Arctic Cat ATV 2005 Operator'S Manual Download Page 82

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GENERAL MAINTENANCE



NOTE: Proper maintenance of

the ATV is important for optimum
performance. Follow the Mainte-
nance Schedule and all ensuing
Maintenance Instructions/Informa-
tion.

If, at any time, abnormal noises, vibra-

tions, or improper functioning 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-
cific items in the maintenance and
care of the ATV.

Summary of Contents for ATV 2005

Page 1: ...tor 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 Operating this...

Page 2: ...d instruction est disponible pour les propri taires canadiens com posez le 1 613 739 1535 Particularly important information is distinguished in this manual by the fol lowing notations California Pro...

Page 3: ...tate provincial rid ing laws Respect your ATV Respect the environment and You will gain the respect of others We also advise you to strictly follow the recommended maintenance pro gram as outlined Thi...

Page 4: ...X 113 Cargo Box Latch Handles 400 TBX 500 TBX 113 Side Storage Compartment Straps 400 TBX 500 TBX 113 Safety Flag Bracket 113 Rack Loading Front and Rear 114 Trailering and Towing 114 Transporting ATV...

Page 5: ...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...

Page 6: ...ate this ATV Some operators at the age of 16 may not be able to operate an ATV safely Parents should supervise the use of the ATV at all times Parents should permit continued use only if they deter mi...

Page 7: ...lways follow these age recommen dations A child under 12 years old should never operate an ATV with an engine size 70 cc or greater A child under 16 years old should never operate an ATV with an engin...

Page 8: ...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 can...

Page 9: ...fety information 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...

Page 10: ...WARNING Indicates a potential hazard that could result in a serious injury or death 8 Warning Labels 250 300...

Page 11: ...WARNING Indicates a potential hazard that could result in a serious injury or death 9 Warning Labels 400 500 650 650 V Twin...

Page 12: ...WARNING Indicates a potential hazard that could result in a serious injury or death 10 Warning Labels 400 TBX 500 TBX...

Page 13: ...8 Gearshift Pedal 9 Auxiliary Brake Pedal 10 Brake Lever Lock 11 Key Switch 12 Reverse Lever 13 Throttle Limiter 14 Throttle Lever 15 Range Control Lever 16 Taillight Brakelight 17 Operator s Manual...

Page 14: ...earshift Pedal 9 Auxiliary Brake Pedal 10 Brake Lever Lock 11 Key Switch 12 Front Differential Lock FIS 13 Throttle Limiter 14 Throttle Lever 15 Reverse Override Switch 16 Taillight Brakelight 17 Oper...

Page 15: ...1 Key Switch 12 Reverse Lever Manual Transmission 12 Low Range High Range Neutral Reverse Lever 13 Throttle Limiter 14 Throttle Lever 15 High Low Range Lever Manual Transmission 16 Taillight Brakeligh...

Page 16: ...Rigth Side Storage Compartment 9 Auxiliary Brake Pedal 10 Brake Lever Lock 11 Key Switch 12 Low Range High Range Neutral Reverse Lever 13 Throttle Limiter 14 Throttle Lever 15 Cargo Box Latch Handle 1...

Page 17: ...ct an authorized Arctic Cat ATV dealer or call 1 800 887 2887 U S or 1 613 739 1535 Canada WARNING POTENTIAL HAZARD Allowing anyone under age 16 to operate this ATV WHAT CAN HAPPEN Use of an ATV by ch...

Page 18: ...er operate this ATV on any public street road or highway even a dirt or gravel one In many states it is illegal to operate an ATV on public streets roads or highways WARNING POTENTIAL HAZARD Operating...

Page 19: ...chances or losing control of the ATV which can result in an acci dent HOW TO AVOID THE HAZARD Always ride at a speed that is proper for the terrain visibility and operating condi tions and your experi...

Page 20: ...HAPPEN Removing even one hand or foot can reduce your ability to control the ATV or could cause you to lose your balance and fall off the ATV If you remove a foot from a footrest your foot or leg may...

Page 21: ...s be especially cautious on these kinds of terrain WARNING POTENTIAL HAZARD Turning improperly WHAT CAN HAPPEN ATV could go out of control causing a collision or rollover HOW TO AVOID THE HAZARD Alway...

Page 22: ...pen the throttle suddenly or make sudden gear changes The ATV could flip over backwards Never go over the top of any hill at high speed An obstacle a sharp drop or another vehicle or person could be o...

