2014-2015 Arctic Cat 500 550 700 1000 Mud Pro TRV ATV Service & Repair Manual

SERVICE MANUAL www.arcticcat.com 500/550/700/1000/ TBX/TRV/MUD PRO

FOREWORD This Arctic Cat Service Manual contains service, maintenance, and troubleshooting information for certain 2015 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: • 2015 90 Service Manual • 2015 150 Service Manual • 2015 300 DVX/Utility Service Manual • 2015 400 Service Manual • 2015 450 Service Manual • 2015 700 Diesel Service Manual • 2015 XC 450 Service Manual • 2015 XR 500/550/700 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. This service manual is designed primarily for use by an Arctic Cat CatMaster Basic Level technician. The procedures found in this manual are of varying difficulty, and certain service procedures in this manual require one or more special tools to be completed. The technician should use sound judgement when determining which procedures can be completed based on their skill level and access to appropriate special tools. 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.

1 TABLE OF CONTENTS General Information ........................................................ 2 General Specifications .................................................. 2 Torque Specifications.................................................... 2 Torque Conversions (ft-lb/N-m) ..................................... 3 Gasoline - Oil - Lubricant .............................................. 4 Genuine Parts ............................................................... 4 Preparation For Storage ............................................... 4 Preparation After Storage ............................................. 5 Periodic Maintenance...................................................... 6 Lubrication Points ......................................................... 6 Air Filter ........................................................................ 6 Valve/Tappet Clearance ................................................ 7 Testing Engine Compression ........................................ 8 Spark Plug(s) ................................................................ 9 Muffler/Spark Arrester .................................................. 9 Engine/Transmission Oil - Filter ................................... 9 Liquid Cooling System ................................................ 11 Front Differential/Rear Drive Lubricant ....................... 12 Nuts/Bolts/Cap Screws ............................................... 13 Shift Lever ................................................................... 13 Hydraulic Brake Systems............................................ 13 Burnishing Brake Pads ............................................... 16 Checking/Replacing V-Belt ......................................... 16 Steering/Frame/Controls............................................... 18 Front Body Panel/Side Panels .................................... 18 Rear Body Panel/Rack................................................ 21 LCD Gauge................................................................. 22 Steering Post/Tie Rods ............................................... 22 Handlebar Grip ........................................................... 26 Throttle Control ........................................................... 27 Steering Knuckles ....................................................... 28 Measuring/Adjusting Toe-Out ..................................... 30 Shift Lever ................................................................... 30 Front Rack .................................................................. 30 Front Bumper Assembly ............................................. 31 Footrests ..................................................................... 31 Belly Panel .................................................................. 31 Exhaust System.......................................................... 31 Taillight Assembly ....................................................... 32 Seat ............................................................................ 32 Side Storage Box (TBX) ............................................. 33 Cargo Box (TBX) ........................................................ 34 Headlights/Taillight-Brakelight ..................................... 34 Troubleshooting .......................................................... 36 Engine/Transmission .................................................... 37 Specifications (500) .................................................... 37 Specifications (550/700/1000) .................................... 38 Troubleshooting .......................................................... 39 Removing Engine/Transmission (500) ........................ 41 Servicing Engine (500) ............................................... 43 Installing Engine/Transmission (500) .......................... 80 Removing Engine/Transmission (550/700) ................. 82 Servicing Engine (550/700) ........................................ 85 Installing Engine/Transmission (550/700) ................. 124 Removing Engine/Transmission (1000) .................... 127 Servicing Engine (1000) ........................................... 131 Installing Engine/Transmission (1000) ...................... 174 Fuel/Lubrication/Cooling.............................................177 Throttle Body ............................................................. 177 Throttle Cable Free-Play ........................................... 179 Engine RPM (Idle) ..................................................... 180 Gas Tank ................................................................... 180 Oil Filter/Oil Pump ..................................................... 180 Testing Oil Pump Pressure........................................ 181 Oil Cooler (1000) ....................................................... 181 Liquid Cooling System .............................................. 183 Troubleshooting ......................................................... 187 Electrical System .........................................................188 Battery ....................................................................... 188 Accessory Receptacle/Connector ............................. 189 Brakelight Switch ....................................................... 189 Engine Coolant Temperature (ECT) Sensor.............. 190 Fan Motor .................................................................. 191 Power Distribution Module (PDM) ............................. 191 Ignition Coil ............................................................... 191 EFI Sensors/Components ......................................... 192 Speed Sensor ........................................................... 193 Electronic Power Steering (EPS) .............................. 193 Ignition Switch ........................................................... 195 Handlebar Control Switches...................................... 196 Drive Select Switch ................................................... 196 Front Drive/Differential Lock Actuator........................ 197 Stator Coil ................................................................. 197 Starter Relay ............................................................. 198 Starter Motor ............................................................. 198 Electronic Control Module (ECM) .............................. 199 Fuel Pump/Fuel Level Sensor ................................... 199 Regulator/Rectifier .................................................... 201 Headlights ................................................................. 201 Taillight - Brakelight ................................................... 201 Tilt Sensor ................................................................. 202 Throttle Position Sensor (TPS) .................................. 203 Gear Position Switch ................................................. 204 RPM Limiter .............................................................. 205 EFI Diagnostic System .............................................. 205 Troubleshooting ......................................................... 210 Drive System/Brake System .......................................211 Front Drive Actuator/Differential Lock........................ 211 Front Differential ........................................................ 212 Drive Axles ................................................................ 224 Rear Gear Case ........................................................ 227 Hub............................................................................ 231 Hand Brake Lever/Master Cylinder Assembly ........... 232 Hydraulic Brake Caliper............................................. 233 Troubleshooting Drive System................................... 236 Troubleshooting Brake System.................................. 237 Suspension...................................................................238 Shock Absorbers ....................................................... 238 Front A-Arms ............................................................. 239 Rear A-Arms ............................................................. 241 Wheels and Tires ...................................................... 243 Troubleshooting ......................................................... 244

