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Arctic Cat 2010 700 Diesel SD, Operator'S Manual, Page: 4 / 96

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Table of Contents

DIVISION 1 - SAFETY

FORWORD ........................................... 1
2-UP ATV SAFETY ALERT .................. 5
HANGTAGS & WARNING 

INFORMATION ................................. 6

RIDER TRAINING COURSE ................ 7
WARNING LABELS .......................... 8-9
WARNINGS ................................... 10-19
PREVENTION................................ 20-24

Safe Riding Clothing and Gear ........... 20
Condition of the ATV ........................... 22
First Aid and Survival .......................... 24

ACTIVE RIDING ................................. 25
SOUND JUDGMENT ..................... 26-31

Environment ........................................ 27
Those Around You............................... 28
Equipment ........................................... 28
Load Capacity Ratings Chart .............. 29
Speedrack ........................................... 29
Personal Choices ................................ 30

SUPERVISION.................................... 32

Taking Responsibility........................... 32

DIVISION II - 

OPERATION/

MAINTENANCE

PREFACE ........................................... 33
PARTS AND ACCESSORIES ............ 33
SPECIFICATIONS .............................. 34
LOCATION OF PARTS AND 

CONTROLS .................................... 35

ATV OPERATION ......................... 36-47

Basic Operating Maneuvers................ 36
How to Handle the TRV (Active Riding 

Techniques) ................................. 39

Tips ..................................................... 45

GENERAL INFORMATION ........... 48-59

TRV Identification Numbers ................ 48
Ignition Switch/Key .............................. 48
Control Locations and Functions ........ 48
Fuel/Vent Hoses.................................. 54
Level Stick (Engine Oil)  ...................... 54
Level Stick (Transmission Lubricant)... 54
Safety Flag Bracket ............................. 55
Rear Rack ........................................... 55
Rack Loading (Front and Rear)........... 55

Rear Seat (Optional)............................ 55
Front Seat Lock ................................... 56
Trailering and Towing ........................... 56
Transporting TRV................................. 57
Fuel-Oil-Lubricant ................................ 57
Break-In Procedure ............................. 59

GENERAL MAINTENANCE ..........60-77

Maintenance Schedule ........................ 61
Liquid Cooling System ......................... 62
Shock Absorbers ................................. 63
General Lubrication ............................. 63
Hydraulic Hand Brake.......................... 65
Auxiliary Brake..................................... 66
Protective Rubber Boots...................... 67
Battery ................................................. 68
Fuel Filter............................................. 71
Idle RPM .............................................. 71
Throttle Cable Adjustment ................... 71
Air Filter ............................................... 72
Draining V-Belt Cover .......................... 73
Tires..................................................... 74
Wheel Removal ................................... 75
Muffler/Spark Arrester ......................... 75
Light Bulb Replacement ...................... 75
Checking/Adjusting Headlight Aim....... 76
Fuses................................................... 77
Electrical Output Terminals.................. 77
Tool Storage Tray/Storage 

Compartment ............................... 77

PREPARATION FOR STORAGE ........ 78
PREPARATION AFTER STORAGE.... 79
LIMITED WARRANTY ........................ 81
WARRANTY PROCEDURE/OWNER 

RESPONSIBILITY........................... 82

CHANGE OF ADDRESS, 

OWNERSHIP, OR WARRANTY 
TRANSFER ..................................... 83

ARCTIC CAT ATV EMISSION 

CONTROL WARRANTY 
STATEMENT ................................... 85

U.S. EPA DIESEL EMISSION 

CONTROL STATEMENT/
WARRANTY COVERAGE............... 86

DECLARATION OF CONFORMITY ... 87
INDEX ................................................. 88
MAINTENANCE RECORD ............89-90
IDENTIFICATION NUMBERS 

RECORD

............ Inside Back Cover

Summary of Contents for 2010 700 Diesel SD

Page 1: ...his Operator s Manual from this ATV according to the guidelines and agreement with the U S Consumer Product Safety Commission Read this manual carefully It contains important safety information SHARE OUR PASSION TM 2010 2010 700Diesel ...

Page 2: ...TO FOLLOW THE WARN INGS CONTAINED IN THIS MAN UAL CAN RESULT IN SERIOUS INJURY OR DEATH Training is available Canadian own ers call 1 613 739 1535 Particularly important information is distinguished in this manual by the fol lowing notations California Proposition 65 WARNING Never carry a passenger without the optional passenger seat installed The Safety Alert Symbol means ATTENTION BE ALERT YOUR ...

