2007 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

1-1 1 SECTION 1 - GENERAL INFORMATION TABLE OF CONTENTS General Specifications (400/400 TRV - Automatic Transmission) ............. 1-2 General Specifications (400 - Manual Transmission) ................................ 1-3 General Specifications (500 - Manual Transmission) ................................ 1-4 General Specifications (500 - Automatic Transmission) ............................ 1-5 General Specifications (650 H1/650 H1 TBX/650 H1 TRV) ...................... 1-6 General Specifications (700 EFI) .............................................................. 1-7 Break-In Procedure ................................................. 1-8 Gasoline - Oil - Lubricant ........................................ 1-8 Genuine Parts ......................................................... 1-9 Preparation For Storage .......................................... 1-9 Preparation After Storage...................................... 1-10 Back to TOC

1-2 General Specifications* (400/400 TRV - Automatic Transmission) * Specifications subject to change without notice. ** One inch below filler plug threads. *** At the oil level plug threads. CARBURETOR Type Keihin CVK34 Main Jet 135 Slow Jet 38 Pilot Screw Setting (turns) 1 3/4 Jet Needle NAZG Idle RPM (engine warm) 1250-1350 Starter Jet 75 Float Arm Height 17 mm (0.7 in.) Throttle Cable Free-Play (at lever) 3-6 mm (1/8-1/4 in.) ELECTRICAL Ignition Timing 10° BTDC @ 1500 RPM Spark Plug Type NGK CR7E Spark Plug Gap 0.7-0.8 mm (0.028-0.032 in.) Spark Plug Cap 8000-12,000 ohms Ignition Coil Resistance (primary) (secondary) Less than 1 ohm (terminal to ground) 5200-7800 ohms (high tension - plug cap removed - to ground) Ignition Coil Peak Voltage (primary/ CDI) 250-375 DC volts (terminal to ground) Magneto Coil Resistance (trigger) (source) (charging) 160-240 ohms (green to blue) Less than 1 ohm (yellow to white) Less than 1 ohm (black to black) Magneto Coil Peak Voltage (trigger) (source) 5.04-7.56 volts (green to blue) 0.7-1.05 volts (yellow to white) Stator Coil Output (no load) 60 AC volts @ 5000 RPM (black to black #1) (black to black #2) Magneto Output (approx) 220W @ 5000 RPM 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/cm² (5 psi) MISCELLANY Gas Tank Capacity (rated) 24.6 L (6.5 U.S. gal.) 20.8 L (5.5 U.S. gal.) - TRV Rear Drive Capacity 250 ml (8.5 fl oz)** Differential Capacity (front - 4x4) 275 ml (9.3 fl oz)*** Engine Oil Capacity 3.08 L (3.25 U.S. qt) Gasoline (recommended) 87 Octane Regular Unleaded Engine Oil (recommended) SAE 5W-30 Differential/Rear Drive Lubricant SAE Approved 80W-90 Hypoid Drive Belt Width 28.5 mm (1.12 in.) Brake Fluid DOT 4 Taillight/Brakelight 12V/8W/27W Headlight 12V/37W (2) Back to TOC Back to Section TOC Next

