Target Audience:
DIY enthusiasts, first-time mechanics, professional mechanics, dealerships
Features:
Step-by-step instructions, detailed drawings, clear photographs, troubleshooting guides, system illustrations, exploded parts views, diagnostic procedures
Market Segment:
This manual covers a broad range of snowmobile segments including trail performance, mountain riding, and utility/cross-country.
Covered Models:
All 2004 Arctic Cat 2-Stroke Snowmobile Models including: Bearcat 570, Firecat 500/Sno Pro, Firecat 600/Sno Pro/EFI (EB)/EFI EXT/EFI, Firecat 700/Sno Pro/EFI EXT/EFI/Sno Pro, King Cat 900, Mountain Cat 570/600 EFI/800 EFI/900, Pantera 550/600 EFI/800 EFI, Panther 370/570, Sabercat 500/LX, Sabercat 600/LX/EFI EXT/EFI/EFI LX, Sabercat 700 EFI EXT/EFI/EFI LX, Z 370/LX, Z 440 LX, Z 570/LX, ZR 900/Sno Pro
Type:
Service Manual / Workshop Manual / Repair Manual / Shop Manual
Distinction:
This is a service manual, distinct from owner's manuals (operation/safety) and parts catalogs (part numbers).
Language Clarity:
Written in clear, concise English, making it accessible to a wide range of users.
Usability:
PDF format allows for easy navigation, searching, and selective printing of specific sections for workshop use.
Primary Systems:
General Information, Engine, Engine-Related Items, Fuel Systems, Engine Electrical Systems, Chassis Electrical Systems, Steering and Body, Drive Train and Brake Systems, Track/Rear Suspension
Electrical Systems:
Engine electrical (CDI, ignition, charging system) and chassis electrical (lights, switches, gauges, wiring harnesses). Includes wiring diagrams.
Bodywork:
Covers removal and installation of body panels, seat, windshield, and graphics, along with associated fasteners and mounting hardware.
Repair Procedures:
Inspection, Service, Overhaul, Troubleshooting, Tune-up, Maintenance, Removal and Installation, Disassembly and Assembly, Diagnosis and Testing
Engine Overhaul:
Detailed procedures for engine disassembly, inspection of internal components (pistons, rings, cylinders, crankshaft), and reassembly with torque specifications.
Steering System Service:
Covers steering post, tie rods, skis, and linkage inspection and adjustment for proper steering geometry and responsiveness.
Tune Up Procedures:
Comprehensive tune-up procedures including spark plug gap and replacement, air filter cleaning/replacement, and carburetor/fuel injection system adjustments.
Depth:
Comprehensive (from simple maintenance to complete engine and suspension overhaul)
Diagnostic Tools:
While not a digital diagnostic tool itself, the manual specifies required manual tools and provides diagnostic flowcharts for troubleshooting.
Engine Type:
2-Stroke, various displacements (e.g., 370cc, 440cc, 500cc, 570cc, 600cc, 700cc, 800cc, 900cc)
Engine Configurations:
Inline twin-cylinder, triple-cylinder configurations for various models (e.g., 500, 600, 700, 800, 900cc engines are typically twins or triples).
Performance Details:
Specific horsepower and torque figures vary by model and engine variant; manual provides detailed performance tuning and diagnostic data.
Engine Cooling:
Primarily air-cooled engines, with some models featuring fan cooling. Manual details any cooling system components and maintenance if applicable.
Fuel System Coverage:
Carbureted and Fuel Injection (EFI) systems for various models. Manual covers fuel pump, injectors, carburetor adjustment, and troubleshooting.
Carburetor Details:
Specific carburetor models (e.g., Mikuni VM series) are covered, including jetting, needle settings, float bowl adjustment, and cleaning procedures.
Efi Components:
For EFI models, covers fuel pump, pressure regulator, injectors, throttle position sensor (TPS), and ECU troubleshooting.
Transmission Type:
CVT (Continuously Variable Transmission) with Arctic Drive System
Transmission Coverage:
Manual covers clutch inspection, service, belt replacement, primary and secondary clutch calibration, and drive system maintenance.
Clutch Service:
In-depth instructions for servicing primary (drive) and secondary (driven) clutches, including roller inspection, spring replacement, and alignment checks.