Page 3: ...tic Cat ATV dealer for assistance Remember only authorized Arctic Cat ATV deal ers have the knowledge and facilities to provide you with the best service possi ble Know all local state provincial riding laws Respect your ATV and Respect the environment We also advise you to strictly follow the recommended maintenance pro gram as outlined This preventive maintenance program is designed to ensure th...

Page 4: ...fety Flag Bracket 55 Rear Rack 55 Rack Loading Front and Rear 55 Rear Seat Optional 55 Front Seat Lock 56 Trailering and Towing 56 Transporting TRV 57 Fuel Oil Lubricant 57 Break In Procedure 59 GENERAL MAINTENANCE 60 77 Maintenance Schedule 61 Liquid Cooling System 62 Shock Absorbers 63 General Lubrication 63 Hydraulic Hand Brake 65 Auxiliary Brake 66 Protective Rubber Boots 67 Battery 68 Fuel Fi...

Page 5: ... attempt to turn the ATV around on any hill until you have mastered the turning techniques described in this manual on level ground Avoid crossing the side of a steep hill if possible Always use proper procedures if you stall or roll backward when climbing a hill To avoid stalling maintain a steady speed when climbing a hill If you stall or roll backwards follow the special procedure for braking d...

Page 6: ... continued use only if they determine that the operator has the ability to operate the ATV safely Never carry a passenger under the age of 12 Never carry a passenger who can not place both feet on the footrests and who cannot securely hold onto the handholds FOR MORE INFORMATION ABOUT TRV SAFETY contact your local Arctic Cat ATV dealer or 1 613 739 1535 Canada TRV PASSENGER INSTRUCTIONS Operator t...

Page 7: ...icult to control Never operate the ATV on a public road even a dirt or gravel one because you may not be able to avoid colliding with another ATV Also operating the ATV on a public road may be against the law Never operate the ATV without an approved motorcycle helmet eye protection boots gloves long pants and a long sleeved shirt or jacket Never consume alcohol or drugs before or while operating ...

Page 8: ...mation Anyone who rides the ATV should read and understand this information before rid ing The labels should be considered as per manent parts of the ATV If a label comes off or becomes hard to read contact your Arctic Cat ATV dealer for a replacement Pour commander des Etiquettes de Mise en Garde gratuites voyez votre détail lant de autorisé VTT Arctic Cat pour le numéro de pièce 1436 344 2258 41...

Page 9: ...ision Call the CSC at 1 613 739 1535 ext 227 for more details Also available is a bilingual computer based safety training program on a CD ROM from CATV call toll free at 1 877 470 2288 Au canada le conseil canadien de la sécurité CSC offre un cours de con duite de VTT pour enseigner les habi letés d opération sécuritaires de VTT Un cours spécial de conduite de VTT est également offert aux enfants...

Page 10: ... infor mation Anyone who rides the ATV should read and understand this information before riding The labels should be considered as permanent parts of the ATV If a label comes off or becomes hard to read contact your Arctic Cat ATV dealer for a replacement NOTE The location and content of labels on the ATV you have pur chased may differ from those shown on this page DE053B ...

Page 11: ... WARNING Indicates a potential hazard that could result in a serious injury or death 9 Warning Labels DE052B ...

Page 12: ...d in the course and the operating techniques described in this Operator s Manual WARNING POTENTIAL HAZARD Allowing anyone under age 16 to operate this ATV WHAT CAN HAPPEN Use of the ATV by children can lead to severe injury or death of the child Children under the age of 16 may not have the skills abilities or judgment needed to operate the ATV safely and may be involved in a serious accident HOW ...

Page 13: ...uring operation must always keep feet on the footrests and must always keep hands on handholds WARNING POTENTIAL HAZARD Operating this ATV on public streets roads or high ways WHAT CAN HAPPEN You can collide with another ATV HOW TO AVOID THE HAZARD Never operate this ATV on any public street road or highway even a dirt or gravel one In many states it is illegal to operate the ATV on public streets...

Page 14: ...roved helmet eye protection and pro tective clothing WHAT CAN HAPPEN Operating or riding as a passenger on this ATV without an approved helmet increases your chances of a severe head injury or death in the event of an accident Operating or riding as a passenger on this ATV without eye protection can result in an accident and increases your chances of a severe injury in the event of an acci dent Op...

Page 15: ...ID THE HAZARD Always inspect your ATV each time you use it to make sure the ATV is in safe operating condition Always follow the inspection and maintenance procedures and schedules described in this Operator s Manual WARNING POTENTIAL HAZARD Removing hands from handlebar grips operator handholds passenger or feet from the footrests during operation WHAT CAN HAPPEN Removing even one hand or foot ca...

