2012 Arctic Cat 550 700 ATV Repair Manual

FOREWORD This Arctic Cat Service Manual contains service, maintenance, and troubleshooting information for certain 2012 Arctic Cat ATV models (see cover). The complete manual is designed to aid service personnel in service-oriented applications. Arctic Cat offers additional publications (when they become available) to aid in servicing other ATV models. To service models not included in this manual, please refer to the following publications: • 2012 Y-12+ Service Manual • 2012 T-14 Service Manual • 2012 300 DVX/Utility Service Manual • 2012 350 Service Manual • 2012 425 Service Manual • 2012 700 Diesel Service Manual • 2012 450 XC Service Manual • 2012 650 Service Manual • 2012 450/1000 Service Manual This manual is divided into sections. Each section covers a specific ATV component or system and, in addition to the standard service procedures, includes disassembling, inspecting, and assembling instructions. When using this manual as a guide, the technician should use discretion as to how much disassembly is needed to correct any given condition. The service technician should become familiar with the operation and construction of each component or system by carefully studying the complete manual. This manual will assist the service technician in becoming more aware of and efficient with servicing procedures. Such efficiency not only helps build 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. A CAUTION identifies unsafe practices which may result in ATV-related damage. Follow the directive because it deals with the possibility of damaging part or parts of the ATV. The symbol  NOTE: identifies supplementary information worthy of particular attention. The symbol  AT THIS POINT directs the technician to certain and specific procedures to promote efficiency and to improve clarity. At the time of publication, all information, photographs, and illustrations were technically correct. Some photographs used in this manual are used for clarity purposes only and are not designed to depict actual conditions. Because Arctic Cat Inc. constantly refines and improves its products, no retroactive obligation is incurred. All materials and specifications are subject to change without notice. Keep this manual accessible in the shop area for reference. Product Service and Warranty Department Arctic Cat Inc. © 2011 Arctic Cat Inc. August 2011 ®™ Trademarks of Arctic Cat Inc., Thief River Falls, MN 56701 Manual Table of Contents

TM SHARE OUR PASSION. SHARE OUR PASSI ON T A A A A A A V V Manual n Service M S S n v u c a a r M u l a a i e e M S S M n a a r v c ervice S S M s s ls de del od Mod M M M M 0 0 M 50 50 55 55 M l s e d d 0 Mo 5 5 5 5 o o 0 0 M 550 Mode s s ls de del od Mod M M M M 0 0 M 00 00 70 70 7 7 M l 7 s e d d o 00 Mo o o 0 0 0 0 M 700 Mode TABLE OF CONTENTS 1. General Information/Specifications 2. Periodic Maintenance 3. Engine/Transmission 4. Fuel/Lubrication/Cooling 5. Electrical System 6. Drive System/Brake System 7. Suspension 8. Steering/Frame 1 2 3 4 5 6 7 8

1-1 1 SECTION 1 - GENERAL INFORMATION/ SPECIFICATIONS TABLE OF CONTENTS General Specifications ............................................ 1-2 Torque Specifications .............................................. 1-2 Torque Conversions (ft-lb/N-m) ............................... 1-3 Break-In Procedure ................................................. 1-3 Gasoline - Oil - Lubricant ........................................ 1-4 Genuine Parts ......................................................... 1-4 Preparation For Storage .......................................... 1-5 Preparation After Storage........................................ 1-5 Manual Table of Contents

