Arctic Cat 500 4x4 Operator'S Manual Download Page 5 | Manualshive

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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

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Summary of Contents for 500 4x4

Page 1: ...Arctic Cat Models 500 4x4 500 4x4 TRV 650 H1 650 H1 TRV 700 Diesel Operator s manual...

Page 2: ......

Page 3: ...nd 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 onl...

Page 4: ...Page 2 OWNER VEHICLE SURNAME NAME ZIP CITY Street Nr Vehicle model Chassis number Engine number Key number Purchase date Dealer Dealer Dealer s signature and stamp Vehicle owner Owner s signature...

Page 5: ...ONTROLS 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...

Page 6: ...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...

Page 7: ...r 25x11 12 205 60 15 or 25x11 12 Tire Inflation Pressure On Road 0 8 1 0 bar according to load and route 0 8 1 0 bar according to load and route Tire Inflation Pressure On Road 0 8 1 0 bar according t...

Page 8: ...Page 6 Headlight 12V 35W 2 Taillight Brake light 12V 5W 21W Starting System Electric with Manual Recoil according to equipment...

Page 9: ...ion 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 park...

Page 10: ...ing 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 2 l Differential capacity front 275 ml 275 ml Differential Lubricant...

Page 11: ...g brake 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 Inflatio...

Page 12: ...ential capacity front 275 ml Differential Lubricant SAE 80W 90 Hypoid Engine oil capacity 2 l Rear drive capacity 250 ml Gasoline recommended 42 50 Cetan Engine oil recommended SAE 10W 40 Transmission...

Page 13: ...01 Battery under the seat 02 Headlight 04 Seat lock 05 Tool storage under the seat 7 Towing device 09 Gearshift lever 11 Recoil starter 12 Registration number light 13 Operator s Manual Location 21 S...

Page 14: ...rter 015 Drive selector 016 Position light Low beam High beam 017 Horn switch 018 Turn signal switch 19 Mirror 020 Differential lock 21 Winch Switch 23 Emergency Parking brake 19 19 q NOTE The ATV you...

Page 15: ...fe operating conditions Use the checklist you ll find at the next page Brake burnishing procedure The service brake is activated by the foot pedal according to direc tive 93 14A EC homologation or via...

Page 16: ...rn and stop lights Engine oil Check the oil level with the oil level stick and if necessary fill some en gine oil into the crankcase Transmission oil Check the oil level in the front diffe rential as...

Page 17: ...If the temperature is 18 C or be low you should activate the carbu retor pump three times CAUTION It is extremely important to warm up the engine before raising the RPM The engine should be left in t...

Page 18: ...from an extended position Allow the rope to rewind slowly Turning off the engine To turn off the engine rotate the ignition key to the OFF position Picture 500 Shifting Automatic transmission The ARC...

Page 19: ...o direc tive 93 14A EC homologation or via the left hand brake lever both hydraulic The right hand lever only activates the parking auxiliary brake which must not be used as service brake IMPORTANT Fo...

Page 20: ...and push the brake pedal 4 The left hand brake lever disposes of a detent used to block the whole hydraulic system When using the detent the wheels are blocked additionally WARNING Excessive repetitiv...

Page 21: ...Page19...

Page 22: ...ine Serial Number is lo cated at the left side of the recoil starter 500 650 H1 With model 700 Diesel the engine number is located on the back of the engine block between engine and transmission Alway...

Page 23: ...witch 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 th...

Page 24: ...he ignition switch in the LIGHTS position for a long peri od of time when the engine is not running may cause the battery to discharge Always leave the igniti on switch in the OFF position when engine...

Page 25: ...riate transmission gear can lower the temperature q NOTE Debris in front of the engine or pa cked between the oil cooler radiator cooling fins can reduce cooling capability Clean the engine and oil co...

Page 26: ...wheels come to a complete stop then push the 2WD 4WD switch located on the handlebars CAUTION Do not attempt to either engage or disengage the front differential while the ATV is moving Parking brake...

