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

Arctic Cat’s October 2012 service manual, P/N 2259-527, covers these 2013 ATVs: 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.

Text Search, Bookmarks and Wiring Detail

Search and diagram readability: The service text is searchable, with embedded bookmarks covering chapters, individual procedures and the appended wiring diagrams. The diagrams are largely image-based: model and harness captions are searchable, but most internal labels are not. Small connector numbers and wire codes require zooming, and some remain blurred when enlarged.

One printable 270-page PDF contains 257 pages of service content, two cover pages, one foreword page, one main contents page, two blank pages, three notes pages and four appended wiring diagrams. All are included in the total.

Engine Overhaul, EFI Diagnosis and Chassis Service

The following selected service topics summarize part of the manual’s coverage. Additional subjects include headlight aiming and preparation before and after storage.

• Engine and transmission repair: Step-by-step instructions for engine removal, top-side overhaul, crankcase separation, internal transmission assembly, CVT inspection and centrifugal-clutch service.

• Periodic maintenance: Maintenance chart, air-filter cleaning, valve/tappet adjustment, compression testing, oil/filter changes, cooling-system checks and V-belt replacement.

• Fuel and cooling systems: EFI troubleshooting, throttle-body removal and installation, fuel-pump and level-sensor testing, oil-pressure checks, radiator service and thermostat inspection.

• Electrical diagnosis: Starter and charging-system tests, EPS fault isolation, TPS setup, digital-gauge diagnostic modes, DTC charts and model-family wiring diagrams.

• Driveline and brakes: Differential teardown, pinion and ring-gear setup, shim selection, drive-axle inspection, rear gear-case service, brake bleeding and hydraulic-caliper overhaul.

• Suspension, steering and body: Shock absorbers, front and rear A-arms, steering post and tie rods, EPS and non-EPS installation, toe-out adjustment and TBX cargo equipment.

• Factory reference material: Model-specific torque tables, capacities, inspection limits, clearances, electrical test values, special-tool P/Ns, troubleshooting charts, component photographs and exploded or section views.

This manual was written for service personnel working on the covered Arctic Cat ATVs.

Model Coverage Boundaries

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

In-frame access: 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. On the 1000, front top-side components can be serviced in-frame, but rear cylinder-head, cylinder and piston work requires engine removal.

Internal inspection: Top-side sections address rocker arms, valves and guides, valve seats, camshaft inspection, head and cylinder distortion, piston and ring inspection, cylinder honing, timing-system installation and final valve adjustment. Arctic Cat recommends qualified machine-shop service for valves, guides and seats.

Side-component sections cover 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 work reaches the crankshaft and balancer, countershaft, shift forks, secondary output gears, bearing locations, backlash and tooth-contact setup. The 1000 section includes gerotor oil-pump disassembly and inspection; damaged 500 and 700 oil pumps are replaced as assemblies. Driven-pulley assemblies are treated as non-serviceable components.

Special tools: Listed equipment includes Crankcase Separator/Crankshaft Remover 0444-152, Magneto Rotor Remover Set 0444-254, Piston Pin Puller 0644-328 and Valve Clearance Adjuster 0444-255.

The assembly cautions address severe engine damage from a displaced cam-sprocket alignment pin and shaft/face-plate damage from false torque readings at an unseated movable drive face.

Fuel Delivery and Cooling-System Work

Separate 500 and 1000 throttle-body procedures accompany throttle-cable adjustment, gas-tank service and electric fuel-pump/fuel-level-sensor testing. Lubrication and cooling coverage adds oil-pressure testing, the 1000 oil cooler, cooling-fan replacement and model-specific water-pump work.

The fuel-pump and water-pump sections distinguish testing and assembly replacement from internal rebuilding.

Electrical Tests and Gauge Diagnostics

Component testing: The electrical chapter 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, and gear-position switch.

EPS diagnosis: Power-supply and speed-signal checks help distinguish external circuit faults from faults requiring EPS assembly replacement. The EPS unit itself is non-serviceable.

Digital-gauge modes include COOL, FUEL, tACH, SPd, tPS, bArO, AIr and bAtt. The DTC chart links fault descriptions to ECM pins and includes code-clearing information.

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.

Differential, Axle and Brake Service

Differential instructions include input-shaft disassembly, pinion service, seal replacement, backlash adjustment and ring-gear end-play checks. Shim-selection tables, dial-indicator views and secondary-gear tooth-contact illustrations support gear setup.

Rear-drive coverage includes the shock-limiting input assembly used on the 700 Mud Pro and 1000 models. Friction-modified lubricant can damage its shock-limiting clutch pack.

Drive-axle coverage includes removal, installation, boot inspection and hub service; internal axle disassembly and reassembly are referred to the instructions supplied with the appropriate boot repair kit.

Brake coverage includes pad replacement, bleeding, hand-brake lever/master-cylinder inspection and hydraulic-caliper disassembly and reassembly. The hand-brake master cylinder is replaced as a complete assembly.

Steering, Bodywork and Wiring References

Chassis procedures extend to steering knuckles and bearings, wheels and tires, throttle and shift controls, racks, body panels, footrests, exhaust and seats. Separate TBX sections address the side-storage and cargo boxes.

The four appended wiring sheets cover the 1000 Mud Pro/1000 TRV LTD, 700 family, 500/500 TRV and 500 XT, with applicable harness P/Ns. Other diagnostic references include the EPS fault-code table and EFI DTC chart.

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. Arctic Cat recommends authorized-dealer service for hydraulic brakes.

Examples of Gear-Setup and Sensor-Test Data

Front-differential specifications include ring-gear backlash of 0.28–0.38 mm and ring-gear end play of 0.1–0.2 mm, alongside the shim-selection and dial-indicator procedures.

ECT sensor testing includes approximate resistance readings of 2.45k ohms at 20°C (68°F) and 800 ohms at 50°C (122°F). These illustrate the temperature-dependent electrical reference data included in the manual.