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2-10

FI053

10. Install the tappet on the appropriate valve; then

install the camshaft.

11. Using an appropriate bar, rotate the engine through

two full revolutions; then rotate to TDC on the

compression stroke and check the valve tappet

clearance.

NOTE: Rotating the engine ensures that any

excess oil is squeezed from the tappets and tappet
shims. Oil trapped in these areas could result in a
false valve clearance reading.

12. Using a new gasket, apply Three Bond Sealant to

the camshaft end caps of the cylinder head cover

gasket; then install the cylinder head cover and

the four cap screws.

13. Tighten the cap screws to 7 ft-lb; then tighten to 10

ft-lb.

14. Install the valve timing inspection plug and tighten

securely; then install the recoil starter assem-

bly/outer magneto cover and secure with the four

cap screws coated with blue Loctite #242. Tighten

to 6 ft-lb.

15. Install the spark plug cap/high tension lead, front

fenders, front rack, and splash panels; then install

the heat shields and seat making sure the seat locks

securely.

Testing Engine

Compression

To test engine compression, use the following proce-

dure.

1. Remove the high tension lead from the spark plug.

2. Using compressed air, blow any debris from

around the spark plug.

3. Remove the spark plug; then attach the high ten-

sion lead to the plug and ground the plug on the

cylinder head well away from the spark plug hole.

4. Attach the Compression Tester Kit.

NOTE: The engine must be warm and the battery

must be fully charged for this test.

5. While holding the throttle lever in the full-open

position, crank the engine over with the electric

starter until the gauge shows a peak reading (five

to 10 compression strokes).

6. If compression is abnormally low, inspect the

following items.

A. Verify starter cranks engine over at normal

speed (approximately 400 RPM).

B. Gauge functioning properly.

C. Throttle lever in the full-open position.

D. Valve/tappet clearance correct.

E. Valve not bent or burned.

F. Valve seat not burned.

NOTE: To service valves, see Section 3.

7. Pour 29.5 ml (1 fl oz) of oil into the spark plug

hole, reattach the gauge, and retest compression.

8. If compression is now evident, service the piston

rings (see Section 3).

Spark Plug

A light brown insulator indicates that a plug is correct.

A white or dark insulator indicates that the engine may

need to be serviced or the carburetor (if equipped) may

need to be adjusted. To maintain a hot, strong spark,

keep the plug free of carbon.

! WARNING

Always wear safety glasses when using compressed
air.

! CAUTION

On the 700 EFI, do not ground the spark plug on the
cylinder head cover. The cover is made of magne-
sium and any contact with spark or electrical arc will
severely pit the surface.

PEAK COMPRESSION

MODEL

PSI

400

95-115

500

70-85

700 EFI

130-155

H1 Models

155-175

Back to TOC

Back to Section TOC

Next

Back

FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983

www.mymowerparts.com

Содержание 500H1

Страница 1: ...d consumer confidence but also saves time and labor All Arctic Cat ATV publications and decals display the words Warning Caution Note and At This Point to emphasize important information The symbol WARNING identifies personal safety related information Be sure to follow the directive because it deals with the possibility of severe personal injury or even death The symbol CAUTION identifies unsafe ...

Страница 2: ...TV MORE TO GO ON TABLE OF CONTENTS Foreword Click on the red text to go Section 1 General Information Specifications 2 Periodic Maintenance 3 Engine Transmission 4 Fuel Lubrication Cooling 5 Electrical System 6 Drive System 7 Suspension 8 Steering Frame 9 Controls Indicators 1 2 3 4 5 6 7 8 9 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606 678 9623 OR 606 561 4983 www mymowerparts com ...

Страница 3: ...fications 1 3 Torque Conversions ft lb N m 1 5 Tightening Torque General Bolts 1 5 Break In Procedure 1 6 Gasoline Oil Lubricant 1 6 Genuine Parts 1 7 Preparation For Storage 1 7 Preparation After Storage 1 7 Back to TOC FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606 678 9623 OR 606 561 4983 www mymowerparts com ...

