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2011 Arctic Cat 450/550/650/700/1000 ATV Service Manual

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Number of pages: 274
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Factory Service Manual for Arctic Cat 450/550/650/700/1000 ATV.

Manual is indexed and searchable for easy access to information. It has hundreds of high quality images and diagrams, a must have manual to perform maintenance and repairs.

Manual Chapters:
- GENERAL INFORMATION/ SPECIFICATIONS
- PERIODIC MAINTENANCE
- ENGINE / TRANSMISSION
- FUEL / LUBRICATION / COOLING
- ELECTRICAL SYSTEM
- DRIVE SYSTEM
- SUSPENSION
- STEERING / FRAME
- CONTROLS / INDICATORS

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Rated: 5 by: Rich R. Posted: Thursday, March 7, 2024 at 7:07PM

Great! All worked-out just great. Manual quality, fast delivery.

Full list of manual chapters:

TABLE OF CONTENTS
1. General Information/Specifications
    General Specifications
    Torque Specifications
    Torque Conversions (ft-lb/N-m)
    Tightening Torque (General Bolts)
    Break-In Procedure
    Gasoline - Oil - Lubricant
        RECOMMENDED GASOLINE
        RECOMMENDED ENGINE/ TRANSMISSION OIL
        RECOMMENDED FRONT DIFFERENTIAL/REAR DRIVE LUBRICANT
        FILLING GAS TANK
    Genuine Parts
    Preparation For Storage
    Preparation After Storage
2. Periodic Maintenance
    Periodic Maintenance Chart
    Periodic Maintenance
        SPECIAL TOOLS
    Lubrication Points
    Air Filter
        CHECKING AND CLEANING DRAINS
    Valve/Tappet Clearance
        Feeler Gauge Procedure
        Valve Adjuster Procedure
    Testing Engine Compression
    Spark Plug(s)
    Muffler/Spark Arrester
    Engine/Transmission Oil - Filter - Strainer
        OIL - FILTER
        STRAINER
    Liquid Cooling System
        Checking/Filling
    Front Differential/Rear Drive Lubricant
    Nuts/Bolts/Cap Screws
    Headlights/Taillight - Brakelight
        CHECKING/ADJUSTING HEADLIGHT AIM
    Shift Lever
        CHECKING ADJUSTMENT
        ADJUSTING SHIFT LEVER
    Frame/Welds/Racks
    Hydraulic Brake Systems
        CHECKING/BLEEDING
        INSPECTING HOSES
        CHECKING/REPLACING PADS
    Burnishing Brake Pads
    Checking/Replacing V-Belt
        REMOVING
        INSTALLING
3. Engine/Transmission
    Engine/Transmission
        SPECIAL TOOLS
    Specifications (450)
    Specifications (550/650/700)
    Specifications (1000)
    Troubleshooting
    Table of Contents (450)
        Removing Engine/ Transmission
        Top-Side Components
        Removing Top-Side Components
            A. Cylinder Head Cover/ Rocker Arms B. Cylinder Head/Camshaft
            C. Cylinder D. Piston
        Servicing Top-Side Components
            VALVE ASSEMBLY
                Cleaning/Inspecting Cylinder Head Cover
                Removing Valves
                Measuring Valve Stem Runout
                Measuring Valve Stem Outside Diameter
                Measuring Valve Face/Seat Width
                Measuring Valve Face Radial Runout
                Measuring Valve Guide (Inside Diameter)
                Servicing Valves/Valve Guides/Valve Seats
                Measuring Rocker Arm (Inside Diameter)
                Measuring Rocker Arm Shaft (Outside Diameter)
                Installing Valves
            PISTON ASSEMBLY
                Cleaning/Inspecting Piston
                Removing Piston Rings
                Cleaning/Inspecting Piston Ring Grooves
                Measuring Piston-Ring End Gap (Installed)
                Measuring Piston Pin, Connecting Rod Small End, and Piston-Pin Bore
