🏷️ Basic Information

Make:

Arctic Cat

Model:

Snowmobile Service Manual

Year:

2002

Manual Product Id:

2002ACSM

👋 Introduction

Positioning:

Essential DIY and professional resource for owners of 2002 Arctic Cat snowmobiles, emphasizing ease of home maintenance and repair.

Competitors:

Direct competitor to factory service manuals and other aftermarket repair guides for the 2002 Arctic Cat snowmobile lineup. Offers comprehensive coverage across multiple popular models.

Features:

Detailed model coverage, extensive diagnostic information, step-by-step repair procedures, printable format, emphasis on home mechanic accessibility.

📋 Manual Details

Covered Models:

BEARCAT WIDETRACK, MOUNTAIN CAT (500, 570, 600EFI, 600EFI LE, 800, 800EFI, 800LE, 800EFI LE, 1000), PANTERA (550, 600 EFI, 800 EFI), PANTHER (440, 570 ESR, 570 R), THUNDERCAT, Z370 (370, 370 ES), Z440 (440, 440 ES), Z570 (570, 570 ESR, 570 SS), ZL (500, 550, 550 ESR, 600 EFI, 600 EFI ESR, 600 EFI SS, 600 EFI SS EB, 800 EFI ESR, 800 EFI SS), ZR (120, 500, 500 LE EB, 500 CC, 600, 600 EFI, 600 EFI CC, 800, 800 EFI, 800 EFI CC), ZRT 600

Pages:

710

Type:

Service Manual

Language:

English

Format:

PDF Download

📖 Manual Coverage

Systems:

General Information, Engine Mechanical, Engine Related Items, Fuel Systems, Engine Electrical Systems, Chassis Electrical Systems, Track and Rear Suspension, Steering and Body, Drivetrain and Brake Systems

Engine Mechanical:

Detailed coverage of engine teardown, rebuilding, piston inspection, cylinder honing, crankshaft service, valve timing (if applicable to specific models, though most are 2-stroke), and component torque specifications.

Engine Electrical:

Includes ignition system (CDI, stator, coils, spark plugs), starting system (recoil and electric start components), lighting systems, and wiring diagrams for troubleshooting electrical faults.

Chassis Electrical:

Covers handlebar controls, kill switches, hand/thumb warmer circuits, gauge cluster electrical connections, and battery maintenance for electric start models.

Track Rear Suspension:

Procedures for track inspection, tension adjustment, slide rail maintenance, bogie wheel bearing checks, and shock absorber service. Covers various suspension designs used across the model range.

Steering Body:

Includes ski alignment, spindle service, steering post lubrication, handlebar mounting, seat removal, hood and side panel removal/installation, and bumper/skirt maintenance.

Drivetrain Brakes:

Detailed information on the Arctic Drive System (clutches), chaincase inspection and oil changes, reverse mechanism (if equipped), brake caliper service, master cylinder overhaul, and rotor inspection.

General Information:

Includes basic safety precautions, vehicle identification numbers (VIN), towing information, storage procedures, and general specifications relevant to all models.

Procedures:

Routine Maintenance, Troubleshooting, Repair, Component Disassembly and Reassembly, Adjustments, Inspections, Electrical Diagnostics, Clutch Service, Suspension Service, Brake System Maintenance, Fuel System Servicing, Engine Overhaul

Maintenance Procedures:

Step-by-step guides for oil changes, filter replacements (air and fuel), spark plug checks and replacement, belt inspections, lubrication points, and coolant system flushing.

Troubleshooting Guides:

Extensive troubleshooting trees and diagnostic flowcharts for common starting, running, electrical, and performance issues specific to the 2002 Arctic Cat engine and electrical systems.

Repair Procedures:

Comprehensive instructions for component replacement, such as engine rebuilds, transmission service, suspension repairs, and bodywork modifications.

Engine Tune Up:

Covers procedures for timing adjustments, carburetor synchronization and tuning, and emissions control system checks where applicable.

Depth:

Comprehensive - Covers from basic scheduled maintenance to in-depth engine and component overhaul, including diagnostics and repair procedures for all covered systems.

Diagnostic Capabilities:

Provides diagnostic procedures for electrical systems using multimeters, identifying ignition timing issues, and diagnosing fuel delivery problems in both carbureted and EFI systems.

Rebuild Procedures:

Detailed, illustrated instructions for complete engine rebuilds, including specifications for critical wear components like pistons, rings, bearings, and gaskets.

Torque Specifications:

Provides precise torque values for critical fasteners across all major components, essential for proper assembly and preventing damage.

Wiring Diagrams:

Detailed, model-specific wiring diagrams are included, crucial for diagnosing and repairing electrical system faults, including lighting, ignition, and accessories.

📊 Manual Specifications

File Type:

PDF

Searchability:

PDF format typically allows for text searching, greatly enhancing the ability to quickly locate specific information.

Print Options:

Printable, allowing users to print only necessary sections for convenient workshop use.

