2009 Arctic Cat ATV 400 TRV, 500, 550, 700, 1000 Thundercat Service Manual (P/N 2258-380)

• Model coverage: 2009 Arctic Cat 400 TRV; 500 Automatic and 500 Manual; 550 H1 TRV; 700 H1 EFI; 550/700 H1 Cruiser; and 1000 H2 Thundercat and H2 Cruiser configurations.
• Separate engine/transmission chapters cover the 400, 500 Automatic/H1, 500 Manual, and H2 layouts, including engine removal and installation, top-end repair, cam timing, piston and valve service, crankcase separation, internal inspection, and reassembly.
• Transmission content distinguishes the 500 manual clutch and multi-speed geartrain from the automatic/H1/H2 drive and driven pulleys, centrifugal and one-way clutches, V-belt, recoil starter, output shafts, and internal bevel-drive setup.
• Fuel, lubrication, and cooling procedures include 400/500 Keihin carburetor service, H1/H2 electronic fuel injection and throttle-body work, fuel-pump testing, oil-pressure checks, oil-cooler service, and model-specific radiator, thermostat, fan, and water-pump repair.
• Electrical diagnosis covers CDI-equipped 400/500 models and ECU-controlled EFI models, with component-level multimeter and peak-voltage tests, sensor and actuator checks, ECU error-code retrieval and clearing, ignition-timing verification, and TPS adjustment.
• Drive-system and chassis work spans the front differential and electronic differential lock, drive axles and CV boots, rear gear case, hubs, hydraulic calipers, brake bleeding and pad burnishing, shocks, A-arms, steering post and tie rods, steering knuckles, and toe-in adjustment.

This 349-page PDF contains the English-language Arctic Cat factory service content copyrighted in August 2008. Arctic Cat describes the manual as designed to aid service personnel. Its overhaul depth and reliance on dedicated pullers, compressors, test equipment, and precision measuring tools make it best suited to service technicians and experienced owners with established workshop skills.

Repair Depth by Configuration

The engine section is organized around the actual powertrain variants rather than one generic procedure. It shows which top-side, left-side, and right-side repairs can be completed with the engine in the frame and when center-crankcase work requires complete engine/transmission removal. Coverage extends through cylinder-head and valve inspection, piston and ring service, camshaft and rocker-arm checks, starter and magneto components, oil-pump service, gear-train inspection, bearing and seal replacement, crankshaft work, and final installation checks.

Automatic and manual transmissions receive distinct treatment. The manual-transmission chapter follows the clutch, shift forks, shift cam, countershaft, driveshaft, reverse gearing, and output shaft through disassembly, inspection, and assembly. Automatic and H1/H2 procedures cover CVT components plus the internal transmission and bevel-drive assemblies. Backlash, tooth contact, and shim-selection charts support repairs where correct gear mesh matters.

Factory Diagnostics, Tools, and Visual References

EFI diagnosis goes beyond a basic fault list. The manual identifies active and stored ECU codes for the CKP, APS/MAP, TPS, ECT, IAT, tilt, injector, ignition-coil, ISC, fuel-pump relay, cooling-fan relay, ECU power, and H2 communication circuits. It also documents the factory diagnostic-connector workflow and the post-repair code-clearing check.

Named service equipment includes the Crankcase Separator/Crankshaft Remover 0444-009, Driven Pulley Compressors 0444-121 and 0444-140, Oil Pressure Test Kit 0644-495, Diagnostic Harness 0486-219, Test Plug/Error Code List 0444-216, and Pinion Gear/Shaft Removal Tool 0444-127. Visual support includes the 400/500 carburetor schematic; keyed assembly views for the water pump, clutch/oil-pump group, and manual-transmission crankcase geartrain; cam-timing alignment views; and bevel-gear tooth-contact illustrations with correction charts.

Model-specific tables supply component torque specifications, fluid capacities and lubricant requirements, valve and engine clearances, inspection and wear limits, compression data, clutch and gear measurements, gearcase setup values, carburetor adjustments, and electrical resistance, peak-voltage, and charging-system test specifications.

Important Scope and Shop Cautions

The manual flags direction-sensitive transmission dogs, gears, and bushings; a reversed component or missed oil-port alignment can cause shift malfunction or severe engine damage. It also warns that unsupported axles can damage inner CV joints and that brake calipers must not hang from their hoses.

The foreword directs Y-12, T-14, DVX 300/250 Utility, and 366 service to separate publications; 700 Mud Pro-specific work requires the separate supplement. This volume provides electrical fault-isolation procedures and connector/test-point guidance, but it does not contain a separate wiring-diagram section. Frame coverage includes crack and weld inspection plus body and rack removal, not frame-welding standards.

Fuel-system service, spring-loaded clutch and recoil assemblies, hydraulic brakes, and work beneath a raised ATV carry model-specific safety warnings. Proper support equipment, eye protection, fuel-handling precautions, and the specified brake fluid and lubricants are required before repair work begins.