Target Audience:
Owners of 2004 Arctic Cat 250, 300, 400, and 500 series ATVs seeking to perform their own maintenance, repairs, and diagnostics.
Manual Advantage:
Offers comprehensive coverage for multiple ATV models within a single, easily accessible digital format, unlike fragmented or proprietary service information.
Delivery Method:
Instant download post-payment, eliminating shipping delays and costs.
Usability:
Designed for ease of use on various devices (computers, tablets, smartphones) for on-the-trail or workshop reference.
Support:
Includes a lifetime protection policy for lost or damaged files.
Covered Models:
250 4x2, 250 4x4, 300 4x4, 400 4x2, 400 4x2 AUTO, 400 4x4 (ATC), 400 4x4, 400 4x4 AUTO (ACT), 400 4x4 AUTO, 400 4x4 AUTO TBX, 500 4x4, 500 4x4 AUTO, 500 4x4 AUTO TBX, 500 4x4 AUTO TRV
Type:
Repair Manual / Service Manual / Workshop Manual
Format Type:
Downloadable PDF
Engine:
Detailed coverage of engine removal, installation, tuning, and internal component overhaul (pistons, rings, valves, crankshaft, etc.). Includes specific torque values and clearances.
Fuel System:
Carburetor adjustment, cleaning, and rebuilding. Fuel pump operation, fuel filter replacement, and fuel line maintenance.
Lubrication And Cooling:
Oil change procedures, fluid specifications, oil filter replacement. Radiator maintenance, fan operation, thermostat testing, and coolant flush.
Transmission Drivetrain:
Manual and Automatic transmission service, including fluid checks, changes, and internal repairs. Drive chain inspection, adjustment, and replacement. CV joint maintenance and boot replacement.
Steering:
Steering column maintenance, tie rod end replacement, steering linkage adjustments, and troubleshooting steering play.
Shocks Suspension:
Front and rear shock absorber inspection, service, and replacement. Suspension arm bushings and ball joint checks and replacement.
Bodywork:
Panel removal and installation, fender repairs, and cosmetic maintenance. Seat and rack installation/removal.
Intake Exhaust:
Air filter inspection and replacement. Exhaust system inspection for leaks and damage. Muffler and pipe maintenance.
Electrical System:
Battery testing and maintenance, charging system (stator, regulator/rectifier) diagnostics. Starter motor and solenoid testing. Lighting system troubleshooting. Ignition system components (spark plug, coil). Wiring diagrams for all electrical circuits.
Maintenance:
Routine maintenance schedules, lubrication points, filter replacement intervals (oil, air), spark plug maintenance, and general cleaning procedures.
Troubleshooting:
Comprehensive diagnostic procedures for common and complex issues across all systems. Symptom-based troubleshooting guides.
Repair Rebuild:
Detailed step-by-step instructions for disassembling, inspecting, repairing, and reassembling major components and systems, including engine internals, transmissions, and suspension.
Diagnostics:
Fault finding, testing procedures for electrical components, fuel system diagnostics, and mechanical system checks.
Depth Level:
Advanced diagnostics, complete engine and transmission rebuilds, detailed electrical system troubleshooting, and component-level repair.
File Type:
PDF (Portable Document Format)
Searchability:
Fully searchable text for quick access to information.
Print Readability:
Optimized for clear printing, allowing users to print specific pages for workshop use.
Binding:
Not Applicable (Digital Download)
Paper Quality:
Not Applicable (Digital Download)
Engine Type:
Single-cylinder, 4-stroke
Displacement Cc 250:
Approximately 248.9 cc (specific variants may differ slightly)
Engine Type:
Single-cylinder, 4-stroke
Displacement Cc 300:
Approximately 287 cc
Engine Type:
Single-cylinder, 4-stroke, SOHC
Displacement Cc 400:
Approximately 375 cc
Engine Type:
Single-cylinder, 4-stroke, SOHC
Displacement Cc 500:
Approximately 498.5 cc
Cooling System:
Liquid-cooled (all covered models)
Carburetor Type:
Mikuni (specific models vary, e.g., Mikuni BSR42/BSR40)
Ignition System:
CDI (Capacitor Discharge Ignition)
Transmission Type Manual:
5-speed manual with reverse (e.g., 250, 300, 400 models)
Transmission Type Automatic:
CVT (Continuously Variable Transmission) with Hi/Low range and Reverse (e.g., 400 AUTO, 500 AUTO models)
Drive System:
2WD or 4WD (selectable or automatic engagement depending on model)
Final Drive:
Shaft drive with enclosed U-joints and differentials.
Cv Fluid:
Specific CVT fluid required (refer to manual for exact type, often a proprietary blend or specified SAE grade).
Typical Length In:
Approx. 78-82 inches (varies by model)
Typical Width In:
Approx. 46-48 inches (varies by model)
Typical Height In:
Approx. 45-48 inches (varies by model)
Typical Dry Weight Lbs:
Approx. 550-650 lbs (varies significantly by model and configuration)
Typical Ground Clearance In:
Approx. 7-11 inches (varies by model)
Infotainment System:
Not Applicable (Basic ATV controls, no digital infotainment system).
Driver Assistance Features:
None (standard controls for throttle, brake, gear selection, 2WD/4WD).
Connectivity Options:
None (standard analog instrumentation).
Oil Change Interval Hours:
Typically every 100 hours or annually (refer to specific model recommendations within the manual).
Air Filter Inspection:
Inspect every 20-40 hours or as needed based on operating conditions. Clean or replace as necessary.
Spark Plug Replacement:
Replace typically every 100-200 hours or as indicated by performance.
Engine Oil Type:
SAE 10W-40 or 20W-50, API SG or higher (refer to manual for exact specification, e.g., Arctic Cat SYN-4 4-Stroke Oil).
Engine Oil Capacity Qts:
Approx. 2.0-2.5 quarts (varies by model, check dipstick).
Coolant Type:
Ethylene glycol-based antifreeze, compatible with aluminum engines (typically a 50/50 mix with distilled water).
Common Wear Items:
CV boots, tie rod ends, wheel bearings, brake pads, and drive belts (for CVT models) are common wear items.
Carburetor Issues:
Carburetor clogging due to fuel varnish or debris is a common maintenance point for older carbureted models.
Arctic Cat Atv History:
Arctic Cat has a long history in powersports, transitioning from snowmobiles to ATVs and UTVs, known for their utility and off-road capabilities.
2004 Model Context:
The 2004 models represent a mature generation of Arctic Cat ATVs, incorporating improvements based on previous years of production. The 400 and 500 series were particularly popular for their performance and utility.
Manufacturing Location:
Typically manufactured in Thief River Falls, Minnesota, USA.
