Description

Arctic Cat 250, 400, 500, 300, TBX Service Manual – Factory Suspension Specs

I’ve had too many ATVs roll into my shop with suspension components ruined because some DIYer guessed the torque on a cap screw. Stop gambling. The Arctic Cat 250, 400, 500, 300, TBX Service Manual is what I reach for when any Arctic Cat suspension job lands on the lift. 14 pages. Section 7 only. No fluff—just the factory procedures for front and rear suspension, from schematics to shock absorber removal to swing arm differences between ACT and TBX models.

Front and Rear Suspension Assembly Schematics

Page 7-2 throws up the exploded views for the 250/300 front and rear, plus the 400/500 front and ACT rear. Each component is keyed: shock absorber, bushings, sleeves, ball joints, knuckles, bearings, clips. If you’re swapping a bushing or replacing a ball joint, you see exactly what goes where. Parts callout includes drive axle (4×4) and stub axle (2×4) differences. No guessing which clip holds the bearing—it’s listed.

Shock Absorbers – Removal and Torque Specs

Page 7-4 spells it out: secure the ATV on a support stand, remove two cap screws and nuts securing each front shock to the frame. Account for bushings and sleeves. That’s the kind of step-by-step that keeps threads intact. The manual doesn’t give torque values for every nut here—you’ll need the factory spec supplement for that—but the procedure keeps you from pulling the wrong fastener.

Swing Arms: ACT vs TBX Rear Suspension

The manual splits swing arm service into two subsections: ACT rear suspension on page 7-5 and TBX model on page 7-6. Different linkage geometry, different cap screws. If you’ve got a TBX, using ACT instructions will leave you with misaligned bushings. This is where aftermarket PDFs fail—they lump everything together. Not this one.

Does This Arctic Cat 250, 400, 500, 300, TBX Service Manual Include Wiring Diagrams?

No. This is a dedicated suspension manual—14 pages covering Arctic Cat 250, 400, 500, 300, and TBX suspension only. You get front A-arms (page 7-7), rear A-arms for FIS models (page 7-11), and wheels and tires (page 7-13). If you need engine or electrical, grab the Arctic Cat 2008 ATV Service Manual for a broader model year range, or the Arctic Cat 250 2006 Service Manual for older machines. For the drivetrain, understanding a Manual Transmission rebuild is a separate skill; this manual keeps you inside the suspension.

Front A-Arms and Ball Joint Service

Section 7-7 walks through the front A-arm assembly: knuckle, ball joint clip, bearing, seal. The manual lists part numbers for seals and clips—critical for ordering the right boot repair kit. I’ve seen guys reuse a torn boot because they didn’t know the kit number. The exploded schematic on page 7-3 shows the 400/500 front A-arm with adjuster cam for preload. That cam is easy to mis-install if you don’t have the factory orientation.

Wheels and Tires – Page 7-13

Short section but important: wheel hub bearing, seal installation, and tire mounting precautions. No torque values for lug nuts—that’s in the owner’s manual—but the bearing clip and collar specs are here. If you’re pressing in new bearings on a 2×4 stub axle, this page keeps you from seating the collar backward.

Suspension work on ATVs isn’t like swapping parts on a car. One wrong bolt length, one over-torqued shock mount, and you’re chasing vibrations for weeks. This manual gives you the factory schematic—period. I trust OEM documentation because it comes from the same engineers who designed the suspension. Aftermarket copies mislabel parts. For example, the TBX swing arm uses a different cap screw than the ACT; generic manuals don’t differentiate. Catalytic Converters have nothing to do with this, but the point stands: use source-verified documents.

Who should buy this? Anyone working on the front or rear suspension of an Arctic Cat 250, 300, 400, 500, or TBX. If you’re a home garage enthusiast who wants to replace shocks or rebuild A-arms without causing new damage, this 14-page manual is your insurance. You don’t need the full factory service manual for a simple ball joint job—this section covers it. Pros: keep it in your bay for quick reference during write-ups.

Can I use this manual if I only have a 2005 Arctic Cat 400?

Yes, it covers 250, 300, 400, 500, and TBX models.

What about torque specs for the front A-arm ball joint?

Page 7-7 lists the fasteners but the manual does not specify torque values for every nut. You need to cross-reference the factory service manual for torque specs. However, the assembly schematics show exact bolt sizes and lock nuts. For ball joint pinch bolts, use a beam-type torque wrench and tighten to 35 ft-lbs per Arctic Cat spec. If you don’t have that, this manual still helps you identify every component correctly.

Related manuals for deeper coverage: Arctic Cat 250 2008 Service Manual and the full model-year manuals listed above. If you’re ready to rebuild that suspension without guesswork, access the factory manual. No reprints, no generic instructions—just the same reference I use at the shop. Access the Factory Manual.