Arctic Cat 2006 ATV Service Manual: 400, 500, 650 H1 & 650 V-Twin

This October 2005 Arctic Cat service publication covers the 2006 400 and 500 manual and automatic models, their TBX/TRV automatic variants, and the 650 H1 and 650 V-Twin ATVs.

PDF Text Search and Page Count

Search and diagram detail: Body text is searchable throughout the manual; some diagram labels are embedded as images. PDF bookmarks and working contents-page links are absent. Small engine-brake connector numbers are easier to read when enlarged.

The single printable, English-language PDF contains 520 pages: 518 numbered service-section pages, plus the foreword and unnumbered contents overview already included in that total.

Powertrain Repair and ATV System Diagnosis

These selected workshop topics are part of the manual's coverage. Other examples include storage preparation and TBX cargo-box removal.

• Maintenance and tune-up: Scheduled service, valve/tappet adjustment, engine-compression testing, air-filter care, oil/filter/strainer service, V-belt checks, and brake bleeding.

• Engine and transmission: Step-by-step removal and installation, in-frame top-, left-, and right-side work, crankcase separation/joining, valve and piston inspection, crankshaft service, clutch/CVT repair, and final adjustment.

• Fuel, lubrication, and cooling: Keihin carburetor service, throttle/choke/idle adjustment, fuel-pump tests, oil-pump service and pressure testing, plus radiator, thermostat, fan, and water-pump procedures.

• Electrical diagnosis: Resistance, peak-voltage, output-voltage, and signal-voltage tests for the starter, magneto, CDI, relays, switches, sensors, front-drive actuator, and V-Twin engine-brake system.

• Driveline service: FIS front-differential and rear-gear-case teardown, pinion/ring-gear shim selection, backlash checks, and axle/CV-joint service.

• Brakes and chassis: Hydraulic-brake checks and pad replacement, steering toe-in, shock absorbers, and both VP swing-arm and FIS A-arm rear-suspension service.

• Factory references: Model-specific torque tables, capacities, approved lubricants, clearances, wear limits, Condition/Remedy troubleshooting charts, and labeled assembly views.

Arctic Cat designed this manual for service personnel. It assumes the reader can judge the required level of disassembly and use support stands, presses, pullers, gauges, and electrical test equipment.

Variant-Specific Powertrain Detail

Separate chapters cover the 400 manual, 400 automatic, 500 manual, combined 500 automatic/650 H1, and 650 V-Twin powertrains. These divisions let you select the matching teardown, inspection, and installation procedures before opening the engine.

Transmission internals: Manual-model coverage reaches the primary clutch, shift forks, secondary gears, driveshaft, and countershaft. Automatic-model repair adds centrifugal-clutch, primary one-way-drive, and driven-pulley inspections.

The V-Twin chapter has its own drive-clutch, driven-pulley, V-belt-cover, crankshaft, and output-bevel-gear procedures.

Fuel and Cooling Differences

Carburetor data separates the 400/500, 650 H1, and dual-carburetor V-Twin systems, including V-Twin synchronization checks. The vacuum-pulse pump on the 400 FIS/500/650 H1 and the V-Twin electric pump have different tests; both pumps are specified as replacement assemblies.

Cooling layouts: Water-pump work is split among the 500 manual, 500/650 H1 automatic, and V-Twin designs. The V-Twin pump is serviced through the alternator cover; oil-cooler work is separated for the 400 and 650 H1.

Electrical Tests and Wiring Coverage

V-Twin coverage includes belt-failure and inspection-mode clearing, engine-brake controller supply/output tests, and forward/reverse, speed, and tilt-sensor checks. Electrical diagnosis also covers starter-motor overhaul, regulator/rectifier tests, ignition timing, and fuse-block/power-distribution-module layouts.

Engine-brake connector drawings identify the test connections. Full vehicle wiring diagrams are not included.

Gear-Case Setup and Brake Service Limits

Gear-case repair explains production/ratio tags and housing-based shim selection, with backlash and end-play checks. Hydraulic calipers and the hand-brake master cylinder are specified as nonserviceable replacement assemblies.

Workshop References and Assembly Cautions

Keihin carburetor schematics and manual/automatic-transmission Oil Flow Charts show component and lubrication layouts. Front and Rear Suspension Assembly Schematics and the Auxiliary Brake Assembly Schematic accompany the chassis procedures.

Mechanical tools: Named equipment includes the Crankcase Separator/Crankshaft Remover (p/n 0444-009), Pinion Gear/Shaft Removal Tool (p/n 0444-127), and Boot Clamp Pliers (p/n 0444-120).

Electrical test equipment: The manual specifies a Fluke Model 73 Multimeter (p/n 0644-191) and Peak Voltage Reading Adapter (p/n 0644-307); readings may vary with other meters.

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 V-Twin section warns that retightening a loosened ratchet-type cam-chain tensioner without the required reset can damage 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.

Selected Ring-Gear Setup Specifications

The drive-system specification table lists ring-gear backlash of 0.28–0.38 mm (0.011–0.015 in.) and ring-gear end play of 0.1–0.2 mm (0.004–0.008 in.). These reference ranges accompany the gear-case shimming and inspection procedures.