Arctic Cat 1000 Thundercat 2009 Factory Service Repair Manual

TABLE OF CONTENTS Click on the blue text to go. Section 1. General Information/Specifications 2. Periodic Maintenance 3. Engine/Transmission 4. Fuel/Lubrication/Cooling 5. Electrical System 6. Drive System 7. Suspension 8. Steering/Frame 9. Controls/Indicators 1 2 3 4 5 6 7 8 9

1-1 1 SECTION 1 - GENERAL INFORMATION/ SPECIFICATIONS TABLE OF CONTENTS General Specifications ............................................ 1-2 Torque Specifications .............................................. 1-3 Torque Conversions (ft-lb/N-m) ............................... 1-6 Tightening Torque (General Bolts) .......................... 1-6 Break-In Procedure ................................................. 1-6 Gasoline - Oil - Lubricant ........................................ 1-6 Genuine Parts ......................................................... 1-7 Preparation For Storage .......................................... 1-7 Preparation After Storage........................................ 1-8 Back to TOC

1-2 General Specifications* * Specifications subject to change without notice. ** One inch below plug threads. *** At the plug threads. 400 TRV 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) 20.8 L (5.5 U.S. gal.) Rear Drive Capacity 250 ml (8.5 fl oz)** Front Differential Capacity 275 ml (9.3 fl oz)*** Engine Oil Capacity 3.3 L (3.5 U.S. qt) - Overhaul 2.8 L (3.0 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.) Brake Fluid DOT 4 Taillight/Brakelight 12V/8W/27W Headlight 12V/37W (2) 500 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) - Manual 2.5 L (2.6 U.S. qt) - Automatic 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 (Automatic) (minimum) 38 mm (1.33 in.) Brake Fluid DOT 4 Taillight/Brakelight 12V/8W/27W Headlight 12V/27W (2) H1 Models 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/Cruiser 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) - 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) H2 Models 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.) - Cruiser Coolant Capacity 3.3 L (3.5 U.S. qt) Differential Capacity 275 ml (9.3 fl oz)** Rear Drive Capacity 250 ml (8.5 fl oz)*** Engine Oil Capacity 2.8 L (3.0 U.S. qt) Gasoline (recommended) 87 Octane Regular Unleaded Engine Oil (recommended) Arctic Cat ACX All Weather (Synthetic) Front 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

1-3 1 Torque Specifications * w/Blue Loctite #243 ** w/Red Loctite #271 *** w/Green Loctite #609 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 (500)* Frame 12 16 Coil (EFI Models) 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 BRAKE COMPONENTS Brake Disc* Hub 15 20 Brake Hose Caliper 20 27 Brake Hose Master Cylinder 20 27 Brake Hose Auxiliary Brake Cylinder 20 27 Master Cylinder (Rear) Frame 12 16 Hydraulic Caliper Knuckle 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 (400/500/H1 Models) Frame 35 47 A-Arm (H2 Models) Frame 50 68 Knuckle Ball Joint 35 47 Shock Absorber Frame 35 47 Shock Absorber Upper A-Arm 35 47 Knuckle A-Arm 35 47 SUSPENSION COMPONENTS (Rear) Shock Absorber (Upper) Frame 35 47 Shock Absorber (Upper) (H2 Models) Frame 50 68 Shock Absorber (Lower) Lower A-Arm 20 27 A-Arm Frame 35 47 A-Arm (H2 Models) Frame 50 68 Knuckle A-Arm 35 47 Knuckle (H2 Models) A-Arm 50 68 DRIVE TRAIN COMPONENTS (400 TRV) Part Part Bolted To Torque ft-lb N-m Engine Mounting Through-Bolt Frame 38 52 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 59 80 Driven Bevel Gear Nut** Driven Shaft 59 80 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 20 27 Rear Drive Input Shaft/Housing Differential Housing 23 31 Wheel Hub 40 54 Rear Drive Gear Case Frame 38 52 Engine Output Shaft** Rear Gear Case Input Flange 20 27 DRIVE TRAIN COMPONENTS (500 - Manual Transmission) Engine (Lower Rear/Front) Frame 40 54 Front Differential Frame/Differential Bracket 38 52 Pinion Housing Differential Housing 23 31 Differential Housing Cover*** Differential Housing 23 31 Drive Bevel Gear Nut*** Shaft 72 98 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 Inspection Plug Front Differential/ Rear Drive 48 in.-lb 5.5 Wheel Hub 40 54 Rear Drive Input Shaft/Housing Differential Housing 23 31 Rear Drive Gear Case Frame 45 61 Engine Output Shaft** Rear Gear Case Input Flange 20 27 Back to TOC Back to Section TOC Next Back

