Snowmobile 2-Stroke 2002 Service Repair Manual

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Tipo: Snowmobile

Proveedor:

SKU: 73075

Etiquetas: 2002 4 Stroke Engines Manuals Engines Kawasaki Sno Jet Snowmobile Unknown

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Descripción

This manual covers the 2002 Arctic Cat 2-Stroke Snowmobiles, a line renowned for its powerful twin-cylinder engines and performance-oriented designs, catering to both trail riding and aggressive mountain excursions. Arctic Cat has a long heritage in snowmobile manufacturing, and the 2002 lineup featured a diverse range of 2-stroke engines, from 120cc to 1000cc, with increasing adoption of Electronic Fuel Injection (EFI) and advanced suspension systems. These snowmobiles are characterized by their aggressive styling, aerodynamic fairings, and robust engineering, built for reliability and exhilarating performance in challenging winter conditions. This comprehensive service repair manual provides detailed information for owners, mechanics, and technicians to maintain and repair all 2002 Arctic Cat 2-Stroke models. It covers a wide array of systems, including general information, engine components, fuel systems (carburetion and EFI), electrical systems, chassis, drivetrain, brakes, and suspension. The manual includes routine maintenance procedures, in-depth troubleshooting guides, component disassembly and reassembly instructions, engine tuning, and detailed diagnostic procedures, offering a complete resource from basic upkeep to complete engine rebuilds and electrical system repairs.

🏷️ Basic Information

Identification

Make:

Arctic Cat

Model:

2-Stroke Snowmobiles

Year:

Codes

Manual Product Code:

Not Specified

👋 Introduction

Market Position

Segment:

Performance and Trail Snowmobiles

Target Audience:

DIY mechanics, snowmobile enthusiasts, service technicians

Competitive Analysis

Competitors 2002:

Ski-Doo, Yamaha, Polaris

Key Features

Brand Strength 2002:

Known for powerful twin-cylinder engines and a focus on aggressive riding and trail performance.

📋 Manual Details

Coverage Areas

Model Coverage List:

• All 2002 2-Stroke Models

• 2002 Arctic-Cat 120 cc Model

• 2002 Arctic-Cat Twin F/C Models

• 2002 Arctic-Cat 500/600/800 cc Twin Models

• 2002 Arctic-Cat 550 cc Models

• 2002 Arctic-Cat Triple Models

• 2002 Arctic-Cat Bearcat W/T

• 2002 Arctic-Cat Mountain Cat 500

• 2002 Arctic-Cat Mountain Cat 570

• 2002 Arctic-Cat Mountain Cat 600 EFI

• 2002 Arctic-Cat Mountain Cat 600 EFI LE

• 2002 Arctic-Cat Mountain Cat 800

• 2002 Arctic-Cat Mountain Cat 800 LE

• 2002 Arctic-Cat Mountain Cat 800 EFI

• 2002 Arctic-Cat Mountain Cat 800 EFI LE

• 2002 Arctic-Cat Mountain Cat 1000

• 2002 Arctic-Cat Pantera 550

• 2002 Arctic-Cat Pantera 600 EFI

• 2002 Arctic-Cat Pantera 800 EFI

• 2002 Arctic-Cat Panther 440

• 2002 Arctic-Cat Panther 570

• 2002 Arctic-Cat Thundercat

• 2002 Arctic-Cat Z 370

• 2002 Arctic-Cat Z 440

• 2002 Arctic-Cat Z 570

• 2002 Arctic-Cat Z 570 SS

• 2002 Arctic-Cat Z 570 esr

• 2002 Arctic-Cat ZL 500

• 2002 Arctic-Cat ZL 550

• 2002 Arctic-Cat ZL 550 esr

• 2002 Arctic-Cat ZL 600 EFI

• 2002 Arctic-Cat ZL 600 EFI esr

• 2002 Arctic-Cat ZL 600 EFI SS

• 2002 Arctic-Cat ZL 600 EFI SS esr

• 2002 Arctic-Cat ZL 600 EFI SS (EB)

