This manual provides comprehensive service and repair information for the 2009 ATV lineup, including the 400 TRV, 500 Automatic, 500 Manual, 550 H1, 550 H1 TRV, 700H1, 700 H1 Cruiser, Thundercat, and 1000 H2 Cruiser ATV. The brand is recognized for its durable off-road vehicles, and this documentation reflects the factory standards for maintaining these machines. The 2009 model year represents a significant iteration, incorporating advancements such as Electronic Fuel Injection (EFI) on certain models and refined suspension and bodywork, building on the heritage of robust engineering.
This factory service manual is designed to be an indispensable resource for ATV owners, independent repair shops, and dealerships. It covers all essential systems, from general information and periodic maintenance to detailed procedures for the engine, transmission, fuel, lubrication, cooling, electrical, drive, suspension, steering, frame, controls, indicators, and brake systems. Within its pages, you will find step-by-step instructions, troubleshooting guides, wiring schematics, torque specifications, and fluid recommendations, enabling efficient and accurate maintenance and repair across the entire 2009 model range.
2009 ARCTIC CAT OFFICIAL FACTOTY SERVICE | REPAIR | SHOP MANUAL - COVERS: ARCTIC CAT 400 TRV, 500 AUTOMATIC, 500 MANUAL, 550 H1, 550 H1 TRV, 700H1, 700 H1 CRUISER, THUNDERCAT AND 1000 H2 CRUISER ATV - INSTANT DOWNLOAD!
VERY HIGH QUALITY FACTORY SERVICE MANUAL - BEST MANUAL YOU COULD GET ANYWHERE!!
SERVICE MANUAL COVERS:
1. General Information/Specifications
2. Periodic Maintenance
3. Engine/Transmission
4. Fuel/Lubrication/Cooling
5. Electrical System
9. Controls/Indicators
General Specifications ............................................ 1-2
Torque Specifications .............................................. 1-3
Torque Conversions (ft-lb/N-m) ............................... 1-6
Tightening Torque (General Bolts) .......................... 1-6
Break-In Procedure ................................................. 1-6
Gasoline - Oil - Lubricant ........................................ 1-6
Genuine Parts ......................................................... 1-7
Preparation For Storage.......................................... 1-7
Preparation After Storage........................................ 1-8
Periodic Maintenance Chart.................................... 2-2
Periodic Maintenance.............................................. 2-3
Lubrication Points.................................................... 2-3
Air Filter................................................................... 2-3
Valve/Tappet Clearance
(Feeler Gauge Procedure) ................................... 2-4
(Valve Adjuster Procedure)
(400/500/H1 Models) ........................................... 2-5
(Valve Adjuster Procedure) (H2 Models).............. 2-6
Testing Engine Compression .................................. 2-6
Spark Plug(s) .......................................................... 2-7
Muffler/Spark Arrester ............................................. 2-7
Engine/Transmission Oil - Filter - Strainer .............. 2-8
Front Differential/Rear Drive Lubricant .................. 2-10
Adjusting Clutch (500 Manual Transmission) ........ 2-11
Steering Components ........................................... 2-11
Driveshaft/Coupling............................................... 2-11
Suspension/Shock Absorbers/Bushings ............... 2-11
Nuts/Bolts/Cap Screws.......................................... 2-12
Headlights/Taillight-Brakelight ............................... 2-12
Shift Lever ............................................................. 2-13
Frame/Welds/Racks .............................................. 2-14
Electrical Connections........................................... 2-14
Hydraulic Brake Systems ...................................... 2-14
Burnishing Brake Pads.......................................... 2-15
Checking/Replacing V-Belt
(Automatic Transmission)................................... 2-16
Engine/Transmission ............................................... 3-2
Specifications (400)................................................. 3-2
Specifications (500)................................................. 3-3
Specifications (H1 Models)...................................... 3-4
Specifications (H2 Models)...................................... 3-4
Troubleshooting ....................................................... 3-5
400 Table of Contents ............................................. 3-9
500 (Automatic Transmission)/H1 Models
Table of Contents ............................................... 3-50
500 (Manual Transmission) Table of Contents .... 3-102
H2 Models Table of Contents .............................. 3-166
Fuel/Lubrication/Cooling ......................................... 4-2
Carburetor Specifications (400/500)........................ 4-2
Carburetor Schematics (400/500) ........................... 4-2
Carburetor (400/500)............................................... 4-2
Electric Choke (400/500)......................................... 4-7
Electronic Fuel Injection (EFI Models) .................... 4-8
Throttle Cable Free-Play ....................................... 4-10
Engine RPM (Idle)................................................. 4-11
Gas Tank ............................................................... 4-11
Oil Filter/Oil Pump ................................................. 4-12
Testing Oil Pump Pressure.................................... 4-12
Oil Cooler (400/700/H2 Models)............................ 4-12
Liquid Cooling System (500/H1/H2 Models) ......... 4-13
Electric Fuel Pump/Fuel Level Sensor
(EFI Models) ...................................................... 4-18
Vacuum Pulse Fuel Pump (500)............................ 4-20
Troubleshooting (400/500)..................................... 4-21
Troubleshooting (EFI Models) ............................... 4-21
Electrical System..................................................... 5-2
Specifications .......................................................... 5-2
Battery..................................................................... 5-3
RPM Limiter............................................................. 5-4
2009 ARCTIC CAT OFFICIAL FACTOTY SERVICE | REPAIR | SHOP MANUAL - COVERS: ARCTIC CAT 400 TRV, 500 AUTOMATIC, 500 MANUAL, 550 H1, 550 H1 TRV, 700H1, 700 H1 CRUISER, THUNDERCAT AND 1000 H2 CRUISER ATV - INSTANT DOWNLOAD!