1-2 General Specifications Specifications subject to change without notice. * One inch below plug threads. ** At the plug threads. Torque Specifications CHASSIS Brake Type Hydraulic w/Brake Lever Lock and Auxiliary Brake Tire Size (700 Mud Pro) (700 Mud Pro) Front - 25 x 8-12 Rear - 25 x 10-12 Front - 28 x 9-14 Rear - 28 x 11-14 Tire Inflation Pressure 0.35 kg/cm² (5 psi) 0.49 kg/cm² (7 psi) - TRV/ Cruiser MISCELLANY Spark Plug Type NGK CPR8E Spark Plug Gap 0.5-0.6 mm (0.019-0.024 in.) Gas Tank Capacity 21.6 L (5.7 U.S. gal.) - FIS 21.9 L (5.8 U.S. gal.) - TBX 20.0 L (5.3 U.S. gal.) - TRV/ Cruiser Coolant Capacity 2.9 L (3.0 U.S. qt) Rear Drive Capacity 250 ml (8.5 fl oz)* Front Differential Capacity 275 ml (9.3 fl oz)** Engine Oil Capacity (approx) 2.5 L (2.6 U.S. qt) - Overhaul 1.9 L (2.0 U.S. qt) - Change Gasoline (recommended) 87 Octane Regular Unleaded Engine Oil (recommended) Arctic Cat ACX All Weather (Synthetic) Differential/Rear Drive Lubricant SAE Approved 80W-90 Hypoid Drive Belt Width (minimum) 35.6 mm (1.40 in.) Brake Fluid DOT 4 Taillight/Brakelight 12V/8W/27W Headlight 12V/27W (2) ELECTRICAL SYSTEM Ignition Timing 10° BTDC @ 1500 RPM Spark Plug Cap 5000 ohms Ignition Coil (primary) Resistance (secondary) Less than 5.0 ohms (terminal (+) to terminal (-)) 12k-19k ohms (high tension - plug cap - to terminal (+)) Ignition Coil Primary Voltage Battery Voltage (orange (+) to blue/white(-)) Stator Coil (crankshaft position sensor) Resistance (AC generator) 150-250 ohms (blue to green) Less than 1 ohm (yellow to yellow) Crankshaft Position Sensor AC Voltage 2.0 volts (blue to green) AC Generator Output (no load) 75 AC volts @ 5000 RPM (yellow to yellow) EXHAUST COMPONENTS Part Part Bolted To Torque ft-lb N-m Exhaust Pipe Engine 20 27 Spark Arrester Muffler 48 in.-lb 5.5 ELECTRICAL COMPONENTS Engine/Harness Ground Cap Screw Crankcase 8 11 Coil Air Filter Housing 7 10 STEERING COMPONENTS Steering Post Bearing Housing Frame 20 27 Steering Post Bearing Flange Frame 20 27 Lower Steering Bearing Washer Cap Screw*** Steering Post 40 54 Tie Rod End Knuckle/Steering Post 30 41 EPS Housing Frame 35 47 BRAKE COMPONENTS Brake Disc* Hub 15 20 Brake Hose Caliper 20 27 Brake Hose (Banjo-Fitting) Master Cylinder 20 27 Brake Hose Auxiliary Brake Cylinder 20 27 Master Cylinder (Rear) Frame 12 16 Hydraulic Caliper Knuckle (w/“Patch-Lock”) 20 27 Master Cylinder Clamp Master Cylinder 6 8 Brake Pedal Brake Pedal Axle 25 34 CHASSIS COMPONENTS Footrest Frame (8 mm) 20 27 Footrest Frame (10 mm) 40 54 SUSPENSION COMPONENTS (Front) A-Arm Frame 50 68 Knuckle Ball Joint 35 47 Shock Absorber Frame/Upper A-Arm 50 68 Knuckle A-Arm 50 68 SUSPENSION COMPONENTS (Rear) Shock Absorber (Upper) Frame 50 68 Shock Absorber (Lower) Lower A-Arm 20 27 A-Arm Frame 50 68 Knuckle A-Arm 35 47 Section Table of Contents Manual Table of Contents

