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It's a long post but a quick reference for the Manual for 2005 Arctic Cat utility ATV's

Table of Contents
1. General Information
2. Periodic Maintenance/Tune-Up
3. Engine/Transmission
4. Fuel/Lubrication/Cooling
5. Electrical System
6. Drive System
7. Suspension
8. Steering/Frame
9. Controls/Indicators
10. Aids for Maintenance
11. Troubleshooting

1. General Information
General Specifications (250)................................... 1-2
General Specifications (300)................................... 1-3
General Specifications
(400/400 TBX - Automatic Transmission) ............ 1-4
General Specifications
(400 - Manual Transmission) ............................... 1-5
General Specifications
(500 - Manual Transmission) ............................... 1-6
General Specifications
(500/500 TBX/TRV - Automatic Transmission) .... 1-7
General Specifications
(650 H1) .............................................................. 1-8
General Specifications
(650 V-Twin) ........................................................ 1-9
Break-In Procedure ............................................... 1-10
Gasoline - Oil - Lubricant ...................................... 1-10
Genuine Parts ....................................................... 1-11
Preparation For Storage........................................ 1-11
Preparation After Storage...................................... 1-12

2. Periodic Maintenance/Tune-Up
Periodic Maintenance Chart.................................... 2-2
Lubrication Points.................................................... 2-3
Battery..................................................................... 2-3
Fuses ...................................................................... 2-4
Air Cleaner (250/300) .............................................. 2-5
Air Cleaner/Filter (400 FIS/ACT) ............................. 2-9
Air Cleaner/Filter (TBX/500/650 H1/650 V-Twin)... 2-11
Valve/Tappet Clearance
(Feeler Gauge Procedure) ................................ 2-13
Valve/Tappet Clearance
(Valve Adjuster Procedure)................................ 2-14
Valve/Tappet Clearance (650 V-Twin -
Feeler Gauge Procedure).................................. 2-15
Valve/Tappet Clearance (650 V-Twin -
Valve Adjuster Procedure)................................. 2-16
Testing Engine Compression ................................ 2-17
Spark Plug............................................................. 2-17
Muffler/Spark Arrester ........................................... 2-18
Gas/Vent Hoses .................................................... 2-18
Adjusting Throttle Cable ........................................ 2-18
Adjusting Choke Cable (650 V-Twin) ..................... 2-19
Adjusting Engine RPM (Idle) ................................. 2-19
Engine/Transmission Oil - Filter - Strainer
(250/300) ........................................................... 2-20
Engine/Transmission Oil - Filter - Strainer
(400/500/650 H1/650 V-Twin)............................ 2-22
Front Differential/Rear Drive Lubricant .................. 2-24
Adjusting Clutch (250/300).................................... 2-25
Adjusting Clutch
(400/500 Manual Transmission) ........................ 2-26
Tires ...................................................................... 2-26
Steering Components ........................................... 2-27
Driveshaft/Coupling............................................... 2-27
Suspension/Shock Absorbers/Bushings ............... 2-27
Nuts/Bolts/Cap Screws.......................................... 2-27
Ignition Timing....................................................... 2-27
Headlight/Taillight-Brakelight ................................. 2-28
Switches................................................................ 2-29
Reverse Shift Lever ............................................... 2-29
Frame/Welds/Racks .............................................. 2-33
Electrical Connections........................................... 2-33
Hydraulic Brake Systems ...................................... 2-34
Auxiliary Brake (250/300/400 ACT). ...................... 2-36
Burnishing Brake Pads.......................................... 2-38
Coolant (500/650 H1/650 V-Twin) ......................... 2-38
Checking/Replacing V-Belt
(400/500/650 H1) .............................................. 2-38
Checking/Replacing V-Belt
(650 V-Twin) ...................................................... 2-40

3. Engine/Transmission
Engine/Transmission ............................................... 3-2
Specifications (250/300).......................................... 3-2
Specifications (400 - Automatic Transmission)........ 3-3
Specifications (400 - Manual Transmission)............ 3-4
Specifications (500 - Automatic Transmission)........ 3-6
Specifications (500 - Manual Transmission)............ 3-7
Specifications (650 H1) ........................................... 3-9
Specifications (650 V-Twin) ................................... 3-10
250/300 Table of Contents .................................... 3-11
400 (Manual Transmission)
Table of Contents ............................................... 3-79
400 (Automatic Transmission)
Table of Contents ............................................. 3-149
500 (Automatic Transmission)/650 H1
Table of Contents ............................................. 3-206
500 (Manual Transmission)
Table of Contents ............................................. 3-264
650 V-Twin Table of Contents.............................. 3-339