Страница 4: ...atic mini mum 38 mm 1 33 in 500 35 5 mm 1 40 in 650 H1 Brake Fluid DOT 4 Taillight Brakelight 12V 8W 27W Headlight 12V 27W 2 700 EFI CHASSIS Brake Type Hydraulic w Brake Lever Lock and Auxiliary Brake Tire Size Front 25 x 8 12 Rear 25 x 10 12 Tire Inflation Pressure 0 35 kg cm 5 psi MISCELLANY Gas Tank Capacity rated 24 6 L 6 5 U S gal 20 8 L 5 5 U S gal TRV Coolant Capacity 2 9 L 3 0 U S qt Diffe...

Страница 5: ...acket 38 52 Pinion Housing Differential Housing 23 31 Differential Housing Cover Differential Housing 23 31 Drive Bevel Gear Nut Shaft 72 98 Lock Collar Differential Housing 125 169 Hub Nut Shaft Axle max 200 270 Oil Drain Plug Front Differential Rear Drive 45 in lb 5 Oil Fill Plug Front Differential Rear Drive 16 22 Oil Drain Plug Engine 16 22 Inspection Plug Front Differential Rear Drive 48 in l...

Страница 6: ...ng 7 9 5 ENGINE TRANSMISSION 400 500 Automatic Transmission Part Part Bolted To Torque ft lb N m Clutch Shoe Crankshaft 94 127 Clutch Cover Housing Assembly Crankcase 8 11 Crankcase Half 6 mm Crankcase Half 8 11 Crankcase Half 8 mm Crankcase Half 16 22 Cylinder Head Cap Screw Crankcase 28 38 Cylinder Head 6 mm Cylinder 8 11 Cylinder Head 8 mm Cylinder 18 24 Cylinder Head Cover Cylinder Head 7 9 5 ...

Страница 7: ...ensioner Plug Cam Chain Ten sioner 60 in lb 7 Camshaft Holder Cylinder Head 7 9 5 Timing Inspection Plug Magneto Cover 17 23 Crankshaft Balancer Drive Gear Cap Screw Crankshaft Balancer 37 50 ft lb N m ft lb N m ft lb N m ft lb N m 1 1 4 26 35 4 51 69 4 76 103 4 2 2 7 27 36 7 52 70 7 77 104 7 3 4 1 28 38 1 53 72 1 78 106 1 4 5 4 29 39 4 54 73 4 79 107 4 5 6 8 30 40 8 55 74 8 80 108 8 6 8 2 31 42 2...

Страница 8: ...s oxygenates either ethanol or MTBE are added to the gasoline Oxygenated gasolines containing up to 10 ethanol 5 methane or 5 MTBE are acceptable gasolines When using ethanol blended gasoline it is not neces sary to add a gasoline antifreeze since ethanol will pre vent the accumulation of moisture in the fuel system RECOMMENDED ENGINE TRANSMISSION OIL The recommended oil to use is Arctic Cat 4 Cyc...

Страница 9: ...he upper steering post bushing and plungers of the shock absorbers 7 Tighten all nuts bolts cap screws and screws Make sure rivets holding components together are tight Replace all loose rivets Care must be taken that all calibrated nuts cap screws and bolts are tightened to specifications 8 On liquid cooled models fill the cooling system to the bottom of the stand pipe in the radiator neck with p...

Страница 10: ...aim adjust or replace as necessary 8 Tighten all nuts bolts cap screws and screws making sure all calibrated nuts cap screws and bolts are tightened to specifications 9 Check tire pressure Inflate to recommended pres sure as necessary 10 Make sure the steering moves freely and does not bind 11 Check the spark plug Clean or replace as neces sary CAUTION The ignition switch must be in the OFF positi...

Страница 11: ... Filter Strainer 2 12 Front Differential Rear Drive Lubricant 2 14 Adjusting Clutch 400 500 Manual Transmission 2 15 Tires 2 15 Steering Components 2 15 Driveshaft Coupling 2 16 Suspension Shock Absorbers Bushings 2 16 Nuts Bolts Cap Screws 2 16 Ignition Timing 2 16 Headlights Taillight Brakelight 2 16 Shift Lever 2 17 Frame Welds Racks 2 19 Electrical Connections 2 19 Hydraulic Brake Systems 2 19...

