Arctic Cat 700 Diesel ATV (2008) Factory Service Manual

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

Searchable Service Text and Bookmarked Sections

Text search and wiring detail: The contents and service chapters are searchable. Bookmarks link to all nine chapters and the main-harness wiring diagram. The diagram is an image, so its labels are outside text search. Zoom in to read the small connector pin numbers and wire-color codes.

The download contains one printable, 180-page English PDF, including 178 numbered service pages, the opening table of contents, and the wiring diagram at the end.

Diesel Engine, Drivetrain, and Chassis Service

These are selected topics from the manual. The maintenance chapter also covers spark arrester cleaning and shift linkage adjustment.

• 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 testing.
• 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 and water pump replacement.
• Electrical diagnosis: Glow plug controller and coolant temperature sensor 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.

The manual is written for service technicians. Engine and transmission work calls for precision measuring equipment and the special tools listed in the relevant procedures.

Engine and Injection Service

The Periodic Maintenance Chart organizes jobs such as V-belt inspection, throttle cable adjustment, and fuel filter replacement. Component photos accompany disassembly and assembly, and the torque tables cover engine, drivetrain, and chassis fasteners.

Cylinder head and crankcase: The manual distinguishes work that can be done with the engine in the frame from cylinder head and crankcase jobs that require engine removal. It also shows how to remove the transmission separately, so a shop can plan how much disassembly a job requires.

The internal inspection procedures cover pistons, rings, connecting rods, and main bearings. A piston protrusion chart links the measured height to head gasket thickness and identification holes. The cylinder head section illustrates the bolt pattern and staged torque-and-angle tightening.

Injector and timing belt work: Step-by-step instructions cover static injector timing and timing belt replacement, with the Fuel Injector Timing Tool (0444-234) and Timing Belt Tensioning Tool (0444-231). Incorrect camshaft positioning during timing belt service can damage the valves.

The injector installation procedure includes nozzle protrusion checks. Arctic Cat recommends a qualified diesel injection facility for internal injector service, which requires specialized instruments, training, and a clean room.

Transmission, Differential, and Axle Repair

Transmission disassembly and inspection cover the high and low ranges, reverse gear, shift dogs, and output drive. The final-drive procedures cover pinion bearings, axle seals, differential lock components, and shim selection using backlash and end play measurements.

The front differential and rear gear case use opposite lock collar thread directions and have different shim selection instructions. The axle section covers inner joint disassembly and warns that letting an unsupported axle hang can damage the inner CV joint.

Brake, Suspension, and Steering Work

The brake procedures cover pad wear checks, and the caliper and master cylinder are serviced by replacing the assemblies. The shock absorber procedures cover spring removal and inspection of the rods, bodies, bushings, and mounts. Steering and suspension checks include A-arm ball joints and knuckle bearings.

Cooling Checks and Electrical Fault Tracing

The cooling section covers radiator inspection and air removal after refilling. The oil and water pumps are treated as replacement assemblies. The engine oil viscosity chart accompanies the lubricant recommendations.

Electrical procedures identify test wires and expected readings for the starter interlocks and selectable front drive. The Battery Charging Chart provides separate charging guidance. For a hard-start complaint, the engine troubleshooting charts use the presence or absence of exhaust smoke to help distinguish glow plug or compression faults 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 Clearance and Oil Pressure Specs

Valve clearance: The cold-engine specification is 0.20 mm (0.008 in.) for both intake and exhaust valves.

Oil pressure: The test specifies a minimum of 1.1 kg/cm² (15.6 psi) at 900 RPM with the oil at 120°C (248°F). The test section lists possible causes for readings above or below specification.