1-3 1 General Specifications* (400 - Manual Transmission) * Specifications subject to change without notice. ** One inch below filler plug threads. *** At the oil level plug threads. CARBURETOR Type Keihin CVK34 Main Jet 135 Slow Jet 38 Pilot Screw Setting (turns) 1 3/4 Jet Needle NAZG Idle RPM (engine warm) 1250-1350 Starter Jet 75 Float Arm Height 17 mm (0.7 in.) Throttle Cable Free-Play (at lever) 3-6 mm (1/8-1/4 in.) ELECTRICAL Ignition Timing 10° BTDC @ 1500 RPM Spark Plug Type NGK CR7E Spark Plug Gap 0.7-0.8 mm (0.028-0.032 in.) Spark Plug Cap 8000-12,000 ohms Ignition Coil Resistance (primary) (secondary) Less than 1 ohm (terminal to ground) 5200-7800 ohms (high tension - plug cap removed - to ground) Ignition Coil Peak Voltage (primary/ CDI) 250-375 DC volts (terminal to ground) Magneto Coil Resistance (trigger) (source) (charging) 160-240 ohms (green to blue) Less than 1 ohm (yellow to white) Less than 1 ohm (black to black) Magneto Coil Peak Voltage (trigger) (source) 5.04-7.56 volts (green to blue) 0.7-1.05 volts (yellow to white) Stator Coil Out- put (no load) 60 AC volts @ 5000 RPM (black to black #1) (black to black #2) Magneto Output (approx) 220 W @ 5000 RPM 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/cm² (5 psi) MISCELLANY Gas Tank Capacity (rated) 24.6 L (6.5 U.S. gal.) Rear Drive Capacity 250 ml (8.5 fl oz)** Differential Capacity (front - 4x4) 275 ml (9.3 fl oz)*** Engine Oil Capacity 3.08 L (3.25 U.S. qt) Gasoline (recommended) 87 Octane Regular Unleaded Engine Oil (recommended) SAE 5W-30 Differential/Rear Drive Lubricant SAE Approved 80W-90 Hypoid Brake Fluid DOT 4 Taillight/Brakelight 12V/8W/27W Headlight 12V/37W (2) Back to TOC Back to Section TOC Next Back

1-4 General Specifications* (500 - Manual Transmission) * Specifications subject to change without notice. ** At the oil level plug threads. *** At the filler plug threads. CARBURETOR Type Keihin CVK36 Main Jet 138 Slow Jet 40 Pilot Screw Setting (turns) 1 3/4 Jet Needle NFKG Idle RPM (engine warm) 1250-1350 Starter Jet 85 Float Arm Height 17 mm (0.7 in.) Throttle Cable Free-Play (at lever) 3-6 mm (1/8-1/4 in.) ELECTRICAL Ignition Timing 10° BTDC @ 1500 RPM Spark Plug Type NGK CR6E Spark Plug Gap 0.7-0.8 mm (0.028-0.032 in.) Spark Plug Cap 8000-12,000 ohms Ignition Coil Resistance (primary) (secondary) Less than 1 ohm (terminal to ground) 5200-7800 ohms (high tension - plug cap removed - to ground) Ignition Coil Peak Voltage (primary/ CDI) 140-215 DC volts (terminal to ground) Magneto Coil Resistance (trigger) (source) (charging) 160-240 ohms (green to blue) Less than 1 ohm (yellow to white) Less than 1 ohm (black to black) Magneto Coil Peak Voltage (trigger) (source) 4.2-6.3 volts (green to blue) 0.40-0.62 volt (yellow to white) Stator Coil Out- put (no load) 60 AC volts @ 5000 RPM (black to black #1) (black to black #2) Magneto Output (approx) 325W @ 5000 RPM 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/cm² (5 psi) MISCELLANY Gas Tank Capacity (rated) 24.6 L (6.5 U.S. gal.) Coolant Capacity 2.9 L (3.0 U.S. qt) Differential Capacity 275 ml (9.3 fl oz)** Rear Drive Capacity 250 ml (8.5 fl oz)*** Engine Oil Capacity 3.4 L (3.5 U.S. qt) Gasoline (recommended) 87 Octane Regular Unleaded Engine Oil (recommended) SAE 5W-30 Differential/Rear Drive Lubricant SAE Approved 80W-90 Hypoid Brake Fluid DOT 4 Taillight/Brakelight 12V/8W/27W Headlight 12V/27W (2) Back to TOC Back to Section TOC Next Back