1-4 * w/Blue Loctite #243 ** w/Red Loctite #271 *** w/Green Loctite #609 DRIVE TRAIN COMPONENTS (500 - Automatic Transmission/H1 Models) 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 Hub 40 54 Rear Drive Gear Case Frame 38 52 Engine Output Shaft ** Rear Gear Case Input Flange 20 27 DRIVE TRAIN COMPONENTS (H2 Models) Engine Mount (Rear) Frame 45 61 Front Differential Frame/Differential Bracket 38 52 Rear Gear Case Frame 38 52 Pinion Housing Differential Housing 23 31 Differential Housing Cover*** Differential Housing 23 31 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 Wheel Hub 40 54 Rear Drive Input Shaft/ Housing Differentail Housing 23 31 Rear Output Drive Flange Rear Yoke Flange 20 27 Shift Cam Stopper Shift Stopper 8 11 Shift Cam Plate Shift Cam Shaft 8 11 Shifter Housing Crankcase 8 11 Engine Output Shaft** Rear Gear Case Input Flange 20 27 ENGINE/TRANSMISSION (400 TRV) Part Part Bolted To Torque ft-lb N-m Clutch Shoe** Crankshaft 147 199 Clutch Cover/Housing Assembly Crankcase 8 11 Left-Side Cover Crankcase 8 11 Crankcase Half (6 mm) Crankcase Half 10 13.5 Crankcase Half (8 mm) Crankcase Half 21 28 Cylinder Nut Crankcase Half 8 11 Cylinder Head (Cap Screw) Crankcase 28 38 Cylinder Head (6 mm) Cylinder 8 11 Cylinder Head (8 mm) Cylinder 20 27 Cylinder Head Cover Cylinder Head 8 11 Oil Pump Drive Gear** Crankshaft 63 86 Driven Pulley Nut** Driveshaft 147 199 Ground Cable Engine 8 11 Output Shaft Flange Nut Output Shaft 59 80 Magneto Rotor Nut Crankshaft 107 146 Cam Sprocket** Camshaft 11 15 Starter Motor Crankcase 8 11 V-Belt Cover Crankcase 8 11 Valve Adjuster Jam Nut Valve Adjuster 7 9.5 Oil Fitting Engine 8 11 Oil Pump* Crankcase 8 11 Movable Drive Face Nut** Clutch Shaft 147 199 Oil Cooler Hose Clamps Engine/Oil Cooler 30 in.-lb 3.4 ENGINE/TRANSMISSION (500 - Manual Transmission) Clutch Shoe Crankshaft 94 127 Clutch Sleeve Hub Countershaft 72 98 Crankcase Half (6 mm) Crankcase Half 8 11 Crankcase Half (8 mm) Crankcase Half 16 22 Cylinder Head (Cap Screw) Cylinder 28 38 Cylinder Head (6 mm Nut) Cylinder 8 11 Cylinder Head (8 mm Nut) Cylinder 18 24 Cylinder Head Cover Cylinder Head 7 9.5 Left-Side Cover Crankcase Half 8 11 Oil Pump Drive Gear** Crank Balancer Shaft 36 49 Oil Strainer Cap Strainer 16 22 Oil Pump* Crankcase 7 9.5 Output Shaft Gear Output Shaft 72 98 Rear Output Shaft Output Joint 20 27 Recoil Starter Left-Side Cover 6 8 Starter Motor Crankcase 8 11 Reverse Cam Stopper Housing Crankcase 16 22 Right-Side Cover Crankcase 8 11 Magneto Rotor Nut Crankshaft 116 157 Shift Stop Housing Crankcase 16 22 Cam Sprocket** Camshaft 11 15 Starter Cup Crankshaft 25 34 Movable Drive Face Nut** Driveshaft 72 98 Engine Damper Thermostat Housing 7 9.5 Back to TOC Back to Section TOC Next Back

