Market Position:
Essential technical resource for owners and technicians maintaining 2002 Arctic Cat ATVs. Provides factory-level detail for reliable repairs and upkeep.
Competitive Analysis:
This manual offers superior value by covering a broad range of 2002 Arctic Cat ATV models within a single document, including variations in drivetrain and suspension. It's a factory-level guide, providing accuracy unmatched by generic repair books.
Key Features:
Includes detailed part diagrams, torque specifications, wiring diagrams, troubleshooting guides, and step-by-step repair procedures. Offers a complete reference for all maintenance and repair tasks.
Coverage Areas:
2002 Arctic Cat 250 2x4, 2002 Arctic Cat 300 2x4, 2002 Arctic Cat 300 4x4, 2002 Arctic Cat 375 2x4, 2002 Arctic Cat 375 4x4, 2002 Arctic Cat 400 2x4, 2002 Arctic Cat 400 4x4, 2002 Arctic Cat 500 4x4, 2002 Arctic Cat 500 4x4 TBX. Covers all variations including automatic/manual transmissions, FIS and ACT rear suspensions.
Manual Type:
Factory Repair Manual / Service Manual
Format:
PDF (Downloadable)
Systems Covered:
Engine, Transmission, Drivetrain (2WD/4WD), Suspension (Front/Rear), Brakes, Electrical System, Fuel System, Cooling System, Ignition System, Steering System, Chassis, Body Panels, Accessories.
Procedures Included:
Complete tear down and rebuild procedures, scheduled maintenance, routine servicing, troubleshooting, diagnostics, repair procedures, installation of components, adjustments, fluid changes, tune-ups.
Technical Depth:
Comprehensive. Covers from basic maintenance to in-depth engine and transmission overhauls. Includes detailed diagnostic flowcharts and specific repair instructions.
Wheel Bearing Maintenance:
Includes procedures for inspecting, greasing, and replacing wheel bearings to prevent premature failure and maintain smooth wheel rotation.
Throttle Cable Adjustment:
Detailed instructions for adjusting throttle cable free play to ensure proper throttle response and prevent sticking.
Gearshift Linkage Adjustment:
For manual transmission models, covers adjustment of gearshift linkage for precise gear engagement.
Radiator And Cooling System:
While primarily air-cooled, some models might have oil coolers or specific fan systems. The manual covers maintenance of these components and coolant checks if applicable.
Exhaust System Maintenance:
Includes inspection and maintenance of the exhaust system for leaks and damage, and potential recommendations for muffler packing or spark arrestor cleaning.
Starter Motor And Charging System:
Detailed troubleshooting for the electric starter motor, battery condition, and charging system (rectifier, stator output) to ensure reliable starting.
Body Panel Removal And Installation:
Instructions for removing and reinstalling plastic body panels, fenders, and trim pieces for access to internal components.
Engine Type:
Air-cooled, 4-stroke, SOHC (Single Overhead Camshaft) gasoline engines.
Engine Displacement Range:
Approximately 246cc to 499cc, depending on the specific model variant (e.g., 250, 300, 375, 400, 500).
Fuel System Type:
Carburetor-based fuel delivery system. Specific carburetor models and jetting will vary by engine displacement.
Carburetor Tuning:
Includes instructions for carburetor disassembly, cleaning, reassembly, and adjustment of idle speed, mixture screws, and pilot/main jets for optimal performance and fuel efficiency.
Performance Notes:
While exact horsepower and torque figures are model-specific and detailed within the manual, these engines were designed for reliable utility and trail performance typical of their displacement classes.
Engine Construction Notes:
Features cast-iron cylinder blocks and aluminum cylinder heads. Piston design, connecting rod type (conrod), and crankshaft specifications are detailed for rebuilds.
Cooling System Type:
Air-cooled, with potential for oil cooling depending on the model variant. Maintenance of cooling fins and oil levels is critical and covered.
Engine Component Rebuild:
Covers detailed procedures for engine overhaul, including piston and cylinder inspection/replacement, valve clearance adjustment, camshaft installation, crankshaft balancing, and bearing checks.
Transmission Type Options:
Automatic (CVT - Continuously Variable Transmission) and Manual transmission options are covered, depending on the specific model variant.
Transmission Features:
Includes coverage of forward, neutral, and reverse gears for automatic models, and standard gear shifting for manual transmission models. Drive-by-wire throttle systems may also be covered for specific models.
