650) - Carburetor schematics (650) - Carburetor (650) - Removing - Disassembling - Cleaning and inspecting - Assembling - Installing - Electric choke (650) - Removing - Inspecting/testing - Installing - Electronic fuel injection (efi) - Troubleshooting - Removing (h1) - Removing (h2) - Installing (h1) - Installing (h2) - Throttle cable free-play - Engine rpm (idle) - Gas tank - Removing - Cleaning and inspecting - Installing - Oil filter/oil pump - Testing oil pump pressure - Oil cooler (700/1000) - Removing - Installing - Liquid cooling system - Radiator - Removing - Cleaning and inspecting - Installing - Thermostat - Removing (h1) - Removing (h2) - Inspecting - Installing (h1) - Installing (h2) - Cooling fan - Removing - Installing - Water pump (h1) - Removing - Installing - Water pump (h2) - Removing - Installing - Electric fuel pump/fuel level sensor (efi) - Testing - Removing - Inspecting - Installing - Vacuum pulse fuel pump (650) - Testing - Removing - Installing - Troubleshooting (650) - Troubleshooting (efi) 5. ELECTRICAL SYSTEM - Electrical system - Special tools - Electrical connections - Specifications - Battery - Rpm limiter - Testing electrical components - Accessory receptacle/connector - Voltage - Brakelight switch (auxiliary) - Voltage (wiring harness side) - Resistance (switch connector) - Brakelight switch (handlebar control) - Voltage (wiring harness connector) - Resistance (switch connector) - Coolant temperature and cooling fan switches (650) - Engine coolant temperature (ect) sensor (efi) - Fan motor - Resistance (fan motor connector) - Power distribution module (pdm) - Fuses - Relays - Ignition coil - Resistance - Primary winding - Secondary winding - Spark plug cap - Peak voltage - Primary/cdi (650) - Primary voltage - ecu (h1) - Primary voltage - ecu (h2) - Efi sensors/ components (efi) - Crankshaft position (ckp) sensor - Manifold absolute pressure (map) sensor (550/700/ thundercat/1000 mud pro) - Manifold absolute pressure/ inlet air temperature (map/iat) sensor (450) - Speed sensor - Electronic power steering (eps) - Ignition switch - Voltage - Resistance - Handlebar control switches - Resistance (hi beam) - Resistance (lo beam) - Diode (starter button) - Resistance (emergency stop) - Resistance (reverse override) - Drive select switch - Resistance - Voltage - Front drive/differential lock actuator - Voltage - Stator coil (650) - Voltage (ac generator - regulated output) - Voltage (charging coil - no load) - Resistance (charging coil) - Resistance (trigger coil) - Peak voltage (650) - Trigger coil - Stator coil/crankshaft position (ckp) sensor (efi) - Voltage (ac generator - regulated output) - Voltage (ac generator - no load) - Resistance (ac generator) - Resistance (crankshaft position sensor) - Ac voltage - Crankshaft position sensor - Starter relay - Starter motor - Testing voltage - Removing - Installing - Cdi unit (650) - Electronic control unit (ecu) (efi) - Regulator/rectifier - Testing - Headlights - Voltage - Taillight - brakelight - Voltage (taillight) - Voltage (brakelight) - Ignition timing - Ecu error codes (550/700/700 cruiser/700 mud pro/1000) - Ecu error code list - Ecu malfunction codes (450/1000 cruiser/1000 mud pro) - Code list - Tilt sensor (efi) - Supply voltage - Output voltage - Throttle position sensor (tps) (550/700/700 cruiser/1000) - Inspecting - Removing - Installing/adjusting - Throttle position sensor (tps) (450) - Inspecting - Removing - Installing/adjusting - Throttle position sensor (tps) (1000 cruiser/1000 mud pro) - Inspecting - Removing - Installing/adjusting - Troubleshooting 6. DRIVE SYSTEM - Drive system - General information - Special tools - Front drive actuator/differential lock - Removing - Installing - Front differential - Removing differential - Disassembling input shaft - Assembling input shaft - Disassembling differential assembly - Disassembling pinion gear - Assembling pinion gear - Shimming procedure/shim selection - Backlash - Ring gear end-play - Assembling differential assembly - Removing/installing axle seal - Installing differential - Drive axles - Removing rear drive axle - Removing front drive axle - Cleaning and inspecting - Disassembling axles - Assembling axles - Installing rear drive axle - Installing front drive axle - Rear gear case - Removing - Ring gear/thrust button - Removing - Inspecting - Installing/shimming - Rear drive input shaft/ housing (700 mud pro/1000) - Removing/disassembling - Cleaning and inspecting - Assembling/installing - Installing - Hub - Removing - Cleaning and inspecting - Installing - Hydraulic brake caliper - Removing/disassembling - Cleaning and inspecting - Assembling/installing - Troubleshooting drive system - Troubleshooting brake system 7. SUSPENSION - Suspension - Shock absorbers - Removing - Cleaning and inspecting - Installing - Front a-arms - Removing - Cleaning and inspecting - Installing - Rear a-arms - Removing - Cleaning and inspecting - Installing - Wheels and tires - Tire size - Tire inflation pressure - Removing - Cleaning and inspecting - Installing - Checking/inflating - Troubleshooting 8. STEERING/FRAME - Steering/frame - Steering post/tie rods - Removing - Cleaning and inspecting - Installing (models without electronic power steering) - Installing (electronic power steering models) - Handlebar grip - Removing - Inspecting - Installing - Steering knuckles - Removing and disassembling - Cleaning and inspecting - Assembling and installing - Measuring/adjusting toe-out - Front rack - Removing - Cleaning and inspecting - Installing - Front bumper assembly - Removing - Cleaning and inspecting - Installing - Front body panel/side panels - Removing - Cleaning and inspecting - Installing - Footrests - Removing - Cleaning and inspecting - Installing - Belly panel - Removing/installing - Exhaust system - Removing muffler - Inspecting muffler - Installing muffler - Rear body panel/rack - Removing - Cleaning and inspecting - Installing - Taillight assembly - Removing - Inspecting - Installing - Seat - Removing/installing - Removing/installing (trv) - Side storage box (tbx) - Removing - Cleaning and inspecting - Installing - Cargo box (tbx) - Removing - Cleaning and inspecting - Installing - Troubleshooting 9. CONTROLS/INDICATORS - Hand brake lever/master cylinder assembly - Removing - Inspecting - Installing - Throttle control - Removing - Installing - Adjusting - Shift lever - Removing - Installing - Speedometer/ tachometer/lcd - Replacing
Arctic Cat ATVs 450cc. 550cc. 650cc. 700cc. 1000cc. (2011) Service Manual
inicio - index
coche - car
moto
4x4
quad - buggy
cami?n - truck
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