Arctic Cat 500 - 4x4 Operator Manual

Arctic Cat
Models 500 4x4/ 500 4x4 TRV / 650 H1/ 650 H1 TRV / 700 Diesel
Operator`s manual
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INTRODUCTION
Congratulations for purchasing a high quality All-Terrain-Vehicle (ATV) by ARCTIC CAT. Be sure, as the owner/operator of
the ATV to become thoroughly familiar with its basic operation, maintenance and storage procedures. Carefully read the
Operator’s Manual before starting your ATV.
Particularly important information is distinguished in this manual by the notations „Warning, Caution and Note“. !! WARNING !!
refers to the safety of ATV operators, bystanders or persons inspecting or repairing the ATV. Please follow exactly the
instructions in order not to endanger your health or even your life. !! PRECAUTION !! indicates special precautions that must
be taken to avoid damage to the ATV. n NOTE provides key information to make procedures easier or more clear.
This booklet contains instructions on how to start and operate the ATV as well as some important information on how to
store it in the season break. For bigger repairs and service please contact an authorized ARCTIC CAT ATV dealer.
At the time of publication, all information and illustrations were technically correct. Some illustrations are used for clarity
purposes only and are not designed to depict actual conditions. Because Arctic Cat constantly refines and improves its
products , no retroactive obligation is incurred.
This ARCTIC CAT 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 please contact the warranty service of the company ARCTIC CAT
GmbH, Industriestraße 43, 5600 ST. JOHANN/PG., to ensure a proper registration. This manual was prepared by the
service department of ARCTIC CAT.
When in need of replacement parts, oil or accessories for your ARCTIC CAT ATV, be sure to use only GENUINE ARCTIC
CAT PARTS, OIL AND ACCESSORIES. Only genuine ARCTIC CAT parts, oil and accessories are engineered to meet
the standards and requirements of your ARCTIC CAT ATV. For a complete list of accessories refer to the current ARCTIC
CAT ATV Accessory Catalog. Your ARCTIC CAT ATV dealer will be pleased to aid you in service and maintenance
procedures.
Page 1 Have a good trip! Your Arctic Cat-Team
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OWNER/VEHICLE
SURNAME Vehicle owner
NAME
ZIP/CITY
Street/Nr.
Owner`s signature
Vehicle model
Chassis number
Dealer
Engine number
Key number
Purchase date
Dealer`s signature and stamp

Dealer
Page 2
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Table of contents
Issue Page
TECHNICAL DATA ARCTIC CAT ATV............................................... 4

LOCATION OF PARTS AND CONTROLS .......................................11
OPERATOR´S MANUAL ................................................................ 13
GENERAL INFORMATION ............................................................. 20
CONTROL LOCATIONS AND FUNCTIONS .................................... 22
GASOLINE / OIL / LUBRICANT ..................................................... 30
BREAK-IN PROCEDURE............................................................... 32
GENERAL MAINTENANCE............................................................ 35
PREPARATION FOR STORAGE .................................................... 47
PREPARATION AFTER STORAGE ................................................ 48
FOR YOUR SAFETY ..................................................................... 49
ACTIVE RIDING ............................................................................ 52
TROUBLESHOOTING ................................................................... 64
WARRANTY .................................................................................. 66
NOTES .......................................................................................... 71
PAGE 3
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Technical Data ARCTIC CAT ATV 500 4x4/500 4x4 TRV
Engine and Drive 500 4x4 500 4x4 TRV

Type Four-cycle/Liquid cooled Four-cycle/Liquid cooled
Bore x Stroke 87.5x82 mm 87.5x82 mm
Displacement 493 ccm 493 ccm
Igntion type CDI CDI
Ignition timing 10° BTDC < 1500 turns/min 10° BTDC < 1500 turns/min
Spark plug type NGK CR6E NGK CR6E
Spark plug gap 0.7-0.8 mm 0.7-0.8 mm
Brake type Hydraulic service brake; mechanical parking brake
Carburetor type Keihin CVK 36 Keihin CVK 36
Chassis 500 4x4 500 4x4 TRV
Length (overall) 218 cm 239 cm
Height (overall) 129 cm 129 cm
Width (overall) 124 cm 124 cm
Suspension travel (front and rear) 21 cm 21 cm
Wheelbase 128 cm 148 cm
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Front Tire Size 185-65-15 or 25x8-12 185-65-15 or 25x8-12
Rear Tire Size 205-60-15 or 25x11-12 205-60-15 or 25x11-12
Tire Inflation Pressure 0.8-1.0 bar (according to load and 0.8-1.0 bar (according to load and
On Road route) route)
Tire Inflation Pressure 0.8-1.0 bar (according to load and 0.8-1.0 bar (according to load and
On Road route) route)
Miscellany
Dry weight 310 kg 340 kg
Gas tank capacity 24.6 l 20.8 l
Reserve capacity 2.46 l 2l
Differential capacity (front) 275 ml
Differential Lubricant SAE 80W-90 Hypoid
Rear drive volume 250 ml
Coolant volume 2.9 l
Engine oil capacity 2.5 l
Gasoline EU Unleaded 91 Octane
Engine oil (recommended) SAE 10W-40
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Headlight 12V/35W (2)
Taillight / Brake light 12V/5W/21W
Starting System Electric with Manual Recoil*
* according to equipment
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Technical Data ARCTIC CAT ATV 650 H1/650 H1 TRV
Engine and Drive 650 H1 650 H1 TRV

Type Four-cycle/Liquid cooled Four-cycle/Liquid cooled
Bore x Stroke 97.9x85 mm 97.9x85 mm
Displacement 641 ccm 641 ccm
Ignition type CDI CDI
Ignition timing 10° BTDC < 1500 turns/min 10° BTDC < 1500 turns/min
Spark plug type NGK CR6E NGK CR6E
Spark plug gap 0.7-0.8 mm 0.7-0.8 mm
Carburetor type Keihin CVK-40 Keihin CVK-40
Chassis
Length (overall) 218 cm 239 cm
Height (overall) 129 cm 129 cm
Width (overall) 124 cm 124 cm
Suspension travel (front and rear) 21 cm 21 cm
Wheelbase 128 cm 148 cm
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650 H1 650 H1 TRV
Front Tire Size 185-65-15 or 25x8-12 185-65-15 or 25x8-12
Rear Tire Size 205-60-15 or 25x11-12 205-60-15 or 25x11-12
Tire Inflation Pressure On Road 0.8-1.0 bar (according to load and route)
Tire Inflation Pressure Off Road 0.8-1.0 bar (according to load and route)
Miscellany 650 H1 650 H1 TRV

Dry weight 318 kg 348 kg
Gas tank capacity 24.6 l 20.8 l
Reserve capacity 2.46 l 2l
Differential capacity (front) 275 ml 275 ml
Engine oil capacity 3.4 l
Rear drive volume 250 ml
Gasoline (recommended) EU Unleaded 91 Octane
Taillight / Brakelight 12V/5W/21W
Starting System Electric with Manual Recoil*
* according to equipment
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Technical Data ARCTIC CAT ATV 700 Diesel
Engine and Drive 700 Diesel

Type Four-cycle Diesel/Liquid cooling
Bore x Stroke 75x77.6 mm
Displacement 686 ccm
Chassis
Length (overall) 237 cm
Height (overall) 124.5 cm
Width (overall) 120 cm
Suspension travel (front and rear) 21 cm
Wheelbase 147 cm
Front Tire Size 25x8-12
Rear Tire Size 25x10-12
Tire Inflation Pressure On Road 0.8-1.0 bar (according to load and route)
Tire Inflation Pressure Off Road 0.8-1.0 bar (according to load and route)
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Miscellany 700 Diesel
Dry weight 374 kg
Gas tank capacity 20.8l
Reserve capacity 2l
Differential capacity (front) 275 ml
Engine oil capacity 2l
Rear drive capacity 250 ml
Gasoline (recommended) 42-50 Cetan
Transmission oil SAE 80W-90 Hypoid
Taillight/Brake light 12V/5W/21W
Starting System Electric
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Location of Parts and Controls Models 500 4x4/500 4x4 TRV/650 H1/650 H1 TRV
21
1 5 4
2 13
9
11
22 12 22
7
Symbolic pictures
01.Battery (under the seat)