Binding:

N/A (Digital Download)

Paper Type:

N/A (Digital Download)

⚙️ Engine Specifications

Engine Types Covered:

Two-stroke engines of various displacements including 120cc, 370cc, 440cc, 500cc, 550cc, 570cc, 600cc, 800cc, and 1000cc. Specific EFI (Electronic Fuel Injection) variants are also detailed.

Cooling System:

Covers both liquid-cooled and fan-cooled systems, including coolant capacity, type of coolant required, flushing procedures, and thermostat testing.

Engine Identification:

Details on identifying engine serial numbers and specific engine codes for each model variant, important for parts ordering and diagnostics.

Performance Details:

Manual provides specifications for horsepower, torque, and tuning for the various engine configurations across the model range, crucial for optimal performance and diagnostics.

Carburetor Specifications:

For carbureted models, the manual provides specific jet sizes, needle settings, float bowl adjustments, and synchronisation procedures for Mikuni and Keihin carburetors common on these sleds.

Fuel System Coverage:

Covers carbureted and Electronic Fuel Injection (EFI) systems, including fuel pump, injectors, fuel lines, filters, and tank maintenance. Essential for diagnosing fuel delivery issues.

Efi System Details:

For EFI models, details on throttle bodies, fuel injectors, fuel pressure regulators, MAP sensors, TPS sensors, and ECU diagnostics. Specific EFI system fault codes may be listed.

🔧 Transmission

Transmission Type:

CVT (Continuously Variable Transmission) with Arctic Drive System (ADS) primary and secondary clutches.

Optional Features:

Manual may cover variations in clutch calibration or gear reduction ratios where applicable to specific models.

Transmission Features:

Detailed procedures for clutch inspection, belt replacement, clutch alignment, and troubleshooting common CVT issues like slippage or poor engagement.

📐 Dimensions

Exterior Dimensions:

While specific exterior dimensions (length, width, height) vary significantly by model (e.g., Widetrack vs. Mountain Cat), the manual provides schematics and component dimensions relevant to repair and assembly.

Weight Specifications:

Information on dry weights and operating weights for each model covered, important for transport and handling.

🛡️ Safety Features

Safety Ratings:

N/A (Snowmobiles are not typically rated by organizations like NHTSA or IIHS. Focus is on safe operation and maintenance procedures).

Active Safety:

Guidance on proper maintenance of braking systems, steering mechanisms, and throttle controls, which are critical active safety features.

Passive Safety:

Information related to seat and handlebar integrity, foot stirrup condition, and protective bodywork components.

💡 Technology Features

Infotainment Systems:

Basic instrumentation typical for the era: speedometer, tachometer, engine temp gauge, fuel gauge, and indicator lights. Manual covers diagnostics for these systems.

Driver Assistance:

N/A (Snowmobiles of this era do not feature electronic driver assistance systems in the modern automotive sense).

Connectivity Features:

N/A

🔧 Maintenance

Scheduled Maintenance:

The manual details recommended service intervals for oil changes, spark plug replacement, filter checks, track tension, brake fluid flush, coolant checks, and clutch inspection.

Clutch Maintenance:

Recommended intervals for clutch inspection, cleaning, weight and spring replacement for tuning, and sheave condition checks.

Fluid Recommendations:

Provides specific grades and capacities for engine oil (e.g., Arctic Cat's recommended 2-stroke synthetic oil), coolant (type and mixture ratio), and brake fluid (DOT 4 is common).

Chaincase Oil:

Specifies the correct type and viscosity of gear oil for the chaincase, along with fluid capacity and change intervals.

Brake Fluid:

Specifies the type of brake fluid (commonly DOT 4) and recommended intervals for flushing and replacement to maintain braking performance and prevent corrosion.

Common Issues 2002:

While not explicitly stated as a 'known issues' section, the manual's troubleshooting guides implicitly address common problems of the era such as carburetor issues, clutch wear, exhaust leaks, and electrical connector corrosion.

Suspension Wear:

Guidance on identifying worn bushings, ball joints, and shock absorber leaks, common wear points on snowmobile suspensions.

Fuel System Clogging:

Guidance on cleaning fuel filters, carburetors, and EFI injectors, addressing common issues related to fuel quality or contaminants.

📚 Vehicle History

Arctic Cat Heritage:

Arctic Cat has a long-standing reputation in the snowmobile industry, known for innovation and performance-oriented machines dating back to the 1960s.

Model Evolution 2002:

The 2002 lineup represented a mature stage of Arctic Cat's development, with popular models like the Mountain Cat focusing on deep snow performance, the Pantera on trail comfort, and the Z/ZL series on sport riding. The Widetrack Bearcat continued its legacy as a utility workhorse.

Performance Variants:

The manual covers a wide range of performance levels within the 2002 Arctic Cat lineup, from the entry-level 120 and 370 models to the high-performance 800 and 1000cc machines.