VERY HIGH QUALITY FACTORY SERVICE MANUAL - BEST MANUAL YOU COULD GET ANYWHERE!!
SERVICE MANUAL COVERS:
1. General Information/Specifications
2. Periodic Maintenance
3. Engine/Transmission
4. Fuel/Lubrication/Cooling
5. Electrical System
9. Controls/Indicators
General Specifications ............................................ 1-2
Torque Specifications .............................................. 1-3
Torque Conversions (ft-lb/N-m) ............................... 1-6
Tightening Torque (General Bolts) .......................... 1-6
Break-In Procedure ................................................. 1-6
Gasoline - Oil - Lubricant ........................................ 1-6
Genuine Parts ......................................................... 1-7
Preparation For Storage.......................................... 1-7
Preparation After Storage........................................ 1-8
Periodic Maintenance Chart.................................... 2-2
Periodic Maintenance.............................................. 2-3
Lubrication Points.................................................... 2-3
Air Filter................................................................... 2-3
Valve/Tappet Clearance
(Feeler Gauge Procedure) ................................... 2-4
(Valve Adjuster Procedure)
(400/500/H1 Models) ........................................... 2-5
(Valve Adjuster Procedure) (H2 Models).............. 2-6
Testing Engine Compression .................................. 2-6
Spark Plug(s) .......................................................... 2-7
Muffler/Spark Arrester ............................................. 2-7
Engine/Transmission Oil - Filter - Strainer .............. 2-8
Front Differential/Rear Drive Lubricant .................. 2-10
Adjusting Clutch (500 Manual Transmission) ........ 2-11
Steering Components ........................................... 2-11
Driveshaft/Coupling............................................... 2-11
Suspension/Shock Absorbers/Bushings ............... 2-11
Nuts/Bolts/Cap Screws.......................................... 2-12
Headlights/Taillight-Brakelight ............................... 2-12
Shift Lever ............................................................. 2-13
Frame/Welds/Racks .............................................. 2-14
Electrical Connections........................................... 2-14
Hydraulic Brake Systems ...................................... 2-14
Burnishing Brake Pads.......................................... 2-15
Checking/Replacing V-Belt
(Automatic Transmission)................................... 2-16
Engine/Transmission ............................................... 3-2
Specifications (400)................................................. 3-2
Specifications (500)................................................. 3-3
Specifications (H1 Models)...................................... 3-4
Specifications (H2 Models)...................................... 3-4
Troubleshooting ....................................................... 3-5
400 Table of Contents ............................................. 3-9
500 (Automatic Transmission)/H1 Models
Table of Contents ............................................... 3-50
500 (Manual Transmission) Table of Contents .... 3-102
H2 Models Table of Contents .............................. 3-166
Fuel/Lubrication/Cooling ......................................... 4-2
Carburetor Specifications (400/500)........................ 4-2
Carburetor Schematics (400/500) ........................... 4-2
Carburetor (400/500)............................................... 4-2
Electric Choke (400/500)......................................... 4-7
Electronic Fuel Injection (EFI Models) .................... 4-8
Throttle Cable Free-Play ....................................... 4-10
Engine RPM (Idle)................................................. 4-11
Gas Tank ............................................................... 4-11
Oil Filter/Oil Pump ................................................. 4-12
Testing Oil Pump Pressure.................................... 4-12
Oil Cooler (400/700/H2 Models)............................ 4-12
Liquid Cooling System (500/H1/H2 Models) ......... 4-13
Electric Fuel Pump/Fuel Level Sensor
(EFI Models) ...................................................... 4-18
Vacuum Pulse Fuel Pump (500)............................ 4-20
Troubleshooting (400/500)..................................... 4-21
Troubleshooting (EFI Models) ............................... 4-21
Electrical System..................................................... 5-2
Specifications .......................................................... 5-2
Battery..................................................................... 5-3
RPM Limiter............................................................. 5-4