2 General Information NOTE: Some photographs and illustrations used in this manual are used for clarity purposes only and are not designed to depict actual conditions. NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is necessary. General Specifications Specifications subject to change without notice. * One inch below plug threads. ** At the plug threads. Torque Specifications * w/Blue Loctite #243 ** w/Red Loctite #271 *** w/Green Loctite #609 **** w/Three Bond Sealant ***** w/ “Patch-Lock” MISCELLANY Tire Size (Mud Pro) (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) - FIS/Mud Pro 0.49 kg/cm² (7 psi) - TRV Spark Plug Type NGK CR7E (500) NGK CPR8E (550/700/1000) Spark Plug Gap 0.7-0.8 mm (0.028-0.031 in.) - 500 0.5-0.6 mm (0.019-0.024 in.) - 550/700/1000 Gas Tank Capacity 21.6 L (5.7 U.S. gal.) - FIS 21.9 L (5.8 U.S. gal.) - TBX 20.1 L (5.3 U.S. gal.) - TRV Coolant Capacity 2.9 L (3.0 U.S. qt) - 500/550/700 3.3 L (3.5 U.S. qt) - 1000 Rear Drive Capacity 250 ml (8.5 fl oz)* Front Differential Capacity 275 ml (9.3 fl oz)** Engine Oil Capacity (approx) (500) (550/700) (1000) 2.8 L (3.0 U.S. qt) - Overhaul 2.5 L (2.6 U.S. qt) - Change 2.5 L (2.6 U.S. qt) - Overhaul 1.9 L (2.0 U.S. qt) - Change 2.6 L (2.75 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) 28.5 mm (1.12 in.) - 500/550/700 35.6 mm (1.40 in.) - 1000 Brake Fluid DOT 4 Taillight/Brakelight 12V/8W/27W Headlight 12V/37W (2) - 500/550/700 12V/27W (2) - 1000 ELECTRICAL SYSTEM Ignition Timing 10° BTDC @ 1500 RPM Spark Plug Cap 4000-6000 ohms Ignition Coil Resistance (primary) (secondary) Less than 5.0 ohms - 500/550/700 4.8 ohms - 1000 12k-19k ohms Ignition Coil Primary Voltage Battery Voltage Stator Coil (crankshaft position sensor) Resistance (AC generator) 104-156 ohms Less than 1 ohm Crankshaft Position Sensor AC Voltage 2.0 volts or more AC Generator Output (no load) 75 AC volts @ 5000 RPM EXHAUST COMPONENTS Part Part Bolted To Torque ft-lb N-m Exhaust Pipe Engine 20 27 Spark Arrester Muffler 48 in.-lb 5.5 O 2 Sensor Muffler 19 26 ELECTRICAL COMPONENTS Coil Air Filter Housing 7 10 STEERING COMPONENTS Bearing Housing Frame 20 27 Bearing Flange Frame 20 27 Steering Post Support Frame 20 27 Tie Rod End Knuckle/Steering Post 30 41 Jam Nut Tie Rod 35 47 EPS Housing Frame 35 47 BRAKE COMPONENTS Brake Disc* Hub 15 20 Brake Hose Caliper/Cylinder 20 27 Master Cylinder Frame 12 16 Caliper***** Knuckle 20 27 CHASSIS COMPONENTS Brake Pedal Pedal Axle 25 34 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 Ball Joint 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 DRIVE TRAIN COMPONENTS Front Differential Frame/Differential Bracket 38 52 Oil Fill Plug Front Differential/Rear Drive 16 22 Wheel (Steel) Hub 40 54 Wheel (Aluminum) Hub 80 108 Rear Gear Case Frame 38 52 Hub Shaft/Axle 200 272 Oil Drain Plug Front Differential/Rear Drive 45 in.-lb 5 Pinion Housing Differential Housing 23 31 Differential Housing Cover*** Differential Housing 23 31 Input Shaft Assembly Differential Housing 23 31 Thrust Button** Gear Case Cover 8 11 Input Shaft/Housing Gear Case 23 31 Output Shaft** Rear Gear Case Flange 20 27 Bead Lock Wheel 13 17