1-5 1 General Specifications* (500 - Automatic Transmission) * Specifications subject to change without notice. ** At the oil level plug threads. *** At the filler plug threads. CARBURETOR Type Keihin CVK36 Main Jet 138 Slow Jet 40 Pilot Screw Setting (turns) 1 3/4 Jet Needle NFKG Idle RPM (engine warm) 1250-1350 Starter Jet 85 Float Arm Height 17 mm (0.7 in.) Throttle Cable Free-Play (at lever) 3-6 mm (1/8-1/4 in.) ELECTRICAL Ignition Timing 10° BTDC @ 1500 RPM Spark Plug Type NGK CR6E Spark Plug Gap 0.7-0.8 mm (0.028-0.032 in.) Spark Plug Cap 8000-12,000 ohms Ignition Coil Resistance (primary) (secondary) Less than 1 ohm (terminal to ground) 5200-7800 ohms (high tension - plug cap removed - to ground) Ignition Coil Peak Voltage (primary/ CDI) 140-215 DC volts (terminal to ground) Magneto Coil Resistance (trigger) (source) (charging) 160-240 ohms (green to blue) Less than 1 ohm (yellow to white) Less than 1 ohm (black to black) Magneto Coil Peak Voltage (trigger) (source) 4.2-6.3 volts (green to blue) 0.40-0.62 volt (yellow to white) Stator Coil Output (no load) 60 AC volts @ 5000 RPM (black to black #1) (black to black #2) Magneto Output (approx) 325W @ 5000 RPM 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/cm² (5 psi) MISCELLANY Gas Tank Capacity (rated) 24.6 L (6.5 U.S. gal.) Coolant Capacity 2.9 L (3.0 U.S. qt) Differential Capacity 275 ml (9.3 fl oz)** Rear Drive Capacity 250 ml (8.5 fl oz)*** Engine Oil Capacity 2.5 L (2.6 U.S. qt) Gasoline (recommended) 87 Octane Regular Unleaded Engine Oil (recommended) SAE 5W-30 Differential/Rear Drive Lubricant SAE Approved 80W-90 Hypoid Drive Belt Width (minimum) 38 mm (1.33 in.) Brake Fluid DOT 4 Taillight/Brakelight 12V/8W/27W Headlight 12V/27W (2) Back to TOC Back to Section TOC Next Back

1-6 General Specifications* (650 H1/650 H1 TBX/650 H1 TRV) * Specifications subject to change without notice. ** At the oil level plug threads. *** At the filler plug threads. CARBURETOR Type Keihin CVK36 Main Jet 132 Slow Jet 40 Pilot Screw Setting (turns) 1 1/4 Jet Needle NFKS Idle RPM (engine warm) 1250-1350 Starter Jet 85 Float Arm Height 17 mm (0.7 in.) Throttle Cable Free-Play (at lever) 3-6 mm (1/8-1/4 in.) ELECTRICAL Ignition Timing 10° BTDC @ 1500 RPM Spark Plug Type NGK CR6E Spark Plug Gap 0.7-0.8 mm (0.028-0.032 in.) Spark Plug Cap 4000 ohms Ignition Coil Resistance (primary) (secondary) Less than 1 ohm (terminal to ground) 5200-7800 ohms (high tension - plug cap removed - to ground) Ignition Coil Peak Voltage (primary/ CDI) 142.4-213.6 DC volts (terminal to ground) Magneto Coil Resistance (trigger) (source) (charging) 160-240 ohms (green to blue) Less than 1 ohm (yellow to white) Less than 1 ohm (black to black) Magneto Coil Peak Voltage (trigger) (source) 4.2-6.3 volts (green to blue) 0.40-0.62 volt (yellow to white) Stator Coil Output (no load) 60 AC volts @ 5000 RPM (black to black #1) (black to black #2) Magneto Output (approx) 325W @ 5000 RPM 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/cm² (5 psi) MISCELLANY Gas Tank Capacity (rated) 24.6 L (6.5 U.S. gal.) 20.8 L (5.5 U.S. gal.) - TBX/ TRV Coolant Capacity 2.9 L (3.0 U.S. qt) Differential Capacity 275 ml (9.3 fl oz)** Rear Drive Capacity 250 ml (8.5 fl oz)*** Engine Oil Capacity 3.4 L (3.5 U.S. qt) Gasoline (recommended) 87 Octane Regular Unleaded Engine Oil (recommended) SAE 5W-30 Differential/Rear Drive Lubricant SAE Approved 80W-90 Hypoid Belt Width 35.5 mm (1.40 in.) Brake Fluid DOT 4 Taillight/Brakelight 12V/8W/27W Headlight 12V/27W (2) Back to TOC Back to Section TOC Next Back