                Measuring Piston Skirt/ Cylinder Clearance
                Installing Piston Rings
            CYLINDER/CYLINDER HEAD ASSEMBLY
                Cleaning/Inspecting Cylinder Head
                Measuring Cylinder Head Distortion
                Cleaning/Inspecting Cylinder
                Inspecting Cam Chain Guide
                Honing Cylinder
                Measuring Camshaft Runout
                Measuring Camshaft Lobe Height
                Inspecting Camshaft Bearing Journal
                Measuring Camshaft to Cylinder Head Clearance
                Inspecting Camshaft Spring/Drive Pin
        Installing Top-Side Components
            A. Piston B. Cylinder
            C. Cylinder Head/Camshaft D. Cylinder Head Cover/ Rocker Arms
        Left-Side Components
        Removing Left-Side Components
            A. Water Pump B. Speed Sensor C. Magneto Cover/ Stator Assembly
            D. Rotor/Flywheel E. Starter Clutch/Gear F. Starter Motor
            G. Shift Shaft H. Drive Gear
        Servicing Left-Side Components
            INSPECTING STARTER CLUTCH/GEAR
            REPLACING STARTER CLUTCH ASSEMBLY
            REPLACING STARTER GEAR BEARING
            INSPECTING STATOR/MAGNETO COVER ASSEMBLY
            REPLACING STATOR/ CRANKSHAFT POSITION SENSOR
            REPLACING MAGNETO COVER BEARINGS
        Installing Left-Side Components
            A. Starter Clutch/Gear B. Rotor/Flywheel
            C. Magneto Cover D. Water Pump
        Right-Side Components
        Removing Right-Side Components
            A. V-Belt Cover B. Driven Pulley C. Clutch Cover
            D. Centrifugal Clutch Assembly E. Oil Pump Drive Gear F. Oil Pump Driven Gear
            G. Oil Pump/Oil Strainer
        Servicing Right-Side Components
            INSPECTING CENTRIFUGAL CLUTCH SHOE
            INSPECTING CENTRIFUGAL CLUTCH HOUSING
            INSPECTING PRIMARY ONE-WAY DRIVE
            INSPECTING OIL PUMP
            DRIVEN PULLEY ASSEMBLY
        Installing Right-Side Components
            A. Oil Strainer/Oil Pump
            B. Clutch Cover C. Fixed Drive Face D. Movable Drive Face
        Center Crankcase Components
        Separating Crankcase Halves
        Disassembling Crankcase Half
        Servicing Center Crankcase Components
            SECONDARY GEARS
                Checking Backlash
                Correcting Backlash
                Checking Tooth Contact
                Correcting Tooth Contact
            CRANKSHAFT ASSEMBLY
                Measuring Connecting Rod (Small End Inside Diameter)
                Measuring Connecting Rod (Small End Deflection)
                Measuring Connecting Rod (Big End Side-to-Side)
                Measuring Crankshaft (Runout)
                Measuring Crankshaft (Web-to-Web)
            COUNTERSHAFT
                Disassembling
                ASSEMBLING
        Assembling Crankcase Half
        Joining Crankcase Halves
        Installing Engine/Transmission
    Table of Contents (550/650/700)
        Removing Engine/ Transmission
        Top-Side Components
        Removing Top-Side Components
            A. Valve Cover/Rocker Arms B. Cylinder Head/Camshaft
            C. Cylinder D. Piston
        Servicing Top-Side Components
            VALVE ASSEMBLY
                Cleaning/Inspecting Valve Cover
                Removing Valves
                Measuring Valve Stem Runout
                Measuring Valve Stem Outside Diameter
                Measuring Valve Face/Seat Width
                Measuring Valve Face Radial Runout
                Measuring Valve Guide/Valve Stem Deflection (Wobble Method)
