Arctic Cat 250 300 400 500 2004 utility ATV Repair Service Manual

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The Arctic Cat 250, 300, 400, and 500 Utility ATVs, produced in 2004, represent robust and capable all-terrain vehicles designed for a variety of work and recreational tasks. These models...

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Tipo: Atv

Proveedor:

SKU: 89055

Etiquetas: 2004 250 300 400 500 Arctic Cat ATV Misc Powersports

Variantes de producto

Descripción

The Arctic Cat 250, 300, 400, and 500 Utility ATVs, produced in 2004, represent robust and capable all-terrain vehicles designed for a variety of work and recreational tasks. These models offer a blend of power, durability, and practicality, positioning them as strong contenders in the utility ATV market. Known for their four-stroke, liquid-cooled engines and often featuring selectable 2WD/4WD capabilities, they are engineered to handle demanding terrain. The utility focus is evident in their substantial towing capacities and cargo rack configurations, making them reliable partners for farm work, hauling, and trail exploration. This comprehensive English-language repair service manual provides detailed guidance for the maintenance and repair of the 2004 Arctic Cat 250, 300, 400, and 500 Utility ATVs. It covers all essential systems, including engine overhaul, transmission service, brake system maintenance, electrical diagnostics, and chassis/suspension adjustments. The manual includes step-by-step procedures for routine maintenance, component repair and rebuilds, and troubleshooting common issues, supported by clear diagrams and precise technical specifications. This resource is invaluable for owners, DIY enthusiasts, and professional technicians aiming to ensure the optimal performance and longevity of their Arctic Cat ATVs.

🏷️ Basic Information

Identification

Make:

Arctic Cat

Model:

250, 300, 400, 500 Utility ATV

Year:

Product Type:

Repair Service Manual

Format:

PDF Download

👋 Introduction

Market Position

Segment:

Utility ATV (All-Terrain Vehicle)

Target User:

Owners, DIY mechanics, and professional repair shops seeking detailed repair information.

Competitive Analysis

Key Competitors 2004:

Honda FourTrax, Polaris Sportsman, Yamaha Wolverine/Grizzly, Kawasaki Bayou/Prairie.

Key Features

Manual Benefit:

Enables users to perform maintenance, diagnose issues, and complete repairs efficiently and correctly, saving on labor costs.

Illustration Quality:

Illustrated with clear, step-by-step instructions and diagrams.

📋 Manual Details

Coverage Areas

Included Models:

Arctic Cat 250, 300, 400, 500 Utility ATVs

Applicable Years:

Page Count

Estimated Pages:

Varies by specific model (typically 300-600 pages for a comprehensive service manual)

Manual Type

Type:

Factory Service Manual / Workshop Manual

Language

Language:

English

Format

Digital Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine:

Engine overhaul, disassembly, assembly, tuning, lubrication, cooling system, fuel system (carburetor/injection), exhaust system, ignition system.

Transmission:

Clutch operation, gearbox service, drive shafts, final drive, belt drive maintenance (CVT).

Brakes:

Hydraulic brake system service, caliper and master cylinder repair, fluid bleeding, brake pad replacement, parking brake adjustment.

Electrical:

Wiring diagrams, battery maintenance, charging system (stator, regulator/rectifier), starting system, lighting, ignition system components, CDI unit, fuses, relays.

Chassis And Suspension:

Frame inspection, front and rear suspension geometry, shock absorber service, steering system, wheel bearings, A-arms, ball joints.

Bodywork And Trim:

Body panel removal and installation, seat, fenders, racks, lighting fixtures, graphics.

Procedures Included

Routine Maintenance:

Oil changes, filter replacements (oil, air), spark plug service, chain/belt adjustment, lubrication points.

Troubleshooting:

Diagnostic flowcharts for common problems, symptom-based troubleshooting guides for engine, electrical, and drivetrain issues.

Repair And Rebuild:

Detailed instructions for component disassembly, inspection, repair, and reassembly for all major systems.

Specifications And Torques:

Precise torque values for critical fasteners, critical measurements, and assembly specifications.

Technical Depth

Depth:

Comprehensive (from basic maintenance to complete engine and transmission rebuilds, detailed electrical diagnostics).

📊 Manual Specifications

File Format

Digital Format:

Portable Document Format (PDF)

Print Quality

Image Resolution:

High-resolution scanned images for clear diagrams and text.

Binding Type

Binding Type:

N/A (Digital Download)

Paper Type

Paper Type:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Four-stroke, liquid-cooled, SOHC (Single Overhead Camshaft) for 300/400/500 models; likely carbureted.