1-3 1 * w/Blue Loctite #243 ** w/Red Loctite #271 *** w/Green Loctite #609 **** w/Three Bond Sealant Torque Conversions (ft-lb/N-m) Break-In Procedure A new ATV and an overhauled ATV engine require a “break-in” period. The first 10 hours (or 200 miles) are most critical to the life of this ATV. Proper operation during this break-in period will help assure maximum life and performance from the ATV. During the first 10 hours (or 200 miles) of operation, always use less than 1/2 throttle. Varying the engine RPM during the break-in period allows the components to “load” (aiding the mating process) and then “unload” (allowing components to cool). Although it is essential to place some stress on the engine components during break-in, care should be taken not to overload the engine too often. Do not pull a trailer or carry heavy loads during the 10-hour break-in period. When the engine starts, allow it to warm up properly. Idle the engine several minutes until the engine has reached normal operating temperature. Do not idle the engine for excessively long periods of time. DRIVE TRAIN COMPONENTS Part Part Bolted To Torque ft-lb N-m Engine Mounting Through-Bolt Frame 40 54 Engine (TRV) Engine Cradle 40 54 Engine Cradle (TRV)** Rubber Mount 25 34 Rubber Mount (TRV) Frame Bracket 35 47 Front Differential* Frame/Differential Bracket 38 52 Output Flange Rear Flange Output Joint 20 27 Pinion Housing Differential Housing 23 31 Differential Housing Cover*** Differential Housing 23 31 Drive Bevel Gear Nut*** Shaft 72 98 Differential Gear Case*** Hub 19 26 Lock Collar Differential Housing 125 169 Hub Nut Shaft/Axle (max) 200 272 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 Rear Drive Input Shaft/Housing Differential Housing 23 31 Wheel (Steel) Hub 40 54 Wheel (Aluminum) Hub 80 108 Rear Drive Gear Case* Frame 38 52 Engine Output Shaft ** Rear Gear Case Input Flange 20 27 Thrust Button** Gear Case Cover 8 11 ENGINE/TRANSMISSION Crankshaft Bushing Crankshaft 25 34 Speed Sensor Housing Crankcase 8 11 Clutch Shoe** Crankshaft 221 300 Clutch Cover/Housing Assembly Crankcase 8 11 Crankcase Half (6 mm) Crankcase Half 8 11 Crankcase Half (8 mm) Crankcase Half 20 27 Cylinder Head (Cap Screw) Crankcase 40 54 Cylinder Head Nut (6 mm) Cylinder 8 11 Cylinder Head Nut (8 mm) Cylinder 18 24 Valve Cover**** Cylinder Head 8.5 11.5 Driven Pulley Nut Driveshaft 80 108 Ground Wire Engine 8 11 Magneto Cover Crankcase 8 11 Oil Pump Drive Gear** Crank Balancer Shaft 63 85 Output Shaft Nut Output Shaft 59 80 Outer Magneto Cover Left-Side Cover 6 8 Magneto Rotor Nut Crankshaft 107 145 Cam Sprocket** Camshaft 10 13.5 Starter Motor Crankcase 8 11 V-Belt Cover Clutch Cover 8 11 Drive Pulley Nut** Clutch Shaft 165 224 Movable Drive Face Nut** Clutch Shaft 165 224 Secondary Shaft Bearing Housing Crankcase Half 28 38 Stator Coil** Crankcase 8 11 Starter One-Way Clutch** Flywheel 26 35 Output Yoke Nut Output Shaft 74 100 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 56 76.2 81 110.2 7 9.5 32 43.5 57 77.5 82 111.5 8 10.9 33 44.9 58 78.9 83 112.9 9 12.2 34 46.2 59 80.2 84 114.2 10 13.6 35 47.6 60 81.6 85 115.6 11 15 36 49 61 83 86 117 12 16.3 37 50.3 62 84.3 87 118.3 13 17.7 38 51.7 63 85.7 88 119.7 14 19 39 53 64 87 89 121 15 20.4 40 54.4 65 88.4 90 122.4 16 21.8 41 55.8 66 89.8 91 123.8 17 23.1 42 57.1 67 91.1 92 125.1 18 24.5 43 58.5 68 92.5 93 126.5 19 25.8 44 59.8 69 93.8 94 127.8 20 27.2 45 61.2 70 95.2 95 129.2 21 28.6 46 62.6 71 96.6 96 130.6 22 29.9 47 63.9 72 97.9 97 131.9 23 31.3 48 65.3 73 99.3 98 133.3 24 32.6 49 66.6 74 100.6 99 134.6 25 34 50 68 75 102 100 136 Section Table of Contents Manual Table of Contents

