Arctic Cat 400, 500, 650, 700, 700 H1 ATV 2008 Workshop Service Manual

This 425-page PDF is the July 2007 Arctic Cat service publication for the covered 2008 ATV range. Arctic Cat designed the manual to aid service personnel; its internal engine work, transmission setup, and electrical testing assume an experienced technician with suitable measuring equipment and the special tools identified in the book.

• Covers 2008 Arctic Cat 400, 500, 650, and 700 ATVs, including 400 and 500 manual- and automatic-transmission versions, 650 H1, 700 EFI, and 700 H1 EFI. Applicable 500, 650 H1, and 700 EFI TRV details are identified in the maintenance and chassis material.
• Breaks engine repair into model-specific removal and installation, top-side, left-side, right-side, and center-crankcase procedures, with valve train, cam timing, cylinder, piston, crankshaft, balancer, transmission-shaft, gear, and shift-fork inspection.
• Details manual-transmission clutch service and automatic V-belt drive repair, including primary and centrifugal clutches, one-way drives, drive and driven pulleys, V-belt replacement, oil-pump inspection, and final adjustment checks.
• Separates carburetor, EFI, lubrication, and cooling work: carburetor disassembly and setup, throttle-body removal, electric and vacuum-pulse fuel-pump testing, oil-pressure diagnosis, 400 oil-cooler service, and liquid-cooled radiator, thermostat, fan, and water-pump procedures.
• Provides component-level electrical diagnosis for CDI and ECU systems, stator and CKP circuits, EFI sensors, starter and charging systems, the power distribution module and relays, front-drive controls, ECU error codes, and TPS testing and adjustment.
• Follows the driveline through front-drive actuator service, differential and pinion teardown, shim selection, backlash and tooth-contact checks, CV axle and boot repair, rear gear case removal, hubs, hydraulic brakes, A-arms, steering knuckles, and toe-in adjustment.
• Supplies model-specific torque tables, fluid and lubricant data, maintenance intervals, engine and clutch wear limits, gear-case setup specifications, electrical test values, troubleshooting charts, and storage procedures.

Model-Specific Powertrain Detail

The powertrain material is not a single generic procedure reused for every engine. The 400 and 500 each receive separate manual- and automatic-transmission repair sequences. H1 work is grouped with the 500 automatic section where construction overlaps, while the 700 EFI has its own engine/transmission teardown and assembly sequence. Top-side and side-cover work can often be performed in the frame; center-crankcase service requires engine/transmission removal.

The listed shop tools show the intended repair depth. Examples include the Clutch Sleeve Hub Holder P/N 0444-007, Crankcase Separator/Crankshaft Remover P/N 0444-009, Driven Pulley Compressors P/N 0444-121 and 0444-140, and Piston Pin Puller P/N 0644-328. The 700 EFI also differs from the other covered engines because its rotor/flywheel has no timing marks, so the manual’s normal ignition-timing verification does not apply to that version.

Diagnostics, Charts, and Reference Views

Carbureted applications use a Keihin CVK34 on the 400 and a Keihin CVK36 on the 500 and 650 H1; the EFI sections cover the throttle body, electric fuel pump and level sensor, APS, IAT, ECT, tilt sensor, injector, ISC valve, and TPS. EFI fault work uses the Diagnostic Harness P/N 0486-219 and Test Plug/Error Code List Kit P/N 0444-216, with separate active/stored-code behavior identified for the 700 H1 EFI.

Useful visual references include the exploded Carburetor Schematics, model-specific Oil Flow Charts, the 700 EFI Exhaust Chart and Intake Chart for tappet-shim selection, differential tooth-contact illustrations, and the ECU Error Code List. Electrical coverage is built around connector checks, component tests, peak-voltage and resistance specifications, and fault isolation; this PDF is not a separate full-vehicle wiring-diagram set.

Repair Cautions and Scope

The cautions are specific to the assemblies being repaired. On applicable manual-transmission engines, misaligning a driveshaft bushing’s oil-feed hole with the shaft oil port can cause serious engine damage. During 700 EFI top-end work, losing the cam-chain idler shim into the engine or rotating the engine with the cam chain loose can also damage internal parts.

Engine, axle, suspension, fuel-system, and hydraulic-brake work requires secure vehicle support and the fuel-system and brake-fluid precautions stated in the manual. The publication directs the 2008 Y-12, DVX/Utility 250, 366, DVX 400, 700 Diesel, and Thundercat to separate service manuals, so it should not be selected for those machines.