Page 27: ...ke sure the igniti on switch is in the ON position the transmission is in neutral the reverse shift lever is in the forward position and the parking brake is engaged q NOTE This ATV has safety interlo...

Page 28: ...clockwise to decrease engine RPM maximum or counter clockwise to increase engine RPM maximum 3 Tighten the jam nut securely q NOTE The ATV is equipped with a CDI unit that retards ignition timing when...

Page 29: ...vel should be above the L mark but not higher than the F mark Seat Lock 1 To remove the seat pull the seat lock lever located in the middle on the rear of the seat upwards Rai se the rear end of the s...

Page 30: ...ted 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 sure that the load in the trailer is evenly distributed and p...

Page 31: ...ver carry passengers in a trailer unless the trailer is designed for such use and has a rigid tow bar Allow more stopping distance ATV Transport When transporting the ATV use the following procedure E...

Page 32: ...CAUTION Any oil used in place of the recom mended oil could cause serious engine damage CAUTION You should change the engine and transmission oil of your ATV every 500km and 1500 km later on Please r...

Page 33: ...while fil ling the gas tank Since gasoline expands as its tem perature increases the gas tank must be filled to its rated capacity only Allow the engine to cool before filling the gas tank Care must b...

Page 34: ...not idle the engine for excessively long periods of time During the break in period you should not use more than 1 2 thrott le Short acceleration manoeuvres and riding at different velocities provide...

Page 35: ...sary drain the gasoline or oil into a suitable container Shock absorbers Each shock absorber should be vi sibly checked weekly for excessive fluid leakage cracks or breaks in the lower case or a bent...

Page 36: ...Page 34 q NOTE Please adjust the shock absorbers with the vehicle unladen...

Page 37: ...650 H1 700 Diesel Change the engine oil and oil filter at the scheduled intervals The en gine should always be warm when the oil is changed so the oil will drain easily and completely 1 Park the ATV...

Page 38: ...ant use approved SAE 80W 90 hypoid oil and use the following procedure 1 Place the ATV on level ground 2 Remove the oil filler plug 3 Drain the oil into a drain pan af ter having removed the drain plu...

Page 39: ...d to be fully func tional 1 Press the foot brake pedal or the hand brake at the handlebars respectively 2 With the engine off transmissi on in neutral and the reverse lever in the forward position att...

Page 40: ...odically Battery The battery of the models 500 and 650 H1 is located under the right rear fender 700 Diesel at the rear of the vehicle The level of the battery fluid must be kept between the MAX and M...

Page 41: ...the vent plugs then if necessary fill the battery with dis tilled water to the MAX level indica ted on the battery 4 Charge the battery at 1 4 amps for 10 hours CAUTION Never exceed the standard char...

Page 42: ...en removing or in stalling the spark plug Adjust the gap on the 500 and 650 H1 to 0 7 0 8mm for proper ignition Use a feeler gauge to check the gap When installing the spark plug be sure to tighten it...

Page 43: ...ctic Cat ATV dealer will do this service Gas Vent Hoses Replace the gas hose every two years Do not bend or obstruct the routing of the carburetor vent hose Make certain that the vent hose is securely...

Page 44: ...sing Make sure that the air filter is properly seated in the housing Install the cover and secure with the 4 clamps Install the storage box Vent hose and air filter housing Periodically check the drai...

Page 45: ...pressure Vehicle type front rear 500 650 H1 185 65 15 25x8 12 205 60 15 25x11 12 700 Diesel 25x8 12 25x10 12 Tire inflation pressure In the tool set supplied with your ATV you ll find a barometer to...

Page 46: ...ront Rear Wheel Removal Park the ATV on level ground and engage the parking brake Loosen the lug nuts Elevate the ATV by placing a jack under the axle Remove the wheel Install the wheel and install th...

Page 47: ...ight bulb use the following procedure 1 Rotate the socket counter clockwise and remove it from the housing 2 To remove the bulb from the socket push in and rotate counter clockwise 3 To install the bu...

Page 48: ...d 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 Alwa...