3 * w/Blue Loctite #243 ** w/Red Loctite #271 *** w/Green Loctite #609 **** w/Three Bond Sealant Torque Conversions (ft-lb/N-m) ENGINE/TRANSMISSION Part Part Bolted To Torque ft-lb N-m Clutch Shoe** (500) Crankshaft 147 199 Clutch Shoe** (550/700/1000) Crankshaft 221 300 Driven Pulley** (500) Driveshaft 147 199 Driven Pulley** (700/1000) Driveshaft 162 220 Driven Pulley** (550) Driveshaft 60 81 Ground Wire Engine 8 11 Magneto Cover Crankcase 9.5 13 Speed Sensor Housing (550/700/1000) Crankcase 8.5 11.5 Oil Drain Plug Engine 20 27 Clutch Cover/Housing Crankcase 9.5 13 Cam Sprocket** Camshaft 10 14 Cylinder Crankcase 8 11 V-Belt Cover Clutch Cover/Housing 10 14 Movable Drive Face (500) Centrifugal Clutch Housing 147 199 Movable Drive Face (550/700/1000) Centrifugal Clutch Housing 165 224 Starter Clutch** Flywheel 26 35 Output Shaft Nut** Output Shaft 59 80 Output Yoke Nut** (550/700/1000) Output Shaft 200 270 Valve Cover Cylinder Head 8.5 11.5 Stator Coil (New) Magneto Cover 13 18 Stator Coil (Existing) Magneto Cover 11.5 15 Oil Strainer Cap Crankcase 10 14 Tappet Cover Valve Cover 8.5 11.5 Rotor/Flywheel Crankshaft 107 145 Oil Pump** (500/550/700) Crankcase 8.5 11.5 Water Pump/Housing (500/550/700) Magneto Cover 8 11 Crankcase Half (6 mm) Crankcase Half 10 14 Crankcase Half (8 mm) Crankcase Half 21 28 Cylinder Head (Cap Screw) (500) Crankcase 28 38 Cylinder Head (Cap Screw) (550/700/1000) Crankcase 40 54 Cylinder Head (Nut) (500) Cylinder 20 27 Cylinder Head Nut (6 mm) (550/700/1000) Cylinder 8.5 11.5 Cylinder Head Nut (8 mm) (550/700/1000) Cylinder 21 28 Shift Cam Stopper (550/700/1000) Crankcase 8 11 Starter Motor Crankcase 10 14 Engine (TRV) Engine Cradle 40 54 Engine Cradle (TRV)** Rubber Mount 25 34 Rubber Mount (TRV) Frame Bracket 35 47 Shift Cam Plate Shift Cam Shaft 8 11 ENGINE/TRANSMISSION (500) Oil Pump Drive Gear** Crankshaft 63 85 Cam Chain Tensioner Guide Cylinder Head 11 15 Cam Chain Tensioner Cylinder 10 14 Water Pump Drive Gear Crankshaft 28 38 Engine Mounting Through-Bolt Frame 35 47 Water Pump Cover Water Pump Housing 8 11 ENGINE/TRANSMISSION (550/700) Part Part Bolted To Torque ft-lb N-m Crankshaft Bushing Crankshaft 25 34 Oil Pump Drive Gear** Crank Balancer Shaft 63 85 Outer Magneto Cover Left-Side Cover 10 14 Secondary Shaft Bearing Housing Crankcase Half 28 38 Engine Mounting Through-Bolt Frame 40 54 ENGINE/TRANSMISSION (1000) Crankcase Lower Cover (6 mm) Crankcase 10 14 Crankcase Lower Cover (8 mm) Crankcase 21 28 Oil Filler Cover Crankcase 8 11 V-Belt Housing Crankcase 8 11 Intake Manifold Cylinder 8 11 Oil Pump Cover* Crankcase 8 11 Shift Cam Stopper Spring Shift Cam Stopper 8 11 Shifter Housing Crankcase 8 11 Secondary Drive Gear Nut Gear 74 100 Engine Mount (Rear) Frame 45 61 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

