Arctic Cat 500/700, 700/1000 Mud Pro & 1000 LTD — 2013 ATV Service Manual (P/N 2259-527)

Arctic Cat’s October 2012 service manual, P/N 2259-527, covers the 2013 500 and 700 ATVs, 700/1000 Mud Pro, and 1000 LTD. FIS, TBX, TRV, and TRV LTD information applies to the sections and configurations identified in the manual; the foreword directs 550/1000 FIS owners to a separate service manual.

Searchable Service Text and Appended Wiring Diagrams

Search, bookmarks, and diagram detail: Service text supports PDF searches, and embedded bookmarks navigate the chapters and many individual procedures. The appended wiring diagrams have searchable headings, but their internal labels are not text-searchable. Small connector and wire labels require zooming, and some remain blurred when enlarged.

One printable, English-language 270-page PDF contains the 266-page service manual and four appended wiring-diagram pages. The total includes the front and back covers, front matter, two blank pages, and three notes pages.

Engine, EFI, and Driveline Service

These selected service topics show the manual’s coverage without reproducing its complete contents. Additional subjects include storage preparation and headlight aiming.

• Engine and transmission: Step-by-step procedures cover engine removal, top-end repair, crankcase separation, countershaft assembly, centrifugal-clutch inspection, and CVT belt replacement.

• Fuel, lubrication, and cooling: EFI troubleshooting, fuel-pump pressure testing, oil-pressure checks, radiator service, thermostat inspection, and water-pump replacement.

• Electrical diagnosis: Ignition, charging, starter, and sensor tests accompany Power Distribution Module (PDM) checks, EPS fault charts, and main-harness wiring diagrams.

• Final drive: Front differential disassembly, bevel-gear shimming, backlash and end-play adjustment, drive-axle removal, and rear gear-case service.

• Hydraulic brakes: Main and auxiliary brake bleeding, pad inspection, master-cylinder replacement, and brake-caliper disassembly, inspection, and reassembly.

• Suspension and steering: Shock absorber and A-arm service, ball-joint replacement, steering-knuckle inspection, tie-rod service, and toe-out adjustment.

• Maintenance and specifications: A Periodic Maintenance Chart accompanies compression testing, valve/tappet adjustment, component torque tables, wear limits, and torque-conversion charts.

Written for service personnel, this manual assumes familiarity with ATV systems and access to the specified measuring equipment and special tools.

Engine Repair and CVT Service Limits

Separate engine/transmission sections distinguish the 500, 700, and 1000 procedures. Inspection coverage includes piston and cylinder measurements, valve guides, camshaft journals, crankshaft runout, and transmission components, with crankcase assembly torque sequences and illustrated component layouts.

The in-frame service notes help technicians plan the extent of disassembly. On the 1000, servicing the rear cylinder head, cylinder, or piston requires engine removal, while the front top-end procedures can be performed in the frame.

Clutch and assembly details: The centrifugal-clutch retaining nut has left-hand threads. The manual also warns that incorrect drive-face spline engagement can produce a false torque reading and damage the shaft or face plate; the driven pulley is treated as a replacement assembly.

Special-tool listings identify the Crankcase Separator/Crankshaft Remover, P/N 0444-152, and Magneto Rotor Remover Set, P/N 0444-254.

Fuel Pressure and Cooling-System Checks

Fuel-pump testing distinguishes missing electrical supply from a pump that receives power but does not operate. Fuel-level sensor checks, throttle-body removal, and oil-pressure diagnosis provide further fault-finding coverage.

Cooling procedures include radiator and fan removal, thermostat testing, and separate water-pump replacement instructions for the 500 and 1000. The 1000 also has an oil-cooler service section.

EFI Diagnostics and EPS Fault Isolation

The electrical tests provide reference voltages and resistance values for checking the stator, gear-position switch, and related circuits before selecting replacement components. The LCD gauge’s diagnostic modes display coolant temperature, fuel-sensor output, throttle position, engine speed, and charging-system information.

TPS adjustment: The 500 procedure differs from the 700/1000 TRV/1000 Mud Pro procedure. Adjustment uses a TPS Analyzer Tool, its harness, and a multimeter—not a multimeter alone.

The DTC chart connects faults to ECM pins and clearing conditions. Supporting references include gear-position-switch pin assignments, fuse-layout illustrations, and main-harness diagrams for the 1000 Mud Pro/1000 TRV LTD and the listed 700 configurations.

EPS limits: Troubleshooting covers supply power, relays, wiring, and engine- and vehicle-speed signals. The EPS assembly, including its internal torque-sensing components, is not internally serviceable; the manual warns that disassembly can damage it.

Differential, Brake, and Chassis Work

Tooth-contact illustrations and shim-correction charts support secondary-gear setup. The 700 Mud Pro/1000 rear-drive section also covers the shock-limiting clutch arrangement; a damaged clutch pack is replaced as a unit.

Axle removal and installation are documented, but internal axle disassembly refers to the appropriate boot repair kit’s instructions. Brake-caliper rebuilding is covered, while the hand-brake master cylinder is replaced as an assembly. Arctic Cat recommends hydraulic brake service by authorized dealers.

Chassis procedures distinguish steering systems with and without EPS. TRV seat removal and TBX cargo-box and side-storage-box procedures address configuration-specific access and bodywork.

Sample Valve-Clearance and Engine-Mount Specifications

The 500 engine specification table lists a cold intake valve/tappet clearance of 0.08–0.12 mm, alongside the corresponding inspection and adjustment procedures.

Engine-mount specifications distinguish the models: through-bolts are listed at 47 N-m for the 500 and 54 N-m for the 700. The 1000 rear engine-mount specification is 61 N-m, with its installation procedure specifying 45 ft-lb for the mounting through-bolt flange nuts.