Page 49: ...e engine and allow it to idle Then using Arctic Cat Engine Pre server rapidly inject the preserver into the air filter opening for a peri od of 10 to 20 seconds Install the air filter CAUTION If the i...

Page 50: ...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...

Page 51: ...es Set up a riding course using traffic cones approx 6m wide by 30m long Also have a few posts or lumber at least 10cm in diameter to use as obstacles to climb over 1 Starting Stopping Once around clo...

Page 52: ...arp turns Turns of less than 90 degrees Two laps clockwise three laps counter clockwise 4 Slalom turns Turning in and out of the cones Three laps 5 Quick turns Move two cones 1 Suddenly go left right...

Page 53: ...nd both wheels 7 Traversing hills Up 2 and down 1 hill slope less than 25 degrees Stop start 3 and traverse A on hill Practice this manoeuvre on flat land if a hill is not available 8 K turns U turns...

Page 54: ...re 13 times more likely to have an ATV accident than riders who have over 1 month of experi ence Riding Once the engine s warm the ATV is ready to go Please observe the following points Keep your feet...

Page 55: ...at 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...

Page 56: ...en during turns For this reason be extremely careful in such a situation Use this method for wide turns 1 As you approach the turn slow down 2 Shift your body weight to the inside of the turn 3 Gradua...

Page 57: ...roach the turn slow down 2 Shift your body weight to the inside of the turn 3 You might have to lean into the turn more than you do in a wide turn 4 If shifting your weight and ba lance aren t enough...

Page 58: ...ter you are experienced with your ATV 1 As you approach the turn slow down 2 Turn the handlebars and shift your body weight to the inside of the turn 3 Follow this with slight accelera tion 4 To make...

Page 59: ...ATV on the uphill side 5 If you re to the left of the ATV turn the handlebar all the way left 6 Partially release the brake but lightly hold the brake lever 7 Let the ATV roll to your right side unti...

Page 60: ...ce 2 Lean as far forward as possible For steeper hills come off your seat to stand and lean forward 3 If you lose speed quickly shift to a lower gear At the same time re lease the throttle so your fro...

Page 61: ...Page 59 Riding downhill 1 Shift your body weight as far back on the seat as possible 2 Keep it in a low gear 3 Lightly apply the brake and ease up on the throttle...

Page 62: ...where you absolutely have to side hill follow this method 1 Keep your speed low and con sistent 2 Shift all your body weight to the uphill side of the seat also support your weight on the uphill footr...

Page 63: ...for overcoming obstacles Keep your speed way down Approach the obstacle head on Come up off the seat Keep your weight on the foot rests Apply a little throttle when the front tires make contact with...

Page 64: ...dden obstacles like logs or rocks 2 Keep your speed slow 3 Make sure you have a way out on the other side of the water 4 If you get stuck in the mud try rocking the ATV from side to side 5 Once you ve...

Page 65: ...s 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 WARNING Go slowly and...

Page 66: ...on 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 Was...

Page 67: ...re magnets and sensors properly attached to your vehicle Change the main jets slow jet and low speed fuel screw of the carburetor 500 650 H1 Generally yes But do not direct the jet towards electrical...

Page 68: ...of said parts by Arctic Cat or an authorized Arctic Cat ATV dealer Arctic Cat reserves the right to in spect such parts at its factory The warranty periods are as fol lows 1 24 months form date of sal...

Page 69: ...scribed 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...

Page 70: ...ordance with Arctic Cat s re commendations in the Operator s Manual Arctic Cat will not warrant repairs re quired as a result of not performing standard operator maintenance storage procedures and ser...

Page 71: ...Page 69 Arctic Cat will then process the application and issue a new vehicle certificate for the remaining period of the warranty claim...

Page 72: ...Page 70 Address change Warranty transfer Ownership change Change of address ownership warranty transfer to Name Address Construction year Model Chassis Nr...

Page 73: ...Page 71 Notes...

Page 74: ...Page 72 Notes...

Page 75: ...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 p...

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