02.Headlight 11.Recoil starter
04.Seat lock 12.Registration number light
05.Tool storage (under the seat) 13.Operator´s Manual Location
7.Towing device 21.Storage box
09.Gearshift lever 22.Taillight/Brake light
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Location of Parts and Controls Models 500 4x4/500 4x4 TRV/650 H1/650 H1 TRV/700 Diesel
19 19
21 15 6. Hand brake lever

6
8. Ignition switch
010. Hazard warning switch
8 014. E-Starter
015. Drive selector
23 016. Position light/Low beam/High beam
017. Horn switch
018. Turn signal switch
19. Mirror
14 020. Differential lock
10
21. Winch Switch
20 23. Emergency/Parking brake
q NOTE
The ATV you have purchased may differ slightly
from those shown in the figures of this manual.
16
q NOTE
18 The engine is turned off with the ignition key.
17
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Operator`s Manual
Precautionary measures Check before starting !! IMPORTANT !!
For perfect brake efficiency you
The more you familiarize with the !! WARNING !! have to burnish the brake pads.
operation of your vehicle, the better Always inspect this ATV each
you can handle it. time you use it to make sure it is To do so, please follow the instruc-
in safe operating conditions. Use tions below:
Always wear protective clothing: the checklist you’ll find at the next
Helmet, goggles, long-sleeved page. Choose an area sufficiently large
shirt, long pants and boots with low to safely accelerate your ATV to 30
heels and a good tread which pre- Brake burnishing procedure: km/h.
vents you from slipping. The service brake is activated by Accelerate to 30 km/h, then com-
the foot pedal (according to direc- press brake lever to decelerate to
!! WARNING !! tive 93/14A EC homologation) or 0 – 5 km/h.
Beginning and inexperienced ATV via the left hand brake lever (both Repeat this procedure approx. 20
riders should take a rider training hydraulic). The right hand lever times until brakes are heated up.
course in occasion of which they only activates the parking/auxiliary
obtain or reinforce riding skills and brake which must not be used as When mounting the mirrors, please
get to know some operating tech- service brake. do not screw them in completely to
niques. For further information ple- the stop, but fix them first with the
ase contact an authorized ARCTIC counter-nut. (Otherwise you risk to
CAT dealer. seriously damage the support!)
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ATV - Checkliste
Steering system Fuel Gear linkage

Turn the handlebars completely to Check the fuel level in the tank and Make sure that you can shift into
the right/left – there must be no the fuel pipes. Make sure that the all gears without problems.
resistance. All parts of the steering filler cap is closed.
system must be properly fixed. No Follow these steps to start up the
play is allowed and steering has to Lights engine:
move freely. Inspect all lights (positon lights,
high beam,low beam light, turn and 1. Inspect the vehicle following
Brakes stop lights). the check list
Check the brake fluid level. Activa- 2. Test the hydraulic brake sys-
te the service brake several times. Engine oil tem by pushing the pedal several
Check levers for tightness and ma- Check the oil level with the oil level times.
noeuvrability. Test the parking bra- stick and, if necessary, fill some en- 3. Engage the parking brake.
ke: The wheels must lock when the gine oil into the crankcase.
parking brake is engaged. Check !! WARNING !!
the brake linings for signs of rear. Transmission oil Never start the vehicle if the brake
Check the oil level in the front diffe- systems don’t work properly (if the
Tire pressure rential as well as in the rear drive. brake lever is loose, if there’s not
Make sure that each tire has the enough brake liquid or the parking
right pressure. Check the state of Throttle brake does not lock the wheels).
the tires: tread (at least 1,6 mm for Push the throttle control several Your personal safety depends on
road tires/ at least 3mm for off-road times and check if it returns easily the functionality of the brake sys-
tires). and rapidly into its original position tems. The parking brake may get
(there should be some play). loose, if it is activated for a longer
period of time. Thus, block the
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Start up the engine
wheels with appropriate objects !! WARNING !! time needed for warming up incre-
(stone, wedge). It is very important not to touch or ases. If you don’t warm up the en-
compress the throttle lever during gine sufficiently, there could occur
1. Test the throttle control by the starting procedures. damages which are excluded of
pushing it several times. It must 1. Only Diesel: Preheating warranty.
return immediately and completely
into its original position. !! CAUTION !! Starting a warm engine
Don’t push the E-starter button
!! WARNING !! longer than 30 seconds. Accelerate slightly and press the
If the throttle control doesn’t work E-starter button.
properly the vehicle should not be 1. Push the E-starter button.
started. Emergency starting
!! CAUTION !! Some ATV models have an emer-
1. Shift the transmission into neu- If the temperature is –18°C or be- gency recoil starter to use if the
tral. low, you should activate the carbu- electric starter becomes inoperati-
2. Rotate the ignition key to the retor pump three times. ve. To use the recoil starter follow
O-position. this procedure:
!! CAUTION !!
Starting a cold engine It is extremely important to warm !! WARNING !!
(500, 650 H1) up the engine before raising the Be sure the transmission is in the
RPM. The engine should be left neutral position, there is no gear
If the outdoor temperature is below in the idle position for at least 3 inserted and the parking brake is
+ 5 ºC – 4 minutes before you accelerate engaged when using the emergen-
more than half way. In case of ex- cy recoil starter.
tremely low temperatures, the
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1. Pull the recoil starter handle Picture: 500 Shifting
slowly until resistance is felt; then (Automatic transmission)
give a short, quick pull.
2. Repeat until the engine starts. The ARCTIC CAT ATV with an
automatic transmission has a dual-
range transmission with reverse:
!! WARNING !!
When using the recoil starter, ple-
ase keep exactly to the procedure 1. R (Reverse)
mentioned above. 2. N (Neutral)
3. H (High Range)
!! CAUTION !! 4. L (Low Range)
To avoid damaging the recoil star-
ter, DO NOT pull the recoil rope to To shift the ATV follow these steps:
its limit or release the recoil handle
from an extended position. Allow 1. To engage the high range from
the rope to rewind slowly. neutral, move the shift lever for-
ward.
Turning off the engine 2. To engage the low range from
To turn off the engine, rotate the high range, move the shift lever
ignition key to the OFF-position. outward and forward.
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Braking
!! WARNING !! !! CAUTION !! To do so, please follow the instruc-
The high range is for normal riding Always come to a complete stop tions below:
with light loads. The low range is before attempting to shift from one
for carrying heavy loads or trailer range to the other or into reverse. Choose an area sufficiently large
towing. Compared to HIGH range, Always shift on level ground, or to safely accelerate your ATV to 30
the LOW range position provides engage the parking brake before km/h.
slower speed and greater torque to shifting into another range or into Accelerate to 30 km/h, then com-
the wheels. reverse. press brake lever to decelerate to
0 – 5 km/h.
3. To engage reverse gear from Brake burnishing procedure Repeat this procedure approx. 20
neutral, move the shift lever out- times until brakes are heated up.
ward and rearward into the R po- The service brake is activated by
sition. the foot pedal (according to direc- !! WARNING !!
tive 93/14A EC homologation) or Please note that new brake pads
via the left hand brake lever (both have to be prepared. Don’t put
hydraulic). The right hand lever yourself into situations that require
4=L an immediate braking unless the
only activates the parking/auxiliary
brake which must not be used as brake pads are working properly
3=H service brake. (this may result in serious acci-
dents!).
2=N !! IMPORTANT !!
For perfect brake efficiency you When using the hydraulic brakes,
1=R have to burnish the brake pads. you must be familiar with the follo-
wing points:
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q NOTE 4. The left hand brake lever Parking
Further information on how to disposes of a detent used to block
maintain the hydraulic brake system the whole hydraulic system. When Please observe the following points:
can be found in the Service booklet. using the detent, the wheels are
blocked additionally. • After the ATV stops, shift into
The brake fluid is the most important neutral.
part of the system. Keep an eye on !! WARNING !!
the right level. If there’s some kind of Excessive repetitive use of the • Turn off the engine.
dirt in the brake system or the brake hydraulic brake for high speed
fluid, the fluid has to be changed. stops will cause overheating of the • Try to park only on level surfaces.
(Impurities in the brake fluid lower brake fluid and premature brake pad If you have to park on a hill, shift the
the boiling point). wear. ATV into low gear.
1. Never „ride“ the brake. Even !! WARNING !! • Engage the mechanical parking
maintaining minimal pressure on Use only DOT 4 brake liquid. Don’t brake. (right hand lever)
the brake will cause the brake pads use several types of brake liquids
to drag on the disc. which may result in an unexpected
loss of brakes. Before starting your
2. The service brake is the main ATV check the brake liquid level and
brake for the ATV. the state of the brake pads.
3. In order to stop the vehicle,