Page 23: ...cedures as described in this Operator s Manual Avoid hills with slippery or loose surfaces Shift your weight to the uphill side of the ATV WARNING POTENTIAL HAZARD Stalling rolling backwards or improp...

Page 24: ...You may also regain traction unexpectedly which may cause the ATV to overturn HOW TO AVOID THE HAZARD Learn to safely control skidding or sliding by practicing at slow speeds and on level smooth terra...

Page 25: ...n 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 of accesso ries All parts and accessories added...

Page 26: ...t important to dress cor rectly for ATV riding in order to pre vent scraped skin and serious head injuries It s easy and could save you time in the long run not having to con tend with an injury Of co...

Page 27: ...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 and durable the material...

Page 28: ...to posi tion then disengage it to release the brake Be sure that the auxiliary brake near the footrest is working your brakes could fail during a ride if they re not maintained B Throttle The throttle...

Page 29: ...orse when you re not prepared for them At the minimum during every ATV ride you should have the follow ing items on board Tools Water Identification First Aid Kit For rides that are longer in duration...

Page 30: ...s may be unnecessary when you re familiar with the area But when you re riding on unfamiliar trails it s good to know where you are what s coming up and how to get back Emergency Kit with Flashlight a...

Page 31: ...stments Emergency Starting Braking Stopping Shifting Parking Dismounting the ATV Mounting the ATV To get seated 1 From the left side grab the left side handlebar apply the brake and put your left foot...

Page 32: ...the engine has run for at least 3 minutes 738 436A NOTE If the engine RPM starts to decrease or if the engine starts to stall press the choke lever down until RPM increases then as the RPM stabilizes...

Page 33: ...ents To ensure proper starting and operating performance the following adjust ments should be made for varying ambient temperatures 0 C 32 F Use 5W 30 Arctic Cat 4 Cycle Engine Oil p n 0436 003 18 C 0...

Page 34: ...or each higher gear 3 Press on the front of the gearshift pedal with your toe to shift down each gear and into neutral CAUTION To avoid damaging the recoil starter DO NOT pull the recoil rope to its l...

Page 35: ...e front of the gearshift pedal Repeat this sequence to select each lower gear To shift the ATV into reverse follow these steps 0736 566 1 Bring the ATV to a complete stop 2 Shift the transmission into...

Page 36: ...ty depends on using safe rid ing techniques Statistics from the U S Consumer Product Safety Commission CPSC say that inexperienced riders who don t use safe riding techniques are 13 times more likely...

Page 37: ...he handling if you feel the tires coming off the ground reduce speed shift more of your body weight to the side that s lifting and make the turn wider if possible ATV 0013 ATV 0024 ATV 0025 Wide Turns...

Page 38: ...s on the ground straighten out the handlebars as much as you can 5 Gradually increase your speed as you come out of the turn Quick Turns Quick turns are the most difficult turns and should only be don...

Page 39: ...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 until it faces s...

Page 40: ...down and try climbing again OR 5 If you have lost all forward motion follow the K turn proce dure NEVER OPERATE UP OR DOWN HILLS STEEPER THAN 25 0739 501 Riding Downhill Success in riding downhill de...

Page 41: ...itions or if it just doesn t work stop and get off Dismount the ATV on the uphill side Swerving Swerving is usually an emergency reaction to avoid an obstacle but is sim ilar to quick turns The differ...

Page 42: ...with the obstacle 6 Lean forward and release the throt tle when the front tires clear the obstacle 7 Keep your body loose to absorb any shock 8 If the ATV starts tipping shift your weight to keep it...

Page 43: ...olling back ward lean as far forward as possi ble standing up on the footrests 3 Nice and easy apply the hand brake lever 4 When you come to a stop follow the procedure for the K turn 5 If the ATV con...

Page 44: ...everal times while riding slowly NOTE After riding through water mud snow or slush it is important to dry both brake sys tems before parking the ATV 4 Practice driving in an open snow covered or ice c...

Page 45: ...it has 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...

Page 46: ...eck out your surroundings before and during your ride Night Riding Don t do it It s a lot more difficult to see what s coming Paved Surfaces Don t do it The ATV isn t designed for pavement Its handlin...

Page 47: ...its limits ATV Maintenance You have to maintain your ATV The General Maintenance section of this Operator s Manual tells you about tak ing care of your ATV If at any time abnormal noises vibrations o...

Page 48: ...wn how dangerous these ATV s can be Making good personal choices is your responsibility Load Capacity Ratings Chart ATV Load Capacity Total weight of rider tongue weight and cargo on front and rear ra...