                Measuring Valve Guide (Inside Diameter)
                Servicing Valves/Valve Guides/Valve Seats
                Measuring Rocker Arm (Inside Diameter)
                Measuring Rocker Arm Shaft (Outside Diameter)
                Installing Valves
            PISTON ASSEMBLY
                Cleaning/Inspecting Piston
                Removing Piston Rings
                Cleaning/Inspecting Piston Rings
                Measuring Piston-Ring End Gap (Installed)
                Measuring Piston Pin (Outside Diameter) and Piston-Pin Bore
                Measuring Piston Skirt/Cylinder Clearance
                Installing Piston Rings
            CYLINDER/CYLINDER HEAD ASSEMBLY
                Cleaning/Inspecting Cylinder Head
                Measuring Cylinder Head Distortion
                Cleaning/Inspecting Cylinder
                Inspecting Cam Chain Guide
                Inspecting Cylinder
                Measuring Camshaft Runout
                Measuring Camshaft Lobe Height
                Inspecting Camshaft Bearing Journal
                Measuring Camshaft to Cylinder Head Clearance
                Inspecting Camshaft Spring/Drive Pin
        Installing Top-Side Components
            A. Piston B. Cylinder
            C. Cylinder Head D. Valve Cover
        Left-Side Components
        Removing Left-Side Components
            A. Outer Magneto Cover B. Water Pump C. Cover D. Rotor/Flywheel
        Installing Left-Side Components
        Right-Side Components
        Removing Right-Side Components
            A. V-Belt Cover B. Driven Pulley C. Clutch Cover
        Servicing Right-Side Components
            INSPECTING CENTRIFUGAL CLUTCH SHOE
            INSPECTING CLUTCH HOUSING
            INSPECTING PRIMARY ONE-WAY DRIVE
            INSPECTING OIL PUMP
            DRIVEN PULLEY ASSEMBLY
        Installing Right-Side Components
        Center Crankcase Components
        Separating Crankcase Halves
        Disassembling Crankcase Half
        Servicing Center Crankcase Components
            SECONDARY OUTPUT DRIVE GEARS
                Initial Set-Up
                Checking Backlash
                Correcting Backlash
            CRANKSHAFT ASSEMBLY
                Measuring Connecting Rod (Small End Inside Diameter)
                Measuring Connecting Rod (Small End Deflection)
                Measuring Connecting Rod (Big End Side-to-Side)
                Measuring Crankshaft (Runout)
                Measuring Crankshaft (Web-to-Web)
            COUNTERSHAFT
                Disassembling
                Assembling
        Assembling Crankcase Half
        Joining Crankcase Halves
        Installing Engine/Transmission
    Table of Contents (1000)
        Removing Engine/ Transmission
        Top-Side Components
        Removing Top-Side Components
            A. Valve Cover/Rocker Arms B. Cylinder Head/Camshaft
            C. Cylinders D. Pistons
        Servicing Top-Side Components
            VALVE ASSEMBLY
                Cleaning/Inspecting Valve Cover
                Removing Valves
                Measuring Valve Stem Runout
                Measuring Valve Stem Outside Diameter
                Measuring Valve Face/Seat Width
                Measuring Valve Face Radial Runout
                Measuring Valve Guide/Valve Stem Deflection (Wobble Method)
                Measuring Valve Guide (Inside Diameter)
                Servicing Valves/Valve Guides/Valve Seats
                Measuring Rocker Arm (Inside Diameter)
                Measuring Rocker Arm Shaft (Outside Diameter)
