🏷️ Basic Information

Make:

Arctic Cat

Model:

Snowmobile

Year:

2004

Product Type:

Repair Service Workshop Manual

Product Name Full:

2004 Arctic CAT Snowmobile Repair Service DIY WORK Shop PDF Manual BOTH VOLUMES Instant Download

Manual Identifier:

2004 Arctic Cat Snowmobile Repair Service DIY WORK Shop PDF Manual BOTH VOLUMES

👋 Introduction

Positioning:

DIY repair and maintenance resource for owners of 2004 Arctic Cat snowmobiles, aimed at empowering users to perform service and repairs themselves, saving on dealership costs.

Target Audience:

Snowmobile owners who are comfortable with mechanical tasks and wish to perform their own maintenance and repairs, or those seeking in-depth knowledge for troubleshooting.

Advantage:

Provides access to the same comprehensive repair information used by authorized service centers, offering significant cost savings for owners. Instant download eliminates shipping delays.

Features:

Two-volume set, instant PDF download, full wiring diagrams, extensive model coverage, step-by-step instructions, troubleshooting guides, illustrations, and diagrams.

Diy Focus:

Specifically marketed as a DIY manual, empowering owners with the knowledge and procedures to perform maintenance and repairs themselves, fostering self-sufficiency.

📋 Manual Details

Models Covered:

King Cat 900 1M 162, Mountain Cat 900 1M EFI 159, Mountain Cat 900 1M EFI 151, Mountain Cat 900 1M 159, Mountain Cat 900 1M 151, Mountain Cat 800 1M EFI 159, Mountain Cat 800 1M EFI 151, Mountain Cat 600 1M EFI, Mountain Cat 570 1M, ZR 900 EFI Sno Pro, ZR 900 Sno Pro, ZR 900 EFI, ZR 900, Sabercat 700 EFI LX EXT, F7 Firecat EFI Sno Pro, Sabercat 700 EFI LX, Sabercat 600 EFI LX EXT, F7 Firecat EFI EXT, F7 Firecat Sno Pro, F6 Firecat EFI Sno Pro, Sabercat 600 LX, Sabercat 700 EFI, F7 Firecat, F6 Firecat EFI, Sabercat 600 EFI, F6 Firecat, F5 Firecat Sno Pro, Sabercat 600, F5 Firecat, Sabercat 500 LX, Sabercat 500, Z 570 LX, Z 440 LX, Z 570, Z 370 LX, Z 370, Pantera 800 EFI, T660 Turbo Touring, T660 Turbo Trail, Bear Cat 660 Wide Track, T660 Touring, Pantera 600 EFI, Pantera 550, Panther 570, Bear Cat 570LT, Panther 370

Model Variant Suffixes:

Covers models with various suffixes like 'EFI', 'Sno Pro', 'LX', 'EXT', '1M' which denote specific features, engine configurations, or performance packages.

Estimated Pages:

Likely extensive, covering two volumes. Specific page count not provided, but implied to be comprehensive for the listed models.

Type:

Repair Service / Workshop Manual

Language:

English

Format:

PDF

📖 Manual Coverage

Systems:

General Information, Maintenance, Adjustments, Engine, Transmission, Fuel System, Cooling System, Drive train, Chassis, Brakes, Electrical System, Wiring Diagrams, Troubleshooting, Service Information, Technical Specifications

Electrical System:

Detailed coverage of the electrical system, including battery, stator, ignition system (CDI, coils, spark plugs), lighting (headlights, taillights, brake lights), starter system, and accessory wiring.

Chassis And Suspension:

Covers frame components, suspension geometry, shock absorber service and tuning, front suspension (AWS - Arctic Wide Suspension), and rear suspension systems (e.g., coupled or independent designs).

Braking System:

Comprehensive coverage of the hydraulic disc braking system, including brake pad replacement, caliper service, master cylinder maintenance, brake fluid bleeding, and rotor inspection.

Fuel System:

Detailed procedures for fuel tank removal, fuel line maintenance, fuel pump testing (if applicable), and fuel filter replacement.

Drive Train:

Covers primary and secondary clutches, drive belt, chaincase (if applicable), jackshaft, output shaft, and track drive system components.

Cooling System:

Covers liquid-cooled systems, including radiator, coolant hoses, water pump, thermostat, and coolant level checks and maintenance.

