2013 Arctic Cat 500 / 700 / 1000 ATVs Service & Repair Manual (P/N 2259-527)

• Document identity: Arctic Cat P/N 2259-527, issued October 2012; a 270-page PDF organized into eight service sections, followed by four model-family wiring diagrams.
• Exact model coverage: 500, 500 XT, and 500 TRV; 700, 700 LTD, 700 XT, 700 TBX, 700 TRV LTD, 700 Mud Pro, and 700 TRV XT; 1000 Mud Pro and 1000 TRV LTD.
• Engine and transmission repair: Separate 500, 700, and 1000 procedures cover engine removal and installation, top-side work, magneto and starter-clutch service, CVT and centrifugal-clutch repair, crankcase separation, and internal transmission assembly.
• Fuel, cooling, and electrical diagnosis: Includes EFI fault isolation, throttle-body and fuel-pump service, oil-pressure testing, radiator and thermostat work, component-level electrical tests, EPS diagnosis where equipped, TPS setup, digital-gauge diagnostics, and DTC charts.
• Driveline and brakes: Details front differential teardown, pinion and ring-gear setup, shim selection, backlash and end-play checks, drive-axle/CV joint repair, rear gear-case work, brake bleeding, and master-cylinder/caliper service.
• Suspension, steering, and body: Addresses shocks, front and rear A-arms, steering post and tie rods, EPS and non-EPS installation, toe-out adjustment, racks and body panels, plus TBX side-storage and cargo-box repair.
• Factory reference material: Provides model-specific torque tables, capacities, wear and inspection limits, clearances, electrical test values, special-tool P/Ns, troubleshooting charts, component photographs, and exploded or section views.

Coverage Boundaries

This is not a blanket manual for every 2013 Arctic Cat ATV. The foreword assigns the Y-12+, T-14, 300 DVX/Utility, 400, 400 TRV, 450, XC 450, 700 Diesel, and 550/1000 FIS families to separate publications. Use the exact model list above before selecting parts, wiring, or repair procedures.

Engine and Transmission Repair Depth

The engine chapter follows separate 500, 700, and 1000 repair paths. On the 500 and 700, top-side, left-side, and right-side work can normally be performed with the engine in the frame; center-crankcase service requires engine/transmission removal. The 1000 has an additional boundary: front top-side components can be serviced in-frame, but rear cylinder-head, cylinder, and piston work requires engine removal.

Top-side coverage includes rocker arms, valves and guides, valve seats, camshaft inspection, head and cylinder distortion checks, piston and ring inspection, honing, timing-system installation, and final valve adjustment. Side-component chapters address the water pump, speed sensor, stator/CKP sensor, rotor/flywheel, starter clutch, shift components, V-belt drive, driven pulley, centrifugal clutch, oil strainer, and oil pump. Center-crankcase repair reaches the crankshaft and balancer, countershaft, shift forks, secondary output gears, bearing locations, backlash, and tooth-contact setup. The 1000 chapter includes gerotor oil-pump disassembly and inspection; damaged 500 and 700 pump assemblies are replaced rather than internally repaired.

Factory-numbered tools include the Crankcase Separator/Crankshaft Remover 0444-152, Magneto Rotor Remover Set 0444-254, Piston Pin Puller 0644-328, and Valve Clearance Adjuster 0444-255.

Fuel, Cooling, and Electrical Diagnosis

Fuel and cooling coverage includes EFI troubleshooting, separate 500 and 1000 throttle-body removal and installation, throttle-cable adjustment, gas-tank service, electric fuel-pump and level-sensor testing, oil-pressure testing, the 1000 oil cooler, radiator removal, thermostat inspection, cooling-fan service, and model-specific water-pump work.

The electrical chapter supports component-level fault isolation rather than harness tracing alone. It covers the PDM, fuses and relays, ignition coils, ECT and MAP/IAT sensors, speed and CKP sensors, starter circuit, ECM, regulator/rectifier, tilt sensor, drive-select and differential-lock circuits, TPS inspection and adjustment, gear-position switch, and EPS diagnostics. Digital-gauge modes include COOL, FUEL, tACH, SPd, tPS, bArO, AIr, and bAtt, followed by a DTC code chart. Listed test equipment includes Diagnostic Harness 0486-219, Fluke Model 77 Multimeter 0644-559, Peak Voltage Reading Adapter 0644-307, and Test Plug/Code List 0444-216.

Driveline, Chassis, and Diagrams

Front differential repair covers input-shaft and differential disassembly, pinion service, seal replacement, shim selection, backlash adjustment, ring-gear end-play, and final assembly. The manual also addresses front and rear drive axles, CV-joint inspection and reassembly, hubs, rear gear cases, and the shock-limiting input assembly used on the 700 Mud Pro and 1000 models. Brake work ranges from bleeding and pad replacement to hand-master-cylinder and hydraulic-caliper disassembly, inspection, and reassembly.

Suspension and steering sections handle shock absorbers, A-arms, steering knuckles, wheels and tires, steering post and tie rods, separate EPS and non-EPS installation, toe-out measurement, throttle and shift controls, panels, racks, footrests, exhaust, seats, and TBX cargo equipment.

The last four pages provide wiring diagrams for the 1000 Mud Pro/1000 TRV LTD, 700 family, 500/500 TRV, and 500 XT, with the applicable harness P/Ns. Other useful visuals include the front-differential shim and backlash views and the secondary-gear tooth-contact patterns.

The cautions are assembly-specific. A mispositioned cam-sprocket tab washer can release the alignment pin and cause severe engine damage. Tightening a movable drive face before its splines are fully engaged can produce a false torque reading, loosen the assembly, and damage the shaft and face plate. On 700 Mud Pro and 1000 rear drives, friction-modified lubricant can damage the shock-limiting clutch pack.

Use secure stands and suitable lifting equipment for engine, driveline, suspension, and brake work. Isolate the battery where specified, let hot cooling and exhaust components cool, and use eye and hand protection when handling fuel, oil, coolant, or brake fluid.