Page 16: ... to use extra care when operating on rough slippery or loose terrain WHAT CAN HAPPEN Could cause loss of traction or control which could result in an accident including a rollover HOW TO AVOID THE HAZARD Do not operate on rough slippery or loose terrain until you have learned and practiced the skills necessary to control the ATV on such terrain Always be especially cautious on these kinds of terra...

Page 17: ...e attempting larger hills WARNING POTENTIAL HAZARD Climbing hills improperly WHAT CAN HAPPEN Could cause loss of control or cause the ATV to over turn HOW TO AVOID THE HAZARD Always follow proper procedures for climbing hills as described in this Operator s Manual Always check the terrain carefully before you start up any hill Never climb hills with slippery or loose surfaces Shift your weight for...

Page 18: ...o one side Go straight down the hill where possible WARNING POTENTIAL HAZARD Improperly operating in reverse WHAT CAN HAPPEN You could hit an obstacle or person behind you resulting in serious injury HOW TO AVOID THE HAZARD Before you engage reverse gear make sure there are no obstacles or people behind you When it is safe to proceed go slowly WARNING POTENTIAL HAZARD Improperly operating over obs...

Page 19: ...engage the brake lever lock Have the passenger dismount on uphill side or to a side if pointed straight uphill then the operator should dismount on uphill side or to a side if pointed straight uphill Turn the ATV around and mount following the procedure described in this Operator s Manual WARNING POTENTIAL HAZARD Overloading the ATV or carrying or towing cargo improperly WHAT CAN HAPPEN Could caus...

Page 20: ...ead to an accident HOW TO AVOID THE HAZARD Never operate the ATV in fast flowing water or in water deeper than the footrests Remember that wet brakes may have reduced stopping capability Test your brakes after leaving water If necessary apply them several times to dry out the pads WARNING POTENTIAL HAZARD Improperly crossing hills or turning on hills WHAT CAN HAPPEN Could cause loss of control or ...

Page 21: ... Always maintain proper tire pressure as described in this Operator s Manual WARNING POTENTIAL HAZARD Operating the ATV with improper modifications WHAT CAN HAPPEN Improper installation of accessories or modification of the ATV may cause changes in handling which in some situations could lead to an accident HOW TO AVOID THE HAZARD Never modify the ATV through improper installation or improper use ...

Page 22: ...nd it important to dress cor rectly for riding in order to prevent scraped skin and serious head injuries It s easy and could save you time in the long run not having to contend with an injury Of course it also makes sense to remember the seasons Wear a hat under your helmet and a snowmobile suit in the winter and lighter protective clothing in the summer Following is the minimum protection you ne...

Page 23: ...to completely surround your eyes to prevent getting dirt or other items in your eyes Do not depend on sun glasses for proper eye protection Sun glasses are not recommended they don t prevent objects from flying in through the sides Long Pants and Long Sleeved Shirt The goal is to protect your body from branches long grass airborne objects or anything else that could scrape your skin The more thick...

Page 24: ...g the tire pressure inspect the tread and sidewalls of the tires for cracks cuts or other damage that could indicate they need to be replaced 2 CONTROLS AND CABLES With the engine running and brake applied check all transmission posi tions forward neutral and reverse A Brakes Squeeze your hand brake lever If it feels soft or squishy it could be low on fluid or have a leak refer to the General Main...

Page 25: ...nk of fuel before every ride and while you re at it top off the oil Don t forget to check for fluid leaks around the ATV Watch the overheat lamp to ensure the engine coolant level is adequate 5 CHASSIS Grass and leaves can gum up your sus pension and shocks Clear and clean the suspension arms shock springs and fenders Check smoothness by turning the handlebar full left and full right Check that th...

Page 26: ... become dehydrated you could find yourself physically unable to safely operate your ATV Identification If something does happen to you the emergency personnel will want to know who you are and whom to con tact It s possible you may be in no condition to give them that informa tion Put your I D in your pocket before you ride Without it you re anonymous Cellular Phone It may be necessary to make an ...

Page 27: ... ATV For example when you drive a car quickly into a sharp turn your body is pulled to the outside of the turn by centrifugal force Although a car is relatively stable enough centrifugal force can cause the ATV to overturn Con stantly shifting operator weight is one major difference between driving a car and riding the ATV Knowing how to shift your weight is necessary to avoid rolling or flipping ...

Page 28: ...s a major problem with the brakes tires or engine 1 2 3 Never Sometimes Often 7 Do you thrive on the adrenaline rush you get from speeding and dangerous situations 1 2 3 Never Sometimes Often 8 Do you hurt yourself because you do things that are out of your ability range 1 2 3 Never Sometimes Often 9 Do you tailgate other drivers when you think they re driving too slow 1 2 3 Never Sometimes Often ...