Procedures:

Complete tear down and rebuild, step-by-step repair instructions, minor service, adjustments, major aftermarket projects, troubleshooting, diagnostics, common issues, preventive maintenance.

Troubleshooting Procedures:

Extensive troubleshooting sections covering a wide range of potential issues, including starting problems, engine misfires, poor performance, electrical faults, and operational anomalies. Includes diagnostic charts and symptom-based solutions.

Bodywork And Plastics:

Instructions for removal, installation, and maintenance of body panels, hoods, seats, and other plastic components. May include guidance on minor cosmetic repairs.

Engine Tuning And Adjustment:

Instructions for adjusting carburetor settings (jetting, idle speed), tuning EFI systems (if applicable via diagnostic tools), and optimizing engine performance for different conditions.

Winterization And Storage:

Likely includes recommended procedures for proper snowmobile storage during the off-season, including fuel stabilization, battery care, and general cleaning to prevent damage.

Track And Suspension Adjustment:

Guidance on adjusting track tension, inspecting and adjusting suspension settings for various riding conditions, and servicing suspension components.

Depth:

Comprehensive, from basic maintenance and adjustments to complete engine rebuilds and electrical system diagnostics. Full wiring diagrams included.

Engine Rebuild Depth:

Provides detailed instructions for engine disassembly, component inspection, machining specifications (e.g., piston ring gap, cylinder bore), reassembly, and break-in procedures for various engine types.

Wiring Diagram Detail:

Comprehensive, full-color wiring diagrams illustrating all circuits, component locations, wire colors, and connector pinouts for easy electrical troubleshooting.

Diagnostic Tools:

While not explicitly stating tool requirements, the depth of coverage implies the use of common automotive and specialized snowmobile tools for diagnostics and repair.

Torque Specifications:

Detailed torque specifications for critical fasteners throughout the snowmobile, ensuring proper assembly and preventing component damage.

📊 Manual Specifications

Format Details:

PDF, compatible with Windows and Mac OS. Features easy navigation, view, print, zoom in/out functionality.

Searchability:

PDF format typically allows for text searching, making it easy to quickly locate specific information within the manual.

Quality:

Fully printable, designed to be equivalent to the manual used by authorized service centers. High-resolution illustrations and diagrams.

Illustrations Quality:

Tons of illustrations and diagrams are mentioned, implying a high quality of visual aids for clarity and ease of understanding during repair procedures.

Binding:

Not Applicable (Digital PDF Download)

Paper:

Not Applicable (Digital PDF Download)

⚙️ Engine Specifications

Engine Variants:

Covers a range of Arctic Cat engines including 900cc (EFI and non-EFI), 800cc (EFI), 600cc (EFI), 570cc, 700cc (EFI), 660cc (Turbo and naturally aspirated), 550cc, 440cc, and 370cc engines. Specific engine code details would be found within the manual.

Engine Types:

Includes both 2-stroke and potentially 4-stroke (T660 Turbo models) engines. Manual will differentiate procedures based on engine configuration.

Engine Displacements:

Ranges from 370cc up to 900cc, covering a wide spectrum of power outputs and intended uses.

Performance Details:

Manual provides specifications for horsepower, torque, and other performance metrics relevant to each engine model. Exact figures vary by specific engine and model trim.

Ignition System:

Details on the ignition system, including ignition timing, coil resistance values, CDI unit testing, and spark plug selection and gap specifications.

Fuel System Coverage:

Comprehensive coverage of fuel delivery systems, including carburetors (e.g., Mikuni, Keihin), EFI (Electronic Fuel Injection) systems, fuel pumps, injectors, fuel lines, and fuel filters.

Efi Coverage:

Detailed explanation of EFI systems, including sensors (throttle position sensor, MAP sensor, etc.), ECU (Engine Control Unit), fuel injectors, and diagnostic procedures for EFI-related issues.

Fuel Pump Specifications:

Details on fuel pump type (mechanical or electric) and testing procedures, including pressure and flow rate specifications.

🔧 Transmission

Transmission Type:

CVT (Continuously Variable Transmission) primary and secondary clutch systems are standard on most models listed. Some models may feature specific gearboxes or drive systems. Details on clutch calibration, belt replacement, and maintenance are included.