release the throttle control and push
the brake pedal.
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General Information
ATV-Identification numbers The Engine Serial Number is lo- Always provide the ATV name, Ve-
cated at the left-side of the recoil hicle Identification Number and En-
The Arctic Cat ATV hat two identifi- starter (500/650 H1). gine Serial Number when contacting
cation numbers: Vehicle identificati- an authorized Arctic Cat ATV dealer
on Number (VIN) and Engine Serial With model 700 Diesel, the engine for parts, service, accessories or
Number (ESN). number is located on the back of warranty. If a complete engine must
The Vehicle Identification Number the engine block between engine be replaced, ask the dealer to notify
is located on the frame support rail and transmission. Arctic Cat for correct registration
beneath the rear right-side fender. information.
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Ignition switch key
Two keys come with the ATV. Keep

the spare key in a safe place. An
identifying number is stamped on
each key. Use this number when
ordering a replacement key.
The same applies for the keys of

the anti-theft device.
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Control locations and functions
Ignition switch !! CAUTION !! Speedometer/Indicator Lights

The ignition switch has three posi- Leaving the ignition switch in the
tions: LIGHTS position for a long peri- 1. Speedometer:
od of time when the engine is not The speedometer shows approxi-
OFF-Position: All electrical circuits running may cause the battery to mate speed.
except the accessory plug are off. discharge. Always leave the igniti-
The engine will not start. The key on switch in the OFF position when 2. Odometer: The odometer shows
can be removed in this position. engine is not running. the total distance travelled.
q NOTE Lights Position (level 2): The igniti- 3. Trip Meter: The trip meter is an
The accessory plug is powered by on circuit is complete and the head- odometer which can be reset. It
the battery at all times. lights and taillight are on. The key can be used to show the distance
cannot be removed in this position. travelled on short trips or between
ON-Position (level 1): The ignition gas stops.
circuit is complete and the engine
can run. The key cannot be remo-
ved in this position.
Only 700 Diesel: Preheating.
·
700 Diesel
Control
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4. High Beam Indicator: A blue q NOTE !! WARNING !!
light will illuminate when the lights High engine RPM, low vehicle A continuous use of the ATV with
are on high beam. The light will not speed or heavy load can raise engi- high oil temperature can cause en-
be illuminated when the lights are ne temperature. Decreasing engine gine damage or a premature wear
switched to low beam. RPM, reducing load and selecting of the engine.
an appropriate transmission gear
5. Temperature Indicator: can lower the temperature. Winch Switch
The temperature icon will begin
flashing if the engine overheats. q NOTE To release the cable, slide the togg-
(500/650 H1). Debris in front of the engine or pa- le switch to the left; to spool-in the
cked between the oil cooler/radiator cable, slide the switch to the right.
700 Diesel: The complete display cooling fins can reduce cooling
extinguishes and only the „F“- lamp capability. Clean the engine and
will flash. oil cooler/radiator to remove any
debris preventing air flow.
6. Gear Position Indicator

– Indicates which gearshift position
is selected.
!! CAUTION !!
A continuous use of the ATV with
low oil pressure can cause engine
damage or a premature wear of the
engine.
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Drive Selector
The electrical drive selector allows
the operator to operate the ATV in
either 2-wheel-drive (rear wheels)
or 4-wheel drive (all wheels). For
normal riding on flat, dry, hard
surfaces, 2-wheel drive should be
Parking brake
sufficient. In situations of aggres-
sive trail conditions, 4-wheel drive
would be the desired choice. To eit- !! CAUTION !!
her engage or disengage the front Do not attempt to either engage
wheels, come to a complete stop; or disengage the front differential
then push the 2WD/4WD switch while the ATV is moving.
located on the handlebars.
Parking brake
The parking brake should only be Brake lever lock
applied as an auxiliary brake. Whe-
never a braking situation is needed,
use the service brake. !! WARNING !!
Always check to be sure that the
parking brake has been disen-
gaged before operating the ATV. An
accident could result if the parking
brake is left engaged while the ATV
is operated. The brake may relax
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if left engaged for a long period of Electric starter button started also when engaging the
time. Pushing in on this button activates brake.
Park the vehicle on a flat surface. the starter motor. Before starting
If you can’t do so, block the wheels the engine, make sure the igniti- Choke
and engage a low gear. on switch is in the ON position, The vehicle is equipped with an
the transmission is in neutral, the automatic choke.
Light switch reverse shift lever is in the forward
The light switch has 3 positions: position and the parking brake is Throttle lever
position lights, low beam, high engaged. Control engine RPM with the po-
beam. sition of the throttle lever. Operate
With position „ON“, the position this lever with the thumb. Pushing
lights are on. With position 3, low it forward increases engine RPM.
beam and high beam are on.
q NOTE
This ATV has safety interlock swit-
ches which prevent the starter mo-
tor from activating when the trans-
mission is not in neutral. When the
transmission is shifted into neutral
or into a gear, the models can be
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Throttle Limiter Screw q NOTE Hand brake lever (left side)
Throttle lever travel may be limited The ATV is equipped with a CDI unit Compressing the brake lever will
by adjusting the throttle limiter that retards ignition timing when also apply the brake to the front
screw. The throttle limiter should maximum RPM is approached. and rear wheels.
be adjusted according to the
operator’s skill and experience. To Foot brake pedal (right side)
adjust the throttle limiter, use the Pressing the foot brake pedal
following procedure: downward will apply the brake to
the front and rear wheels.
1. Loosen the jam nut
2. Turn the throttle limiter screw
clockwise to decrease engine RPM
maximum or counter-clockwise to
increase engine RPM maximum.
3. Tighten the jam nut securely. Parking brake lever (right side)
Will block the rear wheels.
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Filler Cap/Refuelling Indicator oil level. Rack Loading Capacity
Turn the filling cap counter clock-
wise. To close it turn the filler cap 1. Unscrew the oil level stick and Vehicle type front rear
clockwise. The refuelling indicator wipe it with a clean cloth.
informs you about the gas level. 2. Install the oil level stick without 500/650 H1/ 45 kg 90 kg
threading it in. 700 Diesel
3. Remove the oil level stick; the
engine oil level should be above
the „L“ mark but not higher than the q NOTE
„F“ mark. When loading the vehicle, respect
the maximum permissible load of
Seat Lock each vehicle!
1. To remove the seat, pull the seat
lock lever (located in the middle on !! WARNING !!
the rear of the seat) upwards. Rai- Make sure the loads on the front
Oil level stick (Automatic trans- se the rear end of the seat. and rear racks will not interfere with
mission 500/600 H1) 2. To lock the seat into position, the ATV controls or obstruct the
There is an oil level stick for che- slide the front of the seat into the view of the operator. Also, make
cking the engine oil level. To check seat retainers and push down firmly sure the loads are evenly distribut-
the oil level, use the following pro- on rear of the seat. The seat should ed, properly secured and will not
cedure: automatically lock into position. shift while operating the ATV.
q NOTE
The vehicle should be on level
ground when checking the engine
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Mirrors q NOTE !! WARNING !!
Your vehicle is equipped with two When mounting the mirrors, please Do not overload the trailer and po-
mirrors, one on the left and one of do not thread them in completely, sition the load well.
the right side of the handlebars. but fix them with the counter-nut
(in order not to damage the mirror
mountings!)
Trailering and towing