Page 29: ...difficult to see and avoid When night riding make sure the lights are properly adjusted and in good working order Reduce speed do not over drive the headlights Never travel in an unfamiliar area or blaze a new trail at night Always carry a flashlight or flare for signaling an emergency Paved Surfaces Don t do it The ATV isn t designed for pavement Its handling becomes more difficult on paved surfa...

Page 30: ...em For their sake keep your eyes open Animals and Nature Respect the outdoors that you love Don t use your ATV to chase animals or birds Drive around young trees rather than over them Keep clear of streams and ditches with standing water Tread Lightly and leave it as you found it The last thing you expected was that your ATV would break down in the middle of the field it s usually so reliable that...

Page 31: ...e weight you carry Load Capacity Ratings Chart Max Load Capacity Total weight of operator and passenger accessory weight tongue weight and cargo on the front and rear rack Tongue Weight Weight on trailer tongue Towing Capacity Total weight of trailer and all cargo in the trailer Speedrack When installing Speedrack accesso ries make sure to read and carefully follow the instructions provided in eac...

Page 32: ...Something to think about there can be legal consequences that will take away all that freedom you love Don t use alcohol or drugs before or during your ride WARNING POTENTIAL HAZARD Overloading the ATV or carrying or towing cargo improperly WHAT CAN HAPPEN Could cause changes in handling which could lead to an accident HOW TO AVOID THE HAZARD Never exceed the stated load capacity Cargo should be p...

Page 33: ...hings in a group than they would con sider doing by themselves When you re riding with others and things start to get out of hand decide whether you re willing to be injured or see your friends injured SIPDE By themselves none of these safe behaviors and sound judgments will go very far But when you put them all together when you re paying atten tion to how you feel when you re monitoring the move...

Page 34: ... had over a year of expe rience with riding an all terrain vehicle or taken a training course it s your responsibility to keep them off your ATV It can be dangerous especially for underaged children all the more reason for you to be firm Experienced Trained Riders If anyone is going to borrow your ATV you are responsible for their supervi sion Before they ride have them take the training course ha...

Page 35: ...r related maintenance operating instructions and storage instructions If major repair or service is ever required contact an authorized Arctic Cat ATV dealer for professional service At the time of publication all informa tion and illustrations in Division II were technically correct Some illustra tions used in Division II are used for clarity purposes only and are not designed to depict actual co...

Page 36: ...AT25 x 8 12 Rear Tire Size AT25 x 10 12 Tire Inflation Pressure 0 35 kg cm 5 0 psi MISCELLANY Dry Weight Approx 373 kg 823 lb Fuel Tank Capacity Rated 20 81 L 5 5 U S gal Coolant Capacity 5 6 L 5 9 U S qt Differential Capacity 275 ml 9 3 fl oz Rear Drive Capacity 250 ml 8 5 fl oz Transmission Capacity 600 ml 20 3 fl oz Engine Oil Capacity With Filter 2 0 L 2 1 U S qt Engine Oil Capacity Without Fi...

Page 37: ...rage Compartment 6 Seat Lock Lever 7 Engine Access Cover 8 Auxiliary Brake Pedal 9 Taillight Brakelight 10 Brake Lever Lock 11 Key Switch 12 Shift Lever 13 Throttle Limiter 14 Throttle Lever 15 Operator s Manual Location 16 Drive Select Switch 17 Digital Gauge 18 Headlight HI LO Switch 19 Starter Button 20 Emergency Stop Switch ...

Page 38: ...p your feet planted on the footrests Starting the Engine Always start with the ATV on a flat level surface Carbon monoxide poi soning can kill you so keep your ATV outside while it s running Follow these steps to start it up 1 Mount the ATV and sit down 2 Engage the brake lever lock 3 Turn on the ignition 4 Shift into neutral 5 Move the emergency stop switch to RUN 6 When the glow plug indicator l...

Page 39: ... reverse To shift the transmission follow these steps 1 To engage the high range from neutral move the shift lever for ward and inward 2 To engage the low range from high range move the shift lever forward NOTE The high range is for nor mal riding with light loads The low range is for carrying heavy loads or trailer towing Compared to HIGH range the LOW range posi tion provides slower speed and gr...

Page 40: ...should double check that the brake lever lock is engaged 2 The passenger should grasp the left shoulder of the operator with the right hand and with the left hand grasp the left side handhold then swing the right leg over the seat and step to the ground on the left side of the ATV 3 The operator should swing the right leg over to the left side of the seat 4 The operator should step to the ground o...

Page 41: ...n the handlebar 2 Hold the brake lever and release the brake lever lock 3 Shift into gear 4 Release the brake slowly and apply the throttle 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 out side footrest At the same time lean your body and the passenger body to the ...