4. Fuel/Lubrication/Cooling
Carburetor Specifications ........................................ 4-2
Carburetor Schematics............................................ 4-2
Carburetor (250/300/400/500/650 H1) .................... 4-4
Carburetor (650 V-Twin) .......................................... 4-9
Cleaning and Inspecting Carburetor...................... 4-14
Throttle Cable Free-Play ....................................... 4-14
Choke Cable Free-Play (650 V-Twin) .................... 4-15
Engine RPM (Idle)................................................. 4-15
Gas Tank (250/300/400 FIS/ACT) ........................ 4-16
Gas Tank (TBX/500/650 H1/650 V-Twin) .............. 4-17
Gas Tank Valve (250/300/400 FIS/ACT/TRV) ...... 4-18
Gas/Vent Hoses ................................................... 4-18
Electric Fuel Pump (650 V-Twin) .......................... 4-18
Vacuum Pulse Fuel Pump (TBX/500/650 H1) ...... 4-18
Oil Flow Charts...................................................... 4-19
Oil Filter/Oil Pump................................................. 4-21
Testing Oil Pump Pressure.................................... 4-23
Oil Cooler (250/300/400)....................................... 4-24
Liquid Cooling System (500/650 H1/650 V-Twin) .. 4-25
Radiator................................................................. 4-26
Hoses/Thermostat (500/650 H1)........................... 4-27
Hoses/Thermostat (650 V-Twin) ............................ 4-27
Fan ........................................................................ 4-28
Servicing Water Pump
(500 - Manual Transmission) ............................. 4-28
Servicing Water Pump
(500/650 H1 - Automatic Transmission) ............ 4-29
Water Pump/Alternator Cover (650 V-Twin) .......... 4-32
Testing Electric Fuel Pump (650 V-Twin)............... 4-34
Testing Vacuum Pulse Fuel Pump
(TBX/500/650 H1) ............................................. 4-36

5. Electrical System
Specifications .......................................................... 5-2
Battery..................................................................... 5-3
RPM Limiter ............................................................ 5-3
Testing Electrical Components................................ 5-3
Accessory Receptacle/Connector (400/500/650 H1/
650 V-Twin).......................................................... 5-4
Brakelight Switch (Auxiliary).................................... 5-4
Brakelight Switch (Handlebar Control) .................... 5-5
Oil Temperature and Cooling Fan Switches
(250/300/400)...................................................... 5-5
Coolant Temperature and Cooling Fan Switches
(500/650 H1/650 V-Twin)..................................... 5-6
Fan Motor (400/500/650 H1/650 V-Twin) ................ 5-6
Fuse Block/Power Distribution Module.................... 5-7
Fuses ...................................................................... 5-8
Ignition Coil ............................................................. 5-8
Indicator Lights (250/300/400 ACT) ...................... 5-11
Electronic Speedometer Speed Sensor (400 FIS/
500/650 H1) ...................................................... 5-12
Electronic Speedometer/Indicator Lights
(650 V-Twin) ...................................................... 5-13
Ignition Switch ....................................................... 5-18
Handlebar Control Switches ................................. 5-18
Front Drive Selector Switch (400 FIS/500/650 H1/
650 V-Twin)........................................................ 5-19
Front Drive Selector Actuator (400 FIS/500/
650 H1/650 V-Twin) ........................................... 5-20
Differential Lock Switch (400FIS/TBX/500/650 H1/
650 V-Twin)........................................................ 5-20
Magneto Coils (250/300/400/500/650 H1) ............ 5-21
Magneto Coils (650 V-Twin) .................................. 5-23
Starter Motor ......................................................... 5-24
Starter Relay (250/300)......................................... 5-29
Starter Relay (400 ACT)........................................ 5-30
Starter Relay (400 FIS/TBX/500/650 H1/
650 V-Twin)........................................................ 5-31
CDI Unit (250/300) ................................................ 5-31
CDI Unit (400 ACT) ............................................... 5-31
CDI Unit (400 FIS/TBX/500/650 H1/650 V-Twin)... 5-32
Regulator/Rectifier ................................................ 5-32
Neutral Start/Front Drive Actuator/Start-in-Gear/
Differential Lock Relays (400 FIS/TBX/500/
650 H1/650 V-Twin) ........................................... 5-32
Neutral Start Relay (400 ACT) .............................. 5-33
Headlights ............................................................. 5-34
Taillight - Brakelight ............................................... 5-34
Ignition Timing (250/300/400/500/650 H1)............ 5-35
Ignition Timing (650 V-Twin) .................................. 5-35
V-Belt Failure Mode Clearing (650 V-Twin)............ 5-36
100-Hour Belt Inspection Mode Clearing
(650 V-Twin) ...................................................... 5-36
Engine Brake Actuator Resistance (650 V-Twin)... 5-36
Engine Brake Controller Power Supply Voltage
(650 V-Twin) ...................................................... 5-37
Controller-to-Engine Brake Actuator Voltage
(650 V-Twin) ...................................................... 5-37
Forward/Reverse Detecting Sensor Resistance
(650 V-Twin) ...................................................... 5-38
Output-to-Actuator Voltage (650 V-Twin)............... 5-38
Output-to-Speed Sensor Voltage (650 V-Twin) ..... 5-38
Speed Sensor Signal Voltage (650 V-Twin)........... 5-39
Tilt Sensor Voltage (650 V-Twin) ........................... 5-39
Wiring Diagrams.................................................... 5-41

