2006 Arctic Cat 650 H1 Service & Repair Manual

TABLE OF CONTENTS Click on the Red text to go. Section 1. General Information 2. Periodic Maintenance/Tune-Up 3. Engine/Transmission 4. Fuel/Lubrication/Cooling 5. Electrical System 6. Drive System 7. Suspension 8. Steering/Frame 9. Controls/Indicators 10. Aids for Maintenance 11. Troubleshooting 1 2 3 4 5 6 7 8 9 10 11

1 TABLE OF CONTENTS

General Specifications* (400/400 TBX/400 TRV - Automatic Transmission) * Specifications subject to change without notice. ** One inch below filler plug threads. *** At the oil level plug threads.

1 General Specifications* (400 - Manual Transmission) * Specifications subject to change without notice. ** One inch below filler plug threads. *** At the oil level plug threads.

General Specifications* (500 - Manual Transmission) * Specifications subject to change without notice. ** At the oil level plug threads. *** At the filler plug threads.

1 General Specifications* (500/500 TBX/500 TRV - Automatic Transmission) * Specifications subject to change without notice. ** At the oil level plug threads. *** At the filler plug threads.

General Specifications* (650 H1) * Specifications subject to change without notice. ** At the oil level plug threads. *** At the filler plug threads.

1 General Specifications* (650 V-Twin) * Specifications subject to change without notice. ** One inch below plug threads. *** At the plug threads.

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. During the break-in period, a maximum of 1/2 throttle is recommended; however, brief full-throttle accelerations and variations in driving speeds con- tribute to good engine break-in. During the break-in period (or whenever the brake pads are replaced), the hydraulic brake pads must be burnished. Slow disc-speed hydraulic brakes must be properly burnished in order to achieve maximum stopping power. 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. 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 4-Cycle Engine Oil (p/n 0436-005) or an equivalent oil which is rated SE, SF, or SG under API service clas- sification. These oils meet all of the lubrication requirements of the Arctic Cat ATV engine. The recommended engine oil viscosity is SAE 10W-40. Ambient temperature should determine the correct weight of oil. See the following viscosity chart for details. ! CAUTION ! WARNING ! CAUTION ! CAUTION

1 RECOMMENDED FRONT DIFFERENTIAL/REAR DRIVE LUBRICANT The recommended lubricant is Arctic Cat Gear Lube (p/n 0436-007) 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 par- ticularly if the tank is filled with cold gasoline and then moved to a warm area. 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 Illustrated Parts Manual for the correct part number, quantity, and description. Preparation For Storage Arctic Cat recommends the following procedure to prepare 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. ! CAUTION ! WARNING ! WARNING ! WARNING ! CAUTION

2006 Arctic Cat 650 H1 Service & Repair Manual

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