2008 Arctic Cat 700 Diesel ATV Factory Service & Repair Manual

This Arctic Cat service manual covers maintenance, troubleshooting, and repair of the 2008 700 Diesel ATV, including its Lombardini unit-injector fuel system and V-belt drivetrain.

• Diesel engine: Engine removal, cylinder-head and crankshaft service, camshaft and rocker-arm inspection, speed-governor service, and timing-belt replacement.

• Fuel system: Unit-injector removal and installation, static injector timing, lift-pump replacement, fuel-filter service, and fuel-shutoff solenoid diagnosis.

• Transmission and final drive: Gear-case disassembly, countershaft and shift-fork inspection, front differential and rear gear-case shimming, and drive-axle boot replacement.

• Lubrication and cooling: Oil-pressure testing, thermostat checks, radiator service, coolant filling and bleeding, and oil-pump and water-pump replacement.

• Electrical diagnosis: Glow-plug controller and ECT thermistor tests, starter and charging-circuit checks, front-drive actuator diagnosis, and the main-harness wiring diagram.

• Brakes and chassis: Hydraulic brake bleeding, caliper replacement, shock-absorber and A-arm inspection, steering-knuckle service, tie-rod work, and toe-in adjustment.

This manual suits technicians familiar with diesel engines and precision measurement, with access to the specialized timing tools and workshop equipment specified for the work.

Engine and Injection Service

The content moves from routine V-belt inspection, throttle-cable adjustment, and fuel-filter replacement to top-side and center-component engine repair. The Periodic Maintenance Chart organizes scheduled work, while component photographs accompany disassembly and assembly procedures.

Internal engine work: Piston and ring inspection, connecting-rod and main-bearing measurements, and cylinder-head service are covered. The piston-protrusion table relates measured height to head-gasket thickness and identification holes; the head-bolt tightening pattern and staged torque/angle procedure are also illustrated.

The manual distinguishes work possible with the engine in the frame from cylinder-head and crankcase repairs requiring removal. It also describes removing the transmission separately, helping a shop plan the necessary disassembly before starting.

Injector service limits: The unit-injector section covers removal, installation, seating checks, and static timing. Internal injector servicing is assigned to a qualified diesel-injection facility with special instruments, training, and a clean room.

Specified equipment includes Fuel Injector Timing Tool P/N 0444-234 and Timing Belt Tensioning Tool P/N 0444-231. The timing procedures warn that incorrect camshaft and crankshaft positioning can cause piston-to-valve contact and severe valve damage.

Transmission, Differential, and Axle Repair

Transmission procedures address the high/low and reverse gear assemblies, shift dogs, countershaft, and output-drive components. Final-drive coverage includes pinion bearings, axle seals, differential-lock components, and shim selection with backlash and end-play checks.

Front differential and rear gear-case instructions distinguish lock-collar thread direction and shimming requirements. Drive-axle procedures cover inner-joint disassembly and boot replacement, with a specific warning that an unsupported hanging axle can damage the inner CV joint.

Brake, Suspension, and Steering Work

Brake coverage includes pad inspection, hydraulic bleeding, and caliper removal and replacement. The caliper and master cylinder are replacement assemblies; internal rebuilding is not covered.

Shock-absorber work includes spring removal and inspection of rods, bodies, bushings, and mounts. Steering and suspension procedures extend to A-arm ball joints, knuckle bearings, tie rods, and front-wheel alignment.

Cooling Checks and Electrical Fault Tracing

Oil-pressure testing includes diagnostic notes on abnormal readings, and an engine-oil viscosity chart accompanies the lubricant recommendations. Cooling procedures cover thermostat testing and coolant air removal; the oil and water pumps are treated as replacement assemblies.

Electrical tests identify connector wires and expected readings for the glow-plug controller, fuel solenoid, starter interlocks, and selectable front drive. The main-harness diagram and Battery Charging Chart support these checks.

Engine troubleshooting charts separate starting faults with smoke from those without smoke, helping distinguish glow-plug or compression problems from interrupted fuel delivery.

Diesel injection, brake work, and lifted-vehicle repairs require the safety precautions and support equipment specified in the manual.

A Preview of Valve and Oil-Pressure Specifications

These examples show a small part of the engine adjustment and test data in the manual. Cold-engine valve clearance is listed as 0.20 mm (0.008 in.) for both intake and exhaust.

For the oil-pressure test, the minimum is 1.1 kg/cm² (15.6 psi) at 900 RPM with the oil at 120°C (248°F). The testing section relates out-of-range readings to possible lubrication-system faults.

Searchable Service Text and Bookmarked PDF Sections

Search, navigation, and wiring detail: The text sections are searchable, and embedded bookmarks link to all nine service sections and the wiring diagram. The final wiring page has no searchable text; its small pin numbers and wire labels are readable when enlarged.

Supplied as one printable, 180-page PDF: 178 numbered service pages, one opening contents page, and one appended wiring-diagram page. Both unnumbered pages are included in the total.