Value Proposition:
Inexpensive way to keep vehicles working properly, saving on repair and maintenance costs
Key Features:
Hundreds of photos and illustrations, comprehensive coverage, digital download format
Market Competition:
Competed against major snowmobile manufacturers like Ski-Doo, Yamaha, and Polaris, offering diverse models catering to trail riding, mountain riding, and utility segments.
Applicable Models:
Bearcat 570, Firecat 500, Firecat 500 Sno Pro, Firecat 600, Firecat 600 Sno Pro, Firecat 600 EFI (EB), Firecat 600 EFI EXT, Firecat 600 EFI, Firecat 600 EFI Sno Pro, Firecat 700, Firecat 700 Sno Pro, Firecat 700 EFI EXT, Firecat 700 EFI, Firecat 700 EFI Sno Pro, King Cat 900, Mountain Cat 570, Mountain Cat 600 EFI, Mountain Cat 800 EFI, Mountain Cat 900, Pantera 550, Pantera 600 EFI, Pantera 800 EFI, Panther 370, Panther 570, Sabercat 500, Sabercat 500 LX, Sabercat 600, Sabercat 600 LX, Sabercat 600 EFI EXT, Sabercat 600 EFI, Sabercat 600 EFI LX, Sabercat 700 EFI EXT, Sabercat 700 EFI, Sabercat 700 EFI LX, Z 370, Z 370 LX, Z 440 LX, Z 570, Z 570 LX, ZR 900, ZR 900 Sno Pro
Manual Type:
Service Repair Workshop Manual
Estimated Page Count:
While an exact page count is not provided, the description emphasizes hundreds of photos and illustrations and comprehensive coverage, suggesting a substantial document likely exceeding 500 pages. Actual page count may vary slightly depending on specific model inclusions.
Digital Delivery:
Instant download capability, eliminating shipping costs and wait times.
Systems Covered:
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, Wiring Diagrams
Procedures Included:
Detailed illustrations, step-by-step instructions for complete disassembly, service, and repair procedures
Technical Depth:
Designed for both do-it-yourselfers and experienced mechanics, covering complete disassembly and repair
Engine Rebuild Procedures:
Includes procedures for engine disassembly, inspection, component replacement (pistons, rings, crankshaft, bearings), and reassembly, crucial for complete engine overhauls.
Suspension Repair:
Detailed steps for servicing and repairing front and rear suspension components, including shock absorbers, springs, trailing arms, and slide rails.
Steering System Maintenance:
Instructions for inspecting, adjusting, and repairing steering components, including handlebars, steering post, spindles, and tie rods.
Diagnostic Troubleshooting
Troubleshooting Guides:
Provides diagnostic flowcharts and symptom-based troubleshooting advice for common mechanical and electrical issues.
Wiring Diagrams Detail:
Comprehensive and clear wiring diagrams are provided, illustrating the entire electrical system for each applicable model, crucial for troubleshooting electrical faults.
Body Panel Removal:
Step-by-step instructions for removing and reinstalling body panels, seats, windshields, and other cosmetic components for access to internal systems.
Carburetor Rebuild:
Detailed instructions and diagrams for rebuilding and overhauling carburetors (e.g., Mikuni VM series) used on many 2004 Arctic Cat models.
Clutch Rebuild:
Comprehensive guide to rebuilding both drive and driven clutches, including replacing weights, springs, buttons, and sheaves.
Ignition System Diagnostics:
Detailed troubleshooting for the ignition system, including CDI units, ignition coils, stator outputs, and trigger coils.
File Quality:
High-quality PDF with printable pages
Software Requirements:
Adobe PDF Reader, WinZip
Operating Systems:
All PC based Windows operating systems & Mac
Image Resolution:
High-resolution images and diagrams suitable for clear viewing and printing.
Binding Type:
N/A (Digital Download - PDF)
Paper Type:
N/A (Digital Download - PDF)
Engine Overview:
Covers a range of engine displacements including 370cc, 440cc, 500cc, 550cc, 570cc, 600cc, 700cc, 800cc, and 900cc across various models. Specific horsepower and torque figures vary by model and are detailed within the manual.
Fuel Systems Covered:
Includes detailed information on fuel systems, carburetion, and EFI (Electronic Fuel Injection) systems as applicable to the specific models.
Engine Configurations:
Covers both 2-stroke and potentially early 4-stroke (EFI) engine technologies prevalent in the 2004 model year, including twin-cylinder configurations.
Cooling System Service:
Coverage of the liquid cooling system, including coolant flushing, thermostat replacement, water pump inspection, and radiator maintenance.
Tuning Guides:
Provides foundational knowledge for engine tuning, including insights into jetting, timing (where adjustable), and exhaust system effects.