1-7 1 General Specifications* (700 EFI) * Specifications subject to change without notice. ** One inch below plug threads. *** At the plug threads. FUEL INJECTION Type Electronic Throttle Body Idle RPM (engine warm) 1200-1400 Throttle Cable Free-Play (at lever) 3-6 mm (1/8-1/4 in.) ELECTRICAL Spark Plug Type NGK CR6E Spark Plug Gap 0.7-0.8 mm (0.028-0.032 in.) Spark Plug Cap 8000-12,000 ohms Ignition Coil Resistance (primary) (secondary) Less than 1 ohm (terminal (+) to terminal (-)) 12k-19k ohms (plug cap to terminal (+)) Ignition Coil Peak Voltage (ECU) 80 volts or more (wire (+) to wire (-)) Stator Coil (crankshaft position Resistance sensor) (charging) 150-250 ohms (blue to white) Less than 1 ohm (yellow to yellow) Crankshaft Position Sensor Peak Voltage 5.0 volts or more (blue to white) Stator Coil Output (no load) 75 AC volts @ 5000 RPM (yellow to yellow) 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/cm² (5 psi) MISCELLANY Gas Tank Capacity (rated) 24.6 L (6.5 U.S. gal.) Coolant Capacity 2.9 L (3.0 U.S. qt) Differential Capacity 275 ml (9.3 fl oz)** Rear Drive Capacity 250 ml (8.5 fl oz)*** Engine Oil Capacity 2.45 L (2.6 U.S. qt) Gasoline (recommended) 87 Octane Regular Unleaded Engine Oil (recommended) SAE 5W-30 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) Back to TOC Back to Section TOC Next Back

1-8 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 compo- nents 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 prop- erly. 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 throt- tle 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. NOTE: Do not be reluctant to heat up the brake pads during the burnishing procedure. 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 nec- essary to add a gasoline antifreeze since ethanol will prevent the accumulation of moisture in the fuel sys- tem. RECOMMENDED ENGINE/ TRANSMISSION OIL The recommended oil to use is Arctic Cat 4-Cycle Engine Oil or an equivalent oil which is rated SE, SF, or SG under API service classification. These oils meet all of the lubrication requirements of the Arctic Cat ATV engine. The recommended engine oil viscosity is SAE 5W-30. Ambient temperature should determine the correct weight of oil. See the following viscosity chart for details. ! CAUTION BRAKE PADS MUST BE BURNISHED TO ACHIEVE FULL BRAKING EFFECTIVENESS. Braking distance will be extended until brake pads are properly bur- nished. TO PROPERLY BURNISH THE BRAKES, USE FOL- LOWING PROCEDURE: • Choose an area sufficiently large to safely accel- erate ATV to 30 mph and to brake to a stop. • Accelerate to 30 mph; then compress brake lever to decelerate to 0-5 mph. • Repeat procedure five times until brakes are bur- nished. • This procedure burnishes the brake pads, stabi- lizes the pad material, and extends the life of the brake pads. ! WARNING Do not attempt sudden stops or put the ATV into a situation where a sudden stop will be required until the brake pads are properly burnished. ! CAUTION Do not use white gas. Only Arctic Cat approved gas- oline 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 castor-based oils. Back to TOC Back to Section TOC Next Back

1-9 1 OILCHARTC 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 ATV0049B 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 cor- rect 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 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. ! CAUTION Prior to storing the ATV, it must be properly serviced to prevent rusting and component deterioration. Back to TOC Back to Section TOC Next Back