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Arctic Cat Service Manuals

Arctic CatThe Arctic Cat service manuals & wiring diagrams for do-it-yourselfers. This manual covers 5 Arctic Cat models: Arctic Cat 250, Arctic Cat 300, Arctic Cat 400, Arctic Cat 500 (Manual Transmission), Arctic Cat 500 (Automatic Transmission).

Contents:
General Information
Contents: specifications (250 cc) 1-2, specifications (300 cc) 1-4, specifications (400 cc) 1-6, specifications (500 cc – manual transmission) 1-8, specifications (500 cc – automatic transmission) 1-10, break-in procedure 1-12, gasoline/oil/lubricant 1-12, genuine parts 1-13, load capacity ratings charts 1-14, preparation for storage 1-15, preparation after storage 1-15
Periodic Maintenance/Tune-Up
Contents: periodic maintenance chart 2-2, lubrication points 2-3, battery 2-3, fuses 2-4, air cleaner (250/300 cc) 2-5, air cleaner/filter (400/500 cc) 2-10, valve/tappet clearance (feeler gauge procedure) 2-12, valve/tappet clearance (valve adjuster procedure) 2-13, testing engine compression 2-13, spark plug 2-14, muffler/spark arrester 2-14, gas/vent hoses 2-15, adjusting throttle cable 2-15, adjusting engine rpm (idle) 2-15, engine/transmission oil – filter – strainer (250/300 cc) 2-16, engine/transmission oil – filter – strainer (400/500 cc) 2-18, front differential/rear drive lubricant 2-20, adjusting clutch (250/300 cc) 2-21, adjusting clutch (400/500 cc manual transmission) 2-22, tires 2-23, steering components 2-23, driveshaft/coupling 2-23, suspension/shock absorbers/bushings 2-23, nuts/cap screws 2-24, ignition timing 2-24, headlight/taillight-brakelight 2-24, switches 2-25, adjusting reverse shift lever (manual transmission) 2-25, adjusting shift lever (automatic transmission) 2-26, indicator/gear position l ights 2-27, frame/welds/racks 2-28, electrical connections 2-28, hydraulic hand brake system 2-28, mechanical foot brake (manual transmission) 2-30, hydraulic foot brake system (automatic transmission) 2-32, burnishing brake pads 2-32, coolant (400/500 cc) 2-33, checking/replacing v-belt (automatic transmission) 2-33
Engine/Transmission
Contents: engine/transmission 3-2, specifications (250/300 cc) 3-2, specifications (400/500 cc) 3-3, 250/300 cc table of contents 3-4, 400/500 cc (manual transmission) table of contents 3-56, 500 cc (automatic transmission) table of contents 3-112, servicing components table of contents 3-154
Fuel/Lubrication/Cooling
Contents: carburetor specifications 4-2, carburetor schematics 4-3, carburetor (mikuni 250/400 cc) 4-5, carburetor (keihin 300/500 cc) 4-13, cleaning and inspecting carburetor 4-21, throttle cable free-play 4-21, engine rpm (idle) 4-22, gas tank 4-23, gas tank valve 4-24, gas/vent hoses 4-25, oil flow charts 4-25, oil pump 4-27, testing oil pump pressure 4-28, oil cooler (250/300 cc) 4-28, liquid cooling system (400/500 cc) 4-29, radiator 4-30, hoses/thermostat 4-32, fan 4-33, servicing water pump (400/500 cc – manual transmission) 4-34, servicing water pump (500 cc – automatic transmission) 4-35
Electrical System
Contents: specifications 5-2, battery 5-3, rpm limiter 5-3, testing electrical components 5-4, accessory receptacle/connector (400/500 cc) 5-4, brakelight switch (foot) 5 -4, brakelight switch (handlebar control) 5-5, oil temperature switch (250/300 cc) 5-6, fan motor (400/500 cc) 5-6, fuse block 5-7, fuses 5-8, gear position lights (300 cc 4×4/400/500 cc – manual transmission) 5-8, gear position switch (manual transmission) 5-9, ignition coil 5-10, indicator lights 5-11, ignition switch 5-13, handlebar control switches 5-13, magneto assembly 5-14, starter motor 5-15, starter relay (250/300 cc) 5-21, starter relay (400/500 cc) 5-22, cdi unit (250/300 cc) 5-23, regulator/rectifier (250/300 cc) 5-23, cdi unit (400/500 cc) 5-24, regulator/rectifier (400/500 cc) 5-25, neutral start relay 5-26, headlights 5-27, taillight – brakelight 5-27, ignition timing 5-28
Drive System
Contents: differential/rear drive/axles assembly schematics 6-2, front differential 6-4, drive axles 6-26, rear axles (400/500 cc) 6-30, hub 6-35, hydraulic hand brake caliper 6-36, hydraulic brake assembly schematics 6-38
Suspension
Contents: front and rear shock absorber assemblies 7-2, swing arms (400/500 cc) 7-5, a-arms 7-6, wheels and tires 7-10
Steering/Frame
Contents: fsteering post/handlebar/tie rods 8-2, handlebar grip 8-6, knuckles 8-6, measuring/adjusting toe-in/toe-out 8-11, body panel assembly schematics 8-13, frame/exhaust assembly schematics 8-15, front rack 8-18, front bumper assembly 8-19, front fender/side panels 8-20, fender flares/extensions 8-21, belly panel 8-21, exhaust system 8-22, rear rack 8-22, rear fender 8-23, adjusting headlight 8-23, taillight assembly 8-24, seat 8-25
Controls/Indicators
Contents: hand brake lever/master cylinder assembly 9-2, mechanical foot brake assembly schematic (manual transmission) 9-4, hydraulic foot brake assembly schematic (automatic transmission) 9-5, throttle control 9-6, gearshift pedal (manual transmission) 9-8, drive selector (300 cc 4×4/500 cc) 9-8, reverse shift lever (manual transmission) 9-8, reverse shift lever and cable (manual transmission) 9-9, shift lever assembly (automatic transmission) 9-12, speedometer/indicator/gear position lights 9-13
Aids For Maintenance
Contents: torque specifications (250/300 cc) 10-2, torque specifications (400/500 cc – manual transmisison) 10-4, torque specifications (500 cc – automatic transmission) 10-6, torque conversions 10-8
Troubleshooting
Contents: engine 11-2, drive 11-7, fuel system 11-8, electrical 11-9, steering/suspension 11-11, brakes 11-12
Free Arctic Cat Repair Manuals