Page 49: ...you to do illegal drugs when you re riding your ATV this is a reality check Something to think about there can be legal consequences that will take away all that freedom you love Don t use alcohol or...

Page 50: ...incial ATV laws before riding It ll also make sure that you can continue to ride in your favor ite areas The quickest way to have a land area closed is by riding over the regulations Group Behavior Pe...

Page 51: ...they ride have them take the training course have them watch the safety video and have them read the Operator s Manual You train them It doesn t matter how you do it as long as you do it ATV s are all...

Page 52: ...IS The 25 year old male died from drowning after the 4 wheeled ATV he was driving overturned and landed on the victim pinning him face down in 6 inches of water in a drainage ditch The victim had fail...

Page 53: ...ion II of this manual covers oper ator related maintenance operating instructions and storage instructions If major repair or service is ever required contact an authorized Arctic Cat ATV dealer for p...

Page 54: ...d Name Arctic Cat Model 250 2x4 650 4x4 400 4x4 500 4x4 300 4x4 250 4x4 650 V Twin 4x4 Standards to which conformity is declared IEC 801 2 1991 IEC 801 3 1984 EN 55011 Class A Manufacturer if not issu...

Page 55: ...6 5 in Wheelbase 127 cm 50 in 127 cm 50 in Front Tire Size AT23 x 8 12 AT23 x 8 12 Rear Tire Size AT24 x 9 12 AT24 x 9 12 Tire Inflation Pressure 0 35 kg cm 5 0 psi 0 35 kg cm 5 0 psi MISCELLANY 4x4 2...

Page 56: ...Height Overall 114 cm 45 in Width Overall 114 cm 45 in Suspension Travel 16 5 cm 6 5 in Wheelbase 127 cm 50 in Front Tire Size AT24 x 9 12 Rear Tire Size AT25 x 10 12 Tire Inflation Pressure 0 35 kg c...

Page 57: ...in 127 cm 50 in Front Tire Size 25 x 8 12 25 x 8 12 Rear Tire Size 25 x 10 12 25 x 10 12 Tire Inflation Pressure 0 35 kg cm 5 0 psi 0 35 kg cm 5 0 psi MISCELLANY ACT FIS Dry Weight Approx 282 kg 622 l...

Page 58: ...in Width Overall 121 cm 47 5 in Suspension Travel Front 25 cm 10 in Suspension Travel Rear 25 cm 10 in Wheelbase 127 cm 50 in Front Tire Size 25 x 8 12 Rear Tire Size 25 x 10 12 Tire Inflation Pressur...

Page 59: ...in 127 cm 50 in Front Tire Size 25 x 8 12 25 x 8 12 Rear Tire Size 25 x 10 12 25 x 10 12 Tire Inflation Pressure 0 35 kg cm 5 0 psi 0 35 kg cm 5 0 psi MISCELLANY ACT FIS Dry Weight Approx 276 kg 609...

Page 60: ...cm 50 in 127 cm 50 in Front Tire Size 25 x 8 12 25 x 8 12 Rear Tire Size 25 x 11 12 25 x 11 12 Tire Inflation Pressure 0 35 kg cm 5 0 psi 0 35 kg cm 5 0 psi MISCELLANY Manual Automatic Dry Weight Appr...

Page 61: ...Suspension Travel Front 25 cm 10 in Suspension Travel Rear 25 cm 10 in Wheelbase 127 cm 50 in Front Tire Size 25 x 8 12 Rear Tire Size 25 x 11 12 Tire Inflation Pressure 0 35 kg cm 5 0 psi MISCELLANY...

Page 62: ...49 3 in Width Overall 120 7 cm 47 5 in Suspension Travel Front 25 cm 10 in Suspension Travel Rear 25 cm 10 in Wheelbase 127 cm 50 in Front Tire Size 26 x 8 12 Rear Tire Size 26 x 11 12 Tire Inflation...

Page 63: ...50 V Twin the Vehicle Identification Number is located on the frame support rail AF927A AF968A On the 250 300 the Engine Serial Number is located on the right side rear of the engine crankcase CD036A...

Page 64: ...ify ing number is stamped on each key Use this number when ordering a replacement key ATV 0055 CONTROL LOCATIONS AND FUNCTIONS Ignition Switch The ignition switch has three positions ATV 0056 OFF posi...

Page 65: ...ted into reverse gear The light will go off when shifted out of reverse 3 Neutral Indicator A green light will illuminate when the transmission is in neutral and the ignition switch is on The light wi...

