2006 Arctic Cat 400, 500, and 650 H1/V-Twin (TBX, TRV, VP, and FIS) Service & Repair Manual (P/N 2257-469)

• Exact 2006 coverage: 400 manual; 400, 400 TBX, and 400 TRV automatic; 500 manual; 500, 500 TBX, and 500 TRV automatic; plus separate 650 H1 and 650 V-Twin sections. The 520-page PDF contains Arctic Cat's October 2005 factory service publication.
• Engine and transmission repair covers complete unit removal and installation, in-frame top-, left-, and right-side work, crankcase separation and joining, valve and piston inspection, crankshaft and transmission service, clutch/CVT repair, and final adjustment.
• Fuel, lubrication, and cooling procedures address model-specific Keihin carburetors, throttle/choke/idle adjustment, pulse and electric fuel pumps, oil-pump service and pressure testing, radiators, thermostats, fans, and the different water-pump arrangements.
• Electrical diagnosis provides component resistance, peak-voltage, output-voltage, and signal-voltage tests for the starter, magneto, CDI, relays, switches, sensors, front-drive actuator, and the 650 V-Twin engine-brake system. Belt-failure and inspection-mode clearing procedures are included for the V-Twin.
• Driveline and chassis work extends through FIS front-differential and rear-gear-case teardown, pinion/ring-gear shim selection, backlash checks, axle and CV-joint service, hydraulic brakes, steering toe-in, and both VP swing-arm and FIS A-arm rear suspension layouts.
• Factory reference material includes model-specific torque tables, capacities and approved lubricants, clearances, wear limits, electrical test specifications, Condition/Remedy troubleshooting charts, and labeled assembly views. Examples include the Keihin carburetor schematics, manual- and automatic-transmission oil-flow charts, FIS/VP suspension schematics, auxiliary-brake schematic, and 650 V-Twin engine-brake connector test diagrams.

Arctic Cat states that this manual was designed to aid service personnel in service-oriented applications. Its procedures assume the reader can judge the required level of disassembly and use support stands, presses, pullers, gauges, and electrical test equipment, making it a workshop-level repair reference rather than a beginner maintenance guide.

Variant-Specific Powertrain Detail

The engine section is divided by actual powertrain instead of giving one generic sequence. The 400 manual, 400 automatic, 500 manual, combined 500 automatic/650 H1, and 650 V-Twin chapters each track removal, teardown, inspection, assembly, and installation for that configuration. Manual-transmission coverage reaches the primary clutch, shift forks, secondary gears, driveshaft, and countershaft. Automatic-model repair adds the centrifugal clutch, primary one-way drive, driven pulley, and related wear checks. The V-Twin chapter has its own drive-clutch, driven-pulley, V-belt-cover, crankshaft, and output-bevel-gear procedures.

Fuel, Cooling, and Electrical Differences

Carburetor data is separated for the 400/500, 650 H1, and dual-carburetor 650 V-Twin systems. The manual also distinguishes the vacuum-pulse fuel pump used on the 400 FIS, 500, and 650 H1 from the V-Twin electric pump. Cooling-system work is split among the 500 manual, 500/650 H1 automatic, and 650 V-Twin water-pump designs, with related radiator, thermostat, fan, hose, oil-flow, and oil-pressure information.

Electrical coverage centers on factory meter tests and fault isolation. It includes a fuse-block/power-distribution-module layout, starter-motor overhaul, relay and actuator checks, ignition timing, and V-Twin engine-brake controller tests. Full vehicle wiring diagrams are not part of this volume.

Tools, Setup Work, and Repair Cautions

Gear-case repair is more than removal and replacement. The manual explains the production/ratio tags, differential and pinion teardown, housing-based shim selection, and verification of ring-gear backlash and end play. Named tools include the Crankcase Separator/Crankshaft Remover (p/n 0444-009), Pinion Gear/Shaft Removal Tool (p/n 0444-127), Boot Clamp Pliers (p/n 0444-120), and the Peak Reading Adapter (p/n 0644-307) used with the specified multimeter.

The model-specific cautions matter during assembly. In the 500 manual-transmission chapter, misaligned oil passages in the splined bushing and driveshaft can starve the assembly of lubrication and cause major damage. The 650 V-Twin section warns that loosening the ratchet-type cam-chain tensioner without the required reset can damage both the tensioner and chain.

Many procedures require the ATV to be securely supported, while fuel-system and hydraulic-brake work carry their own fire, fluid, and final-check warnings. Follow the manual's warning blocks and use the specified equipment throughout any repair.