Description

Arctic Cat 500, 400 FIS, 650 H1, 650 V-Twin Service Manual – Section 6 Drive System

I’ve watched good mechanics burn two billable hours on a front differential because they guessed at a torque spec for a thread-rolling screw. That screw strips the aluminum housing if you over-torque it by 10 ft-lb. This Arctic Cat 500, 400 FIS, 650 H1, 650 V-Twin Service Manual is 36 pages of factory data for Section 6 – the whole drive system. It covers the front drive actuator, front differential, drive axles, ACT rear suspension, rear gear case, hubs, and the hydraulic brake caliper. If you’re touching any of those assemblies on a 500, 400 FIS, 650 H1, or 650 V-Twin, you need the OEM numbers. Aftermarket reprints skip steps, and that’s how you end up with a torn CV boot or a leaking seal.

36 Pages of Factory Drive System Data

This isn’t a whole-machine manual. It’s Section 6 pulled from the full Arctic Cat service set, and it’s dense. Thirty-six pages cover the front drive actuator (400 FIS/500/650 H1/650 V-Twin), front differential for FIS models, drive axles, ACT rear suspension, rear gear case, hubs, and the hydraulic brake caliper. Each subsection has its own schematics and torque values. You get the production date code tags, ratio codes (like “6” for 3.6:1, “1” for 3.1:1), and special tool listings from Arctic Cat Service Parts. No fluff – just the steps you follow on a lift.

Front Drive Actuator and Differential Coverage

The manual walks through the front drive actuator removal and inspection for all four models – 500, 400 FIS, 650 H1, and 650 V-Twin. For FIS models, the front differential section (starting page 6-4) shows you the gear case assembly, shimming, and the exact seal replacement procedure. It notes that die-cast aluminum housings use thread-rolling screws (trilobular) with specific torque values. If you skip the torque spec and just ugga-dugga them, you’ll strip the threads. I’ve seen it happen. Page 6-2 lists the general specifications and special tools required – don’t start without reading that page.

What About the Suspension and Brakes?

The Suspension section is ACT – Arctic Cat’s Active Control Technology for the rear. There’s a schematic on page 6-29 that ties the rear suspension to the rear drive assembly. You need that drawing to see how the swingarm and drive shaft interact. The Brake section covers the hydraulic brake caliper starting page 6-32. It gives you the caliper piston removal, seal replacement, and bleeding procedure. The brake assembly schematics on page 6-34 show you the exact orientation of the pads and springs. If you put them in backwards, the caliper drags. I’ve had guys bring me their ATV after doing that – don’t be that guy.

Read the Torque Specs Before You Touch a Bolt

Every fastener in this manual has a factory torque value. The thread-rolling screws used in the gear case housings have a specific range – the manual tells you where to find it (Section 1 for capacities, but Section 6 for the assembly torque). The hub nut, drive axle bolts, brake caliper mounting bolts – all listed. Don’t rely on a generic chart from a parts store. The difference between 25 ft-lb and 35 ft-lb on a brake caliper bolt can mean a pulled thread or a loose caliper. This manual gives you the right number because it came from the factory.

ACT Rear Suspension: What the Manual Shows

The ACT rear suspension isn’t just springs and shocks. It’s a linked system with the rear gear case. The manual has a full schematic on page 6-29 showing the tie rods, torsion springs, and the drive shaft alignment. You need that schematic to adjust the suspension preload correctly or to diagnose a binding noise. The troubleshooting section (page 6-2) tells you how to differentiate gear case noise from CV joint noise – wheel speed vs. engine RPM. That’s the kind of diagnostic shortcut that saves you an hour of tearing down the wrong component.

Service Manual Depth: 4 Models in One Document

One document covers the 500, 400 FIS, 650 H1, and 650 V-Twin. That means you get one set of procedures for four different machines. The manual flags differences – for example, the front differential applies only to FIS models; the front drive actuator applies to all four. You don’t have to buy a separate manual for each ATV. If you own a 650 H1 and a 400 FIS, this one section covers both drive systems. That’s value, not fluff.

Related Manuals

• Arctic Cat 250 300 400 500 Service Manual”>Arctic Cat 250 300 400 500 Service Manual
• Arctic Cat 250 300 400 500 Service Manual Section 4″>Arctic Cat 250 300 400 500 Service Manual Section 4
• Arctic Cat 250 300 400 500 ATV Electrical System Service”>Arctic Cat 250 300 400 500 ATV Electrical System Service

For background on how a Manual Transmission works (though this manual doesn’t cover that), or to understand Catalytic Converters on newer ATVs, check those external references. But for the drive system on these four Arctic Cats, this is the only source you need.

Does this manual cover the engine?

No. This covers the drive system – Section 6 only.

What torque values are listed?

The manual lists torque values for the thread-rolling screws used in die-cast aluminum housings. It also references Section 1 for capacities. You’ll find values for front differential, rear gear case, brake caliper bolts, hub nuts, and more. The factory spec for the gear case ratio tags is also provided. Don’t guess – use the numbers printed on pages 6-2 and subsequent sections. If you don’t have the exact torque, you’re risking stripped threads or leaks. This manual gives you the range from the factory engineering team, not a generic chart.

Is this manual for 400 FIS only?

No. It covers 500, 400 FIS, 650 H1, and 650 V-Twin. Differences are noted per model.

How many pages?

36 pages.

You need this manual on your workbench if you’re rebuilding a front differential, replacing a drive axle, or servicing the rear brake caliper on any of these Arctic Cats. The factory schematics and torque specs will keep you from making a mistake that costs a hundred dollars in parts. Access the Factory Manual now and keep it loaded on your tablet or print it out – but use it. That’s the only way to get this job done right the first time.