🏷️ Basic Information

Make:

Arctic Cat

Model:

650 V-Twin 4x4 FIS

Year:

2004

Variant:

FIS (Fuel Injection System)

Color Code:

CAT GREEN (Specific to this offering)

Product Code:

A2004ISR4BNAV

Vin Prefix:

Not specified in product info, but typical for ATVs is a 17-character code.

👋 Introduction

Market Position:

The Arctic Cat 650 V-Twin 4x4 FIS was positioned as a high-performance, utility-focused ATV in the mid-2000s market, competing with models from Yamaha (Grizzly), Polaris (Sportsman), and Honda (Foreman/Rancher).

Competitive Analysis:

Its key differentiators were its powerful V-twin engine and its advanced EFI system (FIS), offering improved throttle response and power delivery over carbureted competitors. The 4x4 system with front differential lock (often referred to as 'Arctic Cat's on-demand 4WD') provided excellent traction.

Key Features:

Liquid-cooled V-twin engine, Electronic Fuel Injection (EFI), Selectable 4WD with front differential lock, Independent Front Suspension (IFS), Disc brakes, Shaft drive, High/Low range transmission, Durable chassis and bodywork.

📋 Manual Details

Coverage Areas:

Accelerator, Air Intake, Battery And Starter Motor, Cam Chain, Canopy And Taillight, Cargo Box And Tailgate, Clutch, V-Belt, Magneto Cover, Console, Floor Panel, Cooling, Crank Balancer, Crankshaft And Piston, Cylinder, Cylinder Head And Camshaft/Valve, Dash, Drive Train, Engine And Exhaust, Frame And Related Parts, Front Brake, Front Drive Gearcase, Front Suspension, Gas Tank, Gear Shifting, Hood And Headlight, Magneto, Oil Filter/Pump, Rear And Parking Brake, Rear Suspension, Seat, Secondary Drive, Secondary Transmission, Shifter, Starter Clutch, Steering, Sway Bar, Throttle Body, Tilt Frame, Transmission, Water Pump, Wheel And Tire, Wiring Harness

Page Count:

Not explicitly stated, but typical factory parts manuals for this era and complexity range from 300-600 pages.

Manual Type:

Factory Full Parts Manual

Language:

English

Format:

PDF Download

📖 Manual Coverage

Systems Covered:

Engine (internals, cooling, exhaust, fuel delivery, lubrication), Drivetrain (front and rear drive, transmissions, clutches), Suspension (front and rear), Steering, Brakes (front and rear), Electrical (battery, starter, magneto, wiring harness), Fuel System (gas tank, throttle body), Bodywork (canopy, hood, cargo box, seat, dash), Chassis/Frame, Wheels and Tires, Accessories (cargo box, tailgate).

Procedures Included:

Disassembly, Overhaul, Assembly of all listed components and systems. Identification of all factory-supplied part numbers for replacement and maintenance.

Technical Depth:

Comprehensive. Detailed exploded views, part illustrations, and itemized part listings. Designed for parts identification and ordering, but also valuable for understanding assembly and disassembly sequences for maintenance and repair.

📊 Manual Specifications

File Format:

PDF

Print Quality:

Printable, Zoomable. High-quality digital reproduction suitable for printing individual pages or the entire manual.

Binding Type:

Digital (PDF) - User printable, can be spiral bound or kept electronically.

Paper Type:

N/A (Digital)

⚙️ Engine Specifications

Engine Type:

V-twin, Four-stroke, SOHC

Displacement:

641cc (approx.)

Bore X Stroke:

Not specified in product info, but typically around 72mm x 70mm for this displacement.

Horsepower:

Estimated 50-55 HP at flywheel (typical for this class and era).

Torque:

Not specified in product info.

Fuel System:

Electronic Fuel Injection (EFI)

Cooling System:

Liquid-cooled

Ignition:

Electronic Ignition

Exhaust System:

Dual exhaust outlets, likely with catalytic converter for emissions compliance.

🔧 Transmission

Transmission Type:

Automatic CVT (Continuously Variable Transmission)

Gear Selection:

High, Low, Neutral, Reverse, Park

Drive System:

Shaft Drive, Selectable 4x4 with Front Differential Lock

Clutch Type:

CVT clutch system (primary and secondary clutches)

📐 Dimensions

Length:

Not specified in product info, but typically around 80-85 inches for this class.

