2007 Arctic Cat 400, 500, 650 H1, 700 EFI ATV Service Manual (P/N 2257-693)

• Arctic Cat’s August 2006 factory service manual for the 2007 400 and 500 (automatic and manual transmissions), 650 H1, and 700 EFI, supplied as a 472-page PDF.
• Engine repair coverage includes removal and installation, cylinder-head and piston service, cam timing, and center-crankcase disassembly and reassembly.
• Transmission chapters distinguish manual clutch and geartrain repair from automatic V-belt clutch and driven-pulley service, including one-way clutch inspection.
• Fuel-system procedures range from carburetor overhaul to 700 EFI fuel-pressure testing, ECU error-code diagnosis, and throttle position sensor testing and adjustment.
• Front differential and rear gear case work covers pinion bearings, axle seals, shim selection, ring-gear backlash, and end-play checks.
• Chassis procedures address hydraulic brake bleeding, pad replacement and burnishing, A-arm and ball-joint replacement, and front-wheel toe-in adjustment.

TRV/TBX Coverage and Model Exclusions

Variant coverage includes the 400 TRV automatic, 650 H1 TBX, and 650 H1 TRV. The differential-lock cable adjustment procedure specifically excludes the 400 TRV. Separate publications cover the Y-12, DVX/Utility 250, DVX 400, Prowler, and 700 Diesel.

Engine Data and Drivetrain Specifications

The engine sections identify which top-side and side-component repairs can be performed in the frame and which center-crankcase jobs require engine removal. Internal inspection data includes cylinder head distortion, connecting rod clearances, piston-to-cylinder tolerances, and shift-fork wear limits.

Valve service separates screw-adjusted tappets on the carbureted models from the 700 EFI’s shim-adjusted tappets. Its Intake Chart and Exhaust Chart support replacement-shim selection. The screw-adjuster procedure identifies the Valve Clearance Adjuster, P/N 0444-078.

Secondary bevel-gear service goes beyond disassembly, with tooth-contact assessment and backlash correction. Driveshaft and countershaft assembly procedures address gear placement, bushings, and retaining hardware.

Carburetion, Lubrication, and Cooling

Keihin CVK34 coverage applies to the 400; CVK36 coverage applies to the 500 and 650 H1. Carburetor repair includes float-valve and vacuum-diaphragm inspection. Illustrated references include Carburetor Schematics (400/500/650 H1) and the Throttle Body Assembly (700 EFI) exploded view.

Model-specific Oil Flow Charts trace lubrication paths through the engine and transmission. Oil-pump pressure testing accompanies these diagrams. Oil-cooler service applies to the 400/650 H1. For the liquid-cooled 500/650 H1/700 EFI, coverage includes radiator and thermostat service and water-pump seal replacement.

The guide lists fluid capacities for the cooling system, engine oil, and differentials. Recommended drivetrain lubricants include SAE 80W-90 hypoid gear lube. Component-specific torque tables separate manual-transmission, automatic-transmission, and 700 EFI applications.

Maintenance Clearances and Electrical Diagnostics

Periodic maintenance schedules and lubrication points are backed by valve-clearance specifications, compression testing, spark plug gaps, and battery charging data. The compression-testing section warns that electrical arcing can severely pit the 700 EFI’s magnesium cylinder-head cover.

Ignition and charging diagnostics cover magneto coil resistance, stator output, and regulator/rectifier checks. Starter-motor disassembly and relay testing extend electrical repair coverage beyond basic tune-up work.

For the 700 EFI, the ECU Error Code List identifies sensor, injector, ISC valve, and fuel-pump relay faults. Code retrieval and clearing procedures reference Diagnostic Harness P/N 0486-219; TPS adjustment references Test Plug/Error Code List Kit P/N 0444-216. The manual provides an idle-speed specification, but 700 EFI idle RPM is not adjustable. Ignition-timing verification applies to the carbureted models, not the 700 EFI.

Electrical reference material includes wire-color test points, connector views, and fuse/power-distribution layouts. Full-vehicle wiring diagrams are not included.

Axles, Brakes, and TBX/TRV Bodywork

Drive-axle procedures cover CV-joint disassembly and boot replacement. A specific caution explains that excess joint grease can damage the boot and lead to joint failure. Hydraulic calipers and the hand-brake master cylinder are treated as replacement assemblies, not internally rebuildable units.

Bodywork sections cover TBX side-storage and cargo-box removal, plus TRV seat arrangements. Problem/condition/remedy tables address starting trouble, clutch slipping or dragging, shifting faults, steering pull, and poor braking.

Working on a raised ATV, spring-loaded components, fuel systems, and brakes carries physical risks; always consult a certified technician before undertaking any mechanical work to ensure your safety and vehicle integrity.