Страница 12: ...ssion Oil Level I A Engine Transmission Oil Filter R R R Oil Strainer I I C Front Differential Rear Drive Lubricant I I R 4 Yrs Clutch Manual I l A Tires Air Pressure I I R Steering Components I I I R V Belt Automatic I l R Suspension Ball joint boots drive axle boots front and rear tie rods differential and rear drive bellows I I R Nuts Cap Screws Screws I T A Ignition Timing I Headlight Tailligh...

Страница 13: ...ove the battery from the battery compartment then thoroughly wash the battery and battery com partment with soap and water NOTE If battery posts cable ends or the battery case has a build up of white green powder residue apply water and baking soda to neutralize acid then flush off with warm soapy water 4 Using a wire brush clean the battery posts and cable ends removing all corrosive buildup Repl...

Страница 14: ...e battery posts and cable ends with a light coat of multi purpose grease 11 Connect the battery cables positive cable first then install the battery hold down Fuses The fuses are located in a power distribution module under the seat If there is any type of electrical system failure always check the fuses first NOTE To remove a fuse compress the locking tabs on either side of the fuse case and lift...

Страница 15: ... securing the storage compart ment CF145C CF260B 2 On the 400 remove the storage compartment assembly by elevating the rear of the compart ment moving it rearward and lifting it off 650 H1 650 H1 TRV 700 EFI 700 EFI TRV 700 H1 EFI CAUTION Always replace a blown fuse with a fuse of the same type and rating Back to TOC Back to Section TOC Next Back FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606 678 9623...

Страница 16: ...ork the oil into the element Attach the element to the filter screen 9 Clean any dirt or debris from inside the air cleaner Be sure no dirt enters the carburetor if equipped 10 Place the filter assembly in the air filter housing making sure it is properly positioned and properly seated with the filter screen down CD674 11 Install the air filter housing cover and secure with the retaining clips 400...

Страница 17: ... cap screws are with the proper cover Tighten the cap screws securely Valve Tappet Clearance Valve Adjuster Procedure NOTE For the 700 EFI see Valve Tappet Clear ance 700 EFI in this section To check and adjust valve tappet clearance use the following procedure NOTE On the 500 H1 models the seat storage compartment cover assembly compartment box air filter filter housing and left side right side s...

Страница 18: ...r dial at the proper clear ance setting tighten the jam nut securely with the valve adjuster handle 8 Place the two tappet covers with O rings into posi tion then tighten the covers securely 9 Install the spark plug then install the timing inspection plug Valve Tappet Clearance 700 EFI To check and adjust valve tappet clearance use the following procedure NOTE The seat heat shields splash panels f...

Страница 19: ...at the end of this section for the correct replacement FI051 A Measured tappet clearance from step 4 in verti cal column on left B Present shim size horizontal row at the top C Match measured clearance in vertical column with current shim size in horizontal row to find recommended replacement size 9 Apply engine oil to both surfaces of the tappet shim then place the shim on the valve with the numb...

Страница 20: ...away from the spark plug hole 4 Attach the Compression Tester Kit NOTE The engine must be warm and the battery must be fully charged for this test 5 While holding the throttle lever in the full open position crank the engine over with the electric starter until the gauge shows a peak reading five to 10 compression strokes 6 If compression is abnormally low inspect the following items A Verify star...

Страница 21: ...e arrester CF105A 2 Using a suitable brush clean the carbon deposits from the screen taking care not to damage the screen NOTE If the screen or gasket is damaged in any way it must be replaced 3 Install the spark arrester assembly with gasket then secure with the three cap screws Tighten to 4 0 ft lb CF104 Adjusting Throttle Cable To adjust the throttle cable free play follow this proce dure 1 Sli...

Страница 22: ...ission in neutral start the engine and warm it up to normal operating temperature 2 Turn the idle adjustment screw clockwise one turn past the recommended RPM setting then turn it counterclockwise to 1250 1350 RPM AF920D Engine Transmission Oil Filter Strainer OIL FILTER The engine should always be warm when the oil is changed so the oil will drain easily and completely 1 Park the ATV on level gro...