Width:

Not specified in product info, but typically around 45-48 inches for this class.

Height:

Not specified in product info, but typically around 48-50 inches for this class.

Cargo Rack Capacity Front:

Not specified in product info, but typically 100 lbs.

Cargo Rack Capacity Rear:

Not specified in product info, but typically 200 lbs.

Dry Weight:

Not specified in product info, but likely in the 600-650 lbs range.

Towing Capacity:

Not specified in product info, but typically around 1000 lbs for this class.

Front Tire Size:

Not specified in product info, but commonly 25x8-12.

Rear Tire Size:

Not specified in product info, but commonly 25x10-12.

Wheel Bolt Pattern:

Not specified in product info, but likely a common 4x110 or similar ATV pattern.

🛡️ Safety Features

Safety Ratings:

ATVs are not typically subjected to formal crash test ratings like automobiles. Safety is primarily managed through design and rider education.

Active Safety Features:

Four-wheel disc brakes, Front differential lock for enhanced traction, Engine braking (via CVT).

Passive Safety Features:

All-steel frame construction, Handguards (likely standard), Seat belt anchor points not applicable.

💡 Technology Features

Infotainment Features:

Basic by modern standards. Likely includes a digital hour meter, odometer, speedometer (integrated into dash), and indicator lights for 4WD, oil pressure, etc.

Driver Assistance Features:

Limited. The primary 'assistance' is the selectable 4WD and front differential lock, which are mechanical systems enhancing capability.

Connectivity Features:

None. No integrated Bluetooth, USB ports, or smartphone connectivity.

🔧 Maintenance

Service Intervals:

The manual would detail specific intervals for oil changes (engine and transmission/gearcase), filter replacements, spark plug checks, brake inspections, and valve adjustments. General guidelines: Engine oil change every 100-150 hours or annually, air filter cleaning/replacement as needed based on conditions, CVT belt inspection every 500 hours.

Engine Oil Type:

The manual would specify a specific SAE viscosity grade (e.g., 10W-40 or 20W-50) and JASO MA rating for wet clutch compatibility. API SG or higher is typical.

Engine Oil Capacity:

Not specified in product info, but typically around 2.0-2.5 quarts (1.9-2.4 liters).

Transmission Fluid Type:

The manual would specify either a dedicated ATV transmission fluid or a specific gear oil grade (e.g., SAE 75W-90).

Coolant Type:

A permanent type ethylene glycol-based antifreeze/coolant, mixed 50/50 with distilled water, would be specified.

Brake Fluid Type:

DOT 3 or DOT 4 brake fluid is standard for hydraulic brake systems.

Common Issues:

Potential issues for ATVs of this era can include: CVT belt wear or failure, cooling system leaks (radiator, hoses), carburetor issues (if not EFI), front differential seal leaks, and electrical connector corrosion. The EFI system is generally reliable but can be sensitive to fuel quality.

Parts Identification:

This manual is critical for accurately identifying and ordering replacement parts for all systems, including specific fasteners, seals, bearings, and electrical components.

📚 Vehicle History

Brand Heritage:

Arctic Cat has a long history in powersports, initially known for snowmobiles, and expanded significantly into ATVs in the late 1990s and early 2000s, becoming a significant player in the market.

Model Evolution:

The 650 V-Twin was a flagship model for Arctic Cat, representing a step up in performance and features for the brand. It was part of an aggressive product development push in the early 2000s.

Production Period:

The 650 V-Twin was produced for several model years, including 2004, and was later succeeded by models like the 650 H1 and 700 V-Twin.

Manufacturing Location:

Typically manufactured in Thief River Falls, Minnesota, USA, by Arctic Cat.

🏆 Awards & Recognition

Recognitions:

Specific awards for the 2004 650 V-Twin are not readily available, but Arctic Cat ATVs of this period generally received positive reviews from the powersports media for their performance and capability.

Media Ratings:

This model was generally well-regarded for its power and 4x4 performance, often noted for its superior engine torque compared to some single-cylinder competitors.