2012 Arctic Cat ATV models 550, 700 Service Manual

2012 Arctic Cat ATV 550 & 700 Service Manual

This factory service manual provides complete OEM procedures for the 2012 Arctic Cat 550 and 700 ATV models. All content below is derived strictly from the Table of Contents, including detailed engine and transmission overhaul, EFI diagnostics, lubrication and cooling system service, electrical troubleshooting, driveline servicing, suspension repair, brake system maintenance, and full chassis and steering procedures.

Model Covers:

2012 Arctic Cat 550 ATV
2012 Arctic Cat 700 ATV

Note: Includes complete valve train service, crankcase disassembly, EFI troubleshooting, brake and driveline component teardown, electrical DTC listings, and steering/frame service procedures.

File Format: PDF

Size: 49.13 MB

No. of Pages: 154

Language: English

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

📑 Included Sections:

General Information / Specifications

• Specifications, torque charts, conversion tables
• Break-in procedure for new engines
• Recommended gasoline, engine/transmission oils, lubricants
• Differential and rear drive fluid specifications
• Genuine parts guidelines, storage preparation and reactivation

Periodic Maintenance

• Maintenance chart and required special tools
• Lubrication points and service intervals
• Air filter inspection and drain cleaning
• Valve/tappet clearance measurement and adjustment
• Engine compression testing
• Spark plug inspection and replacement
• Muffler and spark arrester cleaning
• Engine/transmission oil, filter, and strainer servicing
• Cooling system inspection and refilling
• Differential and rear drive lubricant service
• Hardware checks (nuts, bolts, cap screws)
• Headlight aiming, taillight and brakelight checking
• Shift lever inspection and adjustment
• Brake bleeding, pad replacement, hose inspection
• Brake pad burnishing procedure
• V-belt removal and installation

Engine / Transmission

• Specifications, special tools, troubleshooting
• Removing engine/transmission assembly
• Top-side removal: valve cover, rocker arms, head, camshaft, cylinder, piston
• Valve assembly: valve removal, stem OD/runout, seat width, guide ID, rocker arm checks
• Piston assembly: ring removal, ring groove cleaning, end-gap measurement, skirt clearance
• Cylinder–head inspection: distortion measurement, chain guide inspection, camshaft measurements
• Installing piston, cylinder, head, valve cover
• Left-side components: magneto cover, water pump, flywheel, starter clutch/gear
• Left-side servicing: clutch gear inspection, bearing replacement, stator/sensor servicing
• Right-side components: V-belt cover, driven pulley, clutch cover
• Right-side servicing: centrifugal clutch shoe, housing, primary one-way drive, oil pump
• Crankcase separation, disassembly of halves
• Secondary gear setup, backlash checks, crankshaft measurements, countershaft work
• Crankcase reassembly and engine/transmission installation

Fuel / Lubrication / Cooling

• EFI troubleshooting and component removal/installation
• Throttle cable free-play adjustment
• Idle RPM setting procedures
• Fuel tank removal, cleaning, inspection, installation
• Oil filter and oil pump servicing
• Oil pump pressure testing
• Radiator servicing: removal, cleaning/inspection, installation
• Thermostat removal, inspection, installation
• Cooling fan servicing
• Water pump removal/installation
• EFI fuel pump and level sensor testing, removal, installation
• Troubleshooting for fuel, lubrication, and cooling systems

Electrical System

• Electrical testing tools and connector standards
• Battery charging and maintenance
• RPM limiter checks
• Testing electrical components and accessory receptacle voltage
• Brake light switch (auxiliary and handlebar) testing
• ECT sensor and fan motor resistance checks
• PDM: fuses and relays
• Ignition coil primary/secondary resistance and ECU voltage checks
• EFI sensors: CKP, MAP, IAT
• Speed sensor diagnostics
• Electronic power steering (EPS) testing
• Ignition switch and handlebar switch diagnostics
• Drive select switch resistance and voltage tests
• Front drive/differential lock actuator voltage tests
• Stator/CKP sensor voltage and resistance testing
• Starter relay and starter motor testing
• ECU and regulator–rectifier testing
• Headlight, taillight, and brakelight voltage checks
• Ignition timing procedures
• Tilt sensor voltage checks
• TPS inspection, removal, installation, and adjustment
• DTC code list and troubleshooting charts

Drive System / Brake System

• General information and special tools
• Front drive actuator and differential lock removal/installation
• Front differential teardown: input shaft, differential assembly, pinion gear, shimming, backlash, end-play
• Axle servicing: front/rear removal, cleaning, inspection, disassembly, reassembly, installation
• Rear gear case service: ring gear, thrust button, input shaft housing procedures
• Hub removal, cleaning/inspection, installation
• Hand brake lever and master cylinder servicing
• Brake caliper removal, disassembly, inspection, installation
• Troubleshooting for drive and brake systems

Suspension

• Shock absorber removal, inspection, installation
• Front and rear A-arm servicing
• Wheel and tire procedures: size, pressure, inspection, installation
• Suspension troubleshooting

Steering / Frame / Controls

• LCD gauge replacement
• Steering post and tie-rod removal/inspection/installation (EPS & non-EPS)
• Handlebar grip servicing
• Throttle control removal, installation, adjustment
• Steering knuckle teardown, inspection, installation
• Toe-out measurement and adjustment
• Front rack and bumper servicing
• Front body panels and side panel servicing
• Footrest and belly panel removal/installation
• Exhaust muffler removal, inspection, installation
• Rear body panel and rack servicing
• Taillight assembly removal, inspection, installation
• Seat and TRV seat servicing
• TBX side storage box and cargo box servicing
• Troubleshooting for steering, frame, and controls

This 2012 Arctic Cat 550 & 700 Service Manual is an essential technical reference for precise maintenance, diagnostics, and full mechanical overhaul.