1-4 During the break-in period, a maximum of 1/2 throttle is recommended; however, brief full-throttle accelerations and variations in driving speeds contribute to good engine break-in. After the completion of the break-in period, the engine oil and oil filter should be changed. Other maintenance after break-in should include checking of all prescribed adjustments and tightening of all fasteners (see Periodic Maintenance Chart in Section 2). Gasoline - Oil - Lubricant RECOMMENDED GASOLINE The recommended gasoline to use is 87 minimum octane regular unleaded. In many areas, 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 necessary to add a gasoline antifreeze since ethanol will prevent the accumulation of moisture in the fuel system. RECOMMENDED ENGINE/ TRANSMISSION OIL The recommended oil to use is Arctic Cat ACX All Weather synthetic engine oil, which has been specifically formulated for use in this Arctic Cat engine. Although Arctic Cat ACX All Weather synthetic engine oil is the only oil recommended for use in this engine, use of any API certified SM 0W-40 oil is acceptable. OILCHARTJ RECOMMENDED FRONT DIFFERENTIAL/REAR DRIVE LUBRICANT The recommended lubricant is Arctic Cat Gear Lube or an equivalent gear lube which is SAE approved 80W-90 hypoid. This lubricant meets all of the lubrication requirements of the Arctic Cat ATV front differentials and rear drives. FILLING GAS TANK Since gasoline expands as its temperature rises, the gas tank must be filled to its rated capacity only. Expansion room must be maintained in the tank particularly if the tank is filled with cold gasoline and then moved to a warm area. ATV0049B Tighten the gas tank cap securely after filling the tank. Genuine Parts When replacement of parts is necessary, use only genuine Arctic Cat ATV parts. They are precision-made to ensure high quality and correct fit. Refer to the appropriate Illus- trated Parts Manual for the correct part number, quantity, and description. CAUTION Do not use white gas. Only Arctic Cat approved gasoline additives should be used. CAUTION Any oil used in place of the recommended oil could cause serious engine damage. Do not use oils which contain graphite or molybdenum additives. These oils can adversely affect clutch operation. Also, not recommended are racing, vegetable, non-detergent, and cas- tor-based oils. CAUTION Any lubricant used in place of the recommended lubricant could cause serious front differential/rear drive damage. ! WARNING Always fill the gas tank in a well-ventilated area. Never add fuel to the ATV gas tank near any open flames or with the engine running. DO NOT SMOKE while filling the gas tank. ! WARNING Do not overflow gasoline when filling the gas tank. A fire hazard could materialize. Always allow the engine to cool before filling the gas tank. ! WARNING Do not over-fill the gas tank. Section Table of Contents Manual Table of Contents

1-5 1 Preparation For Storage Arctic Cat recommends the following procedure to pre- pare the ATV for storage. 1. Clean the seat cushion (cover and base) with a damp cloth and allow it to dry. 2. Clean the ATV thoroughly by washing dirt, oil, grass, and other foreign matter from the entire ATV. Allow the ATV to dry thoroughly. DO NOT get water into any part of the engine or air intake. 3. Either drain the gas tank or add Fuel Stabilizer to the gas in the gas tank. Remove the air filter housing cover and air filter. Start the engine and allow it to idle; then using Arctic Cat Engine Storage Preserver, rapidly inject the preserver into the air filter opening for a period of 10 to 20 seconds. Stop the engine. Install the air filter and housing cover. 4. Plug the exhaust hole in the exhaust system with a clean cloth. 5. Apply light oil to the upper steering post bushing and plungers of the shock absorbers. 6. 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. 7. Fill the cooling system to the bottom of the stand pipe in the radiator neck with properly mixed coolant. 8. Disconnect the battery cables; then remove the battery, clean the battery posts and cables, and store in a clean, dry area. 9. Store the ATV indoors in a level position. Preparation After Storage Taking the ATV out of storage and correctly preparing it will assure many miles and hours of trouble-free riding. Arctic Cat recommends the following procedure to pre- pare the ATV. 1. Clean the ATV thoroughly. 2. Clean the engine. Remove the cloth from the exhaust system. 3. Check all control wires and cables for signs of wear or fraying. Replace if necessary. 4. Change the engine/transmission oil and filter. 5. Check the coolant level and add properly mixed coolant as necessary. 6. Charge the battery; then install. Connect the battery cables. 7. Check the entire brake systems (fluid level, pads, etc.), all controls, headlights, taillight, brakelight, and headlight 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 pressure as necessary. 10. Make sure the steering moves freely and does not bind. 11. Check the spark plug. Clean or replace as necessary. CAUTION Prior to storing the ATV, it must be properly serviced to prevent rusting and component deterioration. CAUTION If the interior of the air filter housing is dirty, clean the area before starting the engine. CAUTION Avoid storing outside in direct sunlight and avoid using a plastic cover as moisture will collect on the ATV caus- ing rusting. CAUTION The ignition switch must be in the OFF position prior to installing the battery or damage may occur to the ignition system. CAUTION Connect the positive battery cable first; then the nega- tive. Section Table of Contents Manual Table of Contents

2-1 2 SECTION 2 - PERIODIC MAINTENANCE TABLE OF CONTENTS Periodic Maintenance Chart .................................... 2-2 Periodic Maintenance .............................................. 2-3 Lubrication Points .................................................... 2-3 Air Filter ................................................................... 2-3 Valve/Tappet Clearance .......................................... 2-4 Testing Engine Compression .................................. 2-4 Spark Plug............................................................... 2-5 Muffler/Spark Arrester ............................................. 2-5 Engine/Transmission Oil - Filter - Strainer .............. 2-6 Liquid Cooling System ............................................ 2-7 Front Differential/Rear Drive Lubricant .................... 2-8 Nuts/Bolts/Cap Screws............................................ 2-9 Headlights/Taillight-Brakelight ................................. 2-9 Shift Lever ............................................................. 2-10 Hydraulic Brake Systems ...................................... 2-11 Burnishing Brake Pads .......................................... 2-13 Checking/Replacing V-Belt .................................... 2-13 Manual Table of Contents