Drive Train Systems Covered:
Detailed coverage of drive train and brake systems, including clutches, drive belts, chain cases, and braking mechanisms.
Clutch Service:
Detailed information on Primary (Drive) and Secondary (Driven) clutch service, including inspection, cleaning, spring replacement, roller/weight inspection, and calibration for optimal performance.
Drive Belt Replacement:
Detailed instructions for checking drive belt condition, tension, alignment, and replacement, including recommended belt part numbers (e.g., Arctic Cat belts).
Chassis Details:
The manual provides information for various chassis types, including the Firecat, King Cat, Mountain Cat, Pantera, Panther, Sabercat, and Z/ZR platforms. Specific dimensional data for each model is contained within the relevant sections.
Dry Weight Range:
Dry weight varies significantly by model, ranging from approximately 400 lbs for smaller chassis to over 550 lbs for larger touring or mountain models. Specific weights are detailed in the model-specific sections.
Track Specifications:
Information on track types, lug heights, widths, and lengths specific to different models, along with procedures for track tensioning and alignment.
Brake System Coverage:
Comprehensive coverage of brake system components, maintenance, and repair procedures.
Exhaust System Maintenance:
Guidance on inspecting and maintaining the exhaust system, including mufflers and heat shields, for safety and performance.
Electrical Systems Coverage:
Covers both engine electrical systems (ignition, starting, charging) and chassis electrical systems (lighting, instrumentation, accessories), including detailed wiring diagrams for each model.
Dashboard Features:
Details on the function and interpretation of the snowmobile's instrument cluster, including speedometers, tachometers, odometers, fuel gauges, and warning lights.
Efi Diagnostics:
For EFI models, the manual likely includes information on sensor diagnostics (e.g., throttle position sensor, coolant temperature sensor, MAP sensor), fuel injector testing, and ECU troubleshooting.
Lighting Maintenance:
Information on headlight, taillight, and brake light bulb replacement and troubleshooting.
General Maintenance Schedule:
While specific intervals vary by model and usage, the manual provides a framework for regular maintenance tasks such as lubrication, belt inspection, track adjustment, and fluid checks. Users are advised to consult model-specific sections for precise timing.
Fluid Requirements:
The manual details all necessary fluid specifications, including engine oil types (e.g., API TCW-3 for 2-stroke engines, specific grades for 4-stroke where applicable), coolant types, brake fluid specifications, and gearcase oil requirements.
Typical Faults:
The manual is designed to address common issues encountered with 2004 Arctic Cat snowmobiles, potentially including drive belt wear, clutch alignment problems, carburetor tuning, EFI system diagnostics, suspension component wear, and electrical system checks.
Suspension Wear:
Highlights common wear items in the suspension, such as bushings, ball joints, and shock seals, with procedures for their inspection and replacement.
Carburetor Adjustment:
Instructions for proper carburetor cleaning, synchronization, and adjustment for optimal fuel mixture and engine performance, including idle speed settings.
Spark Plug Service:
Guidance on spark plug inspection, gapping, and replacement, including recommended spark plug types and part numbers for various engines (e.g., NGK BR9ECS).
Grease Points:
Identification and maintenance procedures for all chassis lubrication points, including suspension pivots, steering components, and driveshaft bearings.
Air Filter Service:
Instructions for inspecting, cleaning, or replacing air filter elements to ensure optimal engine breathing and longevity.
Fuel Filter Replacement:
Guidance on locating and replacing fuel filters to prevent fuel system contamination.
Arctic Cat Heritage:
Arctic Cat has a long-standing history in snowmobile manufacturing, known for performance-oriented and innovative designs. The 2004 models represent a significant era in their product development.
Firecat Platform:
The Firecat platform, introduced around 2003, was a significant advancement for Arctic Cat, featuring a more centralized mass for improved handling and rider-forward ergonomics. The 2004 models built upon this successful platform with refinements.
Sabercat Platform:
The Sabercat represented a blend of performance and comfort, often featuring larger displacement engines and a more relaxed riding position compared to the sport-oriented Firecat models.
Mountain Cat Series:
The Mountain Cat series is renowned for its deep snow capability, featuring longer tracks, specialized suspension, and powerful engines designed for aggressive mountain riding.
Bearcat Series:
The Bearcat line is typically characterized by its utility and crossover capabilities, often featuring wider tracks and rugged construction for off-trail and work applications.
Pantera Series:
Pantera models were often positioned as versatile trail sleds, balancing comfort, performance, and rider-friendly features for extended riding sessions.
Z And Zr Series:
The Z and ZR series are Arctic Cat's dedicated sport and performance trail snowmobiles, known for their agile handling, powerful engines, and sporty aesthetics.
Manufacturing Locations:
Arctic Cat snowmobiles for this era were primarily manufactured in Thief River Falls, Minnesota, USA.