• 2002 Arctic-Cat ZL 800 EFI esr

• 2002 Arctic-Cat ZL 800 EFI SS

• 2002 Arctic-Cat ZR 500

• 2002 Arctic-Cat ZR 500 CC

• 2002 Arctic-Cat ZR 500 LE (EB)

• 2002 Arctic-Cat ZR 600

• 2002 Arctic-Cat ZR 600 EFI

• 2002 Arctic-Cat ZR 600 EFI CC

• 2002 Arctic-Cat ZR 800

• 2002 Arctic-Cat ZR 800 CC

• 2002 Arctic-Cat ZR 800 EFI

• 2002 Arctic-Cat ZR 800 EFI CC

• 2002 Arctic-Cat ZRT 600

Page Count

Total Pages:

Manual Type

Type:

Service Repair Manual

Language

Language:

English

Format

File Format:

PDF Download

📖 Manual Coverage

Systems Covered

List:

• General Information

• Engine (2-Stroke)

• Engine-Related Components

• Fuel Systems (Carburetion and EFI)

• Engine Electrical Systems (Ignition, CDI, Stator)

• Chassis Electrical Systems (Lighting, Gauges, Accessories)

• Steering System

• Bodywork and Plastics

• Drive Train (Clutch, Drive Sprocket, Chaincase)

• Brake System (Hydraulic and Mechanical)

• Track and Suspension Systems (Front and Rear)

Specific Engine Systems:

Engine top-end (pistons, rings, cylinders), crankcase, crankshaft, lubrication system, cooling system (radiator, hoses, water pump).

Chassis Systems:

Front and rear suspension geometry, shock absorber servicing, steering column, handlebars, seat, fuel tank, tunnel, skis.

Electrical Systems:

Wiring diagrams for all lighting, ignition, charging system (stator), starter motor, and accessory circuits.

Procedures Included

List:

• Routine Maintenance

• Troubleshooting Guides

• Component Disassembly and Reassembly

• Engine Tuning and Adjustments

• Carburetor and EFI System Servicing

• Ignition System Diagnosis

• Brake System Bleeding and Pad Replacement

• Suspension Component Servicing

• Clutch Inspection and Service

• Drive Belt Inspection and Replacement

• Electrical System Diagnostics

• Chassis Lubrication

• Recoil/Electric Start System Service

• Cooling System Servicing (if applicable)

• Exhaust System Inspection

Diagnostic Procedures:

Compression testing, ignition system testing, fuel delivery checks, electrical component resistance testing.

Engine Rebuild:

Detailed steps for cylinder head removal, piston replacement, ring replacement, crankshaft seal replacement, and reassembly.

Electrical Repair:

Component testing (coils, switches, sensors), wire harness repair, fuse replacement, battery maintenance.

Technical Depth

Level:

Comprehensive (from basic maintenance to complete engine rebuilds and diagnostics)

Precision:

Provides specific torque values, clearances, and specifications for accurate repairs.

Troubleshooting Charts:

Includes symptom-based troubleshooting charts to quickly diagnose common performance and operational issues.

📊 Manual Specifications

File Format

Digital Format:

Requirements:

PDF Reader Software

Print Quality

Quality:

High Resolution, Searchable Text

Readability:

Clear, legible diagrams and text, suitable for printing specific pages.

Binding Type

Digital Binding:

N/A (Digital Download)

Paper Type

Digital Medium:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Type:

2-Stroke, Reed Valve (Various Displacements)

Engine Configurations:

Single-cylinder (120cc), Twin-cylinder (various displacements), Triple-cylinder (Thundercat models).

Performance

Displacement Range:

370cc to 1000cc (approximate, varies by model)

Horsepower Range:

Varies widely, from approximately 40 HP for smaller engines to over 150 HP for larger, performance-oriented models.

Fuel System

Induction Type:

Carbureted (Mikuni, Keihin) and Electronic Fuel Injection (EFI)

Carburetor Details:

Includes detailed diagrams and adjustment procedures for common carburetor models (e.g., Mikuni VM series, TM series).