Optional Features:

Not explicitly detailed for this manual, but Arctic Cat may have offered different track lengths or suspension options that could indirectly affect drive train configurations.

Transmission Features:

Manual will cover CVT belt inspection and replacement, clutch adjustments, primary and secondary clutch service, gear case lubrication, and drive chain maintenance (if applicable).

📐 Dimensions

Track Length Variants:

Models listed include various track lengths indicated by numbers like 162, 159, 151, suggesting a range of mountain-specific and trail-oriented chassis configurations.

Seating Capacity:

Primarily single-rider or two-rider seating configurations, depending on the specific model (e.g., Touring models typically offer two-up seating).

Cargo Capacity:

Limited cargo capacity, typically in the form of a small storage bag or rack, depending on the model. Manual will detail any available storage compartments.

Dry Weight Range:

Dry weight varies significantly by model, ranging from lighter trail sleds to heavier mountain-specific machines. Manual will contain specific dry weight for each covered model.

🛡️ Safety Features

Safety Standards:

While specific NHTSA or equivalent ratings are not applicable to snowmobiles in the same way as cars, the manual will cover safe operating procedures, emergency shutdown, and maintenance practices to ensure rider safety.

Active Safety:

Features related to braking systems (hydraulic disc brakes), throttle control, and steering mechanisms will be detailed. Specific safety features like hand warmers and adjustable handlebars are also covered implicitly in maintenance.

Passive Safety:

Includes chassis integrity, suspension design for stability, and bodywork that provides rider protection. Manual will cover maintenance of these components.

💡 Technology Features

Infotainment Features:

Basic instrumentation typically includes speedometer, tachometer, odometer, fuel gauge, and warning lights. Advanced infotainment systems were not common in snowmobiles of this era, but the manual will cover the operation and maintenance of these basic electronic components.

Driver Assistance Features:

While not 'driver assistance' in the automotive sense, the manual covers steering, suspension tuning, and braking systems which are critical for control and safe operation. EFI systems represent a key technological advancement for performance and emissions control.

Connectivity Features:

No external connectivity features (like Bluetooth or Wi-Fi) are expected for this model year. The manual focuses on the internal electrical systems and diagnostics.

🔧 Maintenance

Scheduled Maintenance:

The manual will detail specific mileage or operational hour intervals for tasks such as oil changes, filter replacements, spark plug checks, drive belt inspection, suspension lubrication, and clutch maintenance.

Clutch Maintenance Intervals:

Recommended intervals for clutch inspection, cleaning, weight and spring inspection, and primary/secondary clutch alignment checks.

General Inspection Intervals:

Regular visual inspections of critical components such as steering, brakes, track, and suspension will be recommended.

Fluids:

Includes recommendations for engine oil type and viscosity (e.g., API classification, specific Arctic Cat 2-stroke oil), coolant type and mixture, brake fluid specification (e.g., DOT 4), and grease types for suspension and bearing lubrication.

Coolant Specifications:

Specification for coolant type (e.g., ethylene glycol based) and recommended antifreeze-to-water ratio for optimal freeze protection and heat transfer.

Gearcase Oil:

Specifications for gearcase lubrication, including the type and viscosity of oil required for the drive train and jackshaft bearings.

Common Wear Items:

The manual will likely cover wear items such as drive belts, carbides, wear rods, shock absorbers, and suspension bushings. Troubleshooting sections will address common performance issues related to fuel systems, ignition, and clutches.

Carburetor Cleaning:

Instructions for cleaning and rebuilding carburetors, including jet sizes, float bowl adjustments, and idle speed settings.

📚 Vehicle History

Arctic Cat Heritage:

Arctic Cat is a long-standing American manufacturer of snowmobiles and ATVs, known for its innovation and performance-oriented machines, particularly in the mountain and cross-country racing segments.

2004 Lineup Context:

The 2004 model year represented a period of advanced technology for Arctic Cat, with EFI becoming more prevalent, and the introduction of models like the F-series (Firecat) which emphasized light weight and aggressive styling. Mountain Cat models focused on deep snow capability.

Production Details:

Manufactured by Arctic Cat Inc. in Thief River Falls, Minnesota, USA.

🏆 Awards & Recognition

Industry Awards:

Specific awards for the 2004 models would require historical research, but Arctic Cat snowmobiles have historically been recognized for performance, handling, and innovation in various enthusiast publications and competitions.