Drive Belt Replacement:
Step-by-step instructions with torque specifications for drive clutch bolt removal and replacement of the drive belt.
Gearing Ratios:
While primarily CVT, manual may provide information on fixed gearing ratios for reverse or specialized transmissions if applicable to specific models.
Gearbox Type:
Primarily CVT. Certain utility models might have a fixed gear setup for reverse, detailed in the manual.
Chassis Type:
Various chassis designs tailored to model purpose (e.g., trail, mountain, utility).
Track Dimensions:
Track width, length, and lug height vary significantly by model and intended use (trail vs. mountain). Manual provides specific dimensions.
Ski Stance:
Ski stance varies by model; manual provides specific measurements for alignment and adjustments.
Dry Weight Range:
Dry weight varies significantly by model, typically ranging from approximately 350 lbs to over 500 lbs. Manual provides model-specific weight data.
Rack Capacity:
Utility and touring models feature rear racks or cargo boxes; manual provides details on their capacity and maintenance.
Braking System:
Hydraulic disc brakes with detailed inspection, service, and fluid specifications. Manual covers brake pad replacement, caliper service, and bleeding procedures.
Throttle Control:
Covers throttle cable adjustment, lubrication, and troubleshooting for consistent throttle response.
Engine Kill Switch:
Details the function and troubleshooting of the emergency engine kill switch and its associated tether cord.
Handlebar Controls:
Covers function and service of throttle levers, brake levers, kill switches, and other handlebar-mounted controls.
Safety Features:
Manual covers safety precautions, proper operating procedures, and maintenance of safety systems like tether cords (kill switch).
Suspension Technology:
Covers advanced suspension systems like AWS (Arctic Western Suspension) and FasTrack, including adjustments, component service, and shock absorber maintenance.
Track System Maintenance:
Guidance on track inspection, tension adjustment, and alignment for optimal performance and longevity.
Suspension Adjustment:
Detailed instructions on adjusting front and rear suspension for rider preference and terrain conditions.
Brake System Maintenance:
Detailed procedures for caliper service, rotor inspection, and bleeding the hydraulic brake system.
Electrical Diagnostics:
Detailed troubleshooting for electrical system issues, including testing of coils, stators, rectifiers, and batteries using multimeters.
Dashboard Instruments:
Details operation and troubleshooting for instrument clusters, including speedometers, tachometers, and warning lights.
Scheduled Maintenance:
Manual details recommended service intervals for engine oil, spark plugs, drive belts, suspension lubrication, and track tension adjustments, specific to each model.
Clutch Maintenance Interval:
Recommended intervals for clutch inspection and service are provided, typically based on mileage or operating hours.
Oil Type:
Specifies required 2-stroke synthetic oil and appropriate viscosity grades for engine lubrication, as well as brake fluid type (DOT 4 recommended for hydraulic brakes).
Coolant Type:
While most 2004 2-stroke models are air-cooled, liquid-cooled variants (if applicable) would specify a specific antifreeze/coolant mixture. Manual details if applicable.
Chaincase Oil:
For models with a chaincase, specifies the correct type and amount of gear oil required.
Common Troubleshooting:
Manual includes troubleshooting sections for common issues such as starting problems, engine performance fluctuations, electrical faults, and drive system irregularities.
Suspension Wear:
Highlights common wear points in suspension components like bushings, ball joints, and shock absorbers, with repair procedures.
Brand Focus:
Arctic Cat is known for its performance-oriented snowmobiles, with a strong legacy in racing and recreational riding.
2004 Series Focus:
The 2004 lineup represented a period of significant technological advancement for Arctic Cat, with refined chassis and engine designs across its diverse model range.
Firecat Series:
The Firecat series was a popular platform for Arctic Cat, known for its lightweight design and aggressive styling in 2004.
Sabercat Series:
The Sabercat series in 2004 offered a blend of comfort and performance, often featuring longer tracks for better flotation.
Mountain Cat Series:
The Mountain Cat models in 2004 were designed for deep snow performance with longer tracks and specialized suspension.
Manufacturing Origin:
Arctic Cat snowmobiles are manufactured by Arctco, Inc., a subsidiary of Textron Inc., historically in Thief River Falls, Minnesota, USA.