Page 42: ... the turn 3 Gradually increase your speed as you come out of the turn Sharp Turns After mastering wide turns practice the advanced skill of sharp turns ATV 0038 ATV 0039 ATV 0040 1 Ease off the throttle as you approach the turn to slow down 2 Use the principles of leaning weight shifting and balancing shift your body weight to the inside of the turn 3 You might have to lean into the turn more than...

Page 43: ...e time as you enter the turn use the principles of leaning weight shift ing and balancing shift your body weight to the inside of the turn 3 Follow this with slight accelera tion 4 For multiple turns repeat this movement as needed 5 To make your turn quicker try raising yourself off the seat a few inches as you shift your weight K Turns Use K turns if you accidentally stall while riding uphill you...

Page 44: ...when you sit down 11 Start the engine and follow the method for riding downhill Riding Uphill Many accidents happen while riding on hills and as a result of the ATV rolling or flipping So obviously use extreme caution and follow this method for rid ing uphill ATV 207 1 Accelerate before you start climb ing then maintain a steady pace 2 Both the operator and the passen ger should lean as far forwar...

Page 45: ...ether your skills are advanced or not try to avoid this kind of riding If you re in a situation where you absolutely have to sidehill follow this method ATV 0017 ATV 0028 ATV 0029 1 Keep your speed low and consis tent 2 Shift all your body weight and passenger s body weight to the uphill side of the seat also sup port weight on the uphill footrest 3 Steer like you re driving into the hill 4 If the...

Page 46: ...ur body weight to the inside of the turn 3 Keep your hand off the brake until the emergency is over and you re back in control Crossing Obstacles Crossing obstacles is risky avoid it if possible Riding over logs rocks and ruts means combining all the active rid ing skills into one big motion Your ATV will respond differently for differ ent obstacles logs ruts etc but these are general guidelines f...

Page 47: ... 3 Backing down hills is a bad idea do a U turn or K turn instead to turn around Skidding or Sliding If you lose control after hitting sand ice mud or water 1 Turn your handlebar into the direc tion of the slide 2 Keep your hand off the brakes until you re out of the skid 3 Shift your weight forward Sometimes your ATV may not respond and goes straight ahead instead of let ting you turn Here s how ...

Page 48: ...houlder 5 Take into account that your ATV could stall while crossing give yourself and your passenger enough time to get off the road 6 You have to assume that oncoming cars don t see you and if they do they won t be able to predict your actions 7 It s illegal to cross public roads in some places Know your local laws Driving In Cold Weather NOTE Check that all control levers move freely Make sure ...

Page 49: ... snow covered or ice covered trails 5 Learn how the ATV responds to steering and braking on the type of terrain to be encountered on the ride Stopping The ATV To stop the ATV first release the throt tle lever Next apply the brake Stopping The Engine To stop the engine turn the ignition switch key to the OFF position or set the emergency stop switch to the OFF position WARNING Go slowly and be extr...

Page 50: ...sories or warranty If a complete engine must be replaced ask the dealer to notify Arctic Cat for cor rect registration information IGNITION SWITCH KEY ATV 055 Two keys come with the ATV Keep the spare key in a safe place An identify ing number is stamped on each key Use this number when ordering a replacement key CONTROL LOCATIONS AND FUNCTIONS Ignition Switch The ignition switch has three positio...

Page 51: ...s displayed then repeat edly press and release the Set Reset Button 4 until the cor rect minutes are displayed NOTE Clock memory power is supplied through the 15 amp accessory fuse and verified during gauge power up and reset In the event of clock memory power fail ure blown fuse etc the gauge will power up reset and shut down repeatedly until clock mem ory power is restored Always check the 15 am...

Page 52: ...ash for 30 sec onds then the digital gauge will return to normal with the oil pres sure icon continuing to flash 7 Odometer Trip Meter Odometer registers the total distance the vehicle has traveled The trip meter is resetable and can be used to measure trip or trip legs The odometer cannot be reset NOTE To shift between the odometer ODO or trip meter TRIP press the Mode Button 3 to select the dist...

Page 53: ...i tion provides slower speed and greater torque to the wheels 3 To engage reverse gear from neu tral move the shift lever outward and rearward into the R position Drive Select Switch This switch 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 sufficient In situations of aggres...

Page 54: ...and that the brake when engaged locks the wheels 1 Pump the brake lever 2 or 3 times 2 Engage the brake lever lock 3 Attempt to push the ATV NOTE The brake lever lock must lock the wheels If it doesn t take the ATV to an authorized Arctic Cat ATV dealer for service CAUTION Do not attempt to either engage or disengage the 4WD lock front dif ferential while the ATV is moving WARNING The 4WD lock is ...