This ATV is equipped with a frame
mounted receiver and a standard
5.1 cm (2 in.) receiver hitch. Only
for offroad use.
Please only use genuine ARCTIC
CAT trailer hitch brackets. Make
The mirrors are to be found on the sure that the load in the trailer is !! WARNING !!
vehicle. evenly distributed and properly Never exceed any of the ATV
secured. weight restrictions.
Approximately 60 % of the cargo

load must be located in front of the
axle of the trailer. Spread the car-
go in the trailer so the trailer tongue
weight is approximately 10% of the
trailer load. Never exceed the maxi-
mum trailer tongue weight.
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When towing a trailer, always ATV-Transport !! CAUTION !!
maintain slow speed, avoid sudden When transporting the ATV use the If using additional hold-down straps
accelerations and stopping of the following procedure: in any other area, care must be ta-
ATV. Allow more stopping distance Engage the parking brake and place ken not to damage the ATV.
than when not towing a trailer. the transmission in position L.
Secure the ATV with load rated !! CAUTION !!
!! WARNING !! hold-down straps. When transporting the ATV, make
Riding an ATV without extra caution sure the parking brake is engaged,
when towing a trailer will be hazar- q NOTE the transmission is in first gear and
dous. Tow only at low speeds and Suitable hold-down straps are the ATV is properly secured.
never exceed second gear. Avoid available from your Arctic Cat ATV
sudden accelerations and stopping dealer.
of the ATV. Do not make quick ma-
noeuvres. Avoid uneven surfaces
and do not tow an hills. Never carry
passengers in a trailer unless the
trailer is designed for such use
and has a rigid tow bar. Allow more
stopping distance.
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Gasoline /oil /lubricant
Recommended gasoline !! CAUTION !! of genuine Arctic Cat lubricants.

The recommended gasoline to use You should change the engine
in gasoline vehicles: 91 octane (in and transmission oil of your ATV Recommended Differential Lub-
EU) and for Diesel vehicles: 42-50 every 500km (and 1500 km later ricant (4 x 4)
cetane. on). Please respect in this regard The recommended lubricant for the
the maintenance schedule in your differential is SAE approved 80W-
Recommended engine and trans- service booklet. 90 hypoid. This lubricant meets all
mission oil (except 700 Diesel) of the lubrication requirements of
The recommended oil to use in 700 Diesel: the Arctic Cat ATV.
this ATV is an oil which is rated Engine oil: SAE 10W-40
SE, SF or SG under API service Transmission oil: 80W90 Hypoid !! CAUTION !!
classification. These oils meet all Any lubricant used in place of the
of the lubrication requirements of recommended lubricant could cau-
20W-50
the Arctic Cat ATV engine. The re- se serious differential damage.
commended engine oil viscosity is ENGINE
OIL 10W-40
SAE 10W-40. Ambient temperature
should determine the correct weight 5W-30
of oil. See the viscosity chart or an
authorized Arctic Cat ATV dealer
for details. °C -30 -20 -10 0 10 20 30 40
TEMP
°F -22 -4 14 32 50 68 86 104
!! CAUTION !!
Any oil used in place of the recom-
mended oil could cause serious q NOTE
engine damage. Arctic Cat recommends the use of
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Filling Gas Tank Allow the engine to cool before
filling the gas tank. Care must be
!! WARNING !! taken not to overfill the tank. If
Always fill the gas tank in a well- overfilled, gas may leak onto the
ventilated area. Never add gasoline engine creating a fire hazard.
to the ATV gas tank near any open
flames or with the engine running Tighten the gas tank cap securely
or hot. DO NOT SMOKE while fil- after filing the tank.
ling the gas tank.
!! WARNING !!
Since gasoline expands as its tem- Do not overfill the gas tank.
perature increases, the gas tank
must be filled to its rated capacity
only.
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Break-in Procedure
New ATV and renewed ATV engi- for excessively long periods of only activates the parking/auxiliary
nes require a „break-in“ period. The time. brake which must not be used as
first month is most critical to the life service brake.
of this ATV. Proper operation during During the break-in period, you
this break-in period will help assu- should not use more than 1⁄2 thrott- After the completion of the break-
re maximum life and performance le. Short acceleration manoeuvres in period, the engine oil and oil
from the ATV. and riding at different velocities filter should be changed. Other
provide an optimum break-in of the maintenance after break-in should
During the first 10 hours of operati- engine. include checking of all prescribed
on, always use less than 1⁄2 throttle. adjustments and tightening of all
Varying the engine RPM during the During the break-in period you fasteners. Your Arctic Cat ATV dea-
break-in period aids the engine/ must also burnish brake pads ler will be pleased to do this initial
transmission component mating (hydraulic brake) to achieve full service.
process. Although it is essential to braking effectiveness. To properly
place some stress on the engine burnish the brakes, use the follo-
components during break-in, care wing procedure:
should be taken not to overload the
engine too often. Do not pull a trai- BRAKE BURNISHING PROCE-
ler during the break-in period. DURE
When the engine starts, allow it to The service brake is activated by

warm up properly. Idle the engine the foot pedal (according to direc-
several minutes until the engine tive 93/14A EC homologation) or
has reached normal operating tem- via the left hand brake lever (both
perature. Do not idle the engine hydraulic). The right hand lever
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Air filter Shock absorbers Shock absorbers adjustment
The air filter (including the foam Each shock absorber should be vi- (500/650 H1/700 DIESEL)
element) must be kept clean to sibly checked weekly for excessive
provide good engine power, a low fluid leakage, cracks or breaks in !! CAUTION !!
gas consumption and a long life of the lower case, or a bent shock Use a spanner wrench to adjust
the engine. rod. If any one of these conditions the sleeve to the desired position.
If operated in dusty, wet or muddy is detected, replacement is neces-
conditions, inspect and service the sary. Contact your Arctic Cat ATV
filter more frequently than under dealer.
normal conditions. Position Spring Setting Load
q NOTE Force
!! CAUTION !! When the ATV is operated in ex- 1 Soft Light
Never use your ATV without air tremely cold weather (-23° C or Í Í
2
filter or foam element (danger of colder), a small amount of leakage
engine damage. may be present. Unless the lea- 3
kage is excessive, replacement is 4 Í Í Í
Air Filter Housing Drain Tube not necessary. 5 Stronger Stiff Heavy
Periodically (weekly) check the
drain tube for gasoline or oil accu-
mulation.
!! WARNING !!
If necessary drain the gasoline or
oil into a suitable container.
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q NOTE
Please adjust the shock absorbers
with the vehicle unladen.
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General maintenance
q NOTE General lubrication the filter mounting boss (located

