2005 Arctic Cat ATV (250, 300, 400 AT, 400 MT, 500 MT, 500 AT, 650 H1, 650 V-Twin) Service Manual

2005 Arctic Cat ATV Service Manual (250, 300, 400 AT/MT, 500 AT/MT, 650 H1, 650 V-Twin)

This comprehensive factory service manual provides complete maintenance, diagnostic, and repair procedures for the full 2005 Arctic Cat ATV lineup. Covering all engines, drivetrains, electrical components, chassis systems, and cooling/fuel assemblies, this manual includes detailed schematics, inspection procedures, adjustment specifications, and step-by-step service instructions required for full mechanical overhaul and professional maintenance.

Model Covers:

Arctic Cat 250 (2005)
Arctic Cat 300 (2005)
Arctic Cat 400 / 400 TBX – Automatic (2005)
Arctic Cat 400 – Manual Transmission (2005)
Arctic Cat 500 – Manual Transmission (2005)
Arctic Cat 500 / 500 TBX / 500 TRV – Automatic (2005)
Arctic Cat 650 H1 (2005)
Arctic Cat 650 V-Twin (2005)

Note: Includes full maintenance charts, lubrication points, tuning specifications, carburetor and fuel system procedures, transmission servicing, hydraulic brake details, electrical diagnostics, torque data, troubleshooting charts, and detailed schematics for all systems.

File Format: PDF

Size: 189.62 MB

No. of pages: 670

Language: English

Delivery Method: Instant Download – Access your file immediately after purchase.

📑 Included Sections (Based on Table of Contents):

General Information

• General specifications for all models (250 / 300 / 400 AT / 400 MT / 500 MT / 500 AT / 650 H1 / 650 V-Twin)
• Break-in procedure, gasoline/oil/lubricants, genuine parts
• Preparation for storage and post-storage service

Periodic Maintenance / Tune-Up

• Complete periodic maintenance charts and lubrication points
• Battery, fuses, electrical connections, lights, switches
• Air cleaner, valve/tappet clearance, engine compression test
• Throttle/choke adjustments, idle RPM, spark plug inspection
• Engine/transmission oil service, strainers, filters
• Differential and rear drive lubricant service
• Clutch adjustments, V-belt inspection and replacement
• Steering components, brakes, shock absorbers, suspension bushings
• Nuts/bolts tightening, ignition timing, hydraulic brake systems
• Cooling system service (500 / 650 H1 / 650 V-Twin)

Engine / Transmission

• Engine and transmission specifications for all variants
• Manual and automatic transmission specifications
• Individual engine/transmission breakdowns by model group

Fuel / Lubrication / Cooling

• Carburetor specifications, schematics, inspection and cleaning
• Throttle/choke cable free-play, idle RPM procedures
• Gas tanks, vent hoses, fuel valves, vacuum/electric fuel pumps
• Oil flow charts, oil pump inspection and pressure testing
• Oil cooler service (250 / 300 / 400)
• Liquid cooling systems for 500 / 650 H1 / 650 V-Twin
• Radiator, thermostat, cooling fan, water pump servicing
• Fuel pump testing procedures

Electrical System

• Electrical specifications, RPM limiter, battery testing
• Brake light switches, temperature switches, cooling fan motors
• Fuse block, connectors, ignition coil, indicator lights
• Speedometer and speed sensor systems
• Ignition and handlebar switches, front drive selector
• Differential lock switch and actuators
• Magneto coils, starter motor, CDI units, relays
• Regulator/rectifier, headlight/taillight/brakelight circuits
• Electronic diagnostics (650 V-Twin)
• Complete wiring diagrams

Drive System

• Front drive actuator, front differential (FIS)
• Drive axles, rear suspension (ACT)
• Rear drive and rear gearcase schematics
• Hubs, hydraulic brake calipers, brake schematics

Suspension

• Front and rear suspension schematics
• Shock absorbers, rear suspension swing arms (ACT)
• Front A-arms and rear A-arms (FIS)
• Wheels and tires

Steering / Frame

• Steering post, tie rods, knuckles, handlebar grip
• Toe-in adjustment procedures
• Body panel schematics, frame/exhaust assembly
• Front rack, bumper, fender assemblies
• Footrests, belly panels, rear rack and body panels
• Storage box/cargo box (TBX), headlight adjustment, seat

Controls / Indicators

• Hand brake lever, master cylinder, auxiliary brake schematics
• Throttle control, gearshift pedal (manual)
• Drive selector, differential lock, reverse shift levers
• Speedometer systems and all indicator lights

Aids for Maintenance

• Torque specifications (all engine and transmission types)
• Torque conversions and general bolt torque charts

Troubleshooting

• Engine troubleshooting
• Drive system troubleshooting
• Fuel system diagnostics
• Electrical system diagnostics
• Steering and suspension troubleshooting
• Brake system troubleshooting

This extensive factory service manual provides complete technical coverage for the entire 2005 Arctic Cat ATV range, making it an essential resource for technicians, mechanics, and experienced owners performing repairs, servicing, or full overhauls.