Page 55: ...g the engine make sure the ignition switch is in the ON position the transmission is in neutral the reverse shift lever is in the forward position and the brake lever lock is engaged NOTE This ATV has safety inter lock switches which prevent the starter motor from activating when the transmission is not in neutral Throttle Lever FI475B Control engine RPM with the position of the throttle lever Ope...

Page 56: ...ipe it with a clean cloth 2 Install the level stick and push completely into the tube 3 Remove the level stick the engine oil level should be above the L mark but not higher than the F mark DE024A LEVEL STICK Transmission Lubricant There is a level stick located under the operator s seat for checking the trans mission lubricant level To check the transmission lubricant level use the following proc...

Page 57: ...ition RACK LOADING Front and Rear The front rack and rear rack are designed to carry specified load capaci ties Always refer to the Load Capacity Ratings Chart for proper capacities REAR SEAT Optional 1 To install the optional rear seat remove the rear rack then engage the two front mounting lugs into the mounting rack While holding down firmly on the front of the seat push the seat forward until ...

Page 58: ...the rear end of the seat and slide it rearward 2 To lock the seat into position slide the front of the seat into the seat retainers and push down firmly on rear of seat The seat should auto matically lock into position TRAILERING AND TOWING The TRV is equipped with a frame mounted receiver for a standard 2 in receiver hitch The standard receiver hitch must be purchased separately 738 424A WARNING ...

Page 59: ...he recommended fuel to use is bio diesel blend up to 20 B20 1 or 2 diesel fuel or JP 5 or JP 8 turbine fuel At temperatures above 10 C 14 F use 2 diesel fuel or a biodiesel blend up to 20 At temperatures at or below 10 C 14 F use 1 diesel fuel Die sel fuel with a minimum cetane number below 42 should not be used WARNING Make sure that the load in the trailer is properly secured and will not shift ...

Page 60: ... Cat recommends the use of genuine Arctic Cat lubri cants The recommended lubricant front dif ferential and rear drive is SAE approved 80W 90 hypoid This lubri cant meets all of the lubrication requirements of the ATV Filling Fuel Tank Since diesel fuel expands as its temper ature increases the fuel tank must be filled to its rated capacity only Expan sion room must be maintained in the tank parti...

Page 61: ...g components to cool Although it is essential to place some stress on the engine components during break in care should be taken not to overload the engine too often Do not pull a trailer during the break in period When the engine starts allow it to warm up properly Idle the engine sev eral minutes until the engine has reached normal operating temperature Do not idle the engine for excessively lon...

Page 62: ... of any component of this ATV is detected DO NOT OPERATE THE ATV Take the ATV to an authorized Arctic Cat ATV dealer for inspection and adjustment or repair If the owner operator does not feel qualified to perform any of these main tenance procedures or checks take the ATV to an authorized Arctic Cat ATV dealer for professional service NOTE The following instruc tions and information refer to spe ...

Page 63: ...I R Gear lubricant Front differential rear drive 65 I I 65 Replace every 4 years V Belt 73 I I Muffler spark arrester 75 C Tires air pressure 74 I Inspect every time before riding 34 I Inspect every time before riding Brake components 65 I Inspect every time before riding 66 I Inspect every time before riding Brake fluid 65 I Replace every 2 years Brake hoses 66 I Replace every 4 years Steering I ...

Page 64: ... biode gradable glycol based automo tive type antifreeze NOTE High engine RPM low vehi cle speed or heavy load can raise engine temperature Decreasing engine RPM reducing load and selecting an appropriate transmis sion gear can lower the temperature To check add coolant use the follow ing procedure 1 Check the level of coolant in the coolant expansion tank located under the right front fender The ...

Page 65: ...453 NOTE Before attempting to adjust suspension clean dirt and debris from the sleeve and remove load from the suspension then use the spanner wrench to adjust the sleeve to the desired position NOTE It is recommended that all ATV weight be taken off the sus pension prior to adjusting shock absorber sleeves GENERAL LUBRICATION Cables None of the cables require lubrication however it is advisable t...

Page 66: ...ately three minutes Recheck the oil level 10 Inspect the area around the drain plug and oil filter for leaks Transmission Lubricant Inspecting Changing Check and change the transmission lubricant according to the Maintenance Schedule When adding or changing the lubricant use approved SAE 80W 90 hypoid oil and use the following procedure 1 Place the ATV on level ground 2 Remove the transmission fil...