Proper maintenance of the ATV is on the front-right side of the trans-
important for optimum performance. Cables mission case) and allow the filter to
Follow all given instructions. None of the cables require lubricati- drain completely.
on; however it is advisable to lubri- 4. Remove the old oil filter and
If, at any time, abnormal noises, cate the ends of the cables periodi- dispose of properly. Do not re-use
vibrations, or improper functioning cally with a good cable lubricant. oil filter.
of any component of this ATV is 5. Apply oil to the new filter O-ring
detected, DO NOT OPERATE THE Engine/Transmission Oil and and check to make sure it is positi-
ATV. Take the ATV to an authorized Filter oned correctly.; then install the new
ARCTIC CAT ATV dealer for in- (500/650 H1/700 Diesel) oil filter. Tighten securely.
spection and adjustment or repair. Change the engine oil and oil filter 6. Install the oil filter drain plug and
at the scheduled intervals. The en- tighten securely.
q NOTE gine should always be warm when 7. Install the oil filter drain plug and
The following instructions and infor- the oil is changed so the oil will tighten securely.
mation refer to specific items in the drain easily and completely.
maintenance and care of the ATV.
1. Park the ATV on level ground.
2. Remove the oil filler plug. Be
careful not to allow contaminates to
enter the opening.
3. Remove the drain plugs from
the bottom of the engine and drain
the oil into a drain pan.
4. Remove the oil filter plug from
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8. Install the engine drain plug Front Differential and Rear Drive !! CAUTION !!
and tighten it securely. Pour the re- Lubricant Inspect the oil for any signs of me-
commended oil into the filter hole. tal filings or water. If found, take
Install filter plug. Inspect and change the gear lub- the ATV to an authorized Arctic Cat
9. Start the engine and allow it to ricant at the scheduled intervals. ATV dealer for servicing.
idle for a few minutes. When changing the lubricant, use
10. Turn the engine off and wait approved SAE 80W-90 hypoid oil 1. Pour recommended oil into the
approximately one minute. Re- and use the following procedure: filler hole .
check the oil level.
11. Inspect the area around the 1. Place the ATV on level ground. q NOTE
drain plug and oil filter for leaks. 2. Remove the oil filler plug. If the gear case has a level plug,
3. Drain the oil into a drain pan af- fill to the threads of the level plug.
ter having removed the drain plug. If the gear case has only a fill plug,
4. After all the oil has been drai- fill to within 2.5 cm (1 in.) of the
ned, install the drain plug and tigh- threads of the fill plug
ten securely.
2. Install the filler plug.
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Brake pads Hydraulic Brake !! WARNING !!
The clearance between the brake The hydraulic brake must be pro- Be sure to inspect the hydraulic
pads and brake discs is adjusted perly maintained to be fully func- brake system before each use. Al-
automatically as the brake pads tional. ways maintain brakes according to
wear. Check the thickness of each the maintenance schedule.
of the brake pads as follows: 1. Press the foot brake pedal or
the hand brake at the handlebars Brake fluid
1. Remove a front wheel. respectively. Check the brake fluid level in the
2. Measure the thickness of each 2. With the engine off, transmissi- brake fluid reservoir.
brake pad. on in neutral and the reverse lever If the level in the reservoir is below
3. If thickness of either brake pad in the forward position, attempt to the lower mark, add DOT 4 brake
is less than 2 mm, have brake pads move the ATV. fluid.
replaced. Install the wheel and tigh- 3. If the front and the rear wheels
ten to 65 Nm. are locked, it is adjusted properly.
4. If the wheels are not locked, it
must be adjusted (set up).
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!! CAUTION !! Battery
Be careful not to spill any fluid when The battery of the models 500 and
filling the brake fluid reservoir. Wipe 650 H1 is located under the right
away spilled fluid immediately in or- rear fender. (700 Diesel: at the
der not do damage plastic parts. rear of the vehicle) The level of the
battery fluid must be kept between
!! CAUTION !! the MAX and MIN level lines at all
When the right-hand jam nut can- times. If the level drops below the
not be loosened, both brake pads MIN level line, add only distilled
must be replaced. Take the ATV to water until it reaches MAX level
an authorized Arctic Cat ATV dealer line.
for this service.
!! WARNING !!
Protective Rubber Boots When working on the battery, you
The protective boots should be in- have to be extremely careful in
spected periodically. order to not get in contact with the
battery acid.
If the battery is discharged, remove

the battery from the ATV and char-
ge the battery at the standard char-
ging rate of 1,4 amps for 10 hours.
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!! WARNING !! !! CAUTION !! 6. Place the battery into position in
Anytime service is performed on Do not charge the battery while it the ATV and secure with the hold-
a battery, the following must be is in the ATV with the battery termi- down bracket.
observed: Keep sparks, open fla- nals connected. 7. Attach the vent tube and check
me, cigarettes or any other flame the vent tube to make sure it is not
away. Always wear safety glasses. 3. Remove the vent plugs; then (if crimped and that it is properly secu-
Protect skin and clothing when necessary) fill the battery with dis- red to the frame.
handling batteries. When servicing tilled water to the MAX level indica- 8. Clean the battery posts and ca-
battery in enclosed space, keep the ted on the battery. ble ends.
area well-ventilated. 4. Charge the battery at 1,4 amps 9. Connect cables to the proper
for 10 hours. terminals. Connect the negative
To charge the battery, use the follo- cable last.
wing procedure:
!! CAUTION !! !! CAUTION !!
1. Remove the battery hold-down Never exceed the standard char- Be sure to connect the positive
bracket. ging rate. cable to the positive terminal and
2. Remove the negative battery the negative cable to the negative
cable; then remove the positive 5. After charging, check fluid level terminal!
cable and the battery vent tube. and fill with distilled water as ne-
Remove the battery. cessary; then install vent plugs.
!! WARNING !! !! CAUTION !!
Avoid contact with skin and eyes. Before installing the battery, make
sure the ignition switch is in the
OFF position.
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Spark plug (except 700 Diesel) Use a feeler gauge to check the Engine Idle RPM Adjustment
The ATV comes equipped with a gap. (except 700 Diesel)
specified spark plug (see techni- When installing the spark plug, be To properly adjust the idle, a tacho-
cal data). A light brown insulator meter is necessary. If one is not
indicates that the plug is correct. available, take the ATV to an autho-
A white or dark insulator indicates rized Arctic Cat ATV dealer. (Diesel
that the engine may need to be ser- vehicles must always be taken to
viced or the carburetor may need the dealer!)
to be adjusted. Take the ATV to an To adjust idle RPM:
authorized Arctic Cat ATV dealer.
1. Start the engine and warm it up
q NOTE to normal operating temperature.
If the spark plug fails prematurely sure to tighten it securely. A new 2. Turn the throttle stop screw in
due to cold outside temperature, spark plug should be tightened 1⁄2 our out until the engine idles at the
low speed or low RPM, please con- turn once the washer contacts the recommended RPM.
tact your Arctic Cat ATV dealer. cylinder head. A used plug should
be tightened only 1/8 – 1⁄4 turn. Engine idle RPM
Before removing the spark plug, be
sure to clean the area around the 500/650 H1 1250-1350 turns/min
spark plug. If you do not, dirt could
enter engine when removing or in-
stalling the spark plug.
Adjust the gap on the 500 and 650
H1 to 0.7-0.8mm for proper ignition.
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then slide the rubber boot over the Air filter
adjuster. The air filter inside the air filter
housing must be kept clean to pro-
vide good engine power. If the ATV
is used under normal conditions,
service the filter at the intervals
specified. If operated in dusty, wet
or muddy conditions, inspect and
!! WARNING !! service the filter more frequently.
Adjust the idle to the correct RPM. The air filter is to be found under
Make sure the engine is at normal the storage box:
operating temperature before ad- Carburettor Float Bowl • Remove the two plastic rivets.
justing the idle RPM. Periodically, the float bowl should • Remove the storage box cover
be drained. Your Arctic Cat ATV and slide the loose panelling
Throttle cable adjustment dealer will do this service. element forward.
To adjust the throttle cable free-
play: Gas/Vent Hoses
Replace the gas hose every two
1. Loosen the jam nut. years. Do not bend or obstruct
2. Slide the rubber boot away and the routing of the carburetor vent
turn the adjuster until the throttle hose. Make certain that the vent
lever has proper free-play of 2-4 hose is securely connected to the
mm. carburetor and hose holder and the
3. Tighten the knurled nut against opposite end is always open.
the throttle cable adjuster securely;
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• Pull the storage box out !! CAUTION !! Diesel filter (only 700 Diesel)
• Open the 4 clamps and remove Never put oil into the filter or the The vehicle is equipped with a
the air filter cover. foam element. highly efficient Diesel filter. The
• Remove the filter with the foam • Place the foam around the air filter has to be changed periodically
element. filter and install the filter into the according to the Service manual or
• Separate the foam element from air filter housing. even more often, if the vehicle is
the filter and clean both parts • Make sure that the air filter is also used in winter.
with soapy water. properly seated in the housing.
• Put the foam element in a plastic • Install the cover and secure with Draining V-Belt cover
bag and pour in some air filter the 4 clamps. Install the storage (Automatic transmission)
cleaning solvent; then work the box.
solvent into the element. q NOTE
• Slightly squeeze the element to Vent hose and air filter housing If the ATV has been driven through
remove excess solvent. Periodically check the drain tube water, the V-belt cover must be
• When the element is dry, put it for gasoline, oil or dirt accumula- drained of any water.
into the filter. tion.
To drain the belt cover, us the follo-
wing procedure:
1. Place the ATV on a level sur-

