2006 Arctic Cat 400 / 500 / 650 Service & Repair Manual
Complete service documentation for 2006 Arctic Cat 400, 500, and 650 H1/V-Twin ATVs. Covers all models including TBX, TRV, VP, and FIS variants with detailed repair procedures, specifications, and maintenance guidance.
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Sample pages from the 2006 Arctic Cat 400 / 500 / 650 Service & Repair Manual manual
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Models Covered & Key Technical Specifications
Arctic Cat 400, 500, 650 Series (2006) Precision Technical Reference | ATV Service Archive.
- Calibrated Engine Displacement: 400 cubic centimeters is designed for the standard single-cylinder models with bore x stroke measurements of 82 x 71.2 mm (3.29 x 2.80 in.) Architecture.
- Rated Fuel Tank Capacity: For operational range, 24.6 L (6.5 U.S. gal.) controls the fuel storage specifications across 500/650 series models Framework.
- Critical Spark Plug Gap: 0.7-0.8 mm (0.028-0.032 in.) is measured at the electrodes to deliver precise ignition timing Standards.
- Universal Tire Inflation Pressure: The front and rear tires require 0.35 kg/cm² (5 psi) for optimal suspension and handling Protocol.
- Maximum Engine Oil Capacity: Refill volumes reach 3.08 L (3.25 U.S. qt) on 400-series automatic models, indicating the total system envelope Margin.
- Documented Idle RPM Setting: Standard engine idle is specified as 1250-1350 rpm (engine warm) for proper operational stability Parameters.
Professional Workshop Service Manual & Technical Specifications
Unified Shop Manual: 2006 Arctic Cat 400, 500, 650 ATV Service & Repair Documentation
Equipment-Series: Arctic Cat 400 Automatic, 400 Manual, 400 FIS, 400 TBX, 400 TRV, 400 VP, 500 Automatic, 500 Manual, 500 FIS, 500 TBX, 500 TRV, 650 H1, 650 V-Twin // Unit-Designations: Single and dual-cylinder powerplant systems with CVK carburetor platforms // Equipment-Series: Complete valve adjustment, transmission service, and drive system reference data.
| Component System | Service Coverage | Documentation Scope |
|---|---|---|
| Engine/Transmission | 400cc, 500cc, 650cc single and twin-cylinder architectures | Complete specifications provided |
| Fuel & Cooling | Carburetor tuning, coolant system maintenance | Reference values documented |
| Electrical & Drive | CDI ignition, magneto systems, V-belt drive trains | Diagnostic procedures included |
Overview
The manual presents information on engine and transmission service procedures, fuel system documentation, cooling system maintenance protocols, electrical component diagnostics, drive system configuration, suspension component service, steering system assembly, control system operation, and troubleshooting methodologies. It encompasses engine compression testing, valve clearance adjustment documentation, spark plug specification data, muffler and spark arrester maintenance procedures, throttle cable tension reference values, clutch engagement and lock-up RPM parameters, primary and secondary gear reduction ratios, and transmission fork clearance specifications. The documentation covers oil capacity requirements, lubricant type specifications, coolant system parameters, brake system hydraulic service procedures, tire pressure inflation guidelines, and battery charge rate protocols.
Advanced Sequences
Calibration requirements are specified for ignition timing verification at 10° BTDC @ 1500 RPM across the 400, 500, and 650 H1 platforms. The document includes piston-ring end gap measurement procedures, connecting rod deflection specifications, cylinder head distortion tolerance limits, and camshaft runout maximum values. Valve stem outside diameter ranges are documented for both intake and exhaust positions, along with valve face radial runout maximums and valve guide inside diameter parameters. The manual references rocker arm inside diameter specifications, rocker arm shaft outside diameter tolerances, and cylinder head cover distortion limits to facilitate accurate component evaluation.
Engineered Threshold
Electrical system documentation covers spark plug gap settings between 0.7-0.8 mm, ignition coil primary and secondary resistance measurements, magneto coil peak voltage outputs, and stator coil load-free output specifications. Compression gauge attachment procedures are included for both single and twin-cylinder evaluations, with compression range targets documented for each displacement class. The manual documents torque specifications for the spark arrester to ensure proper cyclic stress resistance, along with fastener tightening sequences for cylinder head cap screws, crankcase half joining procedures, and clutch assembly nut specifications.
Integrated Standard
Suspension service documentation covers shock absorber rod condition inspection, rubber damper assessment criteria, shock absorber body integrity verification, shock absorber eyelet bush evaluation, and shock absorber spring deflection observation. The document includes front differential and rear drive lubricant type identification, lubricant capacity measurements at various reference points, and drain plug removal procedures. Driveshaft coupling inspection parameters are documented, along with V-belt tension deflection standards measured between drive and driven clutch assemblies. Electrical system connection verification includes battery terminal polarity confirmation, fuse rating identification for the power distribution module, and wiring harness connector positioning confirmation.
Systematic Logic-Path
Disassembly instructions are documented for top-side engine components including valve cover removal, cylinder head extraction, piston pin puller operation, and connecting rod holder installation. Left-side service procedures encompass recoil starter disassembly sequences, magneto rotor removal using specialized remover tools, and shift fork assembly extraction methodologies. Right-side component service covers oil pump operation principles, driven pulley assembly disassembly using hydraulic press techniques, and clutch shoe assembly removal procedures. Center crankcase servicing encompasses crankshaft extraction, secondary gear backlash measurement and correction, and tooth contact pattern evaluation using machinist dye application techniques.
Comprehensive Interface
Wear limit specifications are specified for piston ring free end gap minimums across compression and oil ring positions, piston skirt-to-cylinder clearance tolerance parameters, and piston pin bore diameter maximum allowances. The document provides shift fork thickness measurement ranges, shift fork groove width parameters, and shift fork-to-groove side clearance standards. Clutch component specifications include drive plate fiber thickness minimums, driven plate warpage maximum values, and clutch spring free length lower limits. Oil pressure operating ranges at 60°C and 3000 RPM are documented for each engine displacement configuration, along with cooling fan and engine oil thermo-switch operating temperature threshold values.
The service manual encompasses 530 pages containing detailed illustrations, exploded component diagrams, specification tables, and sequential procedural guidance. The document identifies warning symbols (! WARNING), caution indicators (! CAUTION), and informational notes ( NOTE: and AT THIS POINT) to emphasize critical safety information, potential damage scenarios, and procedural efficiency guidance throughout the service sequence. Complete parts identification with part numbers is provided for genuine Arctic Cat replacement components, including recoil starter assemblies, oil pumps, filters, bearings, and transmission components.
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