Page 67: ...107B CF106C 4 After all the oil has been drained install the drain plugs and tighten securely 5 Pour recommended oil into each filler hole CF113A 6 Install the filler plugs HYDRAULIC HAND BRAKE Brake Fluid Check the brake fluid level in the brake fluid reservoir If the level in the reser voir is not visible in the sight glass add DOT 4 brake fluid 738 420A NOTE If the sight glass appears dark ther...

Page 68: ...ce ment of the brake pads when they show excessive wear Check the thickness of each of the brake pads as follows 1 Remove a front wheel 2 Measure the thickness of each brake pad 3 If thickness of either brake pad is less than 1 0 mm 0 039 in take the ATV to an authorized Arctic Cat ATV dealer to have brake pads replaced PR376B 4 Install the wheel and tighten to 40 ft lb AUXILIARY BRAKE The auxilia...

Page 69: ...e play by grasping the steering knuckle and turning it from side to side and up and down 5 If boot damage is present or ball joint free play seems excessive contact an authorized Arctic Cat ATV dealer for service Tie Rod Boots Inner and Outer Right and Left CC792 1 Secure the ATV on a support stand to elevate the front wheels 2 Remove both front wheels 3 Inspect the four tie rod boots for cracks t...

Page 70: ...bat tery posts and cable ends removing all corrosive buildup Replace damaged cables or cable ends 4 Using a multimeter test the battery voltage The meter must read at least 12 5 DC Volts for a fully charged battery NOTE At this point if the meter reads as specified the battery may be returned to service see step 8 5 If the meter reads less than speci fied voltage charge the battery using the follo...

Page 71: ...rger during storage or any extended period of non use This charger MUST have an automatic float stor age safe or pulse maintenance mode to avoid battery damage due to long term overcharging To con nect the maintenance charger use any of the following procedures A Remove the battery cover then connect the charger leads posi tive cable first directly to the battery B Locate the rear accessory con ne...

Page 72: ...les may be the same color but the clamps or ends will be color coded red and black 7 Attach one clamp of the negative black jumper cable to the negative terminal 3 of the good battery B then attach the other clamp of the negative black jumper cable 4 to an unpainted metal surface A on the engine or frame well away from the dead battery and fuel system components WARNING Improper handling or connec...

Page 73: ...to the seal ring of the new fuel filter then install the filter Tighten until the seal ring contacts the filter head then tighten an additional turn 3 Depress and release the manual primer pump to charge the fuel filter and purge any air from the system DE031A NOTE Cycle the manual primer pump until the lever becomes firm and resistance is observed The system will bleed itself through the tank ret...

Page 74: ...t and service the filter more frequently Use the fol lowing procedure to remove the filter and inspect and or clean it NOTE This ATV is equipped with a dry paper air filter and a cotton fabric safety element DE014A 1 Open the air filter access cover and remove the operator s seat then rotate the air filter housing cover counterclockwise and remove from the filter housing DE006A 2 Remove the dry pa...

Page 75: ... the dry paper air filter 8 Check the drain valve in the air filter housing cover for dirt deterioration or poor sealing Clean or replace as required DE015 9 Install the air filter housing cover drain facing downward and lock it in place by turning clockwise DE006A DRAINING V BELT COVER NOTE If the ATV has been driven through water the V belt cover must be drained of any water To drain the belt co...

Page 76: ...t damage to the tire bead or wheel rims If proper tools and related items are not available have this main tenance performed by an authorized Arctic Cat ATV dealer or a qualified tire repair station Tire Repair Tubeless Should a leak or flat tire occur due to a puncture the tire may be repaired using a plug type repair If the damage is from a cut or if the puncture cannot be repaired using a plug ...

Page 77: ...care not to damage the screen CF104 NOTE If the screen or gasket is damaged in any way it must be replaced 3 Install the spark arrester assembly and secure with the three cap screws Tighten cap screws to 48 in lb LIGHT BULB REPLACEMENT The wattage rating of each bulb is shown in the chart When replacing a burned bulb always use the same watt age rating Headlight NOTE The bulb portion of the headli...

Page 78: ...m 20 ft from an aim ing surface wall or similar aiming surface ATV 0070C NOTE There should be an aver age operating load on the ATV when adjusting the headlight aim 2 Measure the distance from the floor to the mid point of each headlight 3 Using the measurements obtained in step 2 make horizontal marks on the aiming surface 4 Make vertical marks which inter sect the horizontal marks on the aiming ...

Page 79: ...d rear wiring harnesses The accessory plug is located on the right side of the instrument pod DE034 TOOL STORAGE TRAY STORAGE COMPARTMENT A basic tool kit is provided with the ATV Maintain the tool kit with the ATV at all times The tool storage tray is located beneath the seat DE011 The storage compartment is located beneath the tool storage tray Remove the tool storage tray to access the stor age...