Drivetrain Options:
Covers both 2WD (rear-wheel drive) and 4WD (four-wheel drive) configurations. Includes details on drive shafts, differentials, and axle maintenance.
Clutch System:
For CVT models, the manual details primary and secondary clutch operation, roller maintenance, and belt replacement procedures. Manual transmission models will have clutch lever and cable adjustments covered.
Suspension Types Covered:
Details the operation and maintenance of front independent suspension (often MacPherson strut or double A-arm) and rear suspension systems, including ACT and FIS configurations. Covers shock absorber and spring adjustments/replacements.
Dry Weight Range:
Typically ranging from approximately 500 lbs to 650 lbs depending on model and 2WD/4WD configuration. Specific weights for each model are detailed in the manual.
Payload Capacity:
The manual will contain specific payload and towing capacities for each model, typically focused on utility tasks.
Length Width Height Range:
Specific dimensions vary significantly by model, but generally fall within typical ATV footprints for this era. The manual provides exact measurements for each model.
Safety Features:
The manual covers brake system operation (hydraulic disc brakes front and rear), suspension tuning for stability, and electrical system diagnostics related to safety features like lights and kill switches.
Brake System Type:
Hydraulic disc brakes on both front and rear axles. Coverage includes brake pad replacement, caliper servicing, master cylinder maintenance, and bleeding procedures.
Electrical Safety Features:
Wiring diagrams are provided for all electrical components, including lighting, ignition, starter system, kill switches, and any accessory wiring, enabling troubleshooting of electrical safety concerns.
Technology Features:
While 2002 ATVs are less technologically advanced than modern machines, the manual covers electronic components such as the ignition system (CDI, stator, coil), battery charging system (rectifier/regulator), switches, lights, and basic instrumentation.
Ignition System Components:
Detailed information on the CDI unit, ignition coil, stator, and spark plug, including resistance values and testing procedures for diagnosing no-spark or weak-spark issues.
Wiring Diagrams:
Complete and detailed wiring diagrams are included, essential for diagnosing and repairing any electrical system fault, including lighting, battery charging, and ignition circuits.
Service Intervals Overview:
The manual provides detailed maintenance schedules, typically including initial break-in service, oil changes (engine oil, transmission/final drive oil), air filter cleaning/replacement, spark plug checks, brake inspections, and lubrication points at specific mileage or time intervals.
Engine Oil Specification:
Specifies recommended SAE viscosity grade (e.g., 10W-40 or 20W-50) and API service classification (e.g., SG or higher) for engine oil. Also details transmission and differential fluid types and capacities.
Common Issues Covered:
The troubleshooting section addresses common issues such as starting problems, carburetor performance, electrical faults, drive train noises, and suspension wear, providing diagnostic steps and repair solutions.
Lubrication Points:
Details specific grease points for suspension linkages, steering components, and other moving parts to ensure smooth operation and prevent wear.
Air Filter Maintenance:
Instructions for inspecting, cleaning, and replacing the air filter element, crucial for engine longevity and performance. Includes any specific filter part numbers.
Tire Pressure Specifications:
Provides recommended tire pressures for front and rear tires for optimal performance and handling across various terrains.
Troubleshooting Approach:
Systematic approach to diagnosing problems, often starting with visual inspections, checking fluid levels, electrical connections, and then moving to component-specific tests.
Engine Oil Change Procedure:
Step-by-step guide for draining old oil, replacing the oil filter (if applicable), and refilling with the correct type and amount of new engine oil. Includes oil capacity figures.
Brake Fluid Specifications:
Specifies the required DOT brake fluid type (e.g., DOT 3 or DOT 4) for the hydraulic brake system and the procedure for flushing and replacing the brake fluid.
Brand Heritage:
Arctic Cat, with a long history in powersports, has consistently produced rugged and capable ATVs designed for utility and recreational use. The 2002 models represent a mature generation of their ATV platform.
Model Evolution Notes:
The 2002 lineup builds upon previous generations, offering refined engines and chassis designs. Key advancements like Independent Front Suspension (FIS) and the Arctic Cat Suspension (ACT) system are integrated into various models, enhancing ride quality and handling.
Production Location:
Arctic Cat ATVs are primarily manufactured in the United States.