                Installing Valves
            PISTON ASSEMBLY
                Cleaning/Inspecting Piston
                Removing Piston Rings
                Cleaning/Inspecting Piston Rings
                Measuring Piston-Ring End Gap (Installed)
                Measuring Piston Pin (Outside Diameter) and Piston-Pin Bore
                Measuring Piston Skirt/Cylinder Clearance
                Installing Piston Rings
            CYLINDER/CYLINDER HEAD ASSEMBLY
                Cleaning/Inspecting Cylinder Head
                Measuring Cylinder Head Distortion
                Cleaning/Inspecting Cylinder
                Inspecting Cam Chain Guide
                Inspecting Cylinder
                Measuring Camshaft Runout
                Measuring Camshaft Lobe Height
                Inspecting Camshaft Bearing Journal
                Measuring Camshaft to Cylinder Head Clearance
                Inspecting Camshaft Spring/Drive Pin (Front Camshaft Only)
        Installing Top-Side Components
            A. Pistons B. Cylinders
            C. Cylinder Head D. Valve Cover
        Left-Side Components
        Removing Left-Side Components
            A. Magneto Cover/Stator Coils B. Water Pump C. Shifter Assembly D. Rotor/Flywheel/Starter Clutch E. Speed Sensor/ Trigger Assembly
        Installing Left-Side Components
        Right-Side Components
        Removing Right-Side Components
            A. V-Belt Cover B. Driven Pulley C. Clutch Cover D. Centrifugal Clutch
        Servicing Right-Side Components
            INSPECTING CENTRIFUGAL CLUTCH SHOE
            INSPECTING CLUTCH HOUSING
            INSPECTING PRIMARY ONE-WAY DRIVE
            DRIVEN PULLEY ASSEMBLY
        Installing Right-Side Components
        Center Crankcase Components
        Separating Crankcase Halves
        Disassembling Crankcase Half
        Servicing Center Crankcase Components
            SECONDARY OUTPUT DRIVE GEARS
                Initial Set-Up
                Checking Backlash
                Correcting Backlash
            OIL PUMP ASSEMBLY
                Disassembling and Inspecting
                Assembling
            CRANKSHAFT ASSEMBLY
                Measuring Connecting Rod (Small End Inside Diameter)
                Measuring Connecting Rod (Small End Deflection)
                Measuring Connecting Rod (Big End Side-to-Side)
                Measuring Crankshaft (Runout)
                Measuring Crankshaft (Web-to-Web)
            COUNTERSHAFT
                Disassembling
                Assembling
        Assembling Crankcase Half
        Joining Crankcase Halves
        Installing Engine/Transmission
4. Fuel/Lubrication/Cooling
    Fuel/Lubrication/Cooling
        SPECIAL TOOLS
    Carburetor Specifications (650)
    Carburetor Schematics (650)
    Carburetor (650)
        REMOVING
        DISASSEMBLING
        CLEANING AND INSPECTING
        ASSEMBLING
        INSTALLING
    Electric Choke (650)
        REMOVING
        INSPECTING/TESTING
        INSTALLING
    Electronic Fuel Injection (EFI)
        TROUBLESHOOTING
        REMOVING (H1)
        REMOVING (H2)
        INSTALLING (H1)
        INSTALLING (H2)
    Throttle Cable Free-Play
    Engine RPM (Idle)
    Gas Tank
        REMOVING
        CLEANING AND INSPECTING
        INSTALLING
    Oil Filter/Oil Pump
    Testing Oil Pump Pressure
    Oil Cooler (700/1000)
        REMOVING
        INSTALLING
    Liquid Cooling System
        RADIATOR
            Removing
            Cleaning and Inspecting
            Installing
        THERMOSTAT
            Removing (H1)
            Removing (H2)
            Inspecting