2-2 Periodic Maintenance Chart A = Adjust I = Inspect C = Clean L = Lubricate D = Drain R = Replace T = Tighten * Service/Inspect more frequently when operating in adverse conditions. ** When using an API certified SM 0W-40 oil. *** When using Arctic Cat ACX All Weather synthetic oil, oil change interval can be increased to every 1,000 miles or every year. Item Initial Service After Break-In (First Month or 100 Miles) Every Day Every Month or Every 100 Miles Every 3 Months or Every 300 Miles Every 6 Months or Every 500 Miles Every Year or Every 1500 Miles As Needed Battery I I C Fuses I R Air Filter I I R Valve/Tappet Clearance I I A Engine Compression I Spark Plug I I R (4000 Mi or 18 Mo) Muffler/Spark Arrester C R Gas/Vent Hoses I I R (2 Yrs) Throttle Cable I I C-L A-R Engine-Transmission Oil Level I A Engine-Transmission Oil/Filter R R*/R**/R*** R Oil Strainer C Front Differential/Rear Drive Lubricant I I R (4 Yrs) Tires/Air Pressure I I R Steering Components I I I R V-Belt 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 I T Ignition Timing I Headlight/Taillight-Brakelight I I R Switches I I R Shift Lever I A-L Handlebar Grips I R Handlebar I I R Gauges/Indicators I I R Frame/Welds/Racks I l Electrical Connections I l C Complete Brake System (Hydraulic & Auxiliary) I I C L-R Brake Pads I I* R Brake Fluid I I R (2 Yrs) Brake Hoses I I R (4 Yrs) Coolant/Cooling System I I R (2 Yrs) Section Table of Contents Manual Table of Contents

2-3 2 Periodic Maintenance This section has been organized into sub-sections which show common maintenance procedures for the Arctic Cat ATV. NOTE: Arctic Cat recommends the use of new gas- kets, lock nuts, and seals and lubricating all internal components when servicing the engine/transmission. NOTE: Some photographs and illustrations used in this section are used for clarity purposes only and are not designed to depict actual conditions. NOTE: Critical torque specifications are located in Section 1. SPECIAL TOOLS A number of special tools must be available to the technician when performing service procedures in this section. NOTE: Special tools are available from the Arctic Cat Service Department. Lubrication Points It is advisable to lubricate certain components periodi- cally to ensure free movement. Apply light oil to the components using the following list as reference. A. Throttle Lever Pivot B. Brake Lever Pivot C. Auxiliary Brake Pedal Pivot Air Filter Use the following procedure to remove the filter and inspect and/or clean it. 1. Remove the fasteners securing the storage compartment and remove the storage compartment. 2. Remove the air filter housing cover and the air filter/frame assembly. 3. Remove the foam element from the frame making sure not to tear the element. CD747 4. Fill a wash pan larger than the element with a non-flammable solvent; then dip the element in the solvent and wash it. NOTE: Foam Air Filter Cleaner and Foam Air Filter Oil are available from Arctic Cat. 5. Squeeze the element by pressing it between the palms of both hands to remove excess solvent. Do not twist or ring the element or it will develop cracks. 6. Dry the element. 7. Put the element in a plastic bag; then pour in air filter oil and work the oil into the element. 8. Squeeze the element to remove excess oil. 9. Clean any dirt or debris from inside the air cleaner. 10. Install the air filter/frame assembly and cover. 11. Install the storage compartment and cover. CHECKING AND CLEANING DRAINS 1. Inspect the drains beneath the main housing for debris and for proper sealing. KX045A Description p/n Compression Tester Kit 0444-213 Oil Filter Wrench 0644-389 Tachometer 0644-275 Timing Light 0644-296 Valve Clearance Adjuster 0444-255 CAUTION A torn air filter can cause damage to the ATV engine. Dirt and dust may get inside the engine if the element is torn. Carefully examine the element for tears before and after cleaning it. Replace the element with a new one if it is torn. Section Table of Contents Manual Table of Contents

2012 Arctic Cat 550 700 ATV Repair Manual

You're Reading a Preview

Recently Viewed