Page 66: ...the ATV is used 9 4WD Indicator Displays 4WD when the front drive selector switch is moved to the 4WD posi tion Display will go off when 2WD is selected 10 Odometer Trip Meters A B Odometer registers...

Page 67: ...ont of the engine or packed between the cooling fins of the radiator can reduce cooling capability Using a hose pressure wash the radiator and the engine to remove any debris preventing air flow 9 Fue...

Page 68: ...e attempting to shift from one range to the other Shift on level ground or engage the brake lever lock High Range Normal riding with light loads Low Range Carrying heavy loads or trailer towing Compar...

Page 69: ...ift the transmission into neutral 3 Pull the range lever up and move it to the desired position forward position for HIGH range rear ward position for LOW range 4 Allow the range lever to lock into po...

Page 70: ...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 Front Drive Selector 300 The mechanical drive selector allo...

Page 71: ...ower to both front wheels To engage the front dif ferential lock rotate the handle fully counterclockwise to LOCK to disen gage the front differential lock rotate the handle fully clockwise to UNLOCK...

Page 72: ...ignition circuit is off The engine cannot be started or will not run If the emergency stop switch is used to stop engine without turning off ignition switch the battery may discharge RUN position The...

Page 73: ...tle lever travel may be limited by adjusting the throttle limiter screw The throttle limiter should be adjusted according to the operator s skill and experience To adjust the throttle lim iter use the...

Page 74: ...cuum fuel pump is incorporated in the gas tank to deliver gasoline to the carburetor The fuel pump operates when the engine is turning Decompression Lever 250 300 NOTE The engine on some mod els can b...

Page 75: ...ly GAS VENT HOSES Replace the gas hose every two years Damage from aging may not always be visible Do not bend or obstruct the routing of the carburetor vent hose Make certain that the vent hose is se...

Page 76: ...TV 0100 KX019A NOTE The ATV should be on level ground when checking the engine oil level 1 Unscrew the oil level stick and wipe it with a clean cloth 2 Install the oil level stick NOTE On the 400 500...

Page 77: ...on the latch release located at the rear of the seat then raise the rear 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...

Page 78: ...signed to carry specified load capaci ties Always refer to the appropriate ATV Load Capacity Ratings Chart for proper capacities TRAILERING AND TOWING The trailer hitch is standard equipment Use a tra...

Page 79: ...mal operating position on all four wheels and the following procedure be used 1 Engage the brake lever lock and place the transmission in first gear 2 If equipped turn the gas tank valve OFF 3 Secure...

Page 80: ...rential Rear Drive Lubricant NOTE Arctic Cat recommends the use of genuine Arctic Cat lubri cants The recommended lubricant front dif ferential and rear drive when applicable is SAE approved 80W 90 hy...

Page 81: ...the engine has reached normal operating temperature Do not idle the engine for excessively long periods of time After the completion of the break in period the engine oil and oil filter should be cha...

Page 82: ...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 qualifie...

Page 83: ...Engine transmission oil and filter 124 127 R R Air filter 139 I I Gear lubricant Front differential rear drive 127 I I 128 Replace every 4 years V Belt Automatic 142 I I Spark arrester muffler 144 C...

Page 84: ...he cooling system to the bottom of the stand pipe in the radiator neck NOTE Use a good quality biode gradable glycol based automo tive type antifreeze SHOCK ABSORBERS Each shock absorber should be vis...

Page 85: ...e and drain the oil into a drain pan 733 441C 4 Remove the three nuts securing the filter cover 733 734A 5 Remove the filter cover then pull out the oil filter element and prop erly discard Remove and...

Page 86: ...Inspect the area around the drain plug and oil filter for leaks Engine Transmission Oil and Filter 400 500 650 Change the engine oil and oil filter at the scheduled intervals The engine should always...

Page 87: ...el 11 Inspect the area around the drain plug and oil filter for leaks Engine Transmission Oil and Filter 650 V Twin Change the engine oil and oil filter at the scheduled intervals The engine should al...

Page 88: ...hen changing the lubri cant use approved SAE 80W 90 hyp oid oil and use the following procedure 1 Place the ATV on level ground 2 Remove each oil filler plug 0736 568 3 Drain the oil into a drain pan...

Page 89: ...n authorized Arctic Cat ATV dealer for service Brake Hoses Carefully inspect the hydraulic brake hoses for cracks or other damage If found take the ATV to an authorized Arctic Cat ATV dealer to have t...

Page 90: ...it is adjusted properly 4 If the rear wheels are not locked it must be adjusted set up To adjust set up the brake use the fol lowing procedure 1 Loosen the right hand jam nut wheel side when viewing f...