            Installing (H1)
            Installing (H2)
        COOLING FAN
            Removing
            Installing
        WATER PUMP (H1)
            Removing
            Installing
        WATER PUMP (H2)
            Removing
            Installing
    Electric Fuel Pump/Fuel Level Sensor (EFI)
        TESTING
        REMOVING
        INSPECTING
        INSTALLING
    Vacuum Pulse Fuel Pump (650)
        TESTING
        REMOVING
        INSTALLING
    Troubleshooting (650)
    Troubleshooting (EFI)
5. Electrical System
    Electrical System
        SPECIAL TOOLS
    Electrical Connections
    Specifications
    Battery
    RPM Limiter
    Testing Electrical Components
    Accessory Receptacle/Connector
        VOLTAGE
    Brakelight Switch (Auxiliary)
        VOLTAGE (Wiring Harness Side)
        RESISTANCE (Switch Connector)
    Brakelight Switch (Handlebar Control)
        VOLTAGE (Wiring Harness Connector)
        RESISTANCE (Switch Connector)
    Coolant Temperature and Cooling Fan Switches (650)
    Engine Coolant Temperature (ECT) Sensor (EFI)
    Fan Motor
        RESISTANCE (Fan Motor Connector)
    Power Distribution Module (PDM)
        FUSES
        RELAYS
    Ignition Coil
        RESISTANCE
            Primary Winding
            Secondary Winding
            Spark Plug Cap
        PEAK VOLTAGE
            Primary/CDI (650)
            Primary Voltage - ECU (H1)
            Primary Voltage - ECU (H2)
    EFI Sensors/ Components (EFI)
        CRANKSHAFT POSITION (CKP) SENSOR
        MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR (550/700/ Thundercat/1000 Mud Pro)
        MANIFOLD ABSOLUTE PRESSURE/ INLET AIR TEMPERATURE (MAP/IAT) SENSOR (450)
    Speed Sensor
    Electronic Power Steering (EPS)
    Ignition Switch
        VOLTAGE
        RESISTANCE
    Handlebar Control Switches
        RESISTANCE (HI Beam)
        RESISTANCE (LO Beam)
        DIODE (Starter Button)
        RESISTANCE (Emergency Stop)
        RESISTANCE (Reverse Override)
    Drive Select Switch
        RESISTANCE
        VOLTAGE
    Front Drive/Differential Lock Actuator
        VOLTAGE
    Stator Coil (650)
        VOLTAGE (AC Generator - Regulated Output)
        VOLTAGE (Charging Coil - No Load)
        RESISTANCE (Charging Coil)
        RESISTANCE (Trigger Coil)
        PEAK VOLTAGE (650)
            Trigger Coil
    Stator Coil/Crankshaft Position (CKP) Sensor (EFI)
        VOLTAGE (AC Generator - Regulated Output)
        VOLTAGE (AC Generator - No Load)
        RESISTANCE (AC Generator)
        RESISTANCE (Crankshaft Position Sensor)
        AC VOLTAGE
            Crankshaft Position Sensor
    Starter Relay
    Starter Motor
        TESTING VOLTAGE
        REMOVING
        INSTALLING
    CDI Unit (650)
    Electronic Control Unit (ECU) (EFI)
    Regulator/Rectifier
        TESTING
    Headlights
        VOLTAGE
    Taillight - Brakelight
        VOLTAGE (Taillight)
        VOLTAGE (Brakelight)
    Ignition Timing
    ECU Error Codes (550/700/700 Cruiser/700 Mud Pro/1000)
        ECU Error Code List
    ECU Malfunction Codes (450/1000 Cruiser/1000 Mud Pro)
        Code List
    Tilt Sensor (EFI)
        SUPPLY VOLTAGE
        OUTPUT VOLTAGE
    Throttle Position Sensor (TPS) (550/700/700 Cruiser/1000)
        INSPECTING
        REMOVING
        INSTALLING/ADJUSTING
    Throttle Position Sensor (TPS) (450)
        INSPECTING
        REMOVING
        INSTALLING/ADJUSTING
    Throttle Position Sensor (TPS) (1000 Cruiser/1000 Mud Pro)
        INSPECTING
        REMOVING
        INSTALLING/ADJUSTING
    Troubleshooting
6. Drive System
    Drive System
        GENERAL INFORMATION