face.
2. Remove the drain bolt from the
cover and allow the water to drain
out.
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3. Shift the range lever to the neu- and type of tires as specified. Tire Tread condition
tral position; then start the engine. The use of worn-out tires on and
4. Accelerate several times to !! WARNING !! ATV is very dangerous. A tire is
„blow out“ any water. Then stop the Always use the size and type of considered to be worn out when
engine. tires as specified and maintain pro- the depth of the tread is less than
5. Install the drain bolt and tighten per tire inflation pressure. 3mm for off road tires and less than
securely. 1,6mm for road tires.
Vehicle Please observe legal regulations of
q NOTE front rear your country!
type
The V-belt and clutches should be Worn-out tires have to be replaced
inspected periodically and the belt 500/650 H1 185/65/15 205/60/15 immediately!
25x8-12 25x11-12
replaced (if necessary).
700 Diesel 25x8-12 25x10-12 Pressure
Type
(all models)
Tire inflation pressure

front rear
In the tool set supplied with your
ATV you’ll find a barometer to
0.8-1.0 bar (according
measure the tire inflation pressure. Road tires
to load and route)
Always check tire pressure before
starting your ATV. Off-road 0.8-1.0 bar (according
Tires tires to load and route)
The ATV has low-pressure tubeless
tires. Below you’ll find a list with the
right tire sizes. Always use the size
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by an authorized Arctic Cat ATV Headlight
dealer.
q NOTE
!! CAUTION !! The bulb portion of the headlight is
When breaking the tire bead loose fragile. When replacing the head-
from the wheel, be extremely care- light bulb, do not touch the glass
ful not to damage the inner wheel portion of the bulb. If the glass is
surface or the tire bead. touched, it must be cleaned with a
dry cloth.
!! WARNING !! Front/Rear Wheel Removal To replace the headlight bulb, use
The use of worn-out tires can be • Park the ATV on level ground and the following procedure:
dangerous and can increase the engage the parking brake. • Remove the sealing and the re-
risk of an accident. • Loosen the lug nuts. tainer.
• Elevate the ATV by placing a jack • Retract the bulb housing from the
Tire Replacement under the axle. retainer and remove the bulb.
The ATV has low-pressure tubeless • Remove the wheel • Install the new bulb .
tires. Air is sealed by the contact • Install the wheel and install the • Install the bulb housing in rever-
surfaces of the inner wheel rim lug nuts. se order.
and the tire bead. If either the inner • Tighten the nuts to 65 Nm
wheel rim or tire bead is damaged, • Remove the jack. !! CAUTION !!
air may leak. Be extremely careful When replacing the headlight bulb,
not to damage these areas when be careful not to touch the glass
replacing tires. If proper tools and portion of the bulb. If the glass is
related items are not available, touched, it must be cleaned with a
have this maintenance performed dry cloth.
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Registration Plate Light Turning Light or Taillight/ Fuses
To replace the registration plate Brakelight At the models 500/650 H1/700 Die-
light bulb, use the following pro- To replace the turning light or sel the fuse box is to be found un-
cedure: taillight/brakelight bulb, use the der the seat.
1. Remove the two screws and following procedure:
remove the lens. q NOTE
2. Pull out the bulb. 1. Rotate the socket counter- To remove the fuse, compress the
3. Install the new bulb by clockwise and remove it from the locking tabs on either side of the
pushing it in. housing. fuse case.
4. Install the lens. Tighten the 2. To remove the bulb from the
two screws securely. socket, push in and rotate counter- If there is any type of electrical
clockwise. system failure, always check the
3. To install the bulb, push in and fuses first.
turn clockwise.
4. Insert the socket into the hou-
sing and rotate it clockwise.
KM143B
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!! CAUTION !! Tools
Always replace a blown fuse with a Under the seat of your ATV you’ll
fuse of the same type and rating. If find a basic tool kit. Maintain the
the new fuse blows after a short pe- tool kit with the ATV at all times.
riod of use, consult an authorized
Arctic Cat ATV dealer immediately.
Electrical Output Terminals

(500/650 H1/700 Diesel)
One output terminal for electrical
accessories is located on the front
wiring harness (less than 180 W).
!! CAUTION !!
Always use electrical accessories
less than 180 W.
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Preparation for storage
!! CAUTION !! Then using Arctic Cat Engine Pre- dry area.

Prior to storing the ATV, it must be server, rapidly inject the preserver 10. If possible, store the ATV in-
properly serviced to prevent rusting into the air filter opening for a peri- doors.
and component deterioration. od of 10 to 20 seconds. Install the
air filter. !! CAUTION !!
Arctic Cat recommends the follo- Avoid storing outside in direct sun-
wing procedure to prepare the ATV !! CAUTION !! light and avoid using a plastic cover
for storage. An authorized Arctic If the interior of the air filter housing as moisture will collect on the ATV
Cat ATV dealer should perform is dirty, clean the area before star- causing rusting.
this service; however the owner/ ting the engine.
operator may perform this service
if desired: 4. Drain the carburettor float bowl.
5. Plug the hole in the exhaust sys-
1. Clean the seat cushion with a tem with a clean cloth.
damp cloth. 6. Apply light oil to the upper stee-
2. Clean the ATV thoroughly by ring post bushing and plungers of
washing dirt, oil, grass and other the shock absorbers.
foreign matter from the entire ATV. 7. Take care that all screws, nuts
DO NOT get water into any part of and holding components are tighte-
the engine or air intake. Allow the ned properly.
ATV to dry thoroughly. 8. Clean the ATV thoroughly.
3. Either drain the gas tank or add 9. Disconnect the battery cables
a fuel stabilizer to the gas in the gas (negative cable first); then remove
tank. Remove the air filter. Start the battery, clean the battery posts
the engine and allow it to idle. and cables and store in a clean
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Preparation after storage
Taking the ATV out of storage and 8. Take care that all screws, nuts
correctly preparing it will assure and holding components are tighte-
many kilometres and hours of trou- ned properly.
ble-free riding. Arctic Cat recom- 9. Make sure the steering moves
mends the following procedure to freely and does not bind.
prepare the ATV: 10. Check the spark plug. Clean or
replace as necessary.
1. Clean the ATV thoroughly.
2. Clean the engine. Remove the
cloth from the exhaust system.
3. Check all control wires and ca-
bles for signs of wear or fraying.
4. Change the engine/transmission
oil and filter.
5. Charge the battery; then install.
Connect the battery cables making
sure to connect the positive cable
first.
6. Check the entire brake system
(fluid level, pads etc.), all controls,
headlights, taillight, brake light and
headlight aim.
7. Check the tire pressure.
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For your safety
Let your dealer demonstrate you 1) Starting & Stopping 2) Turning Left & Right
the operating and riding manoeuv-
res; then practice each manoeuvre. • Once around clockwise and back • Figure 8 using two of the cones
Learn the correct techniques. around counter-clockwise
• Three laps
Set up a riding course using traffic • Stop and start while riding around
cones (approx. 6m wide by 30m course (1)
long). Also, have a few posts or
lumber (at least 10cm in diameter)
to use as obstacles to climb over.
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3) Sharp turns 4) Slalom turns 5) Quick turns
• Turns of less than 90 degrees • Turning in and out of the cones • Move two cones (1)
• Two laps clockwise, three • Three laps • Suddenly go left, right or

