2007 Arctic Cat 700 Diesel ATV Service & Repair Manual

The February 2007 Arctic Cat Service Manual covers maintenance, troubleshooting, and repair of the 2007 Arctic Cat 700 Diesel ATV with its Lombardini diesel powertrain. Its ten sections cover routine service, internal engine and transmission work, electrical diagnosis, and chassis repairs.

• Engine repair: Engine removal, cylinder-head and pre-combustion chamber service, camshaft/rocker-arm inspection, crankshaft measurements, and piston/ring assembly.

• Diesel injection: Lombardini unit injector removal and installation, static injector timing, speed governor service, lift pump replacement, and fuel shutoff diagnosis.

• Transmission and final drive: V-belt and drive clutch service, transmission disassembly, front differential shimming, rear gear-case service, and CV-boot replacement.

• Cooling and lubrication: Oil-pressure testing, radiator inspection, thermostat testing, coolant filling and air bleeding, and water-pump replacement.

• Electrical troubleshooting: Glow plug controller/relay, ECT switch/thermistor, starter circuit, alternator/regulator, speed sensor, and front drive actuator tests.

• Brakes, suspension, and steering: Hydraulic brake bleeding, pad and caliper replacement, shock absorber and A-arm inspection, steering-knuckle bearing service, and toe-in adjustment.

Written for service personnel, this manual assumes the workshop judgment needed to assess component condition and determine how much disassembly a repair requires.

Engine and Transmission Repair

The engine section separates top-side, left-side, right-side, and center-component work. Notes identify operations that can be performed with the engine installed; cylinder-head and crankcase work require engine removal, while the transmission can be removed separately.

Cylinder-head coverage includes valve and guide inspection, pre-combustion chamber replacement, and head-gasket selection. The piston-protrusion chart links the measured protrusion to gasket thickness, helping identify the correct gasket before cylinder-head assembly. Valve, guide, and seat servicing is referred to a qualified machine shop.

Transmission procedures cover the countershaft, shift dogs, shift forks, bearings, and output bevel gears through disassembly, inspection, and reassembly.

The camshaft procedures warn that incorrect crankshaft positioning can cause severe valve damage. Disturbing the torque limiter's sealed adjuster can also cause severe engine damage; the manual treats this separately from fuel-delivery equalization adjustments.

Diesel Injection, Lubrication, and Cooling

Static injector timing is documented with timing-mark illustrations and the specified Timing Fuel Block (P/N 0444-234). Injector removal, installation, nozzle-protrusion checks, and fuel-system priming are covered, but internal injector servicing is referred to a qualified diesel injection facility with specialist instruments, training, and a clean room.

Oil-pressure testing specifies the Oil Pressure Test Kit (P/N 0644-495). Cooling procedures address radiator removal, thermostat operation, hose inspection, and trapped-air prevention during filling. The oil pump and water pump are treated as replacement assemblies rather than rebuildable components.

Electrical Tests and Connector Identification

Component tests provide wire colors, connector references, meter settings, and expected readings. The ECT switch/thermistor pin view and speed-sensor V/G/S connector view help identify the correct test connections.

Engine troubleshooting distinguishes hard starting with white smoke, low-compression symptoms, and starting failures with no fuel reaching the injectors. These distinctions help narrow the investigation toward glow-plug operation, mechanical condition, or fuel supply.

Electrical coverage consists of component tests, connector views, and troubleshooting tables; a complete vehicle wiring schematic is not included.

Final Drive, Brakes, and Chassis

Differential service includes pinion removal, shim selection, backlash and end-play checks, and axle-seal replacement. CV-joint procedures distinguish inner and outer boot work, bearing orientation, and clamp positioning.

The wheel/hub exploded view supports component identification, while the toe-in drawing accompanies steering alignment procedures. Steering-post, tie-rod, body-panel, rack, exhaust, and control-service sections provide access and replacement information.

Brake coverage includes hose inspection, pad replacement, bleeding, and fault diagnosis. Hydraulic calipers and the hand-brake master cylinder are treated as replacement assemblies, not internal overhaul projects.

Maintenance Charts and Assembly Data

The periodic maintenance chart, break-in procedures, oil-viscosity chart, and storage instructions support scheduled service. Component-specific torque tables cover engine/transmission and chassis fasteners, with separate front and rear suspension entries, general-bolt data, and torque conversions.

Review the factory safety warnings and support requirements before lifting the ATV, opening the cooling system, or servicing hydraulic brakes.

A Preview of Valve Settings and Fuel Requirements

These examples show a small selection of the adjustment and fuel specifications included in the manual.

Valve adjustment: Intake and exhaust clearance is 0.20 mm (0.008 in.) with the engine cold.

Fuel selection: The general specifications list 42–50 cetane diesel. B20 biodiesel use is limited to temperatures above -10°C (14°F), and the storage instructions warn against leaving B20 in the fuel system.

Searchable Service Text and PDF Contents

Text search and illustrated detail: The service text supports PDF search, although lettering within some illustrations is outside the text layer. There are no embedded PDF bookmarks. Small labels in the ECT and speed-sensor connector views are readable when enlarged.

One printable, 184-page PDF contains the service manual. The total includes one foreword page and one main contents page; the ten technical sections account for the remaining 182 pages.