Efi Details:

Covers ECU diagnosis, sensor testing (TPS, MAP, IAT), injector cleaning, and fuel pump pressure checks.

Cooling System

Cooling Method:

Liquid-Cooled (most models)

Ignition System

Ignition Type:

CDI (Capacitor Discharge Ignition), Electronic Ignition

🔧 Transmission

Standard

Type:

CVT (Continuously Variable Transmission) with Arctic Drive System (ADS)

Optional

Features:

Variable ratio drive and driven clutches for optimal power delivery across the RPM range.

Features

Drive Belt Spec:

Specific belts vary by model and engine, requiring reference to model-specific documentation.

Clutch Service:

Detailed procedures for primary (drive) and secondary (driven) clutch disassembly, cleaning, inspection for wear, and replacement of springs/weights.

📐 Dimensions

Exterior

General Style:

Aggressive styling, aerodynamic fairings, comfortable seating positions for trail and mountain riding.

Track Dimensions:

Varies by model; track lengths typically range from 121 inches to 159 inches, with varying widths and lug heights.

Weights

Dry Weight Range:

Varies significantly by model, generally ranging from 450-700 lbs.

🛡️ Safety Features

Ratings

Safety Features:

Hand warmers, thumb warmers, high beam headlights, taillights, brake lights, kill switch tether.

Active Features

Control Systems:

Effective hydraulic disc brakes, responsive steering linkage.

Passive Features

Structural Elements:

Reinforced chassis, impact-absorbing plastic components.

💡 Technology Features

Infotainment

Gauge Cluster:

Analog speedometer, tachometer, engine temperature gauge, fuel gauge, various indicator lights (check engine, oil, etc.).

Driver Assistance

Features:

Hand and thumb warmers, electric start (optional on some models).

Connectivity

Features:

Not applicable for this era of snowmobile.

🔧 Maintenance

Service Intervals

General Guidelines:

Regular inspection of drive belt, lubrication of chaincase and suspension components, spark plug replacement, air filter cleaning/replacement, coolant check (if applicable).

Spark Plugs:

Check/replace every 1,000-2,000 miles or annually, depending on usage and spark plug type (e.g., NGK BR9ES, BR10ES).

Chaincase Inspection:

Inspect and change chaincase oil annually or every 2,000 miles.

Suspension Lubrication:

Lubricate grease points on front and rear suspension components every 2,000 miles or annually.

Fluid Specifications

Engine Oil:

2-Stroke Synthetic Snowmobile Oil (API TCW-3 or specific Arctic Cat recommendations, varies by engine).

Coolant:

Ethylene Glycol based antifreeze (50/50 mix with distilled water), specific type based on engine requirements.

Chaincase Oil:

Arctic Cat Chaincase Lube or equivalent (SAE 75W-90 synthetic gear oil often used, check manual for specifics).

Brake Fluid:

DOT 3 or DOT 4 brake fluid, depending on the braking system used (check manual for specific recommendation).

Known Issues

Common Wear Items:

Drive belts, carbides, hyfax (wear strips), suspension bushings, exhaust gaskets, stator coils on high-mileage units.

Efi Considerations:

Potential for clogged injectors or fuel pump issues with aged fuel; requires clean fuel and proper storage.

Engine Overheating:

Can be caused by low coolant, faulty thermostat, blocked heat exchanger fins, or water pump failure.

Track Alignment:

Improper track tension or alignment can lead to premature wear of the track, hyfax, and drive sprockets.

📚 Vehicle History

Brand Heritage

Company Focus:

Arctic Cat has a long history in snowmobile manufacturing, known for performance-oriented designs.

Model Evolution

2002 Lineup Characteristics:

The 2002 model year saw a broad range of 2-stroke engines, from smaller trail machines to powerful mountain sleds with EFI options becoming more prevalent.

Key Innovations 2002:

Increased adoption of EFI, advanced suspension designs (e.g., FasTrack® rear suspension), and more powerful engine options.

Production

Manufacturing Location:

USA (Thief River Falls, Minnesota)