Page 91: ...tes properly AUXILIARY BRAKE FIS Models The auxiliary brake must be main tained to be fully functional NOTE Any time the auxiliary brake is not functioning properly the linkage adjustment procedure sh...

Page 92: ...el in the reservoil is low add D O T 4 brake fluid CD474A NOTE The brake fluid reservoir is located on the battery box above the right rear wheel 400 or under the seat 400 TBX 500 650 650 V Twin 6 Pre...

Page 93: ...ler for service Drive Axle Boots NOTE The FIS 4x4 models have four drive axles and eight boots and the ACT 4x4 models and the FIS 2x4 models have two drive axles and four boots 1 Inspect all drive axl...

Page 94: ...ve the positive cable and the battery vent tube Remove the battery from the ATV Care should be taken not to dam age the vent tube 3 Remove the vent plugs then if necessary fill the battery with dis ti...

Page 95: ...or may need to be adjusted Consult an authorized Arctic Cat ATV dealer if the plug insulator is not a light brown color To help prevent cold weather fouling make sure to thor oughly warm up the engine...

Page 96: ...turn the adjuster until the throttle lever has proper free play of 3 6 mm 1 8 1 4 in ATV 0047 3 Tighten the knurled nut against the throttle cable adjuster securely then slide the rubber boot over the...

Page 97: ...ent by pressing it between the palms of both hands to remove excess solvent Do not twist or wring the element or it will develop cracks 5 Dry the element 6 Put the element in a plastic bag then pour i...

Page 98: ...e duck bill drain beneath the main housing for debris and for proper sealing 733 715B ATV 0087 KX045A DRAINING V BELT COVER Automatic Transmission NOTE If the ATV has been driven through water the V b...

Page 99: ...lace the tires before reaching this minimum specification 0732 649 Tire Replacement The ATV has low pressure tubeless tires Air is sealed by the contact sur faces of the inner wheel rim and the tire b...

Page 100: ...fler has a spark arrester which must be periodically cleaned At the intervals shown in the Maintenance Schedule clean the spark arrester using the following procedure 1 Shift the transmission into neu...

Page 101: ...e adjusted verti cally and horizontally The geometric center of the HIGH beam light zone is to be used for vertical and horizontal aiming 1 Position the ATV on a level floor so the headlights are appr...

Page 102: ...ighten the nut securely B Vertical Loosen nut B and adjust for proper aiming Tighten the nut securely C Turn the nut clockwise to raise the beam and counterclockwise to lower the beam AL670A FUSES The...

Page 103: ...E COMPARTMENT TOOLS A basic tool kit is provided with the ATV 733 708B ATV 1097 738 503A 0737 582 Maintain the tool kit with the ATV at all times The storage compartment on the 400 FIS ACT is located...

Page 104: ...uretor float bowl 5 Plug the hole in the exhaust sys tem with a clean cloth 6 Apply light oil to the upper steer ing post bushing and plungers of the shock absorbers 7 Tighten all nuts bolts cap screw...

Page 105: ...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 brak...

Page 106: ...104 NOTES...

Page 107: ...arts and accessories 4 Until expiration of the new product warranty for all eligible replacement parts Exclusions to this warranty include normal wear abuse or corrosion and the following parts and it...

Page 108: ...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 ATV or part t...

Page 109: ...g of the origi nal warranty Address Change Ownership Change Warranty Transfer CHANGE OF ADDRESS OWNERSHIP WARRANTY TRANSFER TO Name _________________________________________ Address __________________...

Page 110: ...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 111: ...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 Respon...

Page 112: ...ir and the geographically appropriate hourly labor rate The owner may be required to keep receipts and failed compo nents in order to receive compensation Limitations This Emission Control System Warr...

Page 113: ...5 Lubricant 116 Lubricant Inspecting Changing 127 Lubricant Recommended Front Differential Rear DRive 117 Lubrication General 123 Maintenance General 120 Maintenance Record 160 Maintenance Schedule 12...

Page 114: ...112 MAINTENANCE RECORD DATE MILEAGE SERVICE PERFORMED NOTES...

Page 115: ...ATV dealer or for reference in case the ATV is stolen 1 KEY IDENTIFICATION NUMBER The key identification number is stamped on the key as shown in the illustration Record this number in the space prov...

Page 116: ...ion can occur with another vehicle with a passenger passengers affect balance and steering and increase risk of losing control use proper riding techniques to avoid ATV overturns on hills and rough te...

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