Страница 23: ... cloth 12 Install the oil level stick until the threads touch the engine case NOTE On the H1 models the oil level stick should be threaded into the case for checking pur poses 13 Remove the oil level stick the engine oil level should be above the illustrated L mark but not higher than the illustrated F mark ATV 0100 14 Inspect the area around the drain plug and oil filter for leaks 15 On the 700 E...

Страница 24: ...ary To change the lubricant use the following procedure 1 Place the ATV on level ground 2 Remove each oil fill plug AL677C 3 Drain the oil into a drain pan by removing in turn the drain plug from each ATV0082A 737 651B 4 After all the oil has been drained install the drain plugs and tighten to 45 in lb 5 Pour the appropriate amount of approved SAE 80W 90 hypoid gear lubricant into the filler hole ...

Страница 25: ...with the screws Tires TIRE SIZES The ATV is equipped with low pressure tubeless tires of the size and type listed see Section 1 Do not under any circumstances substitute tires of a different type or size TIRE INFLATION PRESSURE Front and rear tire inflation pressure should be 0 35 kg cm 5 0 psi Steering Components The following steering components should be inspected periodically to ensure safe an...

Страница 26: ...kcase cover 2 Using the Tachometer start the engine and run at 1500 RPM ignition timing should be 10 BTDC 3 Install the timing inspection plug If ignition timing cannot be verified the rotor may be damaged the key may be sheared the trigger coil CKP sensor bracket may be bent or damaged or the CDI unit ECU may be faulty Headlights Taillight Brakelight Rotate the ignition switch to the lights posit...

Страница 27: ...ure 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 intersect the horizontal marks on the aiming surface directly in front of the headlights 5 Switch on the lights Make sure the HIGH beam is on DO NOT USE LOW BEAM 6 Observe each headlight beam aim Proper aim is when th...

Страница 28: ... reverse and the R icon appears on the LCD CF258A 3 Tighten the jam nuts securely then shift the trans mission to each position and verify correct adjust ment 4 Install the left side engine cover and seat making sure the seat locks securely in place 5 Loosen the front shift rod jam nut 1 left hand threads then loosen the rear shift rod jam nut 2 right hand threads FI059A FI010A 6 Turn the ignition...

Страница 29: ...The hydraulic brake systems have been filled and bled at the factory To check and or bleed a hydraulic brake system use the following procedure 1 With the master cylinder in a level position check the fluid level in the reservoir If the level in the reservoir is not visible in the sight glass add DOT 4 brake fluid 738 420A AL681 2 Compress the brake lever pedal several times to check for a firm br...

Страница 30: ...usted automatically as the brake pads wear The only maintenance that is required is replacement 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 the brake pads must be replaced PR376B NOTE The brake pads should be r...

Страница 31: ...e initial fill shut the engine off and then fill the cooling system to the bot tom of the stand pipe in the radiator neck Checking Replacing V Belt REMOVING 1 Remove the right side footrest see Section 8 2 Remove the cap screws securing the V belt cover noting the location of the different lengthed cap screws for installing purposes then using a rubber mallet gently tap on the cover tabs to loosen...

Страница 32: ...ll the cover and secure with the cap screws making sure the different lengthed cap screws are in their proper location Tighten the cap screws to 8 ft lb 400 500 H1 Models or 7 ft lb 700 EFI CD083 NOTE Make sure the main engine ground wire is installed and secured in the proper location 6 Secure the front fender to the footrest with the two cap screws Tighten securely 7 Install the right side footr...

Страница 33: ...y to turn the handlebar or rock the ATV forward and backward to align the differential lock splines and allow engagement 3 Return the differential lock selector to the UNLOCK position and listen for the front drive actuator to operate 4 Turn the ignition switch to the OFF position Tighten the jam nut securely then install the boot on the adjuster Back to TOC Back to Section TOC Next Back FOR ARCTI...

Страница 34: ...hart in conjunction with the pro cedure found in Valve Tappet Clearance 700 EFI in this section ATV2152A Back to TOC Back to Section TOC Next Back FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606 678 9623 OR 606 561 4983 www mymowerparts com ...

Страница 35: ...e this chart in conjunction with the pro cedure found in Valve Tappet Clearance 700 EFI in this section Back to TOC Back to Section TOC Back FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606 678 9623 OR 606 561 4983 www mymowerparts com ...

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