laps counter-clockwise straight (2)
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6) Crossing obstacles 7) Traversing hills 8) K-turns & U-turns
• Use posts or lumber at least • Up (2) and down (1) hill (slope • Up and down hill
10cm in diameter (2) less than 25 degrees)
• U-turn on hill
• Cross once each with left, right • Stop, start (3) and traverse (A)
and both wheels on hill • K-turn on hill
Practice this manoeuvre on flat Practice this manoeuvre on

land if a hill is not available. flat land if a hill is not available.
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Active Riding
Riding
Active riding involves moving your Once the engine’s warm, the ATV
body. You must learn to lean and is ready to go. Please observe the
shift your weight into your turns to following points:
maintain control. Keep your feet on the footrests and
both hands on the handlebar. Hold
Statistics say that inexperienced the brake lever and release the
riders are 13 times more likely to parking brake. Shift into first gear.
have an ATV accident than riders Release the brake slowly and apply
who have over 1 month of experi- the throttle with your thumb.
ence!
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Leaning, weight shift and
balance:
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 inside of the footrest. At the
same time, lean your body to the in-
side of the turn. Pay attention to the
handling – if you feel the tires co-
ming off the ground, reduce speed,
shift more of your body weight to
the side that’s lifting and make the
turn wider if possible.
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Wide Turns
About 20 % of ATV accidents hap- 2. Shift your body weight to the 3. Gradually increase your speed
pen during turns. For this reason inside of the turn. as you come out of the turn.
be extremely careful in such a
situation.
Use this method for wide turns:
1. As you approach the turn, slow

down.
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Sharp Turns
After mastering wide turns, practice 3. You might have to lean into the 5. Gradually increase your speed
the advanced skill of sharp turns. turn more than you do in a wide as you come out of the turn.
To make sharp turns, please obser- turn.
ve the following steps:
4. If shifting your weight and ba-
1. As you approach the turn, slow lance aren’t enough to keep the
down. ATV tires on the ground, slow down
and straighten out the handlebars
2. Shift your body weight to the as much as you can.
inside of the turn.
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Quick Turns
Quick turns are the most difficult 3. Follow this with slight accelera-
turns and should only be done af- tion.
ter you are experienced with your
ATV. 4. To make your turn quicker, try
raising yourself off the seat a little
1. As you approach the turn, slow bit as you shift your weight.
down.
2. Turn the handlebars and shift

your body weight to the inside of
the turn.
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K-Turns
Use K-turns if you accidentally stall 5. If you’re to the left of the ATV,
while riding uphill. turn the handlebar all the way left.
1. Stop where you are, apply the 6. Partially release the brake, but
brakes and shift to neutral. lightly hold the brake lever.
2. Shut off the engine. 7. Let the ATV roll to your right
side, until it faces slightly downhill.
3. Keep your body weight shifted shifted uphill when you sit down.
forward. 8. Reapply the brakes.
10. Start the engine and follow the
4. Get off the ATV on the uphill 9. Get back on the ATV from the method for riding downhill.
side. uphill side and keep your weight
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Riding uphill
Roughly 20 % of accidents happen 3. If you lose speed, quickly shift to 5. If you have lost all forward moti-
while riding on hills as a result of in- a lower gear. At the same time, re- on, follow the K-turn procedure.
correct behaviour. So, use extreme lease the throttle so your front tires
caution and follow this method for don’t lift OR
riding uphill: !! WARNING !!
4. If that doesn’t work and the ter- Never climb hills with an angle of
1. Shift down and accelerate rain permits, do a U-turn, go back gradient higher than 25 %.
before you start climbing. Then down and try climbing again, OR
maintain a steady pace.
2. Lean as far forward as possible.

For steeper hills come off your seat
to stand and lean forward.
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Riding downhill
1. Shift your body weight as far 2. Keep it in a low gear. 3. Lightly apply the brake and ease
back on the seat as possible. up on the throttle.
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Sidehilling/Traversing
Sidehilling is considered an advan- 2. Shift all your body weight to the 3. If the ATV feels like it’s tipping,
ced skill; it’s really tricky and unpre- uphill side of the seat; also, support turn the handlebar downhill. If that’s
dictable. So, whether your skills are your weight on the uphill footrest. not possible because of the terrain
advanced or not, try to avoid this or other conditions or if it just
kind of riding. If you’re in a situation doesn’t work, stop and get off. Dis-
where you absolutely have to side- mount the ATV on the uphill side.
hill, follow this method:
1. Keep your speed low and con-

sistent.
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Crossing obstacles
Crossing obstacles is risky. Avoid • Apply a little throttle when the • If the ATV starts tipping, shift your
it if possible. Riding over logs and front tires make contact with the weight to keep it in balance.
rocks means combining all the acti- obstacle.
ve riding skills into one big motion. • Lean forward and release the
These are general guidelines for throttle when the front tires clear
overcoming obstacles: the obstacle.
• Keep your body loose to absorb
• Keep your speed way down. any shock.
• Approach the obstacle head-on.
• Come up off the seat.
• Keep your weight on the foot-
rests.
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Skidding or Sliding Please observe the following: Driving in cold weather
If you lose control after hitting sand,
ice, oil or water: 1. Examine the depth of the water q NOTE
and check for hidden obstacles like Check that all control levers move
1. Turn your handlebar into the logs or rocks. freely. Make sure that they are free
direction of the slide. 2. Keep your speed slow. of ice and snow.
2. Keep your hand off the brakes 3. Make sure you have a way out
until you’re out of the skid. on the other side of the water. !! WARNING !!
3. Shift your weight forward. 4. If you get stuck in the mud, try For your personal safety, it is very
rocking the ATV from side to side. important to wear enough warm
Parking on a hill 5. Once you’ve cleared the water, clothing.
1. Keep it in gear. briefly apply the brakes to make
2. Engage the parking brake. sure they work. 1. With the transmission in neutral,
3. Find something to block the rear move the ATV forward and back-
tires (e.g. wedges). ward to check that the wheels roll
freely. If the ATV will not roll, the
Crossing water tires may be frozen to the ground
Your ATV can only handle water up or the brake pads may be frozen to
to its footrests. Any more than that the discs.
and you risk engine damage. Stay 2. If the tires are frozen to the
away from fast moving rivers. ground, pour warm water around
them to melt the ice.
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!! CAUTION !! !! WARNING !!
Before riding, manually move the Go slowly and be extra careful,
ATV forward and backward to make when riding on snow-covered or
certain that all wheels roll freely. ice-covered terrain. Always be alert
to changing terrain conditions when
1. If the brakes are frozen, take the operating the ATV!
ATV to a warmer area to thaw out
the brakes. 2. Practice driving in an open
snow-covered or ice-covered area
!! WARNING !! before driving on ice-covered
Never attempt to free frozen brakes trails.
by pouring warm water on the bra- 3. Learn how the ATV responds to
ke pads and housings! steering and braking on an ice-co-
vered terrain.
q NOTE
After the brakes thaw, dry them by
applying them several times while
riding slowly.
q NOTE
After riding through water, mud and
snow, it is important to dry both
brake systems before parking the
ATV.
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FAQ´s Troubleshooting
Problem Solution
• Your vehicle cannot be started. ¸ Is the battery attached or does it have to be