6. Drive System
Drive System........................................................... 6-2
General Information................................................. 6-2
Front Drive Actuator (400 FIS/500/650 H1/
650 V-Twin).......................................................... 6-3
Front Differential (FIS Models) ................................ 6-4
Drive Axles ............................................................ 6-19
ACT - Rear Suspension ........................................ 6-25
Rear Suspension/Rear Drive
Assembly Schematics ....................................... 6-29
Rear Gear Case (FIS Models) .............................. 6-30
Hub........................................................................ 6-30
Hydraulic Brake Caliper......................................... 6-32
Hydraulic Brake Assembly Schematics................. 6-34

7. Suspension
Front and Rear Suspension Assembly
Schematics.......................................................... 7-2
Shock Absorbers..................................................... 7-4
Swing Arms (ACT - Rear Suspension).................... 7-5
Front A-Arms........................................................... 7-6
Rear A-Arms (FIS - Rear Suspension).................... 7-9
Wheels and Tires .................................................. 7-11

8. Steering/Frame
Steering Post/Tie Rods ........................................... 8-2
Handlebar Grip........................................................ 8-9
Steering Knuckles ................................................. 8-10
Measuring/Adjusting Toe-In................................... 8-13
Body Panel Assembly Schematics........................ 8-15
Frame/Exhaust Assembly Schematics .................. 8-19
Front Rack............................................................. 8-25
Front Bumper Assembly ........................................ 8-25
Front Fender/Side Panels (250/300/400 FIS/
ACT/TRV) .......................................................... 8-26
Front Body Panel/Side Panels (400 TBX/500/
650 H1/650 V-Twin) ........................................... 8-28
Fender Flares/Extensions (250/300/400 FIS/
ACT/TRV) .......................................................... 8-32
Footrests ............................................................... 8-32
Belly Panel ............................................................ 8-33
Exhaust System .................................................... 8-34
Rear Rack ............................................................. 8-34
Rear Fender (250/300/400 FIS/ACT) .................... 8-35
Rear Body Panel/Rack (500/650 H1/650 V-Twin).. 8-35
Side Storage Box (TBX Models) ........................... 8-37
Cargo Box (TBX Models) ...................................... 8-38
Adjusting Headlight ............................................... 8-38
Taillight Assembly.................................................. 8-39
Seat....................................................................... 8-40

9. Controls/Indicators
Hand Brake Lever/Master Cylinder Assembly......... 9-2
Auxiliary Brake Assembly Schematics .................... 9-4
Throttle Control ....................................................... 9-5
Gearshift Pedal (Manual Transmission)................... 9-7
Drive Selector (300 Model) ..................................... 9-7
Drive Selector (400 FIS/500/650 H1/
650 V-Twin Models) ............................................. 9-8
Front Differential Lock (FIS Models)........................ 9-8
Reverse Shift Lever (Manual Transmission) ............ 9-9
Reverse Shift Lever (500/650 H1/650 V-Twin -
Automatic Transmission) .................................. 9-10
Speedometer (Analog)/Indicator Lights................. 9-12
Speedometer (Electronic)/Indicator Lights
(400 FIS/500/650 H1)........................................ 9-13
Speedometer (Electronic)/Indicator Lights
(650 V-Twin) ...................................................... 9-14

10. Aids for Maintenance
Torque Specifications (250/300)............................ 10-2
Torque Specifications (400/500 - Manual
Transmission) .................................................... 10-3
Torque Specifications (400/500 - Automatic
Transmission/650 H1)........................................ 10-4
Torque Specifications (650 V-Twin) ....................... 10-6
Torque Conversions .............................................. 10-7
Tightening Torque (General Bolts) ........................ 10-7

11. Troubleshooting
Engine ................................................................... 11-2
Drive...................................................................... 11-7
Fuel System .......................................................... 11-8
Electrical................................................................ 11-9
Steering/Suspension ........................................... 11-11
Brakes ................................................................. 11-12
 

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