4 Gasoline - Oil - Lubricant RECOMMENDED GASOLINE The recommended gasoline to use is 87 minimum octane regular unleaded. In many areas, oxygenates are added to the gasoline. Oxygenated gasolines containing up to 10% ethanol or 5% methane 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 which has been specifically formu- lated 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 certi- fied 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. 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. 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. 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 castor-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 gasoline 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. CAUTION If the interior of the air filter housing is dirty, clean the area before starting the engine.

5 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(s). Clean or replace as necessary. CAUTION Avoid storing outside in direct sunlight and avoid using a plastic cover as moisture will collect on the ATV causing 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.

6 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. 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. FI515 CD747 GZ019 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 wring 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. Description p/n Compression Tester Kit 0444-213 Oil Filter Wrench 0644-389 Spanner Wrench 0444-240 Valve Clearance Adjuster 0444-255 500 550/700 1000

7 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 water/oil and for proper sealing. FI704A 2. Replace any drain that is cracked or shows any signs of hardening or deterioration. 3. Wipe any accumulation of oil or gas from the filter housing and drains. Valve/Tappet Clearance To check and adjust valve/tappet clearance, use the following procedure. 1. Remove the timing inspection plug; then remove the tappet covers and spark plug(s) (for more detailed information, see Engine/Transmission - Servicing Top-Side Components). NOTE: On the 1000 models, remove the crankshaft end cap and install the special cap screw (left-hand threads) to rotate the engine. 2. Rotate the crankshaft to the TDC position on the compression stroke (front cylinder on the 1000 models). GZ063 NOTE: At this point, the rocker arms and adjuster screws must not have pressure on them. Feeler Gauge Procedure A. Using a feeler gauge, check each valve/tappet clearance. If clearance is not within specifications, loosen the jam nut and rotate the tappet adjuster screw until the clearance is within specifications. Tighten each jam nut securely after completing the adjustment. CC007D B. On the 1000 models, rotate the engine 270° to the TDC position of the rear cylinder; then repeat step A. 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. CAUTION The drain to the right is the clean air section of the filter housing. Any leak of this drain will allow dirt into the engine intake causing severe engine damage. CAUTION The feeler gauge must be positioned at the same angle as the valve and valve adjuster for an accurate measure- ment of clearance. Failure to measure the valve clearance accurately could cause valve component damage. VALVE/TAPPET CLEARANCE 500 0.08-0.12 mm (0.003-0.005 in.) - Intake 0.15-0.20 mm (0.006-0.008 in.) - Exhaust 550/700/1000 0.08-0.12 mm (0.003-0.005 in.) - Intake 0.13-0.17 mm (0.005-0.007 in.) - Exhaust