Displacement 250:

Approximately 239cc (Specific model variant applies)

Displacement 300:

Approximately 283cc (Specific model variant applies)

Displacement 400:

Approximately 375cc (Specific model variant applies)

Displacement 500:

Approximately 499cc (Specific model variant applies)

Performance

Horsepower Range:

Estimated 15-30 HP depending on model displacement and tuning (specifications vary significantly by model).

Fuel System

Fuel Delivery:

Carburetor (e.g., Mikuni) for most 2004 utility models, though some higher displacement models might have fuel injection options depending on sub-trim.

Fuel Type:

Unleaded gasoline (octane rating as specified in the manual).

🔧 Transmission

Standard

Transmission Type:

Automatic CVT (Continuously Variable Transmission) with high/low range and reverse.

Optional

Optional Gearbox:

N/A for this utility segment in 2004.

Features

Drive Modes:

2WD/4WD selectable, often with locking front differential (on 400/500 models).

Clutch Type:

Automatic centrifugal clutch with drive belt.

📐 Dimensions

Exterior

Dimensions Overall:

Varies by model (typically around 80-85 inches L x 45-50 inches W x 45-50 inches H).

Weights

Dry Weight:

Varies by model (typically 500-700 lbs).

Towing Capacity:

Typically 500-1000 lbs (varies by model).

Cargo Capacity Rack:

Front and rear racks with substantial weight limits (e.g., 50-100 lbs front, 100-200 lbs rear).

🛡️ Safety Features

Ratings

Safety Standards:

Meets ANSI standards for ATVs. (No specific crash test ratings like cars).

Active Features

Braking System:

Hydraulic disc brakes on all wheels, often with sealed parking brake.

Suspension Stability:

Independent front suspension (IFS) on most models for improved handling and stability, rear swingarm or independent suspension depending on model.

Passive Features

Lighting:

Headlights, taillight, brake light for visibility and signaling.

Hand Grips And Levers:

Ergonomically designed controls for safe operation.

💡 Technology Features

Infotainment

Infotainment System:

N/A (Basic utility ATVs of this era typically did not feature advanced infotainment systems beyond essential controls).

Driver Assistance

Driver Assistance Features:

N/A (Focus on mechanical systems and basic controls, no electronic driver aids).

Connectivity

Connectivity Options:

🔧 Maintenance

Service Intervals

Engine Oil Change:

Typically every 50-100 hours or annually (refer to specific manual for exact intervals and conditions).

Air Filter Cleaning Replacement:

Inspect every 20 hours, clean or replace as needed, more frequently in dusty conditions.

Spark Plug Service:

Inspect annually or as recommended, replace as needed (typically based on mileage/hours).

Fluid Specifications

Engine Oil Type:

API SG or higher, SAE 10W-40 or 20W-50 motorcycle/ATV specific oil recommended. (Manual will specify exact viscosity and API rating).

Transmission Oil Type:

Specific Arctic Cat synthetic gear oil or equivalent is often recommended for the CVT and final drive. (Refer to manual for exact part number and type).

Coolant Type:

Ethylene glycol-based antifreeze mixed 50/50 with distilled water (typically green or orange type).

Brake Fluid Type:

DOT 3 or DOT 4 hydraulic brake fluid.

Known Issues

Common Wear Items:

CVT belt wear, suspension bushings, wheel bearings, brake pad wear, starter motor longevity.

Electrical Connections:

Corrosion in electrical connectors, especially in wet environments, can lead to intermittent issues.

📚 Vehicle History

Brand Heritage

Manufacturer:

Arctic Cat (Textron Specialized Vehicles)

Origin:

Founded in 1960, with a strong history in snowmobiles and later expanding into ATVs.

Model Evolution

Utility Atv Development:

Arctic Cat's utility ATVs were developed to compete in the growing recreational and work-use market, emphasizing durability and capability.

2004 Updates:

The 2004 models represented a refinement of Arctic Cat's utility ATV line, building on previous generations with updated styling and potentially improved features across the 250, 300, 400, and 500 series.

Production

Manufacturing Location:

Primarily USA (Thief River Falls, Minnesota)

🏆 Awards & Recognition

Recognitions

Industry Awards:

Specific awards for these models in 2004 are not widely documented in a general sense, but Arctic Cat ATVs were generally well-regarded for their utility and value proposition in the segment.

Ratings

Consumer Reviews 2004:

Generally positive for their ruggedness and towing capabilities, with some criticism of rider comfort on longer rides compared to premium models.