� recharged (for ex after a longer standstill)?
¸ Bring the gear lever into position „N“, or activate the
hand brake lever when you have shifted into a gear.
• You cannot shift into reverse gear and/or you hear

a roaring noise.
¸ Was the vehicle stopped completely before shifting?
• The lights ( horn, blinker,... ) do not work. ¸ Is the ignition key in the correct position?
¸ Examine the fuses in the fuse box.
• The engine stalls. ¸ Is the idling speed to low?
• You cannot switch from 2WD to 4WD. ¸ Did you activate the differential lock?
¸ Move your ATV slightly forward and back.
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FAQ´s
Problem Solution
•• The speedometer does not indicate the correct

speed.
• ¸ Did you pay attention to the unit in which speed is
indicated (km/h or mph )?
¸ Are magnets and sensors properly attached to your
vehicle?
•• Starting from a height of 1500m your vehicle may

not have full output any more.
¸ Change the main jets, slow jet and low speed fuel
screw of the carburetor.
(500/650 H1)
•• Can you use a high pressure cleaner for cleaning
your vehicle? ¸ Generally yes. But do not direct the jet towards
electrical parts (lights, fuses,...)
• What is important when purchasing accessories?
¸ Is it genuine Arctic Cat ™ accessory?
¸ Was it built in by an authorized Arctic Cat ™
dealer?
¸ Please also respect the legal regulations in your
country.
q NOTE
If you cannot remedy these problems with the suggested solutions and/or if there should arise other problems,
please contact your Arctic Cat-dealer.
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Warranty
Arctic Cat extends legal warranty will be paid by Arctic Cat. The war- The following will VOID warranty:
on each new Arctic Cat ATV and ranty is validated upon examination
each part and accessory manuf- of said parts by Arctic Cat or an • Failure to perform the proper
actured or sold by Arctic Cat. War- authorized Arctic Cat ATV dealer. break-in procedure and all related
ranty claims can be made only for Arctic Cat reserves the right to in- maintenance and storage proce-
parts and accessories sold by an spect such parts at its factory. dures.
authorized Arctic Cat ATV dealer. • Repair by anyone other than an
Warranty is extended to the original The warranty periods are as fol- authorized Arctic Cat ATV dealer.
retail purchaser; however, against lows: • Improper use.
a fee of EUR 25,- the balance of • Use of improper carburetor jets
the unused warranty may be trans- 1. 24 months form date of sale and other accessories.
ferred to a second party. – for ATVs. • Use of improper gasoline, lubri-
cating oils or spark plug.
Warranty claims become invalid 2. 6 months from date of sale – for • An accident or subjecting the
when there are other than the ge- batteries. ATV to misuse, abuse or negligent
nuine Arctic Cat parts used. Arctic operation.
Cat does not assume any liability 3. 30 days from date of sale for all • Modification or removal of parts
for consequential damages. parts and accessories. (e.g. muffler, carburettor boot etc.)
unless instructed to do so by Arctic
Arctic Cat assumes the costs for Excluded from this warranty are: Cat.
all parts that are found to be war- • Use of the ATV in any way for
rantable. The repair work MUST be • Defects due to abuse of the racing purposes.
done by an authorized Arctic Cat vehicle or spare parts and acces- • Removal of the engine for use in
ATV dealer. No transportation or sories another vehicle.
rental charges (for rented vehicles) • Parts subject to normal wear:
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• Removal or mutilation of the
Chassis or Engine Number.
• Use of parts not sold by Arctic
Cat.
• Damage due to improper trans-
portation.
• Failure to perform the prescribed
service (1. Service after 500 km, 2.
Service after 1500 km, 3. Service
after 5000 km, afterwards every
5000 km or after 1 year respec-
tively, it depends on what comes
first.
• Inappropriate modifications not
expressly authorized by the manuf-
acturer.
In consideration of the foregoing

any warranty claim is limited in
duration to the various warranty
periods set forth.
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Warranty claims
At the time of purchase of a new part respectively) was actually per- Change of address / ownership
ATV you get a registration card formed. or warranty transfer
which you have to fill out and send It’s the owner’s responsibility to
to Arctic Cat GmbH, Industriestraße maintain and service the ATV in Arctic Cat keeps on file the current
43, 5600 ST. Johann/Pg., Austria. accordance with Arctic Cat’s re- address of the owner of this ATV.
One copy remains with your Arctic commendations in the Operator’s This will allow Arctic Cat to reach
Cat ATV dealer. Manual. the current owner with any impor-
tant safety information. For this
Apart from that the customer recei- Arctic Cat will not warrant repairs re- reason we ask you to inform Arctic
ves a vehicle registration certificate quired as a result of not performing Cat immediately if you move or if
which has to be presented in occa- standard operator maintenance, the ATV is sold to another party.
sion of each warranty claim. storage procedures and service as Please fill out this form completely
outlined in the Operator’s Manual. and send it to Arctic Cat GmbH, In-
Only an authorized Arctic Cat ATV dustriestraße 43, 5600 ST. Johann/
dealer has the right to perform war- Should you have any questions Pg., Austria.
ranty repair work. concerning the warranty, contact an
authorized Arctic Cat ATV dealer. This form may also be used to
If a warrantable condition appears transfer the unused portion of the
to exist, the Arctic Cat ATV dealer original warranty to a second party:
examines the ATV and will repair or Fill out this form completely and
replace, free of charge all damaged send it to Arctic Cat enclosing a
parts. The costumer is then asked copy of the vehicle registration cer-
to sign a warranty form to ensure tificate and an account-only cheque
that warranty work (repair o re- of the amount of EUR 25,-.
placement of the warrantable
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Arctic Cat will then process the
application and issue a new vehicle
certificate for the remaining period
of the warranty claim.
Page 69
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Address change
Warranty transfer
Ownership change
Change of address/ownership/
warranty transfer to:
Name:
Address:
Construction year
& Model:
Chassis Nr.:
"
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Notes
Page 71
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Notes
Page 72
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Note:
All vehicle features in this booklet refer to the basic variation. Further equipment and options are to be found in the
price list.
q NOTE
Some of the information in this booklet may not be up-to-date due to changes performed since printing. The models
shown in the pictures contain, in part, special equipment. Please ask your ATV dealer for the newest information be-
fore placing an order. The producer reserves the right to make price, colour, material, specification and model changes
without notice.
Errors and omissions excepted!
Version 2
Printed July 2008
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Arctic Cat 500 - 4x4 Operator Manual

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Page 1 Have a good trip! Your Arctic Cat-Team

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SURNAME Vehicle owner

Dealer`s signature and stamp

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TECHNICAL DATA ARCTIC CAT ATV............................................... 4

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Engine and Drive 500 4x4 500 4x4 TRV

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Engine and Drive 650 H1 650 H1 TRV

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Miscellany 650 H1 650 H1 TRV

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Engine and Drive 700 Diesel

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01.Battery (under the seat)

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21 15 6. Hand brake lever

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Steering system Fuel Gear linkage

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3. In order to stop the vehicle,

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Two keys come with the ATV. Keep

The same applies for the keys of

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Ignition switch !! CAUTION !! Speedometer/Indicator Lights

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6. Gear Position Indicator

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Trailering and towing

Approximately 60 % of the cargo

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Recommended gasoline !! CAUTION !! of genuine Arctic Cat lubricants.

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When the engine starts, allow it to The service brake is activated by

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q NOTE General lubrication the filter mounting boss (located

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If the battery is discharged, remove

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