        SPECIAL TOOLS
    Front Drive Actuator/Differential Lock
        REMOVING
        INSTALLING
    Front Differential
        REMOVING DIFFERENTIAL
            Disassembling Input Shaft
            Assembling Input Shaft
            Disassembling Differential Assembly
            Disassembling Pinion Gear
            Assembling Pinion Gear
            Shimming Procedure/Shim Selection
            Backlash
            Ring Gear End-Play
            Assembling Differential Assembly
            Removing/Installing Axle Seal
        INSTALLING DIFFERENTIAL
    Drive Axles
        REMOVING REAR DRIVE AXLE
        REMOVING FRONT DRIVE AXLE
        CLEANING AND INSPECTING
        DISASSEMBLING AXLES
        ASSEMBLING AXLES
        INSTALLING REAR DRIVE AXLE
        INSTALLING FRONT DRIVE AXLE
    Rear Gear Case
        REMOVING
        RING GEAR/THRUST BUTTON
            Removing
            Inspecting
            Installing/Shimming
        REAR DRIVE INPUT SHAFT/ HOUSING (700 Mud Pro/1000)
            Removing/Disassembling
            Cleaning and Inspecting
            Assembling/Installing
        INSTALLING
    Hub
        REMOVING
        CLEANING AND INSPECTING
        INSTALLING
    Hydraulic Brake Caliper
        REMOVING/DISASSEMBLING
        CLEANING AND INSPECTING
        ASSEMBLING/INSTALLING
    Troubleshooting Drive System
    Troubleshooting Brake System
7. Suspension
    Suspension
    Shock Absorbers
        REMOVING
        CLEANING AND INSPECTING
        INSTALLING
    Front A-Arms
        REMOVING
        CLEANING AND INSPECTING
        INSTALLING
    Rear A-Arms
        REMOVING
        CLEANING AND INSPECTING
        INSTALLING
    Wheels and Tires
        TIRE SIZE
        TIRE INFLATION PRESSURE
        REMOVING
        CLEANING AND INSPECTING
        INSTALLING
        CHECKING/INFLATING
    Troubleshooting
8. Steering/Frame
    Steering/Frame
    Steering Post/Tie Rods
        REMOVING
        CLEANING AND INSPECTING
        INSTALLING (Models Without Electronic Power Steering)
        INSTALLING (Electronic Power Steering Models)
    Handlebar Grip
        REMOVING
        INSPECTING
        INSTALLING
    Steering Knuckles
        REMOVING AND DISASSEMBLING
        CLEANING AND INSPECTING
        ASSEMBLING AND INSTALLING
    Measuring/Adjusting Toe-Out
    Front Rack
        REMOVING
        CLEANING AND INSPECTING
        INSTALLING
    Front Bumper Assembly
        REMOVING
        CLEANING AND INSPECTING
        INSTALLING
    Front Body Panel/Side Panels
        REMOVING
        CLEANING AND INSPECTING
        INSTALLING
    Footrests
        REMOVING
        CLEANING AND INSPECTING
        INSTALLING
    Belly Panel
        REMOVING/INSTALLING
    Exhaust System
        REMOVING MUFFLER
        INSPECTING MUFFLER
        INSTALLING MUFFLER
    Rear Body Panel/Rack
        REMOVING
        CLEANING AND INSPECTING
        INSTALLING
    Taillight Assembly
        REMOVING
        INSPECTING
        INSTALLING
    Seat
        REMOVING/INSTALLING
        REMOVING/INSTALLING (TRV)
    Side Storage Box (TBX)
        REMOVING
        CLEANING AND INSPECTING
        INSTALLING
    Cargo Box (TBX)
        REMOVING
        CLEANING AND INSPECTING
        INSTALLING
    Troubleshooting
9. Controls/Indicators
    Hand Brake Lever/Master Cylinder Assembly
        REMOVING
        INSPECTING
        INSTALLING
    Throttle Control
        REMOVING
        INSTALLING
        ADJUSTING
    Shift Lever
        REMOVING
        INSTALLING
    Speedometer/ Tachometer/LCD
        REPLACING
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