Page 80: ...st bushing and plungers of the shock absorbers 6 Tighten all nuts bolts cap screws and screws Make sure rivets hold ing components together are tight Replace all loose rivets Care must be taken that all calibrated nuts cap screws and bolts are tightened to specifications 7 Fill the cooling system to the bot tom of the stand pipe in the filler neck with properly mixed coolant 8 Disconnect the batte...

Page 81: ... and add properly mixed coolant as neces sary 6 Charge the battery then install Connect the battery cables making sure to connect the positive cable first 7 Check the entire brake systems fluid level pads etc all con trols headlights taillight brake light and headlight aim adjust or replace if necessary 8 Check the tire pressure Inflate to recommended pressure as neces sary 9 Tighten all nuts bolt...

Page 82: ...80 NOTES ...

Page 83: ... all dealer installed genuine Arctic Cat service parts and accessories 5 Until expiration of the new product warranty paragraphs 1 and 2 above for all eligible replacement parts on new product Exclusions to this warranty include normal wear abuse or corrosion and the following parts and items Tires CV Boots Oil Filter Drive Belt Air Filter Torn or Punctured Upholstery Brake Pads Cracks or Gouges i...

Page 84: ...do business you have moved or you are in a location away from your selling dealer warranty may be performed by any authorized Arctic Cat ATV dealer The authorized Arctic Cat ATV dealer will examine the TRV or part to deter mine if in his opinion a warrantable condition exists If a warrantable condi tion appears to exist the dealer will repair or replace at Arctic Cat s option free of charge includ...

Page 85: ... Cat will then process the application and issue warranty for the balance of the time remain ing of the original warranty Address Change Ownership Change Warranty Transfer CHANGE OF ADDRESS OWNERSHIP WARRANTY TRANSFER TO Name _________________________________________ Address _______________________________________ City State Province Zip Code Postal Code ___________ Phone _________________________...

Page 86: ...Fold Back CHANGE OF ADDRESS OWNERSHIP ARCTIC CAT INC PRODUCT SERVICE AND WARRANTY DEPT P O BOX 810 THIEF RIVER FALLS MN 56701 Place Stamp Here ...

Page 87: ... on its emissions control components If an emission related component on the ATV is defective the component will be repaired or replaced by any authorized Arctic Cat ATV dealer Owner s Emission Control Warranty Responsibilities It is the owner s responsibility to perform the required maintenance listed in the Operator s Manual Arctic Cat recommends the retention of all receipts covering maintenanc...

Page 88: ...n warranty coverage statement contact your local authorized Arctic Cat ATV dealer WARRANTY PERIOD The emission warranty period for this ATV begins on the same date as the standard warranty coverage and continues for two 2 years COMPONENTS COVERED The emissions warranty covers major emissions control components and emission related components listed as follows Engine Components Fuel Air System Pre ...

Page 89: ...y Directive 98 37 EC Date of Issue June 1993 Issued by European Commission Type of Equipment All Terrain Vehicles Brand Name Arctic Cat Model 700 Diesel Standards to which conformity is declared IEC 801 2 1991 IEC 801 3 1984 EN 55012 Manufacturer if not issuing agent Arctic Cat Inc 601 Brooks Ave S Thief River Falls MN 56701 USA ...

Page 90: ...ings Chart 29 Lubricant Inspecting Changing 64 Lubricant Recommended Front Differential Rear Drive 58 Lubricant Recommended Transmission 58 Lubrication General 63 Maintenance General 60 Maintenance Record 89 Maintenance Schedule 61 Mounting the TRV 36 Muffler Spark Arrester 75 Oil and Filter Engine 63 Oil Recommended Engine 58 Operating Maneuvers Basic 36 Operation Maintenance 33 Parking 38 Parts ...

Page 91: ...89 MAINTENANCE RECORD DATE MILEAGE SERVICE PERFORMED NOTES ...

Page 92: ...90 MAINTENANCE RECORD DATE MILEAGE SERVICE PERFORMED NOTES ...

Page 93: ...91 NOTES ...

Page 94: ...92 NOTES ...

Page 95: ...or reference if you ever need a new key 2 VEHICLE IDENTIFICATION NUMBER 3 ENGINE SERIAL NUMBER Record the Vehicle Identification Number and Engine Serial Number in the spaces provided to assist you in ordering parts from your authorized Arctic Cat ATV dealer or for reference in case the ATV is stolen WARNING Indicates a potential hazard that could result in serious injury or death ...

Page 96: ... 2009 Arctic Cat Inc Trademarks of Arctic Cat Inc Thief River Falls MN 56701 Printed in the U S A 218 681 9851 U S 204 982 1772 Canada p n 2258 628 ...

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