8 GZ059 Valve Adjuster Procedure NOTE: The seat, storage compartment cover assembly, compartment box, air filter/filter housing, and left-side/right-side splash panels must be removed for this procedure. A. Place Valve Clearance Adjuster onto the jam nut securing the tappet adjuster screw; then rotate the valve adjuster dial clockwise until the end is seated in the tappet adjuster screw. B. While holding the valve adjuster dial in place, use the valve adjuster handle and loosen the jam nut; then rotate the tappet adjuster screw clockwise until friction is felt. C. Align the valve adjuster handle with one of the marks on the valve adjuster dial. D. While holding the valve adjuster handle in place, rotate the valve adjuster dial counterclockwise until proper valve/tappet clearance is attained. NOTE: Refer to the appropriate specifications in Feeler Gauge Procedure sub-section for the proper valve/tappet clearance. NOTE: Rotating the valve adjuster dial counterclockwise will open the valve/tappet clearance by 0.05 mm (0.002 in.) per mark. E. While holding the adjuster dial at the proper clearance setting, tighten the jam nut securely with the valve adjuster handle. F. Rotate the engine 270° to the TDC position of the rear cylinder; then repeat steps A-E for the rear cylinder. 3. Install the timing inspection plug; then on the 1000 models, remove the cap screw and install the crankcase end cap. 4. Place the tappet covers into position making sure the proper cap screws are with the proper cover. Tighten the cap screws securely. 5. Install the spark plug(s). Testing Engine Compression To test engine compression, use the following procedure. 1. Remove the high tension lead(s) from the spark plug(s). 2. Using compressed air, blow any debris from around the spark plug(s). 3. Remove the spark plug(s); then attach the high tension lead(s) to the plug(s) and ground the plug(s) on the cylinder head(s) well away from the spark plug hole(s). 4. Attach the Compression Tester Kit. NOTE: The engine should be warm (operating temperature) and the battery fully charged for an accurate compression test. Throttle must be in the wide-open throttle (WOT) position. In the event the engine cannot be run, cold values are included. 5. While holding the throttle lever in the full-open position, crank the engine over with the electric starter until the gauge shows a peak reading (five to 10 compression strokes). 6. If compression is abnormally low, inspect the following items. A. Verify starter cranks engine over at normal speed (approximately 400 RPM). B. Gauge functioning properly. C. Throttle lever in the full-open position. D. Valve/tappet clearance correct. E. Engine warmed up. F. Intake not restricted. NOTE: To service valves, see Engine/Transmission. 7. Pour 29.5 ml (1 fl oz) of oil into the spark plug hole, reattach the gauge, and retest compression. 8. If compression is now evident, service the piston rings (see Engine/Transmission). ! WARNING Always wear safety glasses when using compressed air. COMPRESSION Model PSI Hot (WOT) PSI Cold (WOT) 500 95-115 N/A 550 120-140 80-120 700 125-145 100-140 1000 (Front) 125-145 80-120 1000 (Rear) 165-185 150-190

2014-2015 Arctic Cat 500 550 700 1000 Mud Pro TRV ATV Service & Repair Manual

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