1-5 1 * w/Blue Loctite #243 ** w/Red Loctite #271 *** w/Green Loctite #609 ENGINE/TRANSMISSION (500 - Automatic Transmission) Part Part Bolted To Torque ft-lb N-m Clutch Shoe** Crankshaft 94 127 Clutch Cover/Housing Assembly Crankcase 8 11 Crankcase Half (6 mm) Crankcase Half 8 11 Crankcase Half (8 mm) Crankcase Half 16 22 Cylinder Head (Cap Screw) Crankcase 28 38 Cylinder Head (6 mm) Cylinder 8 11 Cylinder Head (8 mm) Cylinder 18 24 Cylinder Head Cover Cylinder Head 7 9.5 Driven Pulley Nut** Driveshaft 80 110 Ground Wire Engine 8 11 Magneto Cover Crankcase 8 11 Movable Drive Face Nut** Fixed Drive Face 72 98 Oil Pump Drive Gear** Crank Balancer Shaft 36 49 Output Shaft Flange Nut Output Shaft 72 98 Recoil Starter Left-Side Cover 6 8 Magneto Rotor Nut Crankshaft 116 157 Cam Sprocket** Camshaft 10 13.5 Starter Cup Crankshaft 25 34 Starter Motor Crankcase 8 11 V-Belt Cover Crankcase 8 11 Valve Adjuster Jam Nut Valve Adjuster 7 9.5 Oil Pump Crankcase 7 9.5 Drive Pulley Nut** Clutch Shaft 80 110 ENGINE/TRANSMISSION (H1 Models) 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 (6 mm) Cylinder 8 11 Cylinder Head (8 mm) Cylinder 18 24 Cylinder Head 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 Output Yoke Nut Driven Output Shaft 74 100 ENGINE/TRANSMISSION (H2 Models) Part Part Bolted To Torque ft-lb N-m Clutch Shoe** Crankshaft 221 300 Clutch Cover/Housing Assembly Crankcase 8 11 Crankcase Half Crankcase Half 8 11 Crankcase Lower Cover (6 mm) Crankcase 8 11 Crankcase Lower Cover (8 mm) Crankcase 20 27 Cylinder Head (Cap Screw) Crankcase 40 54 Cylinder Head (6 mm) Cylinder 8 11 Cylinder Head (8 mm) Cylinder 18 24 Cylinder Head Cover Cylinder Head 8.5 11.5 Driven Pulley Nut** Driveshaft 80 108 Ground Wire Engine 8 11 Magneto Cover Crankcase 8 11 Oil Filler Cover Crankcase 8 11 Speed Sensor Housing Crankcase 8 11 Starter Motor Crankcase 8 11 V-Belt Housing Crankcase 8 11 Intake Manifold Cylinder 8 11 Output Shaft Nut Output Shaft 59 80 Rotor/Flywheel Nut Crankshaft 107 145 Cam Sprocket** Camshaft 10 13.5 V-Belt Cover Clutch Cover 8 11 Movable Drive Face Nut** Clutch Shaft 165 224 Oil Pump Cover* Crankcase 8 11 Oil Strainer Cap Crankcase 8 11 Shift Cam Stopper Crankcase 8 11 Shift Cam Stopper Spring Shift Cam Stopper 8 11 Shift Cam Plate Shift Cam Shaft 8 11 Shifter Housing Crankcase 8 11 Output Yoke Nut Driven Output Shaft 74 100 Back to TOC Back to Section TOC Next Back

1-6 Torque Conversions (ft-lb/N-m) Tightening Torque (General Bolts) 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 accelera- tions 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 pre- scribed 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. 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 Type of Bolt Thread Diameter A (mm) Tightening Torque (Conventional or 4 Marked Bolt) 5 12-36 in.-lb 6 36-60 in.-lb 8 7-11 ft-lb 10 16-25 ft-lb (7 Marked Bolt) 5 24-48 in.-lb 6 6-8 ft-lb 8 13-20 ft-lb 10 29-43 ft-lb ! CAUTION Do not use white gas. Only Arctic Cat approved gasoline additives should be used. Back to TOC Back to Section TOC Next Back

1-7 1 RECOMMENDED ENGINE/ TRANSMISSION OIL The recommended oil to use is Arctic Cat ACX All Weather synthetic engine oil, which has been specifi- cally 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 5W-50 oil is acceptable. OILCHARTI 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 differen- tials and rear drives. FILLING GAS TANK Since gasoline expands as its temperature rises, the gas tank must be filled to its rated capacity only. Expan- sion 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 appro- priate 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. 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; then stop the engine. Install the air filter and housing cover. ! 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. ! 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

1-8 4. On carbureted models, drain the carburetor float chamber. 5. Plug the exhaust hole in the exhaust system with a clean cloth. 6. Apply light oil to the upper steering post bushing and plungers of the shock absorbers. 7. 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. 8. On liquid-cooled models, fill the cooling system to the bottom of the stand pipe in the radiator neck with properly mixed coolant. 9. Disconnect the battery cables; then remove the battery, clean the battery posts and cables, and store in a clean, dry area. 10. 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 prepare 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. On liquid-cooled models, 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 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 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. Back to TOC Back to Section TOC Back

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 (Feeler Gauge Procedure) ................................... 2-4 Valve/Tappet Clearance (Valve Adjuster Procedure) (400/500/H1 Models) ........................................... 2-5 Valve/Tappet Clearance (Valve Adjuster Procedure) (H2 Models).............. 2-6 Testing Engine Compression .................................. 2-6 Spark Plug(s) .......................................................... 2-7 Muffler/Spark Arrester ............................................. 2-7 Engine/Transmission Oil - Filter - Strainer .............. 2-8 Front Differential/Rear Drive Lubricant .................. 2-10 Adjusting Clutch (500 Manual Transmission) ........ 2-11 Steering Components ........................................... 2-11 Driveshaft/Coupling ............................................... 2-11 Suspension/Shock Absorbers/Bushings ............... 2-11 Nuts/Bolts/Cap Screws.......................................... 2-12 Headlights/Taillight-Brakelight ............................... 2-12 Shift Lever ............................................................. 2-13 Frame/Welds/Racks .............................................. 2-14 Electrical Connections........................................... 2-14 Hydraulic Brake Systems ...................................... 2-14 Burnishing Brake Pads .......................................... 2-15 Checking/Replacing V-Belt (Automatic Transmission) ................................... 2-16 Back to TOC

Arctic Cat 1000